Morphology and interfacial strength of nonisothermally fusion bonded hard and soft thermoplastics

Nonisothermally fusion bonded butt joints were prepared by overmolding thermoplastic elastomers (TPEs) onto isotactic polypropylene (iPP) inserts in order to investigate the effect of processing conditions on the bond strength and interfacial microstructure. The mold temperature (Tm) was the most important factor for bond strength, as determined from interfacial mechanical tests. Extensive melting and recrystallization took place at the surface of the iPP insert at high Tm, promoted by migration of plasticizer from the TPE, whereas the original structure of the iPP remained intact at low Tm. Bond strengths of at least 50% of the cohesive strength of the TPE were nevertheless obtained at low Tm, suggesting intimate contact between the TPE melt and the iPP surface to be sufficient to provide useful adhesive bond strengths in these materials. The influence of pressure was less marked than the Tm, high pressures not being necessary to achieve intimate contact for the bonding times of about 5 s used here. However, the combination of a low bonding pressure with a high Tm typically led to poor quality bonds in thick specimens owing to uncompensated shrinkage during solidification, and voiding at the interface and in the melt zone of the iPP insert.