Injection Molded Novel Biocomposites from Polypropylene and Sustainable Biocarbon

Achieving sustainability in composite materials for high-performance applications is a key issue in modern processing technologies. In this work, the structure-property relationships of injection molded polypropylene (PP)/biocarbon composites were investigated with a focus on the thermal properties and specific emphasis on the coefficient of linear thermal expansion (CLTE). Biocomposites were produced using 30 wt.% biocarbon in a PP matrix, and two different sources of biocarbon produced at ~650 and 900 °C were used. The overall results were compared with 30 wt.% glass- and talc-filled PP composites. Due to the lamellar morphology of the talc developed during the extrusion-injection molding processing, talc-filled composites showed an increase in the CLTE in the normal direction (ND), and a reduction in the flow direction (FD) with respect to the neat polymer. Glass fiber composites also showed an improvement in the CLTE with respect to the neat polymer. However, the biocarbon-based composites showed the best properties in the ND, with improved values in biocarbon produced at higher temperature. The FD values for both biocarbon composites were improved with respect to the matrix, while biocarbon created at lower temperature showed slightly lower expansion values. A comprehensive explanation of these overall phenomena is supported by a series of morphological, thermal, mechanical and rheological tests.