Insert injection molding of high-density polyethylene single-polymer composites

A process for making high-density polyethylene (HDPE) single-polymer composites (SPCs) by insert injection molding was investigated. HDPE SPCs with relatively good tensile and interfacial properties were prepared within a short cycle time within a temperature range of 40°C. Melt-spun HDPE fibers were made from the same resin as the matrix. The fibers were heat treated in silicone oil, with and without tension, to study the changes of fiber properties upon exposure to high temperature. HDPE SPCs containing about 30 wt% lab-made HDPE fabric achieved a tensile strength of 50 MPa, 2.8 times that of neat HDPE. The peel strength of HDPE SPCs increased with increasing injection temperature and achieved a maximum value of 16.7 N/cm. Optical micrographs of polished transverse cross-sections of the SPC samples showed that higher injection temperature is beneficial to the wetting and permeation properties of the matrix. Scanning electronic microscope photographs suggested good bonding and compatibility between the fibers and the matrix. POLYM. ENG. SCI., 55:2448–2456, 2015. © 2015 Society of Plastics Engineers