Successive self-nucleation and Annealing technique applied to polypropylene/butyl rubber composites: Recycling alternatives for vacuum bagging materials

The aerospace sector uses butyl rubber to manufacture carbon fiber components through an autoclave or infusion. Both manufacturing techniques require a high vacuum to achieve adequate impregnation of the carbon fiber fabrics with epoxy resin, and butyl rubber is used as the sealant. The aerospace sector discontinues materials with shelf life expired, and butyl rubber is one of the materials most discontinued for not being used within the designated time. This work presents the development of composites using polypropylene and discontinued butyl tape. Composites with 30, 50, and 70 wt% of butyl rubber content were prepared using a twin-screw extruder. The structural analysis showed that the composites with 50 wt% and 70 wt% are similar to butyl rubber, while the compound with 30 wt% of butyl is similar to polypropylene. The degree of crystallinity of the compound with 50 wt% of butyl content was 18% higher than the PP, and the melting temperature decreased by 30% with the higher butyl content. SSA revealed that the highest enthalpic contribution occurred in the crystalline fraction of higher perfection, except for the compound with 50 wt% of butyl content, whose less perfect crystalline populations grew at the expense of the most perfect crystals. The reduction of the crystalline fraction implies that butyl interferes with the formation of crystals, developing populations with lower lamellar thickness that favors the overall crystallinity of the compound. Young’s modulus, yield strength, and nominal strain decreased with butyl rubber content. The composites showed rough failure surfaces with solid butyl rubber particles and poor adhesion to polypropylene. Butyl particles with diverse sizes and geometries lead to sudden failure of the composites and high dispersion in strain values.