Thermal, mechanical, flammability properties, and morphologies of polypropylene/calcium carbonate‐based on carbon nanomaterials and layered silicates composites: A future perspective of new sheet material for flooring application

Abstract Polyvinyl chloride/calcium carbonate (PVC/CaCO 3 ) composites are widely used in the construction industry to fabricate flooring materials. However, PVC materials have raised concern due to the large quantity of plasticizers introduced during PVC product processing. Studies have reported that volatile organic chemicals (VOCs) are toxic with side effects on human health and the environment. Therefore, polypropylene (PP) is proposed as an alternative polymer for developing calcium carbonate‐based polymer composite sheets for flooring applications with improved thermal, mechanical, and flammability properties. This work reviews the scientific and technological advances in the field of polypropylene/calcium carbonate–carbon nanomaterials or clay nanocomposites to develop a better understanding of how to develop superior nanocomposites for use in flooring applications. This work explores various studies about the synergistic effect of combining nanofillers (i.e., carbon nanomaterials or layered clays) with intumescent flame retardants and the synergist effect of nanofillers (i.e., multi‐walled carbon nanotubes/montmorillonite) without intumescent flame retardants on thermal, mechanical, flammability properties, and morphologies of polypropylene. The generated information will facilitate the design of flooring materials based on PP with improved thermal, mechanical, and flammability properties. Therefore, it was confirmed that there is a relationship between the morphology (dispersion state of nanofillers in the PP), and mechanical properties, as well as the flammability of PP composites. Highlights New advances in carbon nanomaterials and clays‐based PP/CaCO 3 composites The relationship between preparation, structure, property, and mechanisms The synergism effect of inorganic flame retardants, multifunctionality, and flooring application Challenges and future outlook on the development of PP/CaCO 3 /inorganic FR