A correlation between the variable melt flow index and the molecular mass distribution of virgin and recycled polypropylene used in the manufacturing of battery cases

This study looked at establishing a correlation between the variable melt flow index (VMFI) values of molten polypropylene (PP) with different piston-load masses using a standard MFI analyser. The study was done using virgin PP and recycled PP obtained from recycling Pb-acid batteries. The study showed that the results would fit a suitable power function equation where the size of the exponent reflects the increase in flow characteristics of the polymer with increased piston-load mass. The established correlation was then compared to the average molecular weight distribution of virgin PP determined by gel permeation chromatography (GPC). Good agreement was obtained for the range of grades of virgin PP samples that correlated well with the Mark-Houwink power law where the inverse of the MFI (1/MFI) would be proportional to the average molecular weight to the power of 3.4 (Mw3.4). GPC analysis cannot be effectively used to study recycled PP, where a number of factors can influence the melt flow properties such as fillers, impurities and the presence of polyethylene in the polymer matrix. Instead, a comparative understanding of the flow behaviour of recycled PP to that of virgin PP was done by using the VMFI method to possibly show the dissimilar polymer melt flow behaviour of using virgin and recycled PP material in injection moulding of new battery cases and lids, or when attempting to seal the lid to the battery case during manufacturing.