Polymeric materials are becoming increasingly adaptable for industrial coatings, and core-shell films have been developed using kaolinite particles and recycled rubber, which are characterized by high thermal stability and enhanced flexibility. Polypropylene was melted and extruded combined with styrene-ethylene-butylene-styrene (SEBS), ground tire rubber (GTR), and kaolinite, and then subjected to the calendaring process to manufacture laminated composites. Several characterizations of the composites, including morphological, mechanical properties, and thermal analysis, were conducted. Micromechanical models have been employed to predict the elastic modulus of composite films and laminates. The addition of 15 wt% kaolinite particles resulted in increases of 14% in elastic modulus, 19.37% in storage modulus, and improved thermal stability. The substitution of kaolinite with SEBS and GTR particles compensated for the strain at yield properties, showing a 29% balance. Overall, the laminates exhibited synergistic properties. Analytical models demonstrated close agreement with the experimental data, suggesting their usefulness as reliable tools for producing core-shell films based on recycled waste and kaolinite.
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