Summary: Via a batch process in an autoclave, foam processing of intercalated PC/clay nanocomposites, having different amounts of clay, has been conducted using supercritical CO2 as a foaming agent. The cellular structures obtained from various foaming temperature‐CO2 pressure ranges were investigated by SEM. The incorporation with nanoclay‐induced heterogeneous nucleation occurs because of a lower activation energy barrier compared with homogeneous nucleation as revealed by the characterization of the interfacial tension between bubble and matrix. The controlled structure of the PCCN foams changed from microcellular (d ? 20 µm and Nc ? 1.0 × 109 cells · cm?3) to nanocellular (d ? 600 nm and Nc ? 3.0 × 1013 cells · cm?3). The mechanical properties of PCCN foams under compression test were discussed.
TEM micrograph for the structure of the cell wall foamed at 160 °C.
