Preparation and balanced mechanical properties of solid and foamed isotactic polypropylene/SEBS composites

This study presents a self-designed foaming apparatus and routes to manufacture foamed isotactic polypropylene (iPP) blends with uniform and dense cells, using styrene-ethylene-butadiene-styrene (SEBS) block copolymer as toughening additive. The addition of SEBS can clearly enhance the impact strength of solid iPP, iPP blends with a 20 wt% SEBS has obtained high notched impact strength of 75 kJ/m², which is ca. 16 times larger than that of neat iPP. Relatively fine microcellular iPP-SEBS foams with the average cell size of several micrometers, and the cell density of 10⁹ cells/cm³ were fabricated using a batch foaming procedure. Moreover, using our self-designed mold and compression foaming method, iPP-SEBS foams with balanced mechanical properties were produced. With the increasing of SEBS, tensile strength and flexural strength were slightly decreased, but the impact strength was increased clearly. The balanced mechanical properties between stiffness and toughness were achieved after compression foaming.     

Microcellular foam of polymer blends of HDPE/PP and their composites with wood fiber

In this study, the effects of batch processing conditions (foaming time and temperature) and blend composition as well as the effect of incorporating wood fiber into the blends on the crystallinity, sorption behavior of CO₂, void fraction, and cellular morphology of microcellular foamed high‐density polyethylene (HDPE)/polypropylene (PP) blends and their composites with wood fiber were studied. Blending decreased the crystallinity of HDPE and PP and facilitated microcellular foam production in blend materials. The void fraction was strongly dependent on the processing conditions and on blend composition. Foamed samples with a high void fraction were not always microcellular. The addition of wood fiber inhibited microcellular foaming. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2842–2850, 2003     

Improving polypropylene microcellular foaming through blending and the addition of nano‐calcium carbonate

This article reports an attempt to improve polypropylene (PP) microcellular foaming through the blending of PP with high‐density polyethylene (HDPE) as a minor component and the incorporation of nano‐calcium carbonate (nano‐CaCO₃) into PP and its blends with HDPE. Three HDPEs were selected to form three blends with a viscosity ratio less than, close to, or greater than unity. Two concentrations of nano‐CaCO₃, 5 and 20 wt %, were used. The blends and nanocomposites were prepared with a twin‐screw extruder. The foaming was carried out by a batch process with supercritical carbon dioxide as a blowing agent. The online shear viscosity during compounding and the dynamic rheological properties of some samples used for foaming were measured. The cell structure of the foams was examined with scanning electron microscopy (SEM), and the morphological parameters of some foams were calculated from SEM micrographs. The rheological properties of samples were used to explain the resulting cell structure. The results showed that the blend with a viscosity ratio close to unity produced a microcellular foam with the minimum mean cell diameter (0.7 μm) and maximum cell density (1.17 × 10¹¹ cells/cm³) among the three blends. A foamed PP/nano‐CaCO₃ composite with 5 wt % nano‐CaCO₃ exhibited the largest cell density (8.4 × 10¹¹ cells/cm³). © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Relationship between cell morphology and impact strength of microcellular foamed high‐density polyethylene/polypropylene blends

Polymer blends, such as those resulting from recycling postconsumer plastics, often have poor mechanical properties. Microcellular foams have been shown to have the potential to improve properties, and permit higher‐value uses of mixed polymer streams. In this study, the effects of microcellular batch processing conditions (foaming time and temperature) and HDPE/PP blend compositions on the cell morphology (the average cell size and cell‐population density) and impact strength were studied. Optical microscopy was used to investigate the miscibility and crystalline morphology of the HDPE/PP blends. Pure HDPE and PP did not foam well at any processing conditions. Blending facilitated the formation of microcellular structures in polyolefins because of the poorly bonded interfaces of immiscible HDPE/PP blends, which favored cell nucleation. The experimental results indicated that well‐developed microcellular structures are produced in HDPE/PP blends at ratios of 50:50 and 30:70. The cell morphology had a strong relationship with the impact strength of foamed samples. Improvement in impact strength was associated with well‐developed microcellular morphology. Polym. Eng. Sci. 44:1551–1560, 2004. © 2004 Society of Plastics Engineers.     

Microcellular foaming of poly(phenylene sulfide)/poly(ether sulfones) blends using supercritical carbon dioxide

Microcellular foaming of poly(phenylene sulfide)/poly(ether sulfones) (PPS/PES) blends presents a promising approach to produce high‐performance cellular materials with tailored microstructures and enhanced properties. This study investigated the effects of multiphase blend composition and process conditions on the foaming behaviors and final cellular morphology, as well as the dynamic mechanical properties of the solid and microcellular foamed PPS/PES blends. The microcellular materials were prepared via a batch‐foam processing, using the environment‐friendly supercritical CO₂ (scCO₂) as a blowing agent. The saturation and desorption behaviors of CO₂ in PPS/PES blends for various blend ratios (10 : 0, 8 : 2, 6 : 4, 5 : 5, 4 : 6, 2 : 8, and 0 : 10) were also elaborately discussed. The experimental results indicated that the foaming behaviors of PPS/PES blends are closely related to the blend morphology, crystallinity, and the mass‐transfer rate of the CO₂ in each polymer phase. The mechanisms for the foaming behaviors of PPS/PES blends have been illustrated by establishing theoretical models. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42634.     

Effect of the high‐density polyethylene melt index on the microcellular foaming of high‐density polyethylene/polypropylene blends

The effect of high‐density polyethylene (HDPE)/polypropylene (PP) blending on the crystallinity as a function of the HDPE melt index was studied. The melting temperature and total amount of crystallinity in the HDPE/PP blends were lower than those of the pure polymers, regardless of the blend composition and melt index. The effects of the melt index, blending, and foaming conditions (foaming temperature and foaming time) on the void fractions of HDPEs of various melt indices and HDPE/PP blends were also investigated. The void fraction was strongly dependent on the foaming time, foaming temperature, and blend composition as well as the melt index of HDPE. The void fraction of the foamed 30:70 HDPE/PP blend was always higher than that of the foamed 50:50 HDPE/PP blend, regardless of the melt index. The microcellular structure could be greatly improved with a suitable ratio of HDPE to PP and with foaming above the melting temperature for long enough; however, using high‐melt‐index HDPE in the HDPE/PP blends had a deleterious effect on both the void fraction and cell morphology of the blends. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 364–371, 2004     

Effect of solvent plasticization on polypropylene microcellular foaming process and foam characteristics

In this research, the effect of crystalline fraction of polypropylene (PP) on cell nucleation behavior was overcome by an introduction of solvent‐plasticized step to the microcellular foaming in a solid‐state batch‐foaming process. Utilizing the plasticization performance of the solvent facilitated the PP to be foamed at the temperatures lower than its melting point with the dramatic development in the cellular morphology of the final foams. In consequence of the heterogeneous cell nucleation sites induction and the crystalline loss, which were induced by solvent, a high cell density (i.e., 10⁹–10¹⁰ cells/cm³) was promoted without the cell sacrificing at the elevated temperatures (155 and 165°C) and favorable PP microcellular foams were accomplished. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

N2‐filled hollow glass beads as novel gas carriers for microcellular polyethylene

N₂‐filled hollow glass beads (HGB) were first used as novel gas carriers to prepare microcellular polymers by compression molding. Dicumyl peroxide was acted as crosslink agent to control the produced microcellular structure of low density polyethylene (LDPE)/HGB. The effect of temperature, pressure and the content of gel on the embryo‐foaming, and final‐foaming structure are investigated. Scanning electronic microscopy shows that the average cell size of microcellular LDPE ranges from 0.1 to 10 μm, and the foam density is about 10⁹–10¹¹ cells/cm³. A clear correlation is established between preserving desirable micromorphologies of microcellular LDPE in different processing stage and tuning processing factors. The pertinent foaming mechanism of microcellular materials foamed with HGB is proposed. Because of the good mechanical strength, low density, weak water‐absorption, and excellent heat insulate ability, microcellular LDPE has great potential application in energy building materials. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Open‐celled microcellular thermoplastic foam

A theoritical model of the production of open‐cell microcellular foam is presented. This model allows the prediction of the conditions necessary to produce these materials. Experiments verify the model quite well. The results of the batch processing experiments indicate the processing parameters that promote the development of open‐celled microcellular polystryene foam. A saturation pressure of 17.2 MPa (2500 psig) provides the nucleation density necessary to form an impinged structure with microcellular bubble density. A foaming temperature of 200°C promotes the formation of both internal and surface porosity. A scaled time between 1 and 2.7 seconds develops a foam structure that intrudes a large volume. Samples foamed at 200°C for 1 and 2 seconds possess pores less than 1 μm in diameter. These samples represent scaled times of 1 and 2 seconds. Therefore, to produce open‐celled microcellular polystyrene foam with batch processing, samples should be saturated at approximately 17.2 MPa (2500 psig) and foamed for a scaled time between 1 and 2 seconds.     

Influence of crystallization on microcellular foaming behavior of polyamide 6 in a supercritical CO2-assisted route

Supercritical CO₂ as a blowing agent has attracted increasing interest in the preparation of microcellular polyamide 6 (PA6) foams. In this work, we developed the supercritical CO₂-assisted method to prepare a series of different microcellular PA6 foams by controlling its crystallization properties in two steps and carefully investigated the corresponding crystallization properties of modified PA6 and foams using various techniques. Initially, a multifunctional epoxy-based chain extender (CE) was used to produce high-melt strength-modified PA6 with improved foaming ability; then, the resulting PA6 was foamed to prepare the microcellular foams of PA6 using supercritical CO₂ as a blowing agent in a batch foaming route. The CE effectively enhanced the melt strength of PA6, and CE usage was optimized to obtain a threshold of high branching without crosslinking. The number of crystals was also adjusted by the saturation temperature. Furthermore, these crystals that formed during the saturation process served as high-efficiency bubble nucleating agents and then limited the growth of bubbles at the same time. The microcellular foams of PA6 were successfully obtained with a cell size of 10.0 μm, and cell density of 2.0 × 10⁹ cells/cm³ at the saturation temperature of 225°C.     

Low density microcellular foam processing in extrusion using CO2

A continuous extrusion process for the manufacture of low-density microcellular polymers is presented. Microcellular polymers are foamed plastics characterized by a cell density greater than 10⁹ cells/cm³ and a fully grown cell size on the order of 10 μm. Previous research on continuous processing of microcellular polymers has focused on control of microcell nucleation in extrusion. This paper presents an effective means for control of cell growth to achieve a desired expansion ratio with CO₂ as a blowing agent in microcellular foam processing. Also, a strategy to prevent deterioration of the cell-population density via cell coalescence during expansion is presented. Promotion of a desired volume expansion ratio and prevention of cell coalescence in microcellular foam processing were experimentally verified. By tailoring the extrusion processing parameters, microcellular HIPS foams with a cell density of 10¹⁰ cells/cm³ and a controlled expansion ratio in the range of 1.5 to 23 were obtained.     

A Taguchi analysis on structural properties of polypropylene microcellular nanocomposite foams containing Fe2O3 nanoparticles in batch process

Polypropylene (PP) as a thermoplastic polymer has been foamed using batch foaming process. CO₂ is used as the blowing agent of the foaming. Ferrous oxide nanoparticles (nano Fe₂O₃) are also added as reinforcement. Effect of different parameters including nanoparticle weight percentage, foaming temperature and time on the structural properties of PP/nano Fe₂O₃ nanocomposites is investigated using Taguchi approach. Scanning electron microscope results depict that an appropriate microcellular structure is obtained with the cell density of 10⁹ cells/cm³ and almost 1 μm of cell size. Analysis of variance results indicated that foaming temperature is the most significant parameter on the structural properties. Cell density and expansion ratio are decreased by increasing foaming temperature. This phenomenon could be due to the reducing melt strength of polymer/gas mixture. It was also inferred that adding 2 wt% of nanoparticles leads to 80% improvement in cell density while cell size and expansion ratio was decreased.     

Mechanical properties of extrusion‐foamed rigid PVC/wood‐flour composites

This study was conducted to characterize the mechanical properties of extrusion‐foamed neat rigid PVC and rigid PVC/wood‐flour composites by using endothermic and exothermic chemical foaming agents (CFAs). The specific elongation at break (ductility) of the samples was improved by foaming, while the opposite trend was observed for the tensile strength and modulus of the samples, regardless of the chemical foaming agent type. In addition, experimental results indicated that foaming reduced the Izod impact resistance of both neat rigid PVC and rigid PVC/wood‐flour composites but that this reduction was not statistically significant for the composites. A comparison between batch microcellular processing and extrusion foam processing was made, which demonstrated that foams with very fine cells (microcellular processed) exhibit better impact strength than foams with larger cells (extrusion processed with CFAs).     

Microcellular foaming of PE/PP blends

Three different polyethylene/polypropylene (PE/PP) blends were microcellular foamed and their crystallinities and melt strengths were investigated. The relationship between crystallinity, melt strength, and cellular structure was studied. Experimental results showed that the three blends had similar variation patterns in respect of crystallinity, melt strength, and cellular structure, and these variation patterns were correlative for each blend. For all blends, the melt strength and PP melting point initially heightened and then lowered, the PP crystallinity first decreased, and then increased as the PE content increased. At PE content of 30%, the melt strength and PP melting point were highest and the PP crystallinity was least. The blend with lower PP crystallinity and higher melt strength had better cellular structure and broader microcellular foaming temperature range. So, three blends had best cellular structure at PE content of 30%. Furthermore, when compared with PE/homopolymer (hPP) blend, the PE/copolymer PP (cPP) blend had higher melt strength, better cellular structure, and wider microcellular foaming temperature range, so it was more suited to be microcellular foamed. Whereas LDPE/cPP blend had the broadest microcellular foaming temperature range because of its highest melt strength within three blends. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 4149–4159, 2007     

Effects of processing parameters and thermal history on microcellular foaming behaviors of PEEK using supercritical CO2

In this study, we mainly investigate the solid‐state foaming of polyether ether ketone (PEEK) with different crystallinities using supercritical CO₂ as a physical blowing agent. The gaseous mass‐transfer and thermophysical behaviors were studied. By altering the parameters of the foaming process, microcellular foams with different cell morphologies were prepared. The effect of crystallization on the cell morphology was also investigated in detail. The results indicate that the crystallization restricts gas diffusion in the material, and the thermophysical behaviors of the saturated PEEK sample with low crystallinity presents two cold crystallization peaks. The cell density decreases and the cell size increases as the saturation pressure increases. The cell density of the microcellular foams prepared under 20 MPa is 1.23 × 10¹⁰ cells/cm³, which is almost 10 times compares to that under 8 MPa. The cell size increases as the foaming time extends or the foaming temperature increases. It is interesting that the cell morphology with a bimodal cell‐size distribution is generated when the samples are foamed at temperatures higher than 320°C for a sufficient time. Additionally, nanocellular foams can be obtained from a highly crystallized PEEK after the decrystallization process. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42576.     

Formation and characterization of polyethylene blends for autoclave‐based expanded‐bead foams

Blends of linear‐low‐density polyethylene (LLDPE), low‐density polyethylene (LDPE), and high‐ density polyethylene (HDPE) were foamed and characterized in this research. The goal was to generate clear dual peaks from the expanded polyethylene (EPE) foam beads made from these blends in autoclave processing. Three blends were prepared in a twin‐screw mixing extruder at two rotational speeds of 5 and 50 rpm: Blend1 (LLDPE with 20 wt% HDPE), Blend 2 (LLDPE with 20 wt% LDPE), and Blend 3 (LLDPE with 10 wt% HDPE and 10 wt% LDPE). The differential scanning calorimetric (DSC) measurement was taken at two cooling rates: 5 and 50°C/min. Although no dual peaks were present, the results showed that blending with HDPE has a more noticeable effect on the DSC curve of LLDPE than blending with LDPE. Also, the rotational speed and cooling rate affected the shape of the DSC curves and the percentage area below the onset point. The DSC characterization of the batch foamed blends revealed multiple peaks at certain temperatures, which may be mainly due to the annealing effect during the gas saturation process. POLYM. ENG. SCI., 2010. © 2009 Society of Plastics Engineers     

Foaming conditions of high density polyethylene–natural rubber blends

Abstract

Foams made from high density polyethylene (HDPE) and natural rubber (NR) blends, using azodicarbonamide as a chemical blowing agent, have been investigated to establish a relationship between the structure and physical properties. The blends of HDPE, NR, epolene wax, chemical blowing agent, and necessary ingredients were prepared on a two roll mill. Subsequently, foamed structures of the blends were obtained by a single stage compression moulding. Results indicate that foaming process variables, i.e. heating time, blowing agent loading, ratio of HDPE/NR, crosslinking agent loading, and ratio of HDPE/NR at a fixed crosslinking agent loading, affect the physical properties of the foams. Attempts were made to relate such properties as foam density, hardness, tensile strength, elongation at break, tear strength, flexural strength, elastic modulus, and gel content to the foam structure. The foam structure was investigated using optical microscopy, in terms of the average cell size and its distribution.     

Microcellular foams of glass–fiber reinforced poly(phenylene sulfide) composites generated using supercritical carbon dioxide

Microcellular foaming of poly(phenylene sulfide) (PPS) and its glass–fiber (GF) reinforced composites using supercritical CO₂ as a blowing agent presents a promising approach to produce novel cellular materials with tailored microstructures. This study investigated the effects of the material composition and process conditions on the foaming behaviors and final morphologies of the microcellular foamed PPS and PPS/GF composites. The rheological and thermal properties as well as the saturation and desorption behaviors of CO₂ in the pure PPS and PPS/GF composites were also detailedly discussed. The results show that microcellular foams with various relative densities, cell sizes, cell‐size distributions, and cell densities can be attained by tailoring the fiber content and key process parameters. At low foaming temperatures below the cold crystallization temperature, the microcellular foamed PPS and PPS/GF composites both present a unimodal cell‐size distribution. At elevated temperatures, the generated crystalline superstructures including spherulites in the polymer matrix and transcrystals around the GF will cause a secondary heterogeneous cell nucleation. This leads to the observations of bimodal and trimodal cell‐size distributions in the pure PPS and the PPS/GF composites, respectively. The mechanisms for the solid‐state foaming behaviors of pure PPS and PPS/GF composites have been illustrated by establishing theoretical models. POLYM. COMPOS., 37:2527–2540, 2016. © 2015 Society of Plastics Engineers     

Microcellular foaming of low‐density polyethylene using nano‐CaCo3 as a nucleating agent

In this study, microcellular foaming of low‐density polyethylene (LDPE) using nano‐calcium carbonate (nano‐CaCO₃) were carried out. Nanocomposite samples were prepared in different content in range of 0.5–7 phr nano‐CaCO₃ using a twin screw extruder. X‐ray diffraction and scanning electron microscopy (SEM) were used to characterize of LDPE/nano‐CaCO3 nanocomposites. The foaming was carried out by a batch process in compression molding with azodicarbonamide (ADCA) as a chemical blowing agent. The cell structure of the foams was examined with SEM, density and gel content of different samples were measured to compare difference between nanocomposite microcellular foam and microcellular foam without nanomaterials. The results showed that the samples containing 5 phr nano‐CaCO₃ showed microcellular foam with the lowest mean cell diameter 27 μm and largest cell density 8 × 10⁸ cells/cm³ in compared other samples. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers     

Preparation and properties of foamed cellulose acetate/polylactic acid blends

In order to improve the foaming performance of pure cellulose acetate (CA), blends were prepared by mixing polylactic acid (PLA) in CA and foamed by supercritical CO₂ (ScCO₂) in this study. The effect of PLA content (percentage by mass of blend) on structure, thermal properties, rheological properties, foaming properties and mechanical properties of the blends was investigated. The results showed that the addition of PLA destroyed the original hydrogen bonds of CA, while the blends had good crystallization properties. At the same time, compared with pure CA, the glass transition temperature (T_g) of the blends decreased, and the initial decomposition temperature (T₀) was reduced from 349.41°C (pure CA) to 334.68°C (CA/20%PLA). In addition, the rheological properties of the blends were improved, and the viscosity was reduced, which was obviously beneficial to foaming process. The pore size and density of the foamed blends both reached the maximum value at 20%PLA. The presence of PLA could degrade the mechanical properties of the blends. However, the overall drop (1.01 KJ/m²) of impact strength of the blends after foaming is much smaller than that before foaming (12.11 KJ/m²), indicating that the improvement of foaming performance was beneficial to improve its impact strength.