Extrusion foaming behavior of a polypropylene/nanoclay microcellular foam

With maleic anhydride grafted polypropylene (PP‐g‐MAH) as a compatibilizer, composites of block‐copolymerized polypropylene (B‐PP)/nanoclay were prepared. The effects of the PP‐g‐MAH and nanoclay content on the crystallization and rheological properties of B‐PP were investigated. The microcellular foaming behavior of the B‐PP/nanoclay composite material was studied with a single‐screw extruder foaming system with supercritical (SC) carbon dioxide (CO₂) as the foaming agent. The experimental results show that the addition of nanoclay and PP‐g‐MAH decreased the melt strength and complex viscosity of B‐PP. When 3 wt % SC CO₂ was injected as the foaming agent for the extrusion foaming process, the introduction of nanoclay and PP‐g‐MAH significantly increased the expansion ratio of the obtained foamed samples as compared with that of the pure B‐PP matrix, lowered the die pressure, and increased the cell population density of the foamed samples to some extent. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44094.     

Tapioca starch‐poly(lactic acid)‐Cloisite 30B nanocomposite foams

Tapioca starch (TS), poly(lactic acid) (PLA), and Cloisite 30B nanocomposite foams, with four clay contents of 1, 3, 5, 7 wt%, were prepared by a melt‐intercalation method. Selected structural, thermal, physical, and mechanical properties were characterized using X‐ray diffraction, scanning electron microscopy, differential scanning calorimetry, thermogravimetry analyses, and an Instron universal testing machine, respectively. XRD results indicated that intercalation of TS/PLA into the nanoclay layers occurred in all four nanocomposite foams. At the same time, tactoid structures were observed in all nanocomposite foams but to a lesser extend with 1 and 3 wt% clay contents. Effect of clay content on melting temperature (T_m), onset degradation temperature, radial expansion ratio, unit density, bulk compressibility and bulk spring index of the nanocomposites were investigated. Among the four nanocomposites, 3 wt% clay content produced significantly different (p < 0.05) properties. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

CO2 foaming based on polystyrene/poly(methyl methacrylate) blend and nanoclay

A poly(methyl methacrylate) (PMMA) and nanoclay composite was dispersed into polystyrene (PS) using a twin‐screw extruder. The mixture was then batch foamed with supercritical CO₂. It was found that the cell density of foams based on the blend is higher than that based on the weight average of the two pure polymer components at the same foaming conditions. The cell size decreases and the cell density increases with the increase of the PMMA domain size. One explanation is that the large PMMA domains serve as a CO₂ reservoir and the nucleation in the PS phase is enhanced by the diffusion of CO₂ from the PMMA phase to the PS phase. Very small PMMA domains cannot function as a CO₂ reservoir, and so they are not able to facilitate the nucleation. A much higher cell density and smaller cell size were observed when nanoclay was located at the interface of the PMMA and the PS domains, serving as the heterogeneous nucleating agents. POLYM. ENG. SCI., 47:103–111, 2007. © 2007 Society of Plastics Engineers     

Blending and foaming thermoplastic starch with poly (lactic acid) by CO2-aided hot melt extrusion

Biomaterials are materials that can be biodegradable or obtained from renewable resources. Among them, poly (lactic acid) (PLA) and thermoplastic starch (TPS) represent an interesting alternative to replace petro-sourced thermoplastics. In this study, blends made by TPS addition to PLA were subjected to a foaming process using supercritical CO₂-aided extrusion. Extruder die temperature and CO₂ content were the most prominent parameters explaining the structure of the foams obtained. Both parameters were intimately linked since the CO₂ flow depends on the melt temperature, the lower the temperature, the higher the CO₂ solubility. Therefore, the die temperature was chosen to pilot the process. Whatever the experimental conditions, a 50/50 (in wt%) blend was poorly foamed due to the strong incompatibility between both biopolymers. However, the blend made of 80 wt% PLA and 20 wt% TPS gave evenly foamed samples. In terms of expansion and type of porosity this blend behaved like pure PLA with high porosity, up to 96%, and the presence of a threshold die temperature separating a close cell porosity at lowest temperatures and an open cell structure above the threshold. This temperature threshold was however significantly lower to that obtained with pure PLA.     

Batch foaming of SAN/clay nanocomposites with scCO2: A very tunable way of controlling the cellular morphology

This paper aims at elucidating some important parameters affecting the cellular morphology of poly(styrene-co-acrylonitrile) (SAN)/clay nanocomposite foams prepared with the supercritical CO₂ technology. Prior to foaming experiments, the SAN/CO₂ system has first been studied. The effect of nanoclay on CO₂ sorption/desorption rate into/from SAN is assessed with a gravimetric method. Ideal saturation conditions are then deduced in view of the foaming process. Nanocomposites foaming has first been performed with the one-step foaming process, also called depressurization foaming. Foams with different cellular morphology have been obtained depending on nanoclay dispersion level and foaming conditions. While foaming at low temperature (40 °C) leads to foams with the highest cell density (∼10¹²-10¹⁴ cells/cm³), the foam expansion is restricted (d∼0.7-0.8 g/cm³). This drawback has been overcome with the use of the two-step foaming process, also called solid-state foaming, where foam expansion occurs during sample dipping in a hot oil bath (d∼0.1-0.5 g/cm³). Different foaming parameters have been varied, and some schemes have been drawn to summarize the characteristics of the foams prepared - cell size, cell density, foam density - depending on both the foaming conditions and nanoclay addition. This result thus illustrates the huge flexibility of the supercritical CO₂ batch foaming process for tuning the foam cellular morphology.     

Preparation of fast‐degrading poly(lactic acid)/soy protein concentrate biocomposite foams via supercritical CO2 foaming

To increase the degradation rate of poly(lactic acid) (PLA), soy protein concentrate (SPC) was introduced via melt compounding using a self‐developed, co‐rotating, non‐twin‐screw extruder. Poly(2‐ethyl‐2‐oxazoline) (PEOX) and diphenyl methane diisocyanate (MDI) were added to plasticize the melt and improve the compatibility between PLA and SPC. The PLA/SPC blends were subsequently foamed using supercritical carbon dioxide (CO₂) as a blowing agent to produce porous composites. The involvement of SPC promoted cold crystallization of PLA but reduced the thermal stability of the blends. PLA showed a strong interfacial bonding with modified SPC, and the SPC formed continuous three‐dimensional networks when its proportion reached 30 wt%. In the foaming process, SPC domains acted as heterogeneous nucleation sites, which resulted in enhanced cell densities and reduced cell diameters. The PLA/SPC (70:30) sample showed the finest cell structure due to the presence of the SPC network. For the same blends, increasing the foaming pressure from 16 to 20 MPa enhanced the cell density by about 5 times. The water absorption rate and the biodegradation rate of the PLA/SPC foams were much higher than that of neat PLA due to the hydrophilicity of SPC and the porous structure of the foams. POLYM. ENG. SCI., 59:1753–1762, 2019. © 2019 Society of Plastics Engineers     

Transport properties of natural gas through polyethylene nanocomposites at high temperature and pressure

High density polyethylene (HDPE)/clay nanocomposites containing nanoclay concentrations of 1, 2.5, and 5 wt% were prepared by a melt blending process. The effects of various types of nanoclays and their concentrations on permeability, solubility, and diffusivity of natural gas in the nanocomposites were investigated. The results were compared with HDPE typically used in the production of liners for the petroleum industry. Four different nanoclays—Cloisite 10A, 15A, 30B and Nanomer 1.44P—were studied in the presence of CH₄ and a CO₂/CH₄ mixture in the temperature range 30–70 °C and pressure range 50–100 bar. The permeability and diffusivity of the gases were considerably reduced by the incorporation of nanoclay into the polymer matrix. Addition of 5 wt% loading of Nanomer 1.44P reduced the permeability by 46% and the diffusion coefficient by 43%. Increasing the pressure from 50 to 100 bar at constant temperature had little influence on the permeability, whereas increasing the temperature from 30 to 70 °C significantly increased the permeability of the gas. Additionally, the effect of crystallinity on permeability, solubility, and diffusivity was investigated. Thus, the permeability of the CO₂/CH₄ mixture in Nanomer 1.44P nanocomposite was reduced by 47% and diffusion coefficient by 35% at 5 wt% loading, 50 °C, and 100 bar, compared with pure HDPE.     

Unique isothermal crystallization phenomenon in the ternary blends of biopolymers polylactide and poly[(butylene succinate)-co-adipate] and nano-clay

Melt and cold isothermal crystallization studies were carried out on polylactide (PLA)/poly[butylene succinate)-co-adipate] (PBSA) neat blend and blend-clay composites. The neat blend and blend-clay composites were prepared by melt-blending in a batch mixer. The weight ratio of PLA to PBSA was fixed at 70:30, while the content of the organoclay was varied from 0 to 9 wt%. The spherulitic growth rates and morphologies of PLA and PBSA in the samples were examined through polarized optical microscopy, while the rate of crystallization and the extent of crystallinity were studied through differential scanning calorimetry. The kinetics of melt and cold crystallization of PLA were adequately described by the Avrami model. There was a strong dependence of the rate of crystallization and extent of crystallinity of PLA on the extent of clay loading and flow induced morphology. For composites with 2 and 6 wt% clay loading, uniquely slower crystallization occurred. A qualitative relationship between phase morphology and crystallization, as affected by clay loading, is therefore described.     

The use of nanoclay in preparation of epoxy anticorrosive coatings

Epoxy/clay nanocomposites (NC) have become a very interesting topic among researchers in the past two decades because nanoclays have a positive effect on the mechanical, thermal and especially barrier and anticorrosive performances of the polymers. In this study epoxy NCs and NC-based epoxy coatings were prepared by the solution intercalation method using Cloisite 30B as nanoclay. WAXD and SEM analyses revealed that a mainly exfoliated structure was obtained in epoxy NC with 1 wt% clay content, while higher clay loadings reduced the number of exfoliated clay nanolayers and produced a mainly intercalated structure. EIS, TGA and DMA analyses showed that epoxy NCs with clay content below 5 wt% exhibited increased corrosion stability, thermal stability, glass transition temperature (T_g) and storage modulus (G′), in both glassy and rubbery states due to the nanoscale dispersion of Cloisite 30B and the barrier effect of individual nanolayers. Enhanced mechanical properties were also noticed at higher clay loadings, but the rate of improvement was lower. The highest extent of exfoliation and the most homogeneous macromolecular network was found for NC with 1 wt% of clay, leading to the highest improvement of thermal and anticorrosive properties. The salt spray test results showed that anticorrosive properties of epoxy coatings in the presence of 3 wt% and especially 1 wt% of Cloisite 30B were significantly better, thus indicating that nanoclay efficiently modifies the commercial epoxy coatings.     

Supercritical CO2 dispersion of nano-clays and clay/polymer nanocomposites

Dispersed polymer/clay nanocomposites are of great interest because they can significantly improve the properties of existing polymeric materials. However, achieving a high level of clay dispersion has been a key challenge in the production of polymer/clay nanocomposites. In this paper, we explore a novel supercritical carbon dioxide (scCO₂) processing method that utilizes scCO₂ to disperse nano-clays. The structure and properties of the clays and the resultant nanocomposites are characterized using a combination of wide-angle X-ray diffraction (WAXD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and rheology. Significant dispersion was achieved with dry Cloisite 93A clay, whereas relatively poor dispersion was achieved with dry Cloisite Na⁺ (natural clay). The extent of clay dispersion appears to be dependent on the ‘CO₂-philicity’, which in turn appears to depend on the surface modifications and inter-gallery spacing. The presence of an acidic hydrogen on the surfactant in Cloisite 93A appears to play a strong role in its ‘CO₂-philicity’. The ability to delaminate dry clays is significant because it will likely increase the ability to produce dispersed clay/polymer nanocomposites via melt processing. In addition to delaminating dry clays, we demonstrate that CO₂-phobic Cloisite Na⁺ (natural clay) can be partially dispersed with scCO₂, using a CO₂-philic polymer, polydimethylsiloxane (PDMS). The dispersed clay/PDMS nanocomposite shows an order of magnitude increase in the dynamic storage modulus at low frequencies, accompanied by the emergence of a ‘solid-like’ plateau, characteristic of dispersed nanocomposites with enhanced clay/polymer interactions.     

Extruded starch–nanoclay nanocomposites: Effects of glycerol and nanoclay concentration

Wheat starch‐Cloisite Na+ nanoclay composites containing different glycerol and nanoclay concentrations were extruded using a twin‐screw extruder. X‐ray diffraction and transmission electron microscopy were used to determine the extent of nanoclay dispersion and thermogravimetric analysis was used to characterize thermal stability of composites. Also, water absorbance was measured for each sample. The extent of nanoclay dispersion in samples containing 47 wt% total plasticizer concentration depended on glycerol concentration. For these samples, adding 5 wt% glycerol produced mostly exfoliated nanoclay, whereas adding 10 or 15 wt% glycerol produced intercalated nanoclay. Also, nanoclay composites exhibited improved thermal stability and reduced water uptake compared to samples with no nanoclay. However, thermal stability and water absorbance were not affected by the extent of nanoclay dispersion. POLYM. ENG. SCI., 47:1898–1904, 2007. © 2007 Society of Plastics Engineers     

Extrusion with Carbon Dioxide (CO2) and Characterization of ABS/Mg (OH)2/Nanoclay Composites

In this paper, carbon dioxide (CO₂) is used to form a high-density microcellular thermoplastic foam structure in order to reduce polymer consumption and facilitate dispersion of Mg (OH)₂ and nanoclay fillers. A twin-screw extruder system was used to predistribute inorganic fillers into the ABS polymer, resulting in composite ABS/filler pellets. This is followed by the use of a single-screw extruder wherein supercritical carbon dioxide is introduced into the formulation. Finally, the resulting foam ABS/filler/CO₂ pellets are injection- molded into test samples. The structure and properties of the composites are characterized using scanning electron microscopy (SEM) and differential scanning calorimetry (DSC). Furthermore, ABS/Mg(OH)₂/nanoclay polymer composite samples are tested to obtain their yield and tensile strengths, elastic moduli, yield and tensile elongations, izod impact strengths, hardness values, heat deflection temperatures (HDT), Vicat softening points, and melt flow indices (MFI). These tests reveal that for the overall reduction in the amount of polymer in the samples, material properties did not generally deteriorate and even showed improvements in some areas. Moreover, resulting injection-molded samples have been shown to possess dimensional integrity due to the continued expansion of CO₂ during the molding operation.     

Study on the effect of dispersion phase morphology on porous structure of poly (lactic acid)/poly (ethylene terephthalate glycol-modified) blending foams

A methodology for blending foam of poly (lactic acid) (PLA)/poly (ethylene terephthalate glycol-modified) (PETG) was proposed. PLA/PETG blends were prepared through a melt blending method, using multiple functionality epoxide as reactive compatibilizer. The effects of blending ratio and compatibilizer content on the dispersion morphology, molecular structure, mechanical properties, and rheological behavior of PLA/PETG blends were studied. Then PLA/PETG blends were foamed using supercritical CO₂ as physical blowing agent, and their porous structure, pore size, as well as pore density were investigated. The results showed that the mechanical properties and rheological parameters such as melt strength and melt elasticity, as well as the porous structure of the foams dispersion morphology of PLA/PETG blends were affected strongly. The melt elasticity of PLA/PETG blends increased with increasing compatibilizer content. Dispersion phase morphology of PLA/PETG blends also had a significant effect on the pore density of all the samples. The results indicated that homogeneous and finer porous morphology of PLA/PETG foams with high expansion ratio could be achieved with a proper content of compatibilizer in the blends.     

Study on properties of nanocomposites based on HDPE,LDPE, PP,PVC, wood and clay

Wood polymer nanocomposite (WPC) was prepared by solution blending of high density polyethylene, low density polyethylene, polypropylene and polyvinyl chloride (1:1:1:0.5) with wood flour and nanoclay. Xylene and tetrahydrofuran were used as solvent and the ratio was optimized at 70:30. TEM study revealed better dispersion of silicate layers in WPC loaded with 3 wt% of clay. WPC loaded with 3 wt% nanoclay exhibited higher thermal stability compared to WPC loaded with 1 and 5 wt% clay. The storage and loss modulus were found to enhance on incorporation of clay to WPC. The damping peak was found to be lowered by the addition of clay to WPC. Limiting oxygen index value increased due to incorporation of nanoclay. WPCs were subjected to exposure to cellulase producing Bacillus sp. and it showed the growth of bacteria as revealed by SEM study. Mechanical properties of WPC decreased due to degradation by bacteria. Water vapour uptake of WPC decreased due to addition of nanoclay.     

Extrusion of PE/PS blends with supercritical carbon dioxide

The effects of dissolved supercritical carbon dioxide on the viscosity and morphological properties were investigated for polyethylene/polystyrene blends in a twin-screw extruder. The viscosities of the blend/CO₂ solutions were measured using a wedge die mounted on the extruder. A considerable reduction of viscosity was found when CO₂ was dissolved in the blend. It was observed that the dissolution of CO₂ into PE/PS blends, regardless of the CO₂ content used, led to decreased shear thinning behavior resulting in an increase of the power law index from 0.29 to 0.34. The cell structures of foamed PE/PS blends showed a typical dependence of pressure and CO₂ concentration, with higher operating pressures and CO₂ content leading to a smaller cell size. Also, it was noted that the size of the dispersed PS phase in the PE/PS phase blends decreased by increasing the CO₂ concentration, and that the dispersed PS phase domains were highly elongated in the direction normal to the cell radius.     

Supercritical CO2 and polycarbonate based nanocomposites: A critical issue for foaming

Supercritical carbon dioxide readily induced foaming of various polymers. In that context, supercritical CO₂ was applied to carbon nanotubes based polycarbonate nanocomposites to ensure their foaming. Surprisingly, efficient foaming only occurs when low pressure is applied while at high pressure, no expansion of the samples was observed. This is related to the ability of supercritical carbon dioxide to induce crystallization of amorphous polycarbonate. Moreover, this behaviour is amplified by the presence of carbon nanotubes that act as nucleating agents for crystals birth. The thermal behaviour of the composites was analysed by DSC and DMA and was related to the foaming observations. The uniformity of the cellular structure was analysed by scanning electron microscopy (SEM). By saturating the polycarbonate nanocomposites reinforced with 1 wt% of MWNTs at 100 bar and 100 °C during 16 h, microcellular foams were generated, with a density of 0.62, a cell size ranging from 0.6 to 4 μm, and a cellular density of 4.1 × 10¹¹ cells cm⁻³. The high ability of these polymeric foams to absorb electromagnetic radiation was demonstrated at low MWNT content as the result of the high affinity of the polycarbonate matrix for MWNTs, and therefore to the good MWNTs dispersion.     

Effects of Process Variables on Microcellular Structure and Crystallization of Polypropylene Foams with Supercritical CO2 as the Foaming Agent—A Study of Microcellular Foaming of Polypropylene

The effects of process variables on the microcellular structure and crystallization of foamed polypropylene (PP) with supercritical CO₂ as the foaming agent were investigated in this article. The cell size increased and the cell density reduced with increased foaming temperature. Differently, both the cell diameter and cell density increased as saturation pressure increased. DSC curves showed that the melting peak was broadened when supercritical CO₂ foaming PP. Furthermore, the width at half-height of the melting peak increased, the melting peak moved to higher temperature, and the melting point and crystallinity enhanced as the foaming temperature lowered and the saturation pressure enhanced.     

Technical optimization of the extraction of andrographolide by supercritical CO2

An experimental design has been built in order to study the influence of different parameters on the crystallization ratio and purity of andrographolide extraction using supercritical CO₂: pressure (8–24 MPa), temperature (40–70 °C) and extraction duration (45–105 min). Crystallization ratios are between 14.32 and 72.29 wt%, and purities are between 43.11 and 79.78 wt%, indicating that the experimental design covers a large range of results. The results indicate that pressure and extraction duration are the most influencing parameters.     

Foam processing and cellular structure of polypropylene/clay nanocomposites

Polypropylene (PP)/clay nanocomposites (PPCNs) were autoclave‐foamed in a batch process. Foaming was performed using supercritical CO₂ at 10 MPa, within the temperature range from 130.6°C to 143.4°C, i.e., below the melting temperature of either PPCNs or maleic anhydride‐modified PP (PP‐MA) matrix without clay. The foamed PP‐MA and PPCN2 (prepared at 130.6°C and containing 2 wt% clay) show closed cell structures with pentagonal and/or hexagonal faces, while foams of PPCN4 and PPCN7.5 (prepared at 143.4°C, 4 and 7.5 wt% clay) had spherical cells. Scanning electron microscopy confirmed that foamed PPCNs had high cell density of 10⁷–10⁸ cells/mL, cell sizes in the range of 30–120 μm, cell wall thicknesses of 5–15 μm, and low densities of 0.05–0.3 g/mL. Interestingly, transmission electron microscopic observations of the PPCNs' cell structure showed biaxial flow‐induced alignment of clay particles along the cell boundary. In this paper, the correlation between foam structure and rheological properties of the PPCNs is also discussed.     

Characterization of latex-based isotactic polypropylene/clay nanocomposites

Polypropylene/clay nanocomposite (PCN) containing 1 wt% organo-modified clay was prepared by latex technology, previously successfully applied for preparation of carbon nanotubes (CNTs)/polymer composites. The level of dispersion of organoclay and the microstructure of the resulting PCNs were characterized by means of X-ray diffraction analysis, transmission electron microscopy (TEM), and scanning electron microscopy (SEM). The obtained results have demonstrated that the latex technique represents a promising method for preparation of PP/clay nanocomposites with good dispersion of exfoliated nanoclay particles. The influence of clay nanoparticles on nonisothermal crystallization of PCN was investigated by DSC. The crystallization onset temperature of the matrix rises for about 5 °C when crystallizing from the quiescent melt. Improved thermal stability of PP/nanoclay was observed as evaluated by TGA. The dynamic mechanical analysis reveals an increase in storage modulus of PP matrix in the nanocomposites for 30% over a temperature range, indicating an increase in the stiffness of the material with the addition of organically modified clay.