The effect of nanoclay on the crystallization behavior, microcellular structure, and mechanical properties of thermoplastic polyurethane nanocomposite foams

Structure-Property Correlation in Natural Rubber Nanocomposite Foams: A Comparison between Nanoclay and Cellulose Nanofiber Used as Nanofillers

Nanocomposite foams of natural rubber (NR) with 5 phr of two kinds of nanofillers, nanoclay (NC) and cellulose nanofiber (CNF), were produced using the latex mixing method and foaming with azodicarbonamide. The effect of the nanofiller on the structure and mechanical properties of NR foams was investigated through SEM, TEM, tensile tests, WAXD, and compression set measurements. Smaller cells with a narrower distribution were attained in the NC/NR foam when compared to the NR and CNF/NR foams, and the expansion ratio was larger due to the suppression of the shrinkage in the NC/NR foam. The foaming of the NR nanocomposites reduced the size of the filler aggregates and improved the dispersion and alignment of nanofillers in the cell walls. The addition of NC and CNF enhanced the tensile strength of the NR foam by 139% and 62%, respectively, without sacrificing the excellent strain of the NR, due to the acceleration of the strain-induced crystallization and small size of the filler aggregates. The compression set of the NR foam could also be reduced in the NC/NR foam compared with the NR and CNF/NR foams.

Using Gas Counter Pressure and Combined Technologies for Microcellular Injection Molding of Thermoplastic Polyurethane to Achieve High Foaming Qualities and Weight Reduction

Microcellular injection molding technology (MuCell®) using supercritical fluid (SCF) as a foaming agent offers many advantages, such as material and energy savings, low cycle time, cost-effectiveness, and the dimensional stability of products. MuCell® has attracted great attention for applications in the automotive, packaging, sporting goods, and electrical parts industries. In view of the environmental issues, the shoe industry, particularly for midsole parts, is also seriously considering using physical foaming to replace the chemical foaming process. MuCell® is thus becoming one potential processing candidate. Thermoplastic polyurethane (TPU) is a common material for molding the outsole of shoes because of its outstanding properties such as hardness, abrasion resistance, and elasticity. Although many shoe manufacturers have tried applying Mucell® processes to TPU midsoles, the main problem remaining to be overcome is the non-uniformity of the foaming cell size in the molded midsole. In this study, the MuCell® process combined with gas counter pressure (GCP) technology and dynamic mold temperature control (DMTC) were carried out for TPU molding. The influence of various molding parameters including SCF dosage, injection speed, mold temperature, gas counter pressure, and gas holding time on the foaming cell size and the associated size distribution under a target weight reduction of 60% were investigated in detail. Compared with the conventional MuCell® process, the implementation of GCP technology or DMTC led to significant improvement in foaming cell size reduction and size uniformity. Further improvement could be achieved by the simultaneous combination of GCP with DMT, and the resulting cell density was about fifty times higher. The successful possibility for the microcellular injection molding of TPU shoe midsoles is greatly enhanced.

Tunable Biodegradable Polylactide-Silk Fibroin Scaffolds Fabricated by a Solvent-Free Pressure-Controllable Foaming Technology

Polylactide (PLA) and silk fibroin (SF) are biocompatible green macromolecular materials with tunable structures and properties. In this study, microporous PLA/SF composites were fabricated under different pressures by a green solid solvent-free foaming technology. Scanning electron microscopy (SEM), dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), X-ray diffraction (XRD), thermogravimetric (TG) analysis, and Fourier transform infrared (FTIR) spectroscopy were used to analyze the morphology, structure, and mechanical properties of the PLA/SF scaffolds. The crystalline, mobile amorphous phases and rigid amorphous phases in PLA/SF composites were calculated to further understand their structure-property relations. It was found that an increase in pore density and a decrease in pore size can be achieved by increasing the saturation pressure during the foaming process. In addition, changes in the microcellular structure provided PLA/SF scaffolds with better thermal stability, tunable biodegradation rates, and mechanical properties. FTIR and XRD analysis indicated strong hydrogen bonds were formed between PLA and SF molecules, which can be tuned by changing the foaming pressure. The composite scaffolds have good cell compatibility and are conducive to cell adhesion and growth, suggesting that PLA/SF microporous scaffolds could be used as three-dimensional (3-D) biomaterials with a wide range of applications.

Synergistic Effect of Cellulose Nanofiber and Nanoclay as Distributed Phase in a Polypropylene Based Nanocomposite System

Since the plastic-based multilayer films applied to food packaging are not recyclable, it is necessary to develop easily recyclable single materials. Herein, polypropylene (PP)-based cellulose nanofiber (CNF)/nanoclay nanocomposites were prepared by melt-mixing using a fixed CNF content of 1 wt %, while the nanoclay content varied from 1 to 5 wt %. The optimum nanoclay content in the PP matrix was found to be 3 wt % (PCN3), while they exhibited synergistic effects as a nucleating agent. PCN3 exhibited the best mechanical properties, and the tensile and flexural moduli were improved by 51% and 26%, respectively, compared to PP. In addition, the oxygen permeability was reduced by 28%, while maintaining the excellent water vapor permeability of PP. The improvement in the mechanical and barrier properties of PP through the production of PP/CNF/nanoclay hybrid nanocomposites suggested their possible application in the field of food packaging.

Reflectance According to Cell Size, Foaming Ratio and Refractive Index of Microcellular Foamed Amorphous Polymer

Microcellular foamed plastic has a cell size of approximately 0.1 to 10 microns inside a foamed polymer and a cell density in the range of 10⁹ to 10¹⁵ cells/cm³. Typically, the formation of numerous uniform cells inside a polymer can be effectively used for various purposes, such as lightweight materials, insulation and sound absorbing materials. However, it has recently been reported that these dense cell structures, which are induced through microcellular foaming, can affect the light passing through the medium, which affects the haze and permeability and causes the diffused reflection of light to achieve high diffuse reflectivity. In this study, the effects of cell size, foaming ratio and refractive index on the optical performance were investigated by applying the microcellular foaming process to three types of amorphous polymer materials. Thus, this study experimentally confirmed that the advantages of porous materials can be implemented as optical properties by providing a high specific surface area as a small and uniform cell formed by inducing a high foaming ratio through a microcellular foaming process.

Fabrication and Properties of Superhydrophobic Waterborne Polyurethane Composites with Micro-Rough Surface Structure Using Electrostatic Spraying

Waterborne polyurethane (WPU) coatings hold advantages of good toughness, low cost and environmental protection. However, the low water contact angle (WCA), poor wear and corrosion resistance make them unsuitable for application in the superhydrophobic coatings such as antipollution flashover coatings for transmission lines, self-cleaning coatings for outdoor equipment and waterproof textiles. A series of superhydrophobic WPU composites (SHWPUCs) with micro-rough surface structure was prepared by electrostatic spraying nano-SiO2 particles on WPU composites with low surface energy. It showed that as the hydrophobic system content rose the WCAs of the composites first increased and then remained stationary; however, the adhesion and corrosion resistance first increased and then decreased. An appropriate addition of the hydrophobic system content would lead to a dense coating structure, but an excessive addition could increase the interfaces in the coating and then reduce the coating performance. When the mass ratio of the WPU dispersion, polytetrafluoroethylene (PTFE) particles and modified polydimethylsiloxane was 8:0.3:0.4, 10 g/m2 nano-SiO2 particles were sprayed on the uncured coating surface to construct the SHWPUC with a WCA of 156°. Compared with pure WPU coating, its adhesion and corrosion resistance increased by 12.5% and one order of magnitude, respectively; its wear rate decreased by 88.8%.

Effects of dynamic mold temperature control on melt pressure, cellular structure, and mechanical properties of microcellular injection-molded parts: An experimental study

In this work, the effects of dynamic mold temperature control (DMTC) on melt pressure, cellular structure, and mechanical properties of microcellular injection molding (MIM)-molded parts are investigated experimentally. It is found that with the increase of the mold temperature, the duration of foaming pressure in the cooling stage increases. Meanwhile, the average cell diameter and cell diameter dispersion increases as well as the cell density decreases in MIM molded parts. The turning point of mold temperature after which the foaming pressure in the cooling stage and the cellular structure in MIM molded parts generate a significant change is around the glass transition temperature of the used plastic material. Under DMTC conditions, with the increase of mold temperature, the tensile strength, flexural strength, and impact strength of MIM molded specimens of single gate without weld line change a little, while the tensile strength, flexural strength of MIM molded specimens of double gates with weld line increase obviously. When the mold temperature increases to 120°C and over, the tensile strength, flexural strength of MIM molded specimens of double gates with weld line reach an equivalent level of specimens of single gate without weld line.

Influence of cell type and skin-core structure on the tensile elasticity of the microcellular thermoplastic polyurethane foam

In this work, the foaming process was employed to achieve lightweight thermoplastic polyurethane materials, and then the hysteresis and residual strain of corresponding materials in the tensile process were quantitatively calculated. In order to study the deformed mechanism, the influences of cell type and skin-core structure on the tensile elasticity of thermoplastic polyurethane foam were investigated. The open-cell thermoplastic polyurethane foam exhibited much lower hysteresis and residual strain compared to thermoplastic polyurethane film without cell structure, which demonstrated that the open-cell structure benefited to the tensile elasticity. In the case of closed-cell thermoplastic polyurethane foam, it had lower hysteresis and residual strain than thermoplastic polyurethane film; however, higher value than the thermoplastic polyurethane film can be observed beyond 100% strain, resulting from the stress concentration in the skin-core structure. Consequently, the hysteresis phenomenon can be improved by adjusting the ratio of skin-core structure. Moreover, the influence of density on the elasticity of the open-cell thermoplastic polyurethane foam was also discussed in this study.