Preparation of nanocellular foams from polycarbonate/poly(lactic acid) blend by using supercritical carbon dioxide

Forefront Research of Foaming Strategies on Biodegradable Polymers and Their Composites by Thermal or Melt-Based Processing Technologies: Advances and Perspectives

The last few decades have witnessed significant advances in the development of polymeric-based foam materials. These materials find several practical applications in our daily lives due to their characteristic properties such as low density, thermal insulation, and porosity, which are important in packaging, in building construction, and in biomedical applications, respectively. The first foams with practical applications used polymeric materials of petrochemical origin. However, due to growing environmental concerns, considerable efforts have been made to replace some of these materials with biodegradable polymers. Foam processing has evolved greatly in recent years due to improvements in existing techniques, such as the use of supercritical fluids in extrusion foaming and foam injection moulding, as well as the advent or adaptation of existing techniques to produce foams, as in the case of the combination between additive manufacturing and foam technology. The use of supercritical CO2 is especially advantageous in the production of porous structures for biomedical applications, as CO2 is chemically inert and non-toxic; in addition, it allows for an easy tailoring of the pore structure through processing conditions. Biodegradable polymeric materials, despite their enormous advantages over petroleum-based materials, present some difficulties regarding their potential use in foaming, such as poor melt strength, slow crystallization rate, poor processability, low service temperature, low toughness, and high brittleness, which limits their field of application. Several strategies were developed to improve the melt strength, including the change in monomer composition and the use of chemical modifiers and chain extenders to extend the chain length or create a branched molecular structure, to increase the molecular weight and the viscosity of the polymer. The use of additives or fillers is also commonly used, as fillers can improve crystallization kinetics by acting as crystal-nucleating agents. Alternatively, biodegradable polymers can be blended with other biodegradable polymers to combine certain properties and to counteract certain limitations. This work therefore aims to provide the latest advances regarding the foaming of biodegradable polymers. It covers the main foaming techniques and their advances and reviews the uses of biodegradable polymers in foaming, focusing on the chemical changes of polymers that improve their foaming ability. Finally, the challenges as well as the main opportunities presented reinforce the market potential of the biodegradable polymer foam materials.

Expanded Polycarbonate (EPC)-A New Generation of High-Temperature Engineering Bead Foams

Bead foams serve in a wide variety of applications, from insulation and packaging to midsoles in shoes. However, the currently used materials are limited to somewhat low temperature or exhibit significant changes in modulus in the temperature range of many applications due to their glass transition. By comparison, polycarbonate (PC) exhibits almost constant mechanics for temperatures up to 130 °C. Therefore, it appears as an advantageous base material for bead foams. The aim of the publication is to provide comprehensive data on the properties of expanded PC (EPC) in comparison to already commercially available expanded polypropylene, EPP, and expanded polyethylene-terephthalate, EPET. A special focus is set on the thermo-mechanical properties as these are the most lacking features in current materials. In this frame, dynamic mechanical analysis, and tensile, bending, compression and impact tests at room temperature (RT), 80 °C, and 110 °C are conducted for the three materials of the same density. Already at RT, EPC exhibits superior mechanics compared to its peers, which becomes more pronounced toward higher temperature. This comes from the low sensitivity of properties to temperature as EPC is used below its glass transition. In summary, EPC proves to be an outstanding foam material over a broad range of temperatures for structural applications.

Poly (lactic acid) blends: Processing, properties and applications

Poly (lactic acid) or polylactide (PLA) is a commercial biobased, biodegradable, biocompatible, compostable and non-toxic polymer that has competitive material and processing costs and desirable mechanical properties. Thereby, it can be considered favorably for biomedical applications and as the most promising substitute for petroleum-based polymers in a wide range of commodity and engineering applications. However, PLA has some significant shortcomings such as low melt strength, slow crystallization rate, poor processability, high brittleness, low toughness, and low service temperature, which limit its applications. To overcome these limitations, blending PLA with other polymers is an inexpensive approach that could also tailor the final properties of PLA-based products. During the last two decades, researchers investigated the synthesis, processing, properties, and development of various PLA-based blend systems including miscible blends of poly l-lactide (PLLA) and poly d-lactide (PDLA), which generate stereocomplex crystals, binary immiscible/miscible blends of PLA with other thermoplastics, multifunctional ternary blends using a third polymer or fillers such as nanoparticles, as well as PLA-based blend foam systems. This article reviews all these investigations and compares the syntheses/processing-morphology-properties interrelationships in PLA-based blends developed so far for various applications.

Morphology and Mechanical Properties of Itaconic Anhydride Grafted Poly(lactic acid) and Thermoplastic Protein Blends

Blends between Novatein thermoplastic protein and polylactic acid (PLA) have been prepared by reactive extrusion using itaconic anhydride grafted PLA. At equal proportions of Novatein and PLA, the absence of a compatibilizer formed a dispersed phase morphology of Novatein in PLA and the incorporation of compatibilizer formed a co-continuous morphology. Incorporating PLA in Novatein can improve the tensile strength of Novatein by 42% and the impact strength by 36% at an equal proportion blend (50/50) in the presence of a compatibilizer. Thermal analysis revealed that 50/50 was the phase inversion point, above and below this composition the material behaved similarly. The effect of compatibilizer was evident in wide-angle X-ray scattering. In the absence of compatibilizer three phases were detected: crystalline Novatein, amorphous Novatein, and amorphous PLA phases. With compatibilizer, the blend was moving towards two phases: crystalline Novatein, and an amorphous blend of Novatein and PLA. Itaconic anhydride grafted PLA improved miscibility between Novatein and PLA, and its use can potentially lead to the production of Novatein/PLA foams.

Multiple actions of poly(ethylene octene) grafted with glycidyl methacrylate on the performance of poly(lactic acid)

Poly(ethylene octene) grafted with glycidyl methacrylate (POE-g-GMA) was employed to improve the rheological and thermal properties, toughness, and foaming behaviors of poly(lactic acid) (PLA) through a chain extension effect.

A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide

Silicone rubber foams were successfully generated by environmentally friendly blowing agent, supercritical carbon dioxide (scCO2), in this research. Firstly, the effect of the saturation time on the cellular structure was investigated. The diffusion of scCO2 into the rubber matrix would be enhanced thus decreasing the viscosity as increasing the saturation time. It would further promote the cell growth, which has a close connection with the cellular structure. After that, the effect of pre-curing time on cellular morphology of silicone rubber foams was further researched in detail. When increasing pre-curing time in the short time range, cell nucleation would be affected more than cell growth in the foaming process. If continuously increasing pre-curing time, both cell nucleation and growth would be restricted thus resulting in the formation of silicone rubber foams with small cell density and small cell size. This investigation not only provided a green way to produce silicone rubber foams, but also guided us to control cellular morphology via the saturation time and pre-curing time.

Current Issues and Challenges in Polypropylene Foaming: A Review

Thermoplastic foams have several advantages in comparison with unfoamed polymers such as lightweight, high strength to weight ratio, excellent insulation property, high thermal stability, high impact strength and toughness, as well as high fatigue life. These outstanding properties lead cellular plastics to various industrial applications in packaging, automotive parts, absorbents, and sporting equipment. Nowadays, polypropylene (PP), because of its outstanding characteristics such as low material cost, high service temperature, high melting point, high tensile modulus, low density, and excellent chemical resistance, is a major resin in the foaming industry. However, foaming of conventional PP is limited by its low melt strength leading to poor cell morphology, cell rupture/coalescence and limited density reduction. To improve PP melt strength, several strategies including particle addition as nucleating agent, introduction of long chain branching, blending with high melt strength polymers and crosslinking have been proposed. In this review, these issues are discussed and analyzed in terms of mechanical, thermal, and rheological characterizations.

The effects of viscoelastic properties on the cellular morphology of silicone rubber foams generated by supercritical carbon dioxide

Silica content, saturation temperature and pressure all have an effect on silicone rubbers' viscoelastic properties, which further has a close connection with the cellular structure.

Effects of enhanced compatibility by transesterification on the cell morphology of poly(lactic acid)/ polycarbonate blends using supercritical carbon dioxide

Poly(lactic acid)/polycarbonate blends were prepared by melt mixing. The transesterification reaction between poly(lactic acid) and polycarbonate was promoted by using tetrabutyl titanate as a catalyst. For poly(lactic acid)/polycarbonate (weight ratio of 75/25) blend with catalyst content up to 0.5 wt%, polycarbonate particles finely dispersed in the poly(lactic acid) matrix and the adhesion between the phases were improved, due to the enhanced compatibility by transesterification reaction. The blends were foamed by using batch-foaming process with CO2 as the blowing agent. Cell density of poly(lactic acid)/polycarbonate blend increased at low-catalyst content, while decreased at high-catalyst content, which was due to the changes of interfacial properties of blend phases through transesterification reaction and crystallinity of polycarbonate component. Cell types of poly(lactic acid)/polycarbonate blends were transferred from submicro-sized and even nanoscale cells to microscale cells by the deceased crystallinity of poly(lactic acid) component, which was caused by the increased degree of transesterification reaction and temperature. The declined viscosity of poly(lactic acid)/polycarbonate blend because of degradation during blend processing led to large cell size and low-cell density. However, the improvement of elasticity and viscosity of poly(lactic acid)/polycarbonate blend by transesterification reaction could decrease the cell size.