A facile methodology to effectively improve the melt strength and microcellular foamability of isotactic polypropylene

Enhancing the Sound and Thermal Insulation Properties of Polypropylene Foam by Preparing High Melt Strength Polypropylene

High-performance polypropylene (PP) foam is a vital polymer product in industrial areas. However, the poor melt strength of ordinary PP homopolymer limits its foaming molding. In this work, high melt strength polypropylene (HMSPP) is prepared by using styrene (St) and tripropylene glycol diacrylate (TPGDA) as comonomers, and then PP foams are prepared by mold foaming method. The results show that adding St in the grafting process of TPGDA will obviously improve the melt strength of the PP matrix, and its melt strength (28 184 Pa.s) is 7.4 times higher than that of pure PP. HMSPP foam has more regular and uniform cells and higher cell density, which significantly improves the sound and thermal insulation properties of PP foam. Compared with pure PP foam, the average sound transmission loss (52.9 dB) of HMSPP foam with a low foaming ratio increased by 64%, and the thermal conductivity (0.0867 W mK-1 ) decreased by 46%. Therefore, the obtained HMSPP foam can be used in sound insulation or thermal insulation area. This work provides an available route for the high-performance utilization of PP foam.

Tuning High and Low Temperature Foaming Behavior of Linear and Long-Chain Branched Polypropylene via Partial and Complete Melting

While existing foam studies have identified processing parameters, such as high-pressure drop rate, and engineering measures, such as high melt strength, as key factors for improving foamability, there is a conspicuous absence of studies that directly relate foamability to material properties obtained from fundamental characterization. To bridge this gap, this work presents batch foaming studies on one linear and two long-chain branched polypropylene (PP) resins to investigate how foamability is affected by partial melting (Method 1) and complete melting followed by undercooling (Method 2). At temperatures above the melting point, similar expansion was obtained using both foaming procedures within each resin, while the PP with the highest strain hardening ratio (13) exhibited the highest expansion ratio (45 ± 3). At low temperatures, the foamability of all resins was dramatically improved using Method 2 compared to Method 1, due to access to lower foaming temperatures (<150 °C) near the crystallization onset. Furthermore, Method 2 resulted in a more uniform cellular structure over a wider temperature range (120–170 °C compared to 155–175 °C). Overall, strong extensional hardening and low onset of crystallization were shown to give rise to foamability at high and low temperatures, respectively, suggesting that both characteristics can be appropriately used to tune the foamability of PP in industrial foaming applications.

A Study of Physico-Mechanical Properties of Hollow Glass Bubble, Jute Fibre and Rubber Powder Reinforced Polypropylene Compounds with and without MuCell® Technology for Lightweight Applications

Lightweighting is one of the key solutions to reduce the carbon footprint of vehicles. Nowadays, it is still challenging to achieve this target because there is a conflict between the cost and final material performance, as well as the fact that many lightweight solutions are restricted to laboratory or small-scale production. In this work, a commercially feasible strategy was adopted to fabricate materials for lightweight applications. Hollow glass bubbles, jute fibres, and rubber powder were used as fillers with polypropylene as the base polymer. Various samples were fabricated using conventional and MuCell^® injection moulding. Their performance was then characterised by their density and morphological, mechanical, and rheological properties. A comparison among hybrid fillers/polypropylene compounds with and without MuCell^® technology was investigated. The filler hybridisation resulted in not only a density reduction of up to approximately 10%, but also improved tensile/flexural modulus and strength. The use of MuCell^® led to a further reduction in density of roughly 10%. Meanwhile, although some compounds fabricated by MuCell^® exhibited some deterioration in their tensile yield strength, tensile modulus, and impact strength, they maintained acceptable mechanical properties for automotive applications.