Rheological and crystallisation behaviour of high melt strength polypropylene under gas-loading

Effect of Janus Nanosheets in Polypropylene on Rheological Properties and Autoclave Foam Performance

Our experiment revealed that the addition of Janus nanosheets to polypropylene (PP) has a significant impact on the viscoelasticity of the composite system. Specifically, when 0.10 wt% of Janus nanosheets were added, the complex viscosity of the composite system increased. However, when we added less than 0.05 wt% of Janus nanosheets, there was a reduction in complex viscosity, which is known as the non-Einstein phenomenon. The Cole-Cole plot showed that the nanosheet network structure did not have a significant effect on the viscosity of the composite system. Additionally, we used carbon dioxide as a foaming agent to autoclave foaming using modified PP from Janus nanosheets, and the results demonstrated that increasing the number of Janus nanosheets decreased the apparent density and strengthened the cell structure of foaming beads, resulting in improved closed porosity.

Influence of Carbon Dioxide on the Glass Transition of Styrenic and Vinyl Pyridine Polymers: Comparison of Calorimetric, Creep, and Rheological Experiments

The glass transition of amorphous polymers determines the mobility of polymer chains and the time scale of relaxation processes. The glass transition temperature is reduced by the presence of low molecular weight molecules, e.g., dissolved gases or organic solvents. The quantitative knowledge of reduction of the glass transition temperature caused by the addition of carbon dioxide in a polymer melt is highly relevant for foam extrusion. However, measurement of the reduction of glass transition temperature caused by gas loading has to be performed under elevated pressure which implies high experimental efforts. In this work, we discuss and compare three methods for determination of the influence of carbon dioxide on thermal properties of amorphous polymers, i.e., calorimetric measurements, creep tests, and rheological experiments. The advantages and disadvantages of these methods are elucidated. Furthermore, the influence of molecular structure of the styrenic and vinylpyridine polymers on the glass transition temperature is discussed. Polystyrene generally shows the highest reduction of glass transition temperature. Poly(2-vinylpyridine) and poly(4-vinylpyridine) show a slightly less pronounced behaviour in comparison to polystyrene because of the lower polarity of polystyrene. Poly(α-methyl styrene) is associated with a different dependence of glass transition temperature on gas loading in calorimetric and rheological experiments.

Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die

This paper aims at a better understanding of the polypropylene (PP) physical extrusion foaming process with the objective of obtaining the lowest possible foam density. Two branched PPs were compared to the corresponding linear ones. Their shear and elongation viscosities were measured as well as their crystalline properties. Trials were conducted in a single screw extruder equipped with a gear pump and a static mixer cooler to adjust the melt temperature at the final die. The effect of decreasing this temperature on the PP foamability and on the pressure drop in the die was analyzed. The foam density of branched PPs varies from high to low values while decreasing the foaming temperature. In the same processing conditions, the foam density of linear PPs does not decrease so much, as already evidenced in the literature. The foamability transition coincides with an increase of the pressure drop in the die. The originality of the work lies in the thermomechanical analysis of the polymer flow in the die which allows the identification of the relevant physical phenomena for a good foamability. The comparison of the experimental pressure drops in the die and the computed ones with the identified purely viscous behavior points out the influence of the foaming temperature and of the PP structure. At high foaming temperature the discrepancy between experimental measurements and the computed pressure drops remains limited. It increases when decreasing the foaming temperature, but the mismatch is much more important for branched PPs than for linear ones. This difference is analyzed as a combination of the activation energy of the viscosity, the elongational viscosity in the convergent geometry of the die which is much more important for branched PPs than for linear ones, and the onset of crystallization which occurs at higher temperature for branched PPs than for linear PPs.

Development of a Rheology Die and Flow Characterization of Gas-Containing Polymer Melts

We present a novel measurement die for characterizing the flow behavior of gas-containing polymer melts. The die is mounted directly on the injection-molding cylinder in place of the mold cavity and thus enables near-process measurement of viscosity (i.e., under the conditions that would be present were a mold attached). This integration also resolves the issue of keeping gas-containing polymer melts under pressure during measurement to prevent desorption. After thermal characterization of the die, various correction approaches were compared against each other to identify the most suitable one for our case. We conducted measurements using polypropylene in combination with two different chemical blowing agents. Increasing the blowing-agent content to up to 6% revealed an interestingly low influence of gases on melt viscosity, which was confirmed by elongational viscosity measurements. For verification, we compared our results to corresponding measurements taken on a high-pressure capillary rheometer and found that they were in excellent agreement. Our die cannot only be used for rheological characterization. Combined with ultrasound sensors, it provides an innovative way of measuring the volumetric flow rate. This development represents an important step in improving the sustainability of gas-containing polymer processing.

New Insights on Expandability of Pre-Cured Epoxy Using a Solid-State CO2-Foaming Technique

Foaming an epoxy is challenging because the process involves the curing reaction of epoxy and hardener (from monomer to oligomer, to a gel and a final three-dimensional crosslinked network) and the loading of gas phase into the epoxy phase to develop the cellular structure. The latter process needs to be carried out at the optimum curing stage of epoxy to avoid cell coalescence and to allow expansion. The environmental concern regarding the usage of chemical blowing agent also limits the development of epoxy foams. To surmount these challenges, this study proposes a solid-state CO₂ foaming of epoxy. Firstly, the resin mixture of diglycidylether of bisphenol-A (DGEBA) epoxy and polyamide hardener is pre-cured to achieve various solid-state sheets (preEs) of specific storage moduli. Secondly, these preEs undergo CO₂ absorption using an autoclave. Thirdly, CO₂ absorbed preEs are allowed to free-foam/expand in a conventional oven at various temperatures; lastly, the epoxy foams are post-cured. PreE has a distinctive behavior once being heated; the storage modulus is reduced and then increases due to further curing. Epoxy foams in a broad range of densities could be fabricated. PreE with a storage modulus of 4 × 10⁴–1.5 × 10⁵ Pa at 30 °C could be foamed to densities of 0.32–0.45 g/cm³. The cell morphologies were revealed to be star polygon shaped, spherical and irregularly shaped. The research proved that the solid-state CO₂-foaming technique can be used to fabricate epoxy foams with controlled density.

Synergetic effect of crystal nucleating agent and melt self-enhancement of isotactic polypropylene on its rheological and microcellular foaming properties

Crystal nucleating agent Bis (3, 4- dimethylbenzylidene) sorbitol (DMDBS) was used to tune the melt strength and microcellular foaming properties of isotactic polypropylene (iPP) in this study. Rheological testing results reveal that the introduction of DMDBS could enhance the storage modulus and complex viscosity of iPP, obviously increase its crystallization onset temperature, compared to its counterparts without DMDBS. The addition of DMDBS could also significantly increase the cell nucleating ability of iPP, due to its large surface, cooperating with a thermal history control treatment. Quite fine microcellular iPP/DMDBS foams were fabricated with relatively small average cell sizes of nano to several micrometers, and cell densities up to 1011∼1012 cells/cm3, using the synergy effect of DMDBS and iPP’s melt self-enhancement. Under a comparatively low re-saturation pressure of 8 to 12 MPa, ideal microcellular foams could be generated, at a temperature zone of 158 to 162°C, which is slightly below to iPP’s original pellets nominal melting point.

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.

Rheology in the Presence of Carbon Dioxide (CO2) to Study the Melt Behavior of Chemically Modified Polylactide (PLA)

For the preparation of polylactide (PLA)-based foams, it is commonly necessary to increase the melt strength of the polymer. Additives such as chain extenders (CE) or peroxides are often used to build up the molecular weight by branching or even crosslinking during reactive extrusion. Furthermore, a blowing agent with a low molecular weight, such as carbon dioxide (CO₂), is introduced in the foaming process, which might affect the reactivity during extrusion. Offline rheological tests can help to measure and better understand the kinetics of the reaction, especially the reaction between the polymer and the chemical modifier. However, rheological measurements are mostly done in an inert nitrogen atmosphere without an equivalent gas loading of the polymer melt, like during the corresponding reactive extrusion process. Therefore, the influence of the blowing agent itself is not considered within these standard rheological measurements. Thus, in this study, a rheometer equipped with a pressure cell is used to conduct rheological measurements of neat and chemical-modified polymers in the presence of CO₂ at pressures up to 40 bar. The specific effects of CO₂ at elevated pressure on the reactivity between the polymer and the chemical modifiers (an organic peroxide and as second choice, an epoxy-based CE) were investigated and compared. It could be shown in the rheological experiments that the reactivity of the chain extender is reduced in the presence of CO₂, while the peroxide is less affected. Finally, it was possible to detect the recrystallization temperature T_rc of the unmodified and unbranched sample by the torque maximum in the rheometer, representing the tear off of the stamp from the sample. T_rc was about 13 K lower in the CO₂-loaded sample. Furthermore, it was possible to detect the influences of branching and gas loading simultaneously. Here the influence of the branching on T_rc was much higher in comparison to a gas loading.

Comparison of the Foamability of Linear and Long-Chain Branched Polypropylene-The Legend of Strain-Hardening as a Requirement for Good Foamability

Polypropylene (PP) is an outstanding material for polymeric foams due to its favorable mechanical and chemical properties. However, its low melt strength and fast crystallization result in unfavorable foaming properties. Long-chain branching of PP is regarded as a game changer in foaming due to the introduction of strain hardening, which stabilizes the foam morphology. In this work, a thorough characterization with respect to rheology and crystallization characteristics of a linear PP, a PP/PE-block co-polymer, and a long-chain branched PP are conducted. Using these results, the processing window in foam-extrusion trials with CO₂ and finally the foam properties are explained. Although only LCB-PP exhibits strain hardening, it neither provide the broadest foaming window nor the best foam quality. Therefore, multiwave experiments were conducted to study the gelation due to crystallization and its influence on foaming. Here, linear PP exhibited a gel-like behavior over a broad time frame, whereas the other two froze quickly. Thus, apart from strain hardening, the crystallization behavior/crystallization kinetics is of utmost importance for foaming in terms of a broad processing window, low-density, and good morphology. Therefore, the question arises, whether strain hardening is really essential for low density foams with a good cellular morphology.

Influence of nucleating agent type on the morphology of extruded polyetherimide foam for printed circuit boards*

This work focuses on the development of foamed high temperature thermoplastic substrates for printed circuit boards. For this application it is necessary to achieve mean cell diameters smaller than 30 µm in order to be able to realize vias and high packaging densities (miniaturization). Different additives as nucleating agents, namely macro- and micro-crystalline talc, silica, calcium carbonate, and wollastonite, were melt-compounded with polyetherimide using a twin-screw extruder. Foamed samples are prepared by foam extrusion using a slit die and CO2 as physical blowing agent. The aim of this study is to analyze the influence of the mean particle size and the particle surface tension on the mean cell diameters. Therefore, the shape of the additives, the foam morphology, and the elongational viscosity were considered. The additives with a suitable particle size and surface tension exhibit a positive influence on the foam morphology, resulting in smaller cell diameters (<30 µm), a narrower cell size distribution and a foam density lower than 900 kg/m3. If the mean particle diameter of the nucleating agents is lower than 0.6 µm in this study, no nucleation effect could be observed. This is related to the fact that no heterogeneous nucleation occurs, if the particle diameter is too small. If the mean particle diameter of the used additives is larger than 1.5 µm, which could be demonstrated in this study in case of polyetherimide, then the additive acts as nucleating agent and heterogeneous nucleation occurs. Furthermore, it was observed that the mean cell diameter was affected by the different surface tensions of the studied nucleating agents.

Effects of chemical modifications on the rheological and the expansion behavior of polylactide (PLA) in foam extrusion

It is well known that polylactide (PLA) is difficult to foam due to its low melt strength. Thus, many ways were described in the literature to enhance the foamability. However, the melt strength was actually determined only in a limited number of publications. In this study, the addition of chemical modifiers was used to change the rheological behavior of PLA and thereby improve its foamability in foam extrusion process. For the first time the use of dicumyl peroxide modified PLA in foam extrusion is described. Both modifications lead to a distinct increase in melt strength. Here, the highest increase was shown for the PLA modified with dicumyl peroxide. Furthermore, strain hardening was observed for PLA modified with the peroxide. Low density foams were achieved for neat and modified PLA in foam extrusion. Neat PLA showed a density of 45 kg/m3, while the peroxide modified PLA showed the highest expansion with a density reduction down to 32 kg/m3. Both modifications result in a more uniform cell structure and an improved compression strength. Here, the foamed, peroxide modified PLA showed outstanding performance compared to neat PLA foam with twice the compression strength (151 Pa) even at a 30% lower density.

Bubble morphological evolution and surface defect formation mechanism in the microcellular foam injection molding process

A multiphase model was established to simulate the bubble morphological evolution in MFIM, and a new phenomenon of surface collapse and pits with the gradient depth was discovered.