Super toughened blends of poly(lactic acid) and poly(butylene adipate-co-terephthalate) injection-molded foams via enhancing interfacial compatibility and cellular structure

Biodegradable poly(lactic acid) (PLA) foams have drawn increasing attention due to environmental challenges and petroleum crisis. However, it still remains a challenge to prepare PLA foams with fine cellular structures and high impact property, which significantly hinders its widespread application. Herein, phase interface-enhanced PLA/ poly(butylene adipate-co-terephthalate) (PBAT) blend foam, modified by a reactive compatibilizer through a simple reactive extrusion, was produced via a core-back foam injection molding technique. The obtained PLA blend foams displayed an impact strength as high as 49.1 kJ/m², which was 9.3 and 6.4 times that of the unmodified PLA/PBAT blend and its corresponding foam, respectively. It proved that the interfacial adhesion and cell size both strongly affected the impact strength of injection-molded PLA/PBAT foams, and two major conclusions were proposed. First, enhancing interfacial adhesion could cause a brittle-tough transition of PLA/PBAT foams. Additionally, for foams with high interfacial adhesion, small cell size (<12 μm) was more favorable for the stretching of cells and extension of the whitened region in comparison with big cell size (cell size >60 μm), leading to the drastic toughening of PLA blends. This study provides a feasible, industrially scalable and practical strategy to prepare super toughened and fully biodegradable PLA materials.

Density graded polymer composite foams

This article reviews the main developments associated with density graded polymer composite foams. After a short introduction, a discussion is made on both density graded polymer-based composites and foams separately to better understand the challenges when both structures are combined together to produce composite foams. In all cases, the basic concepts, fabrication methods, main properties and general applications are presented. Opening for future works are also presented to conclude.

Preparation and mechanism of lightweight wood fiber/poly(lactic acid) composites

The high density and poor thermal insulation of traditional wood-plastic composites limited the application in the field of building materials. In this paper, wood fiber (WF) and PLA were used as raw materials and azodicarbonamide was used as the foaming agent. Lightweight WF/PLA composites were prepared by the hot-pressing foaming method, aiming to obtain renewable, low-density material with high strength-to-weight ratio and thermal insulation performance. The results showed that after adding 20 % WF into PLA, the cell morphology was excellent and the cell size was uniform. The magnification reached the minimum value of 0.36 g/cm³ and the foaming magnification was 3.42 times. The impact strength and compressive strength were 3.16 kJ/m³ and 4.12 MPa, its comprehensive mechanical properties were outstanding. The thermal conductivity of foamed materials was 0.110-0.148 (W/m·K), which was significantly lower than that of unfoamed materials and common wood. Its excellent mechanical properties and thermal insulation can be suitable for application in the construction field to replace traditional wood.

N2O–Assisted Siphon Foaming of Modified Galactoglucomannans With Cellulose Nanofibers

Foaming of most bio-based polymers is challenged by low pore formation and foam stability. At the same time, the developing utilization of bio-based materials for the circular economy is placing new demands for easily processable, low-density materials from renewable raw materials. In this work, we investigate cellulose nanofiber (CNF) foams in which foaming is facilitated with wood-based hemicelluloses, galactoglucomannans (GGMs). Interfacial activity of the GGM is modulated via modification of the molecule’s amphiphilicity, where the surface tension is decreased from approximately 70 to 30 mN m−1 for unmodified and modified GGM, respectively. The chemical modification of GGMs by substitution with butyl glycidyl ether increased the molecule’s hydrophobicity and interaction with the nanocellulose component. The highest specific foam volume using 1 wt% CNF was achieved when modified GGM was added (3.1 ml g−1), compared to unmodified GGM with CNF (2.1 ml g−1). An amount of 96 and 98% of the GGM and GGM-BGE foams were lost after 15 min of foaming while the GGM and GGM-BGE with cellulose nanofibers lost only 33 and 28% of the foam respectively. In the case of GGM-BGE, the foam stability increased with increasing nanofiber concentration. This suggests that the altered hydrophobicity facilitated increased foam formation when the additive was incorporated in the CNF suspension and foamed with nitrous oxide (N2O). Thus, the hydrophobic character of the modified GGM was a necessity for foam formation and stability while the CNFs were needed for generating a self-standing foam structure.

Morphological, thermal and mechanical properties of polypropylene foams via rotational molding

In this work, polypropylene (PP) was foamed via rotational molding using a chemical blowing agent (CBA) based on azodicarbonamide over a range of concentration (0 to 0.5% wt.). The samples were then analyzed in terms of morphological, thermal and mechanical properties. The morphological analysis showed a continuous increase in the average cell size and cell density with increasing CBA content. Increasing the CBA content also led to lower foam density and thermal conductivity. Similarly, all the mechanical properties (tension, flexion and impact) were found to decrease with increasing CBA content. Finally, the efficiency of the rotomolding process was assessed by producing neat PP samples via compression molding. The results showed negligible differences between the rotomolded and compression molded properties at low deformation and rate of deformation indicating that optimal rotomolding conditions were selected.

Micro- and Nanocellulose in Polymer Composite Materials: A Review

The high demand for plastic and polymeric materials which keeps rising every year makes them important industries, for which sustainability is a crucial aspect to be taken into account. Therefore, it becomes a requirement to makes it a clean and eco-friendly industry. Cellulose creates an excellent opportunity to minimize the effect of non-degradable materials by using it as a filler for either a synthesis matrix or a natural starch matrix. It is the primary substance in the walls of plant cells, helping plants to remain stiff and upright, and can be found in plant sources, agriculture waste, animals, and bacterial pellicle. In this review, we discussed the recent research development and studies in the field of biocomposites that focused on the techniques of extracting micro- and nanocellulose, treatment and modification of cellulose, classification, and applications of cellulose. In addition, this review paper looked inward on how the reinforcement of micro- and nanocellulose can yield a material with improved performance. This article featured the performances, limitations, and possible areas of improvement to fit into the broader range of engineering applications.

Experimental-numerical studies of the effect of cell structure on the mechanical properties of polypropylene foams

The effects of the cell size and distribution on the mechanical properties of polypropylene foam were simulated and analyzed by finite element modeling with ANSYS and supporting experiments. The results show that the reduced cell size and narrow size distribution have beneficial influences on both the tensile and impact strengths. Decreasing the cell size or narrowing the cell size distribution was more effective for increasing the impact strength than the tensile strength in the same case. The relationship between the mechanical properties and cell structure parameters has a good correlation with the theoretical model.

Backpressure Optimization in Foam Injection Molding: Method and Assessment of Sustainability

Inspired by the Industry 4.0 trend towards greater user-friendliness and self-optimization of machines, we present a novel approach to reducing backpressure in foam injection molding. Our method builds on the compressibility of polymer-gas mixtures to detect undissolved gas phases during processing at insufficient backpressures. Identification of a characteristic behavior of the bulk modulus upon transition from homogeneous to heterogeneous polymer-gas mixtures facilitated the determination of the minimum pressure required during production to be determined, as verified by ultrasound measurements. Optimization of the pressure conditions inside the barrel by means of our approach saves resources, making the process more sustainable. Our method yielded a 45% increase in plasticizing capacity, reduced the torque needed by 24%, and required 46% less plasticizing work and lower pressures in the gas supply chain. The components produced exhibited both improved mechanical bending properties and lower densities. From an economic point of view, the main advantages of optimized backpressures are reduced wear and lower energy consumption. The methodology presented in this study has considerable potential in terms of sustainable production and offers the prospect of fully autonomous process optimization.

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.

Study on Foaming Quality and Impact Property of Foamed Polypropylene Composites

In the present work, foamed polypropylene (PP) composites were prepared by chemical foaming technology, and the foaming quality and impact property of the foamed PP composites were studied. The results showed that the foaming quality was significantly improved after the introduction of thermoplastic rubber (TPR) and polyolefin elastomer (POE). Meanwhile, it was found that the impact property depended on the intrinsic toughness and contribution of foams (cells) to the PP composites. Furthermore, the data regarding impact property in low temperature showed that when the temperature was between -80 and -20 °C, the impact properties of the foamed PP composites were higher than that of the unfoamed sample, which was due to the impact property being completely contributed by cells under this condition. Meanwhile, when the temperature ranged from -20 to 20 °C, the impact property of the unfoamed sample was higher, which was due to the PP matrix contributing more to the impact property under this temperature. This work significantly improved the foaming quality of foamed PP composites and provided reliable evidence for the improvement of impact property.

Effect of polymer foam anisotropy on energy absorption during combined shear-compression loading

Polymeric foams are extensively used in applications such as packaging, sports goods and sandwich structures. Since in-service loading conditions are often multi-axial, characterisation of foams under multi-axial loading is essential. In this article, quasi-static combined shear-compression behaviour of isotropic expanded polystyrene foam and anisotropic polyethersulfone foam was studied. For this, a testing apparatus which can apply combined compression and transverse shear loads was developed. The results revealed that the shear and compression energy absorption, yield stress and stiffness of foams are dependent on deformation angle. The total energy absorption of the anisotropic polyethersulfone foam is shown to be direction dependent in contrast to isotropic expanded polystyrene. Furthermore, for similar relative density, polyethersulfone foam absorbs more energy than expanded polystyrene foam, regardless of deformation angle. This study highlights the importance of correct positioning of foam cells in anisotropic foams with respect to loading direction to maximise energy absorption capability.

Morphological, mechanical, and thermal properties of injection molded polylactic acid foams/composites based on wood flour

In this work, injection molding was used to produce polylactic acid foams using azodicarbonamide as a chemical foaming agent and to study the effect of wood flour concentration (15, 25, and 40% wt.) on morphology (scanning electron microscopy), density (gas pycnometry), as well as mechanical (tensile, flexural, and impact) and thermal (differential scanning calorimetry) properties. In particular, density reduction was controlled by the amount of material injected (shot size). The results showed that polylactic acid properties increased with wood content, but decreased with density reduction. Nevertheless, specific flexural modulus (per unit weight) always increased with foaming. Foaming was also shown to significantly increase polylactic acid crystallinity.

Polypropylene structural foams: Measurements of the core, skin, and overall mechanical properties with evaluation of predictive models

Relationships for the prediction of various linear mechanical properties of polymeric sandwich foams obtained in injection processes were studied in comparison with shear, tensile, and flexural tests. The samples were obtained by a core-back foam injection molding process that enables one to obtain sandwich materials with dense skins and a foamed core as revealed by the morphological analysis. Tensile, shear, and flexural moduli were investigated for the skin, the core, and the overall foamed structure. In addition, the Poisson’s ratio of the skin was also determined. The core properties were specifically analyzed by machining the samples and removing the skins. Tensile and shear properties of the core can be well described by the Moore equation. The tensile modulus can be calculated by a linear mixing rule with the moduli of the skin and of the core in relation to the thickness of the layers. Shear and flexural moduli are described by a linear mixing rule on the rigidity in agreement with the mechanics of beams. Tensile modulus, out-of-plane shear modulus, and flexural modulus can finally be predicted by the knowledge of only very few data, namely the tensile modulus and Poisson’s ratio of the matrix, the void fraction, and thickness of the core. The equations were proved to be physically meaningful and consistent with each other.

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.

Reinforcement and nucleation of acetylated cellulose nanocrystals in foamed polyester composites

The biodegradable foamed nanocomposites were developed from the reinforcement of surface acetylated cellulose nanocrystals (ACNC) as bionanofillers and the poly(butylene succinate) (PBS) as polymeric matrix. The surface modification of high-efficiency acetylation on the cellulose nanocrystals converted the hydrophilic hydroxyl groups to hydrophobic acetyl groups, which improved the compatibility between rigid nanoparticles and polyester matrix through the similar ester groups of two components. With the introduction of 5 wt% ACNC, the specific flexural strength (σ/ρf) and the specific flexural modulus (E/ρf) of the foamed composites significantly increased by 75.7% and 57.2% in comparison with those of the neat PBS foamed material. Meanwhile, with the change of the ACNC concentrations, the cell size and cell density of the foamed composites can be regulated and achieved the high cell density of 1.95 × 10(5)cells/cm(3) bearing the small average cell size of 178.84 μm (5 wt% ACNC). The microstructure observation of the foamed composites indicated the moderate loading levels of rigid ACNC can serve as the reinforcing phase for the stress transfer and promote the crystallinity advancement of the foamed composites.

Effect of the skin layer on the overall behavior of closed-cell polyethylene foam sheets

This article presents an experimental investigation of the effect of the skin layer on the mechanical behavior of a closed-cell polymeric foam material. The skin layer is a thin layer with increased density due to the manufacturing processes, which results in inhomogeneity. The skin-layer effect is investigated by comparing the stretch-stress characteristics of specimens with and without this skin layer on a particular closed-cell polyethylene foam sheet. The characteristics were recorded via uniaxial tension and compression tests, respectively, in all principal manufacturing directions. Thus, the skin-layer effect can be obtained by analyzing the recorded data points, which are also presented. The skin-layer-free specimens are prepared with a particularly designed assembly in accordance with the ASTM standards.

Influence of foam agent content and talc filler on the microcellular and mechanical properties of injection molded polypropylene and talc filled polypropylene composite foams

In this study, influence of the chemical foaming agent content and talc mineral filler on the microcellular and mechanical properties of pure polypropylene and 20 wt% talc filled polypropylene composite foams was investigated. The chemical foaming agent at 1 wt% and 2 wt% ratios was added to pure polypropylene and talc filled polypropylene composites. Using an injection molding machine, foam materials were produced under a set of process parameters consisting of injection pressure, injection speed, melt temperature, and packing pressure. For each set of process parameters, the cell number, cell size, distance between cells, skin layer thickness, cell density, and the mechanical properties of foam products were recorded. The results indicate that the cell number, cell density, skin layer thickness, tensile strength, and tensile modulus values for microcellular talc filled polypropylene composite foam are higher, while the cell diameter, impact strength, and elongation at break values are lower than that of pure microcellular polypropylene foam.