Oxidization and Chain-Branching Reaction for Recycling HDPE and Mixed HDPE/PP with In-situ Compatibilization by Ozone-Induced Reactive Extrusion

High-density polyethylene (HDPE) and isotactic polypropylene (iPP) are widely used in industrial and residential applications due to their low cost and chemical stability, thus their recycling process can contribute to a circular economy. However, both polymers are non-polar materials, and the incompatibility with most other materials leads to substantially inferior properties of blends. In this work, we propose a flexible compatibilization strategy to improve the compatibility of HDPE/iPP blends. Ozone is adopted to induce reactive extrusion for rapid oxidation of HDPE and chain-branching reactions for both HDPE and HDPE/iPP blends. During extrusion process, ozone oxidizes HDPE effectively in a short time and introduces oxygen-containing groups such as carbonyl and ester groups, which improves the hydrophilicity. The addition of trimethylolpropane triacrylate (TMPTA) could promote branching reaction and facilitate the formation of HDPE-g-iPP copolymers, which improved the compatibility for HDPE/iPP. As a result, the impact strength of ozone-modified HDPE and HDPE/iPP blends increased by 22 % and 82 %, respectively, and the tensile strength also increased. This strategy would have potential applications in the field of sorting-free and solvent-free recycling of waste polyolefin plastics.

The Study of Crystallization Behavior, Microcellular Structure and Thermal Properties of Glass-Fiber/Polycarbonate Composites

Polycarbonate (PC) foam is a versatile material with excellent properties, but its low thermal stability limits its application in high-temperature environments. The aim of this study was to improve the thermal stability of PC foam by adding glass fibers (GF) and to investigate the effect of GF on PC crystallization behavior and PC foam cell morphology. This study was motivated by the need to improve the performance of PC foams in various industries, such as construction, automotive, and medical. To achieve this goal, PC/GF composites were prepared by extrusion, and PC/GF composite foams were produced using a batch foaming process with supercritical carbon dioxide (SC-CO₂) as the blowing agent. The results showed that the addition of GF accelerated the SC-CO₂-induced crystallization stability of PC and significantly increased the cell density to 4.6 cells/cm³. In addition, the thermal stability of PC/GF foam was improved, with a significant increase in the residual carbon rate at 700 °C and a lower weight loss rate than PC matrix. Overall, this study highlights the potential of GF as a PC foam reinforcement and its effect on thermal and structural properties, providing guidance for industrial production and applications.

Production and Application of Polymer Foams Employing Supercritical Carbon Dioxide

Polymeric foams have characteristics that make them attractive for different applications. However, some foaming methods rely on chemicals that are not environmentally friendly. One of the possibilities to tackle the environmental issue is to utilize supercritical carbon dioxide ScCO2 since it is a “green” solvent, thus facilitating a sustainable method of producing foams. ScCO2 is nontoxic, chemically inert, and soluble in molten plastic. It can act as a plasticizer, decreasing the viscosity of polymers according to temperature and pressure. Most foam processes can benefit from ScCO2 since the methods rely on nucleation, growth, and expansion mechanisms. Process considerations such as pretreatment, temperature, pressure, pressure drop, and diffusion time are relevant parameters for foaming. Other variables such as additives, fillers, and chain extenders also play a role in the foaming process. This review highlights the morphology, performance, and features of the foam produced with ScCO2, considering relevant aspects of replacing or introducing a novel foam. Recent findings related to foaming assisted by ScCO2 and how processing parameters influence the foam product are addressed. In addition, we discuss possible applications where foams have significant benefits. This review shows the recent progress and possibilities of ScCO2 in processing polymer foams.

Density Gradients, Cellular Structure and Thermal Conductivity of High-Density Polyethylene Foams by Different Amounts of Chemical Blowing Agent

LDPE (low-density polyethylene) foams were prepared using the improved compression moulding technique (ICM) with relative densities ranging from 0.3 to 0.7 and with different levels of chemical blowing agents (from 1% to 20%). The density gradients, cellular structure and thermal conductivity of the foams were characterized. The density and amount of CBA used were found to have a significant effect on the cellular structure both at the mesoscale (density gradients) and at the microscale (different cell sizes and cell densities). In addition, the thermal conductivity of the samples is very sensitive to the local structure where the heat flux is located. The technique used to measure this property, the Transient Plane Source method (TPS), makes it possible to detect the presence of density gradients. A simple method for determining these gradients based on thermal conductivity data was developed.

Reactive Extrusion Grafting of Glycidyl Methacrylate onto Low-Density and Recycled Polyethylene Using Supercritical Carbon Dioxide

Glycidyl methacrylate (GMA) was grafted onto (recycled) polyethylene (PE) to design a new adhesive with better mechanical properties compared to non-grafted PE. The effects of the amount of GMA, the amount of dicumyl peroxide (DCP) and the use of supercritical carbon dioxide (scCO2) in a reactive extrusion (REX) were evaluated based on the grafting degree and efficiency of the grafted samples. Generally speaking, higher amounts of GMA led to higher functionalization degrees (FD), whereas higher amounts of DCP resulted in a lower FD due to the occurrence of more unfavorable side reactions. The influence of scCO2 showed different outcomes for the two substrates used. Higher FDs were obtained for the low-density polyethylene (LDPE) samples while, by contrast, lower FDs were obtained for the recycled polyethylene (RPE) samples when using scCO2. Additionally, adjusting the screw speed and the temperature profile of the extruder to the half-life time of the radical initiator appeared to have the highest positive impact on the FD. According to the tensile tests, all the grafted samples can withstand higher stress levels, especially the grafted RPE, compared to the non-grafted samples.

Fabrication of branching poly (butylene succinate)/cellulose nanocrystal foams with exceptional thermal insulation

Branching poly (butylene succinate) (BPBS) nanocomposite foams incorporated with cellulose nanocrystals (CNCs) were prepared by supercritical CO₂. Surface modification of CNCs by acetylation was achieved through replacing hydrophilic hydroxyl groups with hydrophobic acetyl groups, which improved the dispersibility of CNCs significantly. The crystallite sizes of CNCs and acetylated CNCs were calculated by Scherrer's formula as 25 and 19 nm, respectively. The initial crystallization temperature of diverse poly (butylene succinate) (PBS) specimens, a crucial factor for regulating cell nucleation type, increased remarkably by 11.8 °C as well as their storage modulus increased by 2 orders of magnitudes, due to branching reaction and bio-filler addition. BPBS/CNCs foam possessed a high volume expansion ratio as 37.1 times and displayed an exceptional thermal conductivity as 0.021 W(m K)^-1. This study provided a promising potential strategy to develop exceptional thermal-insulation polymer foams for composite structures, energy conservation and environment protection.

Crystallization-induced microcellular foaming behaviors of chain-extended polyethylene terephthalate

The microcellular foaming of chain-extended polyethylene terephthalate (CPET) by crystallization induction method was reported in this article. The crystallization behaviors of various polyethylene terephthalate (PET) samples which were affected by the combined effect of pyromellitic dianhydride, Surlyn, and CO2 were investigated. After Surlyn was added to CPET, the crystal nucleation of various CPET samples was improved, and numerous but small spherulites were generated. Two kinds of CPET samples with the content of 0 phr and 1 phr Surlyn were foamed at various temperature by batch foaming method. Changing the saturation temperature could adjust the appearance of high-temperature melting crystals which would affect the final cellular structures in various CPET foams. With the decrease of saturation temperature, the cell size decreased while cell density increased. At the saturation temperature of 265°C and 250°C, the cell density of CPET foam with Surlyn was one magnitude larger than CPET foam without Surlyn. At the saturation temperature of 247°C, the microcellular PET foams with the cell density of 109 cells cm−3 and the cell size less than 10 µm had been developed successfully.

Morphological evaluation of ultralow density microcellular foamed composites developed through CO2-induced solid-state batch foaming technique utilizing water as co-blowing agent

In this work, microcellular acrylonitrile-butadiene-styrene foams were developed with utilization of water as a co-blowing agent and CO2 as the primary blowing agent through the solid-state batch foaming process. The effect of saturation parameters with the content of the co-blowing agent has been studied extensively for various foaming attributes. The co-blowing agent enhanced the average cell size and the expansion ratio which are useful for better thermal insulation. The maximum expansion ratio of 29.9 obtained from the effect of saturation temperature and co-blowing agent, 23.6 from the effect of saturation pressure and co-blowing agent, and 22.4 from the effect of saturation time and co-blowing agent. The co-blowing agent significantly affects the cell morphology of polymeric foam with saturation parameters.