Improving the Continuous Microcellular Extrusion Foaming Ability with Supercritical CO2 of Thermoplastic Polyether Ester Elastomer through In-Situ Fibrillation of Polytetrafluoroethylene

Technical development and application of supercritical CO2 foaming technology in PCL foam production

Polycaprolactone (PCL) has the advantages of good biocompatibility, appropriate biodegradability, non-toxicity, flexibility, and processability. As a result, PCL-based foams can successfully work in bone tissue engineering, medical patches, drug delivery, reinforcing materials, and other applications. A promising technology for producing PCL foam products is supercritical CO2 (ScCO2) foaming technology, which avoids using organic solvents, is green, and has low foaming agent costs. However, due to the limitations of ScCO2 foaming technology, it is no longer possible to use this technology alone to meet current production requirements. Therefore, ScCO2 foaming technology must combine with other technologies to develop PCL foam products with better performance and matching requirements. This paper systematically reviews the technological development of ScCO2 foaming in producing PCL foams. The molding process of ScCO2 foaming and the conventional preparation process of PCL foam products are discussed comprehensively, including the preparation process, advantages, and disadvantages, challenges faced, etc. Six combined technologies for ScCO2 foaming in the production of PCL foams and the applications of PCL foams are presented. Finally, the future remaining research for producing PCL foams by ScCO2 foaming is analyzed.

Generation of Tough, Stiff Polylactide Nanocomposites through the In Situ Nanofibrillation of Thermoplastic Elastomer

Polylactide (PLA) resins are among the most desirable biopolymers due to their biobased and compostable nature, excellent stiffness, and tensile strength. However, the widespread application of PLA has long been hindered by its inherent brittleness. While multiple routes have been successfully developed for the toughening of PLA, this toughening has always come at the cost of compromising the stiffness and strength of the matrix. In this work, we report a robust and scalable method for the development of PLA nanocomposites with an unprecedented combination of stiffness and toughness. Using the in situ nanofibrillation technique, we generated PLA composites containing nanofibrils of thermoplastic polyester elastomer (TPEE). Due to the high aspect ratio of these nanofibrils, they form physically percolated networks at low weight fractions (∼2.8 wt %) which dramatically change the mechanical behavior of the material. We found that, upon network formation, the material transitions from brittle to ductile behavior, dramatically increasing its toughness with only a marginal decrease in Young's modulus. We investigate the peculiar rheological behavior and crystallization kinetics of these blends, and propose an extension of the critical ligament thickness mechanism, wherein intrinsic toughening arises at the fiber-matrix interface in the presence of entangled elastomer networks.

In Situ Visualization for Control of Nano-Fibrillation Based on Spunbond Processing Using a Polypropylene/Polyethylene Terephthalate System

In situ generation of polyethylene terephthalate (PET) nanofibrils in polypropylene (PP) microfibers via fiber spinning in a spunbond process was studied in this work. The effects of polymer flow rate and air speed in the drafter on the formation of PET fibrils were investigated using a pilot scale machine. An in-situ visualization technique was applied to examine the fiber evolution events and stretch profile at die exit. A scanning electron microscope was used to analyze and investigate the morphology of the dispersed domain. The PET dispersed phase was fibrillated within the PP matrix such that a nonofibrillated composite containing fibrils with an average size around 100 nm was obtained. It was found that the final fibril size directly depends on the degree of die swell, the air speed and the polymer flow rate. It was also found that the in situ observed size of the micro-scale PP/PET fibers was well correlated to the size of the nano-scale PET fibers formed in the PP matrix. The visualization results revealed that a smaller fibril diameter was obtainable by increasing the stretching on the spin line and/or decreasing the die swell.

Chemistry, Processing, Properties, and Applications of Rubber Foams

With the ever-increasing development in science and technology, as well as social awareness, more requirements are imposed on the production and property of all materials, especially polymeric foams. In particular, rubber foams, compared to thermoplastic foams in general, have higher flexibility, resistance to abrasion, energy absorption capabilities, strength-to-weight ratio and tensile strength leading to their widespread use in several applications such as thermal insulation, energy absorption, pressure sensors, absorbents, etc. To control the rubber foams microstructure leading to excellent physical and mechanical properties, two types of parameters play important roles. The first category is related to formulation including the rubber (type and grade), as well as the type and content of accelerators, fillers, and foaming agents. The second category is associated to processing parameters such as the processing method (injection, extrusion, compression, etc.), as well as different conditions related to foaming (temperature, pressure and number of stage) and curing (temperature, time and precuring time). This review presents the different parameters involved and discusses their effect on the morphological, physical, and mechanical properties of rubber foams. Although several studies have been published on rubber foams, very few papers reviewed the subject and compared the results available. In this review, the most recent works on rubber foams have been collected to provide a general overview on different types of rubber foams from their preparation to their final application. Detailed information on formulation, curing and foaming chemistry, production methods, morphology, properties, and applications is presented and discussed.

Effects of pressure drop rate and CO2 content on the foaming behavior of newly developed high-melt-strength polypropylene in continuous extrusion

We report systematic studies on the foamability of our novel high-melt-strength long-chain branched polypropylene under supercritical CO2. Continuous foaming experiments were conducted using a tandem extrusion system and a set of filamentary dies with similar pressure drops but different pressure drop rates. The foam expansion was controlled by varying the temperature at the die exit. Under identical CO2 loadings, the expansion ratio plotted as a function of die temperature exhibited similar shapes across multiple pressure drop rates. However, the shape of the curve varied across different amounts of CO2, under which the highest achievable expansion ratio occurred at a lower die temperature with increasing CO2 content. The cell density displayed strong dependence on both the pressure drop rate and the amount of dissolved CO2. The effect of the latter became more apparent at lower pressure drop rates. The average cell size decreased with increasing CO2 loading but generally showed weak dependence on pressure drop rate except at the highest value.

Comparison of Selected Parameters of a Planetary Gearbox with Involute and Convex–Concave Teeth Flank Profiles

This article presents a model of the geometry of teeth profiles based on the path of contact definition. The basic principles of the involute and convex–concave teeth profile generation are described. Due to the more difficult manufacturing of the convex–concave gear profile in comparison to the involute one, an application example was defined that suppressed this disadvantage, namely a planetary gearbox with plastic-injection-molded gears commonly used in vehicle back-view mirror positioners. The contact pressures and the slide ratios of the sun, planet, and ring gears with both teeth profile variants were observed and the differences between the calculated parameters are discussed.