Abstract

This paper presents a fundamental and experimental investigation of cell nucleation and growth mechanisms in Micro-/Nano-Layered (MNL) polymeric structures with alternating film and foam layers. It was found that the cell morphology in MNL structures is governed by the synergy of two categories of parameter: morphological parameters, i.e., layer thicknesses and the number of layer interfaces, and material parameters, i.e., material stiffness and compatibility. The presence of adjacent film layers can significantly increase cell density through two mechanisms: promoting heterogeneous cell nucleation and preventing cell deterioration. The influence of film layers varied in different layer thickness regions and interface densities, where stiffer and more compatible film layers produced higher cell densities by further enhancing these two mechanisms. Moreover, as a stiffness-enhancing strategy, the crystallization of the Polycarbonate was successfully achieved in MNL structures in a high-pressure CO2 environment for the first time, resulting in more pronounced optimization of cell morphology.

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