Abstract
To improve the foaming behavior of a common linear polypropylene (PP) resin, polycarbonate (PC) was blended with PP, and three different grafted polymers were used as the compatibilizers. The solid and foamed samples of the PP/PC 3:1 blend with different compatibilizers were first fabricated by melt extrusion followed by injection molding (IM) with and without a blowing agent. The mechanical properties, thermal features, morphological structure, and relative rheological characterizations of these samples were studied using a tensile test, dynamic mechanical analyzer (DMA), scanning electron microscope (SEM), and torque rheometer. It can be found from the experimental results that the influence of the compatibility between the PP and PC phases on the foaming behavior of PP/PC blends is substantial. The results suggest that PC coupling with an appropriate compatibilizer is a potential method to improve the foamability of PP resin. The comprehensive effect of PC and a suitable compatibilizer on the foamability of PP can be attributed to two possible mechanisms, i.e., the partial compatibility between phases that facilitates cell nucleation and the improved gas-melt viscosity that helps to form a fine foaming structure.
Highlights
Polypropylene (PP) foams are often viewed as one of the most popular lightweight thermoplastic materials
While the foaming behavior of PP/PC blends for injection molding (IM) parts and the effects of compatibilization were analyzed in detail, the learning could be applied as a reference for improving the foaming behaviors of polymer blends
The foaming behavior of PP/PC and the effects of compatibilization were analyzed in detail using foaming IM processing and azodicarbonamide/zinc oxide (AC/ZnO) as blowing agents
Summary
Polypropylene (PP) foams are often viewed as one of the most popular lightweight thermoplastic materials. It has been shown that self-modification generally involves a complex chemical synthesis, and micro- or nanoparticles are difficult to disperse uniformly Compared to these two methods, blending with other polymers could possibly be a relatively economical and effective method to enhance the foamability of pure PP resin. Compared to the reported blended polymers such as PS, PE, and ABS mentioned before, PC has a higher viscous flow temperature except for its more excellent mechanical properties, which may result in an unexpected effect on the foaming behavior of PP resin. After comparing the experimental results of the neat resins and the different PP/PC blends, a better understanding of the influence of the compatibility on the cellular morphology of PP/PC blends was gained
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