In-depth investigation of how carbon nanofiller dispersion affects microcellular foaming behavior in poly(butylene succinate) nanocomposites

Abstract

This study explores the impact of carbon nanotubes (CNTs) dispersion on the microcellular foaming characteristics of poly(butylene succinate) (PBS) matrices. Two distinct dispersion methods, primary (PD) and secondary (SD), were employed to fabricate PBS/CNT nanocomposites, resulting in different filler dispersion states. The PD technique involves the conventional method of direct melt blending PBS with CNTs, while the SD technique adopts a more advanced strategy by integrating the Pickering emulsion template with melt blending, achieving finer CNTs distribution within the PBS matrix. The results reveal that the SD technique leads to significantly more uniform distribution of CNTs, which in turn enhances the melt strength and crystallization of the polymer matrix, thereby broadening the window for microcellular foaming. Notably, foams developed through the SD method exhibited a decrease in cell size to 10.4 μm and an increase in cell density to 1.8×1010 cells·cm‐3. Moreover, this uniform distribution of CNTs contributed to superior cell stability and an increase in compressive strength to 14.0 MPa. These findings highlight the pivotal role of nanofiller dispersion in determining foam properties and establish foundational knowledge for designing PBS foams with consistent and uniform cell structures. Such advancements are crucial for enhancing the applicability and performance of PBS-based materials across a spectrum of industries.