Abstract
AbstractLightweight plastic foams are of great significance for saving resources and reducing energy consumption. Foam injection molding (FIM) shows a promising future to provide lightweight and shape‐complex plastic components. However, it is still challenging to produce lightweight and strong polypropylene (PP) foams by FIM due to PP's poor foaming ability. Herein, rubber and talc are employed to improve PP's foaming ability, and hence to enhance PP foam's mechanical properties. Due to the significantly enhanced rheological properties, injection molded PP composite foam exhibits greatly refined and homogenized cellular structure compared with pure PP foam. Thanks to rubber toughening effect and improved cellular morphology, PP/rubber foam shows much higher ductility than pure PP foam. Moreover, talc particles lead to remarkably enhanced rigidity of PP/rubber foams. Thus, lightweight and strong PP/rubber/talc composite foam is achieved with tensile toughness increased by 82.58% and impact strength increased by 106.21%, and they show broad industrial application prospects.
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