Abstract
A combined in-mold decoration and microcellular injection molding (IMD/MIM) method has been used in this paper. The foamed PP/nano-CaCO3 composites were prepared to investigate their mechanical properties, cellular structure, and surface quality. The content of nano-CaCO3 varied from 0 to 10 wt %. The results showed that nano-CaCO3 acted as a reinforcing phase and nucleating agent, which help to improve the mechanical properties of foamed composites. The cellular structure and mechanical properties were optimum when the nano-CaCO3 content was 6 wt %. In the vertical section, the cell size and density of transition layer on the film side was bigger than that on the non-film side. In the parallel section, the cell ratio of length to diameter of transition layer on the film side was smaller than that on the non-film side, and the cell tile angle was larger than that on the non-film side. With nano-CaCO3 content increasing, the surface quality showed a trend of decreasing first and then increasing.
Highlights
Microcellular injection molding (MIM) is an effective method to achieve weight reduction of plastic products, with some advantages such as high impact strength, high insulation properties and low electrical conductivity [1,2]
By combining rapid heat cycling molding (RHCM) technology with MIM, Huang et al [7] found that surface roughness can be effectively reduced by controlling the mold temperature
These researchers are more concerned with the effect of fillers on the cell morphology and mechanical properties of foam composites, and there are few papers on the effect of fillers on the surface quality of foamed polymers in MIM
Summary
Microcellular injection molding (MIM) is an effective method to achieve weight reduction of plastic products, with some advantages such as high impact strength, high insulation properties and low electrical conductivity [1,2]. A gas-assisted microcellular injection molding was used to improve the surface quality of products with controlling the bubbles nucleation at the filling stage [16]. Mao investigated the content of nano-CaCO3 on mechanical properties and the cell structure in different sections, and it was found that with the 6 wt % addition of nano-CaCO3 , the mechanical properties was optimum [23] These researchers are more concerned with the effect of fillers on the cell morphology and mechanical properties of foam composites, and there are few papers on the effect of fillers on the surface quality of foamed polymers in MIM. IMD/MIM process was used to improve the surface quality of foamed parts, and different content of nano-CaCO3 was added into PP to improve the mechanical properties. The effect of nano-CaCO3 content on the cellular structure, mechanical properties, and surface quality was investigated
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