AbstractControlling sandwich‐structure of poly(ethylene terephthalate) (PET) microcellular foams using coupling of CO2 diffusion and CO2‐induced crystallization is presented in this article. The intrinsic kinetics of CO2‐induced crystallization of amorphous PET at 25°C and different CO2 pressures were detected using in situ high‐pressure Fourier transform infrared spectroscopy and correlated by Avrami equation. Sorption of CO2 in PET was measured using magnetic suspension balance and the diffusivity determined by Fick's second law. A model coupling CO2 diffusion in and CO2‐induced crystallization of PET was proposed to calculate the CO2 concentration as well as crystallinity distributions in PET sheet at different saturation times. It was revealed that a sandwich crystallization structure could be built in PET sheet, based on which a solid‐state foaming process was used to manipulate the sandwich‐structure of PET microcellular foams with two microcellular or even ultra‐microcellular foamed crystalline layers outside and a microcellular foamed amorphous layer inside. © 2011 American Institute of Chemical Engineers AIChE J, 58: 2512–2523, 2012
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