Driven by concerns about the escalating environmental pollution caused by the widespread use of plastic products, there is considerable interest in developing high-performance biodegradable materials. Poly(butylene adipate-co-terephthalate) (PBAT) foams are recognized as a highly sought-after candidate for alleviating plastic pollution, distinguished by their admirable biodegradability and flexibility. However, the extensive applications of PBAT foam are considerably constrained by inadequate melt strength and inherent shrinkage. Herein, a pioneering and scalable strategy, combining the shear-induced in-situ fibrillation process with microcellular foaming, was devised to achieve lightweight and super-resilient PBAT/poly(tetrafluoroethylene) (PTFE) foams. Thanks to the heterogeneous nucleation effect and complex tangled physical networks induced by in-situ nano-fibrillated PTFE, the crystallization and viscoelasticity of PBAT matrix experienced a dramatic enhancement, further bolstering its foaming capabilities and suppressing the shrinkage process. More importantly, the synergy of reduced foam density and reinforcement effect of PTFE nanofibrils played a crucial role in improving the remarkable compression of PBAT/PTFE foams. These foams showed a maximum increase of 40.2 % in strength and 16.3 % in resilience compared to pure PBAT foams. Moreover, the thermal insulation and soil degradation capability of PBAT/PTFE foams were substantially enhanced, achieving 10.3 % biodegradation after just 2 months. This innovative strategy offers a promising avenue for developing high-performance eco-friendly biocomposites.
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