This study delves into the complex relationship between molecular structures and properties within polypropylene (PP) foams, with a particular focus on how various material parameters influence foamability. Multiple linear regression was adopted to efficiently assess the impact of eleven material parameters on foam expansion behavior. A primary finding is the significant role of branching index (g'vis) in shaping the expansion profile (i.e., the foaming window, maximum expansion ratio (Φmax), and optimum foaming temperature (Toptimum)). Additionally, Z-average molecular weight (Mz) is identified as crucial factor influencing the foaming window. Furthermore, the Winter-Chambon parameter n, indicator of the relaxation behavior of a resin in the terminal zone, is distinguished as a key parameter in determining Φmax. The crystallization temperature (Tc) also plays a pivotal role, particularly in its relationship with Toptimum. The research further highlights the significance of long-chain branching (LCB) and suggests strategies for cost reduction by minimizing the degree of LCB without compromising foaming performance, achievable through the adjustment of Mz and n. This strategy was exemplified through the comparison of two LCB PP resins, PP-12 and PP-22, demonstrating the feasibility of achieving similar foamability with adjustments in material parameters. The findings offer a detailed assessment of these parameters' influence on foamability, presenting valuable guidelines for optimizing PP foam production and customizing material properties for targeted applications.
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