A current trend in the progress of bead foams is the use of engineering polymers (i.e., poly(butylene terephthalate) (PBT)), which are more temperature resistant than commodity polymers and thus offer new areas of application. Currently, foaming and molding of PBT bead foams seem to be possible only with an epoxy-based chain extender. This modification leads not only to an increase in molecular weight but also to a changed PBT chain architecture (i.e., branching or even cross-linking). Thereby, the crystallization behavior is considerably slowed down so that the time for chain interdiffusion across neighboring bead surfaces is prolonged. This study investigates the molecular weight influence separately. The crystallization behavior is controlled by varying the length of linear PBTs in such a way that different bead fusion phenomena result. With increasing molecular weight, a lower open cell content (OCC), and therefore a higher expansion behavior during thermomechanical analysis, was observed, which increases the contact area between the beads in the cavity during the steam chest molding process. Adding to the literature shown so far, this study shows that linear chemically unmodified PBT can also be processed into bead foam components using PBTs having a higher molecular weight.

Poly(butylene terephthalate) (PBT) is difficult to foam due to its unfavorable rheological behavior (low melt strength, no strain hardening). In particular, a high expansion and a homogeneous cell morphology are difficult to achieve. This can be altered successfully by addition of multifunctional chain extenders. Chain extenders cause nondefined and rarely understood changes in the polymer architecture usually described as branching. In this contribution, the synthesis of two series of PBT copolyesters with defined short-chain branched units is presented. Dilinoleic derivatives with linear C 9 and C 7 alkyl side chains are employed to reflect short-chain branches and are incorporated into PBT in various molar ratios. Characterization by NMR spectroscopy and size exclusion chromatography demonstrates the random chain structure and high molar masses of the terpolyesters. Incorporation of dilinoleic derivatives results in the reduction of PBT crystallinity, decreased glass transition temperatures, and altered rheological behavior, in particular of extensional rheology characterized by strain hardening. The comparison to control copolyesters without branches proves that strain hardening is caused by the branches. A higher concentration of branches induces stronger strain hardening, resulting in successful foaming. It is demonstrated that the new terpolyesters have properties comparable with PBT treated with chain extenders.