Preparation of short carbon fiber/polypropylene fine-celled foams in supercritical CO₂

Abstract

This article reports an attempt to improve polypropylene fine-celled foaming with the incorporation of short carbon fibers. The carbon fibers with uniform dispersion in polypropylene matrix were obtained in reference to the way of papermaking. The composites were prepared via melt compounding in a twin-screw extruder followed by injection molding. Three concentrations of carbon fibers, 5, 15 and 25 wt.%, were used. The foaming was carried out by a batch foaming process with supercritical CO2 as the physical blowing agent. The results showed the foamed composites had well-defined closed cell structure, but large amount of unfoamed regions and non-uniform cell size distribution were observed at the lowest carbon fibers content. Further incorporating carbon fibers decreased the crystallinity and increased the melt viscoelasticity. As a result, the composites had higher CO2 solubility with the increment of carbon fibers content. It is found that the foamed composite with 25 wt.% carbon fibers had the most uniform size distribution and better cell morphology compared to the other two composites. The increment in the cell density with increasing carbon fibers content indicated that the bubble nucleation was dominated by the heterogeneous mechanism with the addition of carbon fibers. The poorly bonded interface between carbon fibers and polypropylene could serve well as nucleation sites.

Asymmetric microcellular composites: Morphological properties

“…Consequently, some undissolved gases may remain trapped in the microvoids at the fiber-polymer interfaces and thus ''contribute'' to the heterogeneous nucleation effect of the fibers (see Figure 7). 23 According to Wang et al, 45 increasing the cell density with increasing FF content indicates that bubble nucleation is dominated by the heterogeneous mechanism with the addition of fibers. Thus, the enhanced heterogeneous cell nucleation related to the presence of the fibers is the main reason for the improvement in cell morphology (smaller cell sizes, higher cell densities, and lower standard deviations).…”

How much do nanoparticle fillers improve the modulus and strength of polymer foams?

“…However, there are potential problems with this approach. Often the cell number density is calculated from electron microscope images of cross-sections of the foams using the equation 2,[12][13][14] …”

Modelling of effective thermal conductivity of polymer matrix composite foams with biaxially aligned filler networks

“…This trend was consistent with experimental data reported in the previous literature. 20 The observed structure-to-property relationship, both theoretically and experimentally, revealed that foaming would be a feasible approach to promote PMC's k eff . This is especially beneficial for the PMCs with low filler loadings, which is required to ensure good processability of the material systems.…”