Production of microcellular foam based on PP/EPDM: The effects of processing parameters and nanoclay using response surface methodology

Abstract

AbstractMicrocellular foam is a new class of material with superior properties due to smaller cell size and higher cell density compared to ordinary foams. In this work, microcellular foam of PP/EPDM/Organoclay with supercritical nitrogen as physical blowing agent was prepared via batch process. Experimental design was carried out according to Box-Behnken method and the effects of saturation pressure and foaming times as well as organoclay content on nucleation and final foam morphology were studied using response surface methodology (RSM). Three levels of saturation pressure, nanoclay content, and foaming time were chosen. The mathematical model and response surface graphs have been used to illustrate the relationship between considered parameters and foam properties. The results revealed that cell density and average cell diameter were affected by nanoclay content and pressure. Cell density was in the range of 109-1010 cell/cm3. Larger average cell sizes were observed as a result of increasing foaming time. Classic nucleation theory was used to study the nucleation mechanism. Nanoparticles acted as nucleating agents and changed nucleation mechanism from homogenous to heterogeneous by decreasing nucleating free energy. In order to find out nucleating energy reduction, gas-polymer-nanoparticle contact angle (Ө), was calculated by measuring surface and interfacial free energies of neat polymers and nanoparticle. In addition, nucleation efficiency of organoclay was estimated and the results showed that despite low nucleating efficiency, nucleation is dominated by presence of nanoclay.