Investigation of Cell Structure and Expansion Ratio of Microcellular Polypropylene Nanohomocomposites Prepared by a Solid-State Process

Microcellular poly(propylene-ethylene) random copolymer (r-PP-PE)/nanoclay (nanocomposite) and r-PP-PE/nanoclay/polypropylene fibers (nanohomocomposite) were autoclave-foamed via a solid-state microcellular foaming process using supercritical N₂ as a foaming agent. Polypropylene grafted with maleic anhydride (PP-g-MA) was used as a compatibilizer. Amount of PP-g-MA to nanoclay was 3:1. This study investigated the effects of clay content and the presence of polypropylene fiber on the expansion ratio and cell morphology of the samples. The results indicated that nanoclay increased the expansion ratio of the samples, but the expansion ratio for nanohomocomposites was slightly lower than the nanocomposites. In addition, scanning electron microscopy (SEM) observation showed that the nanoclay decreased the cell size and increased the cell density, except for the nanocomposite with the highest nanoclay content, 3 wt%, which had larger cell size compared to the samples with 1.5 wt% nanoclay and less. On the other hand, the simultaneous presence of nanoclay and polypropylene fibers synergistically increased the cell nucleation effect; thus there was a dramatic increase in cell density. The Differential scanning calorimetry (DSC) analysis showed that the microcellular foaming process decreased the crystallinity of both types of samples.