A Study of the Influence of Heterogeneous Nucleation on the Foamability of a Polymer Clay Nanocomposite

Abstract

Polymer composites are fast becoming a material in the manufacturing of automotive interior and exterior parts such as facias and dashboard components. Production of rigid structural foams are ideal because they reduce the overall weight as well as reduce the amount of material used to manufacture the part. Polymer-clay nanocomposites are a classification of materials containing a blend of polymer and a small weight percentage of nanoclay. These materials are currently of interest to automotive part manufacturers because they are known to deliver improved mechanical properties and increase foamability of a polymer. The current study investigates the changes in material properties and the foamability of a thermoplastic polyolefin (TPO)-clay nanocomposite as the degree of intercalation was varied. The TPO-clay nanocomposite was produced by melt blending TPO, nanoclay and maleic anhydride grafted polypropylene (MAHgPP) in a co-rotating twin screw extruder. The material was subjected to a multi-pass process to vary the degree of intercalation. Degree of intercalation was tracked by rheology, XRD and TEM micrographs. Part density, cell density and flexural modulus measurements were performed on foamed and non-foamed injection molded bars to observe changes in the foamability of the material. Material was also processed without clay and analyzed in the same manner. Through TEM and XRD analysis it was found that the degree of intercalation and delamination was varied with increasing number of passes. Rheological measurements showed that the TPO-clay nanocomposite underwent (beta)-scission and intercalation simultaneously. The changes in intercalation had a positive effect on the foamability of the TPO-clay nanocomposite. As well, the TPO-clay nanocomposite experienced an increase in flexural properties for both unfoamed and foamed parts compared to the TPO-PPgMAH blend; TPO-clay nanocomposite experienced a 44% and 23% increase in the flexural modulus for unfoamed and foamed parts respectively. Data also showed that there was a limit to the number of times the TPO-clay nanocomposite can be recycled before the foamability of the material begins to decrease, which was attributed to material degradation.