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We report systematic studies on the foamability of our novel high-melt-strength long-chain branched polypropylene under supercritical CO2. Continuous foaming experiments were conducted using a tandem extrusion system and a set of filamentary dies with similar pressure drops but different pressure drop rates. The foam expansion was controlled by varying the temperature at the die exit. Under identical CO2 loadings, the expansion ratio plotted as a function of die temperature exhibited similar shapes across multiple pressure drop rates. However, the shape of the curve varied across different amounts of CO2, under which the highest achievable expansion ratio occurred at a lower die temperature with increasing CO2 content. The cell density displayed strong dependence on both the pressure drop rate and the amount of dissolved CO2. The effect of the latter became more apparent at lower pressure drop rates. The average cell size decreased with increasing CO2 loading but generally showed weak dependence on pressure drop rate except at the highest value. [ABSTRACT FROM AUTHOR]

While existing foam studies have identified processing parameters, such as high-pressure drop rate, and engineering measures, such as high melt strength, as key factors for improving foamability, there is a conspicuous absence of studies that directly relate foamability to material properties obtained from fundamental characterization. To bridge this gap, this work presents batch foaming studies on one linear and two long-chain branched polypropylene (PP) resins to investigate how foamability is affected by partial melting (Method 1) and complete melting followed by undercooling (Method 2). At temperatures above the melting point, similar expansion was obtained using both foaming procedures within each resin, while the PP with the highest strain hardening ratio (13) exhibited the highest expansion ratio (45 ± 3). At low temperatures, the foamability of all resins was dramatically improved using Method 2 compared to Method 1, due to access to lower foaming temperatures (<150 °C) near the crystallization onset. Furthermore, Method 2 resulted in a more uniform cellular structure over a wider temperature range (120–170 °C compared to 155–175 °C). Overall, strong extensional hardening and low onset of crystallization were shown to give rise to foamability at high and low temperatures, respectively, suggesting that both characteristics can be appropriately used to tune the foamability of PP in industrial foaming applications. [ABSTRACT FROM AUTHOR]

The nonlinear rheological response to extensional flows in entangled polymers is related to the segmental chain stretching and to the chemical identity of the monomeric units. The latter has a strong effect on the drag coefficients, and therefore, quantification of molecular conformation changes in the subnanometer scale (at the monomer level) are crucial to fully understand nonlinear viscoelastic behavior in polymer melts. We report in situ time-resolved extensional rheo-small-angle neutron scattering (tEr-SANS) and wide-angle X-ray scattering (tEr-WAXS) during startup of uniaxial flow on a monodisperse polystyrene melt. Flow-induced segmental alignment was quantified with tEr-SANS, whereas local alignment of the backbone-backbone and phenyl-phenyl interactions were measured with tEr-WAXS. Linear relations between the three alignment factors and stress were observed at low stresses, which confirmed the validity of simple stress-SANS and stress-WAXS rules (SSR and SWR, respectively). Significant differences in SSR and SWR coefficients, as well as the stress values for failure of the two rules suggest very different correlations between global (at the segmental level) and local (at the monomer level) conformations with stress.