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Polymer Microcellular Foam Molding and Its Functionalization

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A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Smart and Functional Polymers".

Deadline for manuscript submissions: closed (15 March 2025) | Viewed by 8047

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Dr. Xiaoli Zhang

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Guest Editor

School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China
Interests: processing, property and application of microcellular foamed polymer and its composites; new technology in polymer processing; development and relationship of structure and property of polymer and its composites
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Prof. Dr. Xia Liao

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Guest Editor

College of Polymer Science and Engineering, State Key Laboratory of Polymer Materials Engineering, Sichuan University, Chengdu 610065, China
Interests: polymer processing; polymer structure and properties; supercritical CO₂ polymer foaming; functional lightweight porous polymer materials
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Special Issue Information

Dear Colleagues,

Polymer microcellular foam is a lightweight materials with a porous structure. In addition to reducing the material’s weight, the existence of tiny voids endows it with good impact resistance, insulation, and sorption properties. Therefore, it is widely used in packaging, transportation, buildings, sports, sound insulation, and oil sorbents. Different from conventional polymer foams, polymer microcellular foams generally have a cell size of about 10 μm, a cell density up to 10⁹ cells/cm³, and contain physical foaming agents, such as carbon dioxide (CO₂) or nitrogen (N₂), instead of chemical foaming agents. The main approaches include batch foaming (rapid temperature rise and/or rapid pressure quench), continuous extrusion foaming, foam injection molding (FIM), and foam compression molding. This Special Issue aims to provide a platform for academic exchange among scholars working in related fields. As Guest Editors, we cordially invite you to submit original research or review articles on this subject. Please also feel free to pass on this invitation to any colleagues you feel may be interested. We look forward to receiving your contributions.

Dr. Xiaoli Zhang
Prof. Dr. Xia Liao
Guest Editors

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Keywords

microcellular foams
properties of microcellular foams
batch foaming
injection or extrusion foaming
microcellular foamed polymer composites
functional application of microcellular foams
electric conductive polymer foams
EMI shielding polymer foams

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Published Papers (6 papers)

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Research

26 pages, 11102 KiB

Open AccessArticle

Integrated Strategies for Controlling Water Cut in Mature Oil Fields in Kazakhstan

by Zhanat Alisheva, Kazim Nadirov, Ahmed N. Al-Dujaili, Gulmira Bimbetova, Zhanna Nadirova, Manap Zhantasov, Nurbol Tileuberdi and Ansagan Dauletuly

Polymers 2025, 17(7), 829; https://doi.org/10.3390/polym17070829 - 21 Mar 2025

Viewed by 426

Abstract

This study analyzed the physical and hydrodynamic characteristics of various horizons in the Kumkol and East Kumkol oil fields by special core analysis to integrate strategies for controlling water cuts and well-intervention procedures for a more effective oil flow rate in mature oil fields in Kazakhstan. The results indicated that the recovery factor (RF) for Horizon I is 48.3% (98.7% water cut), while Horizon II has an RF of 45.5% (97.9% water cut). Horizon III has an RF of 52.7% (98.8% water cut), and Horizon IV has an RF of 32.6% (98.6% water cut) in the Kumkol Field. In the East Kumkol Field, Horizon I has an RF of 49.5% (96.7% of water cut), and Horizon II has an RF of 31% (94.9% of water cut). The average increase in oil flow rate from well optimization ranges from 5.3 to 6.4 tons per day in the Kumkol Field and 5.22 tons per day in the East Kumkol Field. The maximum increase in oil flow rate is 10.8 tons/day for Horizon I in the Kumkol Field and 6.9 tons/day for Horizon II in the East Kumkol Field. The well-intervention procedures are more effective in the Kumkol Field than in the East Kumkol Field. Given the high water cut observed in these mature reservoirs, this study also examines polymer flooding as an enhanced oil recovery (EOR) technique to improve oil displacement efficiency and reduce water production. Polymer flooding has been successfully implemented in high water-cut reservoirs, including the Uzen field in Kazakhstan, demonstrating its ability to modify fluid filtration profiles and enhance oil recovery. The feasibility of applying polymer flooding in the Kumkol and East Kumkol fields is analyzed, along with a comparison of its effectiveness against conventional water shut-off and well-intervention methods. Additional research is needed to assess polymer retention, reservoir compatibility, and the economic feasibility of large-scale implementation. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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16 pages, 8185 KiB

Open AccessArticle

3-Pentadecylphenol (PDP) as a Novel Compatibilizer for Simultaneous Toughened and Reinforced PA10,12 Composites

by Yuwei Jin, Qi Zhang, Xiaokun Zhai, Hao Teng, Youmei Du, Jing Lu, Sumaiya Farzana, Patrick C. Lee, Ruiyan Zhang and Faliang Luo

Polymers 2024, 16(13), 1915; https://doi.org/10.3390/polym16131915 - 4 Jul 2024

Viewed by 1229

Abstract

The utilization of polyamide 10,12 (PA10,12) composites in various industries has been limited constrained by their inherent low toughness, making it a challenge to achieve a balance between toughness and structural integrity through conventional elastomer addition strategies. Herein, we introduce a straightforward method for the concurrent toughening and reinforcement of PA10,12 composites. This is accomplished by blending polyolefin elastomer (POE) and 3-pentadecylphenol (PDP) with the PA10,12 matrix. The incorporation of 5 wt% PDP effectively blurred the PA10,12/POE interface due to PDP’s role as a compatibilizer. This phenomenon is attributed to the formation of intermolecular hydrogen bonds, as evidenced by Fourier Transform Infrared Spectroscopy (FTIR) analysis. Further investigation, using differential scanning calorimetry (DSC), elucidated the crystallization thermodynamics and kinetics of the resulting binary PA10,12/POE and ternary PA10,12/POE/PDP composites. Notably, the crystallization temperature (T_c) was observed to decrease from 163.1 °C in the binary composite to 161.5 °C upon the addition of PDP. Increasing the PDP content to 10% led to a further reduction in T_c to 159.5 °C due to PDP’s capacity to slow down crystallization. Consequently, the ternary composite of PA10,12/POE/PDP (92/3/5 wt%) demonstrated a synergistic improvement in mechanical properties, with an elongation at break of 579% and a notch impact strength of 61.54 kJ/m². This represents an approximately eightfold increase over the impact strength of unmodified PA10,12. Therefore, our work provides the potential of PDP as a compatibilizer to develop nylon composites with enhanced stiffness and toughness. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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13 pages, 5401 KiB

Open AccessArticle

Enhanced High-Performance iPP/TPU/MWCNT Nanocomposite for Electromagnetic Interference Shielding

by Yanru Li, Wenting Yu, Qian Ruan, Kun Li, Xiaoqin Guo, Zhongyi Bai and Jingbo Chen

Polymers 2024, 16(13), 1837; https://doi.org/10.3390/polym16131837 - 27 Jun 2024

Viewed by 1214

Abstract

The rapid development of electronic communication technology has led to an undeniable issue of electromagnetic pollution, prompting widespread attention from researchers to the study of electromagnetic shielding materials. Herein, a simple and feasible method of melt blending was applied to prepare iPP/TPU/MWCNT nanocomposites with excellent electromagnetic shielding performance. The addition of maleic anhydride-grafted polypropylene (PP-g-MAH) effectively improved the interface compatibility of iPP and TPU. A double continuous structure within the matrix was achieved by controlling the iPP/TPU ratio at 4:6, while the incorporation of multi-walled carbon nanotubes endowed the composites with improved electromagnetic shielding properties. Furthermore, by regulating the addition sequence of raw materials during the melt-blending process, a selective distribution of carbon nanotubes in the TPU matrix was achieved, thereby constructing interconnected conductive networks within the composites, significantly enhancing the electromagnetic shielding performance of iPP/TPU/MWCNTs, which achieved a maximum EMI shielding efficiency of 37.8 dB at an iPP/TPU ratio of 4:6 and an MWCNT concentration of 10 wt.%. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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25 pages, 9943 KiB

Open AccessArticle

Phosphorus/Bromine Synergism Improved the Flame Retardancy of Polyethylene Terephthalate Foams

by Jia Du, Jiaxin Zheng, Chunling Xin and Yadong He

Polymers 2024, 16(12), 1690; https://doi.org/10.3390/polym16121690 - 13 Jun 2024

Cited by 1 | Viewed by 1004

Abstract

Polyethylene terephthalate (PET) foams have the characteristics of being lightweight and high strength, as well as offering good heat resistance, minimal water absorption, etc., and they have been widely used in the wind power field. In addition, they are being promisingly applied in automotive, rail, marine, construction, and other related fields. Therefore, the flame retardancy(FR) of PET foams is an issue that requires investigation. The addition of flame retardants would affect the chain extension reaction, viscoelasticity, and foamability of PET. In this study, zinc diethyl hypophosphite (ZDP) and decabromodiphenylethane (DBDPE) were used to form a synergistic FR system, in which ZDP is an acid source and DBDPE is a gas source, and both of them synergistically produced an expanded carbon layer to improve the flame retardancy of PET foams. The ratio of ZDP and DBDPE is crucial for the carbon yield and the expansion and thermal stability of the char layers. At the ZDP/DBDPE ratios of 9/3 and 7/5, the thickness of the char layers is about 3–4 mm, the limiting oxygen index (LOI) values of FR modified PET are 32.7% and 33.6%, respectively, and the vertical combustion tests both reached the V-0 level. As for the extruded phosphorous/bromine synergism FR PET foams, ZDP/DBDPE ratios of 3:1 and 2:1 were applied. As a result, the vertical combustion grade of foamed specimens could still reach V-0 grade, and the LOI values are all over 27%, reaching the refractory grade. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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19 pages, 5634 KiB

Open AccessArticle

Morphology and Compressive Properties of Extruded Polyethylene Terephthalate Foam

by Zhicheng Zhang, Chunling Xin, Chiyuan Ma, Wenchong Xu, Feng Ren and Yadong He

Polymers 2024, 16(6), 776; https://doi.org/10.3390/polym16060776 - 12 Mar 2024

Viewed by 1789

Abstract

The cell structure and compressive properties of extruded polyethylene terephthalate (PET) foam with different densities were studied. The die of the PET foaming extruder is a special multi-hole breaker plate, which results in a honeycomb-shaped foam block. The SEM analysis showed that the aspect ratio and cell wall thickness of the strand border is greater than that of the strand body. The cells are elongated and stronger in the extruding direction, and the foam anisotropy of the structure and compressive properties decrease with increasing density. The compression results show typical stress–strain curves even though the extruded PET foam is composed of multiple foamed strands. The compression properties of PET foam vary in each of the three directions, with the best performing direction (i.e., extrusion direction) showing stretch-dominated structures, while the other two directions show bending-dominated structures. Foam mechanics models based on both rectangular and elongated Kelvin cell geometries were considered to predict the compressive properties of PET foams in terms of relative density, structure anisotropy, and the properties of the raw polymer. The results show that the modulus and strength anisotropy of PET foam can be reasonably predicted by the rectangular cell model, but more accurate predictions were obtained with an appropriately assumed elongated Kelvin model. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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13 pages, 4004 KiB

Open AccessArticle

Lightweight ZnO/Carbonated Cotton Fiber Nanocomposites for Electromagnetic Interference Applications: Preparation and Properties

by Muhammad Waseem, Yuxiang Xie, Kesong Yu, Xiling Zhou, Yingchun Cai, Xiaoli Zhang, Baochen Liu and Jingbo Chen

Polymers 2024, 16(1), 116; https://doi.org/10.3390/polym16010116 - 29 Dec 2023

Cited by 4 | Viewed by 1538

Abstract

Electromagnetic wave pollution has become a significant harm posed to human health and precision instruments. To shelter such instruments from electromagnetic radiation, high-frequency electromagnetic interference (EMI) shielding materials are extremely desirable. The focus of this research is lightweight, high-absorption EMI shielding composites. Simple aqueous dispersion and drying procedures were used to prepare cotton fiber (CF)-based sheets combined with various zinc oxide (ZnO) contents. These composites were carbonated in a high-temperature furnace at 800 °C for two hours. The obtained CF/ZnO samples have densities of 1.02–1.08 g/cm³. The EMI shielding effectiveness of CF-30% ZnO, CF-50% ZnO, and CF-70% ZnO reached 32.06, 38.08, and 34.69 dB, respectively, to which more than 80% of absorption is attributed. The synergetic effects of carbon networks and surface structures are responsible for the high EMI shielding performance; various reflections inside the interconnected networks may also help in improving their EMI shielding performance. Full article

(This article belongs to the Special Issue Polymer Microcellular Foam Molding and Its Functionalization)

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