Open microcellular polylactic acid foams with a fibrous polytetrafluoroethylene additive were prepared by a coreback foam injection molding technique. The effects of this fibrous additive on the foam cell structure were investigated. Fibrous polytetrafluoroethylene forms a network structure in polylactic acid in metering and mixing processes. The fibrous polytetrafluoroethylene network increased the viscoelasticity of polylactic acid and provided polylactic acid with a strain-hardening property. The network also provided heterogeneous bubble nucleation sites for physical foaming. However, because of the slow crystallization rate of polylactic acid, the fibrous polytetrafluoroethylene additive did not promote the nucleation of polylactic acid crystals under fast cooling conditions. During fast cooling, such as injection molding cooling conditions, the crystals induced by the fibrous polytetrafluoroethylene network could not behave as bubble nucleation sites. Thus, changes in rheological properties and the increased number of heterogeneous sites contributed to the decrease in cell size, the increase in the number density of cells and the increase in the open cell content. As the number density of cells increased, the cell walls with the fibrous polytetrafluoroethylene fibrous additive became so thin that they could be easily fibrillated by a stretching operation during the coreback operation, while their strain-hardening property prevented the walls from complete breakage. Synergistically conducting cell reduction and stretching (coreback) operations, high expansion ratio foams with high open cell content were prepared. When we adjusted the foaming temperature and holding time, five-fold expansion (i.e. 80% void ratio) foams with cell diameters less than 25 µm and open cell contents (OCC) higher than 80% were produced.
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