Fabrication and characterization of carbon nanofibers coated expandable thermoplastic microspheres-based polymer composites

Background: Thermoplastic expandable microspheres (TEMs) are spherical particles that consist of polymer shell encapsulating a low boiling point liquid hydrocarbon that acts as the blowing agent. When TEMs are heated at 80-190 C, the polymer shell softens and the hydrocarbon gasifies, causing the microspheres expand leading to increase in volume and decrease in density. TEMs are used in food packaging, elastomeric cool roof coatings, shoe soles, fiber and paper board, and various applications in the automotive industry. It is noted that TEMs are known by its brand name ‘Expancel’ which is also used to refer TEMs in this paper. Objective: The objective of this work was to develop and characterize forms prepared from TEMs with/without carbon nanofibers (CNFs) coatings to study the effect of CNFs on structural, thermal, and mechanical properties. Method: Sonochemical method was used to coat TEMs with various weight percentage (1, 2, and 3 %) of CNF. Neat foam (without CNF) and composite foams (TEMs coated with various wt.% of CNF) were prepared by compression molding the TEMs and TEMs-CNF composites powders. Thermal and mechanical properties of the neat and composite foams were investigated. Result: The mechanical properties of the composite foam were notably improved, which is exhibited by a 54% increase in flexural modulus and a 6% decrease in failure strain with the TEMs-(2 wt.% CNF) composite foam as compared to the neat foam. Improvement in thermal properties of composite foam was demonstrated by a 38% increase in thermal stability at 800 ºC with the TEMs-(1 wt.% CNF) composite foam as compared to the neat foam. However, no change in glass transition of TEMs was observed with the CNF coating. SEM-based analysis revealed that CNFs were well dispersed throughout the volume of the TEMs matrix forming a strong interface. Conclusions: Straightforward sonochemical method successfully triggered efficient coating of TEMs with CNFs resulting to strong adhesion interface. The mechanical properties of composite foams increased up to 2% of CNFs coating and then decreased with the higher coating presumably due to interwoven bundles and aggregation of CNFs, which might have acted as critical flaws to initiate and propagate cracking. Thermal properties of foams increased with the CNFs coating while no change in glass transition temperature was observed due to coating.