A novel method of producing lightweight microcellular injection molded parts with improved ductility and toughness

摘要: Abstract This paper presents a novel method and the underlying mechanisms of improving ductility toughness polymer blend components using microcellular injection molding. By producing special structure morphology in blends proper material formulations, foamed parts can be significantly improved compared to those solid parts. The key is achieve with sub-micron scale immiscible secondary phase uniformly dispersed primary matrix. Upon tensile loading, cavitation facilitates interconnection voids form channels such that stretched component transforms into bundle fibrils. change turns fracture mechanism from crack propagation across matrix shear yielding fibrils loading direction. Process conditions, microstructures, morphologies, mechanical test results three different types blends, namely, polypropylene/high-density polyethylene (PP/HDPE), polypropylene/low-density (PP/LDPE), poly(lactic acid)/poly(3-hydroxybutyrate-co-3-hydroxy-valerate) (PLA/PHBV) are presented. Compared other toughening methods, this achieved more significant improvement while reducing consumption part weight.