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Carbon particulate and controlled-hydrolysis assisted extrusion foaming of semi-crystalline polyethylene terephthalate for the enhanced thermal insulation property

This work presents a facile method to produce low-density PET foams using pristine semi-crystalline resin by moisture-induced controlled-hydrolysis in a tight processing window (moisture content ∼ 0.12 wt.%). We investigated the effect of moisture and moisture containing activated carbon (AC) on the foam expansion ratio, cell morphology, and PET resin degradation and crystallization properties. Controlled-hydrolysis increased the melt-flow rate of PET resin (intrinsic viscosity: 0.52 to 0.54 dL/g) without losing crystallinity, and thus the PET foams possess better tensile properties (∼2 MPa stress and ∼100% strain) and higher thermal stability (>200°C) than chemically modified PET foams. The foam density could be made as low as ∼ 0.15 g/cm3 using a lab scale twin-screw extruder. A strand array die was also designed to produce plate-shaped foam samples. AC allowed easier control of the moisture content and delayed resin degradation in extrusion. Both AC and micrographite (mGr) could stabilize the PET foam morphology in extrusion and serve as good infrared attenuation agents (IAAs) in a simulated housing thermal insulation experiment.