Effect of nanosize CaCO3 and nanoclay on morphology and properties of linear PP/branched PP blend foams

Branched polypropylene (PP) polymer (BPP), two nanoparticles with different aspect ratios, nano CaCO3, and nanoclay (Cloisite 20A), were used for improving the melt strength of linear PP (LPP) and producing microcellular foam via a solid‐state foaming process using supercritical N2 as a physical foaming agent. The effects of BPP and nanoparticles were investigated on the rheological and mechanical properties of the nanocomposite and morphological properties of the foamed samples. The effect of temperature, saturation pressure, and foaming time were studied on the morphological properties of the foams, too. The results showed that the BPP increased the elongation at break of nanocomposite samples, and nano CaCO3 increased tensile strength, elongation at break, and tensile modulus, except at its highest content (15 wt%) and improving the dispersion of nanoclay. The nanoclay improved tensile strength and tensile modulus of nanocomposites, except at its highest content (6 wt%). The nanoclay increased the cell density and reduced the cell size and improved melt strength and cell stability during the foaming process. The nano CaCO3 improved foamability, cell size, and cell density. The simultaneous presence of nanoclay and nano CaCO3 synergistically improved the cell density and decreased the cell size of the foams. The best process conditions were found as 140°C temperature, 80 bar pressure, and 2 h time. The results of the DSC analysis showed that the crystallinity of foamed samples was higher than the nanocomposites and DMTA analysis showed that the tan δ of foamed samples was higher than unfoamed samples. POLYM. COMPOS., 40:E227–E241, 2019. © 2017 Society of Plastics Engineers