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<p>Poly(butylene adipate-co-terephthalate) (PBAT) is an emerging eco-friendly polymer characterized by its biodegradability and superior mechanical properties. However, the preparation of high-strength and functional PBAT foams remains a challenge due to severe shrinkage and poor dimensional stability. This study reports an ultrasonic-enhanced microcellular foaming strategy integrating mica nanosheets to fabricate PBAT foams with high expansion ratio, superior open-cell content, and dimensional stability. Through the incorporation of mica nanosheets as heterogeneous nucleating agents, the method significantly improves cell density and suppresses coalescence, while the ultrasonic intervention enhances cell wall interconnectivity, resulting in an expansion ratio of 24.5, an open-cell content of 91.0%, and a shrinkage rate less than 10%. Cyclic mechanical tests demonstrate outstanding resilience, retaining &gt; 85% shape recovery after 20 compression cycles and 38% tensile strength retention across a 15℃ foaming temperature range. The dimensional stability is attributed to a two-tier mechanism: rapid gas exchange through highly interconnected cells and elastic energy dissipation during cell wall rupture. The integration of mica nanosheets and ultrasonic field modulation provides new insights into enhancing foam dimensional stability, offering potential solutions for other thermoplastic elastomers. This green manufacturing approach provides a scalable solution for biodegradable foam applications in precision packaging, cushioning and oil-water separation.</p>

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Achieving Lightweight, Low-Shrinkage and Superior Elastic Poly (Butylene Adipate-co-Terephthalate) Open-Cell Foams via Ultrasonic-Enhanced Microcellular Foaming

  • 期刊论文

  • 发表日期：

    2025年10月6日

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  • Jing Jiang,
  • Suyu Yang,
  • Min Qiao,
  • Zihui Li,
  • Xiaofeng Wang,
  • Changwei Zhu,
  • Qian Li

摘要

Poly(butylene adipate-co-terephthalate) (PBAT) is an emerging eco-friendly polymer characterized by its biodegradability and superior mechanical properties. However, the preparation of high-strength and functional PBAT foams remains a challenge due to severe shrinkage and poor dimensional stability. This study reports an ultrasonic-enhanced microcellular foaming strategy integrating mica nanosheets to fabricate PBAT foams with high expansion ratio, superior open-cell content, and dimensional stability. Through the incorporation of mica nanosheets as heterogeneous nucleating agents, the method significantly improves cell density and suppresses coalescence, while the ultrasonic intervention enhances cell wall interconnectivity, resulting in an expansion ratio of 24.5, an open-cell content of 91.0%, and a shrinkage rate less than 10%. Cyclic mechanical tests demonstrate outstanding resilience, retaining > 85% shape recovery after 20 compression cycles and 38% tensile strength retention across a 15℃ foaming temperature range. The dimensional stability is attributed to a two-tier mechanism: rapid gas exchange through highly interconnected cells and elastic energy dissipation during cell wall rupture. The integration of mica nanosheets and ultrasonic field modulation provides new insights into enhancing foam dimensional stability, offering potential solutions for other thermoplastic elastomers. This green manufacturing approach provides a scalable solution for biodegradable foam applications in precision packaging, cushioning and oil-water separation.