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<p>Biodegradable poly(butylene adipate-co-terephthalate) (PBAT) foams are promising for sustainable applications, however, their inherent brittleness and poor dimensional recovery give rise to a dilemma between strength and elasticity. Herein, we challenge this trade-off by constructing a compatibilized microcellular blend consisting of PBAT and a bio-based polyether-block-amide (PEBAx) elastomer, with a multifunctional epoxy-based chain extender (CE) as a reactive compatibilizer. The CE formed graft copolymers at the interface, which significantly refined the phase morphology and enhanced interfacial adhesion-both of which were crucial for stabilizing the cellular structure during the foaming process. The optimized ternary foam exhibited a synergistic enhancement: a <i>227</i>% increase in compressive strength, a <i>76.7</i>% reduction in permanent deformation, and a <i>64</i>% improvement in rebound resilience compared to neat PBAT foam, thereby effectively decoupling the conventional property trade-off. Critically, after <i>10</i> compression cycles, the PBAT/CE/PEBAx foam retained <i>92.5</i>% of its initial strength with a low permanent set of only <i>5.5</i>%, demonstrating exceptional fatigue resistance. This microstructural design strategy provides a pathway to high-performance, biodegradable foams suitable for high-demand applications by reconciling the conflict between load-bearing capacity and elastic recovery.</p>

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High-Resilience and Cyclically Stable Bio-Based PBAT Composite Foams Enabled by Chain Extension and PEBAx Reinforcement

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Yuying Han,
  • Yuyuan Fan,
  • Kejian Cui,
  • Hongfu Zhou,
  • Xu Wang,
  • Yafeng Deng,
  • Xiaoling Zang,
  • Xiangdong Wang

摘要

Biodegradable poly(butylene adipate-co-terephthalate) (PBAT) foams are promising for sustainable applications, however, their inherent brittleness and poor dimensional recovery give rise to a dilemma between strength and elasticity. Herein, we challenge this trade-off by constructing a compatibilized microcellular blend consisting of PBAT and a bio-based polyether-block-amide (PEBAx) elastomer, with a multifunctional epoxy-based chain extender (CE) as a reactive compatibilizer. The CE formed graft copolymers at the interface, which significantly refined the phase morphology and enhanced interfacial adhesion-both of which were crucial for stabilizing the cellular structure during the foaming process. The optimized ternary foam exhibited a synergistic enhancement: a 227% increase in compressive strength, a 76.7% reduction in permanent deformation, and a 64% improvement in rebound resilience compared to neat PBAT foam, thereby effectively decoupling the conventional property trade-off. Critically, after 10 compression cycles, the PBAT/CE/PEBAx foam retained 92.5% of its initial strength with a low permanent set of only 5.5%, demonstrating exceptional fatigue resistance. This microstructural design strategy provides a pathway to high-performance, biodegradable foams suitable for high-demand applications by reconciling the conflict between load-bearing capacity and elastic recovery.