Low-Density and High-Performance Fiber-Reinforced PP/POE Composite Foam via Irradiation Crosslinking

This study addresses the challenge of achieving foam with a high expansion ratio and poor mechanical properties, caused by the low melt viscosity of semi-crystalline polypropylene (PP). We systematically employ a modification approach involving blending PP with polyolefin elastomers (POE), irradiation crosslinking, and fiber reinforcement to prepare fiber-reinforced crosslinked PP/POE composite foam. Through optimization and characterization of material composition and processing conditions, the obtained fiber-reinforced crosslinked PP/POE composite foam exhibits both low density and high performance. Specifically, at a crosslinking degree of 12%, the expansion ratio reaches 16 times its original value, and a foam density of 0.057 g/cm³ is reduced by 36% compared to the non-crosslinked PP/POE system with a density of 0.089 g/cm³. The density of the short-carbon-fiber-reinforced crosslinked sCF/PP/POE composite foam is comparable to that of the crosslinked PP/POE system, but the tensile strength reaches 0.69 MPa, representing a 200% increase over the crosslinked PP/POE system and a 41% increase over the non-crosslinked PP/POE system. Simultaneously, it exhibits excellent impact strength, tear resistance, and low heat shrinkage. Irradiation crosslinking is beneficial for enhancing the melt strength and resistance to high temperature thermal shrinkage of PP/POE foam, while fiber reinforcement contributes significantly to improving mechanical properties. These achieve a good complementary effect in low-density and high-performance PP foam modification.