Morphology and Compressive Properties of Extruded Polyethylene Terephthalate Foam

The cell structure and compressive properties of extruded polyethylene terephthalate (PET) foam with different densities were studied. The die of the PET foaming extruder is a special multi-hole breaker plate, which results in a honeycomb-shaped foam block. The SEM analysis showed that the aspect ratio and cell wall thickness of the strand border is greater than that of the strand body. The cells are elongated and stronger in the extruding direction, and the foam anisotropy of the structure and compressive properties decrease with increasing density. The compression results show typical stress-strain curves even though the extruded PET foam is composed of multiple foamed strands. The compression properties of PET foam vary in each of the three directions, with the best performing direction (i.e., extrusion direction) showing stretch-dominated structures, while the other two directions show bending-dominated structures. Foam mechanics models based on both rectangular and elongated Kelvin cell geometries were considered to predict the compressive properties of PET foams in terms of relative density, structure anisotropy, and the properties of the raw polymer. The results show that the modulus and strength anisotropy of PET foam can be reasonably predicted by the rectangular cell model, but more accurate predictions were obtained with an appropriately assumed elongated Kelvin model.