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This work is aimed at studying the foaming behavior of pure ultra-high molecular weight polyethylene (UHMWPE) with supercritical carbon dioxide (scCO2). The effects of foaming temperature and saturation pressure on the final foam structure were investigated by using two different one-step batch foaming processes. An in-situ high-pressure observing system was used to record the crystal change of UHMWPE film during heating and cooling stages with/without pressurized CO2. The results showed that the cell size and the cell density were affected by the combined effects of crystal, temperature, and pressure. Experimental results with different foaming temperatures showed that higher foaming temperatures led to larger cells and lower cell densities. In the processes of foaming during the heating stage (Proc1) and cooling stage (Proc2), the expansion ratio increased first and then decreased with the increase of temperature. Before obtaining the maximum expansion ratio, compare with Proc2, the cell size and expansion ratio of foams were smaller, and the cell density was higher in Proc1. Experimental results with different saturation pressures showed that higher pressure led to lower cell density and larger average cell diameter in Proc1 due to the reduction of crystals and melt strength. While in Proc2, higher saturation pressure led to higher cell density due to the increase of solubility of CO2, and the cell density decreased as the pressure further increased due to cell coalescence.

This work is aimed at studying the foaming behavior of pure ultra-high molecular weight polyethylene (UHMWPE) with supercritical carbon dioxide (scCO 2). The effects of foaming temperature and saturation pressure on the final foam structure were investigated by using two different one-step batch foaming processes. An in-situ high-pressure observing system was used to record the crystal change of UHMWPE film during heating and cooling stages with/without pressurized CO 2. The results showed that the cell size and the cell density were affected by the combined effects of crystal, temperature, and pressure. Experimental results with different foaming temperatures showed that higher foaming temperatures led to larger cells and lower cell densities. In the processes of foaming during the heating stage (Proc1) and cooling stage (Proc2), the expansion ratio increased first and then decreased with the increase of temperature. Before obtaining the maximum expansion ratio, compare with Proc2, the cell size and expansion ratio of foams were smaller, and the cell density was higher in Proc1. Experimental results with different saturation pressures showed that higher pressure led to lower cell density and larger average cell diameter in Proc1 due to the reduction of crystals and melt strength. While in Proc2, higher saturation pressure led to higher cell density due to the increase of solubility of CO 2 , and the cell density decreased as the pressure further increased due to cell coalescence. • The batch foaming behavior of pure UHMWPE with scCO 2 was investigated. • DSC analysis was used to determine the foaming temperatures of UHMWPE. • An in-situ system was used to observe UHMWPE crystal change in pressurized CO 2. • The effects of foaming temperature and saturation pressure on the final foam structure were investigated. • The cell size and cell density of UHMWPE foam were affected by the combined effects of crystal, temperature, and pressure. [ABSTRACT FROM AUTHOR]