Improved expansion ratio and heat resistance of microcellular poly(L-lactide) foam via in-situ formation of stereocomplex crystallites

It is critical to broaden the applications of poly(L-lactic acid) foams by improving heat resistance properties. The stereocomplex crystallites that are formed by melt blending of poly(L-lactic acid)/polylactide possess high melting point of about 220℃ and thus exhibit high heat resistance; therefore, the introduction of stereocomplex crystallites tends to improve the thermal stability of poly(lactic acid) foam. Unfortunately, using the solid-state foaming method, it was found that the expansion ratio of the obtained poly(lactic acid) foams was compromised with the value of 1.7 times once the stereocomplex crystallites were formed during the sample saturation stage. In this study, by applying a high compression molding temperature of 230℃, the as-prepared poly(L-lactic acid) and poly(L-lactic acid)/polylactide blends were amorphous. After being CO₂ saturated at a mild condition, the specimens were foamed at 90–160℃. The wide-angle X-ray diffraction profiles presented that the stereocomplex crystallites and PLA homocrystals were in-situ generated during the foaming process. It is observed that the in-situ formed stereocomplex crystallites could act as the physical cross-linking agent to stabilize the nucleated bubbles and suppress cell coalescence, resulting in the increased expansion ratio (with value of about 23.6–25.6 times) and cell density, especially at high foaming temperatures and extended foaming time. Furthermore, the in-situ formed stereocomplex crystallites during the foaming increased the heat resistance performance of poly(L-lactic acid) foams. This novel crystallization control method helps us to find a balance point in preparing poly(L-lactic acid) foam with high expansion ratio, well-defined cell structure and high heat resistance performance.