Supercritical CO2 and polycarbonate based nanocomposites: A critical issue for foaming

Supercritical carbon dioxide readily induced foaming of various polymers. In that context, supercritical CO2 was applied to carbon nanotubes based polycarbonate nanocomposites to ensure their foaming. Surprisingly, efficient foaming only occurs when low pressure is applied while at high pressure, no expansion of the samples was observed. This is related to the ability of supercritical carbon dioxide to induce crystallization of amorphous polycarbonate. Moreover, this behaviour is amplified by the presence of carbon nanotubes that act as nucleating agents for crystals birth. The thermal behaviour of the composites was analysed by DSC and DMA and was related to the foaming observations. The uniformity of the cellular structure was analysed by scanning electron microscopy (SEM). By saturating the polycarbonate nanocomposites reinforced with 1 wt% of MWNTs at 100 bar and 100 °C during 16 h, microcellular foams were generated, with a density of 0.62, a cell size ranging from 0.6 to 4 μm, and a cellular density of 4.1 × 1011 cells cm−3. The high ability of these polymeric foams to absorb electromagnetic radiation was demonstrated at low MWNT content as the result of the high affinity of the polycarbonate matrix for MWNTs, and therefore to the good MWNTs dispersion.