Solid state microcellular foamed poly(lactic acid): morphology and property characterization.

Poly(lactic acid) or PLA is a plant-based biodegrable plastic which exhibits many properties that are equivalent to or better than many petroleum-based plastics. However, there have been few commercial applications due to its lower impact resistance and higher cost than synthetic plastics. In this paper, the concept of creating microcellular foamed structures in PLA as a means to improve its shortcomings is presented. The effect of the foaming conditions (temperature and time) on the void fraction, volume expansion ratio, impact strength and tensile properties of foamed PLA is discussed. Each step of microcellular processing is addressed including: the manufacture of PLA film; the saturation of the samples with gas; the microcellular foaming of PLA; the void fraction determination, volume expansion ratio calculation, impact and tensile property characterization of foamed samples. The microcellular morphologies developed in PLA samples were a strong function of the foaming conditions. Due to the presence of foamed microcells, a twofold expansion ratio and significant improvements in the impact resistance (twofold increase over unfoamed PLA), strain at break (up to twofold increase over unfoamed PLA) and toughness (up to fourfold increase over unfoamed PLA) were achieved in PLA.