Microcellular injection molding of recycled poly(ethylene terephthalate) blends with chain extenders and nanoclay

Poly(ethylene terephthalate) (PET) resin is one of the most widely used thermoplastics, especially in packaging. Due to thermal and hydrolytic degradations, recycled PET (RPET) exhibits poor mechanical properties and lacks moldability. The effects of adding chain extender (CE) and nanoclay to RPET were investigated. Melt blending of RPET with CE was performed in a thermokinetic mixer (K-mixer). The blended materials were then prepared via solid and microcellular injection molding processes. The effects of CE loading levels and the simultaneous addition of nanoclay on the thermal and mechanical properties and cell morphology of the microcellular components were noted. The addition of 1.3% CE enhanced the tensile properties and viscosity of RPET. The higher amount of CE (at 3%) enhanced the viscosity, but the margin of improvement in mechanical properties diminished. While the solid RPET and CE blends were fairly ductile, the samples with nanoclay and all microcellular specimens showed brittle fractural behavior. Finally, nanoclay and the increase of CE content decreased the average cell size and enlarged the cell density of the microcellular samples.