Lightweight and High Impact Polypropylene Foam Fabricated via Ultra‐Low Gas Pressure Injection Molding

Abstract Foamed materials play an important role in a lightweight design. Foam injection molding (FIM) is advanced and convenient way to fabricate structural materials. Recently, new foam machine developed, which only needs ultra‐low gas pressure microcellular foam. As universal plastic, polypropylene (PP) widely used due its good mechanical properties. But after foaming, the toughness of PP tends decrease. Herein, high‐impact fabricated via FIM technology with nitrogen 6.5 MPa. PP/polyolefin elastomer (POE) tiny cell size 4.13 µm high density 2.7 × 10 9 cm − 3 successfully obtained. Owing superior cellular structure, compared pure foam, adding POE component, maximum impact performance increased by 465%. In this work, easy‐to‐industrialized method for preparing injection‐molded foams are presented.