Simultaneous crosslinking and foaming of ethylene‐propylene diene terpolymers (EPDM) organoclay composite foams

Abstract

This study used ethylene‐propylene diene monomers (EPDM), an elastomer, to develop foams incorporating clay as filler using simple compounding, chemical foaming, and peroxide‐mediated light crosslinking methods. The low‐temperature batch mixer was employed for compounding azodicarbonamide (ADC) as a foaming agent, dicumyl peroxide (DCP) as a crosslinker, followed by compression molding for sheet preparation and the high‐temperature foaming process. Fourier transform infrared spectroscopy (FTIR) equipped with a hot stage attenuated total reflection (ATR) was employed to elucidate the ADC decomposition and foaming. The DCP (0.25 phr) content was optimized based on the foaming expansion ratio (>4) and stability, which was further optimized in conjuncture with clay to generate high‐performance composite foams. The incorporation of 1% organoclay enhances the expansion ratio and specific tensile strength by >7 and ~ 270%, respectively, compared with EPDM foams without clay while displaying a density of 0.11 g/cm3. Overall, the developed foaming process can be extended to other elastomeric polymers for various applications such as protective gears (e.g., helmets and shin guards), thermal/sound insulation, packaging/containment, footwear soles, oil absorption, etc.