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<p>Lightweight materials are essential for advanced green manufacturing and ecological sustainability because they reduce energy consumption, minimize pollution, and improve resource utilization. Herein, a reinforcement strategy utilizing activated carbon (AC) as a functional filler to enhance the foaming behavior of thermoplastic polyester elastomer (TPEE) was developed, enabling the successful fabrication of lightweight, high-strength, and elastic TPEE/AC foams with superior hydrophobic and thermally insulating performance using environmentally friendly microcellular foaming technology. The uniform dispersion of AC enhanced the melt strength and the solubility of CO<sub>2</sub>, thereby significantly improving the foaming behavior, resulting in refined cell structures and reduced shrinkage. The optimized T-A-5 foam achieved a high expansion ratio (16.0), low shrinkage ratio (70.0%), and high recovery ratio (79.4%), outperforming the pure TPEE foam by 15.9%, 12.3%, and 212.6%, respectively. Moreover, the viscoelastic properties of TPEE/AC composites tested under two different conditions revealed contrasting trends in loss factor, indicating that the influence of fillers on TPEE viscoelasticity is highly temperature-dependent and state-sensitive. Further, the lightness and blackness of TPEE/AC foams can be tailored by varying AC content and cellular morphology. Moreover, the TPEE/AC foams exhibited improved compressive strength, low thermal conductivity (35.9 mW·m<sup>−1</sup>·K<sup>−1</sup>), and high hydrophobicity (122.5°). This study provides an effective strategy for designing high-performance TPEE foams with significant potential for energy-saving and environment-friendly applications.</p>

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Activated Carbon-derived Polyester Elastomer Foams with Tailored Structure and Blackness for High-performance Thermally Insulating Applications

  • 期刊论文

  • 发表日期：

    2026年5月14日

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  • Xu-Jiang Sun,
  • Yan-Ru Zhang,
  • Jia-Peng Ma,
  • Xu Wang,
  • Ke-Jian Cui,
  • Ting-Ting Feng,
  • Gui-Long Wang

摘要

Lightweight materials are essential for advanced green manufacturing and ecological sustainability because they reduce energy consumption, minimize pollution, and improve resource utilization. Herein, a reinforcement strategy utilizing activated carbon (AC) as a functional filler to enhance the foaming behavior of thermoplastic polyester elastomer (TPEE) was developed, enabling the successful fabrication of lightweight, high-strength, and elastic TPEE/AC foams with superior hydrophobic and thermally insulating performance using environmentally friendly microcellular foaming technology. The uniform dispersion of AC enhanced the melt strength and the solubility of CO2, thereby significantly improving the foaming behavior, resulting in refined cell structures and reduced shrinkage. The optimized T-A-5 foam achieved a high expansion ratio (16.0), low shrinkage ratio (70.0%), and high recovery ratio (79.4%), outperforming the pure TPEE foam by 15.9%, 12.3%, and 212.6%, respectively. Moreover, the viscoelastic properties of TPEE/AC composites tested under two different conditions revealed contrasting trends in loss factor, indicating that the influence of fillers on TPEE viscoelasticity is highly temperature-dependent and state-sensitive. Further, the lightness and blackness of TPEE/AC foams can be tailored by varying AC content and cellular morphology. Moreover, the TPEE/AC foams exhibited improved compressive strength, low thermal conductivity (35.9 mW·m−1·K−1), and high hydrophobicity (122.5°). This study provides an effective strategy for designing high-performance TPEE foams with significant potential for energy-saving and environment-friendly applications.