Combining microcellular injection molding and insert injection molding, an injection molding technique for glass fiber fabric (GFF) reinforced polypropylene (PP) composite foams was proposed. The GFF was directly set in the mold cavity, and then the PP with supercritical nitrogen (SCN) was injected into the cavity for in-mold impregnation. The impregnation effects of two types of GFFs (EWR300 and EWR600) by the PP/SCF solutions at different injection temperatures (230, 240, and 250 °C) were investigated. The results of the morphological and tensile properties of the samples showed that the interfacial bonding was not good, because of the heterogeneity between the GFF and PP. In comparison with solid PP, the unfoamed GFF/PP did not present a higher tensile strength and presented a lower specific tensile strength. However, the increased tensile strength of the GFF/PP composite foams indicated an improvement in the impregnation effect and interfacial bonding. The SCN decreased the viscosity, which benefited the direct in-mold impregnation of the GFF. Increasing the temperature can improve the interfacial bonding, but it also influenced the foaming and thus led to a decrease in the tensile strength. According to the temperature distribution, the samples from different positions in the mold cavity had different properties.
Keywords: continuous fiber reinforced thermoplastics; glass fiber; in-mold impregnation; microcellular injection molding; polypropylene; supercritical nitrogen.