Low density microcellular foam processing in extrusion using CO₂

wbldb

Park, Chul B.¹; Behravesh, Amir H.¹; Venter, Ronald D.¹

Low density microcellular foam processing in extrusion using CO₂

Polym Eng Sci. November 1998;38(11):1812-1823

Affiliations

¹Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, Ontario, Canada M5S 3G8
Abstract

A continuous extrusion process for the manufacture of low-density microcellular polymers is presented. Microcellular polymers are foamed plastics characterized by a cell density greater than 10⁹ cells/cm³ and a fully grown cell size on the order of 10 μm. Previous research on continuous processing of microcellular polymers has focused on control of microcell nucleation in extrusion. This paper presents an effective means for control of cell growth to achieve a desired expansion ratio with CO₂ as a blowing agent in microcellular foam processing. Also, a strategy to prevent deterioration of the cell-population density via cell coalescence during expansion is presented. Promotion of a desired volume expansion ratio and prevention of cell coalescence in microcellular foam processing were experimentally verified. By tailoring the extrusion processing parameters, microcellular HIPS foams with a cell density of 10¹⁰ cells/cm³ and a controlled expansion ratio in the range of 1.5 to 23 were obtained.
Links

DOI: 10.1002/pen.10351

WoS: 000077729300004

Cited Works (1)

Year	Entry
1997	Matuana LM, Park CB, Balatinecz JJ. Processing and cell morphology relationships for microcellular foamed PVC/wood-fiber composites. Polym Eng Sci. July 1997;37(7):1137-1147.

Cited By (43)

Year	Entry
2002	Naguib HE, Park CB, Panzer U, Reichelt N. Strategies for achieving ultra low-density polypropylene foams. Polym Eng Sci. July 2002;42(7):1481-1492.
2011	Diaz-Acosta CA. Continuous Microcellular Foaming of Polylactic Acid/natural Fiber Composites [PhD thesis]. East Lansing, MI: Michigan State University; 2011.
2016	Naeem ISS. Development of Thermoplastic Foams With Heterogeneous Cellular Structures for Acoustic Applications [PhD thesis]. University of Ontario Institute of Technology; August 2016.
2020	Raktim IK. Design, Development and Experimental Validation of a Lab-Scale System for Rapid Rotational Molding of Functionally Graded Integral-Skin Cellular Polyethylene Composites [Master's thesis]. University of Ontario Institute of Technology; March 2020.
1998	Rizvi GM. Extrusion Foaming of Plastic/wood-Fiber Composites Using a Chemical Blowing Agent [Master's thesis]. University of Toronto; 1998.
1999	Park SS. On-Line Measurement of the PVT Properties of Polymer/CO₂ Solutions Using a Gear Pump [Master's thesis]. University of Toronto; 1999.
2000	Zhang H. Extrusion of Fine-Celled Plastic/wood-Fiber Composite Foams Using CO₂ as a Blowing Agent [Master's thesis]. University of Toronto; 2000.
2001	Guo G. Manufacture of Fine-Celled Plastic/wood-Fiber Composite Foams Using CO₂ as a Blowing Agent [Master's thesis]. University of Toronto; 2001.
2001	Lee PC. Manufacture of Microcellular Open-Celled Polyolefin Foams [Master's thesis]. University of Toronto; 2001.
2001	Naguib HE. Extrusion Processing for Manufacture of Low-Density, Fine-Celled Polypropylene Foams [PhD thesis]. University of Toronto; 2001.
2003	Rizvi GM. Development of Extrusion Processing Technology for Manufacture of Fine-Celled Plastic/wood-Fiber Composite Foams [PhD thesis]. University of Toronto; 2003.
2003	Pop-Iliev R. Processing Integral-Skin Polyolefin Foams in Single-Charge Rotational Foam Molding [PhD thesis]. University of Toronto; 2003.
2004	Lee YH. Polyethylene/clay Nanocomposite Foams Blown With Physical Blowing Agents (PBA): From Microcellular to Nanocellular [Master's thesis]. University of Toronto; 2004.
2005	Xu D. The Role of Die Shape for Promoting Large Volume Expansion Ratios of the Extruded Foams [PhD thesis]. University of Toronto; 2005.
2006	Guo G. Development of Fine-Celled Bio-Fiber Composite Foams Using Physical Blowing Agents and Nano-Particles [PhD thesis]. University of Toronto; 2006.
2006	Lee C-DP. Extrusion Processing of Low-Bulk Density, Microcellular, Open-Cell Thermoplastic Foams [PhD thesis]. University of Toronto; 2006.
2007	Li G. Thermodynamic Investigation of the Solubility of Physical Blowing Agents in Polymer Melts [PhD thesis]. University of Toronto; 2007.
2007	Wang C. Fabrication of Microcellular Ceramics from Polysiloxane-Polyolefin Blends by Using Polymer Foaming Technology [PhD thesis]. University of Toronto; 2007.
2007	Wong H-FS. Mechanical Characterization of Thermoplastic Polyolefin (TPO) Foams [Master's thesis]. University of Toronto; 2007.
2007	Zhu Z. Modeling of Expansion and Collapse of Extruded Filamentary Foam Through Cell-to-Cell Diffusion [PhD thesis]. University of Toronto; 2007.
2008	Kim S-G. A Study on the Foaming Behavior of Thermoplastic Polyolefin (TPO) Blends [PhD thesis]. University of Toronto; 2008.
2008	Lee YH. Foaming of Wood Flour/polyolefin/layered Silicate Composites [PhD thesis]. University of Toronto; 2008.
2008	Li YGG. Development of a Novel Visualization and Measurement Apparatus for the PVT Behaviours of Polymer/gas Solutions [PhD thesis]. University of Toronto; 2008.
2009	Lee JWS. Investigation of Foaming Behaviors in Injection Molding Using Mold Pressure Profile [PhD thesis]. University of Toronto; 2009.
2009	Leung SNS. Mechanisms of Cell Nucleation, Growth, and Coarsening in Plastic Foaming: Theory, Simulation, and Experiment [PhD thesis]. University of Toronto; 2009.
2009	Wang J. Rheology of Foaming Polymers and Its Influence on Microcellular Processing [PhD thesis]. University of Toronto; 2009.
2010	Lee EK. Novel Manufacturing Processes for Polymer Bead Foams [PhD thesis]. University of Toronto; 2010.
2010	Zhang H. Scale-Up of Extrusion Foaming Process for Manufacture of Polystyrene Foams Using Carbon Dioxide [Master's thesis]. University of Toronto; 2010.
2012	Chen N. The Effects of Crosslinking on Foaming of EVA [PhD thesis]. University of Toronto; 2012.
2012	Majithiya KM. The Effect of Molecular Weight on Polypropylene Foaming [Master's thesis]. University of Toronto; 2012.
2012	Naeini AT. Visualization of the Crystallization in Foam Extrusion Process [Master's thesis]. University of Toronto; 2012.
2013	Hasan MM. A Systematic Study of Solubility of Physical Blowing Agents and Their Blends in Polymers and Their Nanocomposites [PhD thesis]. University of Toronto; 2013.
2013	Jung PU. Development of Innovative Gas-Assisted Foam Injection Molding Technology [PhD thesis]. University of Toronto; 2013.
2014	Hossieny N. Development of Expanded Thermoplastic Polyurethane Bead Foams and Their Sintering Mechanism [PhD thesis]. University of Toronto; 2014.
2015	Andalib KMZ. Increasing Void Fraction of the Polypropylene Foams Blown With Chemical Blowing Agents in High Temperature Extrusion [Master's thesis]. University of Toronto; November 2015.
2017	Sanieisichani M. Nanocellular Foams With a Superior Thermal Insulation Property [PhD thesis]. University of Toronto; 2017.
2017	Tabatabaei Naeini A. In-Situ Visualization and Quantification of Polymer Crystallization Under Complex Flows During Foam Extrusion Processing [PhD thesis]. University of Toronto; 2017.
2018	Alshrah MM. Development of Lightweight Organic Aerogels for Thermal Insulation Applications [PhD thesis]. University of Toronto; November 2018.
2019	Hamidinejad S. Thermal and Electrical Properties of Graphene-Based Polymer Nanocomposite Foams [PhD thesis]. University of Toronto; 2019.
2021	Chen Z. The Study on Cell Nucleation and Cell Growth Mechanisms and Behaviors in Multilayered Alternating Film/foam Structures [Master's thesis]. University of Toronto; 2021.
2021	Yu L. Lightweight Foam Structures for Aerospace Application Using High-Performance Polymer PPSU [Master's thesis]. University of Toronto; 2021.
2024	Mark LH. PP and Nanofibrillated-PET Composites from Melt Blowing: Fundamentals to Scale-Up [PhD thesis]. University of Toronto; 2024.
2016	Lee K. Feasibility of Fiber Optic Sensors in Sensing High Refractive Index for the Potential Application of Acquiring Solubility and Diffusivity of Gases and Supercritical Fluids in Polymers [Master's thesis]. University of Victoria; 2016.