Analysis of Bubble Growth in Supercritical CO2 Extrusion Foaming Polyethylene Terephthalate Process Based on Dynamic Flow Simulation

Bubble growth in the polymer extrusion foaming process occurs under a dynamic melt flow. For non-Newtonian fluids, this work successfully coupled the dynamic melt flow simulation with the bubble growth model to realize bubble growth predictions in an extrusion flow. The initial thermophysical properties and dynamic rheological property distribution at the cross section of the die exit were calculated based on the finite element method. It was found that dynamic rheological properties provided a necessary solution for predicting bubble growth during the supercritical CO2 polyethylene terephthalate (PET) extrusion foaming process. The introduction of initial melt stress could effectively inhibit the rapid growth of bubbles and reduce the stable size of bubbles. However, the initial melt stress was ignored in previous work involving bubble growth predictions because it was not available. The simulation results based on the above theoretical model were consistent with the evolution trends of cell morphology and agreed well with the actual experimental results.

A study on fabrication of nanocomposite polyethylene foam through extrusion foaming procedure

Foaming a polymer not only turns it into a lightweight material but also gives some special properties to it. However, the most important issue is controlling the foaming process to achieve a desirable structure with high cell density and low relative density. In the present study, the extrusion foaming process of polyethylene was studied through stepwise amendments. An innovative extrusion system was designed and implemented to produce extrusion foams under different material and process conditions using N2 as blowing agent. In the first step, the final cooling condition was investigated. The air-cooling condition led to a higher cell density/lower cell size compared to the water-cooling condition although a higher relative density was obtained. In the second step, the effects of the addition of talc and the synergetic effect of talc/nanoclay at different contents were investigated in detail. The hybrid of talc/nanoclay had a noticeably improving effect on the cellular structure. In the third step, the effects of processing parameters including the die temperature and screw speed were studied on the foam properties. Finally, up to 49.4% decrease in the relative density of samples was observed, also cell densities up to 2.5 × 104 cell/cm3 and cell sizes as small as 280 µm were achieved.

Novel lightweight open-cell polypropylene foams for filtering hazardous materials

Lightweight polypropylene foams with similar geometries but different porous structures were prepared as filters for potentially hazardous materials via supercritical CO2 extrusion foaming without the use of harmful reagents and the problems of floating micro-nano fibers.