Expanded Beads of High Melt Strength Polypropylene Moldable at Low Steam Pressure by Foam Extrusion

We explore the foam extrusion of expanded polypropylene with a long chain branched random co-polypropylene to make its production process simpler and cheaper. The results show that the presence of long chain branches infer high melt strength and, hence, a wide foamability window. We explored the entire window of foaming conditions (namely, temperature and pressure) by means of an ad-hoc extrusion pilot line design. It is shown that the density of the beads can be varied from 20 to 100 kg/m3 using CO2 and isobutane as a blowing agent. The foamed beads were molded by steam-chest molding using moderate steam pressures of 0.3 to 0.35 MPa independently of the closed cell content. A characterization of the mechanical properties was performed on the molded parts. The steam molding pressure for sintering expanded polypropylene beads with a long chain branched random co-polypropylene is lower than the one usually needed for standard polypropylene beads by extrusion. The energy saving for the sintering makes the entire manufacturing processes cost efficient and can trigger new applications.

Thermoplastic polyurethane foams: From autoclave batch foaming to bead foam extrusion

Two ester-based and one ether-based thermoplastic polyurethane grades have been used to produce thermoplastic polyurethane foams. The foaming process comprised pressure-induced batch foaming, foam extrusion, and bead foam extrusion by using an underwater granulator. Foam density and morphological properties, such as cell size, cell size distribution, and cell density, were measured through different analytical methods. Through autoclave batch foaming a minimum cell size of 10 µm and density of 202 kg/m3 is obtained, which is lower than the densities previously reported in the literature for thermoplastic polyurethane. Extrusion foaming however could not achieve the same range of foam expansion given that the lowest density achieved is 635 kg/m3 and a minimum cell size equal to 46 µm. The production of thermoplastic polyurethane bead foams is also reported for the first time. The minimum density of the obtained foamed beads is 306 kg/m3 and the lowest cell size is 55 µm.

Viscosity measurement of polypropylene loaded with blowing agents (propane and carbon dioxide) by a novel inline method

Decreased viscosity due to the influence of blowing agent in thermoplastic polymer melts is a key issue for understanding the process of foam extrusion. In a process for direct foam extrusion, a novel approach for inline viscosity measurement of single-phase systems in single screw extruders is used to experimentally evaluate a viscosity decrease. Two blowing agents (propane and carbon dioxide) are tested for their effect on the viscosity of a polypropylene melt. While mass fractions of blowing agent below [Formula: see text] show little to no effect in regard to viscosity reduction compared to a pure polymer melt, a mass fraction of [Formula: see text] already results in significantly decreased viscosity values. While melt temperature influences the viscosity of the polymer melt, measurements show no significant additional effect in regard to a lowered viscosity of a single-phase system of polymer and fully dissolved blowing agent.