Foam extrusion of high density polyethylene/wood-flour composites using chemical foaming agents

The Facile and Efficient Fabrication of Rice Husk/poly (lactic acid) Foam Composites by Coordinated the Interface Combination and Bubble Hole Structure

The possibility of agricultural-forestry waste (rice husks) and biodegradable plastics (poly(lactic acid)) being used to produce ecologically friendly foam composite was discussed in this work. The effects of different material parameters (the dosage of PLA-g-MAH, type and content of chemical foaming agent) on the microstructure and physical properties of composite were investigated. PLA-g-MAH promoted the chemical grafting between cellulose and PLA, and made the structure denser, thus improving the interface compatibility of the two phases and resulting in good thermal stability, high tensile strength (6.99 MPa) and bending strength (28.85 MPa) of composites. Furthermore, the properties of rice husk/PLA foam composite prepared by two kinds of foaming agents (endothermic and exothermic) were characterized. The addition of fiber limited the growth of pores, which provided better dimensional stability and narrower pore size distribution, made the interface of the composite bond tightly. And the bubble can prevent crack propagation and improve the mechanical properties of the composite. The bending strength and tensile strength of composite were 37.36 MPa and 25.32 MPa, which increased by 28.35 % and 23.27 %, respectively. Therefore, the composite prepared by using agricultural-forestry wastes and poly(lactic acid) possess acceptable mechanical properties, thermal stability and water resistance, expanding the scope of application.

Morphological and mechanical properties of foamed thick-walled Wood-Plastic-Composite structures

Microcellular wood fiber reinforced polymers offer the possibility to reduce the use of fossil raw materials. In particular, thick-walled structures with thicknesses greater than 6 mm offer a high potential for weight savings. This study investigates the cell structures and mechanical properties of injection-molded test specimens. The influence of different thicknesses (6–10 mm) along with different chemical blowing agents (endothermic, exothermic) with varying dosages (0–2 wt%) is analyzed. The investigations reveal that exothermic chemical blowing agents form finer cells consistently to thin-walled structures than endothermic ones. Higher foaming agent content leads to higher pore fractions, with many small cells coalescing into a large open-pore cell network. The mechanical properties depend mainly on the pore content of the sample. The specific tensile properties deteriorate with the use of chemical blowing agents (CFA), whereas the sandwich structure produced with compact edge layers has a positive influence on the specific flexural properties.

Foamability of Cellulose Palmitate Using Various Physical Blowing Agents in the Extrusion Process

Polymer foams are widely used in several fields such as thermal insulation, acoustics, automotive, and packaging. The most widely used polymer foams are made of polyurethane, polystyrene, and polyethylene but environmental awareness is boosting interest towards alternative bio-based materials. In this study, the suitability of bio-based thermoplastic cellulose palmitate for extrusion foaming was studied. Isobutane, carbon dioxide (CO₂), and nitrogen (N₂) were tested as blowing agents in different concentrations. Each of them enabled cellulose palmitate foam formation. Isobutane foams exhibited the lowest density with the largest average cell size and nitrogen foams indicated most uniform cell morphology. The effect of die temperature on foamability was further studied with isobutane (3 wt%) as a blowing agent. Die temperature had a relatively low impact on foam density and the differences were mainly encountered with regard to surface quality and cell size distribution. This study demonstrates that cellulose palmitate can be foamed but to produce foams with greater quality, the material homogeneity needs to be improved and researched further.

Compression Molding of Thermoplastic Polyurethane Foam Sheets with Beads Expanded by Supercritical CO2 Foaming

Expanded thermoplastic polyurethane (ETPU) beads were prepared by a supercritical CO₂ foaming process and compression molded to manufacture foam sheets. The effect of the cell structure of the foamed beads on the properties of the foam sheets was studied. Higher foaming pressure resulted in a greater number of cells and thus, smaller cell size, while increasing the foaming temperature at a fixed pressure lowered the viscosity to result in fewer cells and a larger cell size, increasing the expansion ratio of the ETPU. Although the processing window in which the cell structure of the ETPU beads can be maintained was very limited compared to that of steam chest molding, compression molding of ETPU beads to produce foam sheets was possible by controlling the compression pressure and temperature to obtain sintering of the bead surfaces. Properties of the foam sheets are influenced by the expansion ratio of the beads and the increase in the expansion ratio increased the foam resilience, decreased the hardness, and increased the tensile strength and elongation at break.

Micro- and Nanocellulose in Polymer Composite Materials: A Review

The high demand for plastic and polymeric materials which keeps rising every year makes them important industries, for which sustainability is a crucial aspect to be taken into account. Therefore, it becomes a requirement to makes it a clean and eco-friendly industry. Cellulose creates an excellent opportunity to minimize the effect of non-degradable materials by using it as a filler for either a synthesis matrix or a natural starch matrix. It is the primary substance in the walls of plant cells, helping plants to remain stiff and upright, and can be found in plant sources, agriculture waste, animals, and bacterial pellicle. In this review, we discussed the recent research development and studies in the field of biocomposites that focused on the techniques of extracting micro- and nanocellulose, treatment and modification of cellulose, classification, and applications of cellulose. In addition, this review paper looked inward on how the reinforcement of micro- and nanocellulose can yield a material with improved performance. This article featured the performances, limitations, and possible areas of improvement to fit into the broader range of engineering applications.

Experimental investigation on the forming and evolution process of cell structure in gas counter pressure assisted chemical foaming injection molded parts

By using a standard stretch spline as the research object, the influence of gas counter pressure (GCP) technology on melt foaming behavior in chemical foaming injection molding (CFIM) process was investigated. Related experimental line for GCP assisted CFIM foam was designed, and the effect of GCP technology on melt flow front, spline surface quality and internal cell was studied. According to the results obtained from the experiment, two critical GCP pressures and one critical GCP holding time were innovation proposed. Two critical GCP pressures are the critical GCP pressure of melt flow front cell not cracking and the critical GCP pressure of melt not foaming, respectively. The critical GCP holding time is the secondary foaming behavior time. Based on the proposed critical GCP pressures and critical GCP holding time, the influence mechanism of GCP technology on melt foaming action during CFIM process was revealed.

Rheology and Extrusion Foaming of Partially Crosslinked Thermoplastic Vulcanizates Silicone

This work focuses on the foaming behavior of thermoplastic vulcanized silicones (TPVs) in which partially crosslinked silicone nodules are dispersed. In these TPVs, silicone nodules dispersed in a low density polyethylene (LDPE) phase have an average size of about 1 μm. The crosslinking densities of the elastomer phase were selected according to their viscoelastic behavior. Surprisingly, linear and non-linear shear rheology appeared more sensitive to formulations than extensional rheology. Indeed, each formulation has an extensional rheological behavior similar to that of pure LDPE and meets the requirements for foaming applications in terms of elongation at break and melt strength. In accordance with non-linear shear rheology, the foaming behavior of these formulations has been correlated to extrusion foaming parameters that are known to control nucleation, i. e. pre-die pressure and die exit depressurization rate. With an appropriate crosslinking density of silicone nodules, the TPV foamability tends to the foamability of pure LDPE to reach a foam density of 0.54 g/cm3 with an average cell size of 140 ± 50 μm and a cell density of 3 × 105 cells/cm3. Since partially crosslinked silicone nodules cannot foam, it is assumed that they improve nucleation while allowing sufficient expansion of the LDPE phase.

Shape memory polymer foams prepared from a heparin-inspired polyurethane/urea

Shape memory foams have been prepared using a heparin-inspired polyurea/urethane that displays excellent resistance to platelet adherence.

Foam extrusion of PP-based wood plastic composites with chemical blowing agents and the Celuka technique

Wood plastic composites have gained relevance in recent years as an alternative to wood boards. However, because the cavities in wood fibres are compressed by high processing pressure during the extrusion of wood plastic composites, the product densities show a range of up to 1.5 g/cm3 depending on wood content and base material. Particularly in large-sized products, this may be disadvantageous for processors and end users. Foaming of the plastic matrix is a promising approach to reduce the density of wood plastic composites products. This article discusses the foam extrusion of PP-based wood plastic composites with chemical blowing agents in combination with the Celuka technique. Integral wood plastic composites foam with a rigid and plain outer layer was produced using a parallel, counter rotating twin screw extruder. The profiles obtained were analysed with respect to foam structure and mechanical properties. It was possible to achieve a density reduction of up to 0.7 g/cm3 in the foamed wood plastic composites profiles. Furthermore, we demonstrate that wood fibre length and type of chemical blowing agent have a strong effect on the resulting foam morphology.

Comparative Effects of mEOC on the Structures and Properties of PP/SGF and PP/EOC/SGF Composite Foams

To improve the impact toughness of short glass fiber (SGF) reinforced polypropylene (PP) composite foams, maleic anhydride grafted ethylene-α-octene copolymer (mEOC) was employed as impact modifier and interfacial compatibilizer. And for comparison, mEOC was also introduced into PP/EOC/SGF composite foams. Then, the foaming qualities, interfacial structures and mechanical properties of samples against varying mEOC contents were examined and compared in detail. Results showed that adequate mEOC significantly improved the foamabilities of the composites, while the optimized mass fraction was 8% for PP/SGF composite foams and 3% for PP/EOC/SGF system. Increased mEOC facilitated the higher impact toughness, which was increased by 77% for PP/SGF composite foams, whereas only 5% for PP/EOC/SGF foams. However, the flexural strengths were just improved slightly, while compressive strengths decreased monotonically with mEOC for the investigated composite foams.

Comparative study of chemical and physical foaming methods for injection-molded thermoplastic polyurethane

Thermoplastic polyurethane is one of the most versatile thermoplastic materials being used in a myriad of industrial and commercial applications. Thermoplastic polyurethane foams are finding new applications in various industries including the furniture, automotive, sportswear, and packaging industries because of their easy processability and desirable customizable properties. In this study, three methods of manufacturing injection molded low density foams were investigated and compared: (1) using chemical blowing agents, (2) using microcellular injection molding with N2 as the blowing agent, and (3) using a combination of supercritical gas-laden pellets injection molding foaming technology and microcellular injection molding processes using co-blowing agents CO2 and N2. Thermal, rheological, microscopic imaging, and mechanical testing were carried out on the molded samples with increasing amounts of blowing agents. The results showed that the use of physical blowing agents yielded softer foams, while the use of CO2 and N2 as co-blowing agents helped to manufacture foams with lower bulk densities, better microstructures, and lower hysteresis loss ratios. Chemical blowing agent-foamed thermoplastic polyurethane showed an earlier onset of degradation. The average cell size decreased and the cell density increased with the use of co-blowing agents. A further increase in gas saturation levels showed a degradation of microstructure by cell coalescence.

Die opening-induced microstructure growth in extrusion foaming of thermoplastic sheets

In this study, the influence of die opening gap on foam attributes during a microcellular extrusion foaming process was investigated. Lower die openings developed higher pressure drops on the foams, as a result of which greater thermodynamic instability was stimulated and, consequently, higher cell density foams along with enhanced expansion ratios were achieved. Further investigations were performed to study the synergistic influence of altering die opening with critical process parameters, namely, screw rotational speed and die temperature, on the foam expansion ratio and morphological transformations. Higher screw rotational speed induced shear nucleation phenomenon, which further enhanced the foaming process significantly. Also, an optimum die temperature was observed, which developed maximum expansion ratio at the lowest die opening gap. This study intends to enhance the understanding of extrusion foam processing among academia as well as among industries.

High-Internal-Phase Emulsion Tailoring Polymer Amphiphilicity towards an Efficient NIR-Sensitive Bacteria Filter

Emulsions having a high internal-phase volume fraction—termed as HIPEs for high internal phase emulsions—are in high demand as templates for functional macroporous materials. Designing molecular surfactants with appropriate amphiphilicity plays a critical role in the HIPE preparation. In this study, successful tailoring of the amphiphilicity of the originally hydrophobic block co-polymer of polystyrene-b-polyvinylpyridine (PS-b-P4VP) is reported. In combination with trifluoroacetic acid, less than 5 wt% of the polymer-CF3COOH system is feasible as a surfactant for HIPE preparation; this is lower than the amounts typically needed for commonly used commercial surfactants. Using the HIPEs as templates, well-defined closed- and open-cell macroporous triacrylate-based monoliths are fabricated simply through the adjustment of the ratio of the water phase to oil phase. After coating the resulting macroporous material with polypyrrole nanoparticles, the system can be exploited as an NIR-sensitive filter for bacteria; it not only excludes oversized bacteria, but it also kills the bacteria with the help of NIR-induced heat.

Properties and Physical Structure of Cellular PVC Coatings

The production of cellular coatings made of polymeric materials by the extrusion process differs from solid coating extrusion in that the polymer produced by the process based on the application of blowing agents has a diphase structure (gas-polymer) with small and evenly distributed gas bubbles. The research described in the paper was conducted using blowing agents with endothermic and exothermic decomposition behaviours, dosed as pellets in the range from 0.4% to 0.8% by weight relative to the weight of the polymer being processed. The extrusion process for modified PVC was conducted using the technological line for the production of electrical cable coatings.

The content of the blowing agents applied in the tests in the amount of up to 0.8 wt% was selected in such a way as to produce cables with a solid coating and center coating. The appearance of the produced cable coatings, their thickness and dimensions comply with the current norms.

In the investigated range of the blowing agent content, the temperature of the extrudate leaving the head decreased by approximately 7%, which can probably be attributed to the endothermic blowing agent decomposition behaviour in the extruder head.

The mechanical properties of cellular products, including their hardness, are affected by the macromolecular shape, orientation and bond. A lower number of cross-linkages in the cellular polymeric material means decreased strength properties of such product.

The results of the cellular coating resistance to water and oil absorption have demonstrated considerably increased absorption of the coatings produced, depending on the residence time in the aggressive environment and type of blowing agent applied.

Analyzing the results of density, porosity and optical examination of the physical structure of thin-walled cellular coatings, it has been determined that the favourable content of the blowing agent in the polymer should amount to 0.6-0.8 wt%, which leads to density decrease by approximately 40%.

Twin screw extrusion with Expancel foaming agent

Foam extrusion of polypropylene with a foaming agent, Expancel 950 MB 80 and 950 MB 120, was performed. The process was performed using a co-rotating twin screw extruder, with an 18 mm screw diameter and 24 L/D ratio. Dependences of polymer mass flow rate, extrudate foam rate, and polymer pressure on screw speed and foaming agent amount were determined and relevant conclusions were drawn.

Microcellular Wood Fibre Reinforced PP Composites

Microcellular wood fibre reinforced polymers have practical significance given the possibility of reducing the density of automotive components due to their microcellular structure, as well as processing and performance advantages. A microcellular foaming process with a chemical foaming agent was applied at an experimental stage to injection moulding, extrusion and compression moulding of wood fibre reinforced polypropylene composites. The focus of the research was to investigate these processes using a chemical foaming agent and to perform comparative studies of the physico-mechanical properties of microcellular materials. The effects of the presence of the chemical foaming agent (exothermic) and variation of its content on density, microvoid content, mechanical properties (tensile and flexural), odour concentration and cell morphology of microcellular polypropylene-wood fibre composites were studied. The morphology, cell size, shape and distribution of the microcells were investigated using scanning electron micrographs. Injection moulding process produced finer microcellular structures in comparison with the other processes. As compared to the non foamed composites, the density reduced maximum 30% (0.741 g/cm3), 20% (0.837 g/cm3) and 22% (0.830 g/cm3) for the injection moulding, extrusion and compression moulding process respectively. The chemical foaming agent reduced the odour concentration in relation to the same non foamed composites. Injection moulding showed better performance in comparison with extrusion and compression moulding in terms of cell morphology, density reduction, odour concentration and mechanical properties.

Natural Fibre-Reinforced Biofoams

Starches and polylactic acids (PLAs) represent the main biobased and biodegradable polymers with potential industrial availability in the next decades for “bio” foams applications. This paper investigates the improvement of their morphology and properties through processing and materials parameters. Starch foams were obtained by melt extrusion in which water is used as blowing agent. The incorporation of natural fibres (hemp, cellulose, cotton linter, sugarcane, coconut) in the starch foam induced a density reduction up to 33%, a decrease in water absorption, and an increase in mechanical properties according to the fibre content and nature. PLA foams were obtained through single-screw extrusion using of a chemical blowing agent that decomposed at the PLA melting temperature. A void content of 48% for PLA and 25% for cellulose fibre-reinforced PLA foams and an improvement in mechanical properties were achieved. The influence of a fibre surface treatment was investigated for both foams.

Cell morphology of extrusion foamed poly(lactic acid) using endothermic chemical foaming agent

Poly(lactic acid) (PLA) was foamed with an endothermic chemical foaming agent (CFA) through an extrusion process. The effects of polymer melt flow index, CFA content, and processing speed on the cellular structures, void fraction, and cell-population density of foamed PLA were investigated. The apparent melt viscosity of PLA was measured to understand the effect of melt index on the cell morphology of foamed PLA samples. The void fraction was strongly dependent on the PLA melt index. It increased with increasing melt index, reaching a maximum value, after which it decreased. Melt index showed no significant effect on the cell-population density of foamed samples within the narrow range studied. A gas containment limit was observed in PLA foamed with CFA. Both the void fraction and cell-population density increased with an initial increase in CFA content, reached a maximum value, and then decreased as CFA content continued to increase. The processing speed also affected the morphology of PLA foams. The void fraction reached a maximum value as the extruder's screw speed increased to 40 rpm and a further increase in the processing speed tended to reduce the void fraction of foamed samples. By contrast, cell-population density increased one order of magnitude by increasing the screw speed from 20 to 120 rpm. The experimental results indicate that a homogeneous and finer cellular morphology could be successfully achieved in PLA foamed in an extrusion process with a proper combination of polymer melt flow index, CFA content, and processing speed.

Influence of Different Endothermic Foaming Agents on Microcellular Injection Moulded Wood Fibre Reinforced PP Composites

Microcellular wood fibre reinforced polypropylene composites, a new development using bio-fibre strengthened plastic, were prepared in an injection moulding process. The influence of three different endothermic chemical foaming agents was examined. The effects of various concentrations (1 to 4 wt.% of the composites) of the chemical foaming agent on the properties of the composites was studied with a view to establishing the concentration-structure-property relationships for these materials.

The influence of wood fibre type (hard wood and soft wood) on the microcellular structure and physico-mechanical properties of the composites was also investigated. Microcell morphology (cell size, shape and distribution) was observed using scanning electron microscope.

The chemical substance of different endothermic foaming agent affected the microcellular structure of hard and soft wood fibre-PP composites. Endothermic foaming agent with chemical substance polymeric microsphere (ESC 5313) showed finer microcellular structures compared to other foaming agents and 4 wt.% content of chemical foaming agent exhibits finer microcellular structures than the other contents. The reinforcing of soft wood fibre showed significantly finer microcellular structures than the hard wood fibre reinforcements. Density reduced maximum 30% and decreased up to 0.721 g/cm3 at soft wood fibre 30 wt.% content with coupling agent maleic anhydride grafted polypropylene (MAH-PP). With the addition of MAH-PP, specific tensile strength and specific flexural strength increased maximum 60% and 55% respectively with foaming agent ESC 5313 at soft wood fibre 30 wt.% content.

Synthesis and applications of emulsion-templated porous materials

This review describes the use of macroemulsions as templates for the production of porous materials. We focus on the use of high internal phase emulsions in order to produce interconnected open porous structures. The review encompasses porous hydrophobic polymers, hydrophilic polymers, composites, silica, metal oxides, and metals. The potential applications of these materials are also discussed.

Extrusion and Injection Moulded Microcellular Wood Fibre Reinforced Polypropylene Composites

Microcellular processing techniques have been applied at an experimental level to both extrusion and injection moulding plastics processing, using wood fibre as reinforcing filler. The focus of the current research is the investigations of these processes using chemical foaming agents and comparative studies of physico-mechanical properties of materials. Results of using different chemical foaming agents (endothermic and exothermic), the variation of their content for producing wood fibre-polypropylene microfoamed composites and the effect of a coupling agent on the composites are presented. Microcells morphology, cell size, shape and distribution were investigated using scanning electron micrographs.