1
|
Griffiths CA, Rees A, Morgan A, Korkees F. Optimisation of 3D Printing for Microcellular Polymers. Polymers (Basel) 2023; 15:3910. [PMID: 37835959 PMCID: PMC10575440 DOI: 10.3390/polym15193910] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/25/2023] [Revised: 09/14/2023] [Accepted: 09/26/2023] [Indexed: 10/15/2023] Open
Abstract
Polymers are extensively used in various industries due to their versatility, durability and cost-effectiveness. To ensure functionality and longevity, polymer parts must have sufficient strength to endure external forces without deformation or breakage. Traditional approaches to increasing part strength involve adding more material; however, balancing strength to weight relationships is challenging. This paper explorers the viability of manufacturing lightweight components using a microcellular foaming polymer. Microcellular foaming has emerged as a helpful tool to achieve an optimal strength-to-weight ratio; offering advantages such as lightweight, improved mechanical properties, reduced material usage, better insulation and improved cost-effectiveness. It can also contribute to improved fuel efficiency and reduced carbon emissions, making them environmentally favourable. The combination of additive manufacturing (AM) and microcellular foaming has opened new possibilities for design innovation. This text highlights the challenges and efforts in incorporating foaming techniques into 3D printing processes, specifically fused filament fabrication (FFF). This study reveals that microcellular polymers are a viable option when balancing part strength and weight. The experiments completed during the formulation of this paper demonstrated that lightweight LW-PLA parts were significantly lighter than standard PLA parts and that a design of experiments approach can be used to optimise strength properties and provide insights into optimising manufacturability. Microcellular polymers present an opportunity for lighter and stronger 3D printed parts, offering potential energy and material savings for sustainable manufacturing practices.
Collapse
|
2
|
Acosta AP, Kairytė A, Członka S, Miedzińska K, Aramburu AB, Barbosa KT, Amico SC, Delucis RDA. Rigid Polyurethane Biofoams Filled with Pine Seed Shell and Yerba Mate Wastes. Polymers (Basel) 2023; 15:polym15092194. [PMID: 37177340 PMCID: PMC10180977 DOI: 10.3390/polym15092194] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2023] [Revised: 04/29/2023] [Accepted: 05/02/2023] [Indexed: 05/15/2023] Open
Abstract
Pine seed shells and yerba mate are common wastes leftover from the food and beverage industry. This study presents the development of rigid polyurethane foams (RPUFs) filled with pine seed shells and yerba mate at 5, 10 and 15 wt%. The fillers were characterized for chemical properties using bench chemistry analyses, and the RPUFs were investigated in terms of chemical, morphological, mechanical, thermal and colorimetric characteristics. The main results indicated that yerba mate showed good compatibility with the polyurethane system, probably because its available hydroxyl groups reacted with isocyanate groups to form urethane bonds, producing increases in mechanical and thermal properties. However, pine seed shell did not appear to be compatible. Anisotropy increased slightly, as there was an increase in the percentage of reinforcement. The mechanical properties of the yerba mate reinforced foams proved stable, while there was a loss of overall up to ~50% for all mechanical properties in those reinforced with pine seed shell. Thermal properties were improved up to ~40% for the yerba mate reinforced foams, while those reinforced with pine nuts were stable. It was possible to observe a decrease in the glass transition temperature (Tg) of ~-5 °C for the yerba mate reinforced foams and ~-14 °C for the pine seed shell reinforced ones.
Collapse
Affiliation(s)
- Andrey Pereira Acosta
- Postgraduate Program in Mining, Metallurgical and Materials Engineering, Federal University of Rio Grande do Sul, Porto Alegre 91501-970, Brazil
| | - Agnė Kairytė
- Laboratory of Thermal Insulating Materials and Acoustics, Institute of Building Materials, Faculty of Civil Engineering, Vilnius Gediminas Technical University, Linkmenų St. 28, 08217 Vilnius, Lithuania
| | - Sylwia Członka
- Institute of Polymer and Dye Technology, Faculty of Chemistry, Lodz University of Technology, Stefanowskiego 12/16, 90-924 Lodz, Poland
| | - Karolina Miedzińska
- Institute of Polymer and Dye Technology, Faculty of Chemistry, Lodz University of Technology, Stefanowskiego 12/16, 90-924 Lodz, Poland
| | - Arthur Behenck Aramburu
- Postgraduate Program in Mining, Metallurgical and Materials Engineering, Federal University of Rio Grande do Sul, Porto Alegre 91501-970, Brazil
| | - Kelvin Techera Barbosa
- Postgraduate Program in Mining, Metallurgical and Materials Engineering, Federal University of Rio Grande do Sul, Porto Alegre 91501-970, Brazil
| | - Sandro Campos Amico
- Postgraduate Program in Mining, Metallurgical and Materials Engineering, Federal University of Rio Grande do Sul, Porto Alegre 91501-970, Brazil
| | - Rafael de Avila Delucis
- Postgraduate Program in Materials Science and Engineering (PPGCEM), Technology Development Center, Federal University of Pelotas (UFPel), Pelotas 96010-610, Brazil
| |
Collapse
|
3
|
Xing J, Liu B, Jiang T, You Y, Zeng X, Yang J, Zhang C, Gong W, He L. Study on the definition, mechanism and controllability of secondary bubbles based on the bubble nucleation model in injection foaming polypropylene. RSC Adv 2023; 13:2746-2755. [PMID: 36756406 PMCID: PMC9850279 DOI: 10.1039/d2ra06702a] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/23/2022] [Accepted: 12/20/2022] [Indexed: 01/21/2023] Open
Abstract
The process of nucleation and growth of polypropylene foam was observed by using visualizations of the mold-opening foam injection molding (MOFIM) and free foaming (FREEF). The fitting of the mathematical model formula was used to supplement the judgment conditions of the secondary bubbles to explore the generation process and formation conditions of the secondary bubbles. The results of changes in blowing agent content and melt temperature proved the rationality of the judgment basis and the appearance of secondary bubbles started from the late stage of balanced-foaming. Then, the combined action of several nucleation mechanisms led to the emergence of secondary bubbles, which was observed utilizing glass fibers as nucleating agents and tracers. The data for the two foaming modes indicated that the formation of secondary bubbles is closely related to temperature and pressure drop. The bubble nucleation model was amended and validated by regulating the temperature variation in the mold cavity to control the number of secondary bubbles, which enabled the nucleation process of secondary bubbles to be fitted to an "S-shaped" curve. Finally, a controllable number of secondary bubbles was obtained from the bimodal bubble structure. Herein, this study enriches our understanding of the formation process of secondary bubbles, and provides theoretical guidance for fabricating high density, small size foam materials.
Collapse
Affiliation(s)
- Jinfu Xing
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China
| | - Bujin Liu
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China
| | - Tuanhui Jiang
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China .,National Engineering Research Center for Compounding and Modification of Polymeric Materials Guiyang 550014 China
| | - Yujing You
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China
| | - Xiangbu Zeng
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China .,National Engineering Research Center for Compounding and Modification of Polymeric Materials Guiyang 550014 China
| | - Jinkui Yang
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China .,National Engineering Research Center for Compounding and Modification of Polymeric Materials Guiyang 550014 China
| | - Chun Zhang
- National Engineering Research Center for Compounding and Modification of Polymeric MaterialsGuiyang 550014China
| | - Wei Gong
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China .,School of Materials and Architectural Engineering, Guizhou Normal University Guiyang 550025 China
| | - Li He
- College of Materials and Metallurgy, Guizhou University Guiyang 550025 China .,National Engineering Research Center for Compounding and Modification of Polymeric Materials Guiyang 550014 China
| |
Collapse
|
4
|
Saini A, Yadav C, Lyu M. Cavity pressure profile study during foam injection molding and its effect on cell formation of polypropylene/chemical blowing agent foam. J Appl Polym Sci 2023. [DOI: 10.1002/app.53643] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/19/2023]
Affiliation(s)
- Arun Saini
- Department of Mechanical System Design Engineering Seoul National University of Science and Technology Seoul Republic of Korea
| | | | - Min‐Young Lyu
- Department of Mechanical System Design Engineering Seoul National University of Science and Technology Seoul Republic of Korea
| |
Collapse
|
5
|
Wang L, Wu M, Ren Q, Weng Z, Li W, Zhu X, Zheng W, Yi X. Strong and high void fraction
PP
/
CNS
nanocomposite foams fabricated by core‐back foam injection molding. J Appl Polym Sci 2022. [DOI: 10.1002/app.53521] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Affiliation(s)
- Long Wang
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
- University of Chinese Academy of Sciences Beijing People's Republic of China
| | - Minghui Wu
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
- Faculty of Science and Engineering University of Nottingham Ningbo China Ningbo People's Republic of China
| | - Qian Ren
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
- University of Chinese Academy of Sciences Beijing People's Republic of China
| | - Zhengsheng Weng
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
| | - Wanwan Li
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
| | - Xiuyu Zhu
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
| | - Wenge Zheng
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Material Technology and Engineering Chinese Academy of Sciences Ningbo Zhejiang People's Republic of China
- University of Chinese Academy of Sciences Beijing People's Republic of China
| | - Xiaosu Yi
- Faculty of Science and Engineering University of Nottingham Ningbo China Ningbo People's Republic of China
| |
Collapse
|
6
|
The controlled preparation of secondary cells realizes the bimodal structure through two different pressure drop methods. POLYMER 2022. [DOI: 10.1016/j.polymer.2022.125198] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
|
7
|
Lin W, Hikima Y, Ohshima M. Microcellular foam of styrene–isobutylene–styrene copolymer with
N
2
using polypropylene as a crystallization nucleating and shrinkage reducing agent. J Appl Polym Sci 2022. [DOI: 10.1002/app.52977] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
- Weiyuan Lin
- Department of Chemical Engineering Kyoto University Kyoto Katsura Japan
| | - Yuta Hikima
- Department of Chemical Engineering Kyoto University Kyoto Katsura Japan
| | - Masahiro Ohshima
- Department of Chemical Engineering Kyoto University Kyoto Katsura Japan
| |
Collapse
|
8
|
Güzel K, Zarges JC, Heim HP. Effect of Cell Morphology on Flexural Behavior of Injection-Molded Microcellular Polycarbonate. MATERIALS 2022; 15:ma15103634. [PMID: 35629661 PMCID: PMC9144126 DOI: 10.3390/ma15103634] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/25/2022] [Revised: 05/09/2022] [Accepted: 05/17/2022] [Indexed: 12/04/2022]
Abstract
The quantitative study of the structure and properties relationship in cellular materials is mostly limited to cell diameter, cell density, skin layer thickness, and cell size distribution. In addition, the investigation of the morphology is generally carried out in two dimensions. Therefore, the interrelation between morphological properties and mechanical characteristics of the foam structure has remained in an uncertain state. In this study, during the physical foaming process, a foam morphology is locally created by using a mold equipped with a core-back insert. The variation in morphology is obtained by modifying the mold temperature, injection flow rate, and blowing agent content in the polymer melt. X-ray microtomography (μCT) is used to acquire the 3D visualization of the cells structure. The Cell Distribution Index (CDI) is calculated to represent the polydispersity in cell size distribution. The relationship between the wide range of morphological qualities and relevant flexural properties is made explicit via a statistical model. According to the results, the morphology, particularly cell shape, characterizes the mechanism of the linear elastic deformation of the closed-cell foams. IR-thermography reveals the bending failure of cellular structures in the tensile region despite the differences in cell diameter.
Collapse
|
9
|
Hasanzadeh R, Azdast T, Mojaver M, Darvishi MM, Park CB. Cost-effective and reproducible technologies for fabrication of tissue engineered scaffolds: The state-of-the-art and future perspectives. POLYMER 2022. [DOI: 10.1016/j.polymer.2022.124681] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
|
10
|
Liu G, Wen S, Wang Y, Zhang J, Huang S, Chen A. Exfoliation and distribution behavior of graphene nanoplatelets in polystyrene-based foams fabricated by supercritical CO2 assisted microcellular foaming. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2021.117331] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
|
11
|
Shaayegan V, Wang C, Ataei M, Costa F, Han S, Bussmann M, Park CB. Supercritical CO2 utilization for development of graded cellular structures in semicrystalline polymers. J CO2 UTIL 2021. [DOI: 10.1016/j.jcou.2021.101615] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
|
12
|
Jiang J, Li Z, Yang H, Wang X, Li Q, Turng LS. Microcellular injection molding of polymers: a review of process know-how, emerging technologies, and future directions. Curr Opin Chem Eng 2021. [DOI: 10.1016/j.coche.2021.100694] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
|
13
|
Sarver JA, Sumey JL, Whitfield RM, Kiran E. Confined batch foaming of
semi‐crystalline
rubbery elastomers with carbon dioxide using a mold. J Appl Polym Sci 2021. [DOI: 10.1002/app.50698] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Affiliation(s)
- Joseph A. Sarver
- Department of Chemical Engineering Virginia Tech Blacksburg Virginia USA
| | - Jenna L. Sumey
- Department of Chemical Engineering University of Virginia Charlottesville Virginia USA
| | | | - Erdogan Kiran
- Department of Chemical Engineering Virginia Tech Blacksburg Virginia USA
| |
Collapse
|
14
|
Rostami-Tapeh-Esmaeil E, Vahidifar A, Esmizadeh E, Rodrigue D. Chemistry, Processing, Properties, and Applications of Rubber Foams. Polymers (Basel) 2021; 13:1565. [PMID: 34068238 PMCID: PMC8153173 DOI: 10.3390/polym13101565] [Citation(s) in RCA: 17] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/25/2021] [Revised: 05/08/2021] [Accepted: 05/08/2021] [Indexed: 01/31/2023] Open
Abstract
With the ever-increasing development in science and technology, as well as social awareness, more requirements are imposed on the production and property of all materials, especially polymeric foams. In particular, rubber foams, compared to thermoplastic foams in general, have higher flexibility, resistance to abrasion, energy absorption capabilities, strength-to-weight ratio and tensile strength leading to their widespread use in several applications such as thermal insulation, energy absorption, pressure sensors, absorbents, etc. To control the rubber foams microstructure leading to excellent physical and mechanical properties, two types of parameters play important roles. The first category is related to formulation including the rubber (type and grade), as well as the type and content of accelerators, fillers, and foaming agents. The second category is associated to processing parameters such as the processing method (injection, extrusion, compression, etc.), as well as different conditions related to foaming (temperature, pressure and number of stage) and curing (temperature, time and precuring time). This review presents the different parameters involved and discusses their effect on the morphological, physical, and mechanical properties of rubber foams. Although several studies have been published on rubber foams, very few papers reviewed the subject and compared the results available. In this review, the most recent works on rubber foams have been collected to provide a general overview on different types of rubber foams from their preparation to their final application. Detailed information on formulation, curing and foaming chemistry, production methods, morphology, properties, and applications is presented and discussed.
Collapse
Affiliation(s)
| | - Ali Vahidifar
- Department of Polymer Science and Engineering, University of Bonab, Bonab 5551761167, Iran;
| | - Elnaz Esmizadeh
- Department of Polymer Science and Engineering, University of Bonab, Bonab 5551761167, Iran;
| | - Denis Rodrigue
- Department of Chemical Engineering, Université Laval, Quebec, QC G1V 0A6, Canada;
| |
Collapse
|
15
|
Ernault E, Diani J, Hallais S, Cocquet C. Relationship between microstructure and mechanical properties of polyether block amide foams. POLYM ENG SCI 2021. [DOI: 10.1002/pen.25712] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
Affiliation(s)
- Estève Ernault
- Laboratoire de Mécanique des Solides CNRS UMR 7649, École Polytechnique, Institut Polytechnique de Paris Palaiseau France
| | - Julie Diani
- Laboratoire de Mécanique des Solides CNRS UMR 7649, École Polytechnique, Institut Polytechnique de Paris Palaiseau France
| | - Simon Hallais
- Laboratoire de Mécanique des Solides CNRS UMR 7649, École Polytechnique, Institut Polytechnique de Paris Palaiseau France
| | | |
Collapse
|
16
|
Ito A, Semba T, Ohshima M. Effect of crosslinking points on bubble nucleation in the microcellular foaming of thermosets. POLYMER 2021. [DOI: 10.1016/j.polymer.2021.123414] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
|
17
|
Li S, Sun X, Wang R, Hu Y, Ma X, Wang J. Experimental investigation on the forming and evolution process of cell structure in gas counter pressure assisted chemical foaming injection molded parts. J CELL PLAST 2020. [DOI: 10.1177/0021955x20950224] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
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.
Collapse
Affiliation(s)
- Shuai Li
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Xuemei Sun
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Rui Wang
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | - Yanyan Hu
- Department of Pediatrics, Linyi People’s Hospital, Linyi, PR China
| | - Xiaofei Ma
- School of Mechanical &Vehicle Engineering, Linyi University, Linyi, PR China
| | | |
Collapse
|
18
|
Highly expanded fine-cell foam of polylactide/polyhydroxyalkanoate/nano-fibrillated polytetrafluoroethylene composites blown with mold-opening injection molding. Int J Biol Macromol 2020; 155:286-292. [DOI: 10.1016/j.ijbiomac.2020.03.212] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/24/2020] [Revised: 03/21/2020] [Accepted: 03/25/2020] [Indexed: 11/17/2022]
|
19
|
Díaz‐Ovalle CO, Castrejón‐González EO, González‐Núñez R, Ramos‐Ojeda E, Herrera‐Pérez G. Analysis of bubble formation during injection molding of polymeric foams by computational fluid dynamics simulations. ASIA-PAC J CHEM ENG 2020. [DOI: 10.1002/apj.2474] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
| | | | | | - Erika Ramos‐Ojeda
- Departamento de IngenieríasTecnológico Nacional de México/I.T. Roque Celaya Mexico
| | - Gabriel Herrera‐Pérez
- Departamento de Ingeniería en MaterialesTecnológico Nacional de México/ITESI Irapuato Mexico
| |
Collapse
|
20
|
Abstract
Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.
Collapse
Affiliation(s)
| | - Andrew Rees
- College of Engineering, Swansea University, Swansea, UK
| | | | | |
Collapse
|
21
|
Multi-dimensional analysis of micro-/nano-polymeric foams by confocal laser scanning microscopy and foam simulations. Chem Eng Sci 2019. [DOI: 10.1016/j.ces.2019.07.007] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
|
22
|
Yilmaz G, Yang H, Turng L. Injection molding of delamination‐free ultra‐high‐molecular‐weight polyethylene. POLYM ENG SCI 2019. [DOI: 10.1002/pen.25234] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Galip Yilmaz
- Polymer Engineering Center, Department of Mechanical EngineeringUniversity of Wisconsin–Madison Madison Wisconsin 53706
- Wisconsin Institute for DiscoveryUniversity of Wisconsin–Madison Madison Wisconsin 53715
| | - Huaguang Yang
- Polymer Engineering Center, Department of Mechanical EngineeringUniversity of Wisconsin–Madison Madison Wisconsin 53706
- Wisconsin Institute for DiscoveryUniversity of Wisconsin–Madison Madison Wisconsin 53715
- College of Mechanical and Electrical EngineeringBeijing University of Chemical Technology Beijing 100029 China
| | - Lih‐Sheng Turng
- Polymer Engineering Center, Department of Mechanical EngineeringUniversity of Wisconsin–Madison Madison Wisconsin 53706
- Wisconsin Institute for DiscoveryUniversity of Wisconsin–Madison Madison Wisconsin 53715
| |
Collapse
|
23
|
Accurate theoretical modeling of cell growth by comparing with visualized data in high-pressure foam injection molding. Eur Polym J 2019. [DOI: 10.1016/j.eurpolymj.2019.07.023] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
|
24
|
Tromm M, Shaayegan V, Wang C, Heim HP, Park CB. Investigation of the mold-filling phenomenon in high-pressure foam injection molding and its effects on the cellular structure in expanded foams. POLYMER 2019. [DOI: 10.1016/j.polymer.2018.11.006] [Citation(s) in RCA: 27] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
|
25
|
Lightweight, super-elastic, and thermal-sound insulation bio-based PEBA foams fabricated by high-pressure foam injection molding with mold-opening. Eur Polym J 2018. [DOI: 10.1016/j.eurpolymj.2018.04.002] [Citation(s) in RCA: 81] [Impact Index Per Article: 13.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
|
26
|
Hou J, Zhao G, Zhang L, Dong G, Wang G. Foaming Mechanism of Polypropylene in Gas-Assisted Microcellular Injection Molding. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b05389] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Junji Hou
- Key Laboratory for Liquid−Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong 250061, PR China
| | - Guoqun Zhao
- Key Laboratory for Liquid−Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong 250061, PR China
| | - Lei Zhang
- Key Laboratory for Liquid−Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong 250061, PR China
| | - Guiwei Dong
- Key Laboratory for Liquid−Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong 250061, PR China
| | - Guilong Wang
- Key Laboratory for Liquid−Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong 250061, PR China
| |
Collapse
|
27
|
Yilmaz G, Ellingham T, Turng LS. Improved Processability and the Processing-Structure-Properties Relationship of Ultra-High Molecular Weight Polyethylene via Supercritical Nitrogen and Carbon Dioxide in Injection Molding. Polymers (Basel) 2017; 10:E36. [PMID: 30966070 PMCID: PMC6415066 DOI: 10.3390/polym10010036] [Citation(s) in RCA: 19] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/08/2017] [Revised: 12/27/2017] [Accepted: 12/28/2017] [Indexed: 01/01/2023] Open
Abstract
The processability of injection molding ultra-high molecular weight polyethylene (UHMWPE) was improved by introducing supercritical nitrogen (scN₂) or supercritical carbon dioxide (scCO₂) into the polymer melt, which decreased its viscosity and injection pressure while reducing the risk of degradation. When using the special full-shot option of microcellular injection molding (MIM), it was found that the required injection pressure decreased by up to 30% and 35% when scCO₂ and scN₂ were used, respectively. The mechanical properties in terms of tensile strength, Young's modulus, and elongation-at-break of the supercritical fluid (SCF)-loaded samples were examined. The thermal and rheological properties of regular and SCF-loaded samples were analyzed using differential scanning calorimetry (DSC) and parallel-plate rheometry, respectively. The results showed that the temperature dependence of UHMWPE was very low, suggesting that increasing the processing temperature is not a viable method for reducing injection pressure or improving processability. Moreover, the use of scN₂ and scCO₂ with UHMWPE and MIM retained the high molecular weight, and thus the mechanical properties, of the polymer, while regular injection molding led to signs of degradation.
Collapse
Affiliation(s)
- Galip Yilmaz
- Polymer Engineering Center, Department of Mechanical Engineering, University of Wisconsin⁻Madison, Madison, WI 53706, USA.
- Wisconsin Institute for Discovery, University of Wisconsin-Madison, Madison, WI 53715, USA.
| | - Thomas Ellingham
- Polymer Engineering Center, Department of Mechanical Engineering, University of Wisconsin⁻Madison, Madison, WI 53706, USA.
- Wisconsin Institute for Discovery, University of Wisconsin-Madison, Madison, WI 53715, USA.
| | - Lih-Sheng Turng
- Polymer Engineering Center, Department of Mechanical Engineering, University of Wisconsin⁻Madison, Madison, WI 53706, USA.
- Wisconsin Institute for Discovery, University of Wisconsin-Madison, Madison, WI 53715, USA.
| |
Collapse
|
28
|
Abstract
Abstract
Recently, several companies have started to use the foaming technology in blow molding processes, primarily in extrusion blow molding. Despite the design complexity involved in the preform blow molding method, substantial advantages result when microcellular foaming and blow molding are combined. In preform and extrusion blow molding, the preform (i. e., the parison) undergoes significant biaxial stress during the inflation stage. Since either extensional or shear stress can dramatically improve cell nucleation, an externally applied stress can cause small-scale, local pressure variations throughout the sample, thus reducing the energy barrier for cell nucleation. So, unlike the current low-pressure foam blow molding technology, where cell nucleation occurs before inflating the preform/parison, we used a high-pressure system to prevent premature foaming in the shaping stage. Consequently, cell nucleation was induced after biaxial stresses were created to induce a higher cell density.
Collapse
Affiliation(s)
- L. H. Mark
- Microcellular Plastics Manufacturing Laboratory , Department of Mechanical and Industrial Engineering, University of Toronto, Toronto , Canada
| | - R. K. M. Chu
- Microcellular Plastics Manufacturing Laboratory , Department of Mechanical and Industrial Engineering, University of Toronto, Toronto , Canada
- Sabic Limburg B.V. , Geleen , The Netherlands
| | - G.-L. Wang
- Microcellular Plastics Manufacturing Laboratory , Department of Mechanical and Industrial Engineering, University of Toronto, Toronto , Canada
- School of Material Science and Engineering , Shandong University, Jinan, Shandong , PRC
| | - C. B. Park
- Microcellular Plastics Manufacturing Laboratory , Department of Mechanical and Industrial Engineering, University of Toronto, Toronto , Canada
| |
Collapse
|
29
|
Luo X, Yu K, Qian K. Morphologies and compression performance of graphene oxide/SiO2 modified phenolic foam. HIGH PERFORM POLYM 2017. [DOI: 10.1177/0954008317731136] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
In this study, the graphene oxide/SiO2 hybrid materials with different sizes (GO/SiO2-80, GO/SiO2-170, GO/SiO2-250) were prepared via in situ preparation. Different sizes and weight fraction of GO/SiO2 were added into phenolic resin to prepare phenolic foam composites. The cell properties, morphologies, and mechanism of GO/SiO2 reinforced PF composites were studied. The results showed that the GO/SiO2-80 can improve the cell structure and compressive property obviously than other size nanoparticles. The PF modified with 1 wt% GO/SiO2-80 exhibited most uniform cell structure, and it showed a mean cell size of 117 µm and narrow cell size distribution from 50 µm to 225 µm. The obtained PF/(1 wt% GO/SiO2-80) also showed an excellent compressive strength and modulus of 0.18 and 3.22 MPa, which has increased by 80% and 61%, respectively, compared to the pure PF. This method may make it possible for using GO/SiO2 hybrid materials to enhance the cell structure and compression performance of the phenolic foam composites with broader applications.
Collapse
Affiliation(s)
- Xia Luo
- Key Laboratory of Eco-Textile, Ministry of Education, Jiangnan University, Wuxi, Jiangsu, People’s Republic of China
| | - Kejing Yu
- Key Laboratory of Eco-Textile, Ministry of Education, Jiangnan University, Wuxi, Jiangsu, People’s Republic of China
| | - Kun Qian
- Key Laboratory of Eco-Textile, Ministry of Education, Jiangnan University, Wuxi, Jiangsu, People’s Republic of China
| |
Collapse
|
30
|
Lee JW, Lee RE, Wang J, Jung PU, Park CB. Study of the foaming mechanisms associated with gas counter pressure and mold opening using the pressure profiles. Chem Eng Sci 2017. [DOI: 10.1016/j.ces.2017.04.005] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
|
31
|
Shaayegan V, Wang C, Costa F, Han S, Park CB. Effect of the melt compressibility and the pressure drop rate on the cell-nucleation behavior in foam injection molding with mold opening. Eur Polym J 2017. [DOI: 10.1016/j.eurpolymj.2017.05.003] [Citation(s) in RCA: 34] [Impact Index Per Article: 4.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
|