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Kim J, Kim SW, Kweon BC, Kim KH, Cha SW. Solid-State Surface Patterning on Polymer Using the Microcellular Foaming Process. Polymers (Basel) 2023; 15:polym15051153. [PMID: 36904394 PMCID: PMC10007601 DOI: 10.3390/polym15051153] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/02/2023] [Revised: 02/20/2023] [Accepted: 02/23/2023] [Indexed: 03/02/2023] Open
Abstract
This study proposes a novel process that integrates the molding and patterning of solid-state polymers with the force generated from the volume expansion of the microcellular-foaming process (MCP) and the softening of solid-state polymers due to gas adsorption. The batch-foaming process, which is one of the MCPs, is a useful process that can cause thermal, acoustic, and electrical characteristic changes in polymer materials. However, its development is limited due to low productivity. A pattern was imprinted on the surface using a polymer gas mixture with a 3D-printed polymer mold. The process was controlled with changing weight gain by controlling saturation time. A scanning electron microscope (SEM) and confocal laser scanning microscopy were used to obtain the results. The maximum depth could be formed in the same manner as the mold geometry (sample depth: 208.7 μm; mold depth: 200 μm). Furthermore, the same pattern could be imprinted as a layer thickness of 3D printing (sample pattern gap and mold layer gap: 0.4 mm), and surface roughness was increased according to increase in the foaming ratio. This process can be used as a novel method to expand the limited applications of the batch-foaming process considering that MCPs can impart various high-value-added characteristics to polymers.
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2
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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
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Gong W, Zhang D, Zhang C, Zeng X, He L, Jiang T. Deformation and Simulation of the Cellular Structure of Foamed Polypropylene Composites. Polymers (Basel) 2022; 14:polym14235103. [PMID: 36501496 PMCID: PMC9736430 DOI: 10.3390/polym14235103] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/07/2022] [Revised: 11/18/2022] [Accepted: 11/18/2022] [Indexed: 11/25/2022] Open
Abstract
Foamed Polymer is an important polymer material, which is one of the most widely used polymer materials and plays a very important role in the polymer industry. In this work, foamed polypropylene (PP) composites are prepared by injection molding, and the cell deformation process within them is studied by combining visualization technology and COMSOL software simulation. The results shows that the deformation of isolated cells depends in temperature, and there is no macroscopic deformation. There was no significant difference between the stress around adjacent cells at different temperatures, but the stress at different positions around the adjacent cells has obvious changes, and the maximum stress at the center of the adjacent cells was 224.18 N·m-2, which was easy to cause a lateral deformation of the cells. With the increase in temperature, the displacement around the adjacent cell gradually increased, the maximum displacement of the upper and lower symmetrical points of the cell was 14.62 μm, which is most likely to cause longitudinal deformation of the cell; the deviation of the cell deformation parameter gradually increased, which led to deformation during the growth of the cell easily. The simulation results were consistent with the visualized cell deformation behaviors of the foamed PP composites.
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Affiliation(s)
- Wei Gong
- School of Materials and Architectural Engineering, Guizhou Normal University, Guiyang 550025, China
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
- School of Mathematical Sciences, Guizhou Normal University, Guiyang 550025, China
- Correspondence: (W.G.); (L.H.); (T.J.)
| | - Di Zhang
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
| | - Chun Zhang
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
| | - Xiangbu Zeng
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
| | - Li He
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
- Correspondence: (W.G.); (L.H.); (T.J.)
| | - Tuanhui Jiang
- National Engineering Research Center for Composite Modified Polymer Materials, Guiyang 550014, China
- Correspondence: (W.G.); (L.H.); (T.J.)
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4
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Gebremedhin KF, Tseng PC, Demewoz NM, Yeh SK. Scalable Fabrication of Anisotropic Nanocellular Foam by Hot-Press Foaming. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c01724] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Kiday Fiseha Gebremedhin
- Department of Materials Science and Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Rd, Da’an District, Taipei City 106, Taiwan, R.O.C
| | - Po-Chih Tseng
- Department of Materials Science and Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Rd, Da’an District, Taipei City 106, Taiwan, R.O.C
| | - Nigus Maregu Demewoz
- Department of Materials Science and Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Rd, Da’an District, Taipei City 106, Taiwan, R.O.C
| | - Shu-Kai Yeh
- Department of Materials Science and Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Rd, Da’an District, Taipei City 106, Taiwan, R.O.C
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5
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Chai K, Xu Z, Chen D, Liu Y, Fang Y, Song Y. Effect of nano
TiO
2
on the cellular structure and mechanical properties of wood flour/polypropylene composite foams via mold‐opening foam injection molding. J Appl Polym Sci 2022. [DOI: 10.1002/app.52603] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
Affiliation(s)
- Kun Chai
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
| | - Zesheng Xu
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
| | - Dong Chen
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
| | - Yingtao Liu
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
| | - Yiqun Fang
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
| | - Yongming Song
- Engineering Research Center of Advanced Wooden Materials (Ministry of Education) Northeast Forestry University Harbin China
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6
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Wang C, Shaayegan V, Costa F, Han S, Park CB. The critical requirement for high-pressure foam injection molding with supercritical fluid. POLYMER 2022. [DOI: 10.1016/j.polymer.2021.124388] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/28/2023]
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7
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Zhao J, Wang G, Zhang A, Zhao G, Park CB. Nanocellular TPU composite foams achieved by stretch-assisted microcellular foaming with low-pressure gaseous CO2 as blowing agent. J CO2 UTIL 2021. [DOI: 10.1016/j.jcou.2021.101708] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
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8
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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]
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9
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Liu B, Jiang T, Zeng X, Deng R, Gu J, Gong W, He L. Polypropylene/thermoplastic polyester elastomer blend: Crystallization properties, rheological behavior, and foaming performance. POLYM ADVAN TECHNOL 2021. [DOI: 10.1002/pat.5240] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/01/2023]
Affiliation(s)
- Bujin Liu
- The Institute of Materials and Metallurgy of Guizhou University Guiyang China
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
| | - Tuanhui Jiang
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
| | - Xiangbu Zeng
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
| | - Rong Deng
- The Institute of Materials and Metallurgy of Guizhou University Guiyang China
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
| | - Jun Gu
- The Institute of Materials and Metallurgy of Guizhou University Guiyang China
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
| | - Wei Gong
- The Institute of Materials and Construction of Guizhou Normal University Guiyang China
| | - Li He
- The Institute of Materials and Metallurgy of Guizhou University Guiyang China
- National Engineering Research Center for Compounding and Modification of Polymer Materials Guiyang China
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Zhao C, Mark LH, Kim S, Chang E, Park CB, Lee PC. Recent progress in micro‐/nano‐fibrillar reinforced polymeric composite foams. POLYM ENG SCI 2021. [DOI: 10.1002/pen.25643] [Citation(s) in RCA: 17] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
Affiliation(s)
- Chongxiang Zhao
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
| | - Lun Howe Mark
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
| | - Sundong Kim
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
| | - Eunse Chang
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
| | - Chul B. Park
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
| | - Patrick C. Lee
- Department of Mechanical and Industrial Engineering University of Toronto Toronto Ontario Canada
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11
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Alekseev ES, Alentiev AY, Belova AS, Bogdan VI, Bogdan TV, Bystrova AV, Gafarova ER, Golubeva EN, Grebenik EA, Gromov OI, Davankov VA, Zlotin SG, Kiselev MG, Koklin AE, Kononevich YN, Lazhko AE, Lunin VV, Lyubimov SE, Martyanov ON, Mishanin II, Muzafarov AM, Nesterov NS, Nikolaev AY, Oparin RD, Parenago OO, Parenago OP, Pokusaeva YA, Ronova IA, Solovieva AB, Temnikov MN, Timashev PS, Turova OV, Filatova EV, Philippov AA, Chibiryaev AM, Shalygin AS. Supercritical fluids in chemistry. RUSSIAN CHEMICAL REVIEWS 2020. [DOI: 10.1070/rcr4932] [Citation(s) in RCA: 30] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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12
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A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods. MATERIALS 2020; 13:ma13102358. [PMID: 32443909 PMCID: PMC7287706 DOI: 10.3390/ma13102358] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/28/2020] [Revised: 05/15/2020] [Accepted: 05/19/2020] [Indexed: 11/17/2022]
Abstract
The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM.
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