Development of a Simplified Foam Injection Molding Technique and Its Application to the Production of High Void Fraction Polypropylene Foams

Wang, Long; Hikima, Yuta; Ohshima, Masahiro; Yusa, Atsushi; Yamamoto, Satoshi; Goto, Hideto

doi:10.1021/acs.iecr.7b03382

Cited by 34 publications

(47 citation statements)

References 44 publications

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“…Increasing the thickness of the material by 18% resulted in an increase in void fraction of 39% in a core-back injection molding application [ 22 ]. Regarding the material properties, changing the structure of PP can lead to a better development and retention of foam [ 15 ]. Such an approach could improve the present results.…”

Section: Resultsmentioning

confidence: 99%

“…Another challenge for producing PP foams by injection molding is the type of technology used. Whereas new injection molding technologies have been introduced for the production of polymer foams [ 15 , 16 , 17 ], the use of standard injection molding technology without any modification can be a challenge for the production of such material [ 15 ]. Making use of modified injection molding machines and chemical blowing agents, which cannot be used to produce material intended for contact with food, it has been possible to produce foams with high void fractions [ 17 , 18 , 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

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Injection Molded PP Foams Using Food Ingredients for Food Packaging Applications

et al. 2021

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A new approach to the creation of polypropylene (PP) based foaming materials was developed using food grade foaming agents that were coated on the PP pellets. More specifically, sodium bicarbonate and organic acids were used to coat PP pellets using either polyethyleneoxide (PEO) or lipid esters as coating stabilizers. In order to overcome the problem of the thermal decomposition of sodium bicarbonate at temperatures lower than the PP melting temperature, which makes the direct foaming during melt mixing impossible, the proposed methodology was proved quite efficient. Thus, new PP masterbatches were prepared, where the foaming agents were incorporated as coating at PP pellets at contents up to 10%, and initially used in Lab scale injection machines in order to find the best combination of materials that resulted in the production of foamed articles. Subsequently selected material combinations were tested in an industrial scale injection molding machine, where an optimization of the injection parameters was attempted. The outcome of this was the production of PP articles with significantly increased void fraction, up to 14%, decreased thermal conductivity, up to 20%, and various pore sizes as was observed via microscopic examination using SEM and CLSM.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Injection Molded PP Foams Using Food Ingredients for Food Packaging Applications

et al. 2021

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“…Cell diameters of 7 mm and cell density of 1.63 Â 10 9 cells/cm 3 were achieved. 48,49 Peng et al 50 also investigated a variation to the standard SCF for MIM by using distilled water with low levels of salt as the PBA. Peng et al 50 integrated a water metering system into the hopper to administer high temperature water along with the polymer.…”

Section: Super Critical Fluidsmentioning

confidence: 99%

Advances in microcellular injection moulding

Llewelyn

Rees

Griffiths

et al. 2020

Journal of Cellular Plastics

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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.

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“…All studies used super-critical fluids (SCF). Fifteen years later, Ergocell, Yusa, et al [103] performed foam injection moulding using no supercritical fluids. PBAs via this type of injection moulding are introduced into the barrel without pressurising them into a supercritical state.…”

Section: Methods and Parameters Associated With Cellulose Nanostrumentioning

confidence: 99%

Cellulose Nanostructure-Based Biodegradable Nanocomposite Foams: A Brief Overview on the Recent Advancements and Perspectives

et al. 2019

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The interest in designing new environmentally friendly materials has led to the development of biodegradable foams as a potential substitute to most currently used fossil fuel–derived polymer foams. Despite the possibility of developing biodegradable and environmentally friendly polymer foams, the challenge of foaming biopolymers still persists as they have very low melt strength and viscosity as well as low crystallisation kinetics. Studies have shown that the incorporation of cellulose nanostructure (CN) particles into biopolymers can enhance the foamability of these materials. In addition, the final properties and performance of the foamed products can be improved with the addition of these nanoparticles. They not only aid in foamability but also act as nucleating agents by controlling the morphological properties of the foamed material. Here, we provide a critical and accessible overview of the influence of CN particles on the properties of biodegradable foams; in particular, their rheological, thermal, mechanical, and flammability and thermal insulating properties and biodegradability.

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Development of a Simplified Foam Injection Molding Technique and Its Application to the Production of High Void Fraction Polypropylene Foams

Cited by 34 publications

References 44 publications

Injection Molded PP Foams Using Food Ingredients for Food Packaging Applications

Injection Molded PP Foams Using Food Ingredients for Food Packaging Applications

Advances in microcellular injection moulding

Cellulose Nanostructure-Based Biodegradable Nanocomposite Foams: A Brief Overview on the Recent Advancements and Perspectives

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