Fabrication of Lightweight Polyphenylene Oxide/High‐Impact Polystyrene Composite Bead Foam Parts via In‐Mold Foaming and Molding Technology

Abstract

Bead foam is one kind of important polymeric foam product, which has the advantages of complex product shape, a wide range of parts density, and a wide variety of available materials. Steam‐chest molding is usually used to prepare bead foams. However, it is challenging to prepare polymers with high melting point (T m) or glass transition temperature (T g). Herein, in‐mold foaming and molding technology (IMFM) is proposed to prepare bead foams from polyphenylene oxide/high‐impact polystyrene composite (PHC). PHC bead foam parts (PHCPs) with densities from 0.11 to 0.25 g cm−3 are successfully prepared by controlling the process parameters. Due to good interbead bonding, the bead foams have superior mechanical properties. The tensile and compression strength for PHCPs with a density of 0.25 g cm−3 are 2.84 and 2.93 MPa, respectively. The PHCPs also show high dimensional stability at 120 °C and good flame‐retardant properties, characterized by a high limiting oxygen index (LOI) value and HBF rating. In addition, the fabrication mechanism behind IMFM is proposed. This technology provides a new way to produce polymer bead foams, especially for engineering materials.

Perspectives on Membrane Development for High Temperature Proton Exchange Membrane Fuel Cells

“…Poly(phenylene oxide)s (PPOs) feature a stiff backbone with large aromatic groups, a high glass transition temperature, and remarkable mechanical stability across a broad temperature range. 54,55 Moreover, most of the PPO-based polymers endure extremely active sites that can be doped with phosphoric acid (PA) as proton conductors or grafted with additional functional groups or side chains to further improve conductivity and stability.…”

“…As an alternative to the conventional PFSA-based PEMs, aromatic polymers with better mechanical and thermal stability have gained popularity recently in order to meet higher operating temperature operating requirements. Poly­(phenylene oxide)­s (PPOs) feature a stiff backbone with large aromatic groups, a high glass transition temperature, and remarkable mechanical stability across a broad temperature range. , Moreover, most of the PPO-based polymers endure extremely active sites that can be doped with phosphoric acid (PA) as proton conductors or grafted with additional functional groups or side chains to further improve conductivity and stability.…”

Progress in the development of bead foams – A review

“…In addition to the welding technologies already commercially available, other novel sintering methods such as selective microwave sintering 117,[129][130][131] and in-mould foaming techniques 132,133 are discussed. The literature given here provides a reference.…”

High‐strength and antistatic PET/CNTs bead foams prepared by scCO2 foaming and microwave sintering

“…Thus, high‐performance PET composites are usually prepared by extrusion foaming after blending with functional fillers or additives, which limits the property and structural complexity of the products 9,26 . Jiang proposed in‐mold foaming and molding technology to welding engineering plastics foam with high melt viscosity 27 . Nevertheless, this method is still unable to accurately weld and enhance the fragile interface in the composites with segregated structure.…”

“…9,26 Jiang proposed in-mold foaming and molding technology to welding engineering plastics foam with high melt viscosity. 27 Nevertheless, this method is still unable to accurately weld and enhance the fragile interface in the composites with segregated structure. Hence, it remains a great challenge to fabricate high-performance composite foam with segregated structure by precisely controlling the interface.…”