Lightweight and High Impact Polypropylene Foam Fabricated via Ultra‐Low Gas Pressure Injection Molding

Ma, Wei; Weng, Zhengsheng; Wu, Minghui; Ren, Qian; Wu, Fei; Long, Wang; Zheng, Wenge

doi:10.1002/mame.202200510

Cited by 4 publications

(7 citation statements)

References 47 publications

(53 reference statements)

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“…A detailed description of this equipment can be referred to in our recent work (Table 1). 14 The foaming gas we used was nitrogen. The gas pressure was ∼8 MPa.…”

Section: Foam Injection Molding With Core-back Operationmentioning

confidence: 99%

“…Recently, we have developed a new type of low gas pressure foam injection molding machine, named LGP-FIM, and the details of the LGP-FIM are described in our previous work. 14 In ProFoam technology, a high-pressure autoclave was employed as the hopper, and gas was introduced into the raw materials prior to transferring to the barrel. In contrast, in LGP-FIM, gas was introduced into the polymer melt in the screw, which is achieved through the special screw design.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, the low gas pressure foam injection molding has better safety, as well as more industrial potential. Recently, we have developed a new type of low gas pressure foam injection molding machine, named LGP-FIM, and the details of the LGP-FIM are described in our previous work . In ProFoam technology, a high-pressure autoclave was employed as the hopper, and gas was introduced into the raw materials prior to transferring to the barrel.…”

Section: Introductionmentioning

confidence: 99%

“…In contrast, in LGP-FIM, gas was introduced into the polymer melt in the screw, which is achieved through the special screw design. Compared to RIC-FIM, we further simplified the machine design and the screw of the machine …”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Significantly Improved Foamability and Mechanical Properties of Polypropylene through a Core–Shell Structure via Low Gas Pressure Foam Injection Molding

Gao

et al. 2023

Ind. Eng. Chem. Res.

Self Cite

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Lightweight plays an important role in energy conservation and emission reduction. Foam injection molding (FIM) is a promising technology for the mass preparation of structural parts. But it is still a challenge to prepare foam with good cellular structure via low gas pressure foam injection molding (LGP-FIM). Polypropylene (PP) as a kind of universal plastic exhibits good mechanical properties, but its mechanical properties are notably deteriorated after foaming. In this study, ethylene-propylene-diene monomer (EPDM) rubber and high-density polyethylene (HDPE) were added to PP to improve its melt strength and increase the gas diffusion rate. As a result, the cell size of the ternary blend attained was ∼2 μm, and the cell density was increased to 10 10 cells/cm 3 . Meanwhile, the tensile toughness of ternary blend foam increased by 668% compared to PP foam. The notched impact strength of ternary blend foam increased by 178% compared to PP foam. Considering the excellent performance of PP foam and the low cost of LGP-FIM, this work presents a method for fabricating high mechanical performance foams that could be easily industrialized.

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“…A detailed description of this equipment can be referred to in our recent work (Table 1). 14 The foaming gas we used was nitrogen. The gas pressure was ∼8 MPa.…”

Section: Foam Injection Molding With Core-back Operationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Significantly Improved Foamability and Mechanical Properties of Polypropylene through a Core–Shell Structure via Low Gas Pressure Foam Injection Molding

Gao

et al. 2023

Ind. Eng. Chem. Res.

Self Cite

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show abstract

“…In a PP composite, it is crucial to consider that the disperse phase has a small and evenly distributed particle size. Any changes in the morphology of the dispersed phase can affect the nucleation effect, which in turn affects the foam's quality 23,24 . Such as Wang et al 25 prepared PP/POE composites with “island” structure and co‐continuous structure.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the foaming properties of polypropylene/basalt fiber composites by altering their rheological and crystallization behavior via polyethylene–octene blending modification

Zhu,

Shen,

Zeng

et al. 2023

Polymer Composites

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The quality of foam in polypropylene/basalt fiber (PP/BF) composite materials is currently unsatisfactory, which restricts their use in industrial applications. To address this limitation, the objective of this study is to improve the foaming properties of PP/BF composite foam by modifying their rheological and crystallization behavior using polyethylene–octene (POE) blending modification. The results demonstrate that the inclusion of POE has a beneficial impact on the rheological and crystallization characteristics of PP/BF composites. Consequently, this creates favorable conditions for the foaming process of PP/BF composite foam. It is conducive to obtaining high foaming quality PP/BF composite foam. The results demonstrate that a 5 wt% POE content yields the best foaming performance for the PP/BF composite foam, with the most uniform cell distribution, a cell size of 54 μm and a cell density is measured at 3.43 × 107 cells/cm3. The optimal temperature range for foaming is between 180 and 200°C. The introduction of POE in PP/BF composite foam may lead to a decrease in its tensile and flexural strength. However, this drawback is offset by a significant improvement in the notch impact strength of the foam. This study's findings will enhance our understanding of the production and application of PP/BF composite foam, making it a valuable material for applications that require exceptional toughness.Highlights Improved the crystallization and rheological properties of PP/BF composites. Significantly improve the foaming quality of PP/BF composites. Make PP/BF composite foam has excellent impact toughness.

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Preparation of Superelastic, Durable, and Lightweight Composite Foams Based on Multiple Cross-Linked Network Regulated Structures

Wang,

Gong,

et al. 2024

Ind. Eng. Chem. Res.

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The polymer material foaming technology plays an important role in energy conservation and emission reduction. However, modulating the structure of rubber/plastic foams to achieve low weight and high resilience is still a challenge. In this paper, ethylene vinyl acetate polymer (EVA)/epoxidized natural rubber (ENR) foams are prepared by chemical foaming kettle compression molding (KCM) with multiple cross-linked network structures consisting of covalent cross-links of EVA−EVA and ENR−ENR and hydrogen-bonded crosslinked networks between hydroxyl and ester groups. As influenced by the hydrogen-bonded cross-linked networks, the cellular restructuring of EVA/ENR foams is no longer limited to changes in the rubber/plastic content. Compared to pure EVA foams, EVA/ENR foams show advantages such as a low weight (13.95 × 10 10 cells/density), a higher ductility (3.42 MJ/m 3 ), a higher resilience (50%), and superior durability (more than 200 cycles at 50% compression). Moreover, due to the binding and anchoring effect of the ENR molecular chains, the thermal stability of EVA/ENR foams is greatly enhanced, with an initial decomposition temperature of around 320 °C, compared to that of EVA foams (∼150 °C). Considering the excellent properties of the EVA/ENR foams and the low cost of the KCM, the present strategy proposes an easy-to-industrialize method of fabricating rubber/plastic composite foams with high mechanical properties.

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Lightweight and High Impact Polypropylene Foam Fabricated via Ultra‐Low Gas Pressure Injection Molding

Cited by 4 publications

References 47 publications

Significantly Improved Foamability and Mechanical Properties of Polypropylene through a Core–Shell Structure via Low Gas Pressure Foam Injection Molding

Significantly Improved Foamability and Mechanical Properties of Polypropylene through a Core–Shell Structure via Low Gas Pressure Foam Injection Molding

Enhancing the foaming properties of polypropylene/basalt fiber composites by altering their rheological and crystallization behavior via polyethylene–octene blending modification

Preparation of Superelastic, Durable, and Lightweight Composite Foams Based on Multiple Cross-Linked Network Regulated Structures

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