Download or read book Manufacturing Highly Expanded Thermoplastic Polyurethane Foams Using Novel Injection Molding Foaming Technologies written by Hrishikesh Ashokrao Kharbas and published by . This book was released on 2016 with total page 144 pages. Available in PDF, EPUB and Kindle. Book excerpt: This thesis summarizes the studies undertaken to achieve the objective of manufacturing injection-molded thermoplastic polyurethane (TPU) foams with high density reductions, desir-able microstructures, and customizable properties. TPU foams are quickly gaining market share in numerous applications in the sports and recreation as well as manufacturing industries. This is because TPU foams can be easily manufactured in a variety of densities, hardnesses, and mechanical properties, ranging from highly resilient to highly compressible foams, with different processing methods, such as injection molding, casting, and extrusion. Typically, TPUs are being foamed to a minimum density of 0.40 g/cm3 (400 kg/m3). It is the aim of this thesis to expand the understanding and processing knowledge of manufacturing TPU foams with densities as low as 0.25 g/cm3 (250 kg/m3), while maintaining desirable microstructures. It is also an aim of this thesis to develop a novel process to control foam properties locally in injection molded TPU foams. In the journey toward achieving the aforementioned objectives, five studies were conducted and are presented in this manuscript. An experimental study evaluating the CBA and PBA foaming of TPU has been undertaken. A novel foam injection molding process using CO2 + N2 as co-blowing agents to exploit the synergistic benefits of co-blowing agents was also evaluated in this study. It was found that PBA foaming can be vastly advantageous for foaming TPU by enabling large reductions in bulk densities without the harmful effects of chemical residue. This novel process of using co-blowing agents yielded the lowest bulk density while achieving the highest cell density and finest average cell size. To resolve the issue of low melt strength at higher temperatures, which leads to cell coalescence and undesirable microstructures, the use of a physical cross-linking agent was considered. It was proposed that a physical cross-linking agent could increase the melt strength of the TPU at higher temperatures, thus enabling aggressive foaming strategies to give enhanced density reductions. It is shown here that extremely low-density TPU foams of bulk density 0.16 g/cm3 (160 kg/m3) can be achieved consistently. In Chapter 3, nanoclay as a reinforcing filler was employed to increase the melt viscosity and to trigger heterogeneous nucleation in the TPU matrix, thereby improving the foamability of TPU while achieving a homogenous microstructure with low average cell size and high cell density. It is generally known that TPU's rebound resilience values decrease with decreasing foam density. It was observed that rebound resilience values could increase significantly if a tunable alignment of microcells can be produced within the part, even while reducing bulk densities. Through the action of mold inserts, the expanding microcells will thereby stretch and align with the intercellular TPU walls and individual molecules in the direction of mold opening. With aligned microcells, the softness of the foams improved significantly, while achieving lower hysteresis loss ratios or energy loss (dissipation). In Chapter 5, a core retraction mold capable of increasing cavity volume was designed and manufactured to enable further study of the phenomenon observed in Chapter 4, with better parameter control. Polypropylene (PP) was the material chosen to validate the capabilities of the mold and the applicability of this technology to materials other than TPU. Core retraction was used with the conventional micro¬cellular injection molding (MIM) process to foam thick PP parts with high density reductions of 30% and 55%. The cavity volume was modified by chang¬ing the retraction distance, which resulted in varying den¬sity reductions. The lowest densities were achieved with a core retraction-aided microcellular injection molding (CR-MIM) process, the results of which could not have been achieved by the conventional MIM process alone. It was shown that the CR-MIM process yielded a better microstructure and a higher tensile modulus than the conventional MIM process. Use of core retraction also yielded more consistent densities and tensile properties at different distances from the gate location. It was shown that by using delay times and holding pressures, cell nucleation and cell growth can be delayed to a more suitable time and melt temperature. Mechanical and energy absorption properties of TPU foam can be varied with the density and microstructure of the foam. In Chapter 6, a new process is developed using core retraction and out-of-mold foaming to develop injection molded parts of varying cross-sections with varying mechanical properties. It was shown that, using this process, very low density foams of less than 0.25 g/cm3 can be produced while maintaining uniform and good microstructures. It was also shown that this technology can be effectively used to vary microstructures, densities, and mechanical properties within an injection molded part locally, depending on the application. In summary, the aforementioned approaches have helped to advance the knowledge of manufacturing TPU foams and other regular thermoplastics with customizable microstructures and mechanical properties for various specific applications.

Download or read book Speciality Plastics Foams Urethane Flexible Rigid Pet Preform Processing Technology Handbook written by NIIR Board of Consultants & Engineers and published by ASIA PACIFIC BUSINESS PRESS Inc.. This book was released on 2005-10-01 with total page 636 pages. Available in PDF, EPUB and Kindle. Book excerpt: Plastic technology is one of the fields where people can show their ability and performance both theoretically and practically. The Indian plastic and polymer industry has taken great strides. In the last few decades, the industry has grown to the status of a leading sector in the country with a sizable base. The material is gaining notable importance in different spheres of activity and the per capita consumption is increasing at a fast pace. Continuous advancements and developments in polymer technology, processing machineries, expertise and cost effective manufacturing is fast replacing the typical materials in different segments with plastics. Some examples of the specialty plastics are polytetra fluoroethylene (PTFE) , thermoplastic polyurethanes (TPU), polysulphones (PSO), polyester sulphone (PES), polyarylates, polyamide imide (PAI), etc. Polyurethane is polymer composed of a chain of organic units joined by carbamate (urethane) links. Polyurethane polymers are formed by combining two bi or higher functional monomers. Urethane foam is an artificial material with several different uses. The manufacturing process can produce foams of varying densities and flexibilities. This means it can serve functions as diverse as bedding, packaging and footwear. It is important to note that urethane foam is most commonly used to refer to a material made from polyurethane. Furniture, bedding, automotive interiors, energy management, footwear and insulation utilize flexible foam technology due to its wide range of density, cushioning ability and versatility of use. Appliance (refrigeration, water heaters), construction panels, roofing boardstock, and spray applied insulation utilize rigid polyurethane foam due its superior insulating and mechanical properties to reduce energy consumption and enhance structural integrity of the finished product. The versatility of the technology and processability makes rigid polyurethane foam uniquely suited for other applications, like architectural molding, energy absorbing materials in automobiles, entry doors, and even picnic coolers. Polymer Energy system is an award winning, innovative, proprietary process to convert waste plastics into renewable energy. Polymers are the most rapidly growing sector of the materials industry. Some fundamentals of the book are properties and applications of speciality plastics, thermoplastic polyurethanes, formation of urethane foams, flexible foams, variables in the preparation of prepolymers, procedures for the preparation of prepolymers, catalyzed prepolymer preparation, application of flexible foams, applications of rigid foams, one-stage injection stretch blow moulding, pet material and applications, injection and co-injection preform technologies, pet film and sheet, plastics as safe & hygienic medium for packaging food & food products. The book covers processes and other required information for the manufacturing of different specialty plastics, Foams, PET and Pre form PET etc. This is very useful book for new entrepreneurs, technocrats, existing units, institutional libraries etc. TAGS Applications of speciality plastics, Business guidance for PET Preform and Plastics industry, Business guidance to clients, Business Plan for a Startup Business, Business start-up, Flexible and Rigid Foams, Flexible Polyurethane Foam, Flexible Polyurethane Foam: Industry, Foam manufacturing process, Foam production process, Formation of urethane foams, How polyurethane foam is made, How polyurethane foam is made, How to make polyurethane foam, How to Start a Foam Production Company, How to Start a PET Preform Production Business, How to Start a Plastic Recycling Manufacturing Business, How to Start a Specialty plastic Manufacturing Business?, How to start a successful PET Preform business, How to Start Specialty plastic Processing Industry in India, Indian polyurethane foam market, Manufacturing of Flexible Foams, Manufacturing of Foams, Manufacturing of Injection and Co-Injection Preform, Manufacturing of Pet & Preform, Manufacturing of Pet Film and Sheet, Manufacturing of Plastic products, Manufacturing of Preform bottles, Manufacturing of Rigid Foams, Manufacturing of Urethane Foams, Manufacturing Polyurethane foams, Most Profitable Specialty plastic Processing Business Ideas, New business model for specialty plastics, New small scale ideas in Specialty plastic processing industry, PE foam, PET (Polyethylene Terephthalate) sheets, PET Bottle Making, PET Preform and Plastics Business, PET Preform Based Small Scale Industries Projects, PET Preform making machine factory, PET Preform Making Small Business Manufacturing, PET Preform Making, Pet preform manufacturing process, Pet preform manufacturing, PET Preform Plastic Injection Molding, PET Processing - Injection Molding Plastics Technology, Plastic Manufacturing Company - Business Plan, Plastic packaging industry, Plastic Protective Packaging, Polyethylene foam, Polyurethane Rigid Foam manufacturing process, Polyurethanes, Preform Injection Molding Production, Process technology books, Production of Polyurethane Foam, Production of rigid polyurethane foam, Profitable growth with Specialty plastics business, Profitable Small Scale PET Preform and Plastics Manufacturing, Properties of speciality plastics, PU foam manufacturing process, Setting up and opening your Specialty plastic Business, Small scale Commercial PET Preform making, Small scale PET Preform production line, Small Scale Specialty plastic Processing Projects, Speciality Plastics, Specialty plastic Based Profitable Projects, Specialty plastic Processing Industry in India, Specialty plastic Processing Projects, Specialty Plastics and Polymer Additives Businesses, Specialty plastics business, Start Your Own Pet Bottle Business, Starting a PET Preform Business, Starting a plastics product manufacturing, Start-up Business Plan for PET Preform Business, Startup ideas, Startup Project for Specialty plastic Business, Startup

Download or read book Novel Injection Molding Foaming Approaches Using Gas laden Pellets written by and published by . This book was released on 2013 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: A novel method of producing injection molded parts with a foamed micro structure has been developed. It has been named supercritical fluid-laden pellet injection molding foaming technology (SIFT). Compared with conventional microcellular injection molding (MIM) tech-nologies, SIFT lowers the equipment costs significantly without sacrificing the production rate, making it a very promising candidate for mass producing foamed injection molded parts. In this study, both nitrogen (N2) and carbon dioxide (CO2) were verified by experiments to be suitable for this process as physical blowing agents. A novel foam injection molding approach using CO2+N2 co-blowing agents was proposed in this study. It has been discovered that when CO2 and N2 were introduced together as co-blowing agents at appropriate ratios, foamed parts with much finer morphology can be produced using this approach compared with using either blowing agent alone. It was first realized by combining the SIFT gas-laden pellets with the microcellular injection molding (MIM), such that N2 and CO2 can be introduced to the foaming process independently in two steps with precise dosage control. This approach has been implemented on several types of commodity polymers with equal success including low density polyethylene (LDPE), poly¬propylene (PP), high impact polystyrene (HIPS), and thermoplastic polyurethane (TPU) with two distinct mold geometries, and all lead to extraordinarily fine cell structures and/or high foam expansion ratio. To enhance the performance of the SIFT technology for future stringent industrial applications, several improvements were made. Methods to further enhance the cell nucleation rate were investigated. For the purpose of prolonging the gas-laden pellets shelf life, low molecular weight (LMW) additives were compounded with the polymer matrix. The experimental results indicate that LMW additives can effectively reduce the gas desorption rate from the pellets and lead to a longer shelf. It was found that at certain blend compositions, the ductility of the molded samples can be dramatically improved while achieving significant weight reduction. This novel ductility enhancing mechanism was investigated in this study. The analysis indicates that to achieve improved ductility, it is important to create a microcellular structure with a sub-micron scale immiscible secondary phase.

Download or read book Foaming with Supercritical Fluids written by Ernesto Di Maio and published by Elsevier. This book was released on 2021-11-06 with total page 486 pages. Available in PDF, EPUB and Kindle. Book excerpt: Foaming with Supercritical Fluids, Volume Nine provides a comprehensive description of the use of supercritical fluids as blowing agents in polymer foaming. To this aim, the fundamental issues on which the proper design and control of this process are rooted are discussed in detail, with specific attention devoted to the theoretical and experimental aspects of sorption thermodynamics of a blowing agent within a polymer, the effect of the absorbed blowing agent on the thermal, interfacial and rheological properties of the expanding matter, and the phase separation of the gaseous phase, and of the related bubble nucleation and growth phenomena. Several foaming technologies based on the use of supercritical blowing agents are then described, addressing the main issues in the light of the underlying chemical-physical phenomena. Offers strong fundamentals on polymer properties important on foaming Outlines the use of supercritical fluids for foaming Covers theoretical points-of-view, including foam formation of the polymer/gas solution to the setting of the final foam Discusses the several processing technologies and applications

Download or read book Handbook of Polymer Foams written by David Eaves and published by iSmithers Rapra Publishing. This book was released on 2004 with total page 304 pages. Available in PDF, EPUB and Kindle. Book excerpt: This Handbook reviews the chemistry, manufacturing methods, properties and applications of the synthetic polymer foams used in most applications. In addition, a chapter is included on the fundamental principles, which apply to all polymer foams. There is also a chapter on the blowing agents used to expand polymers and a chapter is on microcellular foams - a relatively new development where applications are still being explored.

Download or read book Polymeric Foams written by Shau-Tarng Lee and published by CRC Press. This book was released on 2004-05-27 with total page 356 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is the inaugural volume a series entitled Polymeric Foams: Technology and Applications. Generally, thermoplastic and thermoset foams have been treated as two separate practices in industry. Polymeric Foams: Mechanisms and Materials presents the basics of foaming in general build a strong foundation to those working in both thermoplastic a

Download or read book Polymeric Foams written by Shau-Tarng Lee and published by CRC Press. This book was released on 2008-12-24 with total page 328 pages. Available in PDF, EPUB and Kindle. Book excerpt: Explores the Latest Developments in Polymeric FoamsSince the 1960s polymeric foams have grown into a solid industry that affects almost every aspect of modern life. The industry has weathered the energy crisis in the 70s, ozone issues in the 80s, and recycle/reuse in the 90s. However, the pace of development and social climate is rapidly changing a

Download or read book Injection molded Thermoplastic Foams for Sound Insulation written by Davoud Jahani and published by . This book was released on 2015 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Flexible Polyurethane Foams written by Chris Defonseka and published by Walter de Gruyter GmbH & Co KG. This book was released on 2019-08-05 with total page 277 pages. Available in PDF, EPUB and Kindle. Book excerpt: Flexible and viscoelastic polyurethane foams have enormous potential as viable business ventures and have replaced many traditional materials used in everyday life. This book describes the chemistry of flexible and viscoelastic polyurethane foams as well as calculations and formulating methodology for quality production. The author presents detailed information on foam manufacturing, based on over 45 years of hands-on industry experience.

Download or read book Polymeric Foams written by Shau-Tarng Lee and published by CRC Press. This book was released on 2006-08-21 with total page 240 pages. Available in PDF, EPUB and Kindle. Book excerpt: Polymers are among the major hallmarks of 20th-century science, and the explosive outgrowth and tremendous importance of polymeric foams is a testament to their amazing versatility and unique properties. With applications from automotive to acoustic and medical, polymeric foams pervade all areas of our lives. If this growth is to continue into the

Download or read book Blowing Agents and Foaming Processes written by and published by iSmithers Rapra Publishing. This book was released on 2004 with total page 218 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Handbook on Pet Film and Sheets Urethane Foams Flexible Foams Rigid Foams Speciality Plastics Stretch Blow Moulding Injection Blow Moulding Injection and Co Injection Preform Technologies written by NIIR Board of Consultants & Engineers and published by ASIA PACIFIC BUSINESS PRESS Inc.. This book was released on 2018-01-09 with total page 637 pages. Available in PDF, EPUB and Kindle. Book excerpt: Polyester or polyethylene terephthalate (PET) is an unreinforced, semi-crystalline thermo-plastic polyester derived from polyethylene terephthalate. Its excellent wear resistance, low coefficient of friction, high flexural modulus, and superior dimensional stability make it a versatile material for designing mechanical and electro-mechanical parts. PET is fully recyclable and can be easily reprocessed into many other products for many different applications. However, unlike paper and other cellulose products, PET does not readily decompose. However, biodegradable additives are available that enhance the biodegradation of this plastic without affecting the physical properties. Formation of a flexible polyurethane foam is an intricate process employing unique hardware, multiple ingredients and at least two simultaneous reactions. The urethane forming reaction occurs between the isocyanate and the polyol. Polyurethanes, also known as polycarbamates, belong to a larger class of compounds called polymers. Polyurethanes can be produced in four different forms including elastomers, coatings, flexible foams, and cross-linked foams. Elastomers are materials that can be stretched but will eventually return to their original shape. They are useful in applications that require strength, flexibility, abrasion resistance, and shock absorbing qualities. Thermoplastic polyurethane elastomers can be molded and shaped into different parts. This makes them useful as base materials for automobile parts, ski boots, roller skate wheels, cable jackets, and other mechanical goods. When these elastomers are spun into fibers they produce a flexible material called spandex. Spandex is used to make sock tops, bras, support hose, swimsuits, and other athletic apparel. Co-injection is the process of injecting two resins simultaneously through a single gate to form a multi-layer structure. Recently, there has been a re-emergence of interest in co-injection technology spurred on by the development of new resins, barrier systems, controls, and hardware technologies. Increasing demand of polyethylene terephthalate (PET) from food and beverage sector like in carbonated soft drinks packaging, increase demand for packaged food due to rise in consumption of frozen and processed food, rise in demand for electronics and automotive applications/industries and ecofriendly substitution are the most important driving factors in the polyethylene terephthalate market. Also, rapid urbanization, innovative packaging and high economic growth is contribution in increasing the demand for polyethylene terephthalate regardless of the geographical location. This book will be a mile stone for its readers who are new to this sector, will also find useful for professionals, entrepreneurs, those studying and researching in this important area. TAGS Production Process for Polyethylene Terephthalate (PET), Polyethylene Terephthalate (PET) Production and Manufacturing, PET Sheet Making, PET Packaging Film Production, Packaging Films Manufacture, Production of PET Film, Polyester Film Production, PET Film Manufacturing, PET Film Making Plant, PET Film Production, PET Sheet Production, Production of PET Sheet, Film/Sheet Production, PET Sheet Manufacturing Business, PET Sheet Manufacture, PET Sheet Making Unit, How Polyurethane is Made? 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Download or read book Integral Structural Polymer Foams written by Fyodor Anatoljevitsch Shutov and published by Walter de Gruyter GmbH & Co KG. This book was released on 1986-12-31 with total page 320 pages. Available in PDF, EPUB and Kindle. Book excerpt: No detailed description available for "Integral/ Structural Polymer Foams".

Download or read book Microcellular Injection Molding written by Jingyi Xu and published by John Wiley & Sons. This book was released on 2011-01-06 with total page 503 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents the most important aspects of microcellular injection molding with applications for science and industry. The book includes: experimental rheology and pressure-volume-temperature (PVT) data for different gas materials at real injection molding conditions, new mathematical models, micrographs of rheological and thermodynamic phenomena, and the morphologies of microcellular foam made by injection molding. Further, the author proposes two stages of processing for microcellular injection molding, along with a methodology of systematic analysis for process optimization. This gives critical guidelines for quality and quantity analyses for processing and equipment design.

Download or read book Integral Structural Polymer Foams written by Fyodor A. Shutov and published by Springer Science & Business Media. This book was released on 2013-03-14 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: Integral, or structural, foams are one of the most remarkable materials that have been developed over the last fifteen years. As with all rapidly growing fields, the terminology seems to have grown even faster. Thus there are two names for the material structure itself. In the United States and in Japan the term for these plastics is Structural Foams, whereas in Europe and the USSR the term used is usually Integral Foams. We have adhered to the European term in the text and hope our colleagues will bear with us. Integral foams have a specific structure: a cellular core that gradually turns into a solid skin. The skin gives the part its form and stiffness, while the cellular core contributes to the very high strength-to-weight values of the material. These are higher than those of some unfoamed plastics and metals. The sandwich-like structure with its unique mechanical properties was prompted by nature. Wood and bone are strong and light-weight natural materials having a cellular structure. Since the sandwich-like structure of the integral foams resembles that of natural wood, the foams are often referred to as artifical wood or plastic wood, thereby emphasizing not only the formal structural similarity of these materials, but also one of the main functional applications of integral foams - replacement of wooden articles in various fields of engineering and construction.

Download or read book Flexible Polyurethane Foams written by G. Woods and published by Springer. This book was released on 1982-03-31 with total page 334 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Handbook of Foaming and Blowing Agents written by George Wypych and published by Elsevier. This book was released on 2022-03-12 with total page 309 pages. Available in PDF, EPUB and Kindle. Book excerpt: Handbook of Foaming and Blowing Agents, Second Edition includes the most current information on foaming technology, guiding users on the proper selection of formulation, which is highly dependent on the mechanisms of action of blowing agents and foaming agents, as well as dispersion and solubility. The book includes properties of 23 groups of blowing agents and the typical range of technical performance for each group, including general properties, physical-chemical properties, health and safety, environmental impact, and applications in different products and polymers. All information is illustrated by chemical reactions and diagrams. Chapters in the book look at foaming mechanisms with the use of solid blowing agents, which are decomposed to the gaseous products by application of heat, production of gaseous products by chemical reaction, and foaming by gases and evaporating liquids. Introduces the fundamental mechanisms of action of blowing agents and foaming Includes best practice guidance to help engineers and technicians improve the efficiency of their existing foaming processes Enables practitioners to select blowing agents and foaming methods more effectively, thus reducing the risk of poor specification Introduces useful analytical techniques for foaming Discusses the environmental impact of foaming processes