Foam Update March 2016 A. Table of Contents Contents A. Table of Content
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Foam Update March 2016 A. Table of Contents Contents A. Table of Content ............................................................................. 1 B. Editorial ........................................................................................... 2 C. News ................................................................................................ 5 D. Patents and Journals ..................................................................... 10 a. New Foaming Technique: .................................................... 10 b. Blowing Agents: .................................................................. 13 c. Foam products: ..................................................................... 14 d. Applications: ........................................................................ 23 e. Degradable and Sustainable Foam: ..................................... 25 f. Thermoset Foam; PU and Others: ........................................ 28 g. Microcellular and Expanded Particle: ................................. 41 To Give Than To Receive - 1 - Foam Update March 2016 B. Editorial Resin Review for Extruded Foam Resin is a key, or sometimes the key component in direct material cost (DMC). For years, finding a suitable resin for foam processing have been a challenge, since it has not only to meet processing rheology requirements, but to comply with thermodynamic conditions and to its sharp variation for phase change and transformation. The first commercial success is polystyrene (PS) foam in the extrusion process. Flotation dock was made in the early forties. After World War II, thin sheet was made for food tray in the sixties, then thick board for insulation in the seventies. It was attributed to its amorphous morphology that a wide processing window can be established in the single and twin screw processes. Cooling of melt loaded with blowing agent is crucial to obtain quality product, mainly because of thermodynamic stability at lower temperature. Anyway, since PS is so friendly in processing, a tandem line extrusion system was developed to enhance production rate. However, lack of crystallinity arose performance concerns. Crystallization kinetics reveals a threshold at reduced temperature, before which it may be too hot to manage and after which too tough to expand. It was then found by accident that low density polyethylene (LDPE) was able to make nice foam out of the extrusion process when UV was forgot to turn on and nice foam came out of the die in the extrusion experiments in Dow in the early sixties. More dedicated efforts were spent on foam extrusion since then. Japan Styrene Paper (JSP) was a pioneer in foam extrusion. LDPE was attributed to its highly long branched structure to provide additional resistance toward external “disturbance”. The branching resin structure makes a big difference. Thick low density PE board can be made in a tandem foam extrusion system which die outlet is shown in Fig. 1. It simply opens a new chapter for foam extrusion. Nowadays, PE board products up to 40 times expansion is a well-recognized product in the specialty packaging, automotive and sports industries. To Give Than To Receive - 2 - Foam Update March 2016 Fig. 1: Foam Board Extrusion Die Branched polypropylene (PP) was introduced by Himont in 1990, whose low temperature irradiation process was disclosed in the US. Patent 4,916,198. 35 times expansion foam sheet can be made out of the high melt strength (HMS) PP. It simply enlarged polyolefin foam portfolio. For polysondensed polyethylene terephthalate (PET), multi-functional branching agent was introduced to generate branching structure by Du Pont, then by Sinco in Italy to commercialization of the HMS PET. Up to 40 times expansion PET foam sheet can be thermoformed into tray for microwave oven meal, or known as ready meal. Both HMS PP and PET can be made into thick board via “strand” technique for structural applications; such as: wind blade and boat hull. It was indeed encouraging to find out highly branched structure can contribute to melt strength to make difficult to process PP and PET into useful low density foam extrusion products. In the last decade, microcellular study indicated that supercritical CO2 can alter crystallinity significantly. Amorphous polycarbonate could show over 20% crystallinity after saturated with CO2. It sure opens the door to establish melt strength through fine crystallinities which becomes source of strength without jeopardizing melt elasticity by precise thermal management. Its difficulty clearly increases as scale increases. However, some early lab reports offers very fine cell structure; sub-micron cell size. It is expected that nano cell can reduce thermal transfer significantly. Although the development path may not be easy, we are sure its progress can shed more light in foaming and in combination To Give Than To Receive - 3 - Foam Update March 2016 with branching a bright future will not be far off. Table.1 shows a development summary of resin for foam extrusion. In the next issue, we plan to talk about resin characteristics for molded beads foam. Table. 1: Resin Development Summary for Foam Extrusion Resin Product Attribute Year Polystyrene Sheet Amorphous 1940’s Polystyrene Board Amorphous 1950’s Low Density PE Sheet Long branching 1960’s Polypropylene Sheet Phase separation 1970’s (PP) HMS PP Sheet, Long Branching 1990’s Board/strand HMS PET Sheet, Long Branching 1990’s Board/strand PP (batch in the lab Crystallinity 2000’s only) Editorial Office To Give Than To Receive - 4 - Foam Update March 2016 C. News COVESTRO IS OFF AND RUNNING IN 2016 Author(s) Laird, K. Sources Plastics Today Corporate/Assignee N/A Publication Date February 24, 2016 Abstract: Yesterday in Cologne, Germany, materials manufacturer Covestro held its first financial news conference after takeover from Bayer Material Science— ‘a genuine premiere’, as CEO Patrick Thomas described it—presenting the results achieved by the company over the past fiscal year. And, across the board, they were convincing results: all financial targets were achieved in 2015. Adjusted EBIDTA shows a substantial increase of 41%, to €1.6 billion, mainly thanks to a more favorable supply and demand situation as well as higher volumes. They expect this year’s macroeconomic environment to be similar to that of 2015. GLOBAL TRANSIT PACKAGING MARKET - INDUSTRY ANALYSIS, GROWTH, TRENDS AND FORECAST 2016 - 2024 Author(s) N/A Sources Industry Today Corporate/Assignee N/A Publication Date February 24, 2016 Abstract: Packaging is an inevitable part of manufacturing industry. The growing global commerce is forcing manufacturers and packers to transport the goods at distant areas facing environmental and physical challenges. Hence, globally safe transportation of goods and materials is anticipated to be one of the major challenges for manufactures. The transit packaging industry hence helps manufacturers and packers by providing resilient, attractive and cost effective solutions for their transportation needs. COVESTRO TRUMPETS ADVANCES IN MEDICAL MATERIALS AT MD&M WEST Author(s) Sparrow, N. Sources Plastics Today To Give Than To Receive - 5 - Foam Update March 2016 Corporate/Assignee N/A Publication Date February 10, 2016 Abstract: Covestro debuted its Baymedix FP505 prepolymer at MD&M West. The material is used to create non-yellowing aliphatic foams, which feature enhance fluid absorption and retention, explained Bentley Mah, Senior Technical Sales Specialist, from the Covestro booth (#2021). "We have increased the dry strength of one of our foams that has been on the market and, most importantly, enhanced its moisture-management properties and breathability for wound-care applications," said Mah. Baymedix FP505 absorbs up to 19 times its weight and will retain more than 60% of the fluid, even when an object "with the weight of a bowling ball" is placed on top of it, added Mah. Unlike aromatic foams, which may turn yellow and become brittle, aliphatic foams made from Baymedix FP505 retain their pristine appearance, which is desirable in a healthcare setting, said Mah. Tangible and chemical samples of Baymedix FP505 are now available from Covestro. CHEMICAL FOAMING AGENTS FOR THE PLASTICS PROCESSING INDUSTRY Author(s) N/A Sources Plastics Today Corporate/Assignee N/A Publication Date February 10, 2016 Abstract: Bergen International focuses exclusively on providing plastic processors with the best performing chemical foaming agents (CFAs) for low-density foaming processes. Foamazol™ chemical foaming agents are available for many processes such as, injection molding, co-injection injection molding, gas counter-pressure molding, rotational molding, structural foam molding, co-extrusion, chemical foam extrusion, direct gas extrusion, wood-plastic composites extrusion, and wire & cable extrusion processes. Bergen manufactures various types of Foamazol™ chemical foaming agents including endothermic, exothermic and endo/exo blends….in a variety of forms such as pelletized masterbatches, powders and liquids…for a range of polymers including polyolefins, styrenics, engineering resins or PVC…at a variety of decomposition temperatures. To Give Than To Receive - 6 - Foam Update March 2016 UPDATED: HOW A 3D-PRINTED BRACE HELPED KEEP CAROLINA PANTHERS' THOMAS DAVIS IN THE SUPER BOWL Author(s) Sparrow, N. Sources Plastics Today Corporate/Assignee N/A Publication Date February 8, 2016 Abstract: Panthers’ Linebacker Thomas Davis was the first player to wear a 3D-printed device in a Super Bowl game.