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
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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.
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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
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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
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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
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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. Davis broke a bone in his forearm during the NFC Championship game. That kept him out of the rest of the game, but it did not keep the Panthers out of Super Bowl 50. And Davis showed determination all of last week that he would be on that stage with his team.
His injured right forearm has a metal plate held together with 12 screws, but that can't compensate for the fact that he's still healing or, more importantly, absorb the impact of a tackle, each of which has the force of approximately 1,600 pounds, reports the Medical Daily. Davis reached out to Whiteclouds, a 3D-printing lab headquartered in Ogden, UT, that works with the likes of NASA, Marvel and Walmart, for a solution. Whiteclouds scanned his arm and designed a 3D-printed shock-absorbing brace using its XRD technology, a blend of plastic and rubber-like materials. The conformable Poron microcellular product instantly dissipates force upon impact, absorbing as much as 90% of energy at high-speed impact, according to Whiteclouds.
Design and engineering of the brace took just eight hours, reports CNET, and it was printed in a little over one day on a Stratasys Connex industrial 3D printer. Davis had been wearing the brace during practice, and doctors examined his arm again on Friday, but the full practice load was a clear indication that he would be ready for the game of his life on Sunday, said ESPN. And he was: He finished second on the team in the number of tackles (seven).
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Foam Update March 2016
FOAMS PIPELINE REVIEW 2016 MARKET SIZE, SHARE, GROWTH, ANALYSIS, FORECAST Author(s) N/A Sources www.medgadget.com Corporate/Assignee N/A Publication Date February 4, 2016 Abstract: The report ” Foams Global 2016 pipeline review” includes comprehensive information on the Foams pipeline products with comparative analysis of the products at different stages of development of Foams scenario. The Foams report reviews major players involved in the Foams pipeline product development. It also includes information about Foams clinical trials in progress, which includes, trial status, Foams trial phase, trial start and end dates, and, the number of trials for the key Foams diagnostic tests pipeline products.
CURRENT AND PROJECTED AEROSPACE FOAMS MARKET SIZE IN TERMS OF VOLUME AND VALUE 2015-2025 Author(s) N/A Sources www.digitaljournal.com Corporate/Assignee N/A Publication Date February 1, 2016 Abstract: Foams are an important class of materials that find a variety of applications across a diverse set of industries. The low density, cellular structured materials namely foams are used either for cushioning, as insulating materials, for vibration damping or for packaging applications. The aerospace industry necessitates materials that fulfil the intended function, are lighter in weight at the same time exhibit exceptional strength and resilience. The foams that cater to the demands of aerospace industry are collectively termed as aerospace foams. The most commonly used foams for aerospace applications include polyurethane foam, polyethylene foam, metal foams, and ceramic foams.
RIGID POLYURETHANE (PU) FOAMS MARKET IS EXPECTED TO GROW OWING TO ENHANCED DEMAND IN CONSTRUCTION AND REFRIGERATION INDUSTRIES TILL 2020: GRAND VIEW RESEARCH, INC. Author(s) N/A Sources www.digitaljournal.com Corporate/Assignee N/A Publication Date N/A Abstract: Polyurethane (PU) foams vary from rigid or flexible foams to stiff or strong elastomers.
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Foam Update March 2016
Rigid and flexible foams comprise 59% of the PU industry. Rigid PU foams are mainly used for insulation and broadly used in construction and refrigeration sectors.
Volumes of the rigid polyurethane (PU) foams market are estimated to grow at a CAGR of 5.3% from 2013 to 2020. The market will be worth around USD 20 billion by 2020. This may be attributed to growing construction sector in emerging economies; especially India, Brazil, and China. Governmental support for using rigid PU foams in refrigeration applications in the U.S. would also boost global sales.
MARKET OVERVIEW ON GLOBAL POLYURETHANE FOAMS INDUSTRY : SWOT ANALYSIS, COMPETITIVE LANDSCAPE 2015 DEVELOPMENTS & EXPANSION Author(s) N/A Sources www.digitaljournal.com Corporate/Assignee N/A Publication Date February 17, 2016 Abstract: The report on the global Polyurethane Foams market provides an extensive overview of the developments in the market during the forecast period. It includes an analysis of the several parameters such as market drivers, restraints, opportunities, and key market trends that will influence the progression of this market during the forecast period. Following this, market size estimates and revenue projections that are of interest for market participants are covered in the report. This includes projections for the overall market and also the major segments of the market based on relevant criteria, which are useful for market entities
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D. Patents and Journals
a. New Foaming Technique
ADAPTATION DEVICE FOR PRODUCTION OF FOAM Inventor(s) Poizot, F. Sources US Pat.: 9,265,385 Corporate/Assignee Rieke Corporation Publication Date February 23, 2016 Abstract: The present invention relates to an adaptation device arranged to transform a pump not specific to the production of foam into a foam pump. The device comprises a supply conduit extending from the inlet of the pump as far as an elbow below the level of foaming liquid and rising above the level of the liquid to terminate in air added to the structure of a pump for fluids. The supply conduit comprises a suction hole enabling suction of liquid when air circulates before the hole. A filtering grate is added to a discharge conduit and connected to the pumping outlet. The foaming liquid comprises, in part, water to produce foam without additional water.
SUB-AMBIENT PRESSURE MORPHOLOGY CONTROL PROCESS FOR USE IN MOLDING EXTRUDED POLYMER FOAMS, AND PARTS PRODUCED THEREFROM Inventor(s) Beard, B., Ermie, P., Lambert, C., Myers, J., Vorenkamp, E., Wagener, S. Sources US Pat.App.: 20160052180 Corporate/Assignee N/A Publication Date February 25, 2016 Abstract: A method of sub-ambient pressure processing of blow-molded polymer foams and skin-over-foam sandwich panel configurations for lightweight components having improved structural properties. The method can create either skinned or un- skinned foams that offer smooth interior and exterior surfaces, zero or controlled surface porosity, skins of pre-defined thickness, and
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foam cells that are expanded and oriented normal to the material plane, effectively spherical or polyhedral in nature, and offering improved bending and compressive strength.
PACKAGED DAIRY BEVERAGE Inventor(s) Clavier, M. L., Delattre, J., Guezet, C., Rey-garcia, M. Sources WO 2015185545 Corporate/Assignee N/A Publication Date December 10, 2015 Abstract: A packaged product consisting essentially of a chilled dairy beverage in closed cup is disclosed. The beverage may be foamed by shaking, to provide pleasant foamy texture.
USING OF EXPANDABLE FILLERS TO PRODUCE LOW DENSITY PARTICLEBOARD Author(s) Shalbafan, A., Tackmann, O., Welling, J. Sources European Journal of Wood and Wood Products 74, No.1, Jan. 2016, p.15-22 Corporate/Assignee N/A Publication Date September 19, 2015 Abstract: In this study three types of layered lightweight particleboard were produced by using different amounts of expandable polystyrene in the core layer as the filler material. The objective of this study was to compare the effect of varying amounts of expandable filler (5, 10 and 15 %) for two panel densities (450 and 500 kg/m3) and two panel thicknesses (16 and 19 mm) on the panel properties. The results showed that using expandable fillers has a significant effect on the bending properties, internal bond, edge screw withdrawal resistance, thickness swelling and water absorption. The surface soundness and face screw withdrawal resistance were not affected by the usage of expandable filler, as it depends mainly on the quality and density of the surface layer. Panel density and panel thickness also have significant influence on the physical and mechanical properties of the panels produced. Physical and mechanical properties of the boards did not dramatically change when the amount of expandable filler was increased from 5 to 15 %.
EFFECT OF E-GLASS FIBERS AND PHLOGOPITE MICA ON THE MECHANICAL PROPERTIES AND DIMENSIONAL STABILITY OF RIGID PVC FOAMS Author(s) Jamel, M. M., Khoshnoud, P., Gunashekar, S., Abu-Zahra, N. Sources Polymer Plastics Technology and Engineering 54, No.15, 2015, p.1560-1570 Corporate/Assignee N/A Publication Date June 15, 2015
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Abstract: In this work, short E-glass fibers and mica were used to enhance the dimensional stability and mechanical properties of extruded rigid polyvinyl chloride foams. Experimental results show that the dimensional stability increased by 50%, and heat resistance of the polyvinyl chloride foam improved as the amount of reinforcing solids increased in the composites. The storage modulus, tensile, and flexural strengths of the composites improved by 220, 82, and 46%, respectively. Scanning electron microscope micrographs show good interaction between glass fibers and foam cells and a good dispersion and orientation of the mica flakes along the cell walls of the polyvinyl chloride foam.
DILUENT SELECTION FOR NYLON 11 AND NYLON 12 THERMALLY INDUCED PHASE SEPARATION SYSTEMS Author(s) Funk, C. V., Koreltz, M. S., Billovits, G. F. Sources Journal of Applied Polymer Science 133, No.13, 2016, paper 43237, pp.11 Corporate/Assignee N/A Publication Date December 10, 2015 Abstract: Nylon 11 and Nylon 12 are commercially important polymers due to their unique combination of mechanical strength, chemical resistance, and processability. Products have been prepared from these polymers via thermally induced phase separation (TIPS) for many years. Nevertheless, known diluents for Nylon 11 and 12 pose specific processing problems, and it would be desirable to find a diluent that allows low processing temperatures, has a high flash point, is inexpensive, and exhibits low toxicity. This work investigated a variety of alternative diluents not previously documented in the literature. A fundamental study was also performed to determine which factors are important in selecting a diluent for preparing Nylon liquid–
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liquid TIPS membranes. The information gathered in this study, including phase diagrams for all feasible systems investigated, will be important in shaping future formulation work for Nylon use in microporous membranes.
3D X-RAYS APPLICATION FOR PRECISION MEASUREMENT OF THE CELL STRUCTURE OF EXTRUDED POLYSTYRENE Author(s) Lim, J. Y., Kim, K. Y., Shin, H. S., Yeom, S., Lee, S. E. Sources IOP Conference Series: Materials Science and Engineering 103, 2015, paper 012019, pp.6 Corporate/Assignee N/A Publication Date N/A Abstract: While the thermal performance of existing insulation materials have been determined by blister gases, the thermal performance of future insulation materials will be dependent on the cell size and independent foam content as we use eco-friendly blister gases with a higher thermal conductivity. However, with the current technology we are only able to guess the whole cell size and independent foam content through SEM applied 2D fragmentary scanning but are still far from the level of accurate cell structure data extraction. Under this situation, we utilised X-ray CT scanned 3D images to identify and shape the cell structure and proposed a method of inferring the whole distribution and independent foam content as accurately as possible. According to X-ray CT scanning images and SEM images, the shape was similar but according to tracer applied CT scanning images, the cell size distribution was 380 400 (mu)m within the range of the general insulation diameter distribution which had the highest reliability. As for extrusion foaming polystyrene, we need additional image processing to identify the independent foam content as its density is too low. So, it is recommended to raise the 3D cell structure completeness of XPS by improving the scanning accuracy. 6 Refs.
b. Blowing Agents
NON-VOC PROCESSING AIDS FOR USE IN MANUFACTURING FOAMS USING LOW GLOBAL WARMING POTENTIAL BLOWING AGENTS Inventor(s) Delaviz, Y., Bourdeaux, C. J., Han, X., Brammer, S. T., Fabian, B. A., Weekley, M. Z. Sources US Pat.App.: 20160017111 Corporate/Assignee N/A Publication Date January 21, 2016 Abstract: A foamable polymeric mixture is provided that includes a polymer composition, at least one blowing agent, and at least one non-VOC processing aid comprising one or more of an adipate ester; benzoate; fatty acids and their derivatives, propylene carbonate; ethylene
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oxide/propylene oxide block copolymer; styrene-methyl methacrylate copolymer; and a dispersion of organic salt of a fatty acid in copolymer. The blowing agent comprising at least one of carbon dioxide, hydrofluoroolefins, hydrochlorofluoroolefins and hydrofluorocarbons, and mixtures thereof.
c. Foam Products
SILICONE RESIN FOAM AND SEALING MATERIAL Inventor(s) Gotoh, M., Nakamura, K. Sources US Pat.App.: 20160053069 Corporate/Assignee Sekisui Chemical Co., Ltd. Publication Date February 25, 2016 Abstract: A silicone resin foamed body according to the present invention comprises: a silicone resin cured product (A); and a plurality of particles (B) dispersed in the silicone resin cured product (A) and each having a cavity portion (b1) therein, wherein the silicone resin foamed body has a cavity portion (C) surrounded with the silicone resin cured product (A) or with the silicone resin cured product (A) and the particles (B) in the silicone resin cured product (A).
FLEXIBLE FOAMS HAVING AN ABRASIVE SURFACE Inventor(s) Schade, M., Von benten, R., Scherr, G. Sources US Pat.App.: 20160046780 Corporate/Assignee BASF SE Publication Date February 18, 2016 Abstract: The invention relates to flexible foams with a flexible, abrasive surface which comprise 1 to 90% by weight of a mixture, based on the uncoated substrate, which comprises the condensation product of 99.985 to 20% by weight of at least one precondensate of a heat- curable resin, 0 to 10% by weight of a polymeric thickener selected from the group consisting of biopolymers, associative thickeners and/or completely synthetic thickeners, 0.01 to 10% by weight of a curing agent, 0 to 10% by weight of surface-active substances or surfactants, 0 to 15% by weight of dyes, pigments, or mixtures thereof and 0 to 75% by weight of water, where this mixture comprises 10 to 70% by weight of one or more binders based on the above mixture, from the group of polyacrylates, polymethacrylates, To Give Than To Receive - 14 -
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polyacrylonitriles, copolymers of acrylic acid esters and acrylonitrile, styrene and acrylonitrile, acrylic acid esters and styrene and acrylonitrile, acrylonitrile and butadiene and styrene, polyurethanes, melamine-formaldehyde resins, phenol-formaldehyde resins, urea-formaldehyde resins, melamine-urea-formaldehyde resins, melamine-urea-phenol- formaldehyde resins, urea-glyoxal resins.
METHOD FOR MODIFYING POLYOLEFIN TO INCREASE LONG CHAIN BRANCHING Inventor(s) Tzoganakis, C., Penlidis, A., Amintowlieh, Y. Sources US Pat.App.: 20160039980 Corporate/Assignee N/A Publication Date February 11, 2016 Abstract: A method of modifying polyolefin to have long chain branching comprising mixing polyolefin and a photoinitiator and irradiating the mixture with UV radiation. The modified polyolefin of the method and the use of said modified polyolefin.
ETHYLENE-BASED POLYMER COMPOSITIONS AND FOAMS Inventor(s) Low, B. T. Sources US Pat.: 9,249,271 Corporate/Assignee Dow Global Technologies LLC Publication Date February 2, 2016 Abstract: The invention provides a composition comprising the following: A) a first polymer selected from the following: i) an ethylene/.alpha.-olefin interpolymer; or ii) an ethylene/.alpha.-olefin multi-block interpolymer; B) a second polymer selected from the following: iii) an ethylene/.alpha.-olefin interpolymer; iv) an ethylene/.alpha.-olefin/non- conjugated diene interpolymer; or v) an ethylene/.alpha.-olefin multi-block interpolymer; and wherein the first polymer has a density from 0.880 to 0.910 g/cc, and the second polymer has a density less than, or equal to, 0.867 g/cc, and wherein the weight ratio of the first polymer to the second polymer is from 0.5 to 9.
BLOWN FILMS WITH IMPROVED TOUGHNESS Inventor(s) Wang, J., Jain, P., Demirors, M., Patel, R. M., Guerra, S. M., Leano, M. E., Ma, H., Bilgen, M., Olajide, F. O. Sources WO 2015200743 Corporate/Assignee Dow Global Technologies Llc Publication Date December 30, 2015 Abstract: Blown films formed from polyethylene are provided that can have desirable properties. In
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one aspect, a blown film comprises a layer formed from a composition comprising a first composition, wherein the first composition comprises at least one ethylene-based polymer and wherein the first composition comprises a MWCDI value greater than 0.9, and a melt index ratio (I10/I2) that meets the following equation: I10/I2 ≥ 7.0 - 1.2 x log (I2).
CAST FILMS WITH IMPROVED TOUGHNESS Inventor(s) Wang, J., Jain, P., Demirors, M., Patel, R. M., Guerra, S. M., Leano, M. E., Sources WO 2015200742 Corporate/Assignee Dow Global Technologies Llc Publication Date December 30, 2015 Abstract: Cast films formed from polyethylene are provided that can have desirable properties. In one aspect, a cast film comprises a layer formed from a composition comprising a first composition, wherein the first composition comprises at least one ethylene-based polymer and wherein the first composition comprises a MWCDI value greater than 0.9, and a melt index ratio (I10/I2) that meets the following equation: I10/I2 ≥ 7.0 - 1.2 x log (I2).
METHOD FOR PRODUCING THIN-WALLED CONTAINERS BY MEANS OF INJECTION MOLDING, AND THIN-WALLED CONTAINERS PRODUCED IN SUCH A MANNER Inventor(s) Conte, M. Sources WO 2016005033 Corporate/Assignee Weidenhammer Packaging Group GMBH Publication Date January 14, 2016 Abstract: The invention relates to a method for producing a thin-walled container, wherein a thermoplastic polymer is plasticized and the plasticized polymer is injected into the molding chamber (4) of a mold (1) with a wall/flow ratio of at least 250 via an injection channel (5). The polymer is then distributed along the base and wall of the molding chamber (4) in the molding chamber (4) so that the polymer completely fills the molding chamber. The polymer is then solidified, thereby forming the container, and removed from the mold (1). The aim of the invention is to allow the production of a thin- walled container which is mixed with solid filler or reinforcing materials by means of injection molding. This is achieved in that a powder or particulate filler is added to the polymer or a polymer which is mixed with such a filler is used, and a propellant is added
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to the polymer or a polymer which is mixed with a propellant is used, said propellant being expanded in the molding chamber (4) of the mold (1). The invention further relates to a thin-walled container which is produced in such a manner, in particular as a packing container.
POLYSTYRENE RESIN FOAM Inventor(s) Kazuhiko, M., Hirotoshi, T., Masashi, O. Sources JP 2016000471 Corporate/Assignee N/A Publication Date January 7, 2016 Abstract: The present invention has an excellent antistatic performance while maintaining a high beautiful striped pattern of the design characteristics, and further, the production is also simple and inexpensive, to provide a novel polystyrene resin foam. The invention relates to a polystyrene resin foam 1 having a polystyrene type resin foamed layer 2, containing an antistatic agent on at least one surface of the emitting foam layer 2, streaky antistatic layer 3 are laminated, the the surface resistivity of the surface of the foam (a) is 1 × 10 8 Omega～1 × 10 13 is Ω, polystyrene resin foam, characterized in that the spacing of 該筋 shaped antistatic layers is 20mm or less.
PLASTIC COMPOSITE BOARD AND ITS MANUFACTURING METHOD Inventor(s) Zhang, M. Sources CN 104999756 Corporate/Assignee N/A Publication Date October 28, 2015 Abstract: The present invention relates to a plastic composite board and its manufacturing method, the plastic composite panel includes a thin film micro foam board member and re-attached to the surface of the micro-foam plate made of polyethylene terephthalate constituted the micro-foam plate renewable materials polyethylene or polypropylene recycled materials or renewable materials PVC-based material and foaming agent azodicarbonamide constituted mixed with ingredients, its production method comprises PE renewable materials dry mix was added and the heating extruder, and upper and lower surfaces coated with the motherboard institutions, stereotypes complete the steps on the surface of the film board member. Micro foam board member can cause film was posted on the kind of plastic composite panels at bending toughness is very strong and difficult to break, with a certain
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tensile strength, and the production costs are very bottom.
ONLINE MICRO FOAMED POLYPROPYLENE THERMAL FILM SHEET AND MANUFACTURING METHOD THEREOF Inventor(s) Jiang, C. Sources CN 104985902 Corporate/Assignee N/A Publication Date October 21, 2015 Abstract: The present invention provides a micro foamed polypropylene thermal film online sheet, which is a thin film layer by the PP and PP-foam layer, the production methods are: PP material into an extruder food-grade micro-foam, heated temperature of 160 ℃ -210 ℃, foam concentrate PP material used in the production of CO and decomposition of the material under heating 2 gas, CO 2 gas in the extrusion process is decomposed into a large number of uniform microbubbles closed hole, extruder screw extrusion layer PP foam sheet, film tension adjuster for PP printed film tension control, while taking advantage of PP foam layer sheet having an extruder die just when extruded from a high temperature bonding on PP film layer, setting cooling unit for PP film layer and the foam layer PP micro heat bonding step, PP foam layer sheet thermally bonded after the PP film layer is composed of amorphous cooled chillers made to deal with stereotypes, it hot-line the film does not need glue, so that the real food safety packaging.
A POLYMERIC MICRO-FOAM FILM Inventor(s) Wu, Y., Pan, J., Chen, P. Sources CN 104987523 Corporate/Assignee Qingdao Honest Polymer Technology Co., Ltd. Publication Date October 21, 2015 Abstract: The present invention discloses a method for preparing polymer micro-foam film, comprising the steps of: 1) the 200- 500μm thick polymer film and the spacer material, uniform crop membrane. 2) The membrane is placed in a supercritical fluid reactor, control at higher temperature and pressure, supercritical fluid penetration in the polyester membrane, the swelling is
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saturated. 3) After reaching saturation, assisted ultrasonic technology inside the polymer film homogeneous nucleation, the release of supercritical fluid reactor, nucleation has taken the web. 4) The membrane was placed under a heat source, the internal air nucleation and growth, cell shape, to obtain a uniform pore size, fine micro-cell foam film. The process is simple, clean and non-polluting, high efficiency; the thickness of the resulting polymer micro foamed films in 300-1000μm between product density in 0.25- 0.65g / cm 3 between the aperture in the 5-20μm Room pore density in 1010 -10 12 cells / cm 3 ; visible light reflection, reaching more than 98%.
BE SUITABLE FOR POLYESTER FILM OF KNURLING Inventor(s) Wang, W., Jin, H., Chen, L. Sources CN 204586027 Corporate/Assignee Nanjing Lan Po into New Materials Co., Ltd. Publication Date August 26, 2015 Abstract: The utility model discloses a be suitable for polyester film of knurling, including high foaming layer of PET and the compound little foaming layer of the PET on surface about the high foaming layer of PET, the porosity of the high foaming layer of PET is 45%- 82%, and the aperture is 4-8 mu m, and thickness is 35-140 mu m. The utility model discloses be suitable for polyester film of knurling has increased the temperature difference between softening point and fusing point, makes it can satisfy knurling technology demand, the density of film that adopts the preparation of foaming technique is low, greatly reduced the cost, the film top layer has certain stiffness, has fine processing property, the preparation environmental protection of membrane, pollution-free.
AN OPEN CELL POLYMER FOAM MATERIAL AND PREPARATION METHOD Inventor(s) Zheng, W., Pang, Y., Wang, S., Wang, K., Wu, F. Sources CN 105001512 Corporate/Assignee Ningbo Institute of Material Technology and Engineering Publication Date August 28, 2015 Abstract: The present invention provides a method for preparing an open cell polymeric foam, comprising the steps of: a polypropylene Weigh 100 parts by weight, 0.5 to 5 parts by
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Foam Update March 2016
weight of a nucleating agent, the polyolefin-containing ethylenic parts by weight of 10 to 100, opening b screw the polypropylene, nucleating agents, containing ethylene-based polyolefin and filler openings uniformly mixed to obtain a mixture, and the mixture was added to the extruder, and the extruder; 1 to 30 parts by weight of the filler hole 1/5 ~ 1/3 through a supercritical state of carbon dioxide, extruded and foamed to give openings containing the filler openings polymer foam material, the filler openings containing polymer foam material comprises openings a first plurality of apertures; c containing the openings of the open-cell foam filler material is immersed in an etching solution, so that the filler opening is etched to form a plurality of second apertures, opening to obtain a polymer foam material. The present invention also provides an open cell polymeric foam material. The opening polymer foams having opening rate, suction rate, good benefits.
A FOAM MATERIAL AND PREPARATION METHOD OF POLYETHYLENE Inventor(s) Daixiao, C. Sources CN 105175647 Corporate/Assignee N/A Publication Date December 23, 2015 Abstract: The present invention discloses a polyethylene foam material and preparation method, the polyethylene foam by the following components by weight portion: polyethylene 80-86 parts, 11-18 parts of inorganic filler, montan wax acid B 10-15 parts of diester, trimethylolpropane trivinyl ether 5-15 parts of 1,4-butanediol diacrylate 3-6 parts, parts 3- 5 polyacrylamide, polyoxyethylene sorbitol 1-3 parts anhydride, di-n-butyl tin dilaurate 1- 3 parts, 0.5-1.8 parts of silicic acid trimethyl 1-2 parts and blowing agents. The present invention also provides a method for preparing a polyethylene foam.
PREPARATION AND FOAMING MECHANISM OF FOAMABLE POLYPROPYLENE BASED ON SELF-ASSEMBLED NANOFIBRILS FROM SORBITOL NUCLEATING AGENTS Author(s) Wang, W., Zhou, S., Xin, Z., Shi, Y., Zhao, S., Meng, X. Sources Journal of Materials Science 51, No.2, Jan. 2016, p.788-796 Corporate/Assignee N/A Publication Date September 10, 2015
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Abstract: A strategy to prepare foamable isotactic polypropylene (iPP) was proposed by introducing crystal nucleating agent, 1,3:2,4-bis(p-methylbenzylidene) sorbitol (S20), and the foaming mechanism was also investigated. When a proper concentration (above 0.3 wt%) of S20 was added, iPP/S20 exhibited excellent foaming performance, yielding uniform cells with well-defined structures and higher cell density than those of neat iPP. The results of rheological analysis and TEM confirmed the formation of S20 nanofibrils in iPP matrix. The existence of these nanofibrils increased the melt viscosity of iPP and enhanced the bubble nucleation in the foaming process, and thus should be responsible for the improved foaming ability of iPP. Moreover, iPP/S20 could be foamed in a remarkably wide temperature range from 143 to 163 °C. In comparison, another crystal nucleating agent, sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl)-phosphate (NA40), contributed little to the foamability of iPP although it also induced the crystallization of iPP.
A NEW STRATEGY FOR PREPARATION OF LONG-CHAIN BRANCHED POLYPROPYLENE VIA REACTIVE EXTRUSION WITH SUPERCRITICAL CO2DESIGNED FOR AN IMPROVED FOAMING APPROACH Author(s) Wang, K., Wang, S., Wu, F., Pang , Y., Liu, W., Zhai, W., Zheng , W. Sources Journal of Materials Science 51, No.5, Mar. 2016, p.2705-2715 Corporate/Assignee N/A Publication Date November 18, 2015 Abstract: A novel strategy was designed for the preparation of a long-chain branched polypropylene (PP) with improved foamability via reactive extrusion in the presence of supercritical CO2 (scCO2). Benzoyl peroxide was used as a radical initiator and trimethylolpropane triacrylate (TMPTA) was applied as a polyfunctional reactive monomer during extrusion. Fourier transform infrared spectroscopy and high temperature GPC confirmed that TMPTA was grafted onto PP chains, and the presence of scCO2promoted the grafting and branching reactions, and hindered polymer degradation. A possible mechanism was proposed to explain the effect of scCO2 on the branching reactions. In addition, rheological behavior of pure PP and modified PP samples was studied to investigate the effect of long chain branching of PP on the melt viscosity and strength, and foaming behavior was studied to confirm the subsequent effect on its foamability. It was found that the long chain branching increased the melt viscosity and strength of modified PP samples, which favored the foamability, and that the foaming windows were expanded in the presence of scCO2. Thus, it provided an advanced foaming approach via preparation of long-chain branched PP through reactive extrusion with scCO2 both working as the reactive medium and the foaming agent.
MORPHOLOGICAL AND MECHANICAL CHARACTERIZATION OF FOAMED POLYETHYLENE VIA BIAXIAL ROTATIONAL MOLDING To Give Than To Receive - 21 -
Foam Update March 2016
Author(s) Moscoso-Sánchez, F., Mendizábal, E., Jasso-Gastinel, C. F., Ortega-Gudiño, P., Robledo-Ortíz, J. R., González-Núñez, R., Rodrigue, D. Sources Journal of Cellular Plastics 51, No.5-6, 2015, p.489-503 Corporate/Assignee N/A Publication Date December 31, 2014 Abstract: Foamed linear medium density polyethylene parts were prepared by rotational molding in biaxial mode, using different amounts of chemical-blowing agent (azodicarbonamide). Morphological and mechanical properties are presented and discussed in terms of foam density, cell density, average cell diameter, and open cell content. Internal air temperature of the mold was measured as a function of time. Significant differences were observed between unfoamed and foamed parts. The use of an exothermic chemical-blowing agent increased the peak internal air temperature and part cooling was slower due to the presence of gas bubbles acting as insulating material. The most important changes were observed for foam density: adding 1 phr of azodicarbonamide the density decreased from 0.931 g/cm3 (0 phr azodicarbonamide) to 0.295 g/cm3. Finally, the mechanical properties were highly influenced by azodicarbonamide content. Tensile and impact properties were correlated with part density using a simple power–law equation.
FOAMING OF REACTIVELY MODIFIED POLYPROPYLENE: EFFECTS OF RHEOLOGY AND COAGENT TYPE Author(s) Zhang, Y., Parent, J. S., Kontopoulou, M., Park, C. B. Sources Journal of Cellular Plastics 51, No.5-6, 2015, p.505-522 Corporate/Assignee N/A Publication Date December 31, 2014 Abstract: A series of linear controlled rheology polypropylenes were produced through reaction with dicumyl peroxide in the melt state, to investigate the effect of molecular weight and viscosity on foaming. Foaming experiments by compression molding, using a chemical blowing agent (azodicarbonamide), and by batch foaming using nitrogen-blowing agent, revealed that lower viscosity promoted higher expansion ratios and larger cells, due to reduced resistance to cell growth. Linear polypropylene was further modified using trimethylolpropane trimethacrylate and triallyl trimesate coagents. Coagent modification resulted in pronounced changes in the shear thinning and elasticity of the modified polypropylenes. However, evidence of long-chain branching was only present in polypropylene modified by triallyl trimesate. Foams based on coagent-modified polypropylenes had higher expansion ratios than their degraded counterparts. This was ascribed in part to the lower viscosities, and to a nucleating effect, arising from the presence of a finely dispersed phase of coagent-rich nanoparticles. Strain hardening in polypropylenes modified by triallyl trimesate further resulted in a finer cell structure, due to suppressed coalescence.
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d. Applications
DEEP DRAW METHOD OF MAKING IMPACT AND VIBRATION ABSORBING ARTICLES AND THE ARTICLES FORMED THEREBY Inventor(s) Fox, R. B., Wyner, D. M., Waksman, J., Gaudet, J. E. Sources US Pat.: 9,254,591 Corporate/Assignee Polyworks, Inc. Publication Date February 9, 2016 Abstract: The present disclosure relates to cushioning members, methods of making and methods of using, particularly to cushioning members comprising a plurality of spaced apart pillars comprising a polymeric material.
FOAM MOLDING SYSTEM AND METHOD OF OPERATION Inventor(s) Osterday, J. R., Snead, S. L. Sources US Pat.App.: 20160031133 Corporate/Assignee N/A Publication Date February 4, 2016 Abstract: A foam molding system and method of operation are provided. The foam molding system includes a molding assembly configured to mix a plurality of constituent materials to form a molding material. A dispenser is operably coupled to receive the molding material. A carrier is positioned to receive the molding material from the dispenser, the carrier being removably coupled to the foam molding machine. An RFID module is coupled to the carrier. An RFID reader is arranged to receive a signal from the RFID module when the carrier is arranged in the foam molding machine. A controller is operably coupled to the RFID reader and the molding assembly, wherein the controller includes a processor that is responsive to executable computer instructions for changing molding parameters in response to the RFID reader receiving the signal from the RFID module.
PROTECTIVE PACKAGE ASSEMBLY WITH IMPROVED SAFETY FOR A HOUSEHOLD APPLIANCE
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Inventor(s) Bolukbasi, D. C., Fidan, C., Yanik, I., Canigur, I., Ozturk, F. M. Sources WO 2016000740 Corporate/Assignee N/A Publication Date January 7, 2016 Abstract: The present invention relates to a protective package assembly (1) for a household appliance (2) comprising a main body (3). The protective package assembly (1 ) comprises one or more than one corner segment (5a, 5b, 5c), wherein each corner segment (5a, 5b, 5c) extends along a respective corner section (6a, 6b, 6c) of the main body (3), and wherein each corner segment (5a, 5b, 5c) has an inner surface (7) which faces the outer surface (8) of the respective corner section (6a, 6b, 6c) of the main body (3).
MICROSPHERES Inventor(s) Quittmann, U., Wilhelm, V., Brehm, H. Sources WO 2015197162 Corporate/Assignee N/A Publication Date December 30, 2015 Abstract: The invention relates to microspheres and the use thereof, in particular as a laser- absorbing additive, and to a method for the production thereof.
HAVING A FLAME-RETARDANT EFFECT OF FOAMED POLYPROPYLENE AND ABSORBENT POLYMER COMPOSITE MATERIAL AND ITS PREPARATION METHOD Inventor(s) Chen, S., Wu, K., Yu, Z., Jiang, Y., Wu, J., Wu, Y., Fan, Y. Sources CN 104987591 Corporate/Assignee Anhui Prescription New Material Technology Co., Ltd. Publication Date October 21, 2015 Abstract: The present invention discloses a flame-retardant effect of foamed polypropylene and absorbent polymer composite material, characterized in that the preparation of the
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following parts by weight of the raw material made of: 95-98 high melt strength polypropylene, low density polyethylene ethylene 2-3, 2-3 isopropyl azodicarboxylate, polydimethylsiloxane 0.6-0.8, 3-4 antimony trioxide, red phosphorus 1-2, deionized water amount, methylcellulose Su 4-5, 13-15, butyl acrylate, dodecyl methacrylate 7.5-9, N, N ,- methylene bisacrylamide 0.08-0.1, 0.5-0.6 azobisisobutyronitrile, ethyl acetate 11-12.5 phosphate, diisooctyl 2-3; excellent flame retardant properties of the present invention, to avoid spontaneous combustion products after the suction caused by the reduced security risks; widely used in oil spills, water pollution control, water separator and hazardous chemicals protection and emergency treatment and other fields.
ANALYSIS OF SANDWICH PLATES WITH COMPRESSIBLE CORE USING LAYERWISE REFINED PLATE THEORY AND INTERFACE STRESS CONTINUITY Author(s) Sanjib, G., Wilfried, B. Sources Journal of Composite Materials 50, No.2, 2016, p.201-217 Corporate/Assignee N/A Publication Date February 23, 2015 Abstract: Lightweight sandwich materials are essential in construction in aircraft, spacecraft, and marine applications. Foam core sandwich materials are not only lightweight but extremely good in thermal insulation purposes. In construction of marine vehicles (i.e., boats, yachts), some sport goods (i.e., surf board), and in the packaging industry soft foam core (i.e., polyvinyl chloride (PVC), polyurethane, polystyrene) sandwiches are used. Polymeric or organic foam core sandwiches are being used in National Aeronautics and Space Administration spacecraft for shock absorption under impact from meteoroid and multilayer thermal insulation. High fidelity analysis tools for sandwich materials are in demand by the engineering community. An attempt has been made here to analyze a sandwich plate considering a three-layer approach using refined higher order plate theory for all the three layers. Moreover, the compressibility (i.e., thickness strain) of the central thick core layer has been considered in the analysis. The continuity of displacements and stresses at each layer interface has also been taken into account in the formulation using Lagrangian multiplier approach. The aforementioned theory has been implemented in an in-house Fortran code. Using this approach, various polymer composite and sandwich plates have been analyzed and the results are compared with other reliable published results. The correlations are found to be good for plates with various aspect ratios and ply orientations.
e. Degradable and Sustainable Foam
POLYMER FOAM Inventor(s) Leufgens, M., Scheirs, J.
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Sources US Pat.: 9,255,197 Corporate/Assignee Tristano Pty Ltd. Publication Date February 9, 2016 Abstract: The present invention relates to foam comprising thermoplastic starch, polyolefin, polyolefin wax, ethylene vinyl alkanoate copolymer, and ethylene acrylic copolymer, and also to a method of preparing the same.
MICRO-FOAMED PLYLACTIC ACID MATERIAL AND PREPARATION METHOD THEREOF Inventor(s) Zhi, Z., Li, B. Sources CN 104910596 Corporate/Assignee N/A Publication Date September 16, 2015 Abstract: The invention discloses a micro-foamed plylactic acid material and a preparation method thereof. The disadvantages of high application cost, poor toughness, small quantity of molecular branched chains, unstable processing, easy molecular chain fracture, low melt viscosity and strength, and unfavourable foaming molding of polylactic acid are overcome in the invention. The method comprises the following steps: preparing a dibenzoyl peroxide tackified polydactyl acid/poly(butylene succinate) composite material through a melt blending technology, preparing a sample through compression molding, swelling the sample with supercritical carbon dioxide as a foaming agent, and rapidly releasing pressure to obtain the micro-foamed plylactic acid material. The preparation method has the advantages of low temperature foaming, high speed pressure relief, simple foaming process and short time, and the micro-foamed plylactic acid material prepared in the invention has the advantages of uniform cell dimension, large cell density and small material density.
ENVIRONMENTALLY FRIENDLY PACKAGING MATERIAL AND METHOD Inventor(s) Xu, Z., Xu, S. Sources CN 105153561 Corporate/Assignee Hefei Zhong Hao New Materials Co., Ltd. Publication Date December 16, 2015 Abstract: The present invention provides an environmentally friendly packaging materials, including the following parts by weight of a raw material composition: 60-80 parts of polystyrene, 10-20 parts of glycerin, 30 to 40 parts of corn starch, 12-16 parts of glycerol, alkyd 25-35 parts of resin, 5-15 parts of calcium propionate, 3-5 parts of borax, titanium dioxide 3-5 parts, 4-6 parts of foaming agent, 35-45 parts of hydrogen peroxide. The present invention is a material readily available, simple formula, manufacturing process safety, reliability,
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and high mechanical strength, good toughness, non-polluting, non-toxic, natural degradation and high degree.
IMPACT OF FOAMING AIR ON MELTING AND CRYSTALLIZATION BEHAVIORS OF MICROPOROUS PLA SCAFFOLDS Author(s) Sheng, S., Wang, F., Ma, Q., Hu, X. Sources Journal of Thermal Analysis and Calorimetry 122, No.3, Dec. 2015, p.1077- 1088 ISSN: 1388-6150 Corporate/Assignee N/A Publication Date June 25, 2015 Abstract: Poly(lactic acid) (PLA) is a green synthetic polymer which has many excellent properties useful for various applications. In this study, PLA scaffolds were fabricated at 2.0– 6.0 MPa saturation pressures by using a solvent-free solid-state air gas foaming technique. Differential scanning calorimetry analysis was used to investigate the melting behavior and the mechanism of isothermal crystallization kinetics of these PLA scaffolds. Kinetics theories, such as Avrami analysis which was established for crystal growth studies of synthetic polymers, are for the first time utilized to investigate the air gas foamed scaffolds. Results showed that 6.0 MPa scaffolds had a 3D spherulitic crystal growth kinetics which is different from the raw PLA and 3.0 MPa foams. The experimental results also proved that two types of crystals: defective α′ and stable α coexisted in the PLA foams, and the contents of these two crystals were varied at different isothermal crystallization temperatures. Compared with the raw PLA, the crystallinities of PLA foams increased slightly after isothermal crystallization. However, the air gas molecules also hindered the crystallization rates of PLA foams. In addition, single crystals or perfect large crystals with α-form can be produced at a high isothermal crystallization temperature, such as 110 °C.
DEVELOPMENT OF FOAMED PACKAGING MADE FROM CELLULOSE ACETATE FOR HOT FOOD CONTACT Author(s) Kabasci, S., Zepnik, S., Hendriks, S., Hopmann, C., Radusch, H-J., van Luck, F. Sources Advances in Plastics Technology apt '15. Proceedings of the 11th International Conference held in Sosnowiec, Poland, 13-15 October 2015 Editor(s): Institute for Engineering of Polymer Materials and Dyes, Gliwice Gliwice, Poland: Institute for Engineering of Polymer Materials and Dyes, Gliwice, 2015, paper 6, p.121-129 Corporate/Assignee Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT, Oberhausen; Martin Luther University Halle-Wittenberg; RWTH Aachen University; AIXtrusion Consulting
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Publication Date N/A Abstract: The contribution shows results of extrusion foamed externally plasticised cellulose acetate (plCA) and its potential for producing thermoformed trays. Using a mixture of HFO-1234ze and ethanol as blowing agent, foam density and density reduction in the range of standard PS foam sheets were obtained. The foam constitutes a fine and homogeneous morphology with closed cells. The plCA foam sheets were successfully thermoformed to packaging trays. The results show that plCA is a promising biopolymer for extrusion foaming and can be a suitable alternative to PS. 12 Refs.
THERMAL PROPERTIES AND CELLULAR STRUCTURE OF CORNSTARCH- BASED FOAMS FORMED BY EXTRUSION TECHNOLOGY Author(s) Lui, W., Peng, J. Sources Journal of Food Processing and Preservation 2015 (December), 39 (6), 1605- 1617 Corporate/Assignee N/A Publication Date October 22, 2014 Abstract: The aim of this work was to investigate the edible corn grit/PVOH (polyvinyl alcohol) blends of their thermal properties by using differential scanning calorimetry (DSC) and thermogravimetric analysis, and the average pore sizes and cellular structures of the blend foams were also characterized by using scanning electron microscopy. The thermal decomposition of edible corn grit/PVOH blends shifted slightly toward lower temperature compared to PVOH. This result shows that edible corn grit/PVOH blends suppress the thermal stability of PVOH. DSC result shows that PVOH and edible corn grits were miscible. Furthermore, the cell sizes become smaller and more uniform and the cell walls become thinner with the increase in PVOH ratio. Moreover, using the CaCO3 also made the cell sizes become smaller and more uniform. Corn-based foams have practical mechanical properties, but they are difficult to mold into shaped products. They will have a greater commercial potential if the extrusion process were more amenable to making molded foam articles, such as food and beverage containers, and if it were compatible with fiber or other reinforcing materials.
f. Thermoset Foam; PU and Others
POLYURETHANE FOAM AND ASSOCIATED METHOD AND ARTICLE Inventor(s) Peters, E. N. Sources US Pat.: 9,266,997 Corporate/Assignee Sabic Global Technologies B.V. Publication Date February 23, 2016 Abstract:
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A polyurethane foam is prepared from a reaction mixture that includes an aromatic isocyanate compound, and blowing agent, and a polyol that itself includes a poly(phenylene ether) having a number average molecular weight of 600 to 2000 atomic mass units and an average of 1.5 to 3 hydroxyl groups per molecule. Use of the poly(phenylene ether) is associated with faster formation of polyurethane, and increased compression force deflection. The polyurethane is useful for forming articles including bedding, furniture, automotive interiors, mass transportation interiors (seating, padding, instrument panels, door panels, steering wheels, armrests, and headrests), flooring underlay (foam, rebond binder), packaging, textiles, lining and gasketing applications, acoustic dampening materials, and weather stripping.
CELLULAR STRUCTURES AND VISCOELASTIC POLYURETHANE FOAMS Inventor(s) Obi, B. E., Schrock, A. K., Gamboa, R. R., Shafi, A. Aou, K. Sources US Pat.: 9,266,996 Corporate/Assignee Dow Global Technologies LLC Publication Date February 23, 2016 Abstract: The present invention discloses a structure comprising a plurality of three dimensional cells, wherein each cell comprises exterior walls defining an interior void wherein the walls comprise a plurality of struts and windows, the struts forming borders for the plurality of windows, wherein the struts have a plurality of pores. The present invention further discloses a viscoelastic foam having a ratio of elastic modulus (E') at 20.degree. C. to 25% compression force deflection (CFD) of 25 to 125.
ISOCYANATE-BASED POLYMER FOAM WITH IMPROVED THERMAL INSULATION PROPERTIES Inventor(s) Yin, Y., Chen, J. G., Wang, B., Ye, L., Parenti, V., Mu, L., Zhang, Y. Sources US Pat.: 9,267,035 Corporate/Assignee Dow Global Technologies LLC Publication Date February 23, 2016 Abstract: This invention relates to rigid isocyanate-based polymer foam comprising a carbon black component comprising at least 50 weight percent of a fluorinated carbon black. Said foam having improved thermal properties, specifically, rigid polyurethane and/or polyisocyanurate foams for use in insulation applications.
LOW DENSITY FULL WATER BLOWN POLYURETHANE RIGID FOAM Inventor(s) Girotti, C. Sources US Pat.: 9,266,991 Corporate/Assignee Dow Global Technologies LLC
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Publication Date February 23, 2016 Abstract: A formulation for preparing a low density, full water blown polyurethane rigid foam includes an isocyanate component; an isocyanate-reactive component comprising from 30- 50 wt % of a first polyether polyol having a functionality greater than 5 and an OH value from 350-550 mg.sub.KOH/g; from 5 to 25 wt % of a diol having an OH value from 100- 300 mg.sub.KOH/g; and from 15 to 35 weight percent of a second polyether polyol having a functionality from 3 to 5; further including from 1.5 to 5 wt % of a catalyst selected from dimethylbenzylamine and/or 1,2-dimethyl-imidazole; from greater than 0 to 1 wt % of a trimerization catalyst selected from a glycine salt and/or tris(dimethyl aminomethyl) phenol; greater than 4.1 wt % water as a blowing agent; and any additional constituents selected such that the formulation, excluding the isocyanate component, totals 100 wt % and, the formulation absent the isocyanate component, has a dynamic viscosity from 540 to 864 mPa*s at 20.degree. C. Processing under one-shot conditions can yield a rigid form having a molecular weight per crosslink ratio from 380 to 420. The formulation offers good processability, while the foam shows desirable dimensional stability and mechanical properties at unexpectedly low applied density.
USE OF POLY(BUTYLENE OXIDE) POLYOL TO IMPROVE DURABILITY OF MDI-POLYURETHANE FOAMS Inventor(s) Aou, K., Gamboa, R. R., Obi, B. E. Sources US Pat.: 9,255,174 Corporate/Assignee Dow Global Technologies LLC Publication Date February 9, 2016 Abstract: Embodiments of the present invention relate to polyurethane foams having high air flow while maintaining viscoelastic properties. In one embodiment, a reaction system for preparation of a viscoelastic polyurethane foam is provided. The reaction system comprises (a) a polyisocyanate component and (b) an isocyanate reactive component. The isocyanate reactive component comprises (i) from 35 to 74% by weight of the isocyanate reactive component of one or more propylene oxide rich (PO-rich) polyols having a combined number average equivalent weight from 200 to 500, (ii) from 24 to 50% by weight of the isocyanate reactive component of one or more ethylene oxide rich (EO-rich) polyols having a combined number average equivalent weight from 200 to 2,800, and (iii) from 2 to 10% by weight of the isocyanate reactive component of one or more butylene oxide rich (BO-rich) polyethers having a number average equivalent weight of 2,000 or more.
LOW-SCORCH FLAME-RETARDANT POLYURETHANE FOAMS Inventor(s) Tebbe, H., Hansel, J. Sources US Pat.App.: 20160046778
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Corporate/Assignee N/A Publication Date February 18, 2016 Abstract: Low-scorch flame-retardant polyurethane foams include phosphorus-containing propionic ester flame retardants. Methods for producing and using the foams are also provided.
FLAME RETARDANT POLYURETHANE FOAM AND METHOD FOR PRODUCING SAME Inventor(s) Neff, R., Wang, L., Gershanovich, A. Sources US Pat.App.: 20160046779 Corporate/Assignee BASF SE Publication Date February 18, 2016 Abstract: A polyurethane foam having an initial UL 94 vertical flame classification of V-0 and maintaining a UL 94 vertical flame classification of V-0 after one week of heat aging at 150.degree. C. is formed as the reaction product of an isocyanate component and an isocyanate-reactive component in the presence of a blowing agent. The isocyanate component includes an isocyanate-containing compound and a non-reactive phosphorous compound that is present in an amount ranging from 1 to 20 weight percent based on the total weight of the polyurethane foam. The isocyanate-reactive component includes a polyether polyol and expandable graphite that is present in an amount ranging from 3 to 30 weight percent based on the total weight of the polyurethane foam.
PROCESS FOR PRODUCING FLEXIBLE POLYURETHANE FOAM USING NATURAL OIL POLYOLS Inventor(s) Burdeniuc, J. J., Tobias, J. D., Keller, R. J. Sources US Pat.App.: 20160032042 Corporate/Assignee Air Products and Chemicals, Inc. Publication Date February 4, 2016 Abstract: A composition and process useful to make flexible polyurethane foams and in particular flexible molded polyurethane foams is disclosed. The usage of dipolar aprotic liquids such as DMSO, DMI, sulfolane, N-methyl-acetoacetamide, N, N-dimethylacetoacetamide as well as glycols containing hydroxyl numbers OH#.ltoreq.1100 as cell opening aides for 2- cyanoacetamide or other similar molecules containing active methylene or methine groups to make a polyurethane foam is also disclosed. The advantage of using cell opener aids results in a) no foam shrinkage; b) lower use levels of cell opener; c) foam performance reproducibility d) optimum physical properties. In addition, combining the acid blocked amine catalyst together with the cell opener and the cell opener aid results in a less corrosive mixture as well as provides a method that does not require mechanical crushing for cell opening.
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METHOD OF OBTAINING ENVIRONMENT-FRIENDLY POLYOLS FROM WASTE LEFT AFTER TRANSESTERIFICATION OF PLANT OILS, AND METHOD OF OBTAINING RIGID POLYURETHANE FOAMS Inventor(s) Józef, H., Lukasz, P., Magdalena, D., Michal, S. Sources EP 2957583 Corporate/Assignee N/A Publication Date December 23, 2015 Abstract: Method of obtaining environment-friendly polyols from waste left after transesterification of plant oils is characterized in that the said waste is heated to a temperature in the range between 160 and 240°C, preferably between 175 and 185°C, under reduced pressure in order to distill the volatile fraction. The distillation proceeds until no more condensate appears, and the resultant product has a hydroxyl number between 400 and 1200 mg KOH/g. Then the mixture is cooled below 100°C, and acidified with a protonic acid, more preferably with sulphuric acid pH 4.5 to 9, preferably from 6.5 to 7.5. Next, the reaction mixture is heated under reduced pressure to a temperature between 100 and 120°C until water stops to appear. Polyols are also produced from polyglycols extended with fatty acids and modified fatty acids. The object of the invention is also the method of obtaining polyurethane foams by using polyols that had been obtained by the method according to the invention. The foams additionally contain substances which retard their flammability.
PROCESS FOR THE PREPARATION OF LIGNIN BASED POLYURETHANE PRODUCTS Inventor(s) Langlois, A., Drouin, M. Sources WO 2015021541 Corporate/Assignee Enerlab 2000 Inc. Publication Date February 19, 2015 Abstract: A process for the production of a lignin based polyurethane products is provided. The process comprises mixing at least one dried lignin and at least one isocyanate to form a lignin-isocyanate mixture, and submitting the lignin-isocyanate mixture to a polymerization reaction. The polymerization reaction may include heating the lignin- isocyanate mixture, adding at least one catalyst to the lignin-isocyanate mixture, or mixing the lignin-isocyanate mixture with a resin comprising at least one polyol, in the presence of at least one catalyst. The lignin based polyurethane products obtained by the process may be rigid foams, flexible foams, rigid boards, rigid blocks, coatings, packagings, adhesives, binders, sealants, elastomers, Thermoplastic Polyurethanes or Reaction Injection Moldings. There is also provided a mixture comprising at least one dried lignin and at least one isocyanate for use in the production of a lignin based polyurethane products.
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ISOCYANATE-EPOXY-FOAM SYSTEM Inventor(s) Prissok, F., Kamm, A., Harms, M. Sources WO 2015011269 Corporate/Assignee BASF SE Publication Date January 29, 2015 Abstract: The invention relates to a method for producing a hard foam, comprising the following steps: at least one polyisocyanate is reacted with a mixture containing at least one polyepoxide, water and at least one additional hydrogen azide compound, said reaction taking place in the presence of a metal-free Lewis base with at least one nitrogen atom, hard foams obtained according to said type of method, and to the use of the claimed hard foam for producing insulating materials, vacuum insulation panels, cooling devices, components, wind rotor blades or elements boat and vehicle construction.
SANDWICHLIKE COATING CONSISTING OF ALTERNATING MONTMORILLONITE AND Β-FEOOH FOR REDUCING THE FIRE HAZARD OF FLEXIBLE POLYURETHANE FOAM Author(s) Wang, W., Pan, H., Shi, Y., Yu, B., Pan, Y., Liew, K. M., Song, L., Hu, Y. Sources ACS Sustainable Chemistry and Engineering 3, No.12, 7 Dec. 2015, p.3214- 3223 Corporate/Assignee N/A Publication Date October 23, 2015 Abstract:
A novel nanocoating, composed of montmorillonite (MMT) nanosheets and β-FeOOH nanorods, was deposited on the surface of flexible polyurethane (FPU) foams through a layer-by-layer assembly technique to reduce its flamability. The coating growth was
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performed by alternately immersing FPU foams into polyethylenimine (PEI) solution, MMT-alginate suspension, and β-FeOOH dispersion. Structural and morphological characterization indicated that MMT nanosheets and β-FeOOH nanorods were distributed homogeneously on the surface of the matrix and formed a sandwichlike topology. The coated FPU foams showed the lower peak heat release rate (PHRR), compared to the counterparts fabricated by introduction of MMT nanosheets or β-FeOOH nanorods alone. Furthermore, the concentration of volatile products released from the coated FPU foams was reduced remarkably, indicating that the binary components had tremendous advantages in reducing the flamability of the material. These significant improvements in flame retardancy and toxic gas suppression could be attributed to the following: the MMT-based layers and the network formed by β-FeOOH nanorods exhibited a “labyrinth effect” to retard the permeation of heat, oxygen, and mass between the flame and underlying FPU matrix.
VEGETABLE OIL-BASED POLYOLS FOR SUSTAINABLE POLYURETHANES Author(s) Alagi, P., Hong , S. C. Sources Macromolecular Research 23, No.12, Dec. 2015, p.1079-1086 ISSN: 1598-5032 Corporate/Assignee N/A Publication Date November 18, 2015 Abstract:
Vegetable oils (VOs) are one of the most important bio-renewable resources in the chemical industry due to their biodegradability, universal availability and low price. Using VO-based polyols to substitute petroleum-based polyols is considered a prime and novel route towards preparing sustainable polyurethane (PU). In this context, recent progress on preparing VO- based polyols and PUs is briefly summarized in this article. Especially, thiol-ene reactions allow for the synthesis of VO-based polyols with different functionalities in keeping with
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efficient click chemistry principles. The studies indicated that VO-based polyols and the resulting PUs can be eco-friendly families of industrially important polymers with a low environmental footprint.
RIGID POLYURETHANE FOAMS FROM COTTONSEED OIL USING BIO- BASED CHAIN EXTENDERS: A RENEWABLE APPROACH Author(s) Pawar, M. S., Kadam, A. S., Singh, P. C., Kusumkar, V. V., Yemul, O. S. Sources Iranian Polymer Journal 25, No.1, Jan. 2016, p.59-68 ISSN: 1026-1265 Corporate/Assignee N/A Publication Date December 08, 2015 Abstract: A series of polyurethane rigid foams were prepared by one step process from cottonseed oil (Gossypium arboreum). The thermal properties of cottonseed oil-based foams were similar to those of petroleum resource-based foam. Cottonseed oil having an iodine value of 110/100 g I2 was epoxidized using an industrial process followed by polyol preparation using bio-based chain extenders such as ethylene glycol (polyol1) and lactic acid (polyol2). The polyols were further formulated with diphenylmethane diisocyanate (MDI) at a constant NCO/OH ratio (1.2:1) using water and cyclopentane as blowing agents to obtain rigid polyurethane foams. The thermal behavior of polyurethane foams based on cottonseed oil as well as petroleum resource-based foams were studied by differential scanning calorimetry and thermogravimetric analysis. The physico-chemical properties of polyols, such as acid number, hydroxyl number, and Brookfield viscosity were determined. The chemical structures of polyols were elucidated by the Fourier transform infrared and nuclear magnetic resonance (1H NMR) spectroscopies. Cottonseed oil-based polyurethane foams displayed thermal stability comparable to that of PPG foams. The research findings demonstrated that there is promise in using cottonseed oil- based polyols for the preparation of polyurethane foams by replacing the petroleum resource-based polyols. PU foam samples were tested for possible environmentally friendly plant grown substrate by seed germination method.
SYNTHESIS OF FUNCTIONALIZED POLYURETHANE FOAM USING BES CHAIN EXTENDER FOR LEAD ION REMOVAL FROM AQUEOUS SOLUTIONS Author(s) Gunashekar, S., Abu-Zahra, N. Sources Journal of Cellular Plastics 51, No.5-6, 2015, p.453-470 Corporate/Assignee Department of Materials Science and Engineering, University of Wisconsin-Milwaukee, Milwaukee, WI, USA Publication Date November 25, 2014 Abstract: Polyurethane foams functionalized with sulphonic acid groups have been found to be strong cation exchangers. This novel property of the foam was used to exchange lead
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Foam Update March 2016
(Pb2+) ions from aqueous solutions. Polyurethane foam synthesis is based on addition polymerization of an isocyanate (–NCO) with a polyol. The primary reaction is due to the reaction of the highly reactive –NCO groups of the isocyanate with the hydroxyl (–OH) groups of the polyol to form the urethane species. Toluene-2,4-diisocyanate,2,6- diisocyanate (CAS: 584-84-9) was reacted with polypropylene glycol 1200 (CAS 25322- 69-4) in 2:1 molar ratio to form a linear pre polymer. The linear pre-polymer was further polymerized using N,N-bis(2-hydorxyethyl)-2-aminoethane-sulfonic acid (CAS 10191- 18-1) chain extender. An organotin catalyst was used to accelerate the reaction and distilled water was used as a foaming agent to synthesize the functionalized polyurethane foam. The synthesized foam has an open cell content ranging from 70% to 91% and the density ranges from 160 to 432 kg/m3 depending on the foam formulation. The foam was exposed to Pb2+ solutions of known concentrations by batch process. The amount of remaining Pb2+ in the solution in parts per billion (ppb) was determined using an inductively coupled plasma mass spectrometer. The maximum Pb2+ ions exchanged per gram of the foam was measured to be 50–54 ppb from a 100 ppb Pb2+ solution over a period of 90 min. In this paper, we present the foam synthesis procedure with the design of experiments to study the effect of processing variables on the performance of this material.
THE EFFECTS OF ALUMINUM HYDROXIDE AND AMMONIUM POLYPHOSPHATE ON THE FLAME RETARDANCY AND MECHANICAL PROPERTY OF POLYISOCYANURATE–POLYURETHANE FOAMS Author(s) Liu, Y., He, J., Yang, R. Sources Journal of Fire Sciences 33, No.6, 2015, p.459-472 Corporate/Assignee National Laboratory of Flame Retardant Materials, School of Materials Science and Engineering, Beijing Institute of Technology, Beijing, P.R. China Publication Date October 6, 2015 Abstract: Ammonium polyphosphate and aluminum hydroxide were added simultaneously to polyisocyanurate–polyurethane foams as flame retardants. The effects of aluminum hydroxide and ammonium polyphosphate on the fire retardancy and mechanical property of polyisocyanurate–polyurethane foams were investigated. Thermogravimetric and thermogravimetric–Fourier-transform infrared spectroscopy were used to investigate the thermal stability and decomposition of the foams. Cone calorimeter tests, the limiting oxygen index, and scanning electron microscopy were used to study the fire performance of aluminum hydroxide and ammonium polyphosphate. The results show that the compressive strength of the foams increases upon the addition of both aluminum hydroxide and ammonium polyphosphate. The flame retardancy of the polyisocyanurate– polyurethane foams can be significantly improved under the effect of aluminum hydroxide and ammonium polyphosphate. After the addition of 5-phr aluminum hydroxide and 15-phr ammonium polyphosphate, the limiting oxygen index value increases from 21.2% for the reference sample to 28.0%, while the peak heat release rate
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Foam Update March 2016
reduces from 159.8 kW/m2 for the reference sample to 76.8 kW/m2. The effects between aluminum hydroxide and ammonium polyphosphate occur in the condensed phase. Spherical projections with “villi-like” particles are formed covering the surface of char to hinder flame and energy transmission.
STUDY ON DOWNWARD FLAME SPREAD BEHAVIOR OF FLEXIBLE POLYURETHANE BOARD IN EXTERNAL HEAT FLUX Author(s) Ma, X., Tu, R., Zhao, Y., Xie, Q. Sources Journal of Thermoplastic Composite Materials 28, No.12, 2015, p.1693-1707 Corporate/Assignee State Key Laboratory of Fire Science, Department of Safety Science Engineering, University of Science and Technology of China, Hefei, Anhui, China College of Mechanical Engineering and Automation, Huaqiao University, Xiamen, Fujian, China Publication Date February 8, 2015 Abstract: In this work, the downward flame spread of flame of flexible polyurethane (FPU) foam with a different width was studied in an external radiant heat source. The effects of external radiation heat flux on the main parameters of flame spread, such as the flame height, mass loss rate, flame spread rate and flame pulsation frequency were investigated. The experimental results show that the flame spread of the FPU is an accelerating process when there is an external radiation condition and is a steady one without it. As the flame spread over board, the amount of pyrolysis gases involved in the combustion process showed a positive relationship with the external radiation heat flux. The flame height is under a combined effect of width and external radiation heat flux. However, the flame pulsation frequency shows a negative correlation with the fuel width and the radiation heat flux. Finally, an empirical equation approximation of linear pool fire is introduced to analyze the flame spread behavior of FPU as well as the validation with experiment data.
PREPARATION AND CHARACTERIZATION OF HIGHLY THERMOSTABLE POLYISOCYANURATE FOAMS MODIFIED WITH EPOXY RESIN Author(s) Chen, K., Tian, C., Cao, F., Liang, S., Jia, X., Wang, J. Sources Journal of Applied Polymer Science 133, No.13, 2016, paper 43085, pp.8 Corporate/Assignee N/A Publication Date December 8, 2015 Abstract: A series of epoxy resin–modified polyisocyanurate (EP-PIR) foams with oxazolidone (OX) rings and isocyanurate (IS) rings have been successfully prepared by the reaction of polymethylene polyphenyl isocyanate (PAPI) and diglycidyl ether of bisphenol-A (DGEBA). Fourier transform infrared spectroscopy and differential scanning calorimetry are performed to investigate the influence of curing temperature on the chemical structure
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Foam Update March 2016
of EP-PIR foams. The results indicate that low temperature is beneficial to the formation of the IS ring, and high temperature is in favor of the OX ring. The influence of the mole ratio of [PAPI]/[DGEBA] on the mechanical properties and thermal stability has also been studied. With the increase of [PAPI]/[DGEBA], the specific compressive strength shows a maximum of 0.0135 ± 0.0003 MPa m3/kg. The optimized mole ratio of [PAPI]/[DGEBA] is around 2.5 to reach the better mechanical and thermal properties, and the glass-transition temperature is as high as 323.5°C.
IN SITU POLYMERIZATION OF POLYURETHANE-SILVER NANOCOMPOSITE FOAMS WITH INTACT THERMAL STABILITY, IMPROVED MECHANICAL PERFORMANCE, AND INDUCED ANTIMICROBIAL PROPERTIES Author(s) Madkour, T. M., Abdelazeem, E. A., Tayel, A., Mustafa, G., Siam, R. Sources Journal of Applied Polymer Science 133, No.11, 2016, paper 43125, pp.10 Corporate/Assignee N/A Publication Date November 24, 2015 Abstract: Silver nanoparticle-reinforced thermoplastic polyurethane (PU/AgNP) nanocomposite foams were prepared using in situ polymerization techniques in accordance with DOW chemicals’ industrial standards. The foams exhibited improved mechanical performance, induced antimicrobial properties, and intact stability when subjected to a thermal degradation treatment. Scanning electron microscopy (SEM) indicated a homogeneous dispersion of the silver nanoparticle (AgNP) within the polymeric matrix at low filler loadings and a cluster formation at higher loadings. SEM also indicated the agglomeration of the silver nanofiller particles as a result of the thermal degradation treatment, which caused them to lose their nanoscopic characteristics and act as ordinary silver metal. Molecular modeling techniques were used to explain these observations and confirmed the higher repulsive interactions between the polymer chains and the silver nanoparticles with the increase in the nanofiller content. Stress relaxation of the nanocomposites showed optimum mechanical performance and lowest hysteresis for the 0.1% AgNP nanocomposites due to the confinement of the PU chains between the large number of the nanoparticles. Incubation with 0.1% foam inhibited the growth of Klebseilla spp. and Escherichia coli and to some extent Staphylococcus spp. This is very interesting as the same nanocomposite loaded with 0.1% AgNp has also shown the best mechanical performance highlighting the strong action of this “unclustered” low concentration on both the material and biomedical sides.
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Foam Update March 2016
PREPARATION AND CHARACTERIZATION OF CYANATE/EPOXY FOAM Author(s) Fan, C., Tian, C., Chen, K., Gao, X., Jia, X., Wang, J. Sources High Performance Polymers 28, No.1, 2016, p.96-109 Corporate/Assignee Institute of Chemical Materials, China Academy of Engineering Physics, Mianyang, China Material Science and Engineering College, Southwest University of Science and Technology, Mianyang, China Publication Date February 23, 2015 Abstract: A new type of cyanate (CE)/epoxy (EP) foam with bisphenol-A dicyanate ester prepolymer and diglycidyl ether of bisphenol-A (BADCy/DGEBA) has been successfully prepared through a two-step process. The structure and properties of CE/EP foam were studied. The results reveal that the CE/EP foams, with relatively uniform cell structure, were composed of closed cells as confirmed by scanning electron microscopy. The compressive strength increased from 0.507 MPa to 3.021 MPa, and the compressive modulus (E) increased from 15 MPa to 123 MPa as the density increased from 0.103 g cm−3 to 0.305 g cm−3. Dynamic mechanical analysis revealed that the CE/EP foams possessed a high glass transition temperature (Tg) (203°C) and that density had only a little impact on T g. Moreover, the excellent thermal stability presented with the onset of weight loss taken at 5% value was above 320°C, and the residual weight of the foam was more than 21.6% at 800°C. With increase in the density of CE/EP foams, the dielectric constants (ε) gradually decreased. For the foam with density of ρ = 0.162 g cm−3, the value of ε was as low as 2.28 at the frequency of 10 kHz.
EXPERIMENTATION AND SIMULATION OF MOISTURE DIFFUSION IN FOAM-CORED POLYURETHANE SANDWICH STRUCTURE Author(s) Huo, Z., Mohamed, M., Nicholas, J. R., Wang, X., Chandrashekhara, K. Sources Journal of Sandwich Structures and Materials 18, No.1, 2016, p.30-49 Corporate/Assignee Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO, USA Publication Date April 23, 2015 Abstract: The moisture diffusion behavior of two-part thermoset polyurethane neat resin, woven E- glass fiber-reinforced polyurethane face sheet, closed-cell rigid polyurethane foam core and their corresponding sandwich specimens was investigated in this study. The vacuum- assisted resin transfer molding process was used to manufacture the polyurethane sandwich panels. Open-edge moisture diffusion experiment was conducted for sandwich panel and its constituents by immersing each type of samples in distilled water at room temperature for nearly seven months. Moisture diffusivities and solubility for neat resin, face sheet and foam core specimens were characterized according to the experimental analysis. The moisture diffusion behavior for closed-cell polyurethane foam was found to
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deviate significantly from classical Fick’s law, and a multi-stage diffusion model was thus proposed to explain this deviation using a time-dependent diffusivity scheme. A user-defined subroutine was developed to implement this scheme into the commercial finite element analysis code ABAQUS. A three-dimensional dynamic finite element model was developed to predict the moisture diffusion behavior in neat resin, face sheet, foam core and sandwich specimens. This finite element model was then validated by comparing simulation results with experimental findings.
THE INFLUENCE OF CHAIN EXTENDER ON PROPERTIES OF POLYURETHANE-BASED PHASE CHANGE MATERIALS MODIFIED WITH GRAPHENE Author(s) Pielichowska, K., Nowak, M., Szatkowski, P., Macherzyńska, B. Sources Applied Energy 162, No.1, 2016, p.1024-1033 Corporate/Assignee AGH University of Science and Technology, Faculty of Materials Science and Ceramics, Department of Biomaterials, Al. Mickiewicza 30, 30-059 Kraków, Poland Publication Date November 14, 2015 Abstract: In this paper polyurethane-based phase change materials (PCMs) modified with graphene for thermal energy storage were obtained in situ using a one-step bulk polymerization method. Polyurethanes (PUs) have been synthesized with 1,4-butanediol as a chain extender or without a chain extender. FTIR-ATR, DSC, TGA, SEM, OM and ultrasonic techniques were used for characterization of the obtained composites containing up to 4 wt.% of graphene. FTIR-ATR analysis confirmed PU structure and proved that there was no chemical reaction between polyurethane and graphene. The highest heat of phase transition and crystallinity were found for PU system synthesized without the chain extender and modified with 1.0 wt.% of graphene. Microscopic observation results indicated spherulite structures typical for poly(ethylene glycol) (PEG) which was used to form soft segments, with regions of lamellar crystal bundles radiating from the center of a spherulite. Thermal cycling tests were done by 50 and 100 heating/cooling cyclings in air and nitrogen atmosphere for verification of the thermal reliability and chemical stability – it has been found the heat of phase transition was generally not diminished. Importantly, the thermal conductivity of the PCMs was improved after modification with graphene. Generally, PUPEG without chain extender exhibited higher heat of phase transition, higher thermal stability and better thermal reliability.
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g. Microcellular and Expanded Particle
POLYLACTIC ACID-BASED RESIN EXPANDED BEADS AND MOLDED ARTICLE THEREOF Inventor(s) Shinohara, M., Oikawa, M. Sources US Pat.App.: 20160032070 Corporate/Assignee JSP Corporation Publication Date February 4, 2016 Abstract: Polylactic acid-based resin expanded beads obtained by releasing a softened, pressurized foamable resin composition, which has a polylactic acid-based resin and a physical blowing agent, to a low pressure atmosphere to foam and expand the resin composition, where the polylactic acid-based resin satisfies the conditions (1) to (3) shown below, and exhibits excellent secondary expansion properties and fusion bonding properties. A polylactic acid-based resin expanded beads molded article obtained by in-mold molding of the polylactic acid-based resin expanded beads exhibits excellent mechanical properties. MT.ltoreq.30 mN (1) log MT.ltoreq.0.93 log .eta.-1.75 (2) CT.sub.1/2.gtoreq.600 sec (3) where MT represents a melt tension [mN] at 190.degree. C., .eta. represents a melt viscosity [Pas] at 190.degree. C. and a shear speed of 20 sec.sup.-1, and CT.sub.1/2 represents a half crystallization time [sec] at 110.degree. C.
A METHOD FOR THE PREPARATION OF PLA BEAD FOAMS Inventor(s) Park, C. B., Nofar, M. Sources US Pat.App.: 20160039990 Corporate/Assignee N/A Publication Date February 11, 2016 Abstract: The present invention relates to a method for the preparation of PLA beads, more particularly expanded PLA bead foams. In addition, the present invention relates to a method for the preparation of moldings by sintering PLA beads. The method comprises the following steps: A) providing unfoamed PLA pellets, B) heating said unfoamed PLA pellets to an annealing temperature and saturating with a blowing agent, C) maintaining said PLA pellets on the annealing temperature and saturating with said blowing agent, D) depressurizing and cooling the saturated PLA pellets of step C) to room temperature to form expanded PLA bead foams.
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BIOCOMPOSITES BASED ON POLY(LACTIC ACID)/WILLOW-FIBER AND THEIR INJECTION MOULDED MICROCELLULAR FOAMS Author(s) Zafar, M. T., Zarrinbakhsh, N., Mohanty, A. K., Misra, M., Maiti, S. N., Ghosh, A. K. Sources Express Polymer Letters 10, No.2, 2016, p.176-186 Corporate/Assignee 1. Centre for Polymer Science and Engineering, Indian Institute of Technology Delhi, 110 016 New Delhi, India 2. Bioproducts Discovery and Development Centre, Department of Plant Agriculture, Crop Science Building, University of Guelph, Guelph, ON, N1G 2W1, Canada 3. School of Engineering, Thornbrough Building, University of Guelph, Guelph, ON, N1G 2W1, Canada Publication Date September 28, 2015 Abstract: Natural fiber reinforced biocomposites have recently attracted many researchers because of their biodegradability, cost effectiveness and ecofriendliness. The present study investigates the properties of willow-fiber reinforced poly(lactic acid) based composites and their foam processability. Microcellular foams of the composites were prepared by foam injection moulding using nitrogen gas as the blowing agent. The effects of willow- fiber addition on the morphology, mechanical properties, thermal stability, crystallization, and heat deflection temperature (HDT) were studied. At 30 weight percent [wt%] willow-fiber content, unfoamed composites showed good improvement in specific tensile and flexural moduli. Addition of willow-fiber increased crystallinity and the rate of crystallization and yielded narrow crystallite size distribution as observed by differential scanning calorimetry (DSC). Scanning electron microscopy (SEM) results of the foamed composites revealed that increase in willow-fiber content caused smaller average cell size and higher cell density. Specific notch impact strength of foamed composites at both 20 and 30 wt% willow-fiber content showed increasing trend compared to that of their unfoamed counterparts.
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