Development of Expanded Thermoplastic Polyurethane Bead Foams and Their Sintering Mechanism

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Development of Expanded Thermoplastic Polyurethane Bead Foams and Their Sintering Mechanism Development of Expanded Thermoplastic Polyurethane Bead Foams and Their Sintering Mechanism by Nemat Hossieny A thesis submitted in conformity with the requirements for the degree of Doctor of Philosophy Department of Mechanical and Industrial Engineering University of Toronto © Copyright by Nemat Hossieny 2014 Development of Expanded Thermoplastic Polyurethane Bead Foams and Their Sintering Mechanism Nemat Hossieny Degree of Doctor of Philosophy Department of Mechanical and Industrial Engineering University of Toronto 2014 Abstract Polymer bead foaming technology represents a breakthrough in the production of low density plastic foamed components that have a complex geometrical structure and has helped to expand the market for plastic foams by broadening their applications. In this research, the unique microstructure of thermoplastic polyurethane (TPU) consisting of phase-separated hard segment (HS) domains dispersed in the soft segment (SS) matrix has been utilized to develop expanded TPU (E-TPU) bead foam with microcellular morphologies and also to create inter-bead sintering into three dimensional products using steam-chest molding machine. The phase-separation and crystallization behavior of the HS chains in the TPU microstructure was systematically studied in the presence of dissolved gases and also by changing the microstructure of TPU by melt- processing and addition of nano-/micro-sized additives. It was observed that the presence of gas improved the phase separation (i.e. crystallization) of HSs and increased the overall crystallinity of the TPU. It was also shown that by utilizing the HS crystalline domains, the overall foaming behavior of TPU (i.e. cell nucleation and expansion ratio) can be significantly improved. Moreover, the HS crystalline domains can be effective for both sintering of the beads as well strengthening the individual beads to improve the property of the moulded part. It was also observed that unlike other polymer bead foaming technologies, the E-TPU bead foaming ii sintering does not require formation of double melting-peak. The original broad melting peak existing in the TPU microstructure due to the wide size distribution of HS crystallites can be effectively utilized for the purpose of sintering as well as maintenance of the overall dimensional stability of the moulded part. iii Acknowledgments I would like to express my sincere gratitude and appreciation to my supervisor, Professor Chul B. Park for providing me with the continuous guidance, enthusiasm and encouragement to assist me in conducting a successful research. His visions, insights and suggestions have an everlasting influence on my personal and professional growth. I feel extremely honored and fortunate to have such a supportive mentor. I would like to thank my Ph.D. committee members, Professor Hani Naguib and Professor Glenn D. Hibbard for their valuable comments and suggestions offered during the course of my Ph.D. research. Also, I am grateful for Professor Anup Ghosh and Professor Lidan You for their valuable feedback in my Ph.D. final oral examination. I am grateful of the financial support and scholarships from Ontario Graduate Scholarship (OGS), Consortium of Cellular and Micro-Cellular Plastics (CCMCP), and Natural Sciences and Engineering Research Council of Canada (NSERC) funding for Network for Innovative Plastics Materials and Manufacturing Processes (NIPMMP). My special thanks goes to Kara Kim for her kind assistance. I would like to extend my acknowledgment to my colleagues and other members of Microcellular Plastic Manufacturing Laboratory. Their advice, assistance and friendship have contributed to the successful completion of my research. Special thanks goes to Dr. Changwei Zhu, Dr. Saleh Amani, Hasan Mahmood, Dr. Reza Barzegari, Dr. Reza Nofar, Dr. Amir Ameli, Alireza Tabatabaei, Mehdi Saniei, Vahid Shaayegan, Lun Howe Mark, Weidan Ding, Davoud Jahani, Ali Rizvi, Mo Xu, Sai Wang, Raymond Chu, Dr. Peter Jung, Dr. Anson Wong, Hui Wang, Anne Zhao as well as everyone else who helped me in my Ph.D. studies. I am also grateful for the many undergraduate students who have assisted me during the course of my research. Also, to the administrative staff in our department: Konstantine, Brenda, Ceaser and Jho: thank you for your kind assistance on the various administrative matters. Finally, my special thanks go to my family members in India and Canada for their support, encouragement and patience throughout the course of this Ph.D. research. iv Table of Contents Acknowledgments .......................................................................................................................... iv Table of Contents ............................................................................................................................ v List of Tables .................................................................................................................................. x List of Figures ................................................................................................................................ xi List of Symbols ............................................................................................................................ xix Chapter 1 Introduction .................................................................................................................... 1 1.1 Thermoplastic Foams .......................................................................................................... 1 1.2 Classification of Thermoplastic Foams .............................................................................. 1 1.3 Bead Foam Technology ...................................................................................................... 2 1.4 Research Motivation ........................................................................................................... 2 1.5 Objective of Thesis ............................................................................................................. 3 1.6 Organization of Thesis ........................................................................................................ 4 1.7 References ........................................................................................................................... 5 Chapter 2 Literature Review ........................................................................................................... 7 2 Literature Review ....................................................................................................................... 7 2.1 Basic and General Principles of Foaming ........................................................................... 7 2.1.1 Polymeric foams and foaming process ................................................................... 7 2.1.2 Polymeric foams and foaming process ................................................................... 8 2.1.3 Supercritical CO2 (scCO2) foaming ...................................................................... 11 2.2 Extrusion Foaming Technology ........................................................................................ 17 2.3 Injection Foam Molding Technology ............................................................................... 19 2.3.1 Conventional foam injection molding and microcellular injection molding technologies .......................................................................................................... 19 2.3.2 Low-pressure and high-pressure foam injection molding technologies ............... 20 2.4 Rotational Foam Molding Technology ............................................................................. 22 v 2.5 Bead Foam Molding Technology ..................................................................................... 24 2.5.1 Bead fabrication .................................................................................................... 25 2.5.2 Bead bonding ........................................................................................................ 26 2.5.3 Bead foam materials ............................................................................................. 33 2.6 Thermoplastic polyurethane .............................................................................................. 40 2.7 References ......................................................................................................................... 42 Chapter 3 Phase Separation and Crystallization of TPU in the Presence of Dissolved Gas:- Effects of Processing, Nano-/Micron-Sized Additives and Gas Types ................................... 57 3 Phase Separation and Crystallization of TPU in the Presence of Dissolved Gas .................... 57 3.1 Introduction ....................................................................................................................... 57 3.2 Experimental Procedure .................................................................................................... 59 3.2.1 Materials ............................................................................................................... 59 3.2.2 Sample preparation ............................................................................................... 59 3.2.3 Rheological analysis ............................................................................................. 60 3.2.4 Atomic force microscopy ...................................................................................... 61 3.2.5 Crystallization
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