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TPV Foaming by CO2 Extrusion: Processing and Modelling.

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This study optimizes extrusion foaming of thermoplastic vulcanizates (TPVs) using carbon dioxide (CO2). Precise control of process parameters yields homogeneous, low-density foams by managing CO2 content and nucleation.

Keywords:
TPVextrusion foamingmodellingphysical foaming

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Area of Science:

  • Materials Science
  • Polymer Processing
  • Computational Modeling

Background:

  • Extrusion foaming is a key process for producing lightweight polymer materials.
  • Controlling foam morphology is crucial for achieving desired material properties.
  • Carbon dioxide (CO2) is an environmentally friendly blowing agent for polymer foaming.

Purpose of the Study:

  • To investigate the influence of extrusion foaming process parameters on the morphology of commercial thermoplastic vulcanizates (TPVs) using CO2.
  • To develop a numerical model for simulating cell growth during extrusion foaming.
  • To establish a predictive model for foam density and cell structure.

Main Methods:

  • Extrusion foaming of TPVs with CO2 as the blowing agent.
  • Systematic variation of process parameters: saturation pressure, die geometry, temperature, and nucleation.
  • Development and application of numerical models for cell growth and polymer flow dynamics.
  • Analysis of foam morphology, including cell size and distribution.

Main Results:

  • Homogeneous TPV foams with densities below 500 kg/m³ were achieved through precise control of saturation pressure, die geometry, temperature, and nucleation.
  • An optimal CO2 content is necessary to mitigate coalescence, which is exacerbated by longer residence times and early nucleation.
  • The proposed model accurately predicts the plasticizing effect of CO2 on polymer flow and simulates the foaming process inside and outside the die.
  • The model successfully predicts final cell foam radius and density for optimized nucleation parameters.

Conclusions:

  • Precise control over extrusion foaming parameters is essential for producing high-quality, low-density TPV foams.
  • Understanding and controlling CO2 content is critical to prevent cell coalescence and ensure foam homogeneity.
  • The developed numerical models provide valuable tools for predicting and optimizing the TPV extrusion foaming process.