PVC微孔塑料加工工艺与泡孔结构及耐热性关系研究

以超临界CO2为发泡剂,用动态发泡实验装置在不同的发泡温度、气体饱和压力及振动频率和振幅等加工工艺条件下制备了聚氯乙烯(PVC)微孔塑料。研究发现,发泡温度存在着一个最佳温度范围,使得泡孔密度最大、泡孔尺寸最小;气体饱和压力越大,泡孔结构越好;当剪切速率较低时,在发泡过程中施加强振动作用能显著提高泡孔密度,减小泡孔尺寸,当剪切速率较高时,施加较弱的振动作用即可改善泡孔形态,而施加较强的振动作用可能会产生较大的剪切热和脉动剪切应力,从而破坏泡孔结构;PVC微孔塑料的维卡软化温度与泡孔结构有着密切的关系,泡孔密度越大、泡孔尺寸越小,维卡软化温度就越高。     

工艺参数对PC塑料泡孔结构影响

采用自制的微孔发泡模拟机研究了温度和压力以及气体饱和时间对微孔聚碳酸酯（PC）泡孔结构的影响。结果表明，对于微孔PC泡沫塑料的成型存在一个最佳温度值;随着饱和压力升高，泡孔直径变小，泡孔的密度增大；气体饱和时间对PC泡沫塑料泡孔结构的影响不是很明显，在一定的饱和时间范围内，延长PC发泡时间有利于得到更均匀的泡孔结构。     

振动作用对PS和PVC微孔塑料泡孔结构影响的研究

以超临界CO2为发泡剂，用动态发泡实验装置制备了PS和PVC微孔塑料，通过扫描电镜照片观察和研究了振动作用对PS和PVC微孔塑料泡孔结构的影响。结果表明，当剪切速率较低时，在PS发泡过程中施加较弱的振动作用即可显著提高泡孔密度，减小泡孔直径；而在PVC发泡过程中，只有施加相对较强的振动作用才能达到同样的效果。当剪切速率较高时，不论何种发泡体系，施加较弱的振动作用可以改善泡孔的形态；而施加较强的振动作用可能会产生较大的剪切热和脉动剪切应力，从而破坏泡沫的微孔结构。     

不饱和聚酯微孔塑料的研究

采用自制的成型设备研究了超饱和气体法制备不饱和聚酯微孔塑料的工艺和配方.采用显微镜对试样进行分析,确定不饱和聚酯微孔塑料的泡孔直径及密度,分析了影响泡孔直径及密度的因素.结果表明:Ⅰ阶段保压时间是主要影响因素.在室温下用超饱和气体法制备微孔塑料较优的工艺和配方为:Ⅰ阶段5 MPa和Ⅱ阶段2 MPa压力各保压30 min,固化剂含量4%,促进剂含量3%,制备的微孔塑料泡孔直径为10 μm,泡孔密度为4.70×1011个/cm3.     

振动力场作用下温度对超临界CO2/PS微孔塑料气泡形态的影响

以超临界CO2为发泡剂,用自行研制的动态发泡模拟机将机械振动力场引入到PS微孔塑料成型过程中,初步研究了振动力场作用下温度对微孔塑料气泡形态的影响.实验发现,发泡温度越高,气泡核长大的速度越快,导致气泡合并甚至破裂.但发泡温度过低时,超临界CO2在PS熔体中的扩散速率较低,最终制品的泡孔密度小,气泡分布也不均匀.在微孔塑料成型过程中施加振动,有利于发泡剂在熔体中的分散和混合,从而在较低的温度(130℃)下制备出泡孔直径为18μm、泡孔密度为7×107个/cm3的微孔塑料.     

微孔聚碳酸酯的制备工艺与泡孔结构研究

使用超临界CO2流体作为发泡剂在不同条件下制得一系列微孔聚碳酸酯(PC)。通过扫描电子显微镜观察分析了各种制备工艺参数对微孔PC泡孔结构和分布的影响。结果表明,饱和阶段的时间超过3.5 h时,试样中的CO2基本达到饱和;饱和阶段压力的增加会使泡孔直径减小,泡孔密度增大;而发泡温度的增加和发泡时间的延长则会使泡孔直径增大,泡孔密度减小。当完全发泡时,试样的泡孔结构在厚度方向上有明显区别:试样表皮部分未发泡,有致密的表皮结构;试样表层附近泡孔直径较小,泡孔密度较大;试样中心处的泡孔直径较大,泡孔密度较小。     

振动力场作用下成核剂对微孔发泡的影响

研究了不同种类、不同含量成核剂和压力释放速率、振幅、频率等工艺参数对聚苯乙烯（PS）泡孔形态的影响。结果表明，加入一定量碳酸钙、滑石粉、铁粉、镁铝水滑石和聚二甲基硅氧烷橡胶（PDMS）均能较好地增大泡孔密度、减小泡孔直径，而碳粉对泡孔结构影响不大；成核剂含量有一个最佳值；系统压力释放速率的增大有利于泡孔形态；振动力场的引入改善了气泡的形态。     

微孔塑料挤出成型的研究

以超临界CO2作为物理发泡剂,对低密度聚乙烯(LDPE)进行了微孔发泡的研究。介绍了微孔塑料成型过程中聚合物/气体均相体系的形成、气泡成核和气泡长大及定型这三个步骤。并分析了加工工艺因素(温度、压力)等对制品中泡孔尺寸和密度的影响:泡孔直径随挤出压力的增加而减小;泡孔密度随压力的增加而增加;泡孔直径随压力降速率的增大而减小;泡孔密度随压力降速率的增大而增加;而适当提高温度有利于减小泡孔直径、增加泡孔密度。     

工艺条件对超临界CO_2发泡材料泡孔结构的影响

微孔发泡材料的泡孔结构主要采用泡孔尺寸和泡孔密度来表征。泡孔尺寸一般使用SigmaScan和Image-pro两种图像分析软件测量,而泡孔密度主要用Kumar法和初始未发泡试样泡孔密度计算法计算。工艺条件的不同,特别是发泡温度、饱和压力、发泡时间、添加成核剂、引入另一聚合物相等工艺条件的改变,都会对发泡材料的泡孔形貌产生影响。发泡温度和饱和压力对泡孔形貌的影响尤甚,并且对泡孔结构的影响趋势是相同的,即随发泡温度或饱和压力的增加,泡孔结构由好变差,存在最佳值。加入合适的成核剂及引入另一聚合物相,亦能起到促进发泡的效果。     

PP微孔发泡试样泡孔结构与拉伸性能的变化关系研究

通过仿真分析得到超临界N2注射成型聚丙烯(PP)微孔发泡试样的泡孔结构与拉伸性能之间的关联机制,即泡孔尺寸与拉伸性能成反比关系;然后利用控制变量法进行PP微孔发泡试样的超临界N2注射成型实验,研究注气时间、注射温度、注射速率对试样泡孔结构和拉伸性能的影响规律,揭示在不同工艺参数下试样泡孔结构与拉伸性能之间的变化关系。结果表明,注气时间和注射温度下泡孔尺寸与拉伸性能的变化关系总体上符合由仿真分析得到的关联机制;随注气时间增加,泡孔结构和拉伸性能总体上劣化;注射速率对泡孔结构和拉伸性能的影响相对较小,但较高的注射速率有利于减小泡孔尺寸;与其它两种工艺参数相比,不同注射温度下泡孔结构和拉伸性能之间的变化关系比较稳定。在保持较短的注气时间和较高的注射速率下,通过调整注射温度可获得泡孔尺寸小、密度高且拉伸性能好的PP微孔发泡试样。     

Effect of processing parameters on cell morphology of polycarbonate foam

Abstract

The purpose of this research is to investigate the effect of processing parameters on the cell morphology of polycarbonate (PC) foam. In this study, foamed PC was prepared using a dynamic simulation foaming set-up. The cell morphology was compared at different temperatures, pressures, gas saturation times, pressure drop rates and shear rates. The cell morphology of foamed samples was characterised using SEM. It was found that foamed samples with better morphology could be obtained by varying mechanical properties, such as pressure, pressure drop rate and gas saturation time. Optimum temperature and shear rate for microcellular foaming of PC are presented.     

Open-celled microcellular foaming and the formation of cellular structure by a theoretical pattern in polystyrene

An open-celled structure was produced using polystyrene and supercritical carbon dioxide in a novel batch process. The required processing conditions to achieve open-celled structures were predicted by a theoretical model and confirmed by the experimental data. The theoretical model predicts that at least a saturation pressure of 130 bar and a foaming time between 9 and 58 s are required for this system to produce an open-celled structure. The foaming temperature range has been selected to be higher than the polymer glass transition temperature yet not higher than a temperature limit where the gas starts leaving the system. The experimental results in the batch foaming process verified the model substantially. The SEM pictures showed the presence of pores between the cells, and the mercury porosimetry test results verified the overall open-celled structure. Experimental results also showed that by increasing the saturation pressure and the foaming temperature, there was a drop in the time required for open-celled structure formation. At saturation pressure of 130 bar, foaming temperature of 150 °C and a foaming time of 60 s, open-celled microcellular polystyrene foams were obtained using supercritical CO₂ in the batch process. Based on the results, a schematic diagram, depicting the process of foam structure formation from nucleation to bubble coalescence and gas escape from polymer, was proposed. Theoretical calculations showed that by increasing foaming time, cell size was increased and cell density was reduced and the experimental results verified this prediction.     

聚丙烯挤出发泡中的关键技术——加工设备和成型工艺研究

从聚丙烯挤出发泡的加工设备包括挤出机的类型、发泡机头的设计、发泡剂的注入和计量控制以及聚丙烯挤出发泡的成型工艺包括螺杆转速、压力降和压力降速率、成核剂的分散、发泡机头的温度等系统介绍了聚丙烯挤出发泡中的一些关键技术。目前的研究表明：采用双螺杆挤出机进行挤出发泡时需要考虑发泡剂逃逸和压力的升高与稳定；可以通过改变机头的形状和尺寸获得不同的压力降和压力降速率，从而控制挤出发泡的成核速率。提高螺杆转速、增加压力降和压力降速率有利于优质发泡材料的获得；优选适宜的发泡机头温度可以抑制气体逃逸，提高发泡倍率，获得更低密度的聚丙烯发泡材料。     

聚醚酰亚胺均相成核发泡行为研究

以超临界CO₂为发泡剂,采用间歇式发泡技术制备了聚醚酰亚胺（PEI）微孔泡沫。通过改变发泡温度、发泡压力与样品浸泡时间等工艺条件,研究了PEI的均相成核发泡行为。实验还通过二次降压法制备了具有复合泡孔结构的PEI微孔泡沫材料。结果表明,复合泡孔结构提高了PEI微孔泡沫的发泡倍率,第一次压力降ΔP₁与第二次保压时间Δt₂是影响复合泡孔结构参数的重要影响因素。     

Performance optimization of acrylonitrile butadiene styrene/thermoplastic polyurethane composite foams blown with carbon dioxide using Taguchi technique

In this study, acrylonitrile butadiene styrene (ABS)/thermoplastic polyurethane (TPU) composite foam blown with CO₂ was fabricated. Optimization was done by design of experiment (DOE) on the cellular structure using the Taguchi method. Foaming time (20, 40, and 80 s), saturation pressure (4, 5.5, and 7 MPa), and foaming temperature (80, 90, and 120°C) are the input parameters. The results obtained from the signal-to-noise (S/N) analysis showed that the most effective factor on the cell density (CD) was the saturation pressure and its influence rate was 48.05%, and also, the CD improved with the increase in the saturation pressure because the high saturation pressure leads to an enhancement in gas solubility and the rate of cell nucleation. Moreover, the foaming temperature and the foaming time had a noteworthy impact on the void fraction and the cell size (CS), and they should be controlled accurately. The impression rate of the foaming time on the CS was 50.86%, and also, with increase in the temperature and the time of foaming, the void fraction showed an increasing trend. The optimal values for the CD, the CS, and the void fraction were predicted to be 1.18 × 10⁹ cells/cm³, 5.37 μm, and 0.5744%, respectively.     

ABS微孔发泡材料气体扩散行为分析

采用化学交联模压法制备了丙烯腈-苯乙烯-丁二烯共聚物(ABS)微孔发泡材料,研究了发泡温度、发泡压力及发泡时间对ABS微孔发泡材料气体的扩散行为及泡孔结构的影响,结果表明:气体吸收量随着发泡温度、发泡压力和发泡时间的增加,先增大后减小;随着气体吸收量的增加,制品的泡孔尺寸逐渐减小,泡孔密度逐渐增大,增加气体吸收量有利于提高发泡效果。当发泡温度为170℃、发泡压力为10 MPa、发泡时间为12min时,泡孔密度约为2.87×108个/cm3,可满足工业上微孔发泡材料泡孔密度的要求。     

Production of microcellular foam plastics by supercritical carbon dioxide

The production of microcellular plastic was studied in the polymethyl metacrylate (PMMA)-supercritical carbon dioxide and polycarbonate (PC)-supercritical carbon dioxide systems. The test pieces of PMMA and PC were put into a saturation vessel of which temperature and pressure were kept constant. Supercritical carbon dioxide at temperature between 303K and 393K and pressure between 100 bar and 250 bar was used as a foaming agent. After saturation of carbon dioxide, the pressure was quickly released to atmospheric pressure. The samples were immediately taken out from the vessel and heated in an oil bath. The fractured part of the sample was used for microstructure analysis with SEM. The effect of the saturation temperature, pressure of sorption and the foaming time on the cell mean size and cell density of the foam was investigated by considering the solubility of carbon dioxide in PMMA and PC. The foam morphologies of the foamed plastics were affected by solubility of carbon dioxide, which was directly related to saturation temperature and pressure. The cell density increased and, consequently, the cell size decreased with the solubility of carbon dioxide. The foaming time can be used a controlling factor to obtain the desired foam structure and the volume expansion ratio.     

振动力场对含有成核剂的微孔塑料泡孔结构的影响

在微孔塑料成型加工过程中,成核剂的加入可以增加泡孔成核点数量,从而增加泡孔密度,改善泡孔的结构,但如果纳米级成核剂在发泡过程中分散性不好,会使泡孔分布不均匀,影响泡孔质量。在实验中,对含有成核剂(纳米碳酸钙)的发泡材料(聚苯乙烯)施加振动场,通过比较发现,施加振动后,纳米级成核剂的分散效果明显改善,颗粒分布变得更均匀,从而使得泡孔分布更均匀,改善了泡孔的结构,提高了微孔塑料泡孔结构质量。     

Optimized Polystyrene Cell Morphology by Orthogonal Superposition of Oscillatory Shear

A novel dynamic microcellular foaming technology is presented in the form of mechanical vibration, forming an oscillatory shear orthogonal superposition upon steady shear flow. The effects of steady and oscillatory shear on polystyrene foam processing were investigated with a novel dynamic foam processing simulator. Cell morphology was analyzed by using a scanning electron microscope (SEM). The results show that the oscillatory shear has a significant influence on the cell morphology. A fine cell structure with nearly spherical cell shape is nucleated with properly arranged rotor speed and vibration parameters. At the same time, cell density increases remarkably with the introduction of vibration.