Document Type : Original research
Authors
1 Mechanical Engineering Department, Faculty of Engineering, Urmia University, Urmia, Iran
2 Microcellular Plastics Manufacturing Laboratory, Department of Mechanical and Industrial Engineering, University of Toronto, 5 King’s College Road, Toronto M5S 3G8, Canada
Abstract
Rotational molding is a process used to produce seamless, one-piece, and hollow polymeric parts. Foam rotational molding has recently become an increasingly important process in the foam industry. However, foam rotational molding is still a challenging process to fabricate polymeric foams. The focus of this manuscript was to assess the effect of material parameters on the foam properties of samples produced by rotational molding. Rotational molding experiments were performed on a laboratory-scale two-axis rotational machine, designed and manufactured by the authors. The effects of microtalc as nucleating agent, nanoclay as reinforcing agent, and their synergetic effect were investigated on the cell density, cell size, and expansion ratio of hybrid microtalc/nanoclay polyethylene nanocomposites. The cell density was improved by 96% and 89% by addition of 1 wt% of microtalc and nanoclay, respectively, compared to pure polyethylene foams. The cell size was reduced by 20% and 17.5% in 1 wt% of microtalc and nanoclay, respectively. However, the synergetic effect of using both microtalc and nanoclay at 1 wt% was more significant compared to their individual effects. The cell density was enhanced by 313% and the cell size was decreased by 35% compared to pure samples.
Keywords
Main Subjects
- Höfler G, Lin RJ, Jayaraman K (2018) Rotational moulding and mechanical characterisation of halloysite reinforced polyethylenes. J Polym Res 25: 132
- Hasanzadeh R, Azdast T, Doniavi A, Lee RE (2019) Multi-objective optimization of heat transfer mechanisms of microcellular polymeric foams from thermal-insulation point of view. Therm Sci Eng Prog 9: 21-29
- Wang G, Zhao G, Dong G, Mu Y, Park CB, Wang G (2018) Lightweight, super-elastic, and thermal-sound insulation bio-based PEBA foams fabricated by high-pressure foam injection molding with mold-opening. Eur Polym J 103: 68-79
- Moradian M, Azdast T, Doniavi A (2020) Investigating the effect of foam properties on the attenuation of coaxial cables with foamed polyethylene dielectric. Polym Adv Technol 31: 3328-3340
- Moradian M, Azdast T, Doniavi A (2021) Changes in signal transmission speed in coaxial cables through regulating the foam structure of the polyethylene dielectric section. Polyolefins J 8: 41-48
- Qian W, Zhao K, Zhang D, Bowen CR, Wang Y, Yang Y (2019) Piezoelectric material-polymer composite porous foam for efficient dye degradation via the piezo-catalytic effect. ACS Appl Mater Interfaces 11: 27862-27869
- Cherukupally P, Acosta EJ, Hinestroza JP, Bilton AM, Park CB (2017) Acid–base polymeric foams for the adsorption of micro-oil droplets from industrial effluents. Environ Sci Technol 51: 8552-8560
- Rashahmadi S, Hasanzadeh R, Mosalman S (2017) Improving the mechanical properties of poly methyl methacrylate nanocomposites for dentistry applications reinforced with different nanoparticles. Polym Plast Technol Eng 56: 1730-1740
- Li M, Zhang Y, Zhu F, Zhao X, Li R, Wang H, Liu J, Li X, Chang H, Lin T (2021) Influence of PA6 particle filler on morphology, crystallization behavior and dynamic mechanical properties of poly (ε-caprolactone) as an efficient nucleating agent. J Polym Res 28: 461
- Eungkee Lee R, Hasanzadeh R, Azdast T (2017) A multi-criteria decision analysis on injection moulding of polymeric microcellular nanocomposite foams containing multi-walled carbon nanotubes. Plast Rubber Compos 46: 155-162
- Wang L, Zhou H, Wang X, Mi J (2016) Evaluation of nanoparticle effect on bubble nucleation in polymer foaming. J Phys Chem C 120: 26841- 26851
- Valapa RB, Loganathan S, Pugazhenthi G, Thomas S, Varghese TO (2017) An overview of polymer–clay nanocomposites. In: Clay-polymer nanocomposites, Elsevier, pp: 29-81
- Crawford RJ (1996) Recent advances in the manufacture of plastic products by rotomoulding. J Mater Process Technol 56: 263-271
- Crawford RJ, Throne JL (2001) Rotational molding technology. William Andrew
- Crawford RJ (2003) Vision 2020 through 2002. J Rotation 12: 16-19
- Greco A, Maffezzoli A (2004) Powder-shape analysis and sintering behavior of high-density polyethylene powders for rotational molding. J Appl Polym Sci 92: 449-460
- Olinek J, Anand C, Bellehumeur CT, (2005) Experimental study on the flow and deposition of powder particles in rotational molding. Polym Eng Sci 45: 62-73
- Spence AG, Crawford RJ (1996) The effect of processing variables on the formation and removal of bubbles in rotationally molded products. Polym Eng Sci 36: 993-1009
- Van Hooijdonk JPF, Mark Kearns P, Armstrong CG, Crawford RJ (2001) Effect of processing conditions on the properties of rotationally moulded polypropylene. J Rotation 6: 28-30
- Pick ELT, Harkin-Jones 2003b Understanding the impact behavior of rotomoulded linear low density polyethylene. J Rotation 13: 26-30
- Pick L, Harkin-Jones E, Kearns MP, Crawford RJ (2003) A Comparison between the impact performance of rotationaly moulded linear low density polyethylene with metallocene polyethylene. J Rotation 9: 21-25
- Laguna-Gutierrez E, Lopez-Gil A, Saiz-Arroyo C, Van Hooghten R, Moldenaers P Rodriguez- Perez MA (2016) Extensional rheology, cellular structure, mechanical behavior relationships in HMS PP/ montmorillonite foams with similar densities. J Polym Res 23: 251
- Hasanzadeh R, Azdast T, Doniavi A, Rostami M (2019) A prediction model using response surface methodology based on cell size and foam density to predict thermal conductivity of polystyrene foams. Heat Mass Transfer 55: 2845- 2855
- Jamalpour S, Ghaffarian SR, Jangizehi A (2018) Effect of matrix− nanoparticle supramolecular interactions on the morphology and mechanical properties of polymer foams. Polym Int 67: 859- 867
- Azdast T, Lee RE, Hasanzadeh R, Moradian M, Shishavan SM (2019) Investigation of mechanical and morphological properties of acrylonitrile butadiene styrene nanocomposite foams from analytical hierarchy process point of view. Polym Bull 76: 2579-2599
- Pop-Iliev R, Dong N, Xu D, Park CB (2007) Visualization of the foaming mechanism of polyethylene blown by chemical blowing agents under ambient pressure. Adv Polym Technol: J Polym Process Ins 26: 213-222
- Doroudiani S, Park CB, Kortschot MT (1996) Effect of the crystallinity and morphology on the microcellular foam structure of semicrystalline polymers. Polym Eng Sci 36: 2645-2662
- Archer EV (2003) An investigation of the rotational moulding of foamed metallocene polyethylenes. Doctoral dissertation, Queen's University of Belfast
- Liu G, Park CB, Lefas JA (1998) Production of low-density LLDPE foams in rotational molding. Polym Eng Sci 38: 1997-2009
- Abd El-Salam HM, Mohamed RA, Shokry A (2019) Facile polyacrylamide graft based on poly (2-chloroaniline) silver nano-composites as antimicrobial. Int Polym Mater Polym Biom 68: 278-286
- Dubey N, Kushwaha CS, Shukla SK (2020) A review on electrically conducting polymer bio-nanocomposites for biomedical and other applications. Int J Polym Mater Polym Biom 69: 709- 727
- Nofar M, Majithiya K, Kuboki T, Park CB (2012) The foamability of low-melt-strength linear polypropylene with nanoclay and coupling agent. J Cell Plast 48: 271-287
- Zhai, W, Park CB (2011) Effect of nanoclay addition on the foaming behavior of linear polypropylene-based soft thermoplastic polyolefin foam blown in continuous extrusion. Polym Eng Sci 51: 2387-2397
- Dugad R, Radhakrishna G, Gandhi A (2020) Recent advancements in manufacturing technologies of microcellular polymers: A review. J Polym Res 27: 182
- Yetgin SH, Una, H, Mimaroglu A (2014) Influence of foam agent content and talc filler on the microcellular and mechanical properties of injection molded polypropylene and talc filled polypropylene composite foams. J Cell Plast 50: 563- 576
- Zhao J, Qiao Y, Wang G, Wang C, Park CB (2020) Lightweight and tough PP/talc composite foam with bimodal nanoporous structure achieved by microcellular injection molding. Mater Des 195: 109051
- Azdast T, Hasanzadeh R (2020) Increasing cell density/decreasing cell size to produce microcellular and nanocellular thermoplastic foams: A review. J Cell Plast 57: 769-797
- Chen Y, Weng C, Wang Z, Maertens T, Fan P, Chen F, Zhong M, Tan J, Yang J (2019) Preparation of polymeric foams with bimodal cell size: An application of heterogeneous nucleation effect of nanofillers. J Supercrit Fluids 147: 107- 115
- Yang C, Zhao Q, Xing Z, Zhang W, Zhang M, Tan H, Wang J, Wu G (2019) Improving the supercritical CO2 foaming of polypropylene by the addition of fluoroelastomer as a nucleation agent. Polymers 11: 226
)
