A process for making microcellular thermoplastic parts

TLDR

The paper proposes a novel process for producing microcellular thermoplastic parts. The method integrates deformation into the foaming cycle to decouple cell nucleation and growth from deformation, and studies a nitrogen–polystyrene system to establish key process parameter relationships. Experiments show deformation pressures do not reduce bubble nucleation, and the process successfully produces a microcellular polystyrene container.

Abstract

Abstract A novel process to produce microcellular thermoplastic parts is described. This is achieved by integrating the deformation process in the foaming cycle in such a way that the cell nucleation and growth processes are effectively uncoupled from deformation. The nitrogen‐polystyrene system is studied and the relationships between the essential process parameters are established. It is experimentally shown that the pressures associated with deformation do not reduce the number of bubbles nucleated. The process synthesized is demonstrated by making a microcellular polystyrene container.