An experimental technique for predicting foam processability and physical properties

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Abstract
Thermoplastic foam properties and processing stability depend strongly on the ability to obtain the proper rheological properties for the polymer melt at temperatures where the decomposition of a chemical blowing agent may be controlled. An experimental technique has been developed which allows stable processing conditions to be determined for the continuous extrusion of foamed thermoplastics with known foam properties. The technique involves a thermal analysis of the polymer‐blowing agent formulation to determine the range of controllable extrusion temperatures. Rheological analysis was carried out using a slit die to establish a relationship between the thermal blowing characteristics of the polymer composition and rheological data which correlate with foam extrudability and the physical properties of the foam. This provides a means of predicting both processability and foam properties which aid in the scale‐up to production. The rheological‐foam property correlations were confirmed by continuous foam extrusion on a laboratory extruder.

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