Foaming method by effusing SCF through plastic granules

Abstract

A method of microcellular foam molding an article includes feeding plastic granules to a hopper; supplying a supercritical fluid (SCF) to the hopper to effuse through the plastic granules; conveying the effused plastic granules to a mixer; and conveying the effused plastic granules in the mixer to a mold of an injection molding machine to perform foam molding on the effused plastic granules to produce a foamed article. The mold is kept at 10-50° C. and 7-70 Mpa for a foaming time of 50-120 seconds.

Claims

1. A method of microcellular foam molding an article, comprising the steps of: (1) feeding plastic granules to a hopper; (2) supplying a supercritical fluid (SCF) to the hopper to effuse through the plastic granules; (3) conveying the effused plastic granules to a mixer; and (4) conveying the effused plastic granules in the mixer to a mold of an injection molding machine to perform foam molding on the effused plastic granules to produce a foamed article; and wherein in step (4) for no chemical crosslinking, the mold is kept at 10-50° C. and 7-70 Mpa for a foaming time of 50-120 seconds.

2. The method of claim 1, wherein in step (2) the effusion occurs in 7-70 Mpa and 35-140° C. for 0.5-8 hours.

3. The method of claim 1, wherein in step (2) the SCF is carbon dioxide, water, methane, ethane, methanol, ethanol, ethylene, propylene, acetone, nitrogen, or a combination thereof.

4. The method of claim 1, wherein the mixer is kept at 7-70 Mpa and 0-100° C.

5. The method of claim 1, wherein the plastic granules are formed of polyolefin compound.

6. The method of claim 5, wherein the polyolefin compound comprises at least one of ethylene-vinyl acetate (EVA), polyolefin elastomer (POE), low-density polyethylene (LDPE), and ethylene propylene diene monomer (EPDM) rubber.

7. The method of claim 6, further comprising the sub-step of adding at least one of fillers and chemical additives to the polyolefin compound; wherein the fillers comprise at least one of calcium carbonate, pulvistalci, zinc oxide, and titanium dioxide; and the chemical additives comprise at least one of paraffin and stearic acid.

8. The method of claim 7, wherein for the polyolefin compound having 100 phr, the fillers have less than 30 phr and the chemical additives have less than 10 phr.

9. The method of claim 1, wherein the plastic granules are formed of elastomers.

10. The method of claim 9, wherein the elastomers comprise at least one of thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and thermoplastic elastomer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a flow chart of a foaming method according to a first preferred embodiment of the invention; and

[0011] FIG. 2 is a flow chart of a foaming method according to a second preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0012] Referring to FIG. 1, a flow chart of a foaming method in accordance with a first preferred embodiment of the invention is illustrated by comprising the following steps as discussed in detail below.

[0013] step 1: feeding plastic granules to a hopper;

[0014] step 2: supplying an SCF to the hopper to effuse through the plastic granules;

[0015] step 3: conveying the effused plastic granules to a mixer; and

[0016] step 4: conveying the effused plastic granules in the mixer to a mold of an injection molding machine to perform foam molding on the effused plastic granules to produce a foamed article.

[0017] Referring to FIG. 2, a flow chart of a foaming method in accordance with a second preferred embodiment of the invention is illustrated by comprising the following steps as discussed in detail below.

[0018] step 10: feeding plastic granules to a hopper;

[0019] step 20: supplying an SCF to the hopper to effuse through the plastic granules;

[0020] step 30: conveying the effused plastic granules to a mixer; and

[0021] step 40: conveying the effused plastic granules in the mixer to a die of an extrusion press to perform foam molding on the effused plastic granules to produce a foamed article.

[0022] Referring to both FIGS. 1 and 2 again, the hopper, the mixer, and the injection molding machine (or the extrusion press) are interconnected and are kept at both a predetermined pressure range and a predetermined temperature range.

[0023] The plastic granules comprise polyolefin compound and elastomers.

[0024] The polyolefin compound comprises at least one of ethylene-vinyl acetate (EVA), polyolefin elastomer (POE), low-density polyethylene (LDPE), ethylene propylene diene monomer (EPDM) rubber. In a first example, EVA is taken as the polyolefin having a 5%-40% mole. In a second example, a combination of EVA and POE having a composition ratio of 100/0.1-0.1/100 is taken as the polyolefin. In a third example, a combination of EVA, POE, and ethylene propylene diene monomer (EPDM) rubber having a composition ratio of 100/0.1/0.1-0.1/100/20.

[0025] At least one of crosslinking agent, filler, and chemical additive can be added to the polyolefin compound. The crosslinking agent reacts with molecules of the polyolefin compound to form bridges between polymer molecular links and in turn form an insolvable substance having a three-dimensional structure. The filler can improve performance or reduce production costs. The chemical additive can increase flowability. For the polyolefin compound having 100 parts per hundred rubber (phr), the crosslinking agent has 0.15 phr-1.1 phr or preferably 0.25 phr-1.0 phr, the filler has less than 30 phr, and the chemical additive has less than 10 phr.

[0026] The crosslinking agent comprises at least one of daichlorophenols (DCP) and Bis(tert-butylperoxy isopropyl) benzene (BIPB).

[0027] Filler comprises at least one of calcium carbonate, pulvistalci, zinc oxide and titanium dioxide.

[0028] Chemical additive comprises at least one of paraffin and stearic acid.

[0029] Preferably, the elastomers comprise at least one of thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and Pebax® Thermoplastic elastomer.

[0030] Examples of the SCF are carbon dioxide, water, methane, ethane, methanol, ethanol, ethylene, propylene, acetone, nitrogen, and a combination thereof.

[0031] The effusion occurs in a pressure range of 7-70 Mpa and a temperature range of 35-140° C. for 0.5-8 hours.

[0032] Preferably, for polyolefin compound, the effusion occurs in a pressure range of 7-70 Mpa and a temperature range of 30-80° C. for 0.5-8 hours; and preferably, for elastomers the effusion occurs in a pressure range of 7-70 Mpa and a temperature range of 50-130° C. for 1-8 hours.

[0033] In the plastic granules effused by SCF, the SCF has a weight percentage of 1-10% (i.e., 1-10 w %).

[0034] The mixer is kept at a pressure range of 7-70 Mpa and a temperature range of 0-100° C. Preferably, for polyolefin compound, the mixer is kept at a pressure range of 7-70 Mpa and a temperature range of 0-80° C.; and preferably, for elastomers, the mixer is kept at a pressure range of 7-70 Mpa and a temperature range of 0-100° C.

[0035] The mixer is used to temporarily store the effused plastic granules. Otherwise, the effused plastic granules may be effused for an excessive period of time and in turn is prevented from supplying to the injection molding machine (or the extrusion press) for production. Advantageously, the method of the invention makes a continuous supplying of the plastic granules to the injection molding machine (or the extrusion press) possible.

[0036] For the plastic granules of polyolefin compound, a chemical crosslinking occurs at the injection molding machine with the mold kept at a predetermined pressure range and a predetermined temperature range.

[0037] For the plastic granules of elastomers, no crosslinking occurs. The effused plastic granules are injected into a mold of the injection molding machine.

[0038] Preferably, for making the crosslinking possible, the mold is kept at a temperature range of 140-200° C. and a pressure range of 7-70 Mpa for a foaming time (or crosslinking time) of 60-950 seconds.

[0039] Preferably, for no crosslinking, the mold is kept at a temperature range of 10-50° C. and a pressure range of 7-70 Mpa for a foaming time of 50-120 seconds.

[0040] In the step 40 of conveying the plastic granules in the mixer to a die of an extrusion press to perform foam molding on the plastic granules in which the effused plastic granules are kept at a temperature range of 140-200° C. and a pressure range of 7-70 Mpa.

[0041] The foamed article produced by the invention contains billions of tiny bubbles having a size from 0.1 to 3 micrometers and the bubbles have a specific gravity of 0.03-0.30 g/cm.sup.3.

[0042] In one experiment, the foamed article undergoes three fatigue tests repeatedly with a load of 10-80 kg. It is found that its stability is increased by 30% in comparison with the article made by a conventional EVA foaming material.

[0043] The foamed article has a bouncing capability of at least 50% by testing with a ball free falling test based on ASTM D2632. Also, the bouncing capability can be maintained for 10 to 60 days in comparison with the article made by a conventional EVA foaming material. This 10 to 60 days period is increased by 30% in comparison with that of the article made by a conventional EVA foaming material.

[0044] The foamed article has many applications including mats, shoes, exercise equipment, toys and packing materials. For a shoe as the produced foamed article of the invention, billions of tiny bubbles of the shoe have a size from 0.1 to 3 micrometers and the bubbles have a specific gravity of 0.05-0.30 g/cm.sup.3; and the shoe has a bouncing capability of at least 50% by testing with a ball free falling test based on ASTM D2632. For mat as the produced foamed article of the invention, billions of tiny bubbles of the mat have a size from 0.1 to 3 micrometers and the bubbles have a specific gravity of 0.03-0.20 g/cm.sup.3; and the shoe has a bouncing capability of at least 50% by testing with a ball free falling test based on ASTM D2632.

[0045] The foaming materials have advantages including low specific gravity, no pollution to the environment, excellent resilience, and smooth surface. The formed article is produced in one process with a great reduction of the manufacturing cost. The step of providing a mixer to temporarily store the effused plastic granules makes a continuous supplying of the plastic granules to the injection molding machine (or the extrusion press) possible. Finally, it not only saves labor but also saves energy.

[0046] Embodiment 1: EVA (e.g., EVA7470 produced by Formosa Plastics Corporation) of 100 phr in which ethenyl acetate in the EVA has 26% mole, calcium carbonate of 1 phr, paraffin of 0.5 phr, and DCP of 0.5 phr are added to a mixer to mix for 12 minutes under conditions of 50° C. and 0.7 Mpa. Then a SCF (e.g., carbon dioxide (CO.sub.2)) is effused through the mixture for 2 hours under conditions of 50° C. and 40 Mpa. Plastic granules effused by the SCF are obtained. The effused plastic granules have a foaming ratio of less than 1.5 and the SCF has 10 wt %. The effused plastic granules are temporarily stored in the mixer. In a foam molding step, the effused plastic granules are conveyed from the mixer to a mold of an injection molding machine to perform foam molding by crosslinking the plastic granules for 60-950 seconds under conditions of 140-200° C., 7-70 Mpa. As a result, a foamed article having a smooth surface is produced.

[0047] Embodiment 2: EVA is replaced by a compound of EVA (60%)/POE (40%) in which ethenyl acetate in the EVA has 26% mole, and POE having a serial number 8150 is produced by Dows Inc. Other manufacturing steps are the same as that of embodiment 1. The produced article is a foamed article.

[0048] The produced foamed article has a specific gravity of 0.13, an average diameter of the bubbles in the produced foamed article is 0.5-2.0 mm, and the bouncing capability of the produced foamed article is 60%.

[0049] Embodiment 3: EVA is replaced by a compound of EVA (60%)/POE (40%) in which ethenyl acetate in the EVA has 26% mole, and POE having a serial number 8150 is produced by Dows Inc. Further, CO.sub.2 is replaced by nitrogen as SCF. Other manufacturing steps are the same as that of embodiment 1. The produced article is a foamed article.

[0050] The produced foamed article has a specific gravity of 0.15, an average diameter of the bubbles in the produced foamed article is 0.5-2.5 mm, and the bouncing capability of the produced foamed article is 58%.

[0051] Embodiment 4: EVA is replaced by a compound of TPU having a serial number 85AU10 produced by Sistron Inc. and the steps of mixing and crosslinking are omitted. Other manufacturing steps are the same as that of embodiment 1. The produced article is a foamed article.

[0052] The produced foamed article has a specific gravity of 0.28, an average diameter of the bubbles in the produced foamed article is 0.5-1.5 mm, and the bouncing capability of the produced foamed article is 55%.

[0053] Exemplary example 1: The conventional MuCell®. Molding Technology is used in which a SCF foaming device is used to produce TPU foaming articles. Hopper is heated to 210° C. and the mold is heated to 30° C. SCF (e.g., nitrogen) is introduced to the injection molding machine to mix with molten TPU. The molten TPU mixture is injected into a mold cavity to form. The SCF reacts with the molten TPU mixture to form bubbles in the mold cavity.

[0054] The produced foamed article has the same size as that of the mold cavity but has irregularities on the surface. The produced foamed article has a specific gravity of 0.4-0.55, an average diameter of the bubbles in the produced foamed article is 0.8-2.0 mm, and the bouncing capability of the produced foamed article is 50%.

[0055] Exemplary example 2: except the prefoaming ratio greater than 1.6 after introducing the SCF, other manufacturing steps are the same as that of embodiment 1. The produced article is a foamed article.

[0056] The produced foamed article has a specific gravity of 0.22, an average diameter of the bubbles in the produced foamed article is 0.5-1.7 mm, and the bouncing capability of the produced foamed article is 50%.

[0057] Exemplary example 3: except the crosslinking agent DCP in the embodiment 1 has 1.25 phr, other manufacturing steps are the same as that of embodiment 1.

[0058] The produced article is a foamed article. The produced foamed article has a specific gravity of 0.32, an average diameter of the bubbles in the produced foamed article is 0.2-0.8 mm, and the bouncing capability of the produced foamed article is 40%.

[0059] Exemplary example 4: except the crosslinking agent DCP in the embodiment 1 has 0.12 phr, other manufacturing steps are the same as that of embodiment 1. The produced article is a foamed article.

[0060] The produced foamed article has a specific gravity of 0.42, an average diameter of the bubbles in the produced foamed article is 0.2-0.6 mm, and the bouncing capability of the produced foamed article is 35%.

[0061] Exemplary example 5: except the crosslinking agent DCP in the embodiment 2 has 0.12 phr, other manufacturing steps are the same as that of embodiment 2.

[0062] The produced article is a foamed article. The produced foamed article has a specific gravity of 0.35, an average diameter of the bubbles in the produced foamed article is 0.1-0.8 mm, and the bouncing capability of the produced foamed article is 42%.

[0063] While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims.