Process for extruding thermoplastic materials using low pressure

Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – By gas forming or expanding

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26421123, B29C 6722

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active

050341715

ABSTRACT:
A process for producing microcellular foamed articles wherein a low pressure compressible, inert gas such as nitrogen is used as a foaming agent. The process comprises introducing a thermoplastic material into an inlet of an extruder having a length to diameter ratio of at least 30:1, said extruder comprising a screw having at least one stage; heating the thermoplastic material in a melt zone to a temperature sufficient to melt or soften the thermoplastic material to form a melted thermoplastic material; injecting an insoluble compressible, inert gas into the melted thermoplastic material at a position approximately 1 to 2 screw diameters downstream of the melt zone; mixing the molten thermoplastic material and the inert, compressible gas to form a homogeneous dispersion of insoluble bubbles within the material; reducing the pressure of the molten thermoplastic material causing the homogeneously dispersed bubbles to expand within the melted thermoplastic material to form a foamed article and cooling the foamed article to a temperature below the melting or softening point of the foamed article.

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