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Foam Extrusion
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November 17-19, 2008 |
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About the Seminar
This seminar covers important materials, equipment, and process issues of
foam extrusion in a comprehensive fashion.
The objectives of this seminar are:
- to teach the basic principles of foam extrusion
- to demonstrate the application of these principles to material selection, equipment selection, setting process conditions, and troubleshooting
- to provide information that processors can take back to the plant to improve production and product quality
Three recognized experts will be the instructors for the seminar.
What the attendees will learn:
- the basic principles of foamed polymers: mechanical properties, characteristic of foamable polymers, additives, foaming agents, and rheology of gas-laden melts
- foaming agents: endothermic versus exothermic, nucleation, compatibility, open cell foams, natural fiber foam composites, and foaming agent chemistry
- extrusion equipment for foam extrusion: single screw extruders, twin screw extruders, tandem extrusion systems, screw and die design for foam extrusion, high versus low density products
- troubleshooting foam extrusion problems: tools for troubleshooting, extrusion instabilities, irregular cell structure, corrugations and striations, poor melt strength, die freeze-off, and case studies
Who should attend:
- Design engineers
- Process engineers and manufacturing engineers
- Manufacturing managers
- Production supervisors/managers
- Technical service personnel
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Course Description
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Course Description
Basic Principles
• Mechanical properties of foams
• Std time behavior: stiffness, strength
• Long time behavior: creep, fatigue
• Short time behavior: impact
• Foamable polymers
• Morphological characteristics
• Characteristics of important resins
• Additives
• Cell stabilizers
• Other agents
• Nucleating agents
• Foaming agents
• Chemical : exo- and endo-thermics
• Physical: atmospheric, hydrocarbons, HCFCs
• Solubility and diffusivity
• Rheology of gas-laden melts
• Bubble mechanics
• Why does a foam stop growing?
• And why does it shrink?
• Open-celled foams
Foaming Agents
• Natural Fiber Foam Composites
• Polymer Structures
• Process of Manufacturing
• Pressurization
• Cooling and Mixing
• Role of Cellular Structures
• Fine Cellular Structure
• Chemistry of the Foaming Agent
• Die Configuration and Extrusion
• Foaming Agent Process and Performance
• Introduction
• Foaming Agent Technologies
• Endothermic & Exothermic Foaming Agents
• Gases & Nucleation
• Elastomeric Foam Design
• What 's happening in the Barrel?
• Blowing Agent Compatibility
• Blowing Agent Process
• Properties of Foam Articles
• Process Improvement using CO2
• Open Cell Foam
• Foaming agent studies
• Foaming agents in IM & Extrusion
• New Equipment Technologies
Hardware
• Twin vs. single screw extruders
• Single- vs. two-stage process
• Screw design for foam extrusion
• Melt temperature distribution
• Die design for foam extrusion
• High vs. low density foam products
• Free foaming method
• Constrained foaming method
• Microcellular foam extrusion
• Coextrusion |
Thermoformability of Low-Density Thin-Gauge Sheet
• Material-Specific Die Design for Thin-Gauge Shee
• Temperature-Dependent Internal Cell Gas Pressure During Cooling
• The Role of Sheet Aging Prior to Thermoforming
• Factors Influencing Secondary Foam Expansion During Reheating
• Internal Cell Gas Pressure
• Temperature-Dependent Tensile Modulus
• Processing Factors Influencing Catastrophic Cell Collapse
Troubleshooting
• Requirements
• Tools for troubleshooting
• Systematic troubleshooting
• Extrusion instabilities
• Frequency of instability
• Functional instabilities
• Solving extrusion instabilities
• Computer aided troubleshooting
• Case studies
• Wear problems
• Mixing problems
• Irregular cell structure
• Dimensional variation

Book authored byJames L. Throne:
Thermoplastic Foam Extrusion is available with foam seminar registration for a discounted price of $55.00. Please check TPE book box on registration form if you desire to purchase the book.
Books authored by Chris Rauwendaal:
- Polymer Extrusion available with registration in any seminar for a discounted price of $75.00 Check appropriate box on registration form.
- Understanding Extrusion
- Troubleshooting the Extrusion Process
- SPC in Injection Molding and Extrusion
- Polymer Mixing
- Mixing in Polymer Processing
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