Analysis of Bubble Growth in Supercritical CO2 Extrusion Foaming Polyethylene Terephthalate Process Based on Dynamic Flow Simulation

Bubble growth in the polymer extrusion foaming process occurs under a dynamic melt flow. For non-Newtonian fluids, this work successfully coupled the dynamic melt flow simulation with the bubble growth model to realize bubble growth predictions in an extrusion flow. The initial thermophysical properties and dynamic rheological property distribution at the cross section of the die exit were calculated based on the finite element method. It was found that dynamic rheological properties provided a necessary solution for predicting bubble growth during the supercritical CO2 polyethylene terephthalate (PET) extrusion foaming process. The introduction of initial melt stress could effectively inhibit the rapid growth of bubbles and reduce the stable size of bubbles. However, the initial melt stress was ignored in previous work involving bubble growth predictions because it was not available. The simulation results based on the above theoretical model were consistent with the evolution trends of cell morphology and agreed well with the actual experimental results.

Automated summary

Bubble growth in polymer extrusion foaming under dynamic melt flow was successfully predicted by coupling dynamic melt flow simulation with bubble growth model. Dynamic rheological properties were found to be crucial for predicting bubble growth during supercritical CO2 PET extrusion foaming. Introduction of initial melt stress could effectively inhibit rapid bubble growth and reduce stable bubble size.