<p> The foaming process has received increased attention by the rotational molding industry in recent years. The use of metallocene catalyzed polyethylenes for producing a cellular structure is a new development in rotational molding. The objective of this work was to investigate the effects of different chemical blowing agents, resin properties and processing conditions on the structure of foamed metallocene polyethylene and obtain a fundamental understanding of the parameters governing the foam structure and part properties.</p> <p> An experimental study was conducted to produce metallocene polyethylene foams in dry-blending-based rotational foam molding. The physical and cell structure properties of the final foamed parts were examined. The critical processing parameters that optimize the foam structure have been identified through adjustments to the molding conditions.</p> <p> The foaming performance of exothermic and endothermic chemical blowing agents were examined and it was revealed that selecting an appropriate chemical blowing agent was crucial as the foam structure depends significantly on the properties of the blowing agent. Exothermic blowing agents resulted in greater foam density reduction compared to endothermic blowing agents.</p> <p> The effect of rheological properties on the foaming process and foam properties was also examined. Rotomolding experiments were performed in monolayer and skin-foam moldings. Observations indicated that the final foam properties were profoundly influenced by the rheological properties of the polymer materials. There was a good correlation between the foam properties produced in both monolayer and two layer moldings. It was discovered that polymer materials with higher extensional viscosity could provide a promising foaming performance at different processing conditions.</p> <p> The effect of the surface tension of the polymer materials was investigated. It was found that type of reaction of the blowing agent (exothermic/endothermic) and composition of gas generated determine whether the surface tension of the resin contributes to the trend of changes in foam properties.</p> / Thesis / Master of Applied Science (MASc)

This thesis focuses on the design, development, and evolution of a novel patent-pending plastic processing technology entitled “Rapid Rotational Foam Molding” with special emphasis on the processing of polyethylene (PE) integral-skin foamed core moldings. Rapid Rotational Foam Molding is a technology deliberately designed to address the intrinsic disadvantage of conventional rotational foam molding, i.e., its very long cycle times. In this context, a physical system that exploits the positive synergistic effects of innovatively combining extrusion melt compounding and rotational foam molding was designed and built. The fundamental processing steps of this system comprise (i) rotationally molding a non-foamable PE powder in a lab-scale oven while, (ii) simultaneously melt compounding and foaming a pre-dry blended foamable PE and chemical blowing agent (CBA) formulation in an on-line lab-scale extruder, and then (iii) filling the newly created foaming material into the non-chilled hollow article thereby created in the mold through a special interface. Two varieties of PE resins ranging from linear low density PE (LLDPE) to high density PE (HDPE) were selected for experimentation with melt flow rates (MFR) ranging from 2.0 to 3.6 g/10min. The implemented CBA was Celogen OT. The materials were characterized using thermal analysis techniques such as differential scanning calorimetery (DSC) and thermogravimetric analysis (TGA) to ensure their correct operating temperatures ranges. Scanning electron microscopy (SEM) was utilized for characterizing the quality of the foam samples and achieved skin-foam interface for the final moldings. Improvements to the achieved molding quality were accomplished through various system and process modifications described throughout this research work.

<p><strong><em>Dedicated to the loving memory of my mother and father,</em></strong></p> <p><strong><em>Zohreh Hojati & Mostafa Emami</em></strong></p> / <p>Commercial interests in polymeric foams continue to increase due to their unique physical characters and the new emerging applications for foamed materials. This thesis investigates the foam development process under non-pressurized conditions as applicable to rotational molding to elucidate the underlying mechanisms in the bubble transformation process and provide an accurate basis for predicting the morphological structure and macroscopic properties of the foamed materials. It was found that the foaming mechanism is comprised of four distinct stages: two stages of bubble nucleation, primary and secondary nucleation, followed by bubble growth and bubble coalescence/shrinkage. Following the nucleated bubbles during the foaming process revealed that primary nucleation was the controlling stage in determining the final cellular structure. Growth and coalescence mechanisms were dynamically active and competed during both heating and cooling cycles.</p> <p>The influence of the rheological properties on the rate of nucleation and the bubble growth mechanism were investigated. Morphological analysis was used to determine the rheological processing window in terms of shear viscosity, elastic modulus, melt strength and strain-hardening, intended for the production of foams with greater foam expansion, increased bubble density and reduced bubble size. Visualization experiments and theoretical predictions showed that higher viscosity could impede the number of nuclei generated in the foaming system. A bubble growth model and simulation scheme was also developed to describe the bubble growth phenomena that occurred in non-pressurized foaming systems. It was verified that the viscous bubble growth model was capable of depicting the growth behaviors of bubbles under various processing conditions.</p> / Doctor of Philosophy (PhD)

Rapid Rotational Foam Molding (RRFM) is a novel patent-pending process that was designed and developed to maximize the synergistic effects resulting from the deliberate combination of extrusion and rotational foam molding and thereby serve as a time-andenergy efficient technology for the manufacture of integral-skin rotationally molded foams of high quality. This thesis presents a thorough study of the scientific and engineering aspects related to the evolution of the RRFM process and its feasibility. This innovative processing technology was assessed and verified through a battery of planned experimental trials conducted utilizing an in-house custom-built industrial-grade lab-scale experimental setup. The experimental trials involved a variety of polypropylene (PP)- based foamable formulations with a chemical blowing agent (CBA) that were compounded and processed by utilizing an extruder and then foamed and injected as a foamed core, instantly, into the cavity of a suitable non-chilled rotationally molded hollow shell made of non-foamed pulverized PP grades. The investigated mold shapes included a cylindrical shaped mold and a rectangular flat shaped mold. The obtained moldings were examined for the quality of the skin surface, the skin-foam interface, and the achieved foam morphologies that were characterized in terms of foam density, average cell size, and average cell density. Optimal processing parameters were successfully determined for three different PP skin-foam formulation combinations. The accomplished reduction in processing time and energy consumption by implementing RRFM were substantial. A variety of processing impediments that hindered the efficiency of the single-charge conventional rotational foam molding practice were resolved by implementing RRFM; these include: the foam/skin invasion into the skin/foam layer of the manufactured article and the premature decomposition of CBA during compounding or subsequent rotational foam molding processing steps. / UOIT