The cell size distribution in a thermoplastic foam to a large extent determines its mechanical and thermal properties. It is difficult to predict because of the many physical processes involved, each affected in turn by an array of factors and parameters. The two most important processes are bubble nucleation and diffusion-driven bubble growth. Neither has been thoroughly understood despite intensive and long-standing research efforts. In this work, we consider foaming by a physical blowing agent dissolved in a polymer melt that contains particulate nucleating agents. We propose a nucleation model based on the concept that heterogeneous nucleation originates from pre-existing microvoids on the solid particles. The nucleation rate is determined by a bubble detachment time. Once nucleated, the bubbles grow as the dissolved gas diffuses through the polymer melt into the bubbles, a process that couples mass and momentum transport. By using the Oldroyd-B constitutive equation, we explore the role of melt viscoelasticity in this process. Finally, we integrate the nucleation and growth models to predict the evolution of the bubble size distribution. A cell model is employed to simulate the effects of neighboring bubbles and the depletion of blowing agents. The latter also causes the nucleation rate to decline once growth of older bubbles is underway. Using the physical and operating parameters of a recent foam extrusion experiment, we are able to predict a cell size distribution in reasonable agreement with measurements.

During polymer foaming with physical blowing agents, plasticization affects the melt viscosity, gas diffusivity in the melt, and the gas-melt interfacial tension. In this paper, we propose a model for plasticization during bubble growth, and estimate its effects under typical foaming conditions. The theoretical model incorporates wellestablished mixture theories into a recent model for diffusion-induced bubble growth. These include the free-volume theories for the viscosity and diffusivity in polymer-blowing agent mixtures and the density gradient theory for the interfacial tension. The viscoelasticity of the melt is represented by an Oldroyd-B constitutive equation. We study the radial growth of a single bubble in an infinite expanse of melt, using parameter values based on experiments on polystyrene-CO 2 systems. Our results show that even at relatively low gas concentrations, plasticization increases the blowing-agent diffusivity markedly and thus boosts the rate of bubble growth. In contrast, the reduction in melt viscosity and interfacial tension has little effect on bubble growth. Though not intended as quantitative guidelines for process design, these results are expected to apply qualitatively to typical foaming conditions and common polymer-blowing agent combinations. POLYM. ENG. SCI., 46: 97-107, 2006. POLYMER ENGINEERING AND SCIENCE-2006 FIG. 3. Radial profiles of (a) gas concentration c(r) and (b) viscosity (r) at different times during bubble growth. The initial concentration is c 0 ϭ 0.2%.

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