Microporous plastic (MCP) is an important innovation in plastics processing technology and has a major impact on the world plastics industry. Almost all plastic materials can be made into ultra-porous plastics.
The advantages of ultra-porous plastics compared to conventional (coarse) foamed plastics:
First, the foams in conventional foamed plastics are large and it is impossible to foam into very thin films or sheets; while microcellular foamed plastics can achieve this purpose, if the micropore size can be as small as 0.1 micron, foaming can be successful. A 20 micron thick sheet or film with good overall physical properties. Also, very fine ultra-microporous fibers can be foamed.
The tested microcellular plastics exhibit better physical properties. Many ultra-porous plastics have better toughness and longer fatigue life. The mechanical strength is also much better than conventional coarse-pore foamed plastics. Although the lowest density limit is currently unknown, the density of ultra-porous plastics can be as low as 0.03 grams per cubic centimeter. At such low density levels, ultra-porous plastics have excellent thermal insulation properties due to the small pore size.
Due to the extremely small pore size, foamed plastics look like non-foamed plastics from the outside, but their intrinsic qualities have good physical properties. Conventional foamed plastics without colorants such as titanium dioxide are also opaque. It is worth paying attention to in the field of plastics processing that successful technologies can produce transparent ultra-microcellular plastics with a pore size of less than 0.05 μm.
Because 70% of the cost of plastic products for foamed plastics is material cost; in many applications, there is hope and possibility to reduce the weight by more than 50%. The use of this technology can reduce the cost of plastic products by more than 35% and has a very large Practical significance. This technology can also improve the physical properties of plastic products while reducing material costs. Since the weight of the article is reduced, the cost of other, for example, transportation, and the like is reduced.
Ultra-microcellular plastics can be tailor made to open and closed cell materials depending on the needs of the application. Open-cell microcellular plastics have been produced from homopolymers or mixtures of two incompatible polymers.
Ultramicrocellular plastics are environmentally friendly because carbon dioxide or nitrogen is used instead of hydrocarbon or fluorine blowing agents in production. The products provided contain less plastic than conventional products and require less material to be recycled or discarded than conventional products. Furthermore, the production of the same plastic products uses less ultra-porous plastic technology and consumes less energy.
There are several conditions that must be met to make ultra-porous plastics:
- The plastic must be saturated with enough gas and nucleated at the same time into a large number of ultrafine pores. As the solubility of gas increases with pressure, higher pressures are required.
- The temperature must be controlled during the development of micropores to control the stability of the plastic matrix.
- A gas must be chosen that has a suitable solubility and diffusivity for the plastic selected.
- In order to form a large number of ultra-micropores, uniform nucleation in the nucleation process must dominate, even if there are uneven nuclei.
Ultra-microcellular plastics can be classified as foamed plastics, but their micropore or cell size is less than 30 microns.
- The micropores or cell sizes are based on the average of the micropores.
- Foam density can be defined as the proportion of foamed plastic.
- The micropore density can be defined as the number of cells per cubic meter of unexpanded plastic (number of bubbles per uncubic plastic per cubic meter). The cell density can be calculated by counting the number of cells in a long range of 100 μm in two orthogonal directions, taking the average value and extrapolating the number of cells in the three-dimensional direction.
In an ideal ultra-microcellular plastic, the cell size can be directly related to the cell density.
In an ideal, fine-grained hexagonal or face-centered cubic structure, the volume occupied by the circular cells is about 74%, and the volume occupied by the plastic between the cavities is 26%. Therefore, the micropore density of an ideal precision-aligned circular microporous plastic is equal to (1/pore size) X (1/0.26). The cell density of a 1 micron microporous ultra-thin plastic is 3.85 x 1012 per cubic centimeter of unexpanded plastic. In addition to closed-cell ultra-microcellular plastics, it is also possible to produce open cell ultra-microcellular plastics.
The advantages of ultra-porous plastics compared to conventional (coarse) foamed plastics:
First, the foams in conventional foamed plastics are large and it is impossible to foam into very thin films or sheets; while microcellular foamed plastics can achieve this purpose, if the micropore size can be as small as 0.1 micron, foaming can be successful. A 20 micron thick sheet or film with good overall physical properties. Also, very fine ultra-microporous fibers can be foamed.
The tested microcellular plastics exhibit better physical properties. Many ultra-porous plastics have better toughness and longer fatigue life. The mechanical strength is also much better than conventional coarse-pore foamed plastics. Although the lowest density limit is currently unknown, the density of ultra-porous plastics can be as low as 0.03 grams per cubic centimeter. At such low density levels, ultra-porous plastics have excellent thermal insulation properties due to the small pore size.
Due to the extremely small pore size, foamed plastics look like non-foamed plastics from the outside, but their intrinsic qualities have good physical properties. Conventional foamed plastics without colorants such as titanium dioxide are also opaque. It is worth paying attention to in the field of plastics processing that successful technologies can produce transparent ultra-microcellular plastics with a pore size of less than 0.05 μm.
Because 70% of the cost of plastic products for foamed plastics is material cost; in many applications, there is hope and possibility to reduce the weight by more than 50%. The use of this technology can reduce the cost of plastic products by more than 35% and has a very large Practical significance. This technology can also improve the physical properties of plastic products while reducing material costs. Since the weight of the article is reduced, the cost of other, for example, transportation, and the like is reduced.
Ultra-microcellular plastics can be tailor made to open and closed cell materials depending on the needs of the application. Open-cell microcellular plastics have been produced from homopolymers or mixtures of two incompatible polymers.
Ultramicrocellular plastics are environmentally friendly because carbon dioxide or nitrogen is used instead of hydrocarbon or fluorine blowing agents in production. The products provided contain less plastic than conventional products and require less material to be recycled or discarded than conventional products. Furthermore, the production of the same plastic products uses less ultra-porous plastic technology and consumes less energy.
There are several conditions that must be met to make ultra-porous plastics:
- The plastic must be saturated with enough gas and nucleated at the same time into a large number of ultrafine pores. As the solubility of gas increases with pressure, higher pressures are required.
- The temperature must be controlled during the development of micropores to control the stability of the plastic matrix.
- A gas must be chosen that has a suitable solubility and diffusivity for the plastic selected.
- In order to form a large number of ultra-micropores, uniform nucleation in the nucleation process must dominate, even if there are uneven nuclei.
Ultra-microcellular plastics can be classified as foamed plastics, but their micropore or cell size is less than 30 microns.
- The micropores or cell sizes are based on the average of the micropores.
- Foam density can be defined as the proportion of foamed plastic.
- The micropore density can be defined as the number of cells per cubic meter of unexpanded plastic (number of bubbles per uncubic plastic per cubic meter). The cell density can be calculated by counting the number of cells in a long range of 100 μm in two orthogonal directions, taking the average value and extrapolating the number of cells in the three-dimensional direction.
In an ideal ultra-microcellular plastic, the cell size can be directly related to the cell density.
In an ideal, fine-grained hexagonal or face-centered cubic structure, the volume occupied by the circular cells is about 74%, and the volume occupied by the plastic between the cavities is 26%. Therefore, the micropore density of an ideal precision-aligned circular microporous plastic is equal to (1/pore size) X (1/0.26). The cell density of a 1 micron microporous ultra-thin plastic is 3.85 x 1012 per cubic centimeter of unexpanded plastic. In addition to closed-cell ultra-microcellular plastics, it is also possible to produce open cell ultra-microcellular plastics.
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