Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

Bulk Density Reduction of Injection

Molded Thermoplastic Foams via a
Mold Design Approach
Ahmad Zia Ahmadzai1 and Amir Hossein Behravesh*
Department of Mechanical Engineering, Tarbiat Modares University, P.O. Box: 14115-
143, Jalaal-e- Al-e- Ahmad Exp. Way, Tehran, Iran

Received: 5 August 2013, Accepted: 8 October 2013

Summary
This study investigates the inter-relationships amongst processing parameters
and mold design and their effects on relative density of injection molded foams.
The limitation in lowering the overall bulk density of polymeric foams is one of the
main drawbacks in injection foaming process. A sheet mold with a rectangular
cavity was designed and manufactured which, includes an overflow channel
connected with the main cavity via a secondary gate, the size of which was
varied in this research. The effects of three parameters including chemical
blowing agent weight percentage, gate width, and part thickness on reduction of
relative density were investigated. Full factorial test experiments were applied in
this research work. The results were used to determine the optimum conditions
in terms of low foam bulk density and high cell density. The results showed that
enhanced cell structure can be achieved at a larger part thickness and adjusting
the secondary gate to an optimum thickness. The conclusions revealed that
part thickness and secondary gate width were the most influential factors on
reduction of relative density and part weight.

Keywords: Foam injection molding, Relative density, Cell population density, Over-
flow cavity, Mold design

INTRODUCTION
Injected molded thermoplastic structural foams represent an important class
of materials with a structure consisting of a cellular core sandwiched between

1 PhD. student
∗The author to which the correspondence should be

addressed: [email protected]
©Smithers Rapra Technology, 2014

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

two un-foamed skins. This structure exhibits higher specific mechanical and
physical properties and advantages such as sound absorption, insulation, light
weight, low shrinkage and sink marks. Furthermore, improved dimensional
stability and closer tolerances, and lower cost (through lower material
consumption, injection and clamping pressure) are other merits [1-6].
The effect of injection process conditions on foam structure and reduction of
relative density was studied by Phannschmidt and Michaeli [7]. Their results
showed that as barrel temperature and injection speed increased, the relative
density of molded part decreased about 50%. Also heterogeneous bubble
distribution was noticed at a higher mold temperature.
Muller and Ehrenstein [8] modified a standard injection-molding equipment
to manufacture foamed parts with a density reduction about 50% in mold-
opening method. They reported that at 4 and 5mm starting thickness, the
weight reduction was in the range between 15 and 30%, hence, the expansion
ratio between 100 and 125% was a safe region for processing. At a higher
expansion ratio (125%), a further increase of stiffness was not observed in
all cases.
Hwang et al. [9] studied the influence of process variables on mechanical
properties of microcellular injection molded PC foams. They found that a
better cell structure was achievable at higher injection speeds where they
achieved a 40% reduction of part weight.
Behravesh and Rajabpour [10] studied the effect of shot size on microstructure
injection molding foams. High Impact Polystyrene (HIPS) and N2 were used
as polymeric material and blowing agent, respectively. They indicated that
the formation and growth of cells strongly depends on the shot size. A
characteristic diagram was introduced showing the inter-relationship of shot
size, foam expansion and mold filling. They achieved an expansion ratio of
1.2 in their research.
Sporrer and Altstadt [11] studied the influence of mold design and processing
parameters on morphology of injection molded foams. The influences of
four processing parameters, namely, mold opening distances, cavity surface
temperature, breathing delay time and melt temperature were investigated.
They examined the structural properties of the foamed parts such as surface
finish, overall bulk density, and skin layer-thickness. Their results showed
that mold cavity surface temperatures could limit the degradation of the
surface finish. A thicker skin layers promoted the higher mechanical values
and stiffness of structural foams.
Carlos Tovar-Cisneros et al. [12] studied the influence of mold temperature
on average cell dimension, cell density, and skin thickness ratio of HDPE

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 Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

structural foams produced via an injection molding process. The mechanical

properties (impact strength and flexural moduli) of foamed parts were tested.
Their results showed that symmetrical skin thicknesses can be obtained with
a homogeneous temperature distribution of the mold plates. Increase in skin
thickness, decrease in cell density, and a slight increase in average cell size
were noticed when the mold temperature decreased. Also the impact strength
and flexural moduli of the structural foams increased with increasing the skin
thickness.
Rezavand et al. [13] studied the microstructural and mechanical properties of
injection molded microcellular foamed parts. They found that relative density
and skin thickness decreased by increasing injection pressure and mold
temperature. Also the relative bulk density and skin thickness were increased
at higher shot sizes.

PROPOSED MOLD DESIGN

In this study a special mold was designed to adopt an innovative method to
promote a larger expansion in manufacture of plastic foamed parts in injection
molding process. The idea in mold design was based on the effective methods of
counter-pressure and mold opening and the experiences in WAIM process [14, 15].
In the counter pressure method, the polymer melt is maintained under pressure
in the mold during injection with an inert gas in a sealed mold. Therefore, the
formation of foam bubbles at the melt front is suppressed and the gas remained
dissolved in the polymer melt. On the other hand counter pressure can also aid
in keeping unwanted volatiles from breaking through the flow front. The high
pressure could prevent early and uneven cell growth which could promote cell
coalescence [10, 13]. Therefore smaller cells sizes are obtained [16].
In the mold opening stroke process, the cavity is filled nearly completely with
the polymer-gas solution during injection. After the injection step, the mold
cavity is opened for a short stroke so that the thickness of the cavity increases
by 50-150%. Packing pressure is omitted in this method. Consequently,
the cavity pressure rapidly reduces while the core material is still at a high
temperature and more space is available for foam expansion. These conditions
enhance the bubble nucleation and permit cell growth to achieve a fine cell
structure of polymer foams.
Fluid Assisted Injection Molding technology (Water Assisted Injection
Molding WAIM and Gas Assisted Injection Molding GAIM) is one of the
plastic manufacturing technologies which are able to produce components
of complicated forms. The concept of the WAIM technology and that of GAIM

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

technology is similar. The manufacture procedure of both is first injecting the

molten plastic into the mold, so as not filling it up completely but forming
the condition of short-shot. Next, a pressurized liquid will be poured into
the mold through the liquid injection nozzle to push forward the polymer
until it fills up the mold cavity. The advantages also include: saving material,
ability to produce complex parts consisting of both thick and thin sections,
less shrinkage and warpage, sink mark and especially better surface quality
without compromising part properties.
Combining the concepts in the three above practiced methods, a mold
was designed consists of a main cavity, a secondary gate and an over-flow
channel. Specification of the secondary gate, implemented between the cavity
and over-flow channel, plays an important role in foam development. The
hypothesis is that upon mold filling and foam expansion, the escaped gas
followed by the expanding foam, which tends to flow through the secondary
gate into the over-flow channel, creates pressure inside the mold cavity
(unfilled portion). This pressure is applied on the body of the foam inside the
main cavity (filled portion), simulating the counter pressure effect. Besides,
the over-flow channel plays the role of “mold opening” mechanism where a
more space is allocated for foam expansion. Thus, it is expected that, with
implementing the over-flow channel via the secondary gate, further expansion
along with a more uniform cell structure can be achieved.

EXPERIMENTATION

Materials and Equipment

The material used for the experiments was general propose polystyrene grade
TAITAREX- GPPS 861 N, ), manufactured by Taita Chemical Co, an amorphous
thermoplastics with a density of 1.04 g/cm3 and a melt index of 7 g/10 min
(ASTMD 1238). A conventional laboratory 70-ton injection molding machine
was utilized and modified to produce cellular injection foamed specimens
parts. Main changes included design and manufacture of screw and a shut-
off nozzle in order to control pressure drop profile [10, 13]. Figure 1 shows
a Schematic experimental setup of injection molding system implemented
in this study. The needle shut-off nozzle, installed at the head of the barrel,
was maintained closed during feeding stage and was opened at the injection
stage. Azidocarbonamide (ADCA) was used as the chemical blowing agent.
Its decomposition temperature ranges between 200 and 210°C. A rectangular
plate mold with variable thicknesses (3.2, 6, 9 and 15 mm) was designed for
the experiments as depicted in Figure 2.

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 Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

Figure 1. Schematic experimental setup of injection molding system implemented in

this study

(a)

(b)

Figure 2. Designed and manufactured sheet mold used in the experiments. (a). layout
of the designed mold cavity, gate, an over-flow cavity, (b) manufactured mold

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

Figure 3. Schematic diagram of the specimen preparation for bulk density

measurements and SEM analysis

Procedure
Full factorial test experiments were conducted for the three selected processing
parameters namely blowing agent amount (0.5, 1.5, and 2.5 wt%), secondary
gate width (closed gate, 3.5, 7, and 14 mm), and part thickness (3.2, 6, 9 and
15 mm). The total number of data points was then 48 (Table 1). The fixed
parameters for these experiments are given in Table 2. To obtain confident
data, at least three specimens were tested for each data point after a steady
process was reached. A water circulation system was used for cooling mold
temperature. The mold temperature was fixed 20°C and measured via two
thermocouples placed at both sides of the mold. Material was dried at 80°C
for 12 hour before processing. The melt temperature was set at 240°C at all
experiments. The delay time between the start of linear motion of screw and
opening the shutoff nozzle, was controlled using an electronic timer. A fixed
delay time of two seconds was set at all experiments. The melt temperature
was maintained and frequently checked with a laser perimeter before injection.

MEASUREMENTS
To measure bulk density and cell population density, samples were cut at the
three different positions, near the gate, middle, and far from the gate of the
specimens, as shown in Figure 2. The samples were about 15×10 mm in size.
The foamed samples were immersed in liquid nitrogen for 20 min and then

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 Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

Table 1. Selected processing conditions for the experiments

Experiment Part Blowing Gate Relative Expansion Cell
No. thickness agent width bulk ratio volume
(mm) (wt%) (mm) density fraction
(g/cm3)
1 3.2 0.5 Closed 0.91 1.14 0.13
gate
2 3.2 0.5 3.5 0.82 1.26 0.22
3 3.2 0.5 7 0.76 1.36 0.28
4 3.2 0.5 14 0.84 1.23 0.2
5 3.2 1.5 Closed 0.85 1.22 0.19
gate
6 3.2 1.5 3.5 0.7 1.48 0.34
7 3.2 1.5 7 0.66 1.57 0.38
8 3.2 1.5 14 0.75 1.38 0.29
9 3.2 2.5 Closed 0.78 1.33 0.26
gate
10 3.2 2.5 3.5 0.68 1.52 0.36
11 3.2 2.5 7 0.61 1.7 0.43
12 3.2 2.5 14 0.7 1.47 0.33
13 6 0.5 Closed 0.82 1.26 0.22
gate
14 6 0.5 3.5 0.74 1.4 0.3
15 6 0.5 7 0.65 1.6 0.39
16 6 0.5 14 0.76 1.36 0.28
17 6 1.5 Closed 0.73 1.42 0.31
gate
18 6 1.5 3.5 0.67 1.55 0.37
19 6 1.5 7 0.62 1.67 0.42
20 6 1.5 14 0.71 1.46 0.33
21 6 2.5 Closed 0.64 1.62 0.4
gate
22 6 2.5 3.5 0.58 1.79 0.46
23 6 2.5 7 0.5 2.08 0.54
24 6 2.5 14 0.6 1.72 0.43
25 9 0.5 Closed 0.75 1.38 0.29
gate
26 9 0.5 3.5 0.62 1.67 0.42
27 9 0.5 7 0.56 1.85 0.48
28 9 0.5 14 0.65 1.6 0.39

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Table 1. Cont'd...
Experiment Part Blowing Gate Relative Expansion Cell
No. thickness agent width bulk ratio volume
(mm) (wt%) (mm) density fraction
(g/cm3)
29 9 1.5 Closed 0.7 1.48 0.34
gate
30 9 1.5 3.5 0.58 1.79 0.46
31 9 1.5 7 0.53 1.96 0.51
32 9 1.5 14 0.63 1.65 0.41
33 9 2.5 Closed 0.61 1.7 0.43
gate
34 9 2.5 3.5 0.54 1.92 0.5
35 9 2.5 7 0.48 2.16 0.56
36 9 2.5 14 0.59 1.76 0.45
37 15 0.5 Closed 0.71 1.46 0.33
gate
38 15 0.5 3.5 0.56 1.85 0.48
39 15 0.5 7 0.51 2.03 0.53
40 15 0.5 14 0.55 1.89 0.49
41 15 1.5 Closed 0.65 1.6 0.39
gate
42 15 1.5 3.5 0.49 2.11 0.54
43 15 1.5 7 0.43 2.4 0.6
44 15 1.5 14 0.5 2.06 0.53
45 15 2.5 Closed 0.56 1.85 0.48
gate
46 15 2.5 3.5 0.45 2.31 0.59
47 15 2.5 7 0.42 2.47 0.61
48 15 2.5 14 0.48 2.16 0.56

Table 2. Fixed processing conditions for the experiments

Injection Melt Delay of Mold Injection Shot size depending on part
nozzle temp. opening temp. pressure thickness
diameter (°C) nozzle (s) (ºC) (MPa) 3.2 mm 6 mm 9 mm 15 mm
(mm)
4 240 2 20 60 85% 75% 65% 55%

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fractured. The fractured surfaces were gold coated and then examined using
a scanning electron microscope (SEM, model Philips XL-30) at an acceleration
voltage of 20 kV to observe the cellular structures. Bulk density was measured
using Archimedes method. The relative bulk density, cell population density
and core density were calculated according to the following formulations,
respectively [16, 17]:

ρ 
ρr =  f 
ρ 
 p (1)

3
 n 2 ρ
N =  2  x p x1012
 L  ρc (2)

 ρ  
  ρp  1(
 f  d − e + e
2 ) 

ρc = ρp  

(
 d − e1 + e2 ) 

  (3)

where, ρr, ρf, ρp and ρc (g/cm3) are relative bulk density, density of foamed
sample, density of the un-foamed part, and core density of the foamed sample,
respectively. N (cells/cm3) is cell population density, n is cell number in a selected
L×L (μm×μm) size area of the SEM picture, d is sample thickness (3.2, 6, 9
and 15 mm in this study) and e1 and e2 are the un-foamed skin thicknesses
of the samples measured using SEM pictures. Figure 4 illustrates a sample
showing the un-foamed skin of the produced part.

Figure 4. Un-foamed skin thickness of the produced part

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

RESULTS AND DISCUSSION

Relative Density
Figure 5 depicts the effect of the parameters (secondary gate width, part
thickness and CBA wt. %) on the average relative density. As it is seen the
relative density decreased rather sharply when the secondary gate was
open and its width increased to 3.5 and 7 mm and then slightly increased
with further increasing the gate width to 14 mm. The graphs suggest that
existence of the secondary gate enhances the foam expansion. Besides, the
graphs clearly show that there is an optimum width at which the expansion
ratio is maximized (or relative density is minimized), regardless of the other
changes (part thickness and blowing agent amount). As it was presumed, the
idea of implementing an overflow channel via a secondary gate is found to
be effective in improving foam expansion in injection molding process. The
proposed phenomenon was that the overflow channel provides more space
for expansion, similar to free expansion experienced in foam extrusion. It is
known that a free expansion, as occurs in foam extrusion, creates a very large
foam expansion [18, 19, and 20]. Hence, the over follow cavity resembles the
free foam expansion.
On the other hand, the secondary gate imposes a resistance to the flow
which causes and maintains a “controlled pressure” against the flow. It must
be mentioned that, in case of closed gate (conventional molding), the system
pressure rises rapidly as the injected melt reaches the end of cavity. It has
been shown that, applying a high pressure on an under-foaming system
could hinder further nucleation and cell growth and even could cause cell
shrinkage and collapse [21, 22]. This novel approach prevents a sudden and
too high a pressure increase, which in turns, enhances the cell growth and
avoids cell shrinkage. It is also postulated that while injecting the melt into
the cavity, portion of the dissolved gas is escaped at the melt front due to a
pressure drop. The escaped gas tends to flow through the resisting secondary
gate which pressurized the gas in a controlled manner. This pressurized gas
hinders the further gas escape and thus promotes further cell nucleation,
growth and expansion. Hence, further increasing the width of secondary gate
is detrimental to the foam expansion and microstructure [23].
The result presented in Table 1 clearly indicate the effect of part thickness
on relative density and foam expansion; the larger the thickness, the larger
the expansion ratio. Part No. 47 exhibited the minimum relative density. This
is attributed to the favorable the largest part thickness (15 mm), a medium
gate width of 7 mm and the highest CBA wt%. Also the results show that

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 Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

Figure 5. Effect of variable parameters on relative density. (a) CBA: 0.5 wt%, (b) CBA:
1.5 wt% and (c) CBA: 2.5 wt%

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

the foam density decreases with increasing blowing agent content down to
a minimum where further increase has negligible effect on the foam density.
Increasing the blowing agent increases the amount of gas dissolved into the
polymer, up to a point where saturation occurs. It also increases the number
of nucleation sites in the molten polymer, which in turn increases the number
of cells in the molten polymer [24].

Un-foamed skin thickness

Figure 6 shows the SEM micrographs of the produced specimens with a
gate width of 7 mm and at various part thicknesses for Region A3 (the region
far from the gate). The figure shows the existence of two different areas as
the core and skin, i.e. a sandwich structure, within the molded parts. Skin
thickness was measured for both sides of each sample to obtain the total
skin thickness and to calculate the total skin ratio (total skin thickness over
the total sample thickness).
The reason for the solid skin layer is assumed to be that the growth of the
gas cell is hampered by the rapid cooling of the mold near the surface. Thus
the melt viscosity increases and as a result, a large resistance against cell
growth and less time available growth time before solidification are promoted

Figure 6. SEM micrographs revealing un-foamed skins of the specimens for various
part thicknesses. (a) 3.2 mm, (b) 6 mm (c) 9 mm and (d) 15 mm (gate width: 7 mm,
CBA: 2.5 wt%)

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[25, 26]. At a lower mold temperature, because of the higher temperature

difference between the core and the surface, heat transfer rates are increased
which yields thicker skin layers [27]. The effect of gate width on the cellular
structure is represented in Figure 7. It shows the un-foamed skin thickness
at the three selected regions and their average value for each injected part.
It is evident that increasing the gate width up to 7mm leads to a decrease in
skin thickness and then increases: 700, 600, 500 and 660 μm at closed gate
3.5, 7 and 14 mm, respectively (part thickness: 15 mm and CBA 2.5 wt%).
Interestingly, the minimum thickness occurs at the gate width of 7 mm, similar
to the bulk density discussed earlier. It must be mentioned that depends on
the application, the existence and the thickness of the skin layer might be
favorable. However, regarding the objective of this research, namely weight
reduction, a minimum skin layer seems to be more favorable.
As seen in Figure 7, increasing blowing agent decreases the skin thickness,
although, the decrease was not proportional to the five-fold increase in the
amount of blowing agent. This result can be attributed to the decrease in
viscosity at the higher amount of blowing agent (plasticizing effect). The viscosity
of molten polymer decreases with increasing blowing agent concentrations due
to higher free volume fraction in the polymer matrix. Melt viscosity has also
been reported to have a strong effect on the skin layer thickness [28, 29]. In
addition, higher amounts of blowing agent increase the number of nucleating
agent particles (chemical blowing agent decomposition residues), which leads
to an easier cell nucleation in the molten polymer. Because cells are nucleated
faster, this can occur more rapidly than the polymer solidification, creating a
thicker foamed core and decreasing the skin thickness.
Figure 8 shows the effect of variable parameters on the un-foamed skin
thicknesses. It was noticeable that the minimum skin thickness was observed
in Parts No. 47 that was produced with 7 mm of gate width and part thickness
of 15 mm. In contrast, maximum skin thickness was formed in Parts No. 1 that
was injected with the closed gate and 3.2 mm of part (Table 3). At the higher
part thickness, the skin thickness is decreased due to the slower cooling rate
at the mold wall promoted by the prolonged cooling of the hot core.

Cell Population Density

The calculated average cell population density of the molded parts is shown
in Figure 9. Regarding the figure and Table 4, the cell population density
shows an increase when the secondary gate width increases to 7 mm and
then decreases at the larger s. gate width for all the injected part thicknesses.
The effect of gate width on cell population density is clearly displayed in

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

Figure 7. Effect of CBA wt% on Un-foamed skin thickness. (a) CBA: 0.5 wt%, (b) CBA:
1.5 wt% and (c) CBA: 2.5 wt% (part thickness: 3.2 mm)

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Table 3. Un-foamed skin thickness at the three selected regions of

the specimens (according to Figure 2)
Part Part Blowing Gate Region 1 Region 2 Region 3 Average
No. thickness agent width (μm) (μm) (μm) (μm)
(mm) (wt%) (mm)
1 3.2 0.5 Closed 700 750 750 730
gate
2 3.2 0.5 3.5 600 550 700 620
3 3.2 0.5 7 550 500 600 550
4 3.2 0.5 14 650 600 700 650
5 3.2 1.5 Closed 650 600 700 650
gate
6 3.2 1.5 3.5 550 520 600 480
7 3.2 1.5 7 500 450 500 480
8 3.2 1.5 14 600 560 550 570
9 3.2 2.5 Closed 500 520 550 520
gate
10 3.2 2.5 3.5 380 350 400 380
11 3.2 2.5 7 450 350 380 390
12 3.2 2.5 14 400 400 450 420
13 6 0.5 Closed 850 800 850 830
gate
14 6 0.5 3.5 700 760 750 740
15 6 0.5 7 650 650 700 667
16 6 0.5 14 760 700 800 750
17 6 1.5 Closed 750 800 800 780
gate
18 6 1.5 3.5 660 600 700 650
19 6 1.5 7 600 500 670 590
20 6 1.5 14 700 700 850 750
21 6 2.5 Closed 600 680 700 660
gate
22 6 2.5 3.5 600 550 600 580
23 6 2.5 7 500 450 500 480
24 6 2.5 14 560 600 650 600
25 9 0.5 Closed 1100 1000 1150 1080
gate
26 9 0.5 3.5 950 900 1000 950
27 9 0.5 7 800 800 850 820
28 9 0.5 14 1000 1050 1100 1050

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

Table 3. Cont'd...
Part Part Blowing Gate Region 1 Region 2 Region 3 Average
No. thickness agent width (μm) (μm) (μm) (μm)
(mm) (wt%) (mm)
29 9 1.5 Closed 1000 1100 1000 1030
gate
30 9 1.5 3.5 800 900 900 870
31 9 1.5 7 700 650 800 720
32 9 1.5 14 900 950 1150 1000
33 9 2.5 Closed 800 950 900 880
gate
34 9 2.5 3.5 700 800 800 770
35 9 2.5 7 650 600 700 650
36 9 2.5 14 750 800 850 800
37 15 0.5 Closed 900 900 950 920
gate
38 15 0.5 3.5 800 750 800 780
39 15 0.5 7 740 700 600 680
40 15 0.5 14 860 650 850 790
41 15 1.5 Closed 750 800 900 820
gate
42 15 1.5 3.5 70 650 760 700
43 15 1.5 7 600 550 640 600
44 15 1.5 14 750 700 800 750
45 15 2.5 Closed 700 700 800 750
gate
46 15 2.5 3.5 600 540 600 580
47 15 2.5 7 500 430 500 480
48 15 2.5 14 660 600 700 650

the figure. The highest cell population density was produced in Part No. 47
that was injected with a gate width of 7 mm and part thickness of 15 mm.
It indicates that fact there is an optimum gate width which could produce
part with a higher cell population density. Interestingly, again, this s. gate
thickness shows the most desirable foam characteristics as indicated earlier.
Also the figure shows that the part thickness is one of the most important
influencing factors on cell population density. This is because a larger space
for cell growth and expansion is available which resembles free expansion
in an extrusion foaming process.

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Figure 8. Effect of blowing agent amount on the un-foamed skin at various gate width
and part thicknesses

Figure 9. Effect of gate width on cell population density at various part thicknesses and
CBA wt%

Figure 9 also indicates that the cell population density is marginally increased
as CBA amount is increased from 0.5 wt% to 2.5 wt%. The plasticizing effect
of blowing agent reduces the melt viscosity which promotes the cell nucleation.
However, since a large portion of dissolved gas escapes while entering the
mold cavity, the effectiveness of increase in the amount of blowing agent is
compromised. Adding that, lower viscosity due to the increase in amount
of blowing agent, promotes the gas escape phenomenon [30]. As a result,
much lower gas is available for cell nucleation and growth compared to the
five-fold increase in the blowing agent amount.

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Ahmad Zia Ahmadzai and Amir Hossein Behravesh

Table 4. Cell population density at the three selected regions and

their average value for each injected part (according to Figure 2)
Part Part Blowing Gate Region Region Region Average
No. thickness agent width 1 (cells/ 2 (cells/ 3 (cells/ (cells/
(mm) (wt%) (mm) cm3) cm3) cm3) cm3)
1 3.2 0.5 Closed 3.50E+06 4.50E+06 3.90E+06 4.00E+06
gate
2 3.2 0.5 3.5 1.00E+07 1.70E+07 1.40E+07 1.40E+07
3 3.2 0.5 7 1.60E+07 2.30E+07 2.10E+07 2.00E+07
4 3.2 0.5 14 6.50E+06 9.80E+06 8.60E+06 8.30E+06
5 3.2 1.5 Closed 4.30E+06 5.80E+06 4.70E+06 4.90E+06
gate
6 3.2 1.5 3.5 1.30E+07 1.70E+07 1.50E+07 1.50E+07
7 3.2 1.5 7 1.90E+07 2.80E+07 2.20E+07 2.30E+07
8 3.2 1.5 14 7.00E+06 1.60E+07 9.00E+06 1.10E+07
9 3.2 2.5 Closed 1.50E+07 2.20E+07 1.70E+07 1.80E+07
gate
10 3.2 2.5 3.5 2.00E+07 2.50E+07 2.30E+07 2.30E+07
11 3.2 2.5 7 2.60E+07 3.00E+07 2.60E+07 2.70E+07
12 3.2 2.5 14 1.20E+07 2.00E+07 1.30E+07 1.50E+07
13 6 0.5 Closed 2.00E+07 2.80E+07 2.60E+07 2.50E+07
gate
14 6 0.5 3.5 3.00E+07 3.90E+07 3.50E+07 3.50E+07
15 6 0.5 7 3.50E+07 4.60E+07 4.00E+07 4.00E+07
16 6 0.5 14 2.90E+07 3.60E+07 3.30E+07 3.30E+07
17 6 1.5 Closed 2.50E+07 2.90E+07 2.70E+07 2.70E+07
gate
18 6 1.5 3.5 3.30E+07 4.60E+07 3.70E+07 3.90E+07
19 6 1.5 7 4.20E+07 4.60E+07 4.50E+07 4.40E+07
20 6 1.5 14 3.50E+07 3.80E+07 3.80E+07 3.70E+07
21 6 2.5 Closed 2.70E+07 3.30E+07 2.90E+07 3.00E+07
gate
22 6 2.5 3.5 3.70E+07 4.80E+07 4.00E+07 4.20E+07
23 6 2.5 7 4.30E+07 5.00E+07 4.20E+07 4.50E+07
24 6 2.5 14 3.40E+07 4.30E+07 4.00E+07 3.90E+07
25 9 0.5 Closed 3.00E+07 3.70E+07 3.80E+07 3.50E+07
gate
26 9 0.5 3.5 4.60E+07 4.90E+07 4.80E+07 4.80E+07
27 9 0.5 7 4.80E+07 5.70E+07 5.50E+07 5.30E+07
28 9 0.5 14 4.10E+07 4.70E+07 4.50E+07 4.40E+07

38 Cellular Polymers, Vol. 33, No. 1, 2014

 Bulk Density Reduction of Injection Molded Thermoplastic Foams via a Mold Design Approach

Table 4. Cont'd...
Part Part Blowing Gate Region Region Region Average
No. thickness agent width 1 (cells/ 2 (cells/ 3 (cells/ (cells/
(mm) (wt%) (mm) cm3) cm3) cm3) cm3)
29 9 1.5 Closed 3.70E+07 3.90E+07 3.80E+07 3.80E+07
gate
30 9 1.5 3.5 4.30E+07 5.80E+07 4.60E+07 4.90E+07
31 9 1.5 7 5.30E+07 5.80E+07 5.60E+07 5.60E+07
32 9 1.5 14 4.30E+07 4.80E+07 4.70E+07 4.60E+07
33 9 2.5 Closed 4.00E+07 4.70E+07 4.30E+07 4.30E+07
gate
34 9 2.5 3.5 4.40E+07 6.50E+07 5.00E+07 5.30E+07
35 9 2.5 7 5.80E+07 6.10E+07 5.90E+07 5.90E+07
36 9 2.5 14 4.30E+07 5.50E+07 4.70E+07 4.80E+07
37 15 0.5 Closed 3.70E+07 4.70E+07 4.60E+07 4.30E+07
gate
38 15 0.5 3.5 5.30E+07 5.60E+07 5.70E+07 5.50E+07
39 15 0.5 7 6.00E+07 6.60E+07 6.20E+07 6.30E+07
40 15 0.5 14 4.90E+07 5.50E+07 5.20E+07 5.20E+07
41 15 1.5 Closed 4.60E+07 4.70E+07 4.60E+07 4.60E+07
gate
42 15 1.5 3.5 5.30E+07 6.10E+07 5.70E+07 5.70E+07
43 15 1.5 7 6.40E+07 7.20E+07 7.1E+07 6.90E+07
44 15 1.5 14 5.00E+07 5.90E+07 5.60E+07 5.50E+07
45 15 2.5 Closed 4.80E+07 5.00E+07 4.60E+07 4.80E+07
gate
46 15 2.5 3.5 6.00E+07 6.80E+07 6.40E+07 6.40E+07
47 15 2.5 7 7.60E+07 8.00E+07 7.20E+07 7.60E+07
48 15 2.5 14 5.20E+07 6.70E+07 5.70E+07 5.90E+07

CONCLUSIONS
An experimental investigation was conducted to study the effect of mold design
and process parameters on the development of foam expansion in injection
molded parts. The main focuses was based on the reduction of relative density
and foam expansion ratio in injection foam molding. A rectangular mold was
designed and manufactured with a variable thickness consisting of a main
cavity and an over-flow cavity. A secondary gate connecting the main and
over-flow cavities with various width was implemented to vary the intensity of
the controlling phenomena, namely mold opening and counter-pressure. The

Cellular Polymers, Vol. 33, No. 1, 2014 39

Ahmad Zia Ahmadzai and Amir Hossein Behravesh

over-flow cavity has been found to be also effective in further coring out the
injected part produced in fluid assisted injection molding. The effect of gate
width, part thickness and CBA wt% on foam development was investigated.
The results concluded the following:
1. Implementing the overflow well and the secondary gate were found to
be highly effective in reduction of bulk density.
2. Bulk density and un-foamed skin thickness decreased and the cell
population density increased as the secondary gate widths were used.
3. There exists an optimum s. gate width at which the foam characteristics,
namely, bulk density, cell population density, are more favorable. It
can be suggested that there is two mechanisms that affect the foam
expansion in injection molding: free expansion and gas escape, both
promoted by larger width of the secondary gate.
4. Bulk density (expansion ratio) and cell morphology are strongly
depending on part thickness. Finer and more uniform cell structure was
formed at a larger part thickness.
5. A higher amount of blowing agent (2.5 wt. %) results in parts with a
larger expansion. However, compared with the five-fold increase in CBA
amount, the increase in part expansion was not impressive.

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