Novel Design Concepts for Rotational Molding of Integral-skin Cellular Polymeric Composites

Abstract

Conventional rotational foam molding, a modification of the traditional rotational molding (or rotomolding) process, has lately been brought into being a distinct plastic processing technology. It is characterized with very lengthy processing times and intensive energy consumption. A recently developed and patented, melt extrusion-assisted rotational foam molding process, referred to as Rapid Rotational Foam Molding (RRFM), has been instrumental in increasing the eco-friendliness of rotational molding operations by dramatically reducing processing cycle times and energy consumption. This paper focuses on identifying possible novel processing concepts that would improve further melt extrusion-assisted rotational foam molding operations. Currently, pioneering attempts are being made to successfully apply physical blowing agents (PBAs) in RRFM and thereby substitute commonly used chemical blowing agents (CBAs). Thereby, fabricating a new class of eco-friendly rotationally foam molded integral-skin cellular composites having ultra low-density foamed cores or layers would advantageously become possible.