Abstract
Bead foam is one kind of important polymeric foam product, which has the advantages of complex product shape, a wide range of parts density, and a wide variety of available materials. Steam‐chest molding is usually used to prepare bead foams. However, it is challenging to prepare polymers with high melting point (T m) or glass transition temperature (T g). Herein, in‐mold foaming and molding technology (IMFM) is proposed to prepare bead foams from polyphenylene oxide/high‐impact polystyrene composite (PHC). PHC bead foam parts (PHCPs) with densities from 0.11 to 0.25 g cm−3 are successfully prepared by controlling the process parameters. Due to good interbead bonding, the bead foams have superior mechanical properties. The tensile and compression strength for PHCPs with a density of 0.25 g cm−3 are 2.84 and 2.93 MPa, respectively. The PHCPs also show high dimensional stability at 120 °C and good flame‐retardant properties, characterized by a high limiting oxygen index (LOI) value and HBF rating. In addition, the fabrication mechanism behind IMFM is proposed. This technology provides a new way to produce polymer bead foams, especially for engineering materials.
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