Simulative study of polymeric core–shell foam particles for the enlargement of the material portfolio in 3‐D high‐frequency welding

Abstract

AbstractThe steam chest molding process is currently state of the art concerning the generation of three‐dimensional polymeric foam components made from particle foams. An adaption of the high‐frequency welding process shows advantages regarding the required energy and the used water. Due to the low dielectric loss factors of the most common foam materials (PE, PP, and PS), they cannot be heated sufficiently by an electric field. To enable heating of these foams, the particles may be coated with a second material that shows a high dielectric loss. The possible heat development of the modified particles was simulatively investigated. To ensure a realistic simulation, the properties of the used materials are analyzed beforehand. The heating simulation shows clear dependence regarding the particle size and the shell thickness. By a suitable combination, sufficient heating is achievable. For single particles, an irregular temperature distribution is calculated, mainly caused by the difference of permittivity resulting in a local variation of electrical flux density. Bigger particles and thicker shells will result in faster heating ramps and higher overall temperatures. The additional calculation regarding a particle–particle interaction shows a homogenization of the temperature distribution across the particle surface.