A 1.25" segmented single screw extruder was custom designed and used for foaming polystyrene with physical blowing agent such as carbon dioxide, nitrogen, and argon. The type of gas, the pressure, nucleating agents, and the extrusion conditions were found to be of significant importance affecting density cell size, cell size distribution, and foam stability. The lowest density achieved was3 lbs/cu.ft. Melt pressure oscillation was found to be a problem, which could be addressed by the addition of talc or endothermic nucleating agents.
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