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Foaming

Foaming. MFG 355. Foaming Overview. Processes to create foams Mechanical, Chemical, Physical, Syntactic (hollow spheres) Processes to shape and solidify foams Molding, RIM, Foam-in-place, Extrusion, Casting, Expanded foam molding Rebond materials Foam product characteristics. Foaming.

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Foaming

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  1. Foaming MFG 355

  2. Foaming Overview • Processes to create foams • Mechanical, Chemical, Physical, Syntactic (hollow spheres) • Processes to shape and solidify foams • Molding, RIM, Foam-in-place, Extrusion, Casting, Expanded foam molding • Rebond materials • Foam product characteristics

  3. Foaming • Mechanical foaming • Mix air into the resin while in a liquid state • Plastisols, vinyl esters, urea formaldehydes, phenolics, polyesters

  4. Foaming • Mechanical foaming • Mix air into the resin while in a liquid state • Plastisols, vinyl esters, urea formaldehydes, phenolics, polyesters Phenolic foam Phenolic foam Polyester foam

  5. Foaming • Chemical foaming • Foaming agents or blowing agents • Chemical reaction that forms a gas/vapor Bread (yeast foam) Urethane foam

  6. Foaming • Physical foaming • Gas is forced into a liquid or molten resin • Pressure is released quickly • Foam is created Shaving cream

  7. Foaming • Syntactic foams • Physically mix in hollow beads • Beads are usually glass or plastic • Wide density capability

  8. Foams • Self-healing plastics • Beads filled with reactive resin • Initiator (catalyst) mixed into the surrounding plastic • Beads crack under pressure of crack growth

  9. Self-healing foams

  10. Processes to Shape and Solidify Foams • Molding • RIM • Foam-in-place • Extrusion • Casting • Expanded foam molding (EPS) • Rebond

  11. Foam Molding Foam Inlet Expandable Mold Fill Position Liquid Resin with Foaming Agent

  12. Foam Molding Foam Inlet Expandable Mold Expanded Position Liquid Resin with Foaming Agent

  13. Molded foams

  14. Reaction Injection Molding Foaming Agent Resin Part A Resin Part B Foamed Part In-line Mixer Mold

  15. RIM

  16. Foam-in-place Foaming Injector Nozzle Refrigerator Walls Foam

  17. Extrusion Foaming Paper Saw Extruder (Resin and Foaming Agent) Belt Drive Expanded Foam Paper

  18. Extrusion foam line

  19. Casting Foams Expanded Foam Open Pan Resin and Foaming Agent

  20. Casting Foams • Skiving the Foamed Bun

  21. Foam Spraying • Foaming agents mixed as they exit the spray nozzle

  22. Expanded Foam Molding • PS is the standard material used • Can be done with PP or PE as well

  23. Expanded Foam Molding Storage Expansion Chamber Tiny Beads Part Mold Expanded Unexpanded Steam or Hot Air Steam or Hot Air

  24. EPS beads

  25. EPS

  26. Rebond • Scrap from other foaming processes • Ground/chopped up • Molded into sheets

  27. Material Considerations for Foamed Parts • Most thermoplastic and thermoset materials can foamed by one or more of the methods • The most commonly foamed resins are PVC, Polyurethane, PS, PE, PP, Epoxy Phenolic, ABS, Ureaformaldehyde, Silicone, Ionomers and Cellulose Acetates

  28. Foam Applications • Strength to weight ratios • Thermal insulation (Celestia product) • Energy absorption • Load bearing

  29. Energy Transmitted Natural vibration frequency Energy (g's) Frequency (Hz) Truck = 4-6, 12-14/ Train = 2-7, 50-70/ Ship = 2-20; Airplane = 1-3, 25-200

  30. Load bearing Polyurethane foam Natural rubber foam Stress Vinyl foam Strain

  31. Compression Set

  32. Thank You

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