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    17 Foaming

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    suhas deshpande
    This document discusses various foaming processes and applications of foams. It describes four main types of foaming processes: mechanical, chemical, physical, and syntactic. It then outlines different shaping and solidification processes like molding, RIM, and extrusion. Finally, it discusses characteristics of foamed products and some common applications where foams provide benefits like strength to weight ratios, thermal insulation, energy absorption, and load bearing.

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    17 Foaming

    Uploaded by

    suhas deshpande
    472 views32 pages
    This document discusses various foaming processes and applications of foams. It describes four main types of foaming processes: mechanical, chemical, physical, and syntactic. It then outlines different shaping and solidification processes like molding, RIM, and extrusion. Finally, it discusses characteristics of foamed products and some common applications where foams provide benefits like strength to weight ratios, thermal insulation, energy absorption, and load bearing.

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    Very good plastic technology presentations

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    This document discusses various foaming processes and applications of foams. It describes four main types of foaming processes: mechanical, chemical, physical, and syntactic. It then outlines different shaping and solidification processes like molding, RIM, and extrusion. Finally, it discusses characteristics of foamed products and some common applications where foams provide benefits like strength to weight ratios, thermal insulation, energy absorption, and load bearing.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    472 views32 pages

    17 Foaming

    Uploaded by

    suhas deshpande
    This document discusses various foaming processes and applications of foams. It describes four main types of foaming processes: mechanical, chemical, physical, and syntactic. It then outlines different shaping and solidification processes like molding, RIM, and extrusion. Finally, it discusses characteristics of foamed products and some common applications where foams provide benefits like strength to weight ratios, thermal insulation, energy absorption, and load bearing.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 32
    At a glance
    Powered by AI
    The key takeaways are that there are various processes to create and shape foams including mechanical, chemical, physical and syntactic foaming. Common materials that can be foamed include thermoplastics and thermosets like PVC, polyurethane, PS, PE, PP, epoxy and phenolic. Some common applications of foams include providing strength to weight ratios, thermal insulation, energy absorption and load bearing.

    The main processes used to create foams are mechanical foaming by mixing air into the resin while liquid, chemical foaming using foaming agents or blowing agents, and physical foaming by forcing gas into a liquid or molten resin under pressure.

    Some common materials that can be foamed include PVC, polyurethane, PS, PE, PP, epoxy phenolic, ABS, ureaformaldehyde, silicone, ionomers and cellulose acetates.

    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
    • Mechanical foaming
    – Mix air into the resin while in a liquid state
    – Plastisols, vinyl esters, urea formaldehydes,
    phenolics, polyesters
    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
    Foaming
    • Chemical foaming
    – Foaming agents or blowing agents
    – Chemical reaction that forms a gas/vapor

    Bread (yeast foam)


    Urethane foam
    Foaming
    • Physical foaming
    – Gas is forced into a liquid or molten resin
    – Pressure is released quickly
    – Foam is created

    Shaving cream
    Foaming
    • Syntactic foams
    – Physically mix in hollow beads
    – Beads are usually glass or plastic
    – Wide density capability
    Foams
    • Self-healing plastics
    – Beads filled with reactive resin
    – Initiator (catalyst) mixed into
    the surrounding plastic
    – Beads crack under pressure of
    crack growth
    Self-healing foams
    Processes to Shape and Solidify
    Foams
    • Molding
    • RIM
    • Foam-in-place
    • Extrusion
    • Casting
    • Expanded foam molding (EPS)
    • Rebond
    Foam Molding
    Foam Inlet

    Expandable Mold
    Fill Position

    Liquid Resin with


    Foaming Agent
    Foam Molding
    Foam Inlet

    Expandable Mold
    Expanded Position

    Liquid Resin with


    Foaming Agent
    Molded foams
    Reaction Injection Molding
    Foaming Agent

    Resin
    Part A

    Resin In-line Foamed


    Part B Mixer Part

    Mold
    RIM
    Foam-in-place
    Foaming Injector
    Nozzle

    Refrigerator Walls

    Foam
    Extrusion Foaming

    Paper

    Saw

    Extruder
    (Resin and Foaming
    Agent)

    Belt Drive

    Paper Expanded Foam


    Extrusion foam line
    Casting Foams
    Expanded
    Foam

    Open Pan

    Resin and
    Foaming Agent
    Casting Foams
    • Skiving the Foamed Bun
    Foam Spraying
    • Foaming agents mixed as they exit the
    spray nozzle
    Expanded Foam Molding
    • PS is the standard material used
    • Can be done with PP or PE as well
    Expanded Foam Molding

    Storage

    Tiny Beads
    Expansion
    Chamber

    Part

    Mold

    Unexpanded Expanded Steam or Hot Air


    Steam or Hot Air
    EPS beads
    EPS
    Rebond
    • Scrap from other foaming processes
    • Ground/chopped up
    • Molded into sheets
    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
    Foam Applications
    • Strength to weight ratios
    • Thermal insulation (Celestia product)
    • Energy absorption
    • Load bearing
    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
    Load bearing

    Polyurethane foam

    Natural rubber foam

    Stress

    Vinyl foam

    Strain
    Compression Set
    Thank You

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