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17 Foaming

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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suhas deshpande
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© Attribution Non-Commercial (BY-NC)
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545 views32 pages

17 Foaming

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.

Uploaded by

suhas deshpande
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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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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