The Structural Foam method could be a depression injection molding process wherever associate degree element is introduced into liquid compound for the aim of reducing density and therefore weight of the finished product.
Structural foam shaped merchandise have cellular cores encircled by rigid, integral skins. Foaming agent (NI, greenhouse gas or CBA) is introduced into the compound soften stream, making a standardized mixture of compound and gas.
The mixture is short-shot injected through nozzles into the mildew during a volume that's but the number needed to mold a solid half. Injection pressure and growth of the polymer/gas mixture fills the mildew.
A porous skin is made once the soften contacts the cold surface of the mildew. The increasing polymer/gas mixture forms the cellular core.
The increasing gas provides the ultimate pack and hold pressure. Once the plastic gas mixture enters the mildew cavity, the gas expands (i.e. foams), filling the cavity and forming cellular structures inside the half. The finished half is usually ten – half-hour less weight than constant solid part.
Advantages over different strategies
Part weight reduced 100% to half-hour
Density Reduction, therefore organic compound savings
Low value N2 or greenhouse gas – a lot of more cost-effective than chemical processing agents (CBA’s)
Large half molding with low clamp force necessities
Mold Cavity Pressure; usually two hundred – 600 psi ( fourteen -41 Bar )
Lower energy prices vs. different IM processes
Lower value metallic element molds vs. high IM machines
Faster cycles because of higher heat transfer of metallic element
Thick wall elements from zero.125″ – 0.500″ ( three – twelve millimeter )
Stiffer elements at a similar weight as IM as a results of cellular foam structure
Complex elements while not sink marks
Higher impact strength than dilutant wall IM
Parts are often sawn, screwed, nailed or pinned like wood
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