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FoamingFoamingOverviewProcessestocreatefoamsMechanical,Chemical,Physical,Syntactic(hollowspheres)ProcessestoshapeandsolidifyfoamsMolding,RIM,Foam-in-place,Extrusion,Casting,ExpandedfoammoldingRebondmaterialsFoamproductcharacteristicsFoamingMechanicalfoamingMixairintotheresinwhileinaliquidstatePlastisols,vinylesters,ureaformaldehydes,phenolics,polyestersFoamingMechanicalfoamingMixairintotheresinwhileinaliquidstatePlastisols,vinylesters,ureaformaldehydes,phenolics,polyestersPolyesterfoamPhenolicfoamPhenolicfoamFoamingChemicalfoamingFoamingagentsorblowingagentsChemicalreactionthatformsagas/vaporBread(yeastfoam)UrethanefoamFoamingPhysicalfoamingGasisforcedintoaliquidormoltenresinPressureisreleasedquicklyFoamiscreatedShavingcreamFoamingSyntacticfoamsPhysicallymixinhollowbeadsBeadsareusuallyglassorplasticWidedensitycapabilityFoamsSelf-healingplasticsBeadsfilledwithreactiveresinInitiator(catalyst)mixedintothesurroundingplasticBeadscrackunderpressureofcrackgrowthSelf-healingfoamsProcessestoShapeandSolidifyFoamsMoldingRIMFoam-in-placeExtrusionCastingExpandedfoammolding(EPS)RebondFoamMoldingFoamInletExpandableMoldLiquidResinwithFoamingAgentFillPositionFoamMoldingFoamInletExpandableMoldLiquidResinwithFoamingAgentExpandedPositionMoldedfoamsReactionInjectionMoldingFoamingAgentFoamedPartMoldIn-lineMixerResinPartAResinPartBRIMFoam-in-placeRefrigeratorWallsFoamFoamingInjectorNozzleExtrusionFoamingPaperPaperExtruder(ResinandFoamingAgent)SawBeltDriveExpandedFoamExtrusionfoamlineCastingFoamsResinandFoamingAgentExpandedFoamOpenPanCastingFoamsSkivingtheFoamedBunFoamSprayingFoamingagentsmixedastheyexitthespraynozzleExpandedFoamMoldingPSisthestandardmaterialusedCanbedonewithPPorPEaswellExpandedFoamMoldingTinyBeadsExpansionChamberStoragePartMoldSteamorHotAirSteamorHotAirUnexpandedExpandedEPSbeadsEPSRebondScrapfromotherfoamingprocessesGround/choppedupMoldedintosheetsMaterialConsiderationsforFoamedPartsMostthermoplasticandthermosetmaterialscanfoamedbyoneormoreofthemethodsThemostcommonlyfoamedresinsarePVC,Polyurethane,PS,PE,PP,EpoxyPhenolic,ABS,Ureaformaldehyde,Silicone,IonomersandCelluloseAcetatesFoamApplicationsStrengthtoweightratiosThermalinsulation(Celestiaproduct)EnergyabsorptionLoadbearingEnergyTransmittedEnergy(g's)Frequency(Hz)NaturalvibrationfrequencyTruck=4-6,12-14/Train=

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