Low pressure foam molding

Structural-web molding is a low pressure foam molding method. It is the phrase usually used to identify the gap between structural foam (SF) molding and injection molding. Its surface does not have the usual SF characteristic swirl pattern. It can produce very large, lightweight parts with smooth surfaces like conventional injection molded parts. 

SF is characterized as a plastic structure with a nearly uniform density foam core and integral near-solid skins (facings). When these structures are used in load-bearing applications, the foam bulk density is typically 50 to 90% of the plastic s unfoamed bulk density. Most SF products (90wt%) are made from different TPs, principally PS, PE, PVC, and ABS. Polyurethane is the primary TS plastic. Unfilled and reinforced SFs represent about 70% of the products. The principal method of processing (75%) is modified low-pressure injection molding. Extrusion and RIM account for about 10% each. 

Structural foam molding is a low-pressure, closed-mold process which provides a finished surface on both sides of the part. In structural foam... 

Expandable foam also uses low pressure, so molds and equipment are usually inexpensive—even cheaper than with structural foam. Many automobile dashboards are made using this process (Figure 2.13). 

In the low pressure process, a short shot of a resia containing a blowiag ageat is forced iato the mold where the expandable material is aUowed to expand to fiU the mold under pressures of 690—4140 kPa (100—600 psi). This process produces stmctural foam products with a characteristic surface swid pattern produced by the coUapse of ceUs on the surface of molded articles. 

This low pressure process, also known as elastic reservoir molding, consists of making basically a sandwich of plastic-impregnated open-celled flexible polyurethane foam between the face layers of fibrous reinforcements. When this plastic composite is placed in a mold and squeezed, the foam is compressed, forcing the plastic outward and into the reinforcement. The elastic foam exerts sufficient pressure to force the plastic-impregnated reinforcement into contact with the heated mold surface. Other plastics are used. 

Process and Equipment. Rigid polyurethane foam processes use Ihe same high or low pressure pumping, metering, and mixing equipment for flexible foams. Subsequent handling of the mixture is determined by the end product desired. Processes include lamination, pour-in-place, molding, bun stock, box loams, and spray. 

Ultem PEI resins are amber and amorphous, with heat-distortion temperatures similar to polyethersulfone resins. Ultem resins exhibit high modulus and are stiff yet ductile. Light transmission is low. In spite of the high use temperature, they are processible by injection molding, structural foam molding, or extrusion techniques at moderate pressures between 340 and 425°C. They are inherently flame retardant and generate little smoke dimensional stabilities are excellent. Large flat parts such as circuit boards or hard disks for computers can be injection-molded to maintain critical dimensions. 

Reaction injection molding (RIM) is a fast, low-pressure, low-temperature, low-cost process for one-step conversion of reactive liquids into large finished solid plastic products. Liquid polyol and liquid diisocyanate are mixed by impingement, pumped instantly to fill a large mold cavity, and polymerize/ cure rapidly to form a thermoset polyurethane product. The cured polymer may be a stiffly flexible product such as automotive bumper covers, front ends, and trim or a rigid foamed product such as furniture and housings (cabinets) for computers, business machines, TY and radio. 

ABS structural foam can be processed by injection molding, through conventional or low pressure injection machines (Chapter 4) by expansion casting in rotational molding machines (Chapter 13) or conveyorized oven systems or it can be extruded into profiles through conventional extruders (Chapter 5). 

EPS molding generates pressures of less than 30 psi (2 kPa) in most mold applications. This low pressure allows the use of inexpensive molds such as aluminum. To process the other expandable plastic foams (EPFs), such as PE, PP, and PMMA, the equipment for EPS can be used with only slight modifications. 

Figure 8.4 Schematic of foam reciprocating injection molding machine for low pressure...

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