DL-A5 (Super-Foam)
Low pressure Physical Microcellular foam injection molding machine
TE-A5 (Super-Foam)
Low pressure Physical Microcellular foam injection molding machine
Schematic diagram of Super-Foam
Technology Introduction Super-Foam
Porous body shape
A technology that produces bubble nuclei by dissolving and dispersing inert gas (nitrogen) in a polymer, and forming a porous product by decompression during the injection process to grow and stabilize the bubble nuclei.
Features and advantages of Super-Foam
Quality improvement
- Prevent shrinkage and deformation
- Improving the quality of injection molded products (removing shrink marks, increasing dimensional accuracy, reducing distortion)
Lighter weight (there is a difference in foaming rate depending on mold and resin conditions and injection method)
- 3-60% foam molding by controlling the ratio of applied resin and physical foam gas
Cost reduction
- Physical foam molding reduces the amount of raw materials required for injection molding to produce products with a small amount of raw materials.
Increased productivity
- Physical foam molding eliminates the holding pressure process, so the overall process time (cycle time) is shortened and productivity is improved.
Stability
- Continuous and stable foam injection equivalent to that of general injection is possible
Energy saving
- Energy saving effect due to lower heater temperature, clamping force, and injection pressure compared to general injection
Reduced maintenance cost
- Low-pressure gas and about 60-70% of the general injection clamping force are used, so the load applied to the machine is small.
- Resin is supplied to the gear, so the wear of the screw and barrel is low (the friction force is small)
- Because it uses low-pressure physical foaming agent, separate pressure intensifying device and control device are not required.
Universality
- A certain amount of physical foam molding is possible regardless of the type even without using a foam-only resin.
Other effects
- Insulation, thermal insulation, cold insulation, cushioning, buoyancy (buoy), sound insulation, sound absorption
Super-Foam test references
Intake manifold (automotive)
- Super-Foam
- Meterial : PA66 + GF40%
- 35% foam
- Raw material reduction and product weight reduction
- Cycle time reduction
- Relieve post-shrink deformation
Roof rack (car)
- Super-Foam
- Meterial : PA66 + GF40%
- 35% foam
- Raw material reduction and product weight reduction
- Cycle time reductio
- Relieve post-shrink deformation
Cooling fan (industrial)
- Super-Foam
- Meterial : PP + GF40%
- 10% foam
- Raw material reduction and product weight reduction
- Increased injection moldability
- Relieve bending
Control box (home appliance))
- Super-Foam
- Meterial : ABS
- 10% foam
- Product structure can be simplified
- Relieve post-shrink deformation
- Relieve bending
Show room operation
We are operating a showroom for the development and sample injection of Super-Foam (low pressure microphysical foam injection molding machine).