Easy-to-process particle foam targets composite foam core needs

This spoiler demonstrator features a carbon fiber-reinforced polymer (CFRP) and SunForce cross section. Source | Asahi Kasei

Japanese technology company Asahi Kasei (Düsseldorf, Germany) is exhibiting its modified polyphenylene ether (mPPE) particle beads foam SunForce. Combination of high processability and design flexibility make it an optimal solution as foam core or sandwich material for composite applications.

According to the company, applications using foam core is rising in an effort to reduce weight and increase the stiffness of parts in various industries. Autoclave methods, such as prepreg compression molding and resin transfer molding generally require high heat resistance of more than 100°C during the composites process. This limits the number of applicable foams is limited — plus, most high heat-resistant foams are in sheet form, which requires pre-cutting, leading to high processing costs and poor productivity.

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SunForce is a particle beads foam based on m-PPE engineering plastic. The foam features high heat resistance, dimensional stability and low water absorption from the modified PPE, in addition to lightweight, thermal insulation and formability originating from the bead foam.

SunForce beads can be molded by in-mold foaming using the steam chest molding process. This, in combination with small-sized beads, enables medium- to high-volume production of composite core parts with accurate, complex and curved shapes and without the need for additional milling. 

The material can be used as foam core or sandwich material for composite applications in the medical, industrial, aeronautical or sports industry.

Visit Asahi Kasei at Booth U89 in Hall 6.