F R A U N H O F E R I N S T I T U T E F O R C H E M I C A L T E C H N O L O G Y I C T

PARTICLE FOAMS

The broad and continually widening application spectrum for particle foam

components ranges from insulation materials in the construction sector,

and packaging and transport containers, through to vehicle and plant const-

ruction. Increasingly, tailored material combinations and processing technolo-

gies are required in order to meet the high demands placed on the components.

1 Particle foams.

2 Various samples and

demonstrators made of particle

foams.

Fraunhofer Institute for

Chemical Technology ICT

Joseph-von-Fraunhofer-Strasse 7

76327 Pfinztal

Germany

Contact

Christoph Mack

Phone +49 721 4640-721

christoph.mack@ict.fraunhofer.de

Aaron Basler

Phone +49 721 4640-539

aaron.basler@ict.fraunhofer.de

www.ict.fraunhofer.de

Properties of expanded particle foams

J Very good thermal insulation properties J High energy absorption per unit weight J Possibility to achieve low component

thicknesses < 20 kg/m³ J High design flexibility in terms of product

geometry

– 3D moldability of the components /

components with near net shape

– Possibility to produce a wide range of

wall thicknesses, down to thin ribs J Homogeneous cell distribution, including

at higher wall thicknesses

Material and process development

Fraunhofer ICT uses modern processing

units and machine technologies for the

development of particle foams. It covers

the entire processing chain on one site,

from the production of beads with tailored

properties and particle pre-treatment

through to the production of the final

component.

Researchers are working to optimize and

further develop production processes for

molded parts in terms of energy consump-

tion, product quality and surface and mold

technology. The development of new

processing concepts for the production of

compounds and hybrid structures continues

to be a key activity within the research

group for foam technologies.

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Particle foam processing

In the area of particle foam processing,

beside facilities for the pre-treatment of

particles (pressure loading and prefoaming),

two highly flexible technologies are availa-

ble for the production of particle foam

components:

Laboratory-scale steam chest

molding machine

This technology, which was developed at

Fraunhofer ICT, enables the production

of samples (200 x 200 x 50 mm3) with a

precisely adjustable density, using even

small quantities of material. This allows the

weldability and mechanical properties to be

investigated.

Freely-programmable steam chest

molding machine (Erlenbach GmbH)

Using this modified industrial unit, pre-ex-

panded particle foam beads can be sintered

to form molded parts at vapor pressures

of 8 bar. The freely-programmable process

control enables the processing parameters

to be adjusted to the material properties

and the geometry of the molded part.

Numerous molds are available for the

steam chest molding machine, allowing, for

example, the cavity to be filled from both

sides.

3 Extrusion line with

underwater granulation.

4 Steam chest molding

machine.

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V06.0

Our offer

In the field of particle foam processing

we offer a range of tailored and market-

oriented research services.

J Process development for the

production of molded parts J Processing of tailored polymer

combinations:

– Thermoplastic polymers, e.g.

polypropylene (PP), polystyrene (PS),

polyethylene (PE)

– Biopolymers, e.g. cellulose aceto-

butyrate (CAB), cellulose propionate

(CP) and polylactic acid (PLA) J Multicomponent parts, e.g. expanded

polypropylene (EPP) and aluminum

particle foam J Dosing technology for large particles

(d = up to 8 mm) J Investigation of weldability J Energy-efficient production of molded

parts, and measurement of energy

consumption J Integrated components / back-foaming

of foils and textiles J Integral skin technology J Development of customer-specific mold

technologies J Tailored solutions