Asahi Kasei Corp.
SunForce™: A Foam Contributing to Mass Production and Increased Shaped Flexibility of FRP Composites
- Technical Classification:
- Products:
- [ Products / Processed Products ]
- Keyword:
- [ ＣＦＲＰ ] [ CFRTP ] [ Complex ] [ Dimensional accuracy ] [ foam ] [ Foam core ] [ Formability ] [ FRP ] [ GFRP ] [ High compression ] [ High heat resistance ] [ high strength ] [ In-mold molding ] [ Low water absorption ] [ mass production ] [ No cutting required ] [ PCM ] [ Precision molding ] [ RTM ]
Point of the Proposed Technology
SunForce™ has the heat resistance of over 100℃ required for CFRP composite processes, so it can be used as a core material in PCM, RTM, etc.
Low water absorption means no pre-drying is required for most applications.
Since the product is shaped by foaming inside a mold, cutting is not required, making it ideal for mass production.
It is also possible to form curved shapes that are difficult to achieve by cutting, and groove shapes for resin flow paths.
Low water absorption means no pre-drying is required for most applications.
Since the product is shaped by foaming inside a mold, cutting is not required, making it ideal for mass production.
It is also possible to form curved shapes that are difficult to achieve by cutting, and groove shapes for resin flow paths.
Effect(s)
Total cost reduction for FRP composites using core materials.
Providing rounded shapes with excellent appearance
Providing rounded shapes with excellent appearance
Conventional Technology
Most of the highly heat-resistant foams generally used as core materials are plate-shaped, so they require cutting beforehand. There are also issues with material costs and mass production. In particular, water-absorbent foams require a drying process before the compounding process.
On the other hand, foams produced by in-mold foaming, which can be shaped using a mold, can reduce cutting costs, but there are very few foams that have the heat resistance to withstand the composite process.
On the other hand, foams produced by in-mold foaming, which can be shaped using a mold, can reduce cutting costs, but there are very few foams that have the heat resistance to withstand the composite process.
New Technology
SunForce™ is a foamed bead made from the modified PPE resin Xylon™, and combines the heat resistance of modified PPE with the lightweight, heat insulating, and formability of foamed beads.
Due to its high heat resistance, SunForce™ shows no noticeable defects such as shrinkage even after undergoing the FRP composite molding process. In addition, since SunForce™ can be formed by in-mold foaming, complex shapes such as curved surfaces can be manufactured.
Since SunForce™ is formed by in-mold foaming, no pre-processing such as cutting is unnecessary. Therefore, as shown in the diagram below, it provides significant benefits particularly for applications that require shaping and medium- to high-volume production of FRP composites.
SunForce™ also has advantages in terms of material cost and mass production.
In addition to lower material costs than conventional high heat-resistant foams, SunForce™ does not require cutting or other pre-processing because it is formed by in-mold foaming. As shown in the conceptual diagram below, SunForce™ can provide significant cost advantages in medium- to high-volume production of complex shapes.
Since SunForce™ is formed by in-mold foaming, no pre-processing such as cutting is unnecessary. Therefore, as shown in the diagram below, it provides significant benefits particularly for applications that require shaping and medium- to high-volume production of FRP composites.
SunForce™ also has advantages in terms of material cost and mass production.
In addition to lower material costs than conventional high heat-resistant foams, SunForce™ does not require cutting or other pre-processing because it is formed by in-mold foaming. As shown in the conceptual diagram below, SunForce™ can provide significant cost advantages in medium- to high-volume production of complex shapes.
Technology Deployment and Cooperation
- Development Stage
-
Commercialization Completed (already delivered: yes)
- Joint Researchers (their role)
- Example of Application
- Technical Problems
- Collaborator needed to Improve
- Technical WEB page
- https://www.asahi-kasei-plastics.com/en/topics/tech-07/
Inquiries
- Personnel / Department
- SunForce Business Dept. /
- Address
- 1-1 Hiratanaka-machi, Suzuka-shi Mie
- Contact
-
TEL:+81-59-379-5157
Outline of Company and Organization
- Location
- 100-0006 Hibiya Mitsui Tower (TOKYO MIDTOWN HIBIYA) 1-1-2 Yurakucho, Chiyoda-ku, Tokyo
- Contact
-
TEL:+81-(0)3-6699-3000
- Capital / No. of Employees
- 103,389,000,000 yen / 49295人
- Product Line
- Major Customers
- Overseas Base(s)
- Certification
- Company/Organization WEB page
- https://www.asahi-kasei.com/
Update date: 2024/12/17