Feasibility of an Innovative Structural Foam Injection Moulding Technology using Super-Heated Water as the Foaming Agent – Foamtech

FoamTech Systems Ltd is part of The TRC group of companies which develops innovative technological solutions to 'real world' Industrial, Agriculture and Food problems using science, engineering, creativity and AI to develop these solutions. FTS has been working on the technology to replace hazardous foaming agents with a more benign substance for almost 4 years. We have tried several methods for introducing a variety of substances into the molten polymer in various ways and forms. The Foamtech process described in this proposal has shown the most promise, and we are now in a position to explore the feasibility of the process further with the view to developing it into a market ready technology. Structural thermoplastic foam-moulded parts are much lighter, with high strength-to-weight ratio than solid plastic. The automotive sector is the main driver to structural foam growth as lifetime energy & CO2 savings drive the need for lightweight components. So, there is growing demand for foam mouldings, but there is a need for good surface finish. In S-O-A, foamed parts are produced by a form of injection moulding using a chemical blowing agent or gas (HFCs, Butane, N2 or CO2). These foaming processes fail to achieve good surface finish due to low process pressure, heat absorption by blowing agent and bubbles forming at part surface, often with a characteristic swirl pattern preventing use of this technology for good quality surface finish parts. Foamtech is an innovative new process to make good quality surface finish foamed parts. Our innovative process introduces a novel substance into molten polymer to create the foamed structure by controlled expansion into a gas. Foamtech offers 50% weight saving (less polymer), 20%+ cycle time reduction (less heat to remove) & 30%+ energy savings (less heat put in) over solid parts. Foamtech aims to provide generally better finish than the S-O-A by virtue of the un-foamed skin, so this crucially would meet automotive sector needs. It is expected to offer better bubble distribution than is seen in other developments. This technology will enable UK moulders to reduce the cost of foam-moulded parts and minimize environmental impact by eliminating need for expensive, environmentally harmful blowing agents such as HFCs, CO2, N2 and hazardous Butane. These advantages will enable UK moulders to be more competitive in a post-COVID economy.