SunForce™: A Foam Core Material Contributing to Cost Reduction and Increased Shape Flexibility of FRP Composites

Challenges in the composite process of FRP and foam core material

Recently, the application of composite materials layered with FRP (Fiber Reinforced Plastics) reinforced with glass or carbon fibers and foam is expanding to reduce weight and increase the stiffness of parts in many applications such as automobiles and aircraft. 

However, autoclave methods, PCM (Prepreg Compression Molding), and RTM (Resin Transfer Molding) known for manufacturing composite materials generally require high heat resistance of over 100°C in the composite process.

Therefore, the applicable foams are limited, and most of the high-heat-resistant foams are in sheet form, requiring pre-cutting, which leads to high processing costs and poor productivity.

The engineering plastic foam beads SunForce™ Suitable for Composite Core Materials with FRP

Asahi Kasei proposes composite corematerials using the PCM method to mold the engineering plastic foam beads "SunForce™ " with FRP as one of the composite methods.

Sunforce™ is a bead foam made from modified PPE resin, possessing characteristics such as heat resistance, dimensional stability, low water absorption from the modified PPE, and lightweight, thermal insulation, and formability from the bead foam.

Additionally, because Sunforce™ is molded through in-mold foaming, it excels in mass production, especially for small to medium-sized parts.

Key Features of FRP Composites Utilizing Sunforce™

The features of composites made from Sunforce™ and FRP using the PCM method are as follows:

Feature 1: Heat Resistance

Due to SunForce™'s high heat resistance, it undergoes the PCM process without noticeable defects such as shrinkage, and its in-mold shaping allows the manufacture of FRP composite materials with complex shapes like curved surfaces.

Feature 2: Mass Production (Cost Reduction)

Sunforce™ has advantages in terms of cost and mass production.

Since Sunforce™ is formed by in-mold foaming, no pre-processing such as cutting is unnecessaryTherefore, 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.

Feature 3: Formability (Shape Flexibility)

Sunforce™ can be shaped by in-mold foaming, allowing the production of FRP composites into complex shapes such as curved surfaces.

Feature 4: Low Water Absorption

Sunforce™ is a foam with a closed-cell structure based on low water-absorption m-PPE resin, offering lower water absorption compared to other foams used in conjunction with FRP.

As described above, using SunForce™ as a foam core material for FRP composites allows the production of lightweight, high-rigidity, complex-shaped FRP composite materials with high mass productivity.

If you are interested, please feel free to contact us.