越升科技：Filling foam｜Lightweight new path

In the field of sheet metal processing, many companies are trying the same thing:While reducing costs, achieve material lightweighting and more environmentally friendly production.An increasingly common practice is:Adding mineral fillers to the material and combining micro foaming technology to reduce material density.

Its advantages are very obvious:

reduce carbon emissions

However, in actual production, when high filling systems and micro foaming processes occur simultaneously, the processing difficulty often increases significantly.

In the production of composite foam sheets, three typical problems are usually encountered.

　　1. Increase in melt load

A high filling system will significantly increase the viscosity of the melt and significantly increase the system load. If the melt conveying is unstable, it can easily cause pressure fluctuations and affect the foaming structure.

　　2. Foam structure is sensitive

Micro foaming is very sensitive to temperature and pressure changes, and once it fluctuates, uneven foaming or local collapse may occur.

　　3. The composite layer structure should be stably matched

Composite sheets are usually composed of multiple layers of structure, and different melts need to bemoldStable convergence in the middle. If the flow or temperature control is not good, it will affect the stability of the layer structure.

In response to the above challenges, this project adoptsCo extrusion systemRealize the production of composite foam sheets.

　　One extruder is responsible for the structural layer melt

　　One extruder is responsible for foaming the core layer

Two molten materials are separated and combined inside the mold, forming a multi-layer composite sheet structure.

In this structural design:

The outer layer provides structural stability and surface quality

The intermediate layer forms a micro foaming lightweight structure

Each layer system adopts mineral filler reinforcement design, which reduces material consumption while ensuring structural performance.

Engineering verification: stable operation and structural consistency

In the on-site process validation, the composite foam sheet production line successfully completed the start-up and continuous operation testing.

During the operation of the system, the melt pressure remains stable, the sheet structure is uniform, and the foaming structure has good consistency.

A stable process window enables the production line to maintain reliable production status under continuous operating conditions and provides a good foundation for subsequent capacity improvement.

Our engineering experience in high filling composite foam systems can be summarized as follows:

　　Stable melt is the foundation

　　Uniform foaming is the core

　　Structural matching is key

Only when the equipment system, process control, and material system form a stable match can the production of composite foam sheets achieve long-term stable operation.

Composite foam sheets are quietly changing one thing: no longer just adding materials, but using structure to make materials more efficient.

Driven by cost pressure, lightweight demand, and environmental trends, it is like an "invisible optimizer" that makes products unconsciously lighter, more energy-efficient, and greener.

It can be foreseen that in the future, more and more industries will make the same choice - not to use more materials, but to useSmarter material solutions.

Original title: Filling × Foaming | Lightweight New Path