Polyethylene foam is well-known for its closed and uniform cellular structure and unique properties. Let’s find out more about this material!
Polyethylene foam is an essential type of closed-cell thermoplastic foam that is based on polyethylene (PE), the most common polymer. Compared to bulky PE materials, the foam type has several benefits, including low density, corrosion resistance, high specific strength, and efficient heat and sound insulation.
This article will explain all the details about PE foam and how filler masterbatch plays a role in improving this material.
Follow along!
1. Understanding Polyethylene Foam Fundamentals
- Definition
Polyethylene foam is a versatile plastic material with unique properties due to its closed, uniform cellular structure. This thermoplastic polymer is extensively utilized in many different applications because it expands when heated and compressed, offering great resilience and lightweight.
- Basic composition and chemical structure
The chemical structure of PE foam is (C2H4)n, meaning this polymer is formed by a long chain of carbon atoms with hydrogen atoms attached. A closed-cell structure of polyethylene foam is produced when the gas bubbles are encased in the polymer matrix.
- Manufacturing process
This closed-cell polyethylene foam is created by an extrusion technique in which a gas—usually carbon dioxide or nitrogen—is added after the polyethylene has melted. The injected gas expands and forms a foam structure as the melt exits the machine.
The manufacturing process can include additives added to its formula to change its properties, creating solid foam sheets. Because of the additives, these sheets are in anti-static variations and are uniform across the material.
Their diverse densities allow them to be used in different applications. The higher density of polyethylene results in cell walls that are either thicker or smaller, making the material stronger.
2. Properties of Polyethylene Foam
PE foam obtains the following properties:
2.1. Physical Properties
- Closed-cell structure: Since the cells are only close to each other (but not interconnected), the material can block liquids and gases.
- Lightweight: This feature makes it easy to handle and apply in different applications.
- Flexible: It’s suitable for many applications.
- Low thermal conductivity: This property makes PE foam a perfect insulating material.
- Dimensional stability: It allows the foam to withstand a variety of manufacturing techniques.
2.2. Chemical Properties
- Resistant to dust, air, moisture, chemical penetration, and degradation: Thanks to these properties, polyethylene foam is ideal for both personal and industrial purposes.
- Antimicrobial properties: It helps prevent the growth of bacteria, molds, etc.
2.3. Mechanical Properties
- Impact resistance: This property makes it perfect for protective packaging and other applications requiring shock absorption.
- High resilience: The ability to return to its original shape after deformation contributes to the effectiveness of PE foam in cushioning applications.
- Strength, density, and rigidity: These characteristics are ideal for products with high standards of strength and durability.
3. Types of Polyethylene Foam
There are 3 types of PE foam:
- Crosslinked Polyethylene Foams
Cross Linked Polyethylene foam, also known as XPE or XLPE foam, is perfect for gasketing applications because they are rigid, resilient, and resistant to moisture and gas penetration. The PE foam insulation and resilience to shock and vibration are also strong. It is also possible to make XLPE static-dissipative and fire retardant.
- Expanded Polyethylene Foams
This type of PE foam is created through heat and pressure. It has a high strength-to-weight ratio and superior thermal resistance. The material is perfect for a variety of applications since they are lightweight, non-abrasive, and recyclable.
- Extruded Polyethylene Foams
In order to generate extruded polyethylene foams, the polyethylene resin is melted and then fed through a mold after specific additives have been mixed with the foam. It is exceptional in light weight, durability, and great insulating qualities.
4. The Role of Filler Masterbatch In Enhancing Polyethylene Foam
Filler masterbatch is a mixture of CaCO3 powder and virgin resin, used in the production of plastics. It can modify the characteristics of materials to improve their qualities.
Using filler masterbatch in PE foam offers various benefits:
- Filler masterbatch supports the foam’s structure and makes it withstand bending and compression better. Therefore, the foam is more rigid.
- During the foam manufacturing process, shrinkage often happens. However, with the help of filler masterbatch, this problem can be minimized and help manufacturers produce consistent product dimensions.
- If you want to achieve a smoothie and a more aesthetic product surface, filler masterbatch can offer a big help.
- Some certain filler masterbatch can make the polyethylene foam easier to mold and process, thus benefiting the processing procedure.
- Lastly, by using less pure polyethylene resin, filler masterbatch can help manufacturers save production costs.
5. Applications of Polyethylene Foam
This closed-cell polyethylene foam is useful in many applications, including:
- Polyethylene foam insulation
Insulation made of polyethylene foam is strong and adaptable and can be used for many applications, including refrigerators, pipelines, walls, floors, and roofs. In addition to being resistant to weathering, corrosion, dampness, and damage, it is sometimes laminated with aluminum foil to improve heat reflectivity. Besides, it helps insulate against sound and vibration.
Furthermore, you can easily find fire-retardant polyethylene foam insulation on the market. All types of this foam are usually adhesive-backed for easier installation.
- Anti-static foams
Polyethylene foams with anti-static properties are protective materials used in semiconductor and electronic device packaging. They reduce shock and vibration during handling and transit, guard against electrostatic discharge, and stop the accumulation of static electricity. This material usually comes in pink color.
- Foam tapes
Polyethylene foam sheets are used as single-sided and double-sided backings for adhesive films in a variety of tapes. Double-sided tapes are perfect for mounting and bonding jobs, while single-sided tapes are utilized for gaskets, cushioning, packing, and insulation.
Polyethylene foam tapes, which come in a variety of thicknesses and degrees of softness, are frequently used in HVAC systems, homes, and businesses because they are more durable than paper or plastic film backings.
- Laminated foams
Combining polyethylene foam sheets with other materials can create thicker layers. The material’s overall durability, mechanical strength, cushioning effect, and insulating qualities are all improved by this lamination procedure.
- Packaging
The foam is ideal for packaging due to its rigidity and durability.
- Flotation devices
The exceptional buoyancy and low water absorption of polyethylene foams are their defining characteristics. These characteristics make them ideal for flotation devices, such as buoyancy aids, swim noodles, and life jackets. They are also frequently used as cushioning beneath the straps of backpacks.
- Furniture
PE foam can improve ergonomics and offer comfort. Chairs, couches, beds, vehicle seats, arm and headrests, and other furniture can all benefit from their use as padding and cushions.
6. Conclusion
We can find polyethylene foam helpful in many applications across industries. Their durability, high buoyancy, and resistance to weathering and chemicals are highly valued.
It’s possible to modify PE foam by using filler masterbatch to meet the requirements of the finished products. All you need to do is find a professional filler masterbatch supplier, such as EuP Egypt, to help you choose the best option.
EuP Egypt is a member of EuP Group and has 15 years of experience in masterbatch. Our factory is equipped with modern machines and German technology, guaranteeing the best quality. Our filler capacity is 180.000 tons per year. With competitive prices, our products have reached 95 countries.
EuP Egypt offers a wide range of filler masterbatch whose main raw material, CaCO3, is exploited from Egypt’s limestone and is of the best quality. It helps improve end-product properties, such as stiffness, bend strength, impact resistance, etc. Furthermore, our products can increase the stability of the manufacturing process and help manufacturers save production costs.
If you want to know more, contact us now!
