co Foam System
Eco Foam System — Supercritical Nitrogen Foam Injection Molding Machine (Prototype #1)
40% lighter with no loss of strength — a new standard for plastic lightweighting and ESG-friendly manufacturing.
Core Technology Summary
The EcoFoam system injects supercritical nitrogen (SCF-N₂) directly into the molten resin, achieving 3–4 times higher foaming efficiency compared to the conventional MuCell process. The foam structure features a uniform micro-cell core and a dense outer skin, maintaining strength while achieving a specific gravity of 0.65 g/cm³ (–34%).
- 200-bar high-pressure nitrogen generator with gas-mixing module
- ±0.5 bar precision pressure control → over 95% cell uniformity
- Automatic residual-gas detection with real-time pressure control system
Validation Results
Certified by KTR: even at a specific gravity of 0.65 (–34%), the material maintains flexural strength of 13–15 MPa, modulus of elasticity of 0.9–1.1 GPa, and Izod impact strength above 65 J/m. This represents a 30% improvement in structural strength compared to EPS or EPP foams.
| Application Case | Details |
|---|---|
| Yanfeng Int. (USA) | Door trim 1.3 kg (previously 2.0 kg → –35%) |
| LG Chem / Gentex | PoC completed — paint-free surface, cost reduction 25–30% |
| Hanwha Q-Cells | Test line in operation |
Economic & ESG Impact
- Raw material usage –30%, OPEX –40%, CO₂ emissions –50%
- No wastewater or VOCs, no chemical blowing agents
- Maintenance interval reduced by 40% → higher process efficiency & lower cost
Commercialization Roadmap
- 1H 2025: First export to Yanfeng (USD 32,500) / UL & NRTL certification
- From 2026: Biodegradable resin foaming tests + Tier-1 OEM mass production
- 2027: Expansion to 280-ton and 500-ton EcoFoam lines with Eta system integration