PVC foam board is known by many names, such as expanded PVC, polyvinyl chloride foam board and Komatex board. Contrary to its name, it is not made of ordinary foam; this plastic-based material is made from foam polyvinyl chloride. This plastic panel was originally created by the German chemist Eugen Baumann in 1872. It is known to be FDA compliant and can therefore be used for both residential and commercial applications. PVC is often cost-effective and easy to use.
Expanded PVC is a lightweight rigid plastic. the density of PVC foam sheets ranges from 3 lbs/ft3 to 25 lbs/ft3. due to its thermoplastic nature, PVC begins to soften at 149°F. In addition, it is highly resistant to moisture and certain chemicals, which makes it both easy to handle and extends its practical applications.
There are two different types of PVC, such as rigid PVC and flexible PVC. rigid PVC is mainly used for more robust applications such as bottles, curtain rails, window frame tubes etc., while flexible PVC is mainly used for flooring, roofing, shower curtains, cable and wire insulation, toys and other items.
PVC Celuka Foam Sheet
Expanded PVC is manufactured by polymerising vinyl chloride in the form of monomers. This is done through a suspension process. Originally PVC foam sheets were manufactured by containing vinyl chloride in a tube and exposing it to sunlight. This produced the solid white plastic now known as expanded PVC.
Expanded PVC foam sheets are non-toxic. Because expanded PVC is made from a non-toxic and environmentally friendly thermoplastic material, it is free of lead, barium, zinc and cadmium and can be recycled.
Rigid PVC cellular foams are PVC products that are an excellent alternative to wood, combining the maintenance-free properties of vinyl with the matt look of painted wood. They allow for easy nailing and screwing while providing resistance to mould, rot and weight reduction. The rigid PVC cellular foam range includes powder compounds that produce lightweight, low density profiles ideal for interior/exterior trim work, windows, garage doors, weather seals, decking, railings, slatted walls and more. These PVC cellular foam extrusion grade compounds can be used as a lightweight timber replacement and can be cut, routed and shaped as easily as real timber, with the added benefits of resistance to rot, warping and cracking. Due to its reduced density (lighter weight), processors are able to make more parts from fewer compounds.
There are two methods of producing porous rigid PVC parts: the 'free foaming' and the Celuka process. In the free-foaming method, the porous PVC melt is free to expand after leaving the die head and before entering the calibrator which is separated from the die head. The mould opening is smaller than the calibrator opening, allowing the foam to expand into the calibrator, producing a uniform distribution of foam density across its thickness and resulting in minimal skin formation.
The Celuka process uses a mandrel inside the mould, usually with little space between the mould and the calibrator. As the profile leaves the mould, the mandrel creates a hollow section, which promotes a foaming action that fills this hollow section by foaming inwards. The cooling of the surface in contact with the calibrator wall creates a very strong, shiny shell on the surface of the part, while filling the foam part inwards.
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