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A review on manufacture of polymeric foam cores for sandwich structures of complex shape in automotive applications

In this work, polymeric foam thermoforming, foam injection moulding, bead foaming and film foaming were reviewed in an effort to explore feasible processes to manufacture sandwich structures of complex geometry for automotive applications. Injection moulded foams generally suffer from high density, poor cell morphologies and unnecessary skin layers. Foamable films currently available are pressure-induced. In order for foamable films to produce foam, high uniformly-distributed pressure needs to be applied, which makes it difficult to manufacture foam parts of three-dimensional complex geometry with foamable films. The majority of commercial high-performance foam cores can be thermoformed. Ideally, thermoformed foam cores would have good mechanical properties if high-performance foam sheets are used. However, the mechanical properties of foams might be reduced during the process of thermoforming, especially around corners. Bead foaming offers a high level of freedom in foam geometry to be moulded, and inserts can be integrated into foam cores during the process of moulding. Moreover, foam cores with high density in high stressed areas and low density in low stressed areas can be manufactured with foam beads of different densities. However, due to nonhomogeneous degree of fusion and weak bonds and voids between beads, bead foams generally show mechanical properties lower than their block counterpart. Relatively speaking, thermoforming with high-performance foam sheets and moulding with high-performance foam beads hold great potentials for mass production of sandwich cores of complex geometry for automotive applications. However, further investigation on the mechanical properties of thermoformed foams and high-performance bead foams is still in need to confirm their suitability.