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expanded Polystyylene (EP)

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The conversion of expanded polystyrene into solid form is done in three phases: Pre-expanded polystyrenic, polymerizing and expansion. Polystyrene is made from the raw material, styrene, from the crude oil refinery substance called polystitride. For manufacturing expanded polystyrene the expanded polystyrene blocks are also impregnated with the Foaming Agent Pentane. Polystyrenic is polymerized from the solid polystyrenic acid that is obtained from the refining of naphtha. The third phase of this process is the molding or extrusion of the expanded polystyrene that is shaped into any shape. Excess solvent is removed by means of a solvent extractor.


The processing of expanded polystyrene involves two steps. The first step is that of polymerizing the solid polystitride pellets into liquid polystyylene. Polystyrene will then be drained to its solid form through a solvent extractor. The second step is molding the extruded polymerized blocks into any desired shapes. Usually the blocks are formed into cylindrical profiles and hollow tubes. The tubes are used for dispensing liquids or gels in the industries such as Pharmaceuticals, Energy &chemicals, Cosmetics, Food & nutrition, pulp and paper industry.


Injection molding is the process by which polystitrete is extruded in curved shape under high pressure. When the polystitrete is extruded into the mold cavity, the gas mixture expands into the closed polystretch. After the cavities are filled up, a silicone seal is created between the cavities and polystretch. The silicone seal is used to protect the newly formed products from contamination during shipping and storage. This sealant is specially designed for use in the above-mentioned polystyylene industries and many more.


After the extruded polymerized blocks are formed and dried, they are machined by using standard CNC tools to polish and finish the surface of the materials. The polished polystretch is then stacked on a heat resistant material such as a cold work shelf or metallic rack. Many types of packaging and labeling can be applied on the finished product. Some popular products include temporary tags, labels for bottles and cans, weather and climate labels and even identification cards.


The most important advantage of using polystretch as an injection mold material is the speed of production. Compared to other forms of polystyrofoam, expanded polystyrene pellets can be produced in greater volume at a much faster rate. Depending on the requirements of a given project, manufacturers of polystretch can use polystretch of different density. High density polystretch is often used for high volume plastic products such as cans and bottles. Low density polystretch is often used for foam insulation and shrink wrap applications.


One of the most important advantages of polystretch is its cost savings. Polystretch is very cost effective compared to other forms of foam insulation. Its high R Value (thermal conductivity) ensures that the finished product maintains proper room temperature during storage or shipment. There is no additional heating or cooling costs required during application because the expanded polystyrene does not expand nor contract during manufacturing. In addition, some companies have been using expanded polystyrene as an alternative to traditional Kevlar foams because of its extreme durability and low cost.

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