Sponge Slabstock Foaming Machine-Closed Static Mold Foaming

The closed static mold foaming (E-max) process was developed by Unifoam in the mid-1980s. It utilizes the overflow trough and fall plate system of Maxfoam, where foaming takes place inside a fully enclosed, stationary mold with a length ranging from 20 to 40 meters. The working principle is illustrated in Figure 10-26. The raw material tank, mixing head, and overflow trough system are mounted on a mobile worktable. During foaming, the worktable gradually moves from one end of the mold to the other, laying foam inside the mold. Simultaneously, a roller-type movable mold cover unfolds, sealing the top of the foam block and forming a closed space. Gases released during foaming are extracted by fans and sent to a gas scrubbing and recovery unit. Recyclable components, such as CFC blowing agents, are recovered and reused in the next foaming cycle. The remaining gases, after being scrubbed and filtered by activated carbon to remove harmful substances, are released into the atmosphere, effectively minimizing environmental impact. However, as a batch process, its production capacity is significantly lower than that of continuous production. This process has not been widely adopted and exists only as a pilot workshop at the Draka Interfoam plant in the Netherlands.

Schematic Diagram of Closed Static Mold Foaming Principle