Rigid Cellular PVC & TPE Foam
Auroralite™ rigid PVC cellular foam RPVC products make an excellent wood replacement, combining the maintenance-free features of vinyl with the matte finish look of painted wood. They allow easy nailing and screwing, while providing mildew resistance, rot resistance and weight reduction properties. Our line of Auroralite™ rigid PVC cellular foam includes powder compounds that generate lightweight, low-density profiles ideal for interior/exterior trim work, windows, garage doors, weather seals, decking, railing, slat wall and much more. These PVC cellular foam extrusion grade compounds can be used as a lightweight wood replacement that can be easily cut, routed and shaped just like real wood, with the added benefit of being rot, warp and crack resistant. Because of its reduced density (lighter weight), processors are able to make more parts with less compound.
Extrusion Processes – Free Foam vs. Celuka (‘sell-oo-ka)
There are two methods of producing cellular rigid PVC parts: “free foaming” and Celuka processing. In the free-foam method, the cellular foam PVC melt expands freely after leaving the die head, prior to entering the calibrator, which is separated from the die. The die opening is smaller than the calibrator opening, allowing for the foam to swell into the calibrator, creating an even foam density distribution across its thickness and resulting in minimal skin formation.
The Celuka process utilizes a mandrel inside the die and typically there is little space between the die and calibrator. The mandrel generates a hollow section as the profile exits the die that encourages the foaming action to fill this hollow by inward foaming. The cooling of the surfaces that come into contact with the calibrator walls creates a very strong, glossy outer skin on the part’s surface while inwardly filling the foam part.
Aurora Plastics Adds Value
There is a common misconception that processing cellular foam is difficult. It is really quite easy, and Aurora Plastics can help. We bring years of experience and technical knowledge to the process and can help you achieve your goals using the best quality compounds. Bring us in to the process early, so we can help you develop a system that perfectly suits your needs.