Strengthening Core Foam for Carbon Fiber Molds | K102

The K102 is a composite core foam for carbon fiber molds to reduce weight and hardness reinforcement. Generally, the carbon fiber products on the market like composite boards, hydrofoils, and paddle blades will need it. Because the K102 is a kind of EPOXY EXPANDING FOAM, it can be a “paper” shape before forming, which will be the best space-saving foamcore product on the market. Meanwhile, K102 core foam can be molded in various complex shapes, which has SUCH an obvious advantage over other rigid foam.

K102 Epoxy Foam Core Specification

Item: K102
Foam Density Type: Medium
Theoretical Foaming Ratio@1atm 150℃ 20Min: 4Times
Practical Foaming Ratio: 1.2Times
Initial Density: 0.3 g/cm³
Foaming Density: 0.2-0.35 g/cm³
Hardness: Shore C: >=95
Main Applications: Composite board, hydrofoils, and paddle blades
Custom: Yes

Categories: Foam Cores, Epoxy Expanding Foam

Description
Parameters
Molding Steps
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Description

Best Shaped Foam for Carbon Fiber Molds

This foam is optimized for applications requiring space-saving solutions without compromising on reinforcement. Its medium density and high hardness make it suitable for high-performance applications in various composite structures.

Space-Saving: The K102 foam is optimized for applications requiring efficient use of space. Its medium density allows for a significant reduction in weight without sacrificing structural integrity, making it an excellent choice for lightweight designs.
Reinforcement: Despite its reduced weight, the K102 foam offers exceptional reinforcement properties. Its high hardness ensures that the material can withstand significant stress and pressure, providing durability and longevity in demanding environments.
Versatility: The K102 foam is suitable for a wide range of high-performance applications. It is particularly effective in the production of composite boards, hydrofoils, and paddle blades, where strength and lightweight characteristics are crucial.

Foam Parameters

Single Piece Weight	200-250g (excluding release paper)
Single Piece Size	Length: 600±5mm; Width: 300±5mm; Thickness: 4.0±1.0mm
Initial Density	0.30±0.05g/cm³
Foaming Temperature	130℃-160℃ (recommended temperature is 150℃)
Free Foaming Ratio	5.0-10.0 times @1atm, 150℃, 20min
Usage Foaming Ratio/Density	1.0-1.5 times, 0.30±0.05g/cm³
Foaming Hardness	Shore A: 78-88 @ρ=0.20g/cm³, 150℃, 30min
Temperature Resistance	100℃ for 1h, baking loss less than 1.0% @ρ=0.20g/cm³, 150℃, 30min

K102 Foam Molding Steps:

Hot Press Molding: Use a hot press machine to mold the material. Preheat the machine’s platen temperature to 140℃-150℃ and maintain it for at least 30 minutes.
Preheat Mold: Push the mold into the press for about 1 minute to preheat it to 50-60℃. Apply a special epoxy foaming release agent (or a verified suitable release agent) 1-3 times, ensuring the solvent in the release agent completely evaporates from the mold surface.
Material Quantity: The quantity of material should be the mold volume multiplied by the usage foaming density. Tear off and weigh the adhesive material strips to the required amount.
Laying Material: Lay the material according to the thickness of the mold cavity. Lay more material in thicker areas and less in thinner areas to ensure the density of the foamed core material is as uniform as possible. Securely lock the upper and lower molds.
Heating and Molding: Heat the platen to 140℃-150℃ and ensure the mold surface temperature meets one of the following conditions:
- Maintain heating and pressing for 15-25 minutes once the upper and lower mold surfaces reach 120℃.
- Maintain heating and pressing for 18-30 minutes once the upper and lower mold surfaces reach 130℃.
Cooling: Allow the mold surface temperature to drop to 30℃-40℃ before removing and opening the mold.
Demolding and Core Material Extraction: Open the mold and remove the core material.
Combining with Carbon Fiber Prepreg: Combine the core material with the carbon fiber prepreg for molding. The recommended platen temperature is 140℃-150℃. Refer to the prepreg’s curing time, which is generally 15-30 minutes.
Final Cooling: Allow the mold surface temperature to drop to 30℃-40℃ before removing and opening the mold.