Polyfil unveils microcellular polymer technology

Polyfil Corporation has introduced a new technology, called Ecocell, which can create a microcellular structure (cells less than 100 micron in size) in many polymers. The product is claimed to reduce polymer use by up to 50 percent and can reduce carbon footprint by up to 45 percent. There is also a decrease in energy consumed with a product made with Ecocell compared to the same product made conventionally, says the company.

Ecocell infuses small particles of gas-generating additives into the polymer melt during processing. Upon induction of a chemical reaction, the particles release a small volume of gas producing a cellular structure at a size unachievable with present day chemical foaming agent (CFA) technology. This will expand the polymer by up to twice its volume at no or little penalty to energy consumption.

Ecocell can be used with low and high density polyethylene, copolymer polyethylenes, polypropylene homopolymers and copolymers, crystal and impact polystyrene, PVDF, TPOs and TPEs.  

Ecocell is intended for use in applications such as thermoforming, sheet, structural foam molded parts, oriented polypropylene films, foamed labelstock, blow molding, injection molding, extruded profiles, plastic lumber and more.