en.Wedoany.com Reported - On June 2, the team led by Professor Zhang Zhenxiu from the School of Molecular Science and Engineering at Qingdao University of Science and Technology independently developed an integrated "process-equipment-material" autoclave supercritical green foaming platform technology, breaking the dual monopoly of foreign countries in the process and equipment of high-end elastomer foaming. The Chinese Chemical Society recently organized a scientific and technological achievement evaluation meeting in Beijing to conduct an authoritative evaluation of the "Key Technology and Green Industrial Application of Polymer Autoclave Supercritical Foaming." After review by the expert panel, it was determined that the key technologies and product performance of this achievement have reached the international leading level.
Supercritical foaming is a key technology for manufacturing high-end lightweight and highly elastic materials. Traditional bead foaming processes are limited by foreign patent barriers, making it difficult to produce elastomer products with ultra-low density and complex shapes. The team took a different approach, pioneering the "small preform to large preform" autoclave-shaped preform mold supercritical foaming process. In simple terms, a smaller preformed blank is first prepared, placed into a specific autoclave, and under supercritical fluid permeation with precise temperature and pressure control, the blank uniformly expands into a large-sized foamed product. This innovation is also paired with a high-pressure nitrogen circulation and recovery system, achieving a nitrogen recovery rate of over 90%, truly realizing green manufacturing and effectively solving the production challenges of elastomer products with ultra-low density, high dimensional accuracy, and uniform cell structure.
Foaming equipment is the "hard nut" for technology implementation. The research team independently developed a clamp-type quick-opening fully automatic supercritical foaming autoclave system, overcoming engineering challenges such as sealing difficulties under high temperature and pressure, low temperature and pressure control accuracy, and poor operational efficiency. This new equipment boasts an impressive pressure release rate, six times higher than the international advanced level, with temperature control accuracy within the autoclave reaching ±1°C. Its overall performance is at the international leading level, achieving domestic substitution of key high-end foaming equipment and supporting green large-scale production at the 10,000-ton level.
Specialty rubber and other elastomers, due to their molecular chain characteristics, are prone to cell collapse or rough morphology during foaming. At the material modification level, the research team started from the "root" of the molecular structure, innovatively constructing a multi-level network structure regulation method. Zhang Zhenxiu explained that this is akin to first building flexible "small bridges" and extensible networks between rubber molecular chains, then reinforcing the weaving, so that the material can be effectively stretched without breaking or collapsing during the foaming expansion process. This significantly broadens the foaming temperature window and successfully overcomes the technical bottleneck of ultra-low density foaming for specialty rubber.
The value of technological breakthroughs is ultimately reflected in industrial applications. Zhang Zhenxiu noted that currently, this achievement has been implemented on a large scale in multiple enterprises. Over the past three years, it has generated cumulative new sales revenue of over 2.1 billion yuan and new profits of over 300 million yuan for partner enterprises, with significant economic benefits. The project has obtained 38 authorized invention patents (including 4 Japanese patents) and published 51 academic papers, establishing a comprehensive independent intellectual property system.
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