PVC / SAN Foam Core
PVC and SAN (styrene-acrylonitrile) rigid foam cores used in structural sandwich composites for automotive closures, floors and battery enclosures — a cost-effective alternative or complement to PMI cores.
Overview
Rigid PVC and SAN foam cores are closed-cell structural foams used as the middle layer in sandwich composites with GFRP or CFRP skins. They provide shear transfer, buckling resistance and thickness at lower cost and often better availability than polymethacrylimide (PMI) cores used in highest-performance aerospace and motorsport parts. Automotive applications include closures, underbodies, load floors and battery enclosure sandwich panels where weight saving must be balanced against cost and process temperature. SAN foams typically improve heat and chemical resistance versus PVC foams. Processing involves CNC cutting of sheets, bonding or infusion with skins, and careful moisture/outgassing control. This entry positions PVC/SAN foam cores alongside PMI as structural sandwich options, not as seating comfort foams.
Automotive Applications
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Properties
Category
Type
Structural Foam Core
Available Colors
Available Forms
Key Properties
- Closed-cell rigid foam for sandwich laminates
- Good strength-to-weight at mid density ranges
- Compatible with infusion, prepreg and adhesive bonding
- Lower cost than PMI for many structural panels
- SAN grades offer improved temperature/chemical resistance vs PVC
- Distinct from soft comfort foams
Technical Specifications
Density
Typically 40–200 kg/m³ for structural sandwich grades
Tensile Strength
Core tensile/shear are density-dependent (e.g. compressive strengths tens to hundreds of kPa to several MPa)
Temperature Resistance
PVC cores typically limited ~60–80°C continuous process/service; SAN grades higher (often ~80–100°C+ depending on grade)
Sustainability
Sustainability Rating
Thermoset sandwich structures with PVC/SAN cores are difficult to recycle; design-for-disassembly and chemical recycling of skins remain immature. Foam density optimisation reduces polymer mass. PVC raises chlorine and plasticiser scrutiny versus SAN in some OEM material policies.