Thermal expansion coefficient and bulk modulus of polyethylene closed‐cell foams

A regular Kelvin foam model was used to predict the linear thermal expansion coefficient and bulk modulus of crosslinked, closed‐cell, low‐density polyethylene (LDPE) foams from the polymer and gas properties. The materials used for the experimental measurements were crosslinked, had a uniform cell size, and were nearly isotropic. Young's modulus of biaxially oriented polyethylene was used for modeling the cell faces. The model underestimated the foam linear thermal expansion coefficient because it assumed that the cell faces were flat. However, scanning electron microscopy showed that some cell faces were crumpled as a result of foam processing. The measured bulk modulus, which was considerably smaller than the theoretical value, was used to estimate the linear thermal expansion coefficient of the LDPE foams. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3741–3749, 2004     

Rigid polyurethane foams reinforced with disilanolisobutyl POSS: Synthesis and properties

This work reports the synthesis of rigid polyurethane (PU) foams modified by disilanolisobutyl polyhedral oligomeric silsesquioxane (DSIPOSS). This open‐cage nanostructure silsesquioxane has 2 hydroxyl groups and therefore can be chemically built directly in the PU backbone to form hybrid polyurethane‐POSS foam. Synthesis procedure using polymeric 4,4′‐diphenylmethane diisocyanate, polyetherol, and DSIPOSS has been elaborated, and the influence of POSS on the cell structure, closed cell content, apparent density, thermal conductivity, and compression strength of the rigid polyurethane composites has been evaluated. The hybrid composite foams containing 1.5 and 2.0 wt% DSIPOSS showed a reduced number of cells and an increased average area of foam cells in comparison with the unmodified PU, while the addition of 0.5wt% of DSIPOSS causes an increase in the number of cells of the foam as compared with the reference and thus a reduction in the average area of cells. X‐ray microtomography provided data on the porous structure of polyurethane hybrid materials, including reduction of the pore surface area. Scanning electron microscopy and energy‐dispersive X‐ray spectroscopy analysis revealed a good homogenization of DSIPOSS in polyurethane matrix. Thermogravimetric analysis results have shown that incorporation of POSS nanoparticles into PU foam does not significantly change the degradation process. The compressive strength of PUF‐POSS hybrids in the direction parallel and perpendicular to the direction of foam rise is greater than the strength of the reference foam already for the lowest DSIPOSS content.     

酚醛泡沫闭孔率测试方法及其主要影响因素的研究

用真密度仪研究了酚醛泡沫闭孔率的测试方法,在测试过程中对不同测试压力下体系达到平衡的时间进行跟踪,并结合扫描电镜观察泡沫在不同压力下测试前后的结构变化,进而对测试压力加以优化选择;利用扫描电镜观察了不同闭孔率酚醛泡沫的微观结构,深入讨论了酚醛泡沫闭孔率与不同微观结构的关系;对不同放置时间的样品进行恒温处理,将处理前后样品的闭孔率、微观结构进行对比分析.结果表明,优化测试条件、确定测试压力是保证闭孔率测试结果高效准确的首要前提;泡沫微观结构缺陷(如针孔、裂纹),是造成泡沫闭孔率低的直接原因;泡沫微观孔结构规整度、后处理程度的差异,是影响闭孔率测试过程(如测试时间过长,体系不易达到平衡)的主要因素.     

Flame‐retardant and mechanical properties of phenolic foams toughened with polyethylene glycol phosphates

Three kinds of polyethylene glycol phosphates (PEGPs) toughening agents were synthesized by esterification of phosphorus pentoxide (P₂O₅) with polyethylene glycol and characterized by Fourier transform infrared spectra and ³¹P nuclear magnetic resonance. A series of lightweight phenolic foams toughened with different loadings of PEGPs were prepared. Optical microscopy results show that the addition of PEGPs with small molecular weight PEG improves the structural homogeneity of phenolic foams obviously. The flame retardancy of toughened phenolic foams was evaluated by using UL 94, limiting oxygen index, and cone calorimeter. The results indicate that the incorporation of PEGPs not only increases the toughness of phenolic foams but also improves their flame retardancy. Moreover, the thermal stability of PEGPs and the toughened foams was investigated by thermogravimetric analysis. Copyright © 2013 John Wiley & Sons, Ltd.     

Prediction of the radiation term in the thermal conductivity of crosslinked closed cell polyolefin foams

The thermal conductivity and the cellular structure as well as the matrix polymer morphology of a collection of chemically crosslinked low‐density closed cell polyolefin foams, manufactured by a high‐pressure nitrogen gas solution process, have been studied. With the aid of a useful theoretical model, the relative contribution of each heat‐transfer mechanism (conduction through the gas and solid phases and thermal radiation) has been evaluated. The thermal radiation can be calculated by using a theoretical model, which takes into account the dependence of this heat‐transfer mechanism with cell size, foam thickness, chemical composition, and matrix polymer morphology. A simple equation, which can be used to predict the thermal conductivity of a given material, is presented. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 993–1004, 2000     

Well‐Controlled Biodegradable Nanocomposite Foams: From Microcellular to Nanocellular

Via a batch process in an autoclave, the foam processing of neat polylactide (PLA) and two different types of PLA/layered silicate nanocomposites has been conducted using supercritical carbon dioxide as a foaming agent. The morphological correlation between the dispersed silicate particles with nanometer dimensions in the bulk and the obtained closed‐cell structure of the foam is discussed. This is the first report that deals with the possibility of preparing biodegradable nanocellular polymeric foams via nanocomposite technology.

SEM image of the freeze‐fracture surface of a PLA/layered silicate foam, exhibiting closed‐cell structure.     

Studying the Suitability of Nineteen Lignins as Partial Polyol Replacement in Rigid Polyurethane/Polyisocyanurate Foam

In this study, nineteen unmodified lignins from various sources (hardwood, softwood, wheat straw, and corn stover) and isolation processes (kraft, soda, organosolv, sulfite, and enzymatic hydrolysis) were used to replace 30 wt.% of petroleum-based polyol in rigid polyurethane/polyisocyanurate (PUR/PIR) foam formulations. Lignin samples were characterized by measuring their ash content, hydroxyl content (Phosphorus Nuclear Magnetic Resonance Spectroscopy), impurities (Inductively Coupled Plasma), and pH. After foam formulation, properties of lignin-based foams were evaluated and compared with a control foam (with no lignin) via cell morphology, closed-cell content, compression strength, apparent density, thermal conductivity, and color analysis. Lignin-based foams passed all measured standard specifications required by ASTM International C1029-15 for type 1 rigid insulation foams, except for three foams. These three foams had poor compressive strengths, significantly larger cell sizes, darker color, lower closed-cell contents, and slower foaming times. The foam made with corn stover enzymatic hydrolysis lignin showed no significant difference from the control foam in terms of compressive strength and outperformed all other lignin-based foams due to its higher aliphatic and p-hydroxyphenyl hydroxyl contents. Lignin-based foams that passed all required performance testing were made with lignins having higher pH, potassium, sodium, calcium, magnesium, and aliphatic/p-hydroxyphenyl hydroxyl group contents than those that failed.     

Preparation and dielectric properties of polyimide foams containing crosslinked structures

In order to obtain cellular materials with low dielectric properties, crosslinked polyimide foams were prepared using 3,3′,4,4′‐benzophenonetetracarboxylic dianhydride (BTDA), 4,4′‐oxydianiline (ODA) and 2,4,6‐triaminopyrimidine (TAP) as monomer via a poly(ester‐amine salt) precursor process. The structures of the precursors and the polyimide foams were characterized by thermogravimetric analysis (TGA) and FT‐IR, while the morphologies of the polyimide foams were viewed from scanning electron microscopy (SEM) measurements. The results revealed that the poly(ester‐amine salt) precursor containing TAP could successfully be converted to a crosslinked polyimide foam with relatively uniform cell structure. Also, the crosslinking of TAP improved the mechanical properties of foams in comparison with the non‐crosslinking systems. With increasing content of TAP, the dielectric constants of the polyimide foams decreased gradually. For the foam with TAP molar ratio at 15%, the dielectric constant was as low as 1.77 at the frequency of 10 kHz. Though the thermal resistance decreased slightly for crosslinked foams, the decomposition temperatures were still maintained above 520°C. Copyright © 2006 John Wiley & Sons, Ltd.     

The effect of post-consumer PET particles on the performance of flexible polyurethane foams

In this work, the use of post-consumer PET (polyethylene terephthalate), PET_pc, as reinforcement filler in flexible polyurethane foams was studied, with the aim of finding alternatives for the recycling of polymer packaging. Density, number of cells per linear centimeter, tensile resistance, strain at break and tear resistance of standard foams were compared to those of foams with PET_pc in the formulation, using 1.5 parts per hundred of polyol of PET_pc (granulometric range 0–297 μm). The produced foams were sectioned into top, mid-top, mid-bottom and bottom layers. Tensile resistance, strain at break and tear resistance of the reinforced foam surpassed those of the standard foam for all layers. The number of cells was constant but density increased towards the base of the block. In addition, the filled foams yielded better wear, compression set and compression resistance than the standard foam, whereas no significant variation in morphology (cell shape) was found.     

Fabrication‐controlled morphology of poly(butylene succinate) nano‐microcellular foams by supercritical CO2

Poly(butylene succinate) urethane ionomer (PBSUIs) foams with nano‐microcellular morphology were fabricated using supercritical CO₂ (sc‐CO₂) at different parameters. Effect of urethane ionic group (UIG) content (ranged from 1% to 5%) on the rheology and crystallization of PBSUIs were evaluated by intrinsic, dynamic rheological, X‐ray diffraction, and differential scanning calorimetry measurements. The results show that the complex viscosity of PBSUIs vastly improved, while their intrinsic viscosity and crystallinity decreased. They also evidenced that CO₂ promoted the formation of crystallites in the amorphous and increased the X_c of PBSU and PBSUIs foams. Scanning electron microscope was employed to explore the influences of UIG content and foaming parameters on the morphologies of PBSUIs microcellular foams, and it revealed that UIG content was the dominated factor. The cell size and cell densities of PBSUIs microcellular foams were smaller than 5.0 micrometers and higher than 1.5 × 10¹⁰ cells/cm³, respectively, even foamed at diverse variations of foam temperature and pressure. Interestingly, PBSUIs with 3% and 5% UIG content achieved microcellular foams in nano‐cells, high‐stretched elliptical shape. The mechanism was ascribed that these PBSUIs with high melt viscosities could retard the CO₂ bubbles to merge during the foam process and induce the cells to stretch and orient in depressururization direction. This study proposed a novel method for fabricating PBS nano‐microcellular foams.     

Preparation and properties of polyimide/chopped carbon fiber composite foams

In this study, a series of reinforced polyimide (PI)/carbon fiber (CF) composite foams were fabricated through thermal foaming of polyester ammonium salt (PEAS) precursor powders. The PEAS precursor powders containing different contents of chopped CF were synthesized from benzophenone‐3,3′,4,4′‐tetracarboxylic dianhydride (BTDA) and 4,4′‐diaminodiphenyl ether (ODA). The effects of different CF loadings on foaming behavior of PEAS/CF composite precursor powders, final cellular morphology, and physical properties of PI composite foams were investigated. The results revealed that the chopped CF acted as nucleation agent in the foaming process. The dispersion of CF can be evaluated using digital microscope. It is interesting to find that the chopped CF were highly oriented along the direction of cell arrises. As a result, the mechanical properties of PI foams were significantly enhanced owing to the incorporation of chopped CF. Furthermore, the thermal stability of PI composite foams were also slightly improved owing to fine dispersion of CF. In addition, the PI/CF composite foam shows uniform cell size distribution and the best comprehensive physical properties as chopped CF loading at around 6 wt%. Copyright © 2016 John Wiley & Sons, Ltd.     

Lightweight lignocellulosic foams for thermal insulation

Foams are mainly composed of dispersed gas trapped in a liquid or solid phase making them lightweight and thermally insulating materials. Additionally, they are applicable for large surfaces, which makes them attractive for thermal insulation. State-of-the-art thermally insulating foams are made of synthetic polymeric materials such as polystyrene. This work focuses on generating foam from surfactants and renewable lignocellulosic materials for thermally insulating stealth material. The effect of two surfactants (sodium dodecyl sulphate (SDS) and polysorbate (T80)), two cellulosic materials (bleached pulp and nanocellulose), and lignin on the foaming and stability of foam was investigated using experimental design and response surface methodology. The volume-optimized foams determined using experimental design were further studied with optical microscopy and infrared imaging. The results of experimental design, bubble structure of foams, and observations of their thermal conductivity showed that bleached pulp foam made using SDS as surfactant produced the highest foam volume, best stability, and good thermal insulation. Lignin did not improve the foaming or thermal insulation properties of the foam, but it was found to improve the structural stability of foam and brought natural brown color to the foam. Both wet and dry lignocellulosic foams provided thermal insulation comparable to dry polystyrene foam.

Graphical abstract

     

Thermal stability of flexible polyurethane foams containing modified layered double hydroxides and zinc borate

Abstract

Flexible polyurethane foams (FPUFs) have been modified to contain layered double hydroxides (LDHs) by dihydrogen phosphate (H₂PO₄ ^?). The thermal stability of the prepared foams has been characterized using thermogravimetric analysis (TGA) at 5, 10, 20, 30, and 40?°C/min heating rates. The experimental data indicate that the temperature range for the two pyrolysis stages of FPUF is about 212–350?°C and 350–565?°C, respectively. Integral programmed decomposition temperature (IPDT) has been calculated according to the measured data, which was found that the IPDT of the modified FPUF was increased to 526?°C. Additionally, the thermal stability of FPUF composite has been also evaluated by the activation energy (E) on the basis of the pyrolysis kinetics of FPUF composites during thermal decomposition using Coats–Redfern integral method. These results manifest that the presence of intercalated LDHs enhances the thermal stability of FPUF.     

X-ray computed tomography-based modeling of polymeric foams: The effect of finite element model size on the large strain response

A hybrid numerical–experimental approach is used to characterize the macroscopic mechanical behavior of polymeric foams. The method is based on microstructural characterization of foams with X-ray computed tomography (CT) and conversion of the data to finite element (FE) models. The 2D models are created from a 3D close-celled foam and subjected to compression loads. Since the large strain regime is explored, contact between elements is incorporated. It is shown that, for calculating the effective Young's modulus, a model consisting of at least 11²–12² cells in the model should be used, whereas for the large strain regime 12²–14² cells in the model are needed. Discretization had a significant influence on the results, where relatively coarse elements caused loss of connectivity in the cell walls and thickening of the cell walls. It is shown that at least three to four elements should be taken over the thickness of the cell walls for these structures. Finally, a good qualitative agreement is observed between the deformations found with the FE models and in situ compression experiments of an open-celled foam during X-ray CT. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 1473–1482, 2010     

Thermal conductivity of open‐cell polyolefin foams

The thermal conductivity and the cellular structure of novel open‐cell polyolefin foams produced by compression molding and based on blends of an ethylene‐vinyl acetate copolymer (EVA) and a low‐density polyethylene (LDPE) have been studied in the temperature range between 24 and 50 °C. The experimental results have shown that the cellular structure of the analyzed materials has interconnected cells because of the presence of large and small holes in the cell walls, this structure being clearly different to the typical structure of open‐cell polyurethane foams. It has been found that at low temperatures the materials have a slightly higher thermal conductivity than closed‐cell polyolefin foams of similar densities. The different mechanisms of heat flow, conduction, convection, and radiation have been analyzed by using experimental measurements and a theoretical model. It has been proved that, in spite of having an open‐cell structure, the convention mechanism is negligible, being the radiation mechanism the one which made different the conductivity of materials with varying cellular structures. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 212–221, 2008     

Sound absorption properties of polyurethane foams derived from crude glycerol and liquefied coffee grounds polyol

The main objective of this study was to evaluate the sound absorption properties of rigid polyurethane foams (PUFs) produced from crude glycerol (CG) and/or liquefied coffee grounds derived polyol (POL). The lignin content of POL proved to have a major influence on the structure and mechanical properties of the foams. Indeed, the POL content increased the cell size of the foams and their stiffness, which subsequently influenced the sound absorption coefficients. The POL derived foam has slightly higher sound absorption coefficient values at lower frequencies, while the CG foam has higher sound absorption coefficient values at higher frequencies. In turn, the foam prepared using a 50/50 mixture of polyols presents slightly higher sound absorption coefficient values in the medium frequencies range due to a balance between the cell structure and the mechanical properties. The results obtained seem to suggest that the mechanisms involved in sound wave absorption depend on the formulation used to prepare the foams. Additionally higher POL contents improved the thermal stability of PUFs as well as their mechanical properties. From this work the suitability of CG and/or POL derived PUFs as sound absorbing materials has been proven.     

Effect of Aging on the Stability of Ceramic Foams Prepared by Thermostimulated Sol-Gel Process

This work presents a new route of preparation of zirconium ceramic foams based on the thermostimulated sol-gel process. This method produces gelled bodies with up to 90% of porosity in the wet gel and can be used to make complex-shaped components. Unfortunately, the shrinkage during the drying step allows to a catastrophic reduction (>50%) of the foam porosity. To improve the foam stability we carried out a systematic study of the effect of gel foam aging on the drying process. Samples were aged in closed vessel at 25°C during different time period (from 6 to 240 h). The shrinkage and the mass loss during drying at 50°C were measured in situ, using a non-contact technique performed with a special apparatus. The results show that the total linear shrinkage decreases from 46% to 8% as the aging period increase from 6 to 240 h. This behavior is followed by a small change of total mass loss, from 42 to 54%. It indicates that by aging the structural stiffness of the foams increases due to secondary condensation reactions. Thus, by controlling the aging period, the porosity can be increased from 67 to 75% and the average size of mesopores of dried foams can be screened from 0.3 to 0.9 m. Finally, these results demonstrate that the thermostimulated sol-gel transition provides a potential route to ceramic foams manufacture.     

Chlorine-Functional Silsesquioxanes (POSS-Cl) as Effective Flame Retardants and Reinforcing Additives for Rigid Polyurethane Foams

The subject of the research was the production of silsesquioxane modified rigid polyurethane (PUR) foams (POSS-Cl) with chlorine functional groups (chlorobenzyl, chloropropyl, chlorobenzylethyl) characterized by reduced flammability. The foams were prepared in a one-step additive polymerization reaction of isocyanates with polyols, and the POSS modifier was added to the reaction system in an amount of 2 wt.% polyol. The influence of POSS was analyzed by performing a series of tests, such as determination of the kinetics of foam growth, determination of apparent density, and structure analysis. Compressive strength, three-point bending strength, hardness, and shape stability at reduced and elevated temperatures were tested, and the hydrophobicity of the surface was determined. The most important measurement was the determination of the thermal stability (TGA) and the flammability of the modified systems using a cone calorimeter. The obtained results, after comparing with the results for unmodified foam, showed a large influence of POSS modifiers on the functional properties, especially thermal and fire-retardant, of the obtained PUR-POSS-Cl systems.     

Shear-induced lamellar ionic liquid-crystal foam

In a recent paper we reported an experimental study of two N-alkylimidazolium salts. These ionic compounds exhibit liquid crystalline behaviour with melting points above 50°C in bulk. However, if they are sheared, a (possibly non-equilibrium) lamellar phase forms at room temperature. Upon shearing a thin film of the material between microscope slides, textures were observed that are strikingly similar to liquid (wet) foams. The images obtained from polarising optical microscopy (POM) were found to share many of the known quantitative properties of a two-dimensional foam coarsening process. Here we report an experimental study of this foam using a shearing system coupled with POM. The structure and evolution of the foam are investigated through the image analysis of time sequences of micrographs obtained for well-controlled sets of physical parameters (sample thickness, shear rate and temperature). In particular, we find that there is a threshold shear rate below which no foam can form. Above this threshold, a steady-state foam pattern is obtained where the mean cell area generally decreases with increasing shear rate. Furthermore, the steady-state internal cell angles and distribution of the cell number of sides deviate from their equilibrium (i.e. zero-shear) values.     

Biobased porous acoustical absorbers made from polyurethane and waste tire particles

The production of flexible polyurethane foams (FPF) with good acoustical performance to control sound and noise and incorporating bio/recycled raw materials is an interesting alternative to conventional acoustic absorbent materials. In this sense, biobased polyols like glycerol (GLY) or hydroxylated methyl esters derived from tung oil (HMETO) as multifunctional polyols, and waste tire particles (WTP) as fillers of low thermal conductivity and good capability for acoustical absorption, are prospective feedstocks for FPF preparation. In this work, FPF were prepared by adding different amounts of these components to a formulation based on a commercial polyether polyol. Results of scanning electron microscopy (SEM) analysis, compression tests and normal-incidence sound absorption coefficient (α_N) measurements are presented and discussed. The addition of WTP or GLY to the commercial formulation enhanced both the modulus and yield stress of the obtained FPF in all cases. Moreover, a high recovery of the applied strain (>90%) was attained 24 h after the compression tests. On the other hand, the normal-incidence sound absorption coefficient, α_N, reached high values mostly at the highest evaluated frequencies (α_N ∼0.62–0.89 at 2000 Hz and α_N ∼0.70–0.91 at 5000 Hz). SEM micrographs revealed that the foams obtained present a combination of open and closed cell structure and both the modifiers and particles tend to decrease the cell size.