A steady‐state mass balance model of the polycarbonate–CO2 system reveals a self‐regulating cell growth mechanism in the solid‐state microcellular process

A simple mechanism regulating polymer mobility is demonstrated to determine initial and final growth states of solid‐state microcellular foams. This mechanism, governed by the extent of plasticization of the polymer by the dissolved gases, is examined with a mass balance model and results from foam growth experiments. Polycarbonate was exposed to CO₂, which acted as both a plasticizing gas and a physical blowing agent driving foam growth. The polycarbonate specimens were saturated to the equilibrium gas concentration at 25 °C for CO₂ pressures of 1–6 MPa in 1‐MPa increments. Equilibrated specimens were heated in a glycerin bath until thermal equilibrium was reached, and a steady foam structure was attained. Glycerin bath temperatures of 30–150 °C in 10 °C increments were examined. Using knowledge of gas solubility, the equation of state for CO₂, the effective glass‐transition temperature as a function of gas concentration, and a model for mass balance within a solid‐state foam, we demonstrate that foam growth terminates when sufficient gas is driven from the polycarbonate matrix into the foam cells. The foam cell walls freeze at the elevated bath temperature because of gas transport from the polycarbonate matrix and the associated rise in the polymer glass‐transition temperature to that of the heated bath. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 868–880, 2001     

Constitutive modeling for characterizing the compressive behavior of PMMA open‐cell foams

A constitutive model for evaluating the compressive behavior of Poly(methyl‐methacrylate) (PMMA) open‐cell foams is herein proposed. Specifically, the study investigates the viscoelastic and viscoplastic behaviors of the PMMA open‐cell foams. The constitutive equation is expressed in terms of the following polymer and foam properties: elastic modulus, relative density, as well as the relaxation and densification constants. PMMA open‐cell foams are manufactured using a gas foaming/particulate leaching method and uniaxial compression tests are performed. The mechanical properties and compressive stress‐strain responses obtained from the experiments are compared with those predicted by the proposed constitutive model. The results suggest that the constitutive model is an apt one for assessing and evaluating the compressive behaviors of PMMA open‐cell foams. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 436–443, 2007     

Effects of starch types on the properties of baked starch foams

In order to determine how the physicochemical properties of starch foams depend on the type of the starch used in baking process, starch foams were prepared using native starch and selected starch derivatives. The morphology, the density, the water adsorption capacity, the impact strength, and the thermal properties were determined for foams made from native starch, pregelatinized starch, hydroxypropylated starch with different degrees of substitution (DS = 0.015–0.025 and DS = 0.1), low distarch phosphate, medium distarch phosphate, and two cationic starch types (DS = 0.027–0.029 and DS = 0.029–0.033). The modified starch foams exhibited a more expanded structure with thinner cell walls than the foam made from native starch. The density of the native starch was 0.21 g cm^?3 , while the density of the modified starch foams was lower, in the range of 0.14–0.17 g cm^?3 except for the starch foam made from medium distarch phosphate. The thermal and physicochemical properties of the foams made from the other starch derivatives were dependent on the functional groups and the degree of cross-linking. The foam made from medium distarch phosphate had a significantly higher density and impact strength that was accompanied by a somewhat lower water adsorptivity.     

Experimental and numerical investigations of the anisotropic deformation behavior of low-density polymeric foams

Low-density porous materials and foams have been widely used for a variety of applications, such as light structural components, impact energy absorption, thermal insulation and sound absorption. The macroscopic deformation of such materials is strongly dependent on their inherent micro-cellular structure. This study investigated the compressive anisotropic deformation behavior of low-density polymeric foam by using X-ray computed tomography (CT) and the finite element method (FEM) in order to understand both the microscopic and macroscopic deformation behavior. The foams used in this study have a closed cell structure, with pores that are elliptical in shape. Three different types of expansion ratios were employed. The porosities of these materials were 93.5, 95, and 96%. From the observations using the X-ray CT method, the averaged pore heights were 1 mm and the aspect ratios were 2, 2.5, and 2.25, respectively. The foam demonstrated anisotropic deformation, dependent on the uni-axial compression direction. It was found that the deformation rigidity in the longitudinal direction was larger than that in the transverse direction. By using the X-ray CT method in situ, the microscopic deformation behavior when subjected to compressive loading was observed. Deformation and collapse of pores was observed for both directions during the loading. In conjunction with this, FEM computations were carried out to elucidate how such pore geometry undergoes elastoplastic deformation and leads to macroscopic deformation behavior. The FEM-created three-dimensional spatial structures were based on elongated rhombic dodecahedrons. It is revealed that the FEM computation shows relatively good agreement with the experimental results. Thus, our experimental and computational models may be useful for microstructural design using anisotropic cellular materials.     

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     

X-ray CT microtomography and mechanical response of foamed polysiloxane elastomers

3D X-ray computer microtomography (CT) experiments have been performed to assess the microstructure of scaled cellular polysiloxane elastomers and to predict how key morphological features alter as a function of compressive loading. In the work reported here, full scale (nominally 600 μm pore size) and half scale (nominally 300 μm pore size) polydimethylsiloxane foams (M97) were prepared using extractable urea particles, and tested. CT test methodology was developed to image foam microstructure at different levels of compression. 1D magnetic resonance imaging (MRI) experiments have also been performed on full scale foams for baseline characterisation. Material porosity, bulk density and dynamic mechanical analysis (DMA) stress/strain responses as a function of compression were recorded. Our results show that undesirable engineering stress responses are evident when the material microstructure (cell size and shape) is non-uniform and complex. This is particularly evident when non-spherical urea particles are used, leading to undesirable scaled foam microstructures with mechanical responses that do not match that shown by ‘full scale’ versions. Through the use of X-ray CT and MRI, our studies have provided insights into the link between manufacturing, polymer architecture (cell size/shape) and mechanical response of scaled M97 cellular materials. The data collected will support materials FEA (finite element model) code development activities, as well as help identify how the material architecture can be modified to achieve more controlled and uniform mechanical responses.     

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     

The role of microstructure on the mechanical properties of polyurethane foams containing thermoregulating microcapsules

Rigid polyurethane foams with up to 50 wt% of microcapsules from LDPE-EVA containing Rubitherm^®RT27 were synthesized. The influence of microcapsules on the foams density, microstructure and mechanical resistance was studied. Cell size and strut and wall thicknesses were analyzed by SEM. The relationships between densities and foam microstructures with their Young's moduli and collapse stress were found by the Gibson and Ashby formulations and the Kerner equation for mechanical properties of composites. It was found a cell structure change from polyhedral closed-cells to spherical or amorphous open-cells. A good agreement between the experimental and theoretical data was observed but requiring a cell form factor. Thus, Fitting parameters confirmed the high trend of these microcapsules to be incorporated into the foam cell walls and the form factors depicted the abrupt change of cell morphology. Thus, these equations are suitable for predicting the mechanical properties of foams containing fillers of low mechanical resistance.     

Solid‐state microcellular and nanocellular polysulfone foams

In this article, we report on the process for creating microcellular and nanocellular polysulfone (PSU) foams. Microcellular foams with cell size up to 8 µm and nanocellular foams with cell size in the range of 20–30 nm were created. A range of CO₂ concentration was achieved by varying saturation temperature, from 5% at 60 °C to 14.7% at ?10 °C. The CO₂ concentration has a strong influence on the cellular structure. There exists a critical concentration window, between 10.7% and 12.3%, within which cell nucleation densities increase rapidly and cell sizes drop from micrometer range to below 1 µm into the nanometer range. Nanofoams with cell nucleation densities exceeding 10¹⁵ cells/cm³ and void fraction of up to 48% are achieved. At the high CO₂ concentration region, the change from closed nanocellular structure to bicontinuous nanoporous structure is observed. Also, nanostructures on the cell wall of microcells are observed and believed to be formed via stress‐induced nucleation/spinodal decomposition. The PSU nanofoams produced in this study present an opportunity to produce polymer nanofoams with a relatively high service temperature. The ability to create cells of different length scales provides an opportunity to study the effect of cell size on the foams properties. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 975–985     

Reagent-loaded and unloaded polyurethane foam as preconcentration matrix in neutron activation analysis

Loaded and unloaded polyurethane foams were examined as a preconcentration matrix in combination with neutron activation analysis. The structure of the foamed polymer is not damaged by short irradiation periods. However the foam skeleton degraded after irradiations for one hour or longer in a neutron flux of 3·10¹³ n ·cm⁻²·s⁻¹. The presence of tin as a major impurity in the polyether-type foam has been detected. This may affect the sensitivity of determination of the relatively short lived isotopes of the elements collected on the foam. On the other hand the polyester-type foam was found to contain only very low amounts of tin. Antimony, indium, gold and mercury collected on the foams were determined with reasonable accuracy.     

Melamine,silica, and ionic liquid as a novel flame retardant for rigid polyurethane foams with enhanced flame retardancy and mechanical properties

Rigid polyurethane (PU) foams were successfully filled with different weight ratios of melamine (1 wt%, 5 wt%, 10 wt%), silica (0.1 wt%) and ionic liquid, 1-Ethyl-3-methylimidazolium chloride, [EMIM]Cl (0.3 wt%). The aim of this study was to improve the flame retardancy of PU foams and to develop the synergistic effect between melamine, silica and ionic liquid on the flame-retardant PU foams. The influence of different loadings of the fillers was examined. The results showed that in comparison with unfilled foam, all modified compositions are characterized by higher density (41–46 kg m⁻³), greater compression strength (134–148 kPa), and comparable thermal conductivity (0.023–0.026 W m⁻¹ K⁻¹). Moreover, the reaction to fire of the PU composites has been investigated by the cone calorimeter test. The results showed that the fire resistance of PU foams containing as little as 1 wt% of melamine is significantly improved. For example, the results from the cone calorimeter test showed that the incorporation of the melamine, silica and ionic liquid significantly reduced the peak of heat release rate (pHRR) by ca. 84% compared with that of unmodified PU foam. SEM results showed that incorporated fillers can form an intumescent char layer during combustion which improves the reaction to fire of the composite foams.     

Effect of biopolymer blends on physical and Acoustical properties of biocomposite foams

Bio‐based foams are the solution to environmental concerns raised by petrochemical‐based open cell foams used in various industries for sound absorption. While conventional petrochemical‐based polymers take centuries to degrade or may not degrade at all, bio‐based polymers decompose to biomass, water, and carbon dioxide in a matter of months when exposed to proper environment. To increase the potential of replacing current petrochemical foams, mechanical as well as acoustic characteristics of bio‐based foams need to be improved. This article studies the effect of blending two bio‐based polymers and physics of the blends on acoustic and mechanical properties of resulting polymer composite foams. Different blends of polylactide with three grades of polyhydroxyalkanoates were foamed and characterized based on acoustic and mechanical performance. Rheological properties of pure polymers as well as their blends were studied and effect of polymer blends on acoustic absorption of the resulting foams was investigated. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2014 , 52, 1002–1013     

Preparation of magnetic polyurethane rigid foam nanocomposites

Super paramagnetic Fe₃O₄@SiO₂ nanoparticle was incorporated into polyurethane rigid foams in order to prepare new corresponded magnetic nanocomposite foams via one-shot method. The core–shell-structured nanoparticles were prepared by sol–gel method and characterized by transmission electron microscopy, X-ray diffraction, as well as Fourier transform infrared spectroscopy techniques. Magnetic nanoparticles were used up to 3 % in the foam formulations and the samples prepared successfully. Thermal, mechanical, and magnetic properties of nanocomposites were studied and the results showed superior properties in comparison with pristine foams.     

Compressive response of composite ceramic particle-reinforced polyurethane foam

Quasi-static and dynamic compressive tests are undertaken on the polyurethane (PU) foam and fumed silica reinforced polyurethane (PU/SiO₂) foam experimentally. The ceramic microspheres with varying mass fractions are adopted to mix with the PU/SiO₂ foam to fabricate the composite particle-reinforced foams. The effects of strain rate and particle mass fraction are discussed to identify and quantify the compressive response, energy-absorbing characteristic, and the associated mechanisms of the composite foams. The results show the initial collapse strength and plateau stress of the foams are improved significantly by reinforcing with the ceramic microsphere within 60 wt% at quasi-static compression. The rate sensitivity is observed on all the foams, but in different patterns due to the influence of ceramic microsphere. The compressive response affected by ceramic microsphere can be attributed to the particle cluster effect and stress wave propagation. Together with the deformation, the compressive characteristic experiences non-monotonic change from the low to high strain rates. The specific energy absorption (SEA) of the foam with 41 wt% ceramic microsphere show the largest magnitude at quasi-static compression. With the increasing strain rate, the ceramic reinforced foam exhibits superior energy absorption efficiency at high strain rates to that of the pure foams.     

Ultra low density and highly crosslinked biocompatible shape memory polyurethane foams

We report the development of highly chemically crosslinked, ultra low density (～0.015 g/cc) polyurethane shape memory foams synthesized from symmetrical, low molecular weight, and branched hydroxyl monomers. Sharp single glass transitions (T_g) customizable in the functional range of 45–70 °C were achieved. Thermomechanical testing confirmed shape memory behavior with 97–98% shape recovery over repeated cycles, a glassy storage modulus of 200–300 kPa, and recovery stresses of 5–15 kPa. Shape holding tests under constrained storage above the T_g showed stable shape memory. A high volume expansion of up to 70 times was seen on actuation of these foams from a fully compressed state. Low in vitro cell activation induced by the foam compared with controls demonstrates low acute bio‐reactivity. We believe these porous polymeric scaffolds constitute an important class of novel smart biomaterials with multiple potential applications. © 2012 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2012     

Synthesis and characterization of a narrow‐bandgap polymer containing alternating cyclopentadithiophene and diketo‐pyrrolo‐pyrrole units for solar cell applications

We have synthesized a narrow‐bandgap conjugated polymer ( PCTDPP ) containing alternating cyclopentadithiophene (CT) and diketo‐pyrrolo‐pyrrole (DPP) units by Suzuki coupling. This PCTDPP exhibits a low band gap of 1.31 eV and a broad absorption band from 350 to 1000 nm, which allows it to absorb more available photons from sunlight. A bulk heterojunction polymer solar cell incorporating PCTDPP and C₇₀ at a blend ratio of 1:3 exhibited a high short‐circuit current of 10.87 mA/cm² and a power conversion efficiency of 2.27%. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 1669–1675, 2010     

Mössbauer, NMR and ATR-FTIR spectroscopic investigation of degradation in RTV siloxane foams

The combination of experimental techniques allowed for a comprehensive study of aging processes occurring in RTV siloxane foams. ¹¹⁹Sn Mössbauer spectroscopy demonstrated that tin residues are composed of Sn(II) and Sn(IV) species. The 27-year-old foams showed only Sn(IV) species with a quadrupole-splitting parameter larger than that observed for SnO₂. Solid-state ²⁹Si NMR differentiated between the various functional linkages in the foams, and showed no significant change of the di- to trifunctional linkage ratios. High-resolution NMR, on solvent extract of foams, showed the presence of water, catalyst, plasticizer, and some silicone oligomers. ATR-FTIR demonstrated changes near the surface of the foam when aged with water and with the presence of the tin catalyst. Gamma irradiation at a low dose had little effect on compression sets. The main changes observed for artificially aged and aged in service foams were related to the presence of the tin catalyst.     

Microcellular foams from polyethersulfone and polyphenylsulfone: Preparation and mechanical properties

Polymeric foams having microcellular structures were successfully prepared from some high-performance thermoplastics, specifically polyethersulfone and polyphenylsulfone. A two-stage batch foaming process was used and the resulting materials had average cell sizes in the range 2-13 μm, and cell densities the order of 10¹⁰-10¹¹ cells/cm³. The foam densities (relative to those of the unfoamed polymers) were in the range 0.90-0.35. Average cell sizes increased with foaming temperature and foaming time; on the other hand, cell densities and relative foam densities decreased slightly with foaming temperature but remained almost constant with foaming time. Experimental values of Young’s modulus in compression and the elastic collapse strength were higher than theoretically predicated at high relative densities, but the discrepancies became small at lower densities. In contrast, Young’s moduli in tension were in very good agreement with theory, but the relative strengths were somewhat lower than predicated.     

Understanding Behavior of Polycaprolactone–Gelatin Blends under High Pressure CO<Subscript>2</Subscript>

Polycaprolactone (PCL) is widely used in biomedical applications as electrospun fibers or porous foams. As PCL is synthetic polymer, many researchers have explored blends of PCL–gelatin to combine mechanical and bioactive properties of individual components. High pressure carbon dioxide (CO2) has been studied to foam and impregnate many biocompatible polymers. In case of PCL–gelatin blends, certain compositions can be swelled reversibly under high pressure CO₂ without permanent deformation. This allows successful impregnation of PCL–gelatin blends under CO₂. This study summarizes effect of different treatments adopted during impregnation process including high pressure CO2 on several blend compositions of PCL–gelatin blends. Stress relaxation, polymer melting and dissolution were observed during several treatments which affects porosity and scaffold structure significantly. Results summarized in this study will aid in optimum selection of PCL–gelatin blend composition for biomedical applications. Furthermore, CO₂ solubility in polymers is restricted due to thermodynamic limitations but can be altered in the presence of a co-solvent to produce better foams. PCL can be foamed using supercritical CO₂. However, CO₂ foaming of PCL–gelatin blend becomes challenging to simultaneous swelling of PCL and compression of gelatin providing blend structural stability. This study has demonstrated ability of supercritical CO₂ to foam PCL–gelatin blends in presence of water to create porous structure. These foams were subjected post-fabrication crosslinking and supercritical CO₂ without losing porosity of foams. Thus, creating a strategy to use environmentally benign processes to fabricate, crosslink and impregnate porous scaffolds for biomedical applications.     

Mechanical properties of polyurethane foams modified by polymer-polyols

The mechanical properties of polyurethane foams based on tolylene diisocyanate and polyether modified by polymer-polyol, which is a styrene-acrylonitrile copolymer grafted onto polyol, were studied. The breaking stress, the hardness at 40% compression, the elongation at break, and the density depend on the amount of both the hard phase in the polymer-polyol and the polymer-polyol component in the polyurethane foam composition. Samples with a density of ～30 kg/m³ were prepared to have other mechanical properties practically identical to those of standard samples with a density of ～37–47 kg/m³.