In situ preparation of cross‐linked polystyrene/poly(methyl methacrylate) blend foams with a bimodal cellular structure

In situ preparation of a cross‐linked poly(methyl methacrylate) (PMMA) and polystyrene (PS) blend and its foaming were investigated for creating a bimodal cellular structure in the foam. Methyl methacrylate (MMA) monomer was dissolved in PS under supercritical CO₂ at a temperature of 60 °C and a pressure of 8 MPa, and the polymerization of MMA was conducted at 100 °C and 8 MPa CO₂, with a cross‐linking agent in PS. The blend was successively foamed by depressurizing the CO₂. CO₂ played the roles of plasticizing the PS and enhancing the monomer dispersion in PS during the sorption process and as a physical blowing agent in the foaming process. The cross‐linking agent was used for controlling the elasticity of polymerized PMMA domains and differentiating their elasticity from that of the PS matrix. The difference in elasticity delayed the bubble nucleation in the PMMA domains from that in the PS and made the cell size bimodal distribution, in which the smaller cells ranging from 10 to 30 µm in diameter were located in the wall of large cells of 200–400 µm in diameter. The effects of the initial MMA content, the concentration of cross‐linking agent, and the depressurization rate on the bimodal cell structure and bulk foam density were investigated. Copyright © 2011 John Wiley & Sons, Ltd.