Electrical conductivity transformation mechanism of GNPs/CB/SR nanocomposite foams

Highly flexible and electrically conductive graphene nanoparticles/carbon black/silicon rubber (GNPs/CB/SR) based nanocomposite foams were formed by using azodicarbonamide (AC) physical foaming technology. The foaming parameters (foaming agent and foaming time) were analyzed to investigate the influence on the electrical properties and microcellular structure. The electrical percolation threshold of GNPs/CB/SR nanocomposite foams approximately decreases from 25% to 30%, as the volume expansion increases through foaming. Nanocomposite foams with conductive fillers of 3–12 wt %, foaming agent of 12–18 wt %, foaming time of about 150–500 s, relative densities of 1.0–0.4 g/cm³ were achieved, providing a scheme to evaluate the transformation of electrical properties with different foaming degree. It is worth noting that the product of AC agent concentration and foaming time reaches a certain value, and the highest electrical conductivity of foamed nanocomposites could be achieved. The nonmonotonicity changing of the electrical conductivity was demonstrated. Combined with the microtopography characterization, the cell growth effect was introduced to illustrate the transformation mechanism of the electrical conductivity. The relationship between the microcellular structure and the electrical conductivity of the foamed nanocomposites was established, which is essential for further optimizations of the foaming materials for the targeted application. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45996.     

Enhanced electrical conductivity in graphene-filled polycarbonate nanocomposites by microcellular foaming with sc-CO2

Electrically conductive polycarbonate (PC) foams containing a low concentration of graphene nanoplatelets (0.5 wt.%) were produced with variable range of expansion ratio by applying a high-pressure batch foaming process using sc-CO₂. The structure of the foams was assessed by means of SEM, AFM and WAXS, and the electrical conductivity was measured in the foam growing direction. Results showed that electrical conductivity of PC composite foams remarkably increased when compared to that of non-foamed PC composite, with both the electrical conductivity and the main cell size of the foams being directly affected by the resultant expansion ratio of the foam. This interesting result could be explained by the development of an interconnected graphene nanoparticle network composed by increasingly well-dispersed and reoriented graphene nanoplatelets, which was developed into the solid fraction of the foam upon foaming by sudden depressurising of the plasticised CO₂-saturated PC preform. Some evidences of morphological changes in the graphene nanoplatelets after foaming were obtained by analysing variations in graphene’s (0?0?2) diffraction plane, whose intensity decreased with foaming. A reduction of the average number of layers in the graphene nanoplatelets was also measured, both evidences indicating that improved dispersion of graphene nanoparticles existed in the PC composite foams. As a result, foams with a proper combination of low density and enhanced electrical conductivity could be produced, enabling them to be used in applications such as electromagnetic interference shielding.     

Thermal‐Insulation,Electrical, and Mechanical Properties of Highly‐Expanded PMMA/MWCNT Nanocomposite Foams Fabricated by Supercritical CO2 Foaming

Foaming behavior of poly(methyl methacrylate) (PMMA)/multi‐walled carbon nanotubes (MWCNTs) nanocomposites and thermally‐insulating, electrical, and mechanical properties of the nanocomposite foams are investigated. PMMA/MWCNT nanocomposites containing various amounts of MWCNTs are first prepared by combining solution and melt blending methods, and then foamed using CO₂. The foaming temperature and MWCNT content are varied for regulating the structure of PMMA/MWCNT nanocomposite foams. The electrical conductivity measurement results show that MWCNTs have little effect on the electrical conductivity of foams with large expansion ratio. Thermal conductivities of both solid and foamed PMMA/MWCNT nanocomposites are measured to evaluate their thermally insulating properties. The gas conduction, solid conduction, and thermal radiation of the foams are calculated for clarifying the effects of cellular structure and MWCNT content on thermal insulation properties. The result demonstrates that MWCNTs endowed foams with enhanced thermal insulation performance by blocking thermal radiation. Moreover, the compressive testing shows that MWCNTs improve the compressive strength and rigidity of foams. This research is essential for optimizing environmentally friendly thermal insulation nanocomposite foams with enhanced thermal‐insulation and compressive mechanical properties.     

Electromagnetic Interference Shielding Foams Based on Poly(vinylidene fluoride)/Carbon Nanotubes Composite

Polymeric electromagnetic interference (EMI) shielding foaming materials are found and applied in many frontier fields such as aerospace, transportation, and portable electronics. In this paper, a foam based on a composite system of poly(vinylidene fluoride) (PVDF) filled with carbon nanotubes (CNTs) is prepared for EMI shielding properties by using a solid-state supercritical CO₂ foaming strategy. PVDF is chosen as the matrix because of its excellent chemical resistance, thermal stability, and flame retardancy. The inclusion of CNTs renders this composite system enhanced complex viscosity and storage modulus by about two orders of magnitude. The electrical conductivity and EMI specific shielding effectiveness of obtained foams can be adjusted and reached the optimum value of 0.024 S m⁻¹ and 29.1 dB cm³ g⁻¹, respectively, originating from the gradual development of interconnected CNTs and conductive CNTs network as well as the introduction of cell structure in PVDF matrix. Interestingly, the reorientation of CNTs caused by foaming process results in electrical conductivity percolation threshold of PVDF/CNTs foams markedly decreases, in comparison to their unfoamed samples. This study provides a facile, efficient, green, and economic route for the preparation of EMI shielding foams consisted of fluorinated polymers and carbonaceous fillers.     

Cellulose nanofibre–poly(lactic acid) microcellular foams exhibiting high tensile toughness

We report here the morphology and tensile properties of polylactic acid–cellulose nanofibre (PLA–CNF) microcellular nanocomposites. Two types of CNF were used for the nanocomposite preparation, native and surface acetylated CNF (ac-CNF). Samples were foamed in a mould to enable tensile testing. The effect of the mould use on the foam morphology was first assessed by comparison with free foamed samples. We found that the mould affected the cell growth stage of the foaming process in neat PLA foam while its effect was less important in nanocomposites. Stiffening and strengthening effect of CNF was greatly enhanced by foaming when compared to their solid counterparts. The most notable change in tensile properties was however the large increase in strain at break resulting in the high tensile toughness of microcellular PLA–CNF nanocomposites. Strain at break increased up to 7.5 times in neat PLA and up to 31.5 times in the foam containing 3% of CNF. Surface acetylation of CNF significantly affected the properties of foams with 9% of CNF loading: while foams with ac-CNF were stiffer, foams with native CNF exhibited higher strain at break and so higher overall toughness.     

Foaming behaviour and cellular structure of LDPE/hectorite nanocomposites

This paper presents the compared analysis of the foaming behaviour and cellular structure of LDPE/hectorite nanocomposites and respective neat LDPE foams. To assess the influence of hectorite on the foaming behaviour and final foam morphology, nanocomposites containing 3 and 7 wt.% of a modified hectorite were first melt-compounded in a twin-screw extruder. Variables such as temperature, pressure and time were optimized to prepare foams in a second stage by a two-step compression-molding process. Crystallinity and crystal structure of the polymer matrix were determined using X-ray scattering (WAXS) and differential scanning calorimetry (DSC). Clay intercalation/exfoliation was analyzed by WAXS and transmission electron microscopy (TEM), with the results indicating that partial exfoliation of the particles was only reached with foaming but not during melt mixing. A quantitative characterization of the cellular structure and morphology of the foamed nanocomposites was done using both scanning (SEM) and transmission electron microscopies. The nanocomposite foams exhibited differences in the crosslinking degree, showing lower gel content values (from 35% of the neat LDPE to as low as 28% for the 7 wt.% hectorite foam), expansion behaviour, cell aspect ratio, with the foamed nanocomposites showing more isometric type of cells, and cell wall texture with regard to the neat LDPE foams. All these differences, analyzed and compared for the three composites, directly affect both the thermal and mechanical responses of the foams and due to that fact are of extreme importance.     

Improving polypropylene microcellular foaming through blending and the addition of nano‐calcium carbonate

This article reports an attempt to improve polypropylene (PP) microcellular foaming through the blending of PP with high‐density polyethylene (HDPE) as a minor component and the incorporation of nano‐calcium carbonate (nano‐CaCO₃) into PP and its blends with HDPE. Three HDPEs were selected to form three blends with a viscosity ratio less than, close to, or greater than unity. Two concentrations of nano‐CaCO₃, 5 and 20 wt %, were used. The blends and nanocomposites were prepared with a twin‐screw extruder. The foaming was carried out by a batch process with supercritical carbon dioxide as a blowing agent. The online shear viscosity during compounding and the dynamic rheological properties of some samples used for foaming were measured. The cell structure of the foams was examined with scanning electron microscopy (SEM), and the morphological parameters of some foams were calculated from SEM micrographs. The rheological properties of samples were used to explain the resulting cell structure. The results showed that the blend with a viscosity ratio close to unity produced a microcellular foam with the minimum mean cell diameter (0.7 μm) and maximum cell density (1.17 × 10¹¹ cells/cm³) among the three blends. A foamed PP/nano‐CaCO₃ composite with 5 wt % nano‐CaCO₃ exhibited the largest cell density (8.4 × 10¹¹ cells/cm³). © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Electrical conductivity of carbon black/single-wall carbon nanotube/low-density polyethylene ternary composite foam

In order to obtain high electrical conductive low-density polyethylene (LDPE) foam, carbon black (CB), single-wall carbon nanotube (SWCNT), and LDPE (CB/SWCNT/LDPE) ternary composite foams were successfully fabricated by chemical compression molding method. The electrical conductivity, mechanical properties, microstructure, density, and crystallinity of the foam were studied in detail. It can be found that CB and SWCNT have synergistic effect. For the CB/SWCNT/LDPE composite foam which containing 19 wt % CB and 0.05 wt % SWCNT, its density is only 0.082 g cm⁻¹ and the electrical conductivity can reach at 2.88 × 10⁻⁵ S cm⁻³, which is far more than 15 orders of magnitudes of pure polyethylene and 4 orders of magnitudes times higher than sample which CB content is 19 wt %. It is noteworthy that ultralow concentration of SWCNT could drastically improve the electrical conductivity and reduce the density of LDPE foams. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48382.     

Electrical conductivity of polyurethane/MWCNT nanocomposite foams

Polymeric foams with electrical conductivity represent a novel and very interesting class of materials rather sporadically studied. In this study, the feasibility to prepare electrically conductive Rigid Polyurethane (PUR) foams at various densities using multiwall carbon nanotubes (MWCNT) at varying contents was investigated. The produced PUR/MWCNT foams exhibited electrical conductivity over a wide range of densities and nanofiller contents. The effect of these two parameters on the electrical conductivity of the final foam system was studied. To explain the behavior, Statistical Percolation laws were employed. Model parameters were elaborated for both cases showing that the percolation model can adequately describe the behavior. The foaming process is analyzed in further detail to assist in the explanation and understanding of theexperimental observations. Finally, a material design map is proposed for the preparation of electrically conductive foams. POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers     

Effect of solvent plasticization on polypropylene microcellular foaming process and foam characteristics

In this research, the effect of crystalline fraction of polypropylene (PP) on cell nucleation behavior was overcome by an introduction of solvent‐plasticized step to the microcellular foaming in a solid‐state batch‐foaming process. Utilizing the plasticization performance of the solvent facilitated the PP to be foamed at the temperatures lower than its melting point with the dramatic development in the cellular morphology of the final foams. In consequence of the heterogeneous cell nucleation sites induction and the crystalline loss, which were induced by solvent, a high cell density (i.e., 10⁹–10¹⁰ cells/cm³) was promoted without the cell sacrificing at the elevated temperatures (155 and 165°C) and favorable PP microcellular foams were accomplished. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Foamability and viscosity behavior of extrusion foamed PLA–pulp fiber biocomposites

This study addresses the effect of fiber reinforcement, chain extension, and physical foaming agent type on foam morphology and viscosity behavior of pulp fiber reinforced poly(lactic acid) (PLA) biocomposites. PLA reinforced with 0, 10, and 20 wt % of bleached kraft pulp fibers with and without chain extender were foamed using two different physical foaming agents (carbon dioxide and isobutane) by extrusion foaming. Densities, foam morphologies, and viscosities were systematically analyzed and compared from the produced foams. As a conclusion, low-density foams are produced with both foaming agents and fiber levels, fiber addition limiting cell growth. Isobutane provides better dimensional stability with narrower cell size distribution, whereas carbon dioxide enables lower foaming temperature. Chain extension is essential to achieve foam with low density and good cell structure. Contrary to nonchain extended PLA, addition of fibers reduced the viscosity of chain extended PLA. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 48202.     

Foaming of rigid PVC/wood‐flour composites through a continuous extrusion process

The effects of chemical foaming agent (CFA) types (endothermic versus exothermic) and concentrations as well as the influence of all‐acrylic processing aid on the density and cell morphology of extrusion‐foamed neat rigid PVC and rigid PVC/wood‐flour composites were studied. Regardless of the CFA type, the density reduction of foamed rigid PVC/wood‐flour composites was not influenced by the CFA content. The cell size, however, was affected by the CFA type, independent of CFA content. Exothermic foaming agent produced foamed samples with smaller average cell sizes compared to those of endothermic counterparts. The experimental results indicate that the addition of an all‐acrylic processing aid in the formulation of rigid PVC/wood‐flour composite foams provides not only the ability to achieve density comparable to that achieved in the neat rigid PVC foams, but also the potential of producing rigid PVC/wood‐flour composite foams without using any chemical foaming agents.     

Gelcasting of alumina foams using agarose solutions

Aqueous gelcasting of dense or cellular ceramics by using biopolymers as gel-formers, instead of monomers, is a promising technology mainly in terms of environmental aspects. The main difficulty of using biopolymer solutions in processing of cellular ceramics by foaming method is their high viscosity, which prevents the foaming capacity of the ceramic suspension. In this work, the procedure for preparing concentrated agarose solutions (4 wt.%) by dissolving under overpressure conditions was evaluated for the gelcasting of alumina foams, and the rheological behaviour of alumina suspensions containing agarose was studied. The viscosity of the gelling solution obtained under overpressure conditions was lower than that prepared by simply heating at 90 °C, thus providing high foaming capacity of the alumina suspensions and consequently manufacturing of highly porous ceramics (86–90%). The microstructure of alumina foams was typically composed of approximately spherical cells interconnected by circular windows. The use of different agarose concentrations in alumina suspensions effected the rheological conditions, which resulted in changes in the pore and window sizes of the resulting ceramics. Depending on agarose concentration (0.50–1.0 wt.% on a dry solids basis) in the starting (35 vol.%) alumina slurry, the mean pore size ranged from 529 to 375 μm, while the mean window size varied from 113 to 77 μm.     

Development of lightweight high‐performance polymeric composites with functionalized nanotubes

In this article, we highlight the various properties of an ultralightweight poly(ether ketone) (PEK) composite. In this study, special emphases were laid on the preparation of low‐density, high‐performance polymeric foams with foaming agents and activators. PEK, foamed PEK, and carbon nanotube (CNT)–reinforced foamed PEK composites were considered for this study. The density of the polymer decreased with the reinforcement of the foaming agent. We also noted that with the reinforcement of the modified CNT in the foamed PEK, there were marginal increases in the density and hardness of the composites. We also noted that the mechanical properties of the CNT‐reinforced foamed PEK was on par with those of basic PEK. Thermogravimetric analysis gave us a clear indication that the thermal stability of the composites was not affected by the reinforcing foaming agent and nanoparticles. Scanning electron microscopy and transmission electron microscopy clearly indicated the formation of foams and also the dispersion of nanoparticles in the composite structure. We also observed that because of the reinforcement of multiwalled CNTs in the composite, there was an improvement in the hardness of the composite. An increase in the specific strength was observed in the foamed PEK composites. The CNT‐reinforced foamed PEK showed a marginal decrease in the specific strength without a compromise in the impact strength. The impact strength of the CNT‐reinforced foamed PEK composite was found to be similar to that of the basic PEK. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43471.     

A conductive foam: Based on novel poly(styrene‐b‐butadiene‐co‐styrene‐b‐styrene) tri‐block copolymer filled by carbon black

In this article, a conductive foam based on a novel styrene‐based thermoplastic elastomer called poly(styrene‐b‐butadiene‐co‐styrene‐b‐styrene) tri‐block copolymer S(BS)S was prepared and introduced. S(BS)S was particularly designed for chemical foaming with uniform fine cells, which overcame the shortcomings of traditional poly(styrene‐b‐butadiene‐b‐styrene) tri‐block copolymer (SBS). The preparation of conductive foams filled by the carbon black was studied. After the detail investigation of cross‐linking and foaming behaviors using moving die rheometer, the optimal foaming temperature was determined at 180°C with a complex accelerator for foaming agent. Scanning electron microscopy (SEM) images shown that the cell bubbles of conductive foam were around 30–50 µm. The conductivity of foams was tested using a megger and a semiconductor performance tester. SEM images also indicated that the conductivity of foams was mainly affected by the distribution of carbon black in the cell walls. The formation of the network of the carbon black aggregates had a contribution to perfect conductive paths. It also found that the conductivity of foams declined obviously with the foaming agent content increasing. The more foaming agent led to a sharp increasing of the number of cells (from 2.93 × 10⁶ to 6.20 × 10⁷ cells/cm³) and a rapid thinning of the cell walls (from 45.3 to 1.4 µm), resulting in an effective conductive path of the carbon black no forming. The conductive soft foams with the density of 0.48–0.09 g/cm³ and the volume resistivity of 3.1 × 10³?2.5 × 10⁵ Ω cm can be easily prepared in this study. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41644.     

Lightweight investigation of long chain branching polypropylene/cellulose nanofiber composite foams

Long chain branching polypropylene (LCBPP)/cellulose nanofiber (CNF) composite foams were prepared by short shot foam injection molding method and their morphological, mechanical, and thermal properties were also investigated. The cellular structure of LCBPP/CNF composite foams was improved with weight reduction (WR) ratios increasing. The cell densities of LCBPP/CNF composite foams were dramatically increasing with WR ratios rising. More, the fine and uniform cellular structures were obtained due to the incorporation of CNF. The highest cell density, specific flexural strength, and modulus could achieved 20 × 10³ cell/cm², 65 MPa/(g/cm³) and 2.7 GPa/(g/cm³), respectively. Furthermore, the specific Charpy impact strengths were also higher than the ones of solid samples. At last, the thermal insulation properties were discussed accordingly.     

Optical transmittance and electrical conductivity of silica glass with biserial and hierarchical network structures made of carbon nanofibers

Silica glass composites, with biserial and hierarchical percolative network made of carbon nanofibers (CNFs), was fabricated using a layer-by-layer technique and spark plasma sintering to obtain high optical transmittance and electrical conductivity. Owing to the network, the critical volume fraction, V_c, for the CNF percolation in the silica glass-matrix composite (0.5–0.7 vol%), when the electrical conductivity of the composite drastically increased with change from insulator (～10^?10 S/m) to conductor (～10^?1 S/m), is smaller than theoretical V_c predicted for the three-dimensional random orientation of CNFs (2.6 vol% for the CNF aspect ratio of 30). The conductivity of the composite with above the V_c of CNFs (～10 S/m) is higher than that reported for the polymer-matrix composite (～10^?5–～10^?3 S/m). Furthermore, high optical transmittance was observed for the electrically conductive composite with V_c of CNFs.     

Effect of sintering on processability vis-a-vis microcellular foaming of ultrahigh molecular weight polyethylene

Processing of ultrahigh molecular weight polyethylene (UHMWPE) involves sintering due to its high melt strength and no flowability above melting temperature. Variations in compression molding pressure during sintering lead to chain rearrangement at the sintered interphase and the boundary, affecting foamability. UHMWPE particles are sintered using compression molding; samples are prepared at two different pressures: UHPE-HP (80 bar) and UHPE-LP (40 bar) at 180°C. The sintering phenomenon of UHMWPE particles is observed through an optical microscope, and their effect on foaming was observed. UHPE-HP foams are systematically studied to obtain the foaming window. Increasing foaming pressure (80–120 bar) made UHPE-HP foams softer (0.350–0.219 g/cm³) with varying average cell size (26.37–46.1 μm) and foam cell density (3.98 × 10⁷–1.06 × 10⁸ cells/cm³), and compression modulus decreased from 9 to 5.4 MPa. DMA results showed a strong dependence of stiffness on crystallinity, and foamed samples exhibit higher stiffness than their unfoamed counterpart. The storage modulus for foamed samples decreases with increase in the gas content. The UHPE-LP foam is relatively softer, with a lower foam density (0.233 g/cm³), a higher expansion ratio, bigger average foam cells (35.13 μm), and lower foam cell density (9.33 × 10⁷ cells/cm³). This is due to constrained crystallinity at the interphase and pre-existing cavities, favoring the foaming.     

Extrusion of polystyrene nanocomposite foams with supercritical CO2

Intercalated and exfoliated polystyrene/nano‐clay composites were prepared by mechanical blending and in situ polymerization respectively. The composites were then foamed by using CO₂ as the foaming agent in an extrusion foaming process. The resulting foam structure is compared with that of pure polystyrene and polystyrene/talc composite. At a screw rotation speed of 10 rpm and a die temperature of 200°C, the addition of a small amount (i.e., 5 wt%) of intercalated nano‐clay greatly reduces cell size from 25.3 to 11.1 μm and increases cell density from 2.7 × 10⁷ to 2.8 × 10⁸ cells/cm³. Once exfoliated, the nanocomposite exhibits the highest cell density (1.5 × 10⁹ cells/cm³) and smallest cell size (4.9 μm) at the same particle concentration. Compared with polystyrene foams, the nanocomposite foams exhibit higher tensile modulus, improved fire retardance, and better barrier property. Combining nanocomposites and the extrusion foaming process provides a new technique for the design and control of cell structure in microcellular foams.     

Preparation and characterization of natural rubber foams: Effects of foaming temperature and carbon black content

The influence of the foaming temperature and carbon black content on the cure behavior and mechanical properties of natural rubber foams was investigated at five temperature zones by 5 °C interval and different feeding ratios of the carbon black. The physical properties of the foamed NRs were then measured as a function of the foaming temperature and carbon black content, respectively. The optimal temperature for vulcanization and foaming of NRs in this study was considered to be 165 °C where density of the foamed NR is lower than that at other four temperature zones. The thickness of each of the struts formed within the rubber matrix decreased with the increasing foaming temperature, while it increased with the increasing carbon black content, supporting the density characteristics. The tensile properties of the foamed NRs such as tensile strength, tear strength and modulus gradually increased with the increasing and carbon black content, while elongation at break decreased.