Crosslinked ethylene butyl acrylate copolymer foams with different cellular structure interconnectivity and tortuosity: Microstructure and physical properties

In this work, the cellular structure, physical properties, and the structure–property relationship of several novel crosslinked ethylene butyl acrylate (EBA) foams with different cellular structure interconnectivity (low tortuosity and high tortuosity) have been analyzed and compared to that of closed cell EBA foams and to that of an open-cell polyurethane foam. The results have shown that these materials present interesting properties highly dependent on the tortuosity of the cellular structure. In particular, it has been proved that reducing the tortuosity allows enhancing the acoustic absorption, the oil uptake, and the cushioning behavior. On the other hand, increasing tortuosity allows improving the impact behavior. In addition, the new open-cell materials present an enhanced damping factor for low-frequency vibrations. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 48161.     

Young’s modulus and thermal conductivity of closed-cell,open-cell and inverse ceramic foams – model-based predictions,cross-property predictions and numerical calculations

Numerical calculations of relative Young’s modulus and thermal conductivity have been performed on computer-generated microstructures of wall-based (closed-cell) and strut-based (open-cell) cellular materials (foams) and inverse foams. The results are compared to rigorous upper bounds (Wiener-Paul, Hashin-Shtrikman), model-based predictions (power-law, exponential) and cross-property predictions (CPRs). It is shown that closed-cell foams exhibit higher property values than open-cell and inverse foams, Kelvin foams higher than random foams, and the difference between closed-cell and open-cell foams is larger than that between Kelvin and random foams. While the properties of closed-cell foams are higher than the power-law prediction, those of inverse and open-cell random foams are between the exponential and power-law predictions, and open-cell Kelvin foams follow the Gibson-Ashby power-law prediction for open-cell foams. The Pabst-Gregorová CPR is shown to predict Young’s modulus with accuracy better than ±0.02 relative property units (better than any model-based relation and any other CPR).     

Evaluation of the salt leaching method for the production of ethylene propylene diene monomer rubber foams

The thermomechanical behavior of ethylene propylene diene monomer (EPDM) foams produced with the salt leaching method has been investigated and compared with the behavior of EPDM foams obtained from conventional blowing agents. Moreover, the salt-leaching process has been optimized to minimize salt residues and the influence of different parameters (such as average particle size and particle size distribution) has been investigated. Scanning electron microscopy and density measurements highlighted that salt-leaching leads to the formation of open-cell porosity with cell dimensions of around 60 to 80 μm, while foams obtained with the two traditional foaming agents lead to closed-cell porosity. Compression set values indicate that the behavior of the foams produced with salt leaching are more similar to the unfoamed rubber, characterized by higher elasticity and low residual deformation. Two theoretical models were successfully applied to the compression curves (Mooney-Rivlin and Exponential-Logarithmic) and they highlighted the effect of foaming on the properties of EPDM rubber and in particular the higher chain extensibility obtained through the salt leaching foaming method.     

Effect of addition of EVA on the technical properties of extruded foam profiles of low-density polyethylene/EVA blends

Some technical properties (static mechanical properties, dynamic mechanical properties, creep-recovery behavior, thermal expansion, and thermal conductivity) of low-density foams (50 kg/m³) made of blends of low-density polyethylene (LDPE) and the ethylene vinyl acetate copolymer (EVA) were studied as a function of the EVA proportion in the blends. These properties were compared with those of a foam made of a blend of EVA and ethylene propylene rubber (EPR). The knowledge of how the EVA proportion influences the behavior of these blend foam materials is a fundamental factor in order to obtain a wide range of polyolefin foams, with similar density, suitable for different applications. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 68: 1237–1244, 1998     

Microstructure and physical properties of open‐cell polyolefin foams

The cellular structure, physical properties, and structure–property relationships of novel open‐cell polyolefin foams produced by compression molding and based on blends of an ethylene/vinyl acetate copolymer and a low‐density polyethylene have been studied and compared with those of closed‐cell polyolefin foams of similar chemical compositions and densities and with those of open‐cell polyurethane foams. Properties such as the elastic modulus, collapse stress, energy absorbed in mechanical tests, thermal expansion, dynamic mechanical response, and acoustic absorption have been measured. The experimental results show that the cellular structure of the analyzed materials has interconnected cells due to the presence of large and small holes in the cell walls, and this structure is clearly different from the typical structure of open‐cell polyurethane foams. The open‐cell polyolefin foams under study, in comparison with closed‐cell foams of similar densities and chemical compositions, are good acoustic absorbers; they have a significant loss factor and lower compressive strength and thermal stability. The physical reasons for this macroscopic behavior are analyzed. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Absorption of benzene by open-cell polyurethane foams

The rate of absorption of benzene by open-cell polyurethane foams of varying pore size (30–85 pores per inch) has been shown to be dependent on the size of the foam samples. Mass transport from the bulk vapor to the matrix surface appears to be a significant resistance when compared with the rate of diffusion in the matrix itself. Even though these foams have a large permeability to air at low pressures, pore diffusion appears to be more significant than bulk flow in describing the absorption process, resulting in absorption behavior which is more characterstic of closed-cell foams. A dual resistance model of the obsorption process, has been used to estimate matrix diffusivities and pore mass transfer coefficients. Although the model was inadequate in some regards to describe completely the absorption process, the significance of the unexpected pore diffusion resistance to mass transfer was quantified. The dependence of pore diffusion on foam size reflected the qualitative interpretation that was apparent from the absorption curves. While the reason for this anomalous behavior remains unknown, open-cell foams cannot be considered simply as a high-surface-area thin-walled form of the matrix material in describing the absorption process; the effect of foam size must also be considered.     

Electrical conductivity and porosity relationship in metal foams

This paper presents a literature review of the experimental data and different authors’ proposed equations related to the measurement and modelling of the electrical conductivity of metal foams. The analysis is based on the classification scheme that considers two different foam categories: open-cell and closed-cell foams. A new empirical equation is presented to describe the relationship between porosity and electrical conductivity in foamed materials. The aim of this equation is to encompass the different behaviours previously described for different types of foams in a single equation.     

Constitutive modeling of HDPE polymer/clay nanocomposite foams

A constitutive model for tensile behavior of high density polyethylene (HDPE)/clay nanocomposite foams was proposed. The elastic modulus of HDPE/clay nanocomposite was developed using micromechanics theory, and the modulus for foams was obtained by using representative volume element (RVE) concept. In order to describe the tensile behavior of the foams, a constitutive equation obtained from a viscoelastic model was proposed. The constitutive model was expressed in terms of microstructural properties of polymer, and physical properties of the foams. The effects of the material parameters and processing conditions on the foam morphologies and mechanical properties of HDPE/clay nanocomposite foams were investigated. Microcellular closed-cell nanocomposite foams were manufactured with HDPE, where the nanoclay loadings of 0.5, 1.0, and 2.0 wt% were used. The effect of clay loading and foaming conditions on the volume expansion ratio, elastic modulus, tensile strength, and elongation at break was investigated. Except for the elongation at break, the mechanical properties were improved with nanoclay loading. The tensile experimental data of the foams were compared with the prediction by the theoretical model. It was demonstrated that the tensile behaviors of HDPE/clay nanocomposite foams were well described by the constitutive model.     

Mechanical characterization of closed‐cell polyolefin foams

Three different experimental techniques [compression experiments at low strain rates, instrumented falling‐weight impact tests, and dynamic mechanical analysis (DMA)] have been used for the mechanical characterization of a collection of crosslinked closed‐cell polyolefin foams of different chemical compositions, densities, and type of cellular structure. The experimental results that it is possible to obtain from each technique are shown, and related to the different applications of these materials. The relationships between the structure and the mechanical properties are also presented. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 156–166, 2000     

A novel process to high-strength and controlled-shrinkage Al2O3 foams with open-cell by Al powder hollowing technology

Ceramic foams with open-cell structures have attracted extensive attention due to their unique structure and superior properties. But these materials often exhibit the weakness of high sintered shrinkage and low strength at high porosity levels. In this work, novel ceramic foams with open-cell structures have been obtained using Al powder by combining direct foaming and gelation freezing (DF–GF). The foams are assembled by hollow Al₂O₃ particles resulting from the Kirkendall effect, in which expanded particles overcome the shrinkage of sintering. The influence of sintering temperature on the microstructure and properties of foams are investigated. The Al₂O₃ foams show near-zero-shrinkage at 1773 K after undergoing the process of first expansion and then shrinkage. Compared to other conventional open-cell foam, this foam displays relatively high compressive strength of 0.35–2.19 MPa at high porosity levels of 89.45%–94.45%, attributed to hierarchical pore structure and reaction bonding between Al and O₂. This method from pore structure design provides a novel route for the preparation of controlled shrinkage and high-compressive strength alumina foam with open-cell toward potential application.     

Poisson’s ratio of porous and cellular materials with randomly distributed isometric pores or cells

The porosity dependence of Poisson's ratio of materials with random microstructure is investigated via analytical and numerical modeling. It is shown that all analytical models predict porosity independence if the solid Poisson ratio is 0.2 and for low porosities a converging trend toward this value with increasing porosity. From all theory-based relations, only power-law and exponential relations allow for auxetic behavior. Numerical calculations on computer-generated digital microstructures (overlapping and isolated spherical pores, pores between overlapping spherical grains, wall-based cellular materials/closed-cell foams, and strut-based cellular materials/open-cell foams) confirm the general qualitative trends of the analytical models, although a closer look reveals significant quantitative differences. Cellular materials and foams exhibit similar features as porous materials in general, but lack their converging trend toward values around 0.2. Comparison of our results with the classical Roberts-Garboczi results shows good agreement, with subtle differences due to the different microstructures generated.     

Fabrication and Characterization of Ceramic Foams Based on Silicon Carbide Matrix and Hollow Alumino-Silicate Spheres

Closed-cell foams were fabricated by incorporating two different grades of hollow alumino-silicate spheres (cenospheres) into a silicon carbide matrix. The matrix was formed by the pyrolysis of a preceramic polymer, and multiple polymer infiltration and pyrolysis (PIP) cycles were employed to minimize the open voids in the material. The physical, mechanical and thermal properties of the fabricated foams were characterized as functions of the number of reinfiltration cycles. The open- and closed-void volume fractions were determined by measurements of bulk and skeletal densities. Mechanical properties, including strength and modulus, were evaluated using four-point bend and compression tests. Finally, thermal properties of the material, including the coefficient of thermal expansion and the thermal conductivity, were determined using dilatometry and the laser-flash technique, respectively. This processing technique results in closed-cell syntactic foams with minimal porosity (∼2–4%), reasonable mechanical strength (∼30 MPa) and very low thermal conductivity (≤1 W/m·K). In this manner, this process can be used for the low-cost and net-shape fabrication of closed-cell silicon carbide-based syntactic foams for high-temperature applications.     

聚氨酯泡沫塑料在低密度炸药制备中的应用

以软质聚氨酯泡沫塑料为载体，制备低密度炸药。探讨了聚氨酯泡沫塑料在低密度炸药中的应用。简单介绍了采用炸药溶液浸渍法、水分散液浸泡法和原料混合发泡法这三种方法的工艺过程以及产品的爆炸性能。     

Improved adhesion of LDPE films to polyolefin foams for automotive industry using low-pressure plasma

The use of polymer films for technical applications has increased considerably in the last years, since they offer good balanced properties. Polymer films find many applications as individual materials or as laminates with other films, foams, membranes, etc. In these cases it is necessary to improve the low intrinsic surface energy of polymer films to ensure their optimum mechanical performance. In this work, low-pressure glow discharge plasma with different gases is used to improve the adhesive properties of a low-density polyethylene (LDPE) film, to obtain the optimum mechanical response of laminates with polyolefin foam for automotive applications (steering wheels). The results show a remarkable increase in T-peel strength of the adhesive joints. Furthermore, since automotive industry is characterized by high technical requirements, the evaluation of the durability of the adhesive joints (in terms of storage conditions: temperature and relative humidity) shows that the T-peel strength of adhesive joints is subjected to an aging process that slightly decreases their mechanical performance, but does not restrict the use of these laminates in automotive uses.     

Studies of polymeric systems for absorbing airborne sound

Sound absorption properties of polymer systems were investigated as functions of temperature, frequency, and chemical composition. Viscoelastic polymers were mixed with rigid polymers to obtain improved acoustical performance. In the case of foamed polymers, it was found that the chemical nature of the polymer is the most important factor controlling sound attenuation if the thin membranes of the closed-cell foams are “acoustically transparent.” Polyurethane-based polymer foams have been developed which possess excellent sound absorption characteristics. The foams are closed-cell, leathery, and “dead,” and can absorb as much as 96% of the normal incident sound energy at 1250 Hz (foam thickness 25 mm). The temperature-dependent acoustical properties of various polymer systems are discussed in terms of viscoelastic theory of polymers.     

The compressive deformation of polymeric foams

An alternative approach has been developed to evaluate compressive stress on polymeric foams. Compressive stress depends primarily on three factors: foam density, deformation strains, and deformation rates. The density dependency derived from this approach agrees closely with the empirical models reported in the literature. Correlations between the dynamic compression and shear deformation are also derived. Experimental data are presented which show that G′ and G″ increase with increasing strain rates, while the damping factor reaches a maximum at low strain rates. Note that the proposed model for the prediction of cell-wall rupture would not apply to foams with high open-cell contents.     

Chemical vapour infiltration and mechanical properties of carbon open-cell foams

In order to improve their mechanical properties, carbon open-cell foams of two different pore sizes were infiltrated with pyrocarbon by chemical vapour deposition at reduced pressure and using pure propane as precursor. The optimal conditions in terms of deposition rate and uniformity in coating thickness, structure and anisotropy were first investigated. Foam specimens were infiltrated at various stages, with two pyrocarbons of distinct microtextures and their morphology, relative density and geometrical features were evaluated.Compressive crushing tests were conducted to determine the influence of the pore size, the pyrocarbon type and the relative density on the mechanical properties of the pyrocarbon-infiltrated foams. They retain their non-brittle and dissipating behaviour up to relative densities of 0.15. The stiffness, crushing strength and dissipated energy increase significantly with the relative density. The crushing behaviour of the pyrocarbon-foam specimens can be essentially explained using simple structural models and failure mechanisms, according to the Gibson & Ashby’s approach for brittle cellular solids.     

Expandable graphite in polyurethane foams: The effect of expansion volume and intercalants on flame retardancy

Several expandable graphites (EGs), differing in expansion volume but with the same mean size, are compared as flame retardants in polyurethane (PUR) foams. Not only common sulfur‐intercalated graphites are investigated but also a new one intercalated with phosphorus. The main aim of this article is to understand which properties of EG are important for its flame retardancy effectiveness in PUR foams. Thermal stability, flammability, and fire behavior are analyzed through limiting oxygen index and cone calorimeter tests. Detailed characterization of the phosphorus‐intercalated graphite is also provided as well as physical–mechanical characterization. The results show that the well‐known sulfur‐intercalated graphites and the one with phosphorus both enhance the residue yield, induce a protective layer, and thus efficiently flame‐retard PUR foams. While the expansion volume of the EGs had a surprisingly limited influence on the performance of the foams, at least in the range tested, the most important feature controlling the effectiveness of EG in terms of flame retardant PUR foams was the type of intercalant. The presence of EG affected the physical–mechanical properties of the foams; however, no significant effect of the expansion volume or intercalant type has been revealed on the physical–mechanical properties of the foams. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45173.     

An experimental and theoretical investigation of the compressive properties of multi-walled carbon nanotube/poly(methyl methacrylate) nanocomposite foams

Polymer nanocomposite foams are promising low density substitutes for nanocomposites. Carbon nanotube/polymer nanocomposite foams possess high strength, low density, and can be made conductive. Good control of foam properties is of great importance in the application of such materials. In the current study, multi-walled carbon nanotubes (MWNTs) with controlled aspect ratio were used to alter the foam morphology in MWNT/poly(methyl methacrylate) (PMMA) nanocomposite foams produced by a supercritical carbon dioxide (CO₂) foaming process. It was found that with the addition of one weight percent of MWNTs, the Young’s modulus of polymer foams increased by as much as 82%, and the collapse strength increased by as much as 104%. The influence of MWNT aspect ratio on the compressive properties of nanocomposite foams was investigated. The addition of MWNTs influenced the foam properties in two ways: improving the compressive properties of the solid matrix, and reducing the bubble size of the nanocomposite foams. A modified constitutive model for predicting the compressive properties of high density closed-cell polymer foams was developed. The influence of the bubble size on the mechanical properties of polymer foams was discussed based on the new model.     

Production of non‐crosslinked thermoplastic foams with a controlled density and a wide range of cellular structures

A novel foaming route, with respect to existing industrial foaming processes, called “Improved Compression Molding” (ICM), which allows producing non‐crosslinked thermoplastic foams in a wide density range, is described in this work. This process is different from others because it is possible to control independently density and cellular structure and therefore, tailored cellular polymers can be produced. To understand the process, a collection of polypropylene foams, with relative densities ranging from 0.3 to 0.6 were produced. The influence of foaming parameters, on foams microstructure and mechanical response was analyzed. Results revealed that for similar densities, foams with different open cell content and cell size can be achieved. In addition, it was proved that mechanical behavior strongly depends on the degree of interconnectivity of the cells. The analysis of the relative mechanical properties allowed determining the influence of microstructure on mechanical behavior as well as quantifying the efficiency of the foaming process to produce light‐weight stiff materials. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42324.