Extrusion of starch‐based loose‐fill packaging foams: effects of temperature,moisture and talc on physical properties

Starch‐based loose‐fill packaging foams were made in a single‐screw laboratory‐scale extruder. Corn starch was blended with polystyrene in the ratio of 70 : 30 and extruded into foams using talc and polycarbonate as additives. Extrusions were carried out at moisture contents of 16, 18 and 20% (dry basis), and at barrel temperatures of 140 and 160°C. The influences of extrusion temperature, moisture content of starch, talc and polycarbonate on the radial expansion and other selected physical properties of starch foams were investigated. The effects of moisture and talc contents on the radial expansion of foams were found to be critical, while the role of temperature was close to significant. The expansion ratio increased when the moisture content was increased from 16 to 18%, and then decreased when moisture content was increased to 20%. In general, the expansion ratios of foams were higher at 160°C as compared to 140°C. Although polycarbonate mixed well with the starch–polystyrene melt, it was not effective as a structural and anti‐shrinking agent, and it did not contribute to the radial expansion. In general, the bulk densities and unit densities of the starch foams decreased as the moisture content and extrusion temperature increased. Scanning electron microscope images showed that the addition of talc yielded foams with smaller‐sized cells, with less expansion of the foam melt, and thus a higher density. X‐ray diffractograms revealed that the crystallinity of starch foams increased post‐extrusion, and there was adequate dispersion of the starch and polystyrene polymers to make the foam water‐resistant. Copyright © 2008 John Wiley & Sons, Ltd.     

基于常温干燥法的纤维素基泡沫制备及性能分析

传统的石油基泡沫难以降解,因而带来环境污染和安全问题。纤维素基泡沫借助其可生物降解的天然特性,逐渐成为研究热点。然而,目前的成型技术在很大程度上依赖于干燥条件（如冷冻干燥和超临界干燥）,存在干燥耗时长、成本高的问题,因而难以实现泡沫的规模化生产。为解决此问题,提出一种常温干燥制备可再生纤维素基泡沫的新方法。以纸浆纤维为主料、纳米纤维素为黏结剂、聚乙烯醇作为纤维分散剂和泡沫助剂,经过充分混合、发泡、排水和干燥后,制成纤维素基泡沫。最后,测试泡沫密度、孔隙率,分析导热性能、力学性能。结果表明：制备的纤维素基泡沫具有密度低（(0.015±0.002)~(0.028±0.004) g/cm3）、孔隙率高（>98%）、热导率低（(0.060±0.003)~(0.069±0.003) W/(m·K)）等特点。纤维素基泡沫在80%应变下的最大应力值为59.366 kPa,比其他文献报道的类似纳米纤维素基泡沫高37.1%。未来,纤维素基泡沫有望替代石油基泡沫,在冷链运输过程中对产品进行缓冲保护和隔热保温。     

Assessment of technical and environmental performances of wheat‐based foams in thermal packaging applications

This paper presents an assessment of the technical and environmental performance of a wheat‐based foam (WBF) and bio‐composite for shipping chilled products. The thermal conductivity of the WBF was found to be higher than that of polyurethane foams commonly used in high‐value insulation packaging, but close to that of low‐density (expanded polystyrene) EPS foams and significantly lower than that of polyethylene (PE) foams, which are typically used in thermal packaging of foods. The insulation performance of a simple cool box constructed from both the WBF and EPS sandwich panels without the use of any refrigerant was studied experimentally. The comparison demonstrated that the performance of the WBF cool box was comparable to that of the EPS counterpart. Two industrial case studies were conducted on WBF cool boxes with refrigerants in comparison with PE or EPS counterparts. The WBF cool boxes had comparable thermal performance to the EPS and PE counterparts on the basis of identical foam thickness. The performance of the WBF cool boxes was also simulated with finite element (FE) modelling. Good agreement was achieved between experimental data and the FE prediction. The model was then used to assist cool box design. WBF cool boxes made from renewable raw materials are inherently biodegradable and may be used as an alternative to those based on polymer foams in thermal packaging applications. Life‐cycle assessment (LCA) was used to investigate environmental profiles of cool boxes made with WBF, EPS and PE foams. The WBF cool boxes offer substantially lower global warming and abiotic depletion potentials than equivalent cool boxes made from petrochemical foams. Copyright © 2010 John Wiley & Sons, Ltd.     

Tailoring properties of reticulated vitreous carbon foams with tunable density

Reticulated vitreous carbon (RVC) foams were manufactured by multiple replications of a polyurethane foam template structure using ethanolic solutions of phenolic resin. The aims were to create an algorithm of fine tuning the precursor foam density and ensure an open-cell reticulated porous structure in a wide density range. The precursor foams were pyrolyzed in inert atmospheres at 700°C, 1100°C and 2000°C, and RVC foams with fully open cells and tunable bulk densities within 0.09–0.42 g/cm³ were synthesized. The foams were characterized in terms of porous structure, carbon lattice parameters, mechanical properties, thermal conductivity, electric conductivity, and corrosive resistance. The reported manufacturing approach is suitable for designing the foam microstructure, including the strut design with a graded microstructure.     

In situ lamination of starch‐based baked foam packaging with degradable films

A technique for making biodegradable food service packaging comprising a starch–fibre core and a biodegradable film laminate is described. The biodegradable films were made of polylactic acid (PLA), polybutylene succinate/terephthalate (PBST), rubber latex and polybutylene adipate/terephthalate (PBAT). The technique involved an in situ process for laminating a baked foam product in a single step. A critical element of the in situ technique involved using a heat insulating fibre sheet to stabilize heat‐sensitive laminate films during the baking/lamination process. The PLA‐, PBST‐ and PBAT‐laminated samples were baked for 6min at 120°C. The latex‐laminated sample, which was much more heat‐stable, did not need the insulating sheet and was baked for 3min at 160°C. Starch‐based foam laminated with PLA, PBST or PBAT generally had higher density and greater tensile and flexural strength than the non‐laminated control. Starch foam laminated with a rubber latex film had tensile and flexural properties similar to the non‐laminated control, due to the low modulus and elasticity of the latex film. The in situ lamination process improved the adhesion of the starch foam core with the fibre sheet, PLA and latex films compared to a post‐lamination process. All of the laminate materials provided a low water vapour permeance. The films degraded in a compost mixture but at a much slower rate compared to starch. Copyright © 2006 John Wiley & Sons, Ltd.     

Wöhlerversuche an bauteilähnlichen Proben aus MRI 153M

Woehler tests on component‐like specimen of MRI 153M The alloy MRI 153M shall increase the application of Magnesium because of its comparable properties to AZ 91 but better static strength properties at temperatures up to 150° C. Constant amplitude tests were performed with component‐like specimen under variable environment conditions. The modified parameters were the notch radius (r=3 mm or r=12 mm), the stress ratio (R=0 or R=‐1), the surrounding temperature (room temperature, 120° C or 150° C) and the cast skin. At room temperature the Woehler curves of MRI 153M trend to higher cycles to crack initiation than AZ 91 and AM 60. If the local stresses are compared, the specimen with r=12 mm show earlier crack initiation because of the influence of size. The decrease of fatigue under higher temperature is about one scatter range and can be valuated as moderate. Between 120° C and 150° C the fatigue values do not show any significant differences. The removal of the cast skin has no influence on the lifetime of the component.     

Prediction of cushion curves of polymer foams using a nonlinear distributed parameter model

Polymer foams are commonly used in the protective packaging of fragile products. Cushion curves are commonly used within the packaging industry to characterize a foam's impact performance. These curves are two-dimensional representations of the deceleration of an impacting mass versus static stress. Cushion curves are currently generated from exhaustive experimental test data. This study represents the first time that the physics of the mass-cushion impact have been analysed by modelling the foam as nonlinear, continuous rod. Using a single mode of vibration and excluding the effects of damping, the maximum displacement during the impact can be obtained from a polynomial describing the maximum elastic energy in the foam. The displacements can be used to recover the amplitude of the deceleration shock pulse. Numerical and analytical analysis of the model with damping is considered in its ability to predict the shock pulse shape, duration, and amplitude at various static stresses, foam thickness, and drop heights as compared with experimental data. Furthermore, both the analytical and numerical results agree and are primarily within the expected lab-to-lab variability of 18% documented in ASTM D1596 - Standard Test Method for Dynamic Shock Cushioning Characteristics of Packaging Material.     

Ceramic foams from preceramic polymers

The direct foaming of preceramic polymer mixtures, followed by high temperature pyrolysis in an inert atmosphere, can be employed to fabricate ceramic foams with impressive strength, stiffness, thermomechanical and thermochemical durability, and electromagnetic properties. Flexural strength and stiffness were superior to those of foams produced using conventional replication process technologies. Excellent strength retention and thermal fatigue resistance was exhibited during long term static and cyclic thermal exposure to 1200 °C in air. Further improvements can be realized through judicious selection of the preceramic polymers and pre-pyrolysis process modifications. Fabrication of foams with graded porosity and multifunctionality, via the incorporation of electrically-, thermally-, and magnetically-active fillers was demonstrated. This direct foaming technology offers substantial opportunity for the near-net shape fabrication of lightweight, inorganic foam structures with tailored thermal, elastic, mechanical, electrical and magnetic characteristics for high temperature applications. Electronic Publication     

Reticulated macroporous ceramic foam supported TiO2 for photocatalytic applications

Ceramic macroporous reticular alumina foams with a pore size of 15, 20 and 25 pores per inch (ppi) were prepared by the Schwartzwalder method and sintered at 1200 °C to preserve a high porosity. TiO₂ thick films were supported on the foam surface by a wash coating process, using Degussa P25 as a TiO₂ nanopowder source. After annealing at 600 °C, films with an adequate adhesion and with a thickness of 5–10 μm were obtained. An increasing pore size of the supported foams improves the specific photocatalytic activity of the TiO₂ coated scaffolds, the flow of solution through the highly active porous foam structure and the better access of light to the active TiO₂ surface.     

SiC-particulate aluminum composite foams produced from powder compacts: foaming and compression behavior

The foaming behavior of SiC-particulate (SiC_p) aluminum composite powder compacts containing titanium hydride blowing agent was investigated by heating to 750°C in a pre-heated furnace. Aluminum powder compacts were also prepared and foamed using similar compaction and foaming parameters in order to determine the effect of SiC_p-addition on the foaming and compression behavior. The SiC_p-addition (10 wt%) was found to increase the linear expansion of the Al powder compacts presumably by increasing the surface as well as the bulk viscosities. The compression tests conducted on Al and 10 and 20% SiC_p foams further showed a more brittle compression behavior of SiC_p/Al foams as compared with Al foams. The collapse stresses of Al and 10% SiC_p/Al foams were also predicted using the equations developed for the open and closed cell foams. Predictions have shown that Al foam samples behaved similar to open cell foams, while 10% SiC_p/Al foam collapse stress values were found between those of open and closed cell foams, biasing towards those of the open cell foams.     

The role of ferrocene on the enhancement of the mechanical and electrochemical properties of coal tar pitch-based carbon foams

In the present study, the role of ferrocene on mechanical and electrochemical properties of coal tar pitch (CTP)-based carbon foam (CFoam) was investigated. The different weight fractions of ferrocene were mixed with CTP and foam was developed from the mixture of CTP and ferrocene by sacrificial template technique. Before the characterisation of foams, it was heat treated at 1000 and 2500 °C in inert atmosphere. It was observed that the bulk density of CFoam increased with the increase in ferrocene content and as a consequence of an improvement of structural properties of the CFoam. The compressive strength increased by 60 and 62 % of 1000 and 2500 °C heat-treated CFoam with 5 wt% of ferrocene content. However, higher content of ferrocene had negative effect on the compressive strength. The electrical and thermal conductivity increased with the increasing ferrocene content and as a result of catalytic graphitization of ligaments in CFoam. The current density increased with the increasing electrical conductivity of CFoam, and it was 102 mA/cm² at 10 wt% ferrocene. The specific capacitance was 865 μF/cm² at scan rate 10 mV/s, which was due to the higher conductivity and surface area of CFoam. This demonstrated that ferrocene could be useful for improving the properties of CFoam.     

应用于包装领域的明胶泡沫性能研究

目的 制作和表征基于明胶的生物基可堆肥降解泡沫材料,并应用于包装领域。方法 明胶泡沫通过机械发泡和在周围环境中干燥制成。研究明胶含量、表面活性剂含量以及发泡温度对泡沫最大发泡倍率(MER)、收缩、密度、结构以及压缩性能的影响。此外,研究不同明胶含量样品的导热率。结果 研究的3个因素对泡沫性能和结构有显著影响。MER值和收缩是黏度相关,并极大地影响泡沫密度、力学性能以及热导率。增加明胶含量制造出了密度和压缩强度更高的泡沫(由于MER值更低)。表面活性剂质量分数从0.75%增加到1.5%由于发泡性提升造成泡沫密度轻微下降。然而,进一步将表面活性剂质量分数提升至3%造成黏度显著增加、MER值下降,从而导致泡沫密度增加。更高的发泡温度可以得到更高的MER,但是由于液态泡沫稳定时间更长,收缩程度更大,泡沫密度更大。结论 明胶泡沫展现出作为低密度传统塑料泡沫(密度小于30 kg/m³)环保替代品极具潜力的性能。研究成功实现了明胶泡沫的低热导率〔0.038～0.039 W/(m.K)〕和相对较低的收缩程度。     

Characterization of rigid polyurethane foams containing microencapsulated Rubitherm<Superscript>®</Superscript> RT27: catalyst effect. Part II

Catalyst Tegoamin 33 has been used for the synthesis of rigid polyurethane (RPU) foams containing microencapsulated Rubitherm^® RT27 and having a high mechanical resistance. These materials could be employed in buildings for thermal insulation and thermal energy storage (TES). The fillers content influence on the foaming process and also the foam properties was evaluated. It was observed that a foam containing up to a 18 wt% of microcapsules can be manufactured, improving the TES capacity while maintaining the mechanical properties of the neat foam. Besides, it was observed that the mechanical resistance of foams synthesized using catalyst Tegoamin 33 are higher than those obtained when catalyst Tegoamin BDE was employed, with the mechanical resistance of the foam containing 21 wt% being higher than those of foams synthesized with catalyst BDE containing only 11 wt% of fillers while maintaining the advantages of an improvement in TES capacity. A general model of reaction curve of n tank-in-series of a same time constant was used to fit the rising curves. This model allowed to predict the final volume of the synthesized foam. Finally, TES capacities and mechanical properties of the synthesized foams were in the range of those reported in literature. Moreover, foam densities satisfied the restriction established by the Spanish regulation for building applications.     

Effect of eggshell powder as nucleating agent on the structure,morphology and functional properties of normal corn starch foams

Corn starch and eggshell powder (with particle sizes of 4–5µm and 8–10µm) composite foams were prepared by extrusion. Effects of eggshell on the structure, morphology, physical properties (unit density and expansion ratio), mechanical properties (spring index and compressibility) and thermal behaviour (thermal transition and stability) of the foams were investigated. Foam cell size decreased and cell population increased with addition of eggshell into starch matrix. The foam unit density, expansion ratio and compressibility decreased significantly (p < 0.05), while the spring index increased significantly (p < 0.05) as the eggshell content increased from 0 to 6wt%. Further increasing eggshell content to 10wt% increased the unit density and compressibility and decreased the expansion ratio and spring index. The thermal transition and stability increased with the addition of eggshell. The optimum eggshell content was 6wt% and the smaller‐sized eggshell powder had a favourable effect on the functional properties of the foams. Copyright © 2006 John Wiley & Sons, Ltd.     

阻尼性半硬质聚氨酯泡沫的制备与性能

半硬质聚氨酯泡沫(SRPUF)因为其较高的压缩硬度、较低的弹性以及较好的吸能效果,常用作吸能减震材料。文中采用一步法模塑成型工艺,以混合聚醚多元醇和改性二苯基甲烷二异氰酸酯(MDI)为原料,全水发泡合成了半硬质聚氨酯泡沫,研究了泡沫稳定剂含量对泡孔结构的影响,异氰酸酯(NCO)指数、微量乙二醇(EG)扩链剂对其阻尼性能的影响。结果表明,泡沫稳定剂含量增加,泡孔越小越均匀;NCO指数提高聚氨酯泡沫的阻尼性能降低;微量乙二醇扩链也可以提高聚氨酯泡沫的阻尼性能;当NCO指数为0.8,5‰乙二醇扩链时,可以制备阻尼性能和热性能较好的半硬质聚氨酯泡沫。     

Fitting stress relaxation experiments with fractional Zener model to predict high frequency moduli of polymeric acoustic foams

This paper presents a time domain method to determine viscoelastic properties of open-cell foams on a wide frequency range. This method is based on the adjustment of the stress–time relationship, obtained from relaxation tests on polymeric foams’ samples under static compression, with the four fractional derivatives Zener model. The experimental relaxation function, well described by the Mittag–Leffler function, allows for straightforward prediction of the frequency-dependence of complex modulus of polyurethane foams. To show the feasibility of this approach, complex shear moduli of the same foams were measured in the frequency range between 0.1 and 16 Hz and at different temperatures between ?20 °C and 20 °C. A curve was reconstructed on the reduced frequency range (0.1 Hz–1 MHz) using the time–temperature superposition principle. Very good agreement was obtained between experimental complex moduli values and the fractional Zener model predictions. The proposed time domain method may constitute an improved alternative to resonant and non-resonant techniques often used for dynamic characterization of polymers for the determination of viscoelastic moduli on a broad frequency range.     

Effect of nano-Calcium Carbonate on microcellular foaming of polypropylene

Using supercritical carbon dioxide as the physical foaming agent, a new batch process was carried out to prepare microcellular polypropylene (PP) and polypropylene/nano-Calcium Carbonate (PP/nano-CaCO₃) foams. Four concentrations of nano-CaCO₃, 3, 5, 7, and 10 wt% were used. The cell structure of foams and advantages of this new process were investigated and explained by thermal properties. Results showed that the foamed PP/5 wt% nano-CaCO₃ produced a microcellular foam with the minimum mean cell diameter (9.55 μm) and maximum cell density (1.50 × 10⁹ cells/cm³) among the four blends. Some unfoamed regions were observed in nanocomposite foams because nano-CaCO₃ could accelerate crystallization in cooling and cryostat stage. The new process took much less time (2.5 h) to foam and had much broader foaming temperature range (about 55 °C). But the foaming temperature range decreased after blending nano-CaCO₃ into PP matrix because nano-CaCO₃-induced isothermal and non-isothermal crystallization at higher temperature. In addition, the cell growth effect on variations of volume expansion ratio in PP/nano-CaCO₃ nanocomposites could be neglected comparing with the heterogeneous cell nucleation effect.     

Mechanical model for the interfacial thermal stress in porous ceramic foam coatings bonded to a substrate

Abstract

Coatings of porous ceramic foams have potential applications in thermal protection systems of space shuttles. This paper develops a mechanics model for evaluation of thermal stress of porous ceramic foam coating/substrate structures under thermal shock temperature variation. Numerical results show that interfacial stresses exhibit singularity at the edge of ceramic foam coating. Stress intensity factor will reduce when ceramic foam coating has a larger density or a larger thermal conductivity. Comparison between beam model and membrane model is made and it suggests that consideration of bending stiffness is essential for correct evaluation of the thermal stress in the ceramic foams.     

Determination of Dynamic Modulus of Syntactic and Particulate Foams by a Non‐Destructive Approach

Abstract: Developments in aviation posed requirement of lightweight, high strength and highly damage‐tolerant materials. Sandwich‐structured composites fulfilling these requirements have become the first choice for many aerospace applications as well as structural components for ground transport and marine vessels. Sandwich composites are a special class of composite materials which are widely used because of their high specific strength and high bending stiffness. Syntactic foams, which are hollow particle‐filled core materials used in sandwich composites, have recently emerged as attractive material for applications requiring low weight, low moisture absorption and high insulation properties. Quasi‐static and dynamic properties of these syntactic foams are commonly determined though various destructive techniques such as quasi‐static compression and split Hopkinson pressure bar testing. However, there is a need for characterising these materials non‐destructively in the field. The present study focuses on the prediction of dynamic Young's modulus using ultrasonic testing in various types of hollow particle‐reinforced syntactic foam and solid particulate composites. Hollow particle‐filled syntactic foams and solid particulate composites are fabricated with three different volume fractions of 10%, 30% and 60%. Longitudinal and shear wave velocities are used for calculating the dynamic modulus. Effect of longitudinal attenuation behaviour along with longitudinal and shear wave velocities on the varying density and volume fraction of syntactic foams is also discussed.     

Durability of shape memory polymer based syntactic foam under accelerated hydrolytic ageing

In this study, accelerated hydrolytic ageing of shape memory polymer (SMP) based syntactic foam after two-dimensional (2D) programming or training (compression in one direction and tension in the transverse direction) was investigated experimentally. Mechanical properties and shape recovery functionality of the aged foam were tested. The results indicate that the moisture absorption for original and programmed foams is less than 1% at room temperature for 90 days. The moisture absorption in saltwater is less than that in rainwater, and the original foam absorbs more moisture compared to the programmed foam. Hydrolytic aged foams exhibit a slight decrease in mechanical strength, and show an increase in ductility, regardless of the original or programmed foams. Water immersion also leads to lowering in glass transition temperature of the foam. Furthermore, the rainwater has a larger influence on the mechanical properties than the saltwater does. It is concluded that the foam basically maintains its shape recovery functionality after 2D programming and moisture attacks.