Microcellular and nanocellular solid-state polyetherimide (PEI) foams using sub-critical carbon dioxide I. Processing and structure

In this study we investigate the solid-state batch foaming of polyetherimide (PEI) using sub-critical CO₂ as a blowing agent. We report on the gas diffusion for various saturation pressures in this system. Foaming process characterization is reported detailing conditions used to create microcellular and nanocellular PEI foams of 40% and higher relative density. Gas sorption, foaming, and resultant morphologies are analyzed and compared to previously reported results on PEI thin films. It was found that equilibrium gas concentrations for PEI sheet begin to significantly exceed that of films for CO₂ pressures above 3 MPa. A large solid-state foaming process window has been identified that allows for the creation of either microcellular or nanocellular structures at comparable density reductions. A transition from micro-scale cells to nano-scale cells was observed at gas concentrations in the range of 94–110 mg CO₂/g PEI. Additionally, a hierarchical structure was observed which consisted of nanocellular structures internal to microcells. The PEI–CO₂ system offers the unique opportunity to compare and contrast the bulk properties of nanofoams and microfoams.