Comparative Study of the Foaming Behavior of Ethylene-Vinyl Acetate Copolymer Foams Fabricated Using Chemical and Physical Foaming Processes

Ethylene-vinyl acetate copolymer (EVA), a crucial elastomeric resin, finds extensive application in the footwear industry. Conventional chemical foaming agents, including azodicarbonamide and 4,4'-oxybis(benzenesulfonyl hydrazide), have been identified as environmentally problematic. Hence, this study explores the potential of physical foaming of EVA using supercritical nitrogen as a sustainable alternative, garnering considerable interest in both academia and industry. The EVA formulations and processing parameters were optimized and EVA foams with densities between 0.15 and 0.25 g/cm3 were produced. Key findings demonstrate that physical foaming not only reduces environmental impact but also enhances product quality by a uniform cell structure with small cell size (50-100 μm), a wide foaming temperature window (120-180 °C), and lower energy consumption. The research further elucidates the mechanisms of cell nucleation and growth within the crosslinked EVA network, highlighting the critical role of blowing agent dispersion and localized crosslinking around nucleated cells in defining the foam's cellular morphology. These findings offer valuable insights for producing EVA foams with a more controllable cellular structure, utilizing physical foaming techniques.

Nanocomposite Foams with Balanced Mechanical Properties and Energy Return from EVA and CNT for the Midsole of Sports Footwear Application

Polymer foam that provides good support with high energy return (low energy loss) is desirable for sport footwear to improve running performance. Ethylene-vinyl acetate copolymer (EVA) foam is commonly used in the midsole of running shoes. However, EVA foam exhibits low mechanical properties. Conventional mineral fillers are usually employed to improve EVA's mechanical performance, but the energy return is sacrificed. Here, we produced nanocomposite foams from EVA and multi-walled carbon nanotubes (CNT) using a chemical foaming process. Two kinds of CNT derived from the upcycling of commodity plastics were prepared through a catalytic chemical vapor deposition process and used as reinforcing and nucleating agents. Our results show that EVA foam incorporated with oxygenated CNT (O-CNT) demonstrated a more pronounced improvement of physical, mechanical, and dynamic impact response properties than acid-purified CNT (A-CNT). When CNT with weight percentage as low as 0.5 wt% was added to the nanocomposites, the physical properties, abrasion resistance, compressive strength, dynamic stiffness, and rebound performance of the EVA foams were improved significantly. Unlike the conventional EVA formulation filled with talc mineral fillers, the incorporation of CNT does not compromise the energy return of the EVA foam. From the long-cycle dynamic fatigue test, the CNT/EVA foam displays greater properties retention as compared to the talc/EVA foam. This work demonstrates a good balanced of mechanical-energy return properties of EVA nanocomposite foam with very low CNT content, which presents promising opportunities for lightweight-high rebound midsoles for running shoes.

Preparation and Characterization of Dual-Modified Cassava Starch-Based Biodegradable Foams for Sustainable Packaging Applications

Starch and its derivatives have recently emerged as a sustainable and renewable alternative for petroleum-based expanded polystyrene (EPS) and expanded polypropylene (EPP) foam materials. In this study, biodegradable foam materials were prepared from cassava starch using a novel dual modification technique, combining microwave treatment and freeze-drying. The foam materials were prepared from starch solutions microwaved over different intervals. The starch-based foam materials were characterized using Fourier transform infrared (FTIR) spectroscopy, thermogravimetric analysis (TGA), X-ray diffraction (XRD), scanning electron microscopy (SEM), ¹³C nuclear magnetic resonance (¹³C-NMR) spectroscopy, and compression set test. Moreover, the water absorption capacities and density values of the foam materials were measured according to ASTM standards. The biodegradability test was carried out according to the aerobic compost environment test. The lowest water absorption capacities of 65.56% and 70.83% were exhibited for the cassava starch foam sample (MWB) prepared at a 20 s microwave treatment time and immersed in distilled water for 2 and 24 h, respectively. Furthermore, the lightweight cassava starch-based foam materials displayed density ranging from 124 to 245 kg/m³. The biodegradation test exhibited significant biodegradation of over 50% after 15 days for all the foam materials prepared. These results suggest that the dual-modified cassava starch-based biodegradable foams show potential in sustainable packaging applications by replacing petroleum-based materials.

Polyolefinic nanocomposite foams: Review of microstructure-property relationships, applications, and processing considerations

In this review, we survey the state of the art on polymeric foams incorporating nano-scale fillers. Particular focus of the review is on foams from polyolefinic nanocomposite formulations incorporating a wide variety of fillers. The nano-scale additives can influence the foam structure and properties in two ways: Firstly, they can act as composite reinforcement to enhance the mechanical properties and functionality of the matrix polymer; and secondly, they can act as foaming-processing aids through modification of the rheological, thermal and crystallization properties of the matrix as well as serving as heterogeneous nucleation sites. Through a combination of these influences, and using advanced processing techniques it is possible to achieve nanocomposite foams that have higher cell density, and more uniform cell size or controlled cell-size distribution. Such controlled foam morphologies, in turn, can yield better specific mechanical properties resulting in more effective light-weighting solutions. Further, the nano-scale additives can impart additional desired functionality resulting in multi-functional foams. In this article, we provide an overview of the mechanical, thermal and a few other relevant functional properties – such as piezoelectric sensitivity, acoustics, and filtration efficiency – of foams prepared using nanocomposite formulations, along with the processing considerations for achieving high quality foams using such materials.

Comparing Multi-Walled Carbon Nanotubes and Halloysite Nanotubes as Reinforcements in EVA Nanocomposites

The influence of carbon multi-walled nanotubes (MWCNTs) and halloysite nanotubes (HNTs) on the physical, thermal, mechanical, and electrical properties of EVA (ethylene vinyl acetate) copolymer was investigated. EVA-based nanocomposites containing MWCNTs or HNTs, as well as hybrid nanocomposites containing both nanofillers were prepared by melt blending. Scanning electron microcopy (SEM) images revealed the presence of good dispersion of both kinds of nanotubes throughout the EVA matrix. The incorporation of nanotubes into the EVA copolymer matrix did not significantly affect the crystallization behavior of the polymer. The tensile strength of EVA-based nanocomposites increased along with the increasing CNTs (carbon nanotubes) content (increased up to approximately 40% at the loading of 8 wt.%). In turn, HNTs increased to a great extent the strain at break. Mechanical cyclic tensile tests demonstrated that nanocomposites with hybrid reinforcement exhibit interesting strengthening behavior. The synergistic effect of hybrid nanofillers on the modulus at 100% and 200% elongation was visible. Moreover, along with the increase of MWCNTs content in EVA/CNTs nanocomposites, an enhancement in electrical conductivity was observed.

Nanoscopic and Macro-Porous Carbon Nano-foam Electrodes with Improved Mass Transport for Vanadium Redox Flow Batteries

Although free-standing sheets of multiwalled carbon nanotubes (MWCNT) can provide interesting electrochemical and physical properties as electrodes for redox flow batteries, the full potential of this class of materials has not been accessible as of yet. The conventional fabrication methods produce sheets with micro-porous and meso-porous structures, which significantly resist mass transport of the electrolyte during high-current flow-cell operation. Herein, we developed a method to fabricate high performance macro-porous carbon nano-foam free standing sheets (Puffy Fibers, PF), by implementing a freeze-drying step into our low cost and scalable surface-engineered tape-casting (SETC) fabrication method, and we show the improvement in the performance attained as compared with a MWCNT sheet lacking any macro pores (Tape-cast, TC). We attribute the higher performance attained by our in-lab fabricated PF papers to the presence of macro pores which provided channels that acted as pathways for electrolytic transport within the bulk of the electrode. Moreover, we propose an electrolytic transport mechanism to relate ion diffusivity to different pore sizes to explain the different modes of charge transfer in the negative and the positive electrolytes. Overall, the PF papers had a high wettability, high porosity, and a large surface area, resulting in improved electrochemical and flow-cell performances.

Mechanical, Electrical and Rheological Behavior of Ethylene-Vinyl Acetate/Multi-Walled Carbon Nanotube Composites

This paper investigates the rheological, mechanical and electrical properties of a Ethylene-Vinyl Acetate (EVA) polymer filled with 1, 3 and 5 wt.% multi-walled carbon nanotubes (MWCNTs). The melt flow and pressure-volume-Temperature (pvT) behaviors of the EVA/MWCNT composites were investigated using a high-pressure capillary rheometer, while the electro-mechanical response was investigated on injection-molded samples. Rheological experiments showed that the melt shear viscosity of the EVA/MWCNT composite is dependent on nanotube loading and, at high shear rates, the viscosity showed temperature-dependent shear thinning behavior with a flow index n < 0.35. The specific volume of the EVA/MWCNT composite decreased with increasing pressure and MWCNT wt.%. The transition temperature, corresponding to the pvT crystallization, increased linearly with increasing pressure, i.e., about 20 to 30 °C when cooling under pressure. The elastic modulus, tensile strength and stress at break increased with increasing MWCNT wt.%, whereas the strain at break decreased, suggesting the formation of MWCNT secondary agglomerates. The electrical conductivity of the EVA/MWCNT composite increased with increasing MWCNT wt.% and melt temperature, reaching ~10⁻² S/m for the composite containing 5 wt.% MWCNTs. Using the statistical percolation theory, the percolation threshold was estimated at 0.9 wt.% and the critical exponent at 4.95.

The Synergy of Double Cross-linking Agents on the Properties of Styrene Butadiene Rubber Foams

Sulfur (S) cross-linking styrene butadiene rubber (SBR) foams show high shrinkage due to the cure reversion, leading to reduced yield and increased processing cost. In this paper, double cross-linking system by S and dicumyl peroxide (DCP) was used to decrease the shrinkage of SBR foams. Most importantly, the synergy of double cross-linking agents was reported for the first time to our knowledge. The cell size and its distribution of SBR foams were investigated by FESEM images, which show the effect of DCP content on the cell structure of the SBR foams. The relationships between shrinkage and crystalline of SBR foams were analyzed by the synergy of double cross-linking agents, which were demonstrated by FTIR, Raman spectra, XRD, DSC and TGA. When the DCP content was 0.6 phr, the SBR foams exhibit excellent physical and mechanical properties such as low density (0.223 g/cm³), reduced shrinkage (2.25%) and compression set (10.96%), as well as elevated elongation at break (1.78 × 10³%) and tear strength (54.63 N/mm). The results show that these properties are related to the double cross-linking system of SBR foams. Moreover, the double cross-linking SBR foams present high electromagnetic interference (EMI) shielding properties compared with the S cross-linking SBR foams.

Elastic behavior of methyltrimethoxysilane based aerogels reinforced with tri-isocyanate

The elastic properties and/or flexibility of polymer reinforced silica aerogels having methyltrimethoxysilane (MTMS) and bis(trimethoxysilylpropyl)amine (BTMSPA) making up the silica structure are examined. The dipropylamine spacer from BTMSPA is used both to provide a flexible linking group in the silica structure, and as a reactive site via its secondary amine for reaction with a tri-isocyanate, Desmodur N3300A. The tri-isocyanate provides an extended degree of branching or reinforcement, resulting in increased compressive strength of the aerogel monoliths while the overall flexibility arising from the underlying silica structure is maintained. The compressive moduli of the reinforced aerogel monoliths in this study range from 0.001 to 158 MPa. Interestingly, formulations across this entire range of modulus recover nearly all of their length after two compressions to 25% strain. Differences in pore structure of the aerogels due to processing conditions and solvent are also discussed.