Electrical conductivity and major mechanical and thermal properties of carbon nanotube-filled polyurethane foams

A Review of Rigid Polymeric Cellular Foams and Their Greener Tannin-Based Alternatives

This review focuses on the description of the main processes and materials used for the formulation of rigid polymer foams. Polyurethanes and their derivatives, as well as phenolic systems, are described, and their main components, foaming routes, end of life, and recycling are considered. Due to environmental concerns and the need to find bio-based alternatives for these products, special attention is given to a recent class of polymeric foams: tannin-based foams. In addition to their formulation and foaming procedures, their main structural, thermal, mechanical, and fire resistance properties are described in detail, with emphasis on their advanced applications and recycling routes. These systems have been shown to possess very interesting properties that allow them to be considered as potential substitutes for non-renewable rigid polymeric cellular foams.

The Effect of Multiwalled Carbon Nanotubes on the Thermal Conductivity and Cellular Size of Polyurethane Foam

Polyurethane (PU) foam is known as the popular material for the applications in many fields of industry and life. To improve the mechanical and thermal properties of this material, in this research, PU foam was reinforced with aniline-modified multiwalled carbon nanotubes (MWCNTs). Fourier transform infrared FTIR spectrum of modified MWCNTs showed the aniline was grafted on the surface of MWCNTs through the appearance of –NH2 stretches. The effect of MWCNTs with and without modification on the density, porosity, compressive strength, and heat conductivity of PU/MWCNT foam nanocomposites was investigated. The dispersibility of MWCNTs in the PU matrix was enhanced after modification with aniline. Compressive strength of PU nanocomposite reached the highest value after adding 3 wt.% of modified MWCNTs into PU foam. Besides, the water uptake of PU nanocomposites using 3 wt.% of MWCNTs was decreased to 13.4% as compared to that using unmodified MWCNTs. The improvement in thermal conductivity of PU/aniline-modified MWCNT nanocomposite was observed due to the change in the cellular size of PU foam in the presence of MWCNTs as shown by SEM images.

Lightweight Porous Polystyrene with High Thermal Conductivity by Constructing 3D Interconnected Network of Boron Nitride Nanosheets

A composite foam consisting of foamed cross-linking polystyrene (c-PS) and boron nitride nanosheets (BNNSs) was synthesized, which shows a higher thermal conductivity (TC) than the corresponding solid counterparts. The BNNS fillers are found to be aligned along the cell wall as a result of the biaxial stress field from cell expansion during the formation of three-dimensional interconnectivity in the foams, resulting in an enhanced TC of 1.28 W/m K, nearly two and four times those of its solid counterpart and pure c-PS, respectively. It is found that the foaming-assisted formation of the filler network is an efficient strategy to improve the TC at low filler loadings in the composites. Furthermore, the composite foams exhibit low density, rather low dielectric constants and dissipation factors at wide frequency and temperature ranges. The present work provides a novel approach to design and prepare lightweight heat conductive polymers with low filler loadings as low-density heat management materials for potential applications in aeronautics and aerospace components.

Structurally Controlled Cellular Architectures for High-Performance Ultra-Lightweight Materials

The design and synthesis of cellular structured materials are of both scientific and technological importance since they can impart remarkably improved material properties such as low density, high mechanical strength, and adjustable surface functionality compared to their bulk counterparts. Although reducing the density of porous structures would generally result in reductions in mechanical properties, this challenge can be addressed by introducing a structural hierarchy and using mechanically reinforced constituent materials. Thus, precise control over several design factors in structuring, including the type of constituent, symmetry of architectures, and dimension of the unit cells, is extremely important for maximizing the targeted performance. The feasibility of lightweight materials for advanced applications is broadly explored due to recent advances in synthetic approaches for different types of cellular architectures. Here, an overview of the development of lightweight cellular materials according to the structural interconnectivity and randomness of the internal pores is provided. Starting from a fundamental study on how material density is associated with mechanical performance, the resulting structural and mechanical properties of cellular materials are investigated for potential applications such as energy/mass absorption and electrical and thermal management. Finally, current challenges and perspectives on high-performance ultra-lightweight materials potentially implementable by well-controlled cellular architectures are discussed.

Polyurethane Foams: Past, Present, and Future

Polymeric foams can be found virtually everywhere due to their advantageous properties compared with counterparts materials. Possibly the most important class of polymeric foams are polyurethane foams (PUFs), as their low density and thermal conductivity combined with their interesting mechanical properties make them excellent thermal and sound insulators, as well as structural and comfort materials. Despite the broad range of applications, the production of PUFs is still highly petroleum-dependent, so this industry must adapt to ever more strict regulations and rigorous consumers. In that sense, the well-established raw materials and process technologies can face a turning point in the near future, due to the need of using renewable raw materials and new process technologies, such as three-dimensional (3D) printing. In this work, the fundamental aspects of the production of PUFs are reviewed, the new challenges that the PUFs industry are expected to confront regarding process methodologies in the near future are outlined, and some alternatives are also presented. Then, the strategies for the improvement of PUFs sustainability, including recycling, and the enhancement of their properties are discussed.

An Aqueous-Based Approach for Fabrication of PVDF/MWCNT Porous Composites

In this paper, we demonstrate the fabrication of conductive porous polymers based on foaming of an aqueous dispersion of polymeric particles and multi-walled carbon nanotubes (CNT). By tuning the surface energy of the constituents, we direct their preferential adsorption at the air-liquid (bubble) interface or within the liquid film between the bubbles. Sintering this bi-constituent foam yields solid closed-cell porous structure which can be electrically conductive if CNT are able to form a conductive path. We measure transport (electrical and thermal), mechanical, and morphological properties of such porous structures as a function of CNT loading and the method used for their surface functionalization. For a fixed polymer volume fraction, we demonstrate the limit in which increasing CNT results in decreasing the mechanical strength of the sample due to lack of adequate polymer-CNT bond. Such lightweight conductive porous composites are considered in applications including EMI shielding, electrostatic discharge protection, and electrets.

The Effect of Foaming on the Electrical Conductivity of Thermoplastic/Carbon Composites Containing Nano and Micro Carbon Fillers in Compression and Injection Molding

The effect of foaming on the electrical conductivity of polystyrene/carbon composites with emphasis on the particle size of conductive filler and molding method has been studied. Carbon black and expanded graphite, as nano carbon fillers, and natural flake graphite, as a micro carbon filler, were used as conductive fillers. Compression and injection molding were employed to investigate the impact of molding method while foaming the composites. Polystyrene and the carbon fillers were mixed in a batch melt mixer and subsequently molded to rectangular sheets either by injection or compression molding. The electrical conductivity of the foam and solid composites were measured by two or four probe methods. The microstructure of the samples was studied by scanning electron microscopy and optical microscopy. The optical images showed a good dispersion and distribution of the filler particles in polystyrene with some degree of agglomeration. The results of electrical conductivity measurements showed that foaming can considerably enhance the electrical conductivity of the composites containing nano carbon fillers i.e. carbon black and expanded graphite but reduced that of the composites containing micro carbon fillers i.e. graphite. The enhancement was more significant in injection molding than compression molding. In the nanocomposites, the nano particles must have been re-localized, redistributed, reoriented or restructured via foaming to increase the electrical conductivity. Such phenomena are not likely to happen for large micro fillers so that the electrical conductivity of polystyrene/graphite composites reduced with foaming due to excluded volume of the cells.

High dielectric permittivity and improved mechanical and thermal properties of poly(vinylidene fluoride) composites with low carbon nanotube content: effect of composite processing on phase behavior and dielectric properties

The composite processing technique and nanofiller concentration and its functionalization significantly alter the properties of polymer nanocomposites. To realize this, multi-walled carbon nanotubes (CNT) were dispersed in a poly(vinylidene fluoride) (PVDF) matrix at carefully selected CNT concentrations by two illustrious methods, such as solution-cast and melt-mixing. Notwithstanding the processing method, CNTs induced predominantly the γ-phase in PVDF, instead of the commonly obtained β-phase upon nanofiller incorporation, and imparted significant improvements in dielectric properties. Acid-treatment of CNT improved its dispersion and interfacial adhesion significantly with PVDF, and induced a higher γ-phase content and better dielectric properties in PVDF as compared to pristine CNT. Further, the γ-phase content was found to be higher in solution-cast composites than that in melt-mixed counterparts, most likely due to solvent-induced crystallization in a controlled environment and slow solvent evaporation in the former case. However, interestingly, the melt-mixed composites showed a significantly higher dielectric constant at the onset of the CNT networked-structure as compared to the solution-cast composites. This suggests the possible role of CNT breakage during melt-mixing, which might lead to higher space-charge polarization at the polymer-CNT interface, and in turn an increased number of pseudo-microcapacitors in these composites than the solution-cast counterparts. Notably, PVDF with 0.13 vol% (volume fraction, f c  = 0.0013) of acid-treated CNTs, prepared by melt-mixing, displayed the relative permittivity of ∼217 and capacitance of ∼5430 pF, loss tangent of ∼0.4 at 1 kHz and an unprecedented figure of merit of ∼10(5). We suggest a simple hypothesis for the γ-phase formation and evolution of the high dielectric constant in these composites. Further, the high-dielectric composite film showed marked improvements in mechanical and thermal properties over the neat PVDF film. These composites with exceptional dielectric properties and concomitant improvement in mechanical and thermal properties offer a great promise for use in flexible and mechanically robust charge storage devices.

Rigid thermosetting epoxy/multi-walled carbon nanotube foams with enhanced conductivity originated from a flow-induced concentration effect

Rigid epoxy/MWCNT foams were innovatively prepared using expandable microspheres, a flow-induced concentration effect increases the inter-connectivity caused by the thermally triggered expansion of microspheres, improving the electric conductivity.

Effect of monomer chemical structures on the cell structures and properties of cyanate ester foams

Cyanate ester (CE) foams with different chemical structures were prepared using bisphenol A dicyanate ester (BADCy), bisphenol E dicyanate ester (BECy), and tetramethyl bisphenol F dicyanate ester (TBFDCy) as monomers, through a two-step process. Rheological tests were performed to investigate the optimal conditions for the preparation of these foams. The results of morphology by scanning electron microscopy showed that cells are in the form of nearly spherical shape in foams from TBFDCy and BADCy and oval in foam from BECy. The thermal properties of the three CE foams were studied by methods of dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), and thermogravimetry/differential thermogravimetry analysis. The glass transition temperature ( Tg) obtained from DMA tests are 274, 264, and 241°C for the foams from TBFDCy, BADCy, and BECy, respectively, which are apparently higher than that tested by DSC method. The Tg, compressive properties, and thermal stabilities of the foams are improved after the introduction of the alkyl-substituent groups to the same aromatic ring of –OCN functionality, and the chemical structure–properties relationships are explained according to the monomer chemical structures.

Preparation and characterization of cyanate/epoxy foam

A new type of cyanate (CE)/epoxy (EP) foam with bisphenol-A dicyanate ester prepolymer and diglycidyl ether of bisphenol-A (BADCy/DGEBA) has been successfully prepared through a two-step process. The structure and properties of CE/EP foam were studied. The results reveal that the CE/EP foams, with relatively uniform cell structure, were composed of closed cells as confirmed by scanning electron microscopy. The compressive strength increased from 0.507 MPa to 3.021 MPa, and the compressive modulus ( E) increased from 15 MPa to 123 MPa as the density increased from 0.103 g cm−3 to 0.305 g cm−3. Dynamic mechanical analysis revealed that the CE/EP foams possessed a high glass transition temperature ( Tg) (203°C) and that density had only a little impact on Tg. Moreover, the excellent thermal stability presented with the onset of weight loss taken at 5% value was above 320°C, and the residual weight of the foam was more than 21.6% at 800°C. With increase in the density of CE/EP foams, the dielectric constants (ε) gradually decreased. For the foam with density of ρ = 0.162 g cm−3, the value of ε was as low as 2.28 at the frequency of 10 kHz.

Electromagnetic interference shielding in 1–18 GHz frequency and electrical property correlations in poly(vinylidene fluoride)–multi-walled carbon nanotube composites

A dilute acid-treatment of MWNT showed a low electrical percolation in PVDF and significant improvements in EMI shielding properties.

Controlling Foam Morphology of Poly(methyl methacrylate) via Surface Chemistry and Concentration of Silica Nanoparticles and Supercritical Carbon Dioxide Process Parameters

Polymer nanocomposite foams have received considerable attention because of their potential use in advanced applications such as bone scaffolds, food packaging, and transportation materials due to their low density and enhanced mechanical, thermal, and electrical properties compared to traditional polymer foams. In this study, silica nanofillers were used as nucleating agents and supercritical carbon dioxide as the foaming agent. The use of nanofillers provides an interface upon which CO2nucleates and leads to remarkably low average cell sizes while improving cell density (number of cells per unit volume). In this study, the effect of concentration, the extent of surface modification of silica nanofillers with CO2-philic chemical groups, and supercritical carbon dioxide process conditions on the foam morphology of poly(methyl methacrylate), PMMA, were systematically investigated to shed light on the relative importance of material and process parameters. The silica nanoparticles were chemically modified with tridecafluoro-1,1,2,2-tetrahydrooctyl triethoxysilane leading to three different surface chemistries. The silica concentration was varied from 0.85 to 3.2% (by weight). The supercritical CO2foaming was performed at four different temperatures (40, 65, 75, and 85°C) and between 8.97 and 17.93 MPa. By altering the surface chemistry of the silica nanofiller and manipulating the process conditions, the average cell diameter was decreased from9.62±5.22to1.06±0.32 μm, whereas, the cell density was increased from7.5±0.5×108to4.8±0.3×1011cells/cm3. Our findings indicate that surface modification of silica nanoparticles with CO2-philic surfactants has the strongest effect on foam morphology.

Thermoplastic polyurethane/single-walled carbon nanotube composites with low electrical resistance surfaces

Thermoplastic polyurethane (TPU)/single-walled carbon nanotube (SWCNT) nanocomposite films were prepared using 1,6-hexane diisocyanate and hydroxyl-terminated polybutadiene (HTPB) in tetrahydrofuran with various concentrations of SWCNTs. The interaction between polyurethane (PU) and SWCNTs in nanocomposite was studied using different methods. The film turns yellowish to grayish-black in colour upon increasing the concentration of SWCNTs in PU matrix. This may be due to the formation of π–π interaction between polyurethane amide functional group and SWCNTs. Differential scanning calorimetric results show that the soft segment of nanocomposite interacts much stronger than hard segment, which results in lowering melting transition temperature of soft segments. The activation energy and thermal stability parameters were determined from thermogravimetric and differential scanning calorimetric analyses. The x-ray photoelectron spectroscopic results show the intermolecular interaction between HTPB-based PU and SWCNT. Mesoporous morphology of the nanocomposites was observed by scanning electron microscopy. The average diameter of the pores was calculated using Gaussian method. The TPU films exhibit about 3.5 times greater resistivity than nanocomposite films. All the analysed data prove that the SWCNTs were well distributed in PU matrix and exhibited as tough films with low electrical resistivity.