CO2-blown nanocellular foams

New weapons against the disease vector Aedes aegypti: From natural products to nanoparticles

Despite the global burden of viral diseases transmitted by Aedes aegypti, there is a lack of effective means of prevention and treatment. Strategies for vector control include chemical and biological approaches such as organophosphates and Bacillus thuringiensis var. israelensis (Bti), among others. However, important concerns are associated, such as resistance in mosquito larvae and deleterious effects on non-target organisms. In this scenario, novel approaches against A. aegypti have been investigated, including natural products (e.g. vegetable oil and extracts) and nanostructured systems. This review focuses on potential strategies for fighting A. aegypti, highlighting plant-based materials and nanomaterials able to induce toxic effects on egg, larva, pupa and adult mosquitoes. Issues including aspects of conventional vector control strategies are presented, and finally new insights on development of eco-friendly nanoformulations against A. aegypti are discussed.

High-Efficiency Near-Infrared-to-Visible Photon Upconversion in Poly(vinyl alcohol) Porous Film

Triplet-triplet annihilation photon upconversion (TTA-UC) has received significant attention in energy harvesting applications such as solar cells. The realization of high upconversion (UC) performance in the form of films is a crucial factor for the incorporation of this technology into large-area devices. Herein, we propose a porous UC film prepared by an emulsification method with a poly(vinyl alcohol) (PVA) aqueous solution and a toluene solution of chromophores (rubrene/Pd-tetraphenyltetraanthraporphyrin pair) that achieved considerable UC performance in the near-infrared (NIR) (810 nm) to visible (560 nm) range with a maximum quantum yield of 3.7% (out of 50%). Notably, the films displayed a UC emission when using an NIR light-emitting diode as a low-power-density noncoherent light source, which was confirmed by the naked eye. Excitation-power-dependent time-resolved photoluminescence measurements showed almost identical triplet lifetimes of emitter species for the films and toluene solutions; however, lower threshold intensities (I_th = 1-2 W/cm²) were observed for the films than those of the solutions (I_th = ∼10 W/cm²). An evaluation of the remaining toluene in the film and UC emission behavior in liquid nitrogen suggested that the chromophores exist as an amorphous solid in the pores, thus enabling hybrid triplet energy transfer (chromophore mobility based and exciton migration) in this unique film. The presented methodology can be generalized to other wavelengths and can enable diverse applications of the TTA-UC technology.

Porous polymeric microparticles foamed with supercritical CO2as scattering white pigments

Nowadays, titanium dioxide (TiO₂) is the most commercially relevant white pigment. Nonetheless, it is widely criticized due to its energy-intensive extraction and costly disposal of harmful by-products. Furthermore, recent studies discuss its potential harm for the environment and the human health. Environment-friendly strategies for the replacement of TiO₂as a white pigment can be inspired from nature. Here whiteness often originates from broadband light scattering air cavities embedded in materials with refractive indices much lower than that of TiO₂. Such natural prototypes can be mimicked by introducing air-filled nano-scale cavities into commonly used polymers. Here, we demonstrate the foaming of initially transparent poly(methyl methacrylate) (PMMA) microspheres with non-toxic, inert, supercritical CO₂. The properties of the foamed, white polymeric pigments with light scattering nano-pores are evaluated as possible replacement for TiO₂pigments. For that, the inner foam structure of the particles was imaged by phase-contrast x-ray nano-computed tomography (nano-CT), the optical properties were evaluated via spectroscopic measurements, and the mechanical stability was examined by micro compression experiments. Adding a diffusion barrier surrounding the PMMA particles during foaming allows to extend the foaming process towards smaller particles. Finally, we present a basic white paint prototype as exemplary application.

Surfactant in a Polyol-CO2 Mixture: Insights from a Classical Density Functional Theory Study

Silicone-polyether (SPE) surfactants, made of a polydimethyl-siloxane (PDMS) backbone and polyether branches, are commonly used as additives in the production of polymeric foams with improved properties. A key step in the production of polymeric foams is the nucleation of gas bubbles in the polymer matrix upon supersaturation of dissolved gas. However, the role of SPE surfactants in the nucleation of gas bubbles is not well understood. In this study, we use classical density functional theory to investigate the effect of an SPE surfactant on the nucleation of CO₂ bubbles in a polyol foam formulation. We find that the addition of an SPE surfactant leads to a ∼3-fold decrease in the polyol-CO₂ interfacial tension at the surfactant's critical micelle concentration. Additionally, the surfactant is found to reduce the free energy barrier and affect the minimum free energy pathway (MFEP) associated with CO₂ bubble nucleation. In the absence of a surfactant, a CO₂-rich bubble nucleates from a homogeneous CO₂-supersaturated polyol solution by following an MFEP characterized by a single nucleation barrier. Adding a surfactant results in a two-step nucleation process with reduced free energy barriers. The first barrier corresponds to the formation of a spherical aggregate with a liquid-like CO₂ core. This spherical aggregate then grows into a CO₂-rich bubble (spherical aggregate with a vapor-like CO₂ core) of a critical size representing the second barrier. We hypothesize that the stronger affinity of CO₂ for PDMS (than polyether) stabilizes the spherical aggregate with the liquid-like CO₂ core, leading to a lower free energy barrier for CO₂ bubble nucleation. Stabilization of such an aggregate during the early stages of the nucleation may lead to foams with more, smaller bubbles, which can improve their microstrustural features and insulating abilities.

Thermal Conductivity of Nanoporous Materials: Where Is the Limit?

Nowadays, our society is facing problems related to energy availability. Owing to the energy savings that insulators provide, the search for effective insulating materials is a focus of interest. Since the current insulators do not meet the increasingly strict requirements, developing materials with a greater insulating capacity is needed. Until now, several nanoporous materials have been considered as superinsulators achieving thermal conductivities below that of the air 26 mW/(m K), like nanocellular PMMA/TPU, silica aerogels, and polyurethane aerogels reaching 24.8, 10, and 12 mW/(m K), respectively. In the search for the minimum thermal conductivity, still undiscovered, the first step is understanding heat transfer in nanoporous materials. The main features leading to superinsulation are low density, nanopores, and solid interruptions hindering the phonon transfer. The second crucial condition is obtaining reliable thermal conductivity measurement techniques. This review summarizes these techniques, and data in the literature regarding the structure and thermal conductivity of two nanoporous materials, nanocellular polymers and aerogels. The key conclusion of this analysis specifies that only steady-state methods provide a reliable value for thermal conductivity of superinsulators. Finally, a theoretical discussion is performed providing a detailed background to further explore the lower limit of superinsulation to develop more efficient materials.

Effect of the Molecular Structure of TPU on the Cellular Structure of Nanocellular Polymers Based on PMMA/TPU Blends

In this work, the effects of thermoplastic polyurethane (TPU) chemistry and concentration on the cellular structure of nanocellular polymers based on poly(methyl-methacrylate) (PMMA) are presented. Three grades of TPU with different fractions of hard segments (HS) (60%, 70%, and 80%) have been synthesized by the prepolymer method. Nanocellular polymers based on PMMA have been produced by gas dissolution foaming using TPU as a nucleating agent in different contents (0.5 wt%, 2 wt%, and 5 wt%). TPU characterization shows that as the content of HS increases, the density, hardness, and molecular weight of the TPU are higher. PMMA/TPU cellular materials show a gradient cell size distribution from the edge of the sample towards the nanocellular core. In the core region, the addition of TPU has a strong nucleating effect in PMMA. Core structure depends on the HS content and the TPU content. As the HS or TPU content increases, the cell nucleation density increases, and the cell size is reduced. Then, the use of TPUs with different characteristics allows controlling the cellular structure. Nanocellular polymers have been obtained with a core relative density between 0.15 and 0.20 and cell sizes between 220 and 640 nm.

Cyclic Gas Dissolution Foaming as an Approach for Simultaneously Reducing Cell Size and Relative Density in Nanocellular PMMA

A new approach to produce nanocellular polymers combining small cell sizes with low relative densities is presented herein. This production method, based on gas dissolution foaming, consists of performing a double saturation and foaming cycle. Thus, nanocellular polymethylmethacrylate (PMMA) has been produced through a first saturation at different saturation conditions (6, 10, and 20 MPa and -32 °C), at constant foaming conditions (60 °C for 1 min). Then, the nanocellular PMMAs obtained from the previous step were again saturated at different saturation conditions, 10 MPa 24 °C, 31 MPa 24 °C, 35 MPa 22 °C, and 6 MPa -15 °C and foamed at different temperatures (40, 80 and 100 °C) for 1 min. This new approach allows the cells created in the first saturation and foaming cycle to further grow in the second cycle. This fact permits producing nanocellular polymethylmethacrylate sheets combining, for the first time in the literature, cell sizes of 24 nm with relative densities of 0.3.

Designer Core-Shell Nanoparticles as Polymer Foam Cell Nucleating Agents: The Impact of Molecularly Engineered Interfaces

The interface between nucleating agents and polymers plays a pivotal role in heterogeneous cell nucleation in polymer foaming. We describe how interfacial engineering of nucleating particles by polymer shells impacts cell nucleation efficiency in CO2 blown polymer foams. Core-shell nanoparticles (NPs) with a 80 nm silica core and various polymer shells including polystyrene (PS), poly(dimethylsiloxane) (PDMS), poly(methyl methacrylate) (PMMA), and poly(acrylonitrile) (PAN) are prepared and used as heterogeneous nucleation agents to obtain CO2 blown PMMA and PS micro- and nanocellular foams. Fourier transform infrared spectroscopy, thermogravimetric analysis, and transmission electron microscopy are employed to confirm the successful synthesis of core-shell NPs. The cell size and cell density are determined by scanning electron microscopy. Silica NPs grafted with a thin PDMS shell layer exhibit the highest nucleation efficiency values, followed by PAN. The nucleation efficiency of PS- and PMMA-grafted NPs are comparable with the untreated particles and are significantly lower when compared to PDMS and PAN shells. Molecular dynamics simulations (MDS) are employed to better understand CO2 absorption and nucleation, in particular to study the impact of interfacial properties and CO2-philicity. The MDS results show that the incompatibility between particle shell layers and the polymer matrix results in immiscibility at the interface area, which leads to a local accumulation of CO2 at the interfaces. Elevated CO2 concentrations at the interfaces combined with the high interfacial tension (caused by the immiscibility) induce an energetically favorable cell nucleation process. These findings emphasize the importance of interfacial effects on cell nucleation and provide guidance for designing new, highly efficient nucleation agents in nanocellular polymer foaming.

Effect of extrudate swell on extrusion foam of polyethylene terephthalate

The effect of extrudate swell on extrusion foam of thermoplastic polymers is presented using an experimental approach supported by a modelling of the phenomenon. Its understanding is fundamental in designing the geometry of a die for extrusion foam and to predict foaming. The extrudate swell is the swelling of a viscoelastic material due to a fast elastic recovery after being subjected to stresses. We show that there exists a link between the extrudate swell and foaming, performing experiments with simple and complex extrusion dies to measure the expansion ratio. It was found that the expansion ratio is anisotropic and the anisotropy in the expansion of the foam is due to the extrudate swell that affects strongly the final shape of the product and it cannot be neglected in standard application for extrusion foam. A simple heuristic model was developed to predict the extrudate swell from geometrical parameters and rheological characterization of the fluid. It was found that the foaming mechanism of polyethylene terephthalate, blown with cyclopentane, changes as function of extrudate swell and the lowest density foam is achieved using the die that has the bigger extrudate swell.

Amorphous Polymers' Foaming and Blends with Organic Foaming-Aid Structured Additives in Supercritical CO2, a Way to Fabricate Porous Polymers from Macro to Nano Porosities in Batch or Continuous Processes

Organic polymers can be made porous via continuous or discontinuous expansion processes in scCO2. The resulting foams properties are controlled by the interplay of three groups of parameters: (i) Chemical, (ii) physico-chemical, and (iii) technological/process that are explained in this paper. The advantages and drawbacks of continuous (extrusion, injection foaming) or discontinuous (batch foaming) foaming processes in scCO2, will be discussed in this article; especially for micro or nano cellular polymers. Indeed, a challenge is to reduce both specific mass (e.g., ρ < 100 kg·m-3) and cell size (e.g., average pore diameter ϕaveragepores < 100 nm). Then a particular system where small "objects" (coreshells CS, block copolymer MAM) are perfectly dispersed at a micrometric to nanometric scale in poly(methyl methacrylate) (PMMA) will be presented. Such "additives", considered as foaming aids, are aimed at "regulating" the foaming and lowering the pore size and/or density of PMMA based foams. Differences between these additives will be shown. Finally, in a PMMA/20 wt% MAM blend, via a quasi one-step batch foaming, a "porous to nonporous" transition is observed in thick samples. A lower limit of pore size (around 50 nm) seems to arise.

Highly Ordered Nanocellular Polymeric Foams Generated by UV-Induced Chemical Foaming

Nanocellular polymer foams have shown significant potential for industrial applications because of their superior thermal, mechanical, and optical properties. Some of these properties may be further improved by enhancing the ordering of cell structures. However, it is challenging for conventional foaming methods to control both the cell size and ordering at the nanoscale. Here, we show an innovative method to produce highly ordered nanocellular polymer foams by incorporating the self-assembly of an asymmetric diblock copolymer with the UV-induced chemical foaming technique. The minor domains are designed to generate a gaseous compound from the partial cleavage of the functional group. It is demonstrated that the gas-producing reaction can be accelerated at a temperature low enough to prevent melting of the whole self-assembled template, by mixing a small amount of photoacid generator into the copolymer, followed by UV irradiation. The result is the production of polymer foams with the nanoscale cells highly aligned to the self-assembled domains.

A new generation of hollow polymeric microfibers produced by gas dissolution foaming

A new and straightforward route to produce polymeric hollow microfibers has been proposed. Polycaprolactone (PCL) hollow fibers are obtained for the first time using an environmentally friendly gas dissolution foaming approach, overcoming its limitations to induce porosity on samples in the micrometric range. Different porous morphologies are achieved from solid PCL microfibers with a well-controlled diameter obtained by conventional electrospinning. The optimization of the foaming parameters provides two sets of well-defined hollow fibers, one showing smooth surfaces and the other presenting an enhanced surface porosity. Accordingly, gas dissolution foaming proves to be not only suitable for the production of hollow polymeric microfibers, but is also capable of providing diverse porous morphologies from the same precursor, solid fibers. Moreover, a preliminary study about the suitability of this new generation of foamed hollow polymeric fibers for drug delivery is carried out, aiming to take advantage of the enhanced surface area and tunable morphology obtained by using the proposed new production method. It is found that the foamed microfibers can be loaded with up to 15 wt% of ibuprofen while preserving the morphology of each kind of fiber. Then, foamed PCL fibers presenting a hollow structure and surface porosity show a remarkable constant release of ibuprofen for almost one and a half days. In contrast, the original solid fibers do not present such behavior, releasing all the ibuprofen in about seven hours.

Increasing cell density/decreasing cell size to produce microcellular and nanocellular thermoplastic foams: A review

Nowadays, polymeric foams have attracted particular attention in scientific and industrial societies due to their unique properties, such as high strength to weight ratio, excellent thermal and sound insulation, and low cost. Researchers have shown that the extraordinary properties of polymeric foams such as superior thermal insulation, can be achieved by increasing the cell density/decreasing the cell size. In this regard, firstly, the most important foaming processes, i.e. batch, extrusion, and injection molding are studied in the present research. Then, cell nucleation stage as the most crucial phenomenon for achieving high cell density/small cell size is investigated in detail. In the next step, the most important researches in the field of polymeric foams are introduced in which the largest cell densities/smallest cell sizes have been achieved. The investigations show that the most remarkable results (highest cell densities/smallest cell sizes) belong to the batch process. Also, the use of nucleating agents, increasing the solubility of blowing agent into the polymer, and the use of nanoparticles are the most efficient solutions to achieve microcellular and nanocellular structures.

A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods

The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM.

Porous Ultra-Thin Films from Photocleavable Block Copolymers: In-Situ Degradation Kinetics Study of Pore Material

On the basis of the major application for block copolymers to use them as separation membranes, lithographic mask, and as templates, the preparation of highly oriented nanoporous thin films requires the selective removal of the minor phase from the pores. In the scope of this study, thin film of polystyrene-block-poly(ethylene oxide) block copolymer with a photocleavable junction groups based on ortho-nitrobenzylester (ONB) (PS-hν-PEO) was papered via the spin coating technique followed by solvent annealing to obtain highly-ordered cylindrical domains. The polymer blocks are cleaved by means of a mild UV exposure and then the pore material is washed out of the polymer film by ultra-pure water resulting in arrays of nanoporous thin films to remove one block. The removal of the PEO materials from the pores was proven using the grazing-incidence small-angle X-ray scattering (GISAXS) technique. The treatment of the polymer film during the washing process was observed in real time after two different UV exposure time (1 and 4 h) in order to draw conclusions regarding the dynamics of the removal process. In-situ X-ray reflectivity measurements provide statistically significant information about the change in the layer thickness as well as the roughness and electron density of the polymer film during pore formation. 4 H UV exposure was found to be more efficient for PEO cleavage. By in-situ SFM measurements, the structure of the ultra-thin block copolymer films was also analysed and, thus, the kinetics of the washing process was elaborated. The results from both measurements confirmed that the washing procedure induces irreversible change in morphology to the surface of the thin film.

Bubble Seeding Nanocavities: Multiple Polymer Foam Cell Nucleation by Polydimethylsiloxane-Grafted Designer Silica Nanoparticles

We describe a successful strategy to substantially enhance cell nucleation efficiency in polymer foams by using designer nanoparticles as nucleating agents. Bare and poly(dimethylsilane) (PDMS)-grafted raspberry-like silica nanoparticles with diameters ranging from ∼80 nm to ∼200 nm were synthesized and utilized as highly efficient cell nucleators in CO₂-blown nanocellular polymethyl methacrylate (PMMA) foams. The successful synthesis of core-shell nanoparticles was confirmed by Fourier transform infrared spectroscopy, thermogravimetric analysis, Brunauer-Emmett-Teller measurements, and transmission electron microscopy. The cell size and cell density of the obtained PMMA micro- and nanocellular foams were determined by scanning electron microscopy. The results show that increased surface roughness enhances the nucleation efficiency of the designer silica particles. This effect is ascribed to a decreased nucleation free energy for foam cell nucleation in the nanocavities at the melt-nucleator interface. For PDMS grafted raspberry-like silica nanoparticles with diameters of 155 and 200 nm, multiple cell nucleation events were observed. These hybrid particles had nucleation efficiencies of 3.7 and 6.2, respectively. The surprising increase in nucleation efficiency to above unity is ascribed to the significant increase in CO₂ absorption and capillary condensation in the corresponding PMMA during saturation. This increase results in the presence of large amounts of the physical blowing agent close to energetically favorable nucleation points. Additionally, it is shown that as a consequence of cell coalescence, the increased number of foam cells is rapidly reduced during the first seconds of foaming. Hence, the design of highly efficient nucleating particles, as well as careful selection of foam matrix materials, seems to be of pivotal importance for obtaining polymer cellular materials with cell dimensions at the nanoscale. These findings contribute to the fabrication of polymer foams with high thermal insulation capacity and have relevance in general to the area of cellular materials.

The mechanics of solid-state nanofoaming

Solid-state nanofoaming experiments are conducted on two polymethyl methacrylate (PMMA) grades of markedly different molecular weight using CO₂ as the blowing agent. The sensitivity of porosity to foaming time and foaming temperature is measured. Also, the microstructure of the PMMA nanofoams is characterized in terms of cell size and cell nucleation density. A one-dimensional numerical model is developed to predict the growth of spherical, gas-filled voids during the solid-state foaming process. Diffusion of CO₂ within the PMMA matrix is sufficiently rapid for the concentration of CO₂ to remain almost uniform spatially. The foaming model makes use of experimentally calibrated constitutive laws for the uniaxial stress versus strain response of the PMMA grades as a function of strain rate and temperature, and the effect of dissolved CO₂ is accounted for by a shift in the glass transition temperature of the PMMA. The maximum achievable porosity is interpreted in terms of cell wall tearing and comparisons are made between the predictions of the model and nanofoaming measurements; it is deduced that the failure strain of the cell walls is sensitive to cell wall thickness.

Hollow-Structured Materials for Thermal Insulation

Heating and cooling represent a significant portion of overall energy consumption of our society. Due to the diffusive nature of thermal energy, thermal insulation is critical for energy management to reduce energy waste and improve energy efficiency. Thermal insulation relies on the reduction of thermal conductivity of appropriate materials that are engineerable in compositions and structures. Hollow-structured materials (HSMs) show a great promise in thermal insulation since the existence of high-density gaseous voids breaks the continuity of heat-transport pathways in the HSMs to lower their thermal conductivities efficiently. Herein, a timely overview of the recent progress in developing HSMs for thermal insulation is presented, with the focus on summarizing the strategies for creating gaseous voids in solid materials and thus synthesizing various HSMs. Systematic analysis of the documented results reveals the relationship of thermal conductivities of the HSMs and the size and density of voids, i.e., reducing the void size below ≈350 nm is more favorable to decrease the thermal conductivity of the HSMs because of the possible confinement effect originated from the nanometer-sized voids. The challenges and promises of the HSMs faced in future research are also discussed.

Nanocellular Polymers: The Challenge of Creating Cells in the Nanoscale

The evolution of technology means that increasingly better materials are needed. It is well known that as a result of their interesting properties, nanocellular polymers perform better than microcellular ones. For this reason, the investigation on nanocellular materials is nowadays a very topical issue. In this paper, the different approaches for the production of these materials in our laboratory are explained, and results obtained by using polymethylmethacrylate (PMMA) are shown. Homogeneous nucleation has been studied by using raw PMMA, while two different systems were used for heterogeneous nucleation; adding nanoparticles to the system and using nanostructured polymers as solid precursors for foaming. The effects of the different parameters of the production process (gas dissolution foaming process) have been evaluated for all systems being possible to establish a comparison between the materials produced by different approaches. Moreover, the limitations and future work to optimise the materials produced are also discussed.