Synergy of supercritical CO 2 and superheated H 2 O for enhanced processability of polyethersulfone towards open cell foams

Open-Celled Foams from Polyethersulfone/Poly(Ethylene Glycol) Blends Using Foam Extrusion

Polyethersulfone (PESU), as both a pristine polymer and a component of a blend, can be used to obtain highly porous foams through batch foaming. However, batch foaming is limited to a small scale and is a slow process. In our study, we used foam extrusion due to its capacity for large-scale continuous production and deployed carbon dioxide (CO₂) and water as physical foaming agents. PESU is a high-temperature thermoplastic polymer that requires processing temperatures of at least 320 °C. To lower the processing temperature and obtain foams with higher porosity, we produced PESU/poly(ethylene glycol) (PEG) blends using material penetration. In this way, without the use of organic solvents or a compounding extruder, a partially miscible PESU/PEG blend was prepared. The thermal and rheological properties of homopolymers and blends were characterized and the CO₂ sorption performance of selected blends was evaluated. By using these blends, we were able to significantly reduce the processing temperature required for the extrusion foaming process by approximately 100 °C without changing the duration of processing. This is a significant advancement that makes this process more energy-efficient and sustainable. Additionally, the effects of blend composition, nozzle temperature and foaming agent type were investigated, and we found that higher concentrations of PEG, lower nozzle temperatures, and a combination of CO₂ and water as the foaming agent delivered high porosity. The optimum blend process settings provided foams with a porosity of approximately 51% and an average foam cell diameter of 5 µm, which is the lowest yet reported for extruded polymer foams according to the literature.

Open-Celled Foams of Polyethersulfone/Poly(N-vinylpyrrolidone) Blends for Ultrafiltration Applications

Since membranes made of open porous polymer foams can eliminate the use of organic solvents during their manufacturing, a series of previous studies have explored the foaming process of various polymers including polyethersulfone (PESU) using physical blowing agents but failed to produce ultrafiltration membranes. In this study, blends containing different ratios of PESU and poly(N-vinylpyrrolidone) (PVP) were used for preparation of open-celled polymer foams. In batch foaming experiments involving a combination of supercritical CO₂ and superheated water as blowing agents, blends with low concentration of PVP delivered uniform open-celled foams that consisted of cells with average cell size less than 20 µm and cell walls containing open pores with average pore size less than 100 nm. A novel sample preparation method was developed to eliminate the non-foamed skin layer and to achieve a high porosity. Flat sheet membranes with an average cell size of 50 nm in the selective layer and average internal pore size of 200 nm were manufactured by batch foaming a PESU blend with higher concentration of PVP and post-treatment with an aqueous solution of sodium hypochlorite. These foams are associated with a water-flux up to 45 L/(h m² bar). Retention tests confirmed their applicability as ultrafiltration membranes.

Simultaneous Wrinkle-Patterning and In Situ Foaming in Polymer Films Using Supercritical Carbon Dioxide

Unique and random wrinkle features are desired for applications, especially in anticounterfeiting. Multifunctional wrinkled materials as well as simple wrinkling methods are desired for more applications. In this study, free-standing wrinkle-patterned porous polymer films were prepared using a modified supercritical CO₂ foaming strategy. Spontaneous wrinkling was generated by applying moderate normal stress to the polymer films while foaming in situ. The wrinkle characteristics (wavelength and amplitude) were shown to be governed by the film thickness and the magnitude of the applied stress. Excessive (>5000 N) or no stress produced no obvious wrinkling or foaming whatsoever. Moreover, different morphologies of the wrinkles such as brain coral and herringbone patterns were achieved depending upon the shape of the mold used to apply the stress. Thus, the patterns show unique features for each batch process. Notwithstanding, geometric shape of the foamed wrinkle area is customizable. The reported wrinkling strategy offers the complementary advantage of patterning a foam in a polymer film and templating a PDMS stamp for different applications such as "mask-less" soft lithography, anticounterfeiting, pattern transfer, flexographic printing, and displays.