Analysis of the foam-forming of non-woven lightweight fibrous materials using X-ray tomography

Synthesis of a robust, water-stable, and biodegradable pulp foam by poly-lactic acid coating towards a zero-plastic earth

Biodegradable cellulosic pulp foams with robustness and water resistance are urgently needed in nowadays to replace petroleum-based plastic foams for environmental sustainability. In this work, a facile protocol to fabricate robust poly-lactic acid (PLA) coated cellulose foams (PCCF) was developed through a combined water-based foaming and PLA melt-coating process using pulp as the raw material. In the synthesis, the so-called PLA coating was realized through melting PLA powders dispersed between fibers by an in-situ heating and post cooling process. Performance tests revealed that the incorporation of PLA coating significantly enhances mechanical strength, water stability, and biodegradability of the synthesized PCCF samples compared with conventional cellulosic foams. Specifically, the low-density PCCF were observed with mechanical strength up to 81.24 kPa, high water stability, and more than 95% degradation in 56 days. As the fabrication process is simple and pulp is highly cost competitive, our proposed synthesis strategy makes the PCCF a promising substitute for petroleum-based plastic foams at large-scale production.

Overview on Foam Forming Cellulose Materials for Cushioning Packaging Applications

Wet foam can be used as a carrier in the manufacturing of lightweight materials based on natural and man-made fibers and specific additives. Using a foam forming method and cellulose fibers, it is possible to produce the porous materials with large area of end-using such as protective and cushioning packaging, filtering, hydroponic, thermal and sound absorption insulation, or other building materials. In comparison with the water-forming used for conventional paper products, foam-forming method provides many advantages. In particular, since fibers inside the foam are mostly trapped between the foam bubbles, the formed materials have an excellent homogeneity. This allows for using long fibers and a high consistency in head box without significant fiber flocking. As result, important savings in water and energy consumptions for dewatering and drying of the foam formed materials are obtained. In cushioning packaging, foam-formed cellulose materials have their specific advantages comparing to other biodegradable packaging (corrugated board, molded pulp) and can be a sustainable alternative to existing synthetic foams (i.e., expanded polystyrene or polyurethane foams). This review discusses the technical parameters to be controlled during foam forming of cellulose materials to ensure their performances as cushioning and protective packaging. The focus was on the identification of practical solutions to compensate the strength decreasing caused by reduced density and low resistance to water of foam formed cellulose materials.

Elastocapillary deformation of thin elastic ribbons in 2D foam columns

The ability of liquid interfaces to shape slender elastic structures provides powerful strategies to control the architecture of mechanical self assemblies. However, elastocapillarity-driven intelligent design remains unexplored in more complex architected liquids - such as foams. Here we propose a model system which combines an assembly of bubbles and a slender elastic structure. Arrangements of soap bubbles in confined environments form well-defined periodic structures, dictated by Plateau's laws. We consider a 2D foam column formed in a container with square cross-section in which we introduce an elastomer ribbon, leading to architected structures whose geometry is guided by a competition between elasticity and capillarity. In this system, we quantify both experimentally and theoretically the equilibrium shapes, using X-ray micro-tomography and energy minimisation techniques. Beyond the understanding of the amplitude of the wavy elastic ribbon deformation, we provide a detailed analysis of the profile of the ribbon, and show that such a setup can be used to grant a shape to a UV-curable composite slender structure, as a foam-forming technique suitable to miniaturisation. In more general terms, this work provides a stepping stone towards an improved understanding of the interactions between liquid foams and slender structures.