Foaming of polymers with supercritical fluids and perspectives on the current knowledge gaps and challenges

Supercritical Impregnation of PETG with Olea europaea Leaf Extract: Influence of Operational Parameters on Expansion Degree, Antioxidant and Mechanical Properties

PETG (poly(ethylene glycol-co-cyclohexane-1,4-dimethanol terephthalate)) is an amorphous copolymer, biocompatible, recyclable, and versatile. Nowadays, it is being actively researched for biomedical applications. However, proposals of PETG as a platform for the loading of bioactive compounds from natural extract are scarce, as well as the effect of the supercritical impregnation on this polymer. In this work, the supercritical impregnation of PETG filaments with Olea europaea leaf extract was investigated, evaluating the effect of pressure (100-400 bar), temperature (35-55 °C), and depressurization rate (5-50 bar min-1) on the expansion degree, antioxidant activity, and mechanical properties of the resulting filaments. PETG expansion degree ranged from ~3 to 120%, with antioxidant loading ranging from 2.28 to 17.96 g per 100 g of polymer, corresponding to oxidation inhibition values of 7.65 and 66.55%, respectively. The temperature and the binary interaction between pressure and depressurization rate most affected these properties. The mechanical properties of PETG filaments depended greatly on process variables. Tensile strength values were similar or lower than the untreated filaments. Young's modulus and elongation at break values decreased below ~1000 MPa and ~10%, respectively, after the scCO2 treatment and impregnation. The extent of this decrease depended on the supercritical operational parameters. Therefore, filaments with higher antioxidant activity and different expansion degrees and mechanical properties were obtained by adjusting the supercritical processing conditions.

Forefront Research of Foaming Strategies on Biodegradable Polymers and Their Composites by Thermal or Melt-Based Processing Technologies: Advances and Perspectives

The last few decades have witnessed significant advances in the development of polymeric-based foam materials. These materials find several practical applications in our daily lives due to their characteristic properties such as low density, thermal insulation, and porosity, which are important in packaging, in building construction, and in biomedical applications, respectively. The first foams with practical applications used polymeric materials of petrochemical origin. However, due to growing environmental concerns, considerable efforts have been made to replace some of these materials with biodegradable polymers. Foam processing has evolved greatly in recent years due to improvements in existing techniques, such as the use of supercritical fluids in extrusion foaming and foam injection moulding, as well as the advent or adaptation of existing techniques to produce foams, as in the case of the combination between additive manufacturing and foam technology. The use of supercritical CO2 is especially advantageous in the production of porous structures for biomedical applications, as CO2 is chemically inert and non-toxic; in addition, it allows for an easy tailoring of the pore structure through processing conditions. Biodegradable polymeric materials, despite their enormous advantages over petroleum-based materials, present some difficulties regarding their potential use in foaming, such as poor melt strength, slow crystallization rate, poor processability, low service temperature, low toughness, and high brittleness, which limits their field of application. Several strategies were developed to improve the melt strength, including the change in monomer composition and the use of chemical modifiers and chain extenders to extend the chain length or create a branched molecular structure, to increase the molecular weight and the viscosity of the polymer. The use of additives or fillers is also commonly used, as fillers can improve crystallization kinetics by acting as crystal-nucleating agents. Alternatively, biodegradable polymers can be blended with other biodegradable polymers to combine certain properties and to counteract certain limitations. This work therefore aims to provide the latest advances regarding the foaming of biodegradable polymers. It covers the main foaming techniques and their advances and reviews the uses of biodegradable polymers in foaming, focusing on the chemical changes of polymers that improve their foaming ability. Finally, the challenges as well as the main opportunities presented reinforce the market potential of the biodegradable polymer foam materials.

Effect of the Material Extrusion Process Parameters on the Compressive Properties of Additively Manufactured Foamed and Nonfoamed Polylactic Acid Structures

This work evaluates the potential for foamable polymer filaments to be used to make lightweight, energy-absorbing structures using additive manufacturing. To achieve this, a commercial, foamable polylactic acid filament was extruded using a material extrusion process to make parts for compression testing. It was found that a maximum foam expansion could be achieved at an extrusion nozzle temperature of 220°C, but that to achieve dimensional accuracy, the material flow rate through the nozzle had to be adjusted by decreasing the extrusion multiplier value. In a novel approach, accurate and faster builds could be achieved by decreasing the infill instead. When compared with porous structures achieved by using partial infilling instead or as well as foaming, all materials were found to follow the same power-law function of the solid fraction. These trends indicated that the mechanical response was, within experimental scatter, a function of the overall solid fraction and not influenced by whether the porosity was within or between the raster lines. Although there was no apparent benefit to the mechanical performance in introducing porosity into a polymer by foaming, foamable filaments are desirable if stiff, lightweight structures with low fractions of interconnected porosity are required and can be used in combination with infilling to produce low-density structures that would be highly suitable for cores in novel lightweight sandwich structures.

Intravitreal implants manufactured by supercritical foaming for treating retinal diseases

Chronic retinal diseases, such as age-related macular degeneration (AMD), are a major cause of global visual impairment. However, current treatment methods involving repetitive intravitreal injections pose financial and health burdens for patients. The development of controlled drug release systems, particularly for biological drugs, is still an unmet need in prolonging drug release within the vitreous chamber. To address this, green supercritical carbon dioxide (scCO2) foaming technology was employed to manufacture porous poly(lactic-co-glycolic acid) (PLGA)-based intravitreal implants loaded with dexamethasone. The desired implant dimensions were achieved through 3D printing of customised moulds. By varying the depressurisation rates during the foaming process, implants with different porosities and dexamethasone release rates were successfully obtained. These implants demonstrated controlled drug release for up to four months, surpassing the performance of previously developed implants. In view of the positive results obtained, a pilot study was conducted using the monoclonal antibody bevacizumab to explore the feasibility of this technology for preparing intraocular implants loaded with biologic drug molecules. Overall, this study presents a greener and more sustainable alternative to conventional implant manufacturing techniques, particularly suited for drugs that are susceptible to degradation under harsh conditions.

Current Trend and New Opportunities for Multifunctional Bio-Scaffold Fabrication via High-Pressure Foaming

Biocompatible and biodegradable foams prepared using the high-pressure foaming technique have been widely investigated in recent decades as porous scaffolds for in vitro and in vivo tissue growth. In fact, the foaming process can operate at low temperatures to load bioactive molecules and cells within the pores of the scaffold, while the density and pore architecture, and, hence, properties of the scaffold, can be finely modulated by the proper selection of materials and processing conditions. Most importantly, the high-pressure foaming of polymers is an ideal choice to limit and/or avoid the use of cytotoxic and tissue-toxic compounds during scaffold preparation. The aim of this review is to provide the reader with the state of the art and current trend in the high-pressure foaming of biomedical polymers and composites towards the design and fabrication of multifunctional scaffolds for tissue engineering. This manuscript describes the application of the gas foaming process for bio-scaffold design and fabrication and highlights some of the most interesting results on: (1) the engineering of porous scaffolds featuring biomimetic porosity to guide cell behavior and to mimic the hierarchical architecture of complex tissues, such as bone; (2) the bioactivation of the scaffolds through the incorporation of inorganic fillers and drugs.

Solid-State Surface Patterning on Polymer Using the Microcellular Foaming Process

This study proposes a novel process that integrates the molding and patterning of solid-state polymers with the force generated from the volume expansion of the microcellular-foaming process (MCP) and the softening of solid-state polymers due to gas adsorption. The batch-foaming process, which is one of the MCPs, is a useful process that can cause thermal, acoustic, and electrical characteristic changes in polymer materials. However, its development is limited due to low productivity. A pattern was imprinted on the surface using a polymer gas mixture with a 3D-printed polymer mold. The process was controlled with changing weight gain by controlling saturation time. A scanning electron microscope (SEM) and confocal laser scanning microscopy were used to obtain the results. The maximum depth could be formed in the same manner as the mold geometry (sample depth: 208.7 μm; mold depth: 200 μm). Furthermore, the same pattern could be imprinted as a layer thickness of 3D printing (sample pattern gap and mold layer gap: 0.4 mm), and surface roughness was increased according to increase in the foaming ratio. This process can be used as a novel method to expand the limited applications of the batch-foaming process considering that MCPs can impart various high-value-added characteristics to polymers.

Solubility of palbociclib in supercritical carbon dioxide from experimental measurement and Peng-Robinson equation of state

Palbociclib is a poorly water-soluble medicine which acts against metastatic breast cancer cells. Among various techniques to improve the solubility of this medicine, applying supercritical technologies to produce micro- and nano-sized particles is a possible option. For this purpose, extraction of solubility data is required. In this research, the solubility of palbociclib in supercritical carbon dioxide (ScCO₂) at different equilibrium conditions was measured at temperatures between 308 and 338 K and pressures within 12-27 MPa, for the first time. The minimum and maximum solubility data were found to be 8.1 × 10^-7 (at 338 K and 12 MPa) and 2.03 × 10^-5 (at 338 K and 27 MPa), respectively. Thereafter, two sets of models, including ten semi-empirical equations and three Peng-Robinson (PR) based integrated models were used to correlate the experimental solubility data. Bian's model and PR equation of state using van der Waals mixing rules (PR + vdW) showed better accuracy among the examined semi-empirical and integrated models, respectively. Furthermore, the self-consistency of the obtained data was confirmed using two distinct semi-empirical models. At last, the total and vaporization enthalpies of palbociclib solubility in ScCO₂ were calculated from correlation results of semi-empirical equations and estimated to be 40.41 and 52.67 kJ/mol, respectively.

Assessing the Impact and Suitability of Dense Carbon Dioxide as a Green Solvent for the Treatment of PMMA of Historical Value

Surface cleaning of plastic materials of historical value can be challenging due to the high risk of inducing detrimental effects and visual alterations. As a result, recent studies have focused on researching new approaches that might reduce the associated hazards and, at the same time, minimize the environmental impact by employing biodegradable and green materials. In this context, the present work investigates the effects and potential suitability of dense carbon dioxide (CO₂) as an alternative and green solvent for cleaning plastic materials of historical value. The results of extensive trials with CO₂ in different phases (supercritical, liquid, and vapor) and under various conditions (pressure, temperature, exposure, and depressurization time) are reported for new, transparent, thick poly(methyl methacrylate) (PMMA) samples. The impact of CO₂ on the weight, the appearance of the samples (dimensions, color, gloss, and surface texture), and modifications to their physicochemical and mechanical properties were monitored via a multi-analytical approach that included optical microscopy, Raman and attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopies, and micro-indentation (Vickers hardness). Results showed that CO₂ induced undesirable and irreversible changes in PMMA samples (i.e., formation of fractures and stress-induced cracking, drastic decrease in the surface hardness of the samples), independent of the conditions used (i.e., temperature, pressure, CO₂ phase, and exposure time).

Applications and Challenges of Supercritical Foaming Technology

With economic development, environmental problems are becoming more and more prominent, and achieving green chemistry is an urgent task nowadays, which creates an opportunity for the development of supercritical foaming technology. The foaming agents used in supercritical foaming technology are usually supercritical carbon dioxide (ScCO₂) and supercritical nitrogen (ScN₂), both of which are used without environmental burden. This technology can reduce the environmental impact of polymer foam production. Although supercritical foaming technology is already in production in some fields, it has not been applied on a large scale. Here, we present a detailed analysis of the types of foaming agents currently used in supercritical foaming technology and their applications in various fields, summarizing the technological improvements that have been made to the technology. However, we have found that today's supercritical technologies still need to address some additional challenges to achieve large-scale production.

Progress in the Foaming of Polymer-based Electromagnetic Interference Shielding Composites by Supercritical CO2

As a critical action plan formulated for peaking carbon dioxide emissions, polymeric electromagnetic interference (EMI) shielding materials based on CO₂ foaming technology have recently been attracting widespread attention in both research and industry, attributable to their efficient use of CO₂ , high specific strength, corrosion resistance and low-cost characteristics. In the past decade, the emergence of novel design concepts and preparation techniques for CO₂ foaming technology has led to the development of new high-performance EMI shielding materials in this field. This review summarizes the research progress made to date on the fabrication of EMI shielding composite foams by supercritical carbon dioxide (scCO₂ ) foaming. We also explore the structure-activity relationships between the component/distribution and EMI shielding properties. Additionally, the application prospects and development challenges of new EMI shielding composite foams are described.

Validation of a compartmental model to predict drug release from porous structures produced by ScCO2 techniques

A global release model is proposed to study the drug release from porous materials for pharmaceutical applications. This model is defined by implementing a compartmental model where the release profile could be explained as the combination of mass transfer phenomena through three compartments as well as a desorption process or dissolution process from the support. This model was validated with five different systems produced with supercritical CO₂ (aerogels, membranes, and fibers), showing different release processes. Numerical results indicate that this compartmental approach can be useful to determine adsorption and desorption constants as well as mass transfer resistances within the material. Likewise, this model can predict lag phases and imbibition phenomena. Therefore, the development of compartmental models can be an alternative to traditional models to successfully predict the drug profile of porous materials, achieving a complete understanding of the involved phenomena regardless of the material characteristics.

Production and Application of Polymer Foams Employing Supercritical Carbon Dioxide

Polymeric foams have characteristics that make them attractive for different applications. However, some foaming methods rely on chemicals that are not environmentally friendly. One of the possibilities to tackle the environmental issue is to utilize supercritical carbon dioxide ScCO2 since it is a “green” solvent, thus facilitating a sustainable method of producing foams. ScCO2 is nontoxic, chemically inert, and soluble in molten plastic. It can act as a plasticizer, decreasing the viscosity of polymers according to temperature and pressure. Most foam processes can benefit from ScCO2 since the methods rely on nucleation, growth, and expansion mechanisms. Process considerations such as pretreatment, temperature, pressure, pressure drop, and diffusion time are relevant parameters for foaming. Other variables such as additives, fillers, and chain extenders also play a role in the foaming process. This review highlights the morphology, performance, and features of the foam produced with ScCO2, considering relevant aspects of replacing or introducing a novel foam. Recent findings related to foaming assisted by ScCO2 and how processing parameters influence the foam product are addressed. In addition, we discuss possible applications where foams have significant benefits. This review shows the recent progress and possibilities of ScCO2 in processing polymer foams.

Developing Insulating Polymeric Foams: Strategies and Research Needs from a Circular Economy Perspective

Insulating polymeric foams have an important role to play in increasing energy efficiency and therefore contributing to combating climate change. Their development in recent years has been driven towards the reduction of thermal conductivity and achievement of the required mechanical properties as main targets towards sustainability. This perception of sustainability has overseen the choice of raw materials, which are often toxic, or has placed research efforts on optimizing one constituent while the other necessary reactants remain hazardous. The transition to the circular economy requires a holistic understanding of sustainability and a shift in design methodology and the resulting research focus. This paper identifies research needs and possible strategies for polymeric foam development compatible with Circular Product Design and Green Engineering, based on an extensive literature review. Identified research needs include material characterization of a broader spectrum of polymer melt-gas solutions, ageing behavior, tailoring of the polymer chains, detailed understanding and modeling of the effects of shear on cell nucleation, and the upscaling of processing tools allowing for high and defined pressure drop rates.

Supercritical Fluid Extraction from Zataria multiflora Boiss and Impregnation of Bioactive Compounds in PLA for the Development of Materials with Antibacterial Properties

In this research, the extraction with supercritical carbon dioxide (SC-CO2) and the subsequent impregnation of the extracted bioactive compounds from Zataria multiflora Boiss (Z. multiflora) into polylactic acid (PLA) films was investigated. The effects of temperature (318 and 338 K), pressure (15 and 25 MPa) and cosolvent presence (0 and 3 mol%) on the extraction yield were studied. The SC-CO2 assisted impregnation runs were carried out in a discontinuous mode at different pressure (15 and 25 MPa), temperature (318 and 328 K), and time (2 and 8 h) values, using 0.5 MPa min−1 as a constant value of depressurization rate. ANOVA results confirmed that pressure, temperature, and time influenced the extraction yield. Moreover, antioxidant activities of extracts of Z. multiflora were evaluated using 2,2-diphenyl-1-picrylhydrazyl (DPPH) radical scavenging assays. In addition, the antibacterial activities of the extracts were screened against standard strains of Staphylococcus aureus (S. aureus) and Escherichia coli (E. coli). The results of this investigation indicated that extracts obtained from the aerial parts of Z. multiflora possessed antioxidant and antibacterial properties. The impregnated samples presented strong antibacterial activity against the selected microorganisms.

Supercritical Fluid Technologies for the Incorporation of Synthetic and Natural Active Compounds into Materials for Drug Formulation and Delivery

Various active compounds isolated from natural sources exhibit remarkable benefits, making them attractive for pharmaceutical and biomedical applications, such as antioxidant, antimicrobial, and anti-inflammatory activities, which contribute to the treatment of cardiovascular diseases, neurodegenerative disorders, various types of cancer, diabetes, and obesity. However, their major drawbacks are their reactivity, instability, relatively poor water solubility, and consequently low bioavailability. Synthetic drugs often face similar challenges associated with inadequate solubility or burst release in gastrointestinal media, despite being otherwise a safe and effective option for the treatment of numerous diseases. Therefore, drug-eluting pharmaceutical formulations have been of great importance over the years in efforts to improve the bioavailability of active compounds by increasing their solubility and achieving their controlled release in body media. This review highlights the success of the fabrication of micro- and nanoformulations using environmentally friendly supercritical fluid technologies for the processing and incorporation of active compounds. Several novel approaches, namely micronization to produce micro- and nano-sized particles, supercritical drying to produce aerogels, supercritical foaming, and supercritical solvent impregnation, are described in detail, along with the currently available drug delivery data for these formulations.

Principles and Guidelines for In-Line Viscometry in Cereal Extrusion

In the food industry, extrusion cooking finds numerous applications thanks to its high productivity and nutrient retention. More specifically, cereal extrusion, e.g., for savory snacks and breakfast products has an important market share. For such applications, rheology, which addresses viscous and elastic contributions, plays an important role in developing, optimizing, and controlling the extrusion manufacturing technique. In this context, conventional off-line rheometers are not ideal for providing data, as the goal is to replicate the exact thermomechanical history to which the food is subjected in the extrusion process. Hence, to achieve reliable analyses, in-line viscometers that have mostly been tested using oil-based polymers were introduced. Biopolymers (e.g., starch), however, are highly sensitive to both heat and mechanical degradation, and the viscometer design has to be adapted accordingly to produce an accurate measurement. Alongside a discussion of the different designs available, this review will address the most common methodologies for measuring the steady shear viscosity, extensional viscosity, and the first normal stress difference for food applications, providing researchers in the biopolymer and food engineering fields with a general introduction to this emerging topic.

Asymmetric resorbable-based dental barrier membrane for periodontal guided tissue regeneration and guided bone regeneration: A review

Guided tissue regeneration (GTR) and guided bone regeneration (GBR) are two common dental regenerative treatments targeted at reconstructing damaged periodontal tissue and bone caused by periodontitis. During GTR/GBR treatment, a barrier membrane is placed in the interface between the soft tissue and the periodontal defect to inhibit soft tissue ingrowth and creating a space for the infiltration of slow-growing bone cells into the defect site. Recently, asymmetric resorbable-based barrier membrane has received a considerable attention as a new generation of GTR/GBR membrane. Despite numerous literatures about asymmetric-based membrane that had been published, there is lacks comprehensive review on asymmetric barrier membrane that particularly highlight the importance of membrane structure for periodontal regeneration. In this review, we systematically cover the latest development and advancement of various kinds of asymmetric barrier membranes used in periodontal GTR/GBR application. Herein, the ideal requirements for constructing a barrier membrane as well as the rationale behind the asymmetric design, are firstly presented. Various innovative methods used in fabricating asymmetric barrier membrane are being further discussed. Subsequently, the application and evaluation of various types of asymmetric barrier membrane used for GTR/GBR are compiled and extensively reviewed based on the recent literatures reported. Based on the existing gap in this field, the future research directions of asymmetric resorbable-based barrier membrane such as its combination potential with bone grafts, are also presented.

Foaming with scCO2 and Impregnation with Cinnamaldehyde of PLA Nanocomposites for Food Packaging

Microcellular nanocomposite foams functionalized with cinnamaldehyde (Ci) were obtained through two-step supercritical foaming and impregnation processing. PLA nanocomposite foams with different C30B concentrations (1, 2, and 3 wt.%) were obtained by foaming with scCO2 at 25 MPa and 135 °C and impregnated with Ci at 12 MPa and 40 °C. The effect of the C30B content and Ci incorporation on the morphological, structural, thermal, and release properties of the developed foams were investigated. The incorporation of Ci was not influenced by C30B’s addition. The presence of C30B and Ci incorporation reduced the average pore diameter slightly and the crystallinity degree of the foams extensively. Simultaneously, the experimental and theoretical characterization of the Ci release from the PLA nanocomposite foams in EtOH 50% was analyzed. The mechanism of Ci release from the foams was defined as a quasi-Fickian diffusion process that could be successfully described using the Korsmeyer–Peppas model. The active PLA foams presented a higher potential of migration and faster release when compared with that reported in commonly used PLA films, showing that biopolymeric foams could be potentially used as active food packaging to improve the migration of active compounds with low migration potentials in order to improve their biological activity in foods.

Combined sterilization and fabrication of drug-loaded scaffolds using supercritical CO2 technology

The access of biodegradable scaffolds to the clinical arena is constrained by the absence of a suitable sterilization technique for the processing of advanced polymeric materials. Sterilization with supercritical CO₂ (scCO₂) may circumvent some technological limitations (e.g., low temperature, no chemical residues on the material), although scCO₂ can plasticize the polymer depending on the processing conditions used. In this latter case, the integration of the manufacturing and sterilization processes is of particular interest to obtain sterile and customized scaffolds in a single step. In this work, scCO₂ was exploited as a concomitantly foaming and sterilizing agent for the first time, developing a one-step process for the production of vancomycin-loaded poly(ε-caprolactone) (PCL) bone scaffolds. The effect of the CO₂ contact time on the sterility levels of the procedure was investigated, and the sterilization efficiency was evaluated against dry spores (Bacillus stearothermophilus, Bacillus pumilus and Bacillus atrophaeus). Vancomycin-loaded PCL scaffolds had relevant sustained release profiles for the prophylaxis of infections at the grafted area, even those caused by methicillin-resistant Staphylococcus aureus (MRSA). The biological performance of the scaffolds was evaluated in vitro regarding human mesenchymal stem cells (hMSCs) attachment and growth. Finally, the biocompatibility and angiogenic response of the manufactured sterile scaffolds was assessed in ovo through chick chorioallantoic membrane (CAM) assays.

Polylactide, Processed by a Foaming Method Using Compressed Freon R134a, for Tissue Engineering

Fabricating polymeric scaffolds using cost-effective manufacturing processes is still challenging. Gas foaming techniques using supercritical carbon dioxide (scCO₂) have attracted attention for producing synthetic polymer matrices; however, the high-pressure requirements are often a technological barrier for its widespread use. Compressed 1,1,1,2-tetrafluoroethane, known as Freon R134a, offers advantages over CO₂ in manufacturing processes in terms of lower pressure and temperature conditions and the use of low-cost equipment. Here, we report for the first time the use of Freon R134a for generating porous polymer matrices, specifically polylactide (PLA). PLA scaffolds processed with Freon R134a exhibited larger pore sizes, and total porosity, and appropriate mechanical properties compared with those achieved by scCO₂ processing. PLGA scaffolds processed with Freon R134a were highly porous and showed a relatively fragile structure. Human mesenchymal stem cells (MSCs) attached to PLA scaffolds processed with Freon R134a, and their metabolic activity increased during culturing. In addition, MSCs displayed spread morphology on the PLA scaffolds processed with Freon R134a, with a well-organized actin cytoskeleton and a dense matrix of fibronectin fibrils. Functionalization of Freon R134a-processed PLA scaffolds with protein nanoparticles, used as bioactive factors, enhanced the scaffolds' cytocompatibility. These findings indicate that gas foaming using compressed Freon R134a could represent a cost-effective and environmentally friendly fabrication technology to produce polymeric scaffolds for tissue engineering approaches.

Preparation of Microcellular Foams by Supercritical Carbon Dioxide: A Case Study of Thermoplastic Polyurethane 70A

In this study, a case study to produce microcellular foam of a commercial thermoplastic polyurethane (TPU) through the supercritical carbon dioxide (CO2) foaming process is presented. To explore the feasibility of TPU in medical device and biomedical application, a soft TPU with Shore hardness value of 70A was selected as the model compound. The effects of saturation temperature and saturation pressure ranging from 90 to 140 °C and 90 to 110 bar on the expansion ratio, cell size and cell density of the TPU foam were compared and discussed. Regarding the expansion ratio, the effect of saturation temperature was considerable and an intermediate saturation temperature of 100 °C was favorable to produce TPU microcellular foam with a high expansion ratio. On the other hand, the mean pore size and cell density of TPU foam can be efficiently manipulated by adjusting the saturation pressure. A high saturation pressure was beneficial to obtain TPU foam with small mean pore size and high cell density. This case study shows that the expansion ratio of TPU microcellular foam could be designed as high as 4.4. The cell size and cell density could be controlled within 12–40 μm and 5.0 × 107–1.3 × 109 cells/cm3, respectively.

Fabrication of Highly Interconnected Poly(ε-caprolactone)/cellulose Nanofiber Composite Foams by Microcellular Foaming and Leaching Processes

In this study, microcellular polycaprolactone (PCL)/sodium bicarbonate (NaHCO₃)/cellulose nanofiber (CNF) composite foams with highly interconnected porous structures were successfully fabricated by microcellular foaming and particle leaching processes. Supercritical CO₂ (scCO₂) served as a physical foaming agent, NaHCO₃ was chosen as a chemical foaming agent and porogen, and CNF acted as a heterogeneous nucleating agent. The effect of scCO₂, NaHCO₃, and CNF on pore structures and the cofoaming mechanism were investigated. The results indicated that the addition of NaHCO₃ and CNF increased the melt strength of the PCL matrix significantly. During the foaming process, the presence of CNF can form a rigid network due to the hydrogen bonding or mechanical entanglement between individual nanofibers, improving the nucleating efficiency but slowing down the cell growth rate. Additionally, due to the interaction of "soft" PCL matrix and "hard" domains in a PCL-based composite during the foaming process, together with the NaHCO₃ leaching process, highly interconnected cell structures appeared. The obtained PCL/NaHCO₃/CNF composite foams had a cell size of 15.8 μm and cell density of 6.3 × 10⁷ cells/cm³, as well as an open-cell content of 82%. The reported strategy in this paper may provide the guidelines and data supports for the fabrication of a PCL-based porous scaffold.

Carbon Capture Utilization for Biopolymer Foam Manufacture: Thermal, Mechanical and Acoustic Performance of PCL/PHBV CO2 Foams

Biopolymer foams manufactured using CO₂ enables a novel intersection for economic, environmental, and ecological impact but limited CO₂ solubility remains a challenge. PHBV has low solubility in CO₂ while PCL has high CO₂ solubility. In this paper, PCL is used to blend into PBHV. Both unfoamed and foamed blends are examined. Foaming the binary blends at two depressurization stages with subcritical CO₂ as the blowing agent, produced open-cell and closed-cell foams with varying cellular architecture at different PHBV concentrations. Differential Scanning Calorimetry results showed that PHBV had some solubility in PCL and foams developed a PCL rich, PHBV rich and mixed phase. Scanning Electron Microscopy and pcynometry established cell size and density which reflected benefits of PCL presence. Acoustic performance showed limited benefits from foaming but mechanical performance of foams showed a significant impact from PHBV presence in PCL. Thermal performance reflected that foams were affected by the blend thermal conductivity, but the impact was significantly higher in the foams than in the unfoamed blends. The results provide a pathway to multifunctional performance in foams of high performance biopolymers such as PBHV through harnessing the CO₂ miscibility of PCL.

Mechanism of Heterogeneous Bubble Nucleation in Polymer Blend Foaming

A three-dimensional heterogeneous bubble nucleation model is constructed to provide a reasonable explanation at the molecular level for the foaming mechanism of polypropylene (PP) and polystyrene (PS) blends. CO₂ solubilities and supersaturation rations are quantitatively calculated to help interpret the contribution of each phase of the blend in the CO₂ dissolution stage. The spatial density profiles of polymer/CO₂ binary melt around different polymer chains are presented to give an intuitive perspective to the thermodynamic driving force. The predicted interfacial tension and contact angles of critical bubbles provide valid evidence to distinguish the wettability of CO₂ in different regions. The values of predicted free-energy barriers, critical radii, and nucleation number densities imply that bubbles that nucleate in the PP and PS blend interfacial region attached to the PS-rich phase achieve the smallest size and largest number density. The reliability of the theoretical model has been tested by partial available experimental data.