Scalable Fabrication of Thermally Insulating Mechanically Resilient Hierarchically Porous Polymer Foams

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.

Anisotropic composite aerogel with thermal insulation and flame retardancy from cellulose nanofibers, calcium alginate and boric acid

With the increasing severity of energy shortages and environmental pollution, there is an urgent need for advanced thermal insulation materials with excellent comprehensive performance, including low thermal conductivity, high flame resistance, and strong compressive strength. Herein, an anisotropic composite aerogel based on cellulose nanofibers (CNF), calcium alginate (CA), and boric acid (BA) is fabricated using a directional freeze-drying strategy. The CA and BA, as double cross-linking agents, associated with oriented porous structure provide the resultant aerogel with good mechanical strength. Additionally, self-flame retardant CA and BA act as synergistic flame retardants that endow the aerogel with excellent flame retardance properties such as a limiting oxygen index value of 44.2 %, UL-94 V-0 rating, and low heat release. Furthermore, this composite aerogel exhibits outstanding thermal insulation performance with a low thermal conductivity of approximately 30 mW m-1 K-1. Therefore, the composite aerogel is expected to have a wide potential application in areas such as construction, automotive industry, batteries, petrochemical pipelines, and high-temperature reaction devices.

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

Highly porous metal oxide-polymer nanocomposites are attracting considerable interest due to their unique structural and functional features. A porous polymer matrix brings properties such as high porosity and permeability, while the metal oxide phase adds functionality. For the metal oxide phase to perform its function, it must be fully accessible, and this is possible only at the pore surface, but functioning surfaces require controlled engineering, which remains a challenge. Here, highly porous nanocomposite beads based on thin metal oxide nanocoatings and polymerized high internal phase emulsions (polyHIPEs) are demonstrated. By leveraging the unique properties of polyHIPEs, i.e., a three-dimensional (3D) interconnected network of macropores, and high-precision of the atomic-layer-deposition technique (ALD), we were able to homogeneously coat the entire surface of the pores in polyHIPE beads with TiO2-, ZnO-, and Al2O3-based nanocoatings. Parameters such as nanocoating thickness, growth per cycle (GPC), and metal oxide (MO) composition were systematically controlled by varying the number of deposition cycles and dosing time under specific process conditions. The combination of polyHIPE structure and ALD technique proved advantageous, as MO-nanocoatings with thicknesses between 11 ± 3 and 40 ± 9 nm for TiO2 or 31 ± 6 and 74 ± 28 nm for ZnO and Al2O3, respectively, were successfully fabricated. It has been shown that the number of ALD cycles affects both the thickness and crystallinity of the MO nanocoatings. Finally, the potential of ALD-derived TiO2-polyHIPE beads in photocatalytic oxidation of an aqueous bisphenol A (BPA) solution was demonstrated. The beads exhibited about five times higher activity than nanocomposite beads prepared by the conventional (Pickering) method. Such ALD-derived polyHIPE nanocomposites could find wide application in nanotechnology, sensor development, or catalysis.

Skinless Polyphenylene Sulfide Foam with Enhanced Thermal Insulation Properties Fabricated by Constructing Aligned Gas Barrier Layers for Surface-Constrained sc-CO2 Foaming

A solid skin layer inevitably forms on the foam surface for supercritical carbon dioxide (sc-CO₂) foaming technology, leading to deterioration of some inherent properties of polymeric foams. In this work, skinless polyphenylene sulfide (PPS) foam was fabricated with a surface-constrained sc-CO₂ foaming method by innovatively constructing aligned epoxy resin/ferromagnetic graphene oxide composites (EP/GO@Fe₃O₄) as a CO₂ barrier layer under a magnetic field. Introduction of GO@Fe₃O₄ and its ordered alignment led to an obvious decrease in the CO₂ permeability coefficient of the barrier layer, a significant increase of the CO₂ concentration in the PPS matrix, and a decrease of desorption diffusivity in the depressurization stage, suggesting that the composite layers effectively inhibited the escape of CO₂ dissolved in the matrix. Meanwhile, the strong interfacial interaction between the composite layer and the PPS matrix remarkably enhanced the heterogeneous nucleation of cells at the interface, resulting in elimination of the solid skin layer and formation of an obvious cellular structure on the foam surface. Moreover, by the alignment of GO@Fe₃O₄ in EP, the CO₂ permeability coefficient of the barrier layer became much lower, and the cell density on the foam surface further increased with decreasing cell size, which was even higher than that of the cross section of foam, attributed to stronger heterogeneous nucleation at the interface than the homogeneous nucleation in the core region of the sample. As a result, the thermal conductivity of the skinless PPS foam reached as low as 0.0365 W/m·k, decreasing by 49.5% compared with that of regular PPS foam, showing a remarkable improvement in the thermal insulation properties of PPS foam. This work provided a novel and effective method for fabricating skinless PPS foam with enhanced thermal insulation properties.

Biomimetic Liquid Metal-Elastomer Composited Foam with Adjustable Thermal Conductivity for Heat Control

The application of traditional materials with constant thermal conductivity in time-varying thermal environments poses great challenges due to their inability of adjusting thermal conductivity according to different requirements, for which reason materials with adjustable thermal conductivity have attracted much attention. However, certain limitations induced by those materials' low softness or harsh adjustment conditions restrict them from being applied in heat dissipation and heat transfer scenarios. In this study, we report a biomimetic liquid metal-elastomer composited foam with adjustable thermal conductivity (B-LM-ECF). Inspired by the rationale of homeothermic animals regulating the thermal conductivity of their subcutaneous tissue, the prepared material adjusts its thermal conductivity via adjusting the volume proportion of liquid metal within it. The thermal conductivity of B-LM-ECF can be adjusted within the range of 0.11-8.4 W·m-1K-1. The adjustment factor η of B-LM-ECF is 76, which is defined as the ratio of the highest to the lowest thermal conductivity of the material. The material enabling reversible switching for itself from thermal insulation to heat dissipation. The prepared material exhibits 45 KPa of Young's modulus with the maximum fracture tensile rate of 600%, facilitating better covering for thermal management objects. We selected a power lithium battery and a smartphone as specific thermal management objects to demonstrate its practical application in thermal management experiment.

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.

Deformation and Simulation of the Cellular Structure of Foamed Polypropylene Composites

Foamed Polymer is an important polymer material, which is one of the most widely used polymer materials and plays a very important role in the polymer industry. In this work, foamed polypropylene (PP) composites are prepared by injection molding, and the cell deformation process within them is studied by combining visualization technology and COMSOL software simulation. The results shows that the deformation of isolated cells depends in temperature, and there is no macroscopic deformation. There was no significant difference between the stress around adjacent cells at different temperatures, but the stress at different positions around the adjacent cells has obvious changes, and the maximum stress at the center of the adjacent cells was 224.18 N·m^-2, which was easy to cause a lateral deformation of the cells. With the increase in temperature, the displacement around the adjacent cell gradually increased, the maximum displacement of the upper and lower symmetrical points of the cell was 14.62 μm, which is most likely to cause longitudinal deformation of the cell; the deviation of the cell deformation parameter gradually increased, which led to deformation during the growth of the cell easily. The simulation results were consistent with the visualized cell deformation behaviors of the foamed PP composites.

Generation of Tough, Stiff Polylactide Nanocomposites through the In Situ Nanofibrillation of Thermoplastic Elastomer

Polylactide (PLA) resins are among the most desirable biopolymers due to their biobased and compostable nature, excellent stiffness, and tensile strength. However, the widespread application of PLA has long been hindered by its inherent brittleness. While multiple routes have been successfully developed for the toughening of PLA, this toughening has always come at the cost of compromising the stiffness and strength of the matrix. In this work, we report a robust and scalable method for the development of PLA nanocomposites with an unprecedented combination of stiffness and toughness. Using the in situ nanofibrillation technique, we generated PLA composites containing nanofibrils of thermoplastic polyester elastomer (TPEE). Due to the high aspect ratio of these nanofibrils, they form physically percolated networks at low weight fractions (∼2.8 wt %) which dramatically change the mechanical behavior of the material. We found that, upon network formation, the material transitions from brittle to ductile behavior, dramatically increasing its toughness with only a marginal decrease in Young's modulus. We investigate the peculiar rheological behavior and crystallization kinetics of these blends, and propose an extension of the critical ligament thickness mechanism, wherein intrinsic toughening arises at the fiber-matrix interface in the presence of entangled elastomer networks.

A direct foaming approach for carbon nanotube aerogels with ultra-low thermal conductivity and high mechanical stability

Thermally insulating materials (TIMs) with ultra-low thermal conductivity, fire-retardancy, and mechanical stability are demanded to improve energy efficiency in many fields, such as petrochemical plants, energy-saving buildings, and aerospace. However, traditional polymer-based TIMs could not meet these demands. Herein, we propose a direct foaming strategy for obtaining carbon nanotube (CNT) aerogels by the gradual expansion of CNT films with H2O2 as a foaming agent at room temperature. The obtained CNT aerogels have hierarchical cellular structures and possess an ultra-low density (4.6 mg cm-3) and thermal conductivity (16.5 mW m-1 K-1) as well as excellent mechanical robustness and fire-resistance. Our results show that such CNT aerogels have promising applications in the field of thermal insulation and present a facile pathway for the design of thermally insulating, fire-retardant materials based on CNTs.

Thermal and Photocatalytic Performance of Unsaturated Polyester Resins Modified with TiO2 Nanoparticles as Panel Bodies for Vehicles

The transport sector is the fastest growing contributor to climate emissions and experiences the highest growth in energy use. This study explores the use of TiO₂ nanoparticles for obtaining photocatalytic nanocomposites with improved infrared reflectance properties. The nanocomposites were prepared by dispersing 0–20 wt% of TiO₂ nanoparticles in an unsaturated polyester resin. The effect of TiO₂ on the curing kinetics was studied by differential scanning calorimetry, showing a significant delay of the curing reactions. The thermal reflectance of the modified resins was characterized by UV-Vis-NIR spectrophotometry, measuring total solar reflectance (TSR). The TiO₂ greatly increased the TSR of the resin, due to the reflectance properties of the nanoparticles and the change in color of the modified resin. These nanocomposites reflect a significant part of near-infrared radiation, which can contribute to a reduction of the use of heating, ventilation, and air conditioning. Moreover, the photocatalytic effect of the TiO₂ modified nanocomposites was studied by monitoring the degradation of an organic model contaminant in an aqueous medium under UV light, and the reusability of the nanocomposites was studied with 5 cycles. The developed nanocomposites are proposed as a solution for reducing global warming and pollutant emissions.

Biobased foams for thermal insulation: material selection, processing, modelling, and performance

With the urgent need for the development of sustainable materials and a circular economy, a surge of research regarding biobased materials and associated processing methods has resulted in many experimental biobased foams. Although several biobased foams are already shown to have thermal and mechanical properties competitive with expanded polystyrene, there remains a fundamental knowledge gap leading to limited understanding of the principles that determine performance. This review outlines the progress in this burgeoning field, introducing materials selection and processing, comparing performance, examining efforts in modelling physical properties, and discusses challenges in applying models to real biobased systems. The focus is on low thermal conductivity, which is a critical property for temperature-controlled applications such as packaging for refrigerated/frozen foods, medications, and vaccines as well as building materials. Currently, the trend in the field is moving towards fully biobased and compostable foams, though partially biobased polyurethane foams remain the most consistent performers. To illustrate the foam structure–property relationship, thermal conductivity, cell size, and density data were compiled. Given the complexity of biobased foams, heat transfer models aid in identifying crucial variables. However, data relevant to the insulation capability of biobased foams is not fully reported in many references. To address this issue, we employed a dimensional analysis to fill the gaps, revealing a power law correlation between thermal conductivity and relative density. Our approach is not intended as a robust prediction technique, but rather a simple demonstration of how biobased foams data could be utilized to predict the most promising materials and methods.

This review outlines the progress in biobased foams with a focus on low thermal conductivity. It introduces materials selection and processing, compares performance, examines modelling of physical properties, and discusses challenges in applying models to real systems.

Adjustable polystyrene nanoparticle templates for the production of mesoporous foams and ZnO inverse opals

The manifold applications of porous materials, such as in storage, separation, and catalysis, have led to an enormous interest in their cost-efficient preparation. A promising strategy to obtain porous materials with adjustable pore size and morphology is to use templates exhibiting the appropriate nanostructure. In this study, close-packed polystyrene (PS) nanoparticles, synthesized by emulsion polymerization, were used to produce porous PS and ZnO inverse opals. The size and distribution of the polystyrene nanoparticles, characterized by dynamic light scattering (DLS), small-angle neutron scattering (SANS), and scanning electron microscopy (SEM), were controlled via the concentration of sodium dodecyl sulfate (SDS). Systematic measurements of the water/styrene-interfacial tension show that the critical micelle concentration (CMC) of the ternary water–styrene–SDS system, which determines whether monodisperse or polydisperse PS particles are obtained, is considerably lower than that of the binary water–SDS system. The assemblies of close-packed PS nanoparticles obtained via drying were then studied by small-angle X-ray scattering (SAXS) and SEM. Both techniques prove that PS nanoparticles synthesized above the CMC result in a significantly unordered but denser packing of the particles. The polystyrene particles were subsequently used to produce porous polystyrene and ZnO inverse opals. While the former consists of micrometer-sized spherical pores surrounded by extended open-cellular regions of mesopores (Rpore ≈ 25 nm), the latter are made of ZnO-nanoparticles forming a structure of well-aligned interconnected pores.

A rapid screening method for thermal conductivity properties of thermal insulation materials by a thermochemiluminescence probe

Acridine-based 1,2-dioxetane as a thermochemiluminescence (TCL) probe for temperature sensing exhibited an excellent response for temperature in the range of 85-130 °C with favorable sensitivity and good resolution. The proposed TCL probe could be applied to screen thermal conductivity properties of different thermal insulation materials.

Carbon particulate and controlled-hydrolysis assisted extrusion foaming of semi-crystalline polyethylene terephthalate for the enhanced thermal insulation property

This work presents a facile method to produce low-density PET foams using pristine semi-crystalline resin by moisture-induced controlled-hydrolysis in a tight processing window (moisture content ∼ 0.12 wt.%). We investigated the effect of moisture and moisture containing activated carbon (AC) on the foam expansion ratio, cell morphology, and PET resin degradation and crystallization properties. Controlled-hydrolysis increased the melt-flow rate of PET resin (intrinsic viscosity: 0.52 to 0.54 dL/g) without losing crystallinity, and thus the PET foams possess better tensile properties (∼2 MPa stress and ∼100% strain) and higher thermal stability (>200°C) than chemically modified PET foams. The foam density could be made as low as ∼ 0.15 g/cm3 using a lab scale twin-screw extruder. A strand array die was also designed to produce plate-shaped foam samples. AC allowed easier control of the moisture content and delayed resin degradation in extrusion. Both AC and micrographite (mGr) could stabilize the PET foam morphology in extrusion and serve as good infrared attenuation agents (IAAs) in a simulated housing thermal insulation experiment.

Wrong expectation of superinsulation behavior from largely-expanded nanocellular foams

This work aims to predict the thermal conductivity of microcellular and nanocellular thermal insulation foams to explore the correlation between the cellular structure and the thermal insulating properties. Closed-cell foam consisting of cell walls and struts was used as the base geometry for modeling. The mathematical correlations to calculate the thickness of cell walls and the diameter of struts for a given cell size, the void fraction and the volume fraction of polymer located in struts were investigated. Then, a mathematical model for the conductive thermal conductivity including the dependency on the void fraction, the strut fraction and the Knudsen effect for gas was introduced. The radiative thermal conductivity was determined by analyzing the attenuation of radiative energy by absorption and scattering based on Mie's theory together with electromagnetic wave interference, as well as interference of propagating waves and tunneling of the radiative energy by evanescent waves in the cells. The thermal conductivity model was validated by experimental data and used to predict the thermal conductivity of polystyrene (PS) and poly(methyl methacrylate) (PMMA) foams at various cell sizes and volume expansion ratios. It was found that the radiative thermal conductivity plays a crucial role in nanocellular foam. The trade-off between the cell size and cell wall thickness when cell walls become thinner and highly transparent to thermal radiation was demonstrated, leading to the optimal volume expansion ratio at which the thermal conductivities were minimized. Perspectives for the manufacture of high-performance thermal insulation foams are also discussed.

Elastic Aerogels of Cellulose Nanofibers@Metal-Organic Frameworks for Thermal Insulation and Fire Retardancy

Metal-organic frameworks (MOFs) with high microporosity and relatively high thermal stability are potential thermal insulation and flame-retardant materials. However, the difficulties in processing and shaping MOFs have largely hampered their applications in these areas. This study outlines the fabrication of hybrid CNF@MOF aerogels by a stepwise assembly approach involving the coating and cross-linking of cellulose nanofibers (CNFs) with continuous nanolayers of MOFs. The cross-linking gives the aerogels high mechanical strength but superelasticity (80% maximum recoverable strain, high specific compression modulus of ~ 200 MPa cm³ g^-1, and specific stress of ~ 100 MPa cm³ g^-1). The resultant lightweight aerogels have a cellular network structure and hierarchical porosity, which render the aerogels with relatively low thermal conductivity of ~ 40 mW m^-1 K^-1. The hydrophobic, thermally stable MOF nanolayers wrapped around the CNFs result in good moisture resistance and fire retardancy. This study demonstrates that MOFs can be used as efficient thermal insulation and flame-retardant materials. It presents a pathway for the design of thermally insulating, superelastic fire-retardant nanocomposites based on MOFs and nanocellulose.

K-Index: A Descriptor, Predictor, and Correlator of Complex Nanomorphology to Other Material Properties

Morphology is a qualitative property of nanostructured matter and is articulated by visual inspection of micrographs. For deterministic procedures that relate nanomorphology to synthetic conditions, it is necessary to express nano- and microstructures numerically. Selecting polyurea aerogels as a model system with demonstrated potential for rich nanomorphology and guided by a statistical design-of-experiments model, we prepared a large array of materials (208) with identical chemical composition but quite different nanostructures. By reflecting on SEM imaging, it was realized that our first preverbal impression about a nanostructure is related to its openness and texture; the former is quantified by porosity ( Π), and the latter is oftentimes related to hydrophobicity, which, in turn, is quantified by the contact angle (θ) of water droplets resting on the material. Herewith, the θ-to-Π ratio is referred to as the K-index, and it was noticed that all polyurea samples of this study could be put in eight K-index groups with separate nanomorphologies ranging from caterpillar-like assemblies of nanoparticles, to thin nanofibers, to cocoon-like structures, to large bald microspheres. A first validation of the K-index as a morphology descriptor was based on compressing samples to different strains: it was observed that as the porosity decreases, the water-contact angle decreases proportionally, and thereby the K-index remains constant. The predictive power of the K-index was demonstrated with 20 polyurea aerogels prepared in 8 binary solvent systems. Subsequently, several material properties were correlated to nanomorphology through the K-index and that, in turn, provided insight about the root cause of the diversity of the nanostructure in polyurea aerogels. Finally, using response surface methodology, K-indexes and other material properties of practical interest were correlated to the monomer, water, and catalyst concentrations as well as the three Hansen solubility parameters of the sol. That enabled the synthesis of materials with up to six prescribed properties at a time, including nanomorphology, bulk density, BET surface area, elastic modulus, ultimate compressive strength, and thermal conductivity.