Analysis of Active and Passive Deformation of Expanded Polystyrene Foam under Short-Term Compression

In this paper, we undertake a detailed analysis of the active and passive deformation of expanded polystyrene (EPS), which is used as a thermal insulating layer in building partitions, under short-term compressive loading. The values of residual strain in 10-40 kg/m³ density EPS after monotonically increasing loading under active deformations of 20%, 30%, 40%, 50%, and 60% with the following complete removal are determined. These values are a physical sign of the elastic-plastic state of EPS. It has been shown that the final destruction of cells takes place in EPS when the active strain reaches 50%. Empirical equations are proposed to estimate the residual strain of EPS based on density with determination coefficients varying from 0.744 to 0.986 at a confidence level of 90%. Moreover, graphical interpretations with regression equations for residual strain dependence on density and compressive strength, as well as density and active strain, were proposed with determination coefficients equal to 0.779 and 0.717, respectively.

Microfluidics-Enabled Soft Manufacture of Materials with Tailorable Wettability

Microfluidics and wettability are interrelated and mutually reinforcing fields, experiencing synergistic growth. Surface wettability is paramount in regulating microfluidic flows for processing and manipulating fluids at the microscale. Microfluidics, in turn, has emerged as a versatile platform for tailoring the wettability of materials. We present a critical review on the microfluidics-enabled soft manufacture (MESM) of materials with well-controlled wettability and their multidisciplinary applications. Microfluidics provides a variety of liquid templates for engineering materials with exquisite composition and morphology, laying the foundation for precisely controlling the wettability. Depending on the degree of ordering, liquid templates are divided into individual droplets, one-dimensional (1D) arrays, and two-dimensional (2D) or three-dimensional (3D) assemblies for the modular fabrication of microparticles, microfibers, and monolithic porous materials, respectively. Future exploration of MESM will enrich the diversity of chemical composition and physical structure for wettability control and thus markedly broaden the application horizons across engineering, physics, chemistry, biology, and medicine. This review aims to systematize this emerging yet robust technology, with the hope of aiding the realization of its full potential.

Tailoring structure and properties of long-lived emulsion foams stabilized by a natural saponin glycyrrhizic acid: Role of oil phase

Novel supramolecular nanofibrils assembled from food-grade saponin glycyrrhizic acid (GA) are effective building blocks to make complex multiphase systems, e.g., emulsion foams. In this work, the effects of different oil phases (castor oil, sunflower oil, dodecane, and limonene) on the formation, stability and structural properties of long-lived emulsion foams prepared by GA nanofibrils (GNs) were investigated. The obtained results showed that soft-solid emulsion foams (4 wt% GNs) can be fabricated, independently of oil phase, and their structural properties, viscoelasticity, and tribological properties can be well tuned by oil phase polarity. Compared to the GNs aqueous foams, the presence of jammed emulsion droplets in the liquid channels and at the surfaces of bubbles can provide a higher bubble stability for emulsion foams. For more polar oil phase (castor oil), GNs showed a higher affinity to the oil-water interface with a lower interfacial tension, thus forming smaller oil droplets and bubbles, which leads to the higher mechanical strength, denser network microstructures, and lower friction coefficients of emulsion foams. However, the limonene foam exhibited weak storage stability and rheological properties, as well as the relatively low lubrication, which may be related to the formation of oil droplet aggregates and clusters induced by the volatility of limonene. GN-based emulsion foams are thermoresponsive, independently of oils, and the temperature-switchable process for the destabilization and regeneration of foams can be controlled and repeated. These emulsion foams based on natural saponin nanofibrils with tunable properties have potential sustainable applications in foods, pharmaceuticals, and personal care products.

Considerations Using Additive Manufacture of Emulsion Inks to Produce Respiratory Protective Filters Against Viral Respiratory Tract Infections Such as the COVID-19 Virus

This review paper explores the potential of combining emulsion-based inks with additive manufacturing (AM) to produce filters for respiratory protective equipment (RPE) in the fight against viral and bacterial infections of the respiratory tract. The value of these filters has been highlighted by the current severe acute respiratory syndrome coronavirus-2 crisis where the importance of protective equipment for health care workers cannot be overstated. Three-dimensional (3D) printing of emulsions is an emerging technology built on a well-established field of emulsion templating to produce porous materials such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPE-based porous polymers have tailorable porosity from the submicron to 100 s of µm. Advances in 3D printing technology enables the control of the bulk shape while a micron porosity is controlled independently by the emulsion-based ink. Herein, we present an overview of the current polyHIPE-based filter applications. Then, we discuss the current use of emulsion templating combined with stereolithography and extrusion-based AM technologies. The benefits and limitation of various AM techniques are discussed, as well as considerations for a scalable manufacture of a polyHIPE-based RPE.

Monodisperse liquid foams via membrane foaming

HYPOTHESIS

It is possible to generate fairly monodisperse liquid foams by a dispersion cell, which was originally designed for the generation of fairly monodisperse emulsions. If this is the case, scaling-up the production of monodisperse liquid and solid foams will be no longer a problem.

EXPERIMENTS

We used the dispersion cell - a batch process - and examined the influence of stirrer speed, membrane pore diameter and injection rate on the structure of the resulting liquid foams. We used an aqueous surfactant solution as scouting system. Once the experimental conditions were known we generated gelatin-based liquid foams and methacrylate-based foamed emulsions.

FINDINGS

We found that (a) the bubble size of the generated liquid foams can be adjusted by varying the membrane pore diameter, (b) no stirrer should be used to obtain monodisperse foams, and (c) the bubble size is not influenced by the air injection rate. Since (i) the output for all investigated systems is up to two orders of magnitude larger compared to microfluidics and (ii) the membrane technology can very easily be scaled-up if run in a continuous process, the use of membrane foaming is expected to be heavily used for the generation of monodisperse liquid and solid foams, respectively.

Formulation and polymerization of foamed 1,4-BDDMA-in-water emulsions

Emulsion and foam templating allow the synthesis of tailor-made polymer foams. A complementary templating route is foamed emulsion templating. The concept is based on the generation of a monomer-in-water emulsion which is subsequently foamed. After polymerization of the foamed emulsion, one obtains open-cell polymer foams with porous pore walls. In the paper at hand, we generated foamed emulsions and synthesized polymer foams which are based on the monomer 1,4-butanediol dimethacrylate (1,4-BDDMA). The main challenge was to find the optimal composition of the emulsion by varying the components systematically. We will discuss that the composition of the monomer-in-water emulsion is key for the stability of the foamed emulsion and thus for the structure of the resulting polymer foam. The final composition of the continuous phase was found to be 65 vol% 1,4-BDDMA, 30 vol% water and 5 vol% glycerol. We foamed and polymerized this emulsion to check the foamed emulsion's suitability as a template for solid polymer foams. We generated a foamed emulsion with a mean bubble diameter of 151 μm ± 90 μm and obtained a highly porous poly(1,4-BDDMA) foam with a pore mean diameter of 366 μm ± 91 μm. Furthermore, the polymer foam has a “sub-porosity” within the pore walls.

Emulsion and foam templating allow the synthesis of tailor-made polymer foams.

Methacrylate-based polymer foams with controllable connectivity, pore shape, pore size and polydispersity

Polymer foams are becoming increasingly important in industry, especially biodegradable polymer foams are in demand. Depending on the application, polymer foams need to have characteristic properties, which include connectivity and polydispersity. We show how polymer foams with tailor-made structures can be synthesized from water-in-monomer emulsions which were generated via microfluidics. As monomer we used 1,4-butanediol dimethacrylate (1,4-BDDMA). Firstly, we synthesised monodisperse open- and closed-cell poly(1,4-BDDMA) foams with either spherical or hexagonal pore shapes by varying the locus of initiation. Secondly, we were able to control the pore diameters and obtained polymer foams of both connectivities and pore shapes with pore sizes from ∼70 μm up to ∼120 μm by means of one microfluidic chip. Finally, we synthesized poly(1,4-BDDMA) foams with controllable polydispersity. Here, the mean droplet diameter was the same as that of the monodisperse counterparts in order to be able to compare the properties of the resulting polymer foams.

X-ray Computed Tomography for Characterization of Expanded Polystyrene (EPS) Foam

Expanded polystyrene (EPS) foam is widely used in building and construction applications for thermal and acoustic insulation. This material is nearly transparent for X-rays, making it difficult to characterize its pore structure in 3D with X-ray tomography. Because of this difficulty, the pore network is often not investigated and is, thus, poorly known. Since this network controls different physical properties, such as the sound absorption, it is crucial to understand its overall structure. In this manuscript, we show how to reveal the pore network of EPS foams through the combination of high resolution X-ray tomography (micro-CT) and saturation techniques. The foams were saturated with CsCl-brine, which acts as a contrasting agent in X-ray micro-CT imaging. This allowed us to separate the beads, making up the foam, from the pore network. Based on the 3D micro-CT results, we were able to assess a representative elementary volume for the polystyrene, which allows for calculating the acoustical parameters from the Johnson–Champoux–Allard (JCA) model, the pore and bead size distribution. The 3D data was also used as input to simulate sound absorption curves. The parametric study showed that an increase in the bead size influenced the sound absorption of the material. We showed that, by doubling the diameter of beads, the absorption coefficient was doubled in certain ranges of frequency.

Preparation of carbon-based hybrid particles and their application in microcellular foaming and flame-retardant materials

Polymeric microcellular foams with high strength and light weight are very important for industrial applications. However, regulating their cell structure and their weak flame retardancy are problematic. We designed single-arm POSS-based ionic liquids ([bel-POSS][PF₆]), and constructed hybrid composites based on physical interaction between ionic liquids and carbon-based materials in PS microcellular foaming. Ionization of bel-POSS could result in a quaternary ammonium reaction and ion-exchange reaction, and the carbon materials exhibit good dispersion through blending. The prepared hybrid composites showed high CO₂ adsorption. Conical calorimeter tests showed that PS composite materials could reduce the heat release rate, total heat release, toxic gases (CO₂ and CO) release, and amount of smoke generated. These carbon materials could affect PS micropore structure, including the cell diameter and density. Upon addition of 5 wt% of carbon materials, the hole diameter decreased by >50%, and the hole density increased nearly ten folds.

Liquid foam templating - A route to tailor-made polymer foams

Solid foams with pore sizes between a few micrometres and a few millimetres are heavily exploited in a wide range of established and emerging applications. While the optimisation of foam applications requires a fine control over their structural properties (pore size distribution, pore opening, foam density, …), the great complexity of most foaming processes still defies a sound scientific understanding and therefore explicit control and prediction of these parameters. We therefore need to improve our understanding of existing processes and also develop new fabrication routes which we understand and which we can exploit to tailor-make new porous materials. One of these new routes is liquid templating in general and liquid foam templating in particular, to which this review article is dedicated. While all solid foams are generated from an initially liquid(-like) state, the particular notion of liquid foam templating implies the specific condition that the liquid foam has time to find its "equilibrium structure" before it is solidified. In other words, the characteristic time scales of the liquid foam's stability and its solidification are well separated, allowing to build on the vast know-how on liquid foams established over the last 20 years. The dispersed phase of the liquid foam determines the final pore size and pore size distribution, while the continuous phase contains the precursors of the desired porous scaffold. We review here the three key challenges which need to be addressed by this approach: (1) the control of the structure of the liquid template, (2) the matching of the time scales between the stability of the liquid template and solidification, and (3) the preservation of the structure of the template throughout the process. Focusing on the field of polymer foams, this review gives an overview of recent research on the properties of liquid foam templates and summarises a key set of studies in the emerging field of liquid foam templating. It finishes with an outlook on future developments. Occasional references to non-polymeric foams are given if the analogy provides specific insight into a physical phenomenon.

Long-Lived and Thermoresponsive Emulsion Foams Stabilized by Self-Assembled Saponin Nanofibrils and Fibrillar Network

Nanofibrils from the self-assembly of the naturally occurring saponin glycyrrhizic acid (GA) can be used to produce an oil-in-water emulsion foam with a long-term stability. Through homogenization and aeration followed by rapid cooling, stable emulsion foams can be produced from the mixtures of sunflower oil and saponin nanofibrils. At high temperatures, the GA fibrils form a multilayer assembly at the interface, creating an interfacial fibrillar network to stabilize the oil droplets and air bubbles generated during homogenization. A subsequent rapid cooling can trigger the self-assembly of free GA fibrils in the continuous phase, forming a fibrillar hydrogel and thus trapping the oil droplets and air bubbles. The viscoelastic bulk hydrogel showed a high yield stress and storage modulus, which lead to a complete arrest of the liquid drainage and a strong slowdown of the bubble coarsening in emulsion foams. The jamming of the emulsion droplets in the liquid channels as well as around the bubbles was also found to be able to enhance the foam stability. We show that such stable foam systems can be destroyed rapidly and on demand by heating because of the melting of the bulk hydrogel. The reversible gel-sol phase transition of the GA hydrogel leads to thermoresponsive emulsion foams, for which the foam stability can be switched from stable to unstable states by simply raising the temperature. The emulsion foams can be further developed to be photoresponsive by incorporating internal heat sources such as carbon black particles, which can absorb UV irradiation and convert the absorbed light energy into heat. This new class of smart responsive emulsion foams stabilized by the natural, sustainable saponin nanofibrils has potential applications in the food, pharmaceutical, and personal care industries.

Effect of Reinforcement at Length Scale for Polyurethane Cellular Scaffolds by Supramolecular Assemblies

This study is aimed to represent the role of carbonaceous nanofillers to reinforce the commercially available polyurethane porous structure. The effect of dimensionality of fillers to anchor the construction of stable three-dimensional (3D) cellular architectures has been highlighted. The cellular frameworks of commercially available thermoplastic polyurethane (TPU) have been fabricated through the thermoreversible supramolecular self-assembly route. It was established that the minimum shrinkage of TPU lattice structures occurred when the solid-state network is strengthened by the topologically engineered 3D hierarchical nanofillers, where the amount of reinforcement was found to play a critical role. It has been established by series of structure-property correlations that reinforcing the cellular structure to endure the capillary stress is equally effective as supercritical drying for producing low-density porous morphologies. The removal of liquid phase from gel is as important as the presence of 3D fillers in the matrix for reinforcing the cellular structures when replacing the solvent phase with air to generate a two-phase solid-gas engineered morphology. The insight into the polyurethane network structure revealed that the dimensionality, amount, and distribution of fillers in the matrix are critical for reinforcing the cellular scaffolds in solid gel without any cross-linking.

Preparation of macroporous scaffolds with holes in pore walls and pressure driven flows through them

Controlling the pore architecture in macroporous scaffolds has important implications for their use as reactor packings and as catalyst supports.

Open Cell Aerogel Foams via Emulsion Templating

The water-in-oil emulsion-templating method is used in this work for fabrication of open cell aerogel foams from syndiotactic polystyrene (sPS). A surfactant-stabilized emulsion is prepared at 60-100 °C by dispersing water in a solution of sPS in toluene. sPS gel, formed upon cooling of the emulsion to room temperature, locks the water droplets inside the gel. The gel is solvent exchanged in ethanol and then dried under supercritical condition of carbon dioxide to yield the aerogel foams. The aerogel foams show a significant fraction of macropores with a diameter of a few tens of micrometers, defined as macrovoids that originated from the emulsified water droplets. In conjunction, customary macropores of diameter 50-200 nm are derived from sPS gels. The macrovoids add additional openness to the aerogel structures. This paper evaluates the structural characteristics of the macrovoids, such as diameter distribution, macrovoid interconnect density, and skin layer density, in conjunction with the final aerogel foam properties.

Stable oil-laden foams: Formation and evolution

The interaction between oil and foam has been the subject of various studies. Indeed, oil can be an efficient defoaming agent, which can be highly valuable in various industrial applications where undesired foaming may occur, as seen in jet-dyeing processes or waste water treatment plant. However, oil and foam can also constructively interact as observed in detergency, fire-fighting, food and petroleum industries, where oil can be in the foam structure or put into contact with the foam without observing a catastrophic break-up of the foam. Under specific physico-chemistry conditions, the oil phase can even be trapped inside the aqueous network of the foam, thus providing interesting complex materials made of three different fluid phases that we name oil-laden foam (OLF). In this review, we focus on such systems, with a special emphasis on dry OLF, i.e. with a total liquid volume fraction, ε smaller than 5%. We first try to clarify the physical and chemical conditions for these systems to appear, we review the different techniques of the literature to obtain them. Then we discuss their structure and identify two different OLF morphologies, named foamed emulsion, in which small oil globules are comprised within the network of the aqueous foam and biliquid foams, where the oil also comprised in the aqueous foam network is continuous at the scale of several bubbles. Last, we review the state of the art of their evolution in particular concerning topological changes, coalescence, coarsening and drainage.