Recent Progress in Processing Functionally Graded Polymer Foams

Dual-functional natural rubber latex foam composites for solar-driven clean water production and heavy metal decontamination

Solar steam generation (SSG) offers a sustainable approach to fresh water production. Herein, a novel dual-functional natural rubber/carbon black composite foam evaporator is presented for a cost-efficient SSG system that both produces fresh water and eliminates heavy metals present in the water. The composite foam is produced using the Dunlop process, and in its optimized form, it absorbed >96 % of sunlight. The foam evaporator exhibited a thermal conductivity of 0.052 W/m⋅K, a water evaporation rate of 1.40 kg/m2/h, converted 83.38 % of light to heat under 1 sun irradiation, and showed outstanding stability. The technology required to produce this composite foam is already available to make large-scale production feasible, while the natural raw materials are abundant. On the basis of its performance qualities, the rubber foam composite appears to be an excellent candidate for application as a viable solar absorber for SSG to produce fresh, clean water for commercial purposes.

Machine Learning Algorithms for Predicting Mechanical Stiffness of Lattice Structure-Based Polymer Foam

Polymer foams are extensively utilized because of their superior mechanical and energy-absorbing capabilities; however, foam materials of consistent geometry are difficult to produce because of their random microstructure and stochastic nature. Alternatively, lattice structures provide greater design freedom to achieve desired material properties by replicating mesoscale unit cells. Such complex lattice structures can only be manufactured effectively by additive manufacturing or 3D printing. The mechanical properties of lattice parts are greatly influenced by the lattice parameters that define the lattice geometries. To study the effect of lattice parameters on the mechanical stiffness of lattice parts, 360 lattice parts were designed by varying five lattice parameters, namely, lattice type, cell length along the X, Y, and Z axes, and cell wall thickness. Computational analyses were performed by applying the same loading condition on these lattice parts and recording corresponding strain deformations. To effectively capture the correlation between these lattice parameters and parts' stiffness, five machine learning (ML) algorithms were compared. These are Linear Regression (LR), Polynomial Regression (PR), Decision Tree (DT), Random Forest (RF), and Artificial Neural Network (ANN). Using evaluation metrics such as mean squared error (MSE), root mean squared error (RMSE), and mean absolute error (MAE), all ML algorithms exhibited significantly low prediction errors during the training and testing phases; however, the Taylor diagram demonstrated that ANN surpassed other algorithms, with a correlation coefficient of 0.93. That finding was further supported by the relative error box plot and by comparing actual vs. predicted values plots. This study revealed the accurate prediction of the mechanical stiffness of lattice parts for the desired set of lattice parameters.

Crashworthiness of Foam-Filled Cylindrical Sandwich Shells with Corrugated Cores

Inspired by material hybrid design, novel hybrid sandwich shells were developed by filling a corrugated cylindrical structure with aluminum foam to achieve higher energy absorption performance. The crushing behavior of the foam-filled corrugated sandwich cylindrical shells (FFCSCSs) was investigated using theoretical and numerical methods. Numerical results revealed a significant enhancement in the energy absorption of FFCSCSs under axial compression, showcasing a maximum specific energy absorption of 60 kJ/kg. The coupling strengthening effect is highly pronounced, with a maximum value of F¯c/F¯ reaching up to 40%. The mechanism underlying this phenomenon can be approached from two perspectives. Firstly, the intrusion of folds into the foam insertions allows for more effective foam compression, maximizing its energy absorption capacity. Secondly, foam causes the folds to bend upwards, intensifying the mutual compression between the folds. This coupling mechanism was further investigated with a focus on analyzing the influence of parameters such as the relative density of the foam, the wall thickness of the sandwich shell, and the material properties. Moreover, a theoretical model was developed to accurately predict the mean crushing force of the FFCSCSs. Based on this model, the influence of various variables on the crushing behavior of the structure was thoroughly investigated through parametric studies.

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.

Quasi-Static Mechanical Response of Density-Graded Polyurea Elastomeric Foams

Density gradation of foam structures has been investigated and found to be a practical approach to improve the mechanical efficacy of protective padding in several applications based on nature-based evidence of effectiveness. This research aims to disclose a discrete gradation approach without adhesives by relying on the properties of the frothed foam slurry to bond and penetrate through previously cured foam sheets naturally. As confirmed by electron microscopy observations, bilayer- and trilayer-graded elastomeric polyurea foam sheets were fabricated, resulting in seamless interfaces. The mechanical performance of seamless, graded foam samples was compared with monolayer, mono-density benchmark foam, considered the industry standard for impact mitigation. All foam samples were submitted to compressive loading at a quasi-static rate, reporting key performance indicators (KPIs) such as specific energy absorption, efficiency, and ideality. Polyurea foams, irrespective of gradation and interface type, outperformed benchmark foam in several KPIs despite the drastic difference in the effective or average density. The average compressive stress-strain curves were fitted into empirical constitutive models to reveal critical insights into the elastic, plateau, and densification behaviors of the tested foam configuration. The novelty of these outcomes includes (1) a fabrication approach to adhesive-free density-graded foam structures, (2) implementation of a diverse set of KPIs to assess the mechanical efficacy of foams, and (3) elucidation of the superiority of polyurea foam-based lightweight protective paddings. Future research will focus on assessing the dynamic performance of these graded foam structures under impact loading conditions at a wide range of velocities.

Density graded polymer composite foams

This article reviews the main developments associated with density graded polymer composite foams. After a short introduction, a discussion is made on both density graded polymer-based composites and foams separately to better understand the challenges when both structures are combined together to produce composite foams. In all cases, the basic concepts, fabrication methods, main properties and general applications are presented. Opening for future works are also presented to conclude.

Progress in the Preparation, Properties, and Applications of PLA and Its Composite Microporous Materials by Supercritical CO2: A Review from 2020 to 2022

The development of degradable plastic foams is in line with the current development concept of being pollution free and sustainable. Poly(lactic acid) (PLA) microporous foam with biodegradability, good heat resistance, biocompatibility, and mechanical properties can be successfully applied in cushioning packaging, heat insulation, noise reduction, filtration and adsorption, tissue engineering, and other fields. This paper summarizes and critically evaluates the latest research on preparing PLA microporous materials by supercritical carbon dioxide (scCO₂) physical foaming since 2020. This paper first introduces the scCO₂ foaming technologies for PLA and its composite foams, discusses the CO₂-assisted foaming processes, and analyzes the effects of process parameters on PLA foaming. After that, the paper reviews the effects of modification methods such as chemical modification, filler filling, and mixing on the rheological and crystallization behaviors of PLA and provides an in-depth analysis of the mechanism of PLA foaming behavior to provide theoretical guidance for future research on PLA foaming. Lastly, the development and applications of PLA microporous materials based on scCO₂ foaming technologies are prospected.

Mechanical and Thermal Properties of Functionally Graded Polyolefin Elastomer Foams

In this work, uniform and graded polyolefin elastomer (POE) foams were prepared using a single-step technology based on a fixed chemical blowing agent (azodicarbonamide) concentration of 4 phr (parts per hundred rubber). The effect of molding temperature, including the average temperature (T_avg) and temperature difference (ΔT), on the foams’ morphology, mechanical properties (tension, compression and hardness) and thermal conductivity was investigated. Two series of samples were produced by fixing T_avg with different ΔT or setting different ΔT, leading to different T_avg. The morphological analyses showed that two or three regions inside the foams were produced depending on the molding conditions, each region having different cellular structure in terms of cell size, cell density and cell geometry. The results obtained for the conditions tested showed a range of density (0.55–0.72 g/cm³), tensile modulus (0.44–0.70 MPa) and compression elastic modulus (0.35–0.71 MPa), with a thermal conductivity between 0.125 and 0.180 W/m.K. Based on the information provided, it can be concluded that the foam’s properties can be easily controlled by the cellular structure and that graded samples are more interesting than uniform ones, especially for thermal insulation applications, such as packaging, construction, transportation, automotive and aerospace industries.

Design Strategy for Vulcanization Accelerator of Diphenylguanidine/Cyclodextrin Inclusion Complex for Natural Rubber Latex Foam with Enhancing Performance

Vulcanization is an essential process to obtain high-performance rubber products. Diphenylguanidine (DPG) is often used as the secondary accelerator in the vulcanization process of natural rubber (NR) latex. However, DPG would make NR latex emulsion exhibit gelation, resulting in the negative vulcanization efficiency. In addition, exposure to DPG might lead to some physiological diseases during the production process of DPG doped NR latex. Hydroxypropyl-β-cyclodextrin (HP-β-CD) with the hydrophobic interior and hydrophilic exterior has the advantages of good water solubility, high bioavailability, reliable stability, and low toxicity. In this study, the inclusion complex of diphenylguanidine-hydroxypropyl-β-cyclodextrin (DPG-HP-β-CD) is prepared by ball milling with a host-guest molar ratio of 1 : 1, which has also been applied to the foaming process of NR latex. The mechanical properties of DPG-HP-β-CD inclusion complex/natural rubber latex foam (DPG-HP-β-CD/NRLF) have been significantly improved, including the tensile strength, elongation at break, hardness, compression set, resilience, and antiaging performance. Further, the usage of DPG has been reduced, leading to the reduction of toxicity and environmental hazards.

Recent Developments in Shape Memory Elastomers for Biotechnology Applications

Shape memory elastomers have revolutionised the world since their introduction in the 20th century. The ability to tailor chemical structures to produce a family of materials in wide-ranging forms with versatile properties has propelled them to be ubiquitous. Recent challenges in the end-of-life management of polymeric materials should prompt us to ask, ‘what innovations in polymeric materials can make a strong case for their use as efficient materials?’ The development of smart elastomers that can acquire, convey, or process a stimulus (such as temperature, pressure, electromagnetic field, moisture, and chemical signals) and reply by creating a useful effect, specifically a reversible change in shape, is one such innovation. Here, we present a brief overview of shape memory elastomers (SMEs) and thereafter a review of recent advances in their development. We discuss the complex processing of structure-property relations and how they differ for a range of stimuli-responsive SMEs, self-healing SMEs, thermoplastic SMEs, and antibacterial and antifouling SMEs. Following innovations in SEMs, the SMEs are forecast to have significant potential in biotechnology based on their tailorable physical properties that are suited to a range of different external stimuli.

Investigating the Emission of Hazardous Chemical Substances from Mashrabiya Used for Indoor Air Quality in Hot Desert Climate

Dubai has the reputation of a continuously growing city, with skyscrapers and mega residential projects. Many new residential projects with poor choices of material and ventilation have led to a faster rise in sick building syndrome (SBS) in Dubai than in any other country, and the IAQ (indoor air quality) has become more critical. Volatile organic compounds (VOCs) and formaldehyde (HCHO) affect the health of residents, producing the phenomenon known as SBS (sick building syndrome). It has been reported that wood materials used for furniture and wooden windows and doors are a significant source of indoor air pollution in new houses. This paper aims to identify the factor elements emitting harmful chemical substances, such as VOCs and HCHO, from wooden mashrabiya (traditional Arabic window) by examining the characteristics of the raw and surface materials through test pieces. As a methodology, a small chamber system was used to test the amount of hazardous chemicals generated for each test piece. For Total volatile organic compounds (TVOC) and HCHO, the blank concentration before the injection and the generation after seven days were measured. The results showed that to reduce TVOC, it is necessary to secure six months or more as a retention period for raw materials and surface materials. The longer the retention period, the smaller the TVOC emission amount. In the case of mashrabiya, an HCHO low-emitting adhesive and maintenance for one month or more are essential influencing factors. It was proven that using raw materials with a three-month or more retention period and surface materials with a one-month or more retention period is safe for indoor mashrabiya. This study is the first study in the Middle East to identify factors and characteristics that affect the emission of hazardous chemicals from wood composite materials, such as wood mashrabiya, that affect indoor air quality in residential projects in Dubai. It analyzes the correlation between emission levels and the retention period of raw and surface materials, in order to provide a new standard for indoor air pollutants.

Ultrasonic-assisted Dunlop method for natural rubber latex foam production: Effects of irradiation time on morphology and physico-mechanical properties of the foam

An ultrasonic-assisted technique was first introduced for the production of natural rubber latex foam (NRLF). The flexible elastomeric foam was formed by a liquid-solid state transformation in an aqueous media. The aim of the current research was to provide a novel strategy for fabricating NRLF using ultrasonication and the Dunlop method, as well as to simultaneously utilize irradiation events to achieve the desired foam properties. NRLFs were exposed to ultrasonication at 25 kHz at the beginning of the gelling process. The effects of irradiation times of 0, 1, 3, 5 and 7 min on the morphology, foaming behaviors, physical properties and mechanical performance of NRLFs were investigated. The results revealed that using ultrasonic irradiation, unfoamed regions and a bimodal structure, which seem to be microstructural defects in conventional NRLF, could be completely eliminated. However, excessive irradiation times of 5 min and longer appeared to affect the physico-mechanical properties of the foams in terms of transient cavitation and the unfavorable physicochemical effects of ultrasonic vibrations. As a result, the optimal ultrasonic irradiation time was found to be 3 min. Using this irradiation duration, a foam with the suitable microcellular structure achieved the most desirable properties, such as its expansion ratio (7-fold increase), foam porosity (85.7%), compression recoverability (98.7%), and tensile strength (307.3 kPa). Moreover, the foam still maintained its characteristic soft nature (hardness less than 100 N) with an indentation hardness of 71.9 N. Therefore, ultrasonic treatment introduced to the conventional Dunlop method is a potentially feasible technique since it improves the morphology and the physico-mechanical properties of NRLFs.

Fire Behavior of Wood-Based Composite Materials

Wood-based composites such as wood plastic composites (WPC) are emerging as a sustainable and excellent performance materials consisting of wood reinforced with polymer matrix with a variety of applications in construction industries. In this context, wood-based composite materials used in construction industries have witnessed a vigorous growth, leading to a great production activity. However, the main setbacks are their high flammability during fires. To address this issue, flame retardants are utilized to improve the performance of fire properties as well as the flame retardancy of WPC material. In this review, flame retardants employed during manufacturing process with their mechanical properties designed to achieve an enhanced flame retardancy were examined. The addition of flame retardants and manufacturing techniques applied were found to be an optimum condition to improve fire resistance and mechanical properties. The review focuses on the manufacturing techniques, applications, mechanical properties and flammability studies of wood fiber/flour polymer/plastics composites materials. Various flame retardant of WPCs and summary of future prospects were also highlighted.

Advanced super-hydrophobic polymer-based porous absorbents for the treatment of oil-polluted water

The threat of environmental pollution caused by spilled oil is rapidly increasing along with the expansion of oil exploration, the development of maritime activities and industrial growth. Oil spill incidents usually affect seriously the ecosystem and human life. Therefore, the treatment and recovery of the oil spill have been considered as an ultra-important issue to protect the environment and to minimize its negative impacts on socio-economic activities. Among methods of oil spill recovery, porous materials have emerged as potential absorbents possessing the capacity of absorbing spilled oil at a fast rate, high adsorption capacity, good selectivity, and high reusability. In this review paper, two types of polymer-based porous absorbents modified surface and structure were introduced for the treatment strategy of the oil-polluted water. In addition, the absorption mechanism and factors affecting the adsorption capacity for oils and organic solvents were thoroughly analyzed. More importantly, characteristics of polymer-based porous materials were discussed in detail based on microstructure analysis, absorption efficiency, and reusability. In general, this paper has provided an overview and a comprehensive assessment of the use of advanced polymer-based porous materials for the treatment of oil-polluted water, although the impacts of environmental factors such as wind, wave, and temperature should be further investigated in the future.

Solid-state foaming of acrylonitrile butadiene styrene through microcellular 3D printing process

The lightweight products with superior specific strength are in great demand in numerous applications such as automotive, aerospace, biomedical, sports, etc. This work focussed on the manufacturing of lightweight products using the cellular three dimensional (3D) printing process. In this work, the continuous microcellular morphology has been developed in a single foamed filament using 3 D printing of carbon-di-oxide (CO2) saturated acrylonitrile butadiene styrene (ABS) filaments. The microcellular structures with average cell size in the range of 6–1040 µm were developed. The influence of printing parameters; nozzle temperature, feed rate, and flow rate on the foam characteristics and cell morphology at different levels were investigated. The different kinds of observed foamed extrudate irregularities were discussed.

Current challenges in thermodynamic aspects of rubber foam

Natural rubber (NR) foam can be prepared by the Dunlop method using concentrated natural latex with chemical agents. Most previous studies have focused on the thermodynamic parameters of solid rubber in extension. The main objective of this study is to investigate the effect of the NR matrix concentration on the static and dynamic properties of NR foams, especially the new approach of considering the thermodynamic aspects of NR foam in compression. We found that the density and compression strength of NR foams increased with increasing NR matrix concentration. The mechanical properties of NR foam were in agreement with computational modelling. Moreover, thermodynamic aspects showed that the ratio of internal energy force to the compression force, Fu/F, and the entropy, S, increased with increasing matrix concentration. The activation enthalpy, ∆Ha, also increased with increasing matrix concentration in the NR foam, indicating the greater relaxation time of the backbone of the rubber molecules. New scientific concepts of thermodynamic parameters of the crosslinked NR foam in compression mode are proposed and discussed. Our results will improve both the knowledge and the development of rubber foams based on the structure-properties relationship, especially the new scientific concept of the thermodynamical parameters under compression.

Blast Alleviation of Sacrificial Cladding with Graded and Uniform Cellular Materials

Graded cellular material is a superb sandwich candidate for blast alleviation, but it has a disadvantage for the anti-blast design of sacrificial cladding, i.e., the supporting stress for the graded cellular material cannot maintain a constant level. Thus, a density graded-uniform cellular sacrificial cladding was developed, and its anti-blast response was investigated theoretically and numerically. One-dimensional nonlinear plastic shock models were proposed to analyze wave propagation in density graded-uniform cellular claddings under blast loading. There are two shock fronts in a positively graded-uniform cladding; while there are three shock fronts in a negatively graded-uniform cladding. Response features of density graded-uniform claddings were analyzed, and then a comparison with the cladding based on the uniform cellular material was carried out. Results showed that the cladding with uniform cellular materials is a good choice for the optimal mass design, while the density graded-uniform cladding is more advantageous from the perspective of the critical length design indicator. A partition diagram for the optimal length of sacrificial claddings under a defined blast loading was proposed for engineering design. Finally, cell-based finite element models were applied to verify the anti-blast response results of density graded-uniform claddings.

Effect of Fillers on the Recovery of Rubber Foam: From Theory to Applications

Natural rubber foam (NRF) can be prepared from concentrated natural latex, providing specific characteristics such as density, compression strength, compression set, and so on, suitable for making shape-memory products. However, many customers require NRF products with a low compression set. This study aims to develop and prepare NRF to investigate its recoverability and other related characteristics by the addition of charcoal and silica fillers. The results showed that increasing filler loading increases physical and mechanical properties. The recoverability of NRF improves as silica increases, contrary to charcoal loading, due to the higher specific surface area of silica. Thermodynamic aspects showed that increasing filler loading increases the compression force (F) as well as the proportion of internal energy to the compression force (F_u/F). The entropy (S) also increases with increasing filler loading, which is favorable for thermodynamic systems. The activation enthalpy (∆H_a) of the NRF with silica is higher than the control NRF, which is due to rubber–filler interactions created within the NRF. A thermodynamic concept of crosslinked rubber foam with filler is proposed. From theory to application, in this study, the NRF has better recoverability with silica loading.