Rapeseed Oil as Feedstock for Bio-Based Thermoset Foams Obtained via Michael Addition Reaction

Rapeseed oil was used to develop thermoset foams via Michael addition reaction by mixing two liquid components, Michael donor and Michael acceptor. The foaming of the curing thermoset was achieved by the physical blowing agent which expanded from the reacting foam mass due to an exothermic curing reaction. The influence of the rapeseed oil-based Michael donor functionality on the foaming process and the characteristics of the obtained thermoset foams was studied. The 1,1,3,3-tetramethylguanidine catalyst's influence on the foaming process kinetics was studied using FOAMAT equipment. The curing of the bio-based thermoset was analysed using a dielectric polarisation sensor. The morphology of the developed thermoset foam was analysed using a scanning electron microscope and the obtained foams were characterized using TGA, DSC, DMA and mechanical analysis tests. A direct correlation between the thermoset foam polymer crosslinking density and foaming reactivity, mechanical properties and glass transition temperature were determined. Obtained rapeseed oil based thermoset foams had a relatively low thermal conductivity of 33.9-35.4 mW/(m·K) which allows their use as thermal insulation material in civil engineering applications.

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.

Hygroscopic and Photothermal All-Polymer Foams for Efficient Atmospheric Water Harvesting, Passive Humidity Management, and Protective Packaging

Environmental humidity and thermal control are of primary importance for fighting global warming, growing energy consumption, and greenhouse gas emissions. Sorption-based atmospheric water harvesting is an emerging technology with great potential in clean water production and passive cooling applications. However, sorption-based humidity management and their hybrid applications are limited due to the lack of energywise designs of hygroscopic materials and devices. Herein, all polymeric 3D foams are developed and evaluated as hygroscopic and photothermal materials. The gas-foaming method generates closed-cell structures with interconnected hydrophilic networks and wrinkled surfaces, expanding hygroscopic, photothermal, and evaporating areas of the 3D foams. These unique advantages lead to efficient water vapor sorption in a wide broad relative humidity (RH) range of 50-90% and efficient water release in a wide solar intensity (0.4-1 sun) and temperature range (27-80 °C). The reversible moisture sorption/release in 50 adsorption/desorption cycles highlights the excellent durability of the 3D foams compared to conventional inorganic desiccants. The 3D foams disclose passive and efficient apparent temperature regulation in warm and humid environments. Moreover, the use of the 3D foams as loose fill for fruit preservation and packaging is demonstrated for the first time by taking the merit of the 3D foams' moisture-absorbing, quick-drying, cushioning, and thermal-insulating properties. This work presents an integrated design of polymeric desiccants and scaffolds, not merely delivering stable water adsorption/desorption but also discovering innovative hybrid applications in humidity management and protective packaging.

Nanostructure of PMMA/MAM Blends Prepared by Out-of-Equilibrium (Extrusion) and Near-Equilibrium (Casting) Self-Assembly and Their Nanocellular or Microcellular Structure Obtained from CO2 Foaming

Blends of poly(methyl methacrylate) (PMMA) and a triblock copolymer poly(methyl methacrylate)-b-poly(butyl acrylate)-b-poly(methyl methacrylate) (MAM) have been obtained following both out-of-equilibrium (extrusion) and near-equilibrium (solvent casting) production routes. The self-assembly capability and the achievable nanostructures of these blends are analyzed by transmission electron microscopy (TEM) regarding their production route and potential for the achievement of nanocellular foams by CO₂ gas dissolution foaming. The influence of the initial nanostructure of the solids on the obtained cellular structure of bulk and film samples is determined by high-resolution scanning electron microscopy (HRSEM) for diverse foaming conditions (saturation pressure, saturation temperature, and post-foaming stage), taking into account the required use of a foaming mold to achieve foams from films. Moreover, the influence of the nanostructuration on the presence of solid outer layers, typical of the selected foaming process, is addressed. Finally, consideration of a qualitative model and the obtained results in terms of nanostructuration, cellular structure, and foaming behavior, allow proposing a detailed cell nucleation, growth, and stabilization scheme for these materials, providing the first direct evidence of the cell nucleation happening inside the poly(butyl acrylate) phase in the PMMA/MAM blends.

Charging of Piezoelectric Cellular Polypropylene Film by Means of a Series Dielectric Layer

Piezoelectric polymer cellular films have been developed and improved in the past decades. These piezoelectric materials are based on the polarization of the internal cells by means of induced discharges in the gas inside the cells. Internal discharges are driven by an external applied electric field. With this polarization method, cellular polypropylene (PP) polymers exhibit a high piezoelectric coefficient d₃₃ and have been investigated because of their low dielectric polarization, high resistivity, and flexibility. Charging polymers foams is normally obtained by applying a corona discharge to the surface with a single tip electrode-plane arrangement or a triode electrode, which consists of a tip electrode-plane structure with a controlled potential intermediate mesh. Corona charging allows the surface potential of the sample to rise without breakdown or surface flashover. A charging method has been developed without corona discharge, and this has provided good results. In our work, a method has been developed to polarize polypropylene foams by applying an insulated high-voltage electrode on the surface of the sample. The dielectric layer in series with the sample allows for a high internal electric field to be reached in the sample but avoids dielectric breakdown of the sample. The distribution of the electric field between the sample and the dielectric barrier has been calculated. Experimental results with three different electrodes present good outcome in agreement with the calculations. High d₃₃ constants of about 880 pC/N have been obtained. Mapping of the d₃₃ constant on the surface has also been carried out showing good homogeneity on the area under the electrode.

Novel Method for Preparing a High-Performance Auxetic Foam Directly from Polymer Resin by a One-Pot CO2 Foaming Process

So far, negative Poisson's ratio foam (auxetic foam) is usually prepared by the transformation of conventional polymer foam, and it is a challenge to prepare auxetic foam directly from polymer resin. In this work, a novel method based on the synergism between the phase transition of water and the permeability rate difference of the CO₂ blowing agent from air in the foaming process is put forward to prepare auxetic foam directly from the polymer resin. Using this method, herein, nylon elastomer (NE) foam with auxetic behavior is successfully prepared from NE resin by a one-pot CO₂ foaming method inside an autoclave aided by water; the obtained auxetic foam has a Poisson's ratio value of -1.29 and has excellent tensile cycle stability and energy absorption performance. This method breaks through the bottleneck for preparing auxetic foams from the polymer resin directly, which is also green and environment-friendly. It is believed that the abovementioned method also applies to other thermoplastic polymers, which paves a way for designing and preparing multifunctional auxetic foam materials in the future via a one-pot CO₂ foaming process. Furthermore, this work first demonstrates that the transformation between auxetic foam and positive Poisson's ratio foam is reversible due to the closed cell structure, which provides an opportunity to reversibly adjust the performance and the shape of polymer foam materials.

Programmable Porous Polymers via Direct Bubble Writing with Surfactant-Free Inks

Fabrication of macroporous polymers with functionally graded architecture or chemistry bears transformative potential in acoustic damping, energy storage materials, flexible electronics, and filtration but is hardly reachable with current processes. Here, we introduce thiol-ene chemistries in direct bubble writing, a recent technique for additive manufacturing of foams with locally controlled cell size, density, and macroscopic shape. Surfactant-free and solvent-free graded three-dimensional (3D) foams without drying-induced shrinkage were fabricated by direct bubble writing at an unparalleled ink viscosity of 410 cP (40 times higher than previous formulations). Functionalities including shape memory, high glass transition temperatures (>25 °C), and chemical gradients were demonstrated. These results extend direct bubble writing from aqueous inks to nonaqueous formulations at high liquid flow rates (3 mL min-1). Altogether, direct bubble writing with thiol-ene inks promises rapid one-step fabrication of functional materials with locally controlled gradients in the chemical, mechanical, and architectural domains.

High-Performance Polymer Foams by Thermally Induced Phase Separation

Macroporous, low-density polyetheretherketone, polyetherketoneketone, and polyetherimide foams are produced using a high-temperature, thermally induced phase separation method. A high-boiling-point solvent, which is suitable to dissolve at least 20 wt% of these high-performance polymers at temperatures above 250 °C, is identified. The foam morphology is controlled by the cooling procedure. The resulting polymer foams have porosities close to 80% with surface areas up to 140 m² g^-1 and elastic moduli up to 97 MPa.

Architected Polymer Foams via Direct Bubble Writing

Polymer foams are cellular solids composed of solid and gas phases, whose mechanical, thermal, and acoustic properties are determined by the composition, volume fraction, and connectivity of both phases. A new high-throughput additive manufacturing method, referred to as direct bubble writing, for creating polymer foams with locally programmed bubble size, volume fraction, and connectivity is reported. Direct bubble writing relies on rapid generation and patterning of liquid shell-gas core droplets produced using a core-shell nozzle. The printed polymer foams are able to retain their overall shape, since the outer shell of these bubble droplets consist of a low-viscosity monomer that is rapidly polymerized during the printing process. The transition between open- and closed-cell foams is independently controlled by the gas used, while the foam can be tailored on-the-fly by adjusting the gas pressure used to produce the bubble droplets. As exemplars, homogeneous and graded polymer foams in several motifs, including 3D lattices, shells, and out-of-plane pillars are fabricated. Conductive composite foams with controlled stiffness for use as soft pressure sensors are also produced.

Hollow-Structured Materials for Thermal Insulation

Heating and cooling represent a significant portion of overall energy consumption of our society. Due to the diffusive nature of thermal energy, thermal insulation is critical for energy management to reduce energy waste and improve energy efficiency. Thermal insulation relies on the reduction of thermal conductivity of appropriate materials that are engineerable in compositions and structures. Hollow-structured materials (HSMs) show a great promise in thermal insulation since the existence of high-density gaseous voids breaks the continuity of heat-transport pathways in the HSMs to lower their thermal conductivities efficiently. Herein, a timely overview of the recent progress in developing HSMs for thermal insulation is presented, with the focus on summarizing the strategies for creating gaseous voids in solid materials and thus synthesizing various HSMs. Systematic analysis of the documented results reveals the relationship of thermal conductivities of the HSMs and the size and density of voids, i.e., reducing the void size below ≈350 nm is more favorable to decrease the thermal conductivity of the HSMs because of the possible confinement effect originated from the nanometer-sized voids. The challenges and promises of the HSMs faced in future research are also discussed.

Facile Oil Removal from Water-in-Oil Stable Emulsions Using PU Foams

Superhydrophobic and oleophilic polyurethane foams were obtained by spray-coating their surfaces with solutions of thermoplastic polyurethane and hydrophobic silicon oxide nanoparticles. The developed functionalized foams were exploited as reusable oil absorbents from stable water-in-oil emulsions. These foams were able to remove oil efficiently from a wide range of emulsions with oil contents from 10 to 80 v.%, stabilized using Span80. The modified foams could reach oil absorption capacities up to 29 g/g, becoming a suitable candidate for water-in-oil stable emulsions separation.

Thermoelectric Nanocomposite Foams Using Non-Conducting Polymers with Hybrid 1D and 2D Nanofillers

A facile processing strategy to fabricate thermoelectric (TE) polymer nanocomposite foams with non-conducting polymers is reported in this study. Multilayered networks of graphene nanoplatelets (GnPs) and multi-walled carbon nanotubes (MWCNTs) are deposited on macroporous polyvinylidene fluoride (PVDF) foam templates using a layer-by-layer (LBL) assembly technique. The open cellular structures of foam templates provide a platform to form segregated 3D networks consisting of one-dimensional (1D) and/or two-dimensional (2D) carbon nanoparticles. Hybrid nanostructures of GnP and MWCNT networks synergistically enhance the material system’s electrical conductivity. Furthermore, the polymer foam substrates possess high porosity to provide ultra-low thermal conductivity without compromising the electrical conductivity of the TE nanocomposites. With an extremely low GnP loading (i.e., ~1.5 vol.%), the macroporous PVDF nanocomposites exhibit a thermoelectric figure-of-merit of ~10⁻³. To the best of our knowledge, this ZT value is the highest value reported for organic TE materials using non-conducting polymers and MWCNT/GnP nanofillers. The proposed technique represents an industrially viable approach to fabricate organic TE materials with enhanced energy conversion efficiencies. The current study demonstrates the potential to develop light-weight, low-cost, and flexible TE materials for green energy generation.

Antibacterial Melamine Foams Decorated with in Situ Synthesized Silver Nanoparticles

A new and straightforward single-step route to decorate melamine foams with silver nanoparticles (ME/Ag) is proposed. Uniform coatings of silver nanoparticles with diameters less than 10 nm are formed in situ directly on the struts surface of the foams, after their dipping in an AgNO₃ solution. We prove that the nanoparticles are stably adhered on the foams, and that their amount can be directly controlled by the concentration of the AgNO₃ solution and the dipping time. Following this production route, ME/Ag foams can be obtained with silver content ranging between 0.2 and 18.6 wt % and excellent antibacterial performance, making them appropriate for various applications. Herein we explore the possibility to use them as antibacterial filters for water treatment, proving that they are able to remove completely Escherichia coli bacteria from water when filtered at flow rates up to 100 mL/h·cm² due to the release of less than 1 ppm of Ag⁺ ions by the foams. No bacterial regrowth was observed after further dilution of the treated water, to arrive below the safety threshold of Ag⁺ for drinking water (0.1 ppm), demonstrating the excellent bactericide performance of the ME/Ag filters.

Multifunctional, Highly Flexible, Free-Standing 3D Polypyrrole Foam

Multifunctional, highly flexible 3D polypyrrole (PPy) foam is fabricated via a simple electrodeposition method by using nickel foam as the template. The 3D PPy foam has a unique interior structure and is robust enough to manipulate directly.