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Materials Science in Foaming Ernesto Di Maio and Salvatore Iannace
Department of Chemical, Materials and Production Engineering
University of Naples Federico II, ItalyNational Research Council
Milan&Naples, Italy
foaming in Naples
the beauty of foam:
“it is like designing materials with air” L.J.Gibson, Cellular Materials, 2001
nice and soft
acoustic absorption
thermal insulation
the most efficient, wonderful structural materials
foams as structural materials
foams as structural materials
structures that we try to mimic
how?
as easy as:
pouring some beer
beating egg white
baking a cake
vs.
vs.
vs.
as easy as:
pouring some beer
making egg white
baking a cake
vs.
vs.
vs.
as easy as:
pouring some beer
making egg white
baking a cake
materials science matters
www.foamlab.unina.it
new characterization tools new processing tools new understanding new materials & products
new characterization tools
• HP-rheology • HP-DSC • pVT • TEM/SEM/optical • …
new characterization tools
• HP-rheology • HP-DSC • pVT • TEM/SEM/optical • coupled sorption/drop shape analysis
• solubility, diffusivity, density, interfacial tension
HP/HT view
MSB
Pastore Carbone et al., Polymer Testing 2013
new characterization tools
Di Caprio et al., Fluid Phase Equilibria, 2016
solubility diffusivity
density interfacial tension
Tammaro, et al. J Cell Past 2015 Tammaro, et al. I&CER 2016
new processing tools
new understanding new materials & products
…playing around with all of the possible strategies to achieve a good foam
with the material with the blowing agents with the nucleating agents with the process
PCL PCL 1%perox
1. macromolecular architecture
Di Maio et al. Macromol. Symp. 2005 Di et al. Macromol. Mater. Eng. 2005
2. blowing agent
Di Maio et al. Poly. Eng. Sci 2005
PCL
CO2N2 CO2/N2
PLA 1% nano
3. nanometric additive
Marrazzo et al. Poly. Eng. Sci 2008 Di. et al J. Pol. Sci. B 2003 Di Maio et al. Plastics Rubbers and Composites 2003 Di Maio et al. Polymer 2004 Di. et al J. Pol. Sci. B 2005
Di Maio et al. Poly. Eng. Sci 2005 Marrazzo et al. J. of Cell. Plast. 2008 Sorrentino et al. J App Pol Sci 2010 Salerno et al. Biotech Bioeng 2011 Tammaro et al. . J. of Cell. Plast. 2015
4. processing
3000bar/s300bar/s
Orsi et al. Nano Research 2014
new materials & products
Contaldi et al. JAPS 2016
new materials & products
Trujillo de Santiago et al. in preparation
new materials & products
so far… thermoplastic foams by physical blowing agents
thermosetting polyurethane foams by physical blowing agents
time
insulating performance
introduction of water as blowing agent
introduction of pentane as co-blowing agent
λ=0.025W/m.K
λ=0.020W/m.K
R. Herrington, K. Hock, Polyurethane Foams, The Dow Chemical Company, 1977
time
insulating performance
?
introduction of pentane as co-blowing agent
λ=0.025W/m.K
λ=0.020W/m.K
introduction of water as blowing agent
time
insulating performance
?
introduction of pentane as co-blowing agent
λ=0.025W/m.K
λ=0.020W/m.K
scCO2
introduction of water as blowing agent
1. sorption under high pressure 2. curing under high pressure 3. foaming at pressure release
how?
Di Caprio et al., Polymer Testing, submitted
rubber impeller
rubber impeller sapphire window
sorption
FT-NIR spectra polyol+CO2
*4950cm-1
*5070cm-1
*CO2 combination bands
t = 0
t = 2days
*Buback et al. Physica B&C 139-140 (1986) 544-546 T. Guadagno, S. G. Kazarian J. Phys. Chem. B. 108 (2004) 13995
T=35°C, Pco2 = 40 bar, tsorption = 2 days scans=32 resolution= 4 cm-1
1,05
1,10
1,15
1,20
1,25
1,30
1,35
1,40
1,45
Abs
orba
nce
4500 5000 5500 6000 6500 7000 7500
Wavenumbers (cm-1)
-NH overtone band 6700 cm-1
-NCO 5347 cm-1
-NCO 4680 cm-1
isocyanate
isocyanate
urethane
curing
FT-NIR spectra polyol+MDI+CO2
sorption time
2h 30’ 7h 17h
CO2 % wt
2.0%wt
3.7%wt
4.1%wt
1.3%wt
40’ 12’
0.7%wt
0’
0%wt
foaming
effect of PBA amount
sorption time
density quality of morfology
without CO2 with CO2
PUFs obtained at 35°C and 0 (left) and 4.0 (right) MPa of CO2.
still far from the insulating performance goal but THAT’S BEAUTIFUL!
@University of Naples
