Materials Science in Foaming Ernesto Di Maio and Salvatore Iannace Department of Chemical, Materials and National Research Council Production Engineering Milan&Naples, Italy University of Naples Federico II, 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
as easy as: pouring some beer vs. vs. making egg white vs. baking a cake
as easy as: pouring some beer vs. materials science matters vs. making egg white vs. baking a cake
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 MSB HP/HT view Pastore Carbone et al., Polymer Testing 2013
new characterization tools solubility diffusivity interfacial density tension Di Caprio et al., Fluid Phase Equilibria, 2016
new processing tools Tammaro, et al. J Cell Past 2015 Tammaro, et al. I&CER 2016
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
1. macromolecular architecture PCL PCL 1%perox Di Maio et al. Macromol. Symp. 2005 Di et al. Macromol. Mater. Eng. 2005
2. blowing agent PCL N 2 CO 2 /N 2 CO 2 Di Maio et al. Poly. Eng. Sci 2005
3. nanometric additive 1% nano PLA 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
4. processing 300bar/s 3000bar/s 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
new materials & products Orsi et al. Nano Research 2014
new materials & products Contaldi et al. JAPS 2016
new materials & products Trujillo de Santiago et al. in preparation
so far… thermoplastic foams by physical blowing agents
thermosetting polyurethane foams by physical blowing agents
insulating performance λ =0.020W/m.K λ =0.025W/m.K time introduction of water introduction of pentane as blowing agent as co-blowing agent R. Herrington, K. Hock, Polyurethane Foams, The Dow Chemical Company, 1977
? insulating performance λ =0.020W/m.K λ =0.025W/m.K time introduction of water introduction of pentane as blowing agent as co-blowing agent
scCO 2 ? insulating performance λ =0.020W/m.K λ =0.025W/m.K time introduction of water introduction of pentane as blowing agent as co-blowing agent
how? 1. sorption under high pressure 2. curing under high pressure 3. foaming at pressure release
Di Caprio et al., Polymer Testing, submitted
rubber impeller
rubber impeller sapphire window
sorption FT-NIR spectra polyol+CO 2 *CO 2 combination bands *4950cm -1 *5070cm -1 t = 2days t = 0 T=35°C, Pco 2 = 40 bar, t sorption = 2 days scans=32 resolution= 4 cm -1 *Buback et al. Physica B&C 139-140 (1986) 544-546 T. Guadagno, S. G. Kazarian J. Phys. Chem. B. 108 (2004) 13995
curing FT-NIR spectra polyol+MDI+CO 2 1,45 isocyanate 1,40 -NCO 4680 cm -1 1,35 1,30 isocyanate Absorbance -NCO 5347 cm -1 1,25 urethane -NH overtone band 6700 cm -1 1,20 1,15 1,10 1,05 7500 7000 6500 6000 5500 5000 4500 Wavenumbers (cm-1)
foaming effect of PBA amount 0’ 12’ 17h 40’ 2h 30’ 7h sorption time 3.7%wt 4.1%wt 0%wt 0.7%wt 1.3%wt 2.0%wt CO2 % wt density quality of morfology sorption time
PUFs obtained at 35°C and 0 (left) and 4.0 (right) MPa of CO 2 . without CO 2 with CO 2
still far from the insulating performance goal but THAT’S BEAUTIFUL!
@University of Naples
@University of Naples Form 830-047-0717 edimaio@unina.it www.foamlab.unina.it
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