Recently, functional applications of thermoplastic foams have received extensive attention from the research and materials communities, focusing on their various applications, key challenges, material systems designs, processing methods, and cellular structure characteristics needed for specific functional applications. This review paper starts with consideration of the microcellular foaming mechanism and basic concepts of microcellular foam processing, followed by polymer modification methods, and crucial factors that determine the performance of thermoplastic foams. Special emphasis has been placed on the synergies between foaming and reinforcements, including functional fillers and polymer blends; improvements in homogeneous, functional properties by achieving uniform cell structure and cell dispersion in polymer systems; and comparison of melt processing and solvent-based methods. Then, a wide array of advanced functional applications for foams-such as lightweight applications, heat and sound insulation, electromagnetic shielding, tissue engineering, oil spill cleanup, shape memory, and flexible materials-will be presented. In particular, the relationships between cellular structure and anticipated properties-including mechanical, barrier, dielectric, biomedical, and other properties required in advanced functional applications-will be discussed. Finally, we will outline a future perspective of lightweight and functional foams and suggest recommended future work regarding functional microcellular foams.
Advanced materials and new lightweighting technologies are essential for boosting the fuel economy of modern automobiles while maintaining performance and safety. A novel approach called subcritical gas-laden pellet injection molding foaming technology (SIFT) was performed to produce foamed polyamide/glass fiber (PA/GF) composite. Gas-laden pellets loaded with nitrogen (N2) were produced by introducing sub-critical N2 into PA/GF composite during compounding using a twin-screw extruder equipped with a simple gas injection unit. Compared to the commercial microcellular injection molding (MIM) technologies, gas-laden pellets enable the production of foamed parts with a standard injection molding machine, which is more cost-effective and easier to implement. To the best of our knowledge, this is the first attempt that the SIFT technology is being used for the PA/GF composites for making foamed parts. The tensile strength, fiber orientation, cell morphology, and densities of foamed PA/GF parts were investigated, and the shelf life of N2-laden PA/GF pellets was examined. Results showed that the N2-laden pellets still possessed good foaming ability after one week of storage under ambient atmospheric conditions. One week is a noticeable improvement compared to those N2-laden neat polymer pellets without glass fibers. With this approach, the weight reduction of foamed PA/GF parts was able to reach 12.0 wt. %. Additionally, a nondestructive analysis of the fiber orientation using micro-computed tomography suggested that the MIM and SIFT samples exhibited a less degree of fiber orientation along the flow direction when compared to the solid samples and that the tensile strength of both technologies was very close at a similar weight reduction. Cell size increased and cell density decreased as the shelf life increased. These findings showed that this processing method could act as an alternative to current commercial foam injection molding technology for producing lightweight parts with greater design freedom.
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