Book Description

Polymer foams belong to the solid foams family which are versatile materials, extensively used for a large number of applications such as automotive, packaging, sport products, thermal and acoustic insulators, tissue engineering or liquid absorbents. Composed of air bubbles entrapped in a continuous solid network, they combine the properties of the polymer with those of the foam to create an intriguing and complex material. Incorporating a foam into a polymer network not only allows one to use the wide range of interesting properties that the polymer offers, but also permits to profit from the advantageous properties of foam including lightness, low density, compressibility and high surface-to-volume ratio. Generally, the properties of polymer foams are strongly related to their density and their structure (bubble size and size distribution, bubble arrangement, open vs closed cells). Having a good control over foam properties is thus achieved by first controlling its density and structure.We developed a technique in which solid foams are generated essentially in a two-step process: a sufficiently stable liquid foam with well-controlled structural properties is generated in a first step, and then solidified in a second one. With such a two-step approach, the generation of solid foams can be divided into a number of well-separated sub-tasks which can be controlled and optimised separately. The transition from liquid to solid state is a sensitive issue of a great importance and therefore needs to be controlled with sufficient accuracy. It is essentially composed of three key steps: foam generation, mixing of reactants and foam solidification and requires the optimisation of foam stability in conjunction with an appropriate choice of both foaming time and solidification time. Furthermore, a good homogeneity of the polymer foam calls for a good mixing of the different reactants involved in the foaming and the polymerisation.A particularly powerful demonstration of the advantages of this approach is given by solidifying monodisperse liquid foams generated using millifluidic technique, in which all bubbles have the same size. In a liquid foam, equal-volume bubbles self-order into periodic, close-packed structures under gravity or confinement. As such, monodisperse foams provide simultaneous control over the size and the organisation of the pores in the final solid with an accuracy which is expected to give rise to a better understanding of the structure-property relationship of porous solids and to the development of new porous materials.We therefore aim to explore the new spectrum of properties, which polymer foams offer when we introduce an ordered structure into them since the most widely used polymer foams nowadays have disordered structures. The goal of our study is to demonstrate the feasibility of this two-step approach for different classes of polymers, including biomolecular hydrogel, superabsorbent polymer and polyurethane.For the generation of the structured polymer foams we use Lab-on-a-Chip technologies which allow the “shrinking” of large-scale set-ups to micro/millimetic scale. It permits also to perform “flow chemistry” in which the various liquid and gaseous ingredients of the foam are injected and mixed in a purpose-designed network of the micro- and millifluidic Lab-on-a-Chip. We adjust this approach according to the requirements of each polymer system, i.e. the foaming and the mixing techniques are chosen to fit the properties of each system, and can be exchanged to fit the properties of the studied systems.