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Polyethylene terephthalate (PET) foams were prepared at different saturation temperatures using two supercritical foaming methods. The average cell size, cell number density, and porosity of PET foams obtained using each foaming method were compared. The crystallinity of the PET samples after the saturation step in the two-step foaming process was measured to observe the CO2-induced crystallization. The crystallinity of PET according to the saturation temperature led to a variation in cell size in the two-step foaming. In contrast, the melting of crystals with the increase in the temperature affected the cell number density of the polymeric foam prepared by one-step foaming method. The influence of the PET crystals on the cell nucleation or cell growth in each foaming method was studied from these results.

The dissolution behavior of dye in supercritical carbon dioxide influences the overall mass transfer that controls a supercritical dyeing process. Increasing the dissolution rate of the dye leads to shortening of the dyeing process time and can improve the efficiency of the process. Controlling the properties of the carbon dioxide flow is a good method to improve the dissolution rate of dyes. In this study, a dissolution kinetic model was designed by quantitatively analyzing and formulating the dissolution phenomenon of dyes using an in situ UV/Vis spectrometer. Through this model, the dissolution rate was compared by varying the geometric shape of the column containing the dye and the flow rate of carbon dioxide. Moreover, the correlation equation between the Reynolds number and Sherwood number was obtained through mass transfer coefficients derived under various conditions. In order to verify the utility of this equation, it was applied to a scaled-up device and the precise result could be predicted. This study can be useful in the design of dyeing processes and make-up equipment.

In this work, micro- and nanocellular acrylonitrile-butadiene-styrene (ABS) foams were prepared by using sub- and supercritical CO2 as blowing agents. The sorption kinetics at 10 MPa was first measured. The sorption amount depended on the saturation temperature Arrheniusly. The diffusivities did not follow the Arrhenius relation. This relation was interpreted by a retrograde behavior of ABS/CO2 system. From the kinetics, ABS discs were saturated at 10 MPa at the temperatures from −20 °C to 40 °C, and foamed at the foaming temperature of 20 °C–80 °C. A network of closed cells with a diameter of 600–700 nm and nanopores with a diameter of 100 nm were observed in the foam obtained at low saturation temperatures and high foaming temperatures. The closed cell densities were in a range from 1.12 × 1012 − 9.87 × 1012 cells/cm3 and an experimental correlation based on the CNT model was used to fit the data.

Synthetic polymer-based gradient foams have considered as promising category of functionally graded materials with unique properties. In this study, the carbon dioxide (CO2) foaming technology has used for PET-PEN (Polyethylene Terephthalate - Polyethylene Naphthalate) copolymer towards porous functional materials with thermal insulation with reasonable mechanical strength. Through scanning electron microscope based morphological characterization, a potential to fabricate gradient foam structures with micro-pores has identified. It has shown that variation of post-foaming temperature can tune the pore size distribution although the very high post-foaming temperature tends to cause structural instability. Thermal measurement data set the limits of operation, confirmed by simultaneous differential scanning calorimeter and thermo-gravimetric analysis. Mechanical stress and thermal conductivity also has measured to find rationale of thermal insulation with reasonable mechanical strength and to elucidate the actual 3D grid foam of copolymer.

In this study, a single paragraph of acrylonitrile-butadiene-styrene (ABS)/recycled polyethylene terephthalate (R-PET) polymeric foams is prepared using CO2 as a blowing agent. First, the sorption kinetics of subcritical and supercritical CO2 are first studied at saturation temperatures from &ndash, 20 to 40 &deg, C and a pressure of 10 MPa, in order to estimate the diffusion coefficient and the sorption amount. As the sorption temperature increases, the diffusion coefficient of CO2 increases while the sorption amount decreases. Then, a series of two-step solid-state foaming experiments are conducted. In this process, a specimen is saturated with liquid CO2 and foamed by dipping the sample in a high-temperature medium at 60 to 120 &deg, C. The effects of foaming temperature and depressurization rate on the morphology and structure of ABS/R-PET microcellular foams are examined. The mean cell size and the variation of the cell size distribution increases as the foaming temperature and the depressurization rate increases.

A partially foamed lattice structure based on synthetic polymers was considered as a functionally graded materials due to their unique properties. In this study, a copolymer is manufactured to be porous functional materials by physical foaming technology, using carbon dioxide. Through morphological characterization, using scanning electron microscope, we identified a potential to fabricate partially foamed structures with micropores. We showed that variation of post-foaming temperature can tune the pore size distribution in the range of 0.9 to 30 &mu, m. Thermal data of the foam grid from differential scanning calorimeter showed some shifts in glass transition, cold crystallization, and melting points. Mechanical strength and thermal conductivity were also measured to find rationale of thermal insulation with tunable mechanical strength and to elucidate the actual 3D lattice foam of a copolymer.

Multiscale structured polymers have been considered as a promising category of functional materials with unique properties. We combined rapid prototyping and gas foaming technologies to fabricate multiscale functional materials of superior mechanical and thermal insulation properties. Through scanning electron microscope based morphological characterization, formation of multiscale porous structure with nanoscale cellular pores was confirmed. Improvement in mechanical strength is attributed to rearrangement of crystals within CO2 saturated grid sample. It is also shown that a post-foaming temperature higher than the glass transition temperature deteriorates mechanical strength, providing process guidelines. Thermal decomposition of filament material sets the upper limit of temperature for 3D printed features, characterized by simultaneous differential scanning calorimetry and thermogravimetric analysis. Porosity of the fabricated 3D structured polylactic acid (PLA) foam is controllable by suitable tuning of foaming conditions. The fabricated multiscale 3D structures have potential for thermal insulation applications with lightweight and reasonable mechanical strength.