Characterization of polycarbonate foam structures prepared by one-step SC-CO2 dissolution process

Abstract

In this communication polycarbonate foams were prepared by a supercritical CO2 dissolution one-step batch foaming process. Firstly, CO2 diffusion behavior in polycarbonate was studied by means of desorption experiments. The cellular structure of foams prepared under different foaming conditions was characterized through scanning electron microscopy. Different foaming temperatures as well as CO2 saturation pressures and times were applied. The foams displayed typical closed-cell structures with cell densities ranging from 3x10⁵ to 3x10⁶ cells/m³ and cell average sizes from around 70 to 150μm. Analysis by X-ray diffraction and differential scanning calorimetry seemed to suggest that slight crystallization took place because of the plasticizing effect of CO2 during saturation and foaming. Thermogravimetric analysis showed a higher thermal stability of the foams when compared to the compact polymer. The preliminary results shown in this work suggest the possibility of developing lightweight polycarbonate components with improved specific thermal properties through carefully controlling the foaming parameters.