Abstract:
A method for creating a foam from a solid thermoplastic material is disclosed. The method includes heating a solid, noncellular thermoplastic material to a temperature greater than the material's glass transition temperature, and below the melting temperature, and then allowing the material to cool; after the material has cooled, saturating the cooled thermoplastic material with a non-reacting gas to provide a gas-saturated material; and heating the gas-saturated material below the melting temperature of the material so that the material remains a solid, and causes nucleation of bubbles, and creation of cells in the material.
Abstract:
A method for making a flat polymer foam having a core layer of nano-sized open, interconnected cells that includes saturating a solid-state polymer with a supercritical fluid, allowing the gas to desorb for at least 35 minutes, and then heating the gas-saturated solid polymer for at least 3 minutes while constraining the foam in the thickness dimension. Any skin layer formed on the exterior may be removed via polishing, thus creating a foam with an open structure from side to side. The foam can be used as a battery separator.
Abstract:
A method for making a flat polymer foam having a core layer of nano-sized open, interconnected cells that includes saturating a solid-state polymer with a supercritical fluid, allowing the gas to desorb for at least 35 minutes, and then heating the gas-saturated solid polymer for at least 3 minutes while constraining the foam in the thickness dimension. Any skin layer formed on the exterior may be removed via polishing, thus creating a foam with an open structure from side to side. The foam can be used as a battery separator.