Ultra-lightweight paper foams: processing and properties

A methodology for producing a low density cellulose-based foam has been developed by combining a surfactant with pulp, mixing at high velocity to entrain air, and then drying in a non-restrained fashion. The structure of the foam, characterized through optical microscopy and X-ray computed tomograph...

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Bibliographic Details
Published in:Cellulose (London) 2014-06, Vol.21 (3), p.2023-2031
Main Authors: Madani, A, Zeinoddini, S, Varahmi, S, Turnbull, H, Phillion, A. B, Olson, J. A, Martinez, D. M
Format: Article
Language:English
Subjects:
Additives
air
Air bubbles
Air Content
Air entrainment
Bioorganic Chemistry
bubbles
Cellulose
Ceramics
Chemistry
Chemistry and Materials Science
Composites
computed tomography
Density
Design of experiments
experimental design
Foams
Glass
infrastructure
Mechanical properties
Microscopy
mixing
Natural Materials
Optical fibers
Optical microscopy
Organic Chemistry
Original Paper
Papermaking
permeability
Physical Chemistry
Polymer Sciences
Process parameters
pulp
Surfactants
Sustainable Development
tensile strength
X-radiation
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Summary:A methodology for producing a low density cellulose-based foam has been developed by combining a surfactant with pulp, mixing at high velocity to entrain air, and then drying in a non-restrained fashion. The structure of the foam, characterized through optical microscopy and X-ray computed tomographic microscopy, consists of pulp fibres in random orientations surrounding air bubbles along with large void spaces. Through careful design of experiments, the effect of fibre type, length distribution, surfactant, and air content on the mechanical behavior and permeability of the foam material was investigated. The results indicate that foamed cellulose materials can be produced at a strength of one-half the tensile strength of a standard handsheet, but having a relative density of only one percent. No chemical additives were used to enhance the strength of these samples as the properties of the foam material are enhanced simply through variation of the process parameters. Thus, a strong cellulose-based foam, with a density as low as 10 mg/cm³, can be fabricated using standard papermaking infrastructure and hence at low cost.
ISSN:0969-0239
1572-882X
DOI:10.1007/s10570-014-0197-3