Polystyrene foams have become more and more important owing to their lightweight potential and their insulation properties. Progress in this field is expected to be realized by foams featuring a microcellular morphology. However, large-scale processing of low-density foams with a closed-cell structure and volume expansion ratio of larger than 10, exhibiting a homogenous morphology with a mean cell size of approximately 10 µm, remains challenging. Here, we report on a series of 4,4'-diphenylmethane substituted bisamides, which we refer to as kinked bisamides, acting as efficient supramolecular foam cell nucleating agents for polystyrene. Self-assembly experiments from solution showed that these bisamides form supramolecular fibrillary or ribbon-like nanoobjects. These kinked bisamides can be dissolved at elevated temperatures in a large concentration range, forming dispersed nano-objects upon cooling. Batch foaming experiments using 1.0 wt.% of a selected kinked bisamide revealed that the mean cell size can be as low as 3.5 µm. To demonstrate the applicability of kinked bisamides in a high-throughput continuous foam process, we performed foam extrusion. Using 0.5 wt.% of a kinked bisamide yielded polymer foams with a foam density of 71 kg/m3 and a homogeneous microcellular morphology with cell sizes of ≈10 µm, which is two orders of magnitude lower compared to the neat polystyrene reference foam with a comparable foam density.
Low thermal conductivity and adequate mechanical strength are desired for extruded polystyrene foams when they are applied as insulation materials. In this study, we improved the thermal insulation behavior and mechanical properties of extruded polystyrene foams through morphology control with the foam nucleating agent 1,3,5-benzene-trisamide. Furthermore, the structureâ»property relationships of extruded polystyrene foams were established. Extruded polystyrene foams with selected concentrations of benzene-trisamide were used to evaluate the influence of cell size and foam density on the thermal conductivity. It was shown that the addition of benzene-trisamide reduces the thermal conductivity by up to 17%. An increase in foam density led to a higher compression modulus of the foams. With 0.2 wt % benzene-trisamide, the compression modulus increased by a factor of 4 from 11.7 ± 2.7 MPa for the neat polystyrene (PS) to 46.3 ± 4.3 MPa with 0.2 wt % benzene-trisamide. The increase in modulus was found to follow a power law relationship with respect to the foam density. Furthermore, the compression moduli were normalized by the foam density in order to evaluate the effect of benzene-trisamide alone. A 0.2 wt % benzene-trisamide increased the normalized compression modulus by about 23%, which could be attributed to the additional stress contribution of nanofibers, and might also retard the face stretching and edge bending of the foams.
