Increasing cell density/decreasing cell size to produce microcellular and nanocellular thermoplastic foams: A review

Nowadays, polymeric foams have attracted particular attention in scientific and industrial societies due to their unique properties, such as high strength to weight ratio, excellent thermal and sound insulation, and low cost. Researchers have shown that the extraordinary properties of polymeric foams such as superior thermal insulation, can be achieved by increasing the cell density/decreasing the cell size. In this regard, firstly, the most important foaming processes, i.e. batch, extrusion, and injection molding are studied in the present research. Then, cell nucleation stage as the most crucial phenomenon for achieving high cell density/small cell size is investigated in detail. In the next step, the most important researches in the field of polymeric foams are introduced in which the largest cell densities/smallest cell sizes have been achieved. The investigations show that the most remarkable results (highest cell densities/smallest cell sizes) belong to the batch process. Also, the use of nucleating agents, increasing the solubility of blowing agent into the polymer, and the use of nanoparticles are the most efficient solutions to achieve microcellular and nanocellular structures.