Fabrication of wrinkled thermoplastic polyurethane foams by dynamic supercritical carbon dioxide foaming

Precise control and regulation of the cell structure in supercritical CO2 (scCO2) foaming is the key to boost the performance and extend the application of polymer foams. In this work, dynamic scCO2 foaming method is proposed to fabricate thermoplastic polyurethane (TPU) foams with unique wrinkly structures by introducing a continuous scCO2 flow field during scCO2 saturation. The scCO2 flow field applied on the TPU matrix generated intramolecular stress and resulted in the formation of wrinkles on the surface of cells. The structure of wrinkles was controlled by pivotal processing factors including foaming temperature, pressure, scCO2 flow rate, and scCO2 flow time. Attributing to the wrinkly structure, the wrinkled foams possessed superior compressive modulus, strength, recoverability, and energy absorption performance than conventional TPU foams, which make them a promising material for buffering and energy absorption applications. The dynamic scCO2 foaming method opens avenue for scCO2 foaming process involves dynamic field.