The effects of silica aerogel on the rheological behaviour and polymer matrix structure of Rigid Polyurethane foams

The incorporation of silica aerogel particles into the isocyanate used to prepare Rigid Polyurethane composite foams drastically modifies its rheological behaviour. The isocyanate changes from being a Newtonian fluid of constant viscosity (0.3 Pa s at 25 °C) to a non-linear power-law material with complex viscosity decreasing from 104 to 101 Pa s with a slope −1 versus frequency. The change in response is caused by the formation of a percolated network of particles at contents above 2.5 wt% of aerogel. Moreover, the addition of aerogel significantly slows down the modulus-build up kinetics and vitrification of the matrix by approximately 4.5 min with every 1 wt% of aerogel added. For the foam with 3.0 wt% of aerogel, the combination of high viscosity at early reaction times coupled with the slow modulus build-up impedes the drainage which leads to a decrease in the fraction of material in the struts of the matrix.