A new microcellular foaming strategy to develop structure-gradient thermoplastic polyurethane foams with enhanced elasticity

Functionally graded polymer foams are advanced materials that exhibit great potential for applications in energy absorption, electromagnetic interference shielding, and high-elasticity due to the graded cellular structure for mechanical performance and functional properties enhancements. However, producing polymer foams with tailored gradient structures remains a significant challenge. Herein, a new microcellular foaming strategy with two-step adsorptions was developed to prepare thermoplastic polyurethane (TPU) foams with gradient cellular structures. The TPU samples were saturated with low-pressure CO2 in the first sorption stage and partially saturated with high-pressure CO2 in the second sorption stage. By regulating CO2 pressure in the first stage and adsorption duration in the second stage, TPU samples with gradient CO2 concentrations were achieved, thereby leading to structure-gradient TPU foams. Finally, a prospective microcellular-macrocellular gradient foam with a cell size range of 30 μm to 400 μm was successfully prepared. The energy loss coefficient of structure-gradient TPU foam can be reduced by 21.5% compared to that of the foam with uniform cellular structure. Structure-gradient TPU foams show significantly enhanced mechanical performance and elasticity, and the underlying mechanism was clarified. The super-elastic TPU foams with tailored gradient structures hold significant promise for broaden applications requiring lightweight, flexibility, and elasticity.