A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide Hao Xua, Yunchuan Hea, Xia Liaoa,*, Tinggang Luob, Guangxian Lia, Qi Yanga, and Chuanjian Zhouc,* aCollege of Polymer Science and Engineering, State Key Laboratory of Polymer Materials Engineering, Sichuan University, Chengdu, Sichuan 610065, China bChina Bluestar Chengrand Research Institute of Chemistry Industry Co. Ltd, Chengdu, Sichuan 610065, China cKey Laboratory of Special Functional Aggregated Materials, Ministry of Education, Shandong University, Jinan, Shandong 250100, China Received: 23 March 2005, Accepted: 10 August 2015 Summary Silicone rubber foams were successfully generated by environmentally friendly blowing agent, supercritical carbon dioxide (scCO2), in this research. Firstly, the effect of the saturation time on the cellular structure was investigated. The diffusion of scCO2 into the rubber matrix would be enhanced thus decreasing the viscosity as increasing the saturation time. It would further promote the cell growth, which has a close connection with the cellular structure. After that, the effect of pre-curing time on cellular morphology of silicone rubber foams was further researched in detail. When increasing pre-curing time in the short time range, cell nucleation would be affected more than cell growth in the foaming process. If continuously increasing pre-curing time, both cell nucleation and growth would be restricted thus resulting in the formation of silicone rubber foams with small cell density and small cell size. This investigation not only provided a green way to produce silicone rubber foams, but also guided us to control cellular morphology via the saturation time and pre-curing time. Keywords: Silicone rubber foam; Supercritical carbon dioxide; Saturation time; Open cell; Pre-curing time; Cellular structure *Corresponding authors: Xia Liao, Tel.:+86-28-8540 8361; E-mail: [email protected] Chuanjian Zhou, Tel.:+86-531-81696515; E-mail: [email protected] ©Smithers Information Ltd. 2016 Cellular Polymers, Vol. 35, No. 1, 2016 19 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou Introduction Silicone rubbers are synthetic polymers based on polyorganosiloxanes with high molecular weight. Their basic backbone is the silicon-oxygen (Si-O) bond and organic groups attached directly to the silicon atom via silicon-carbon (Si-C) bonds [1]. As a result of this special structure, silicone rubbers exhibit a list of superior performance including superior temperature and chemical resistance, good electrical insulation, excellent ozone resistance and biocompatibility, etc. [2]. These characteristics make the silicone rubber widely applied in many areas, such as cure oven, mechanical shock absorbers in the aerospace industry [3-5]. Silicone rubber foams combine the characteristics of silicone rubber and foam materials, for example, a light weight, good resilience, high thermal stability, shape conformance and low compression set [4]. They also provide enhanced temperature range suitability, which offers a wider operating temperature range compared to other organic rubber foams [6]. Hence, silicone rubber foams have been widely used in challenging applications ranging from joint sealants, insulators, aircraft and transportation industry, to biomaterials for wound dressings [3]. The foaming process of silicone rubbers usually bases on the expansion of gaseous phase dispersed through the rubber matrix. Solvent foaming methods and chemical foaming methods are mostly used ways in generating silicone rubber foams [3, 5]. Silicone rubber compounds are mixed with an inert component in solvent foaming methods, which can be dissolved in a specific solvent. In a result, this kind method could cost more blowing agents and need a time-consumed washing process leading to the low production efficiency [7]. In chemical foaming methods, foaming agents usually consist of an organic and inorganic thermally unstable component, which would decompose to gas components upon heating above a certain temperature [7]. The products in the decomposition are harmful to the environment and this method can lead to generating solid residue and sublimate, which remain in the rubber matrix. In addition, the cell size is nonuniform and it is too hard to control the cellular structure of silicone rubber foams via the above two methods. In recent years, supercritical carbon dioxide (scCO2) has been broadly investigated in the production of microcellular foams because of its many unique properties [8, 9]. One advantage is that foams generated by scCO2 own uniform cell size which even can be controlled by adjusting experiment parameters [10]. Furthermore, scCO2, as a green physical blowing agent, also avoids environmental problems generated by chemical blowing agents [10, 11]. To date, most studies on high pressure CO2 polymer foaming have focused on plastic polymers and very little attention has been paid to crosslinked resins such as rubbers [12, 13]. During the foaming of rubbers, viscoelastic 20 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide properties of elastomer matrix have a great effect on the saturation process. Comparing with chemical foaming technology, the simultaneously control of foaming and vulcanizing is difficult in scCO2 foaming, because these two processes progress separately [14]. It also increases the complexity of cellular structure control comparing with the foaming of plastic polymers by scCO2. In this study, the effect of the saturation time and pre-curing time on the cellular structure (cell density and cell size) of silicone rubber foams has been figured out in detail. On the other hand, open porous silicone rubber foams were successfully generated by the scCO2 foaming technology. All these investigations could guide us to control the cellular structure of silicone rubber foams more effectively in the manufacture process. Experimental Preparation of Silicone Rubber Foams Polymethylvinylsiloxane (PMVS) with 0.15-0.18% vinyl was supplied by China Bluestar Chengrand Research & Design Institute of Chemical Industry. The molecular weight of the silicone rubber was about 500,000-700,000. Precipitated silica (921, specific surface area = 150 m2/g) was obtained from Nanchang Nanji Chemical Industry Co. Limited. PMVS, precipitated silica and hydroxyl silicone oil were mixed by the internal mixer at 100oC for about 30 min. After cooling to room temperature, silicone rubber was finally formulated with the addition of dicumyl peroxide (DCP) at ambient temperature for 15 min. Pre-curing specimens with a 2 mm thickness were prepared by compression molding at 120oC for different time. Then disk specimens were placed in an autoclave linked to a CO2 cylinder and they were saturated with CO2 at a specific saturation temperature and pressure. After the saturation, the high pressure CO2 was rapidly released to atmosphere conditions. Finally foamed sheets were quickly placed into a heated oven for a complete post-curing. Cell Structure Observation The foamed samples’ morphology was observed with a Quanta 250 (FEI Company, America) scanning electron microscope (SEM). First, the samples were freeze-fractured in liquid nitrogen and then sputter-coated with gold. The cell size and its distribution were determined from the SEM micrographs. Cellular Polymers, Vol. 35, No. 1, 2016 21 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou Statistics of Cell Density (No), Average Cell Diameter and Open Cell Content No is the cell density defined as the number of bubbles per cubic centimeter of the non-foamed silicone rubber and is given as follows [15]: No = (nM 2/A) 3/2·1/(1-Vf) (1) Vf = 1-ρ/ρf (2) where n is the number of bubbles in the micrograph of the foam sample, A is the area of the micrograph (cm2), Vf is the volume fraction occupied by the voids, ρ is the density of silicone rubber, ρf is the density of silicone rubber foams and M is the magnification factor of the micrograph. Average cell diameter was determined from SEM micrographs, and it was analyzed by software. The image analysis software (Image-Pro Plus) was used to determine cell diameter and count the number of cells in the SEM image. For a single asymmetric cell, the average length of 90 diameters passing through cell’s centroid was regarded as the cell diameter. The angle between neighboring diameters was 2 degree. All cells in the SEM images were used to calculate the average cell diameter. The open cell content was measured by ULTRAFOAM 1000 (Quantachrome Corporation, America). Rheology Measurements Prepared disk-shaped samples were used to measure the dynamic shear rheological properties. Dynamic frequency sweep tests of silicone rubber with various pre-curing time were carried out using a strain-controlled Rheometric Scientific ARES rheometer (TA Instruments, USA). The strain amplitude was set at 1%, large enough to give a reliable signal while keeping the measurement in the linear viscoelastic regime. The rheological functions, such as complex viscosity (η*), storage (G′) and loss modulus (G′′) were measured in an angle frequency range of 0.02 to 100 rad/s. Modifying the geometry of the commercially available high-pressure rheometer (MCR-102, Anton Paar) to the parallel plate, we measured the complex viscosity (η*) of the silicone rubber compounds in a high pressure CO2 atmosphere. 22 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide Results and Discussion Effect of Saturation Time on Cellular Morphology of Silicone Rubber Foams As is well-known, the saturation time is a key factor during the foaming process [16]. The diffusion of CO2 into the rubber matrix has a close relation with the saturation time. As a result of the scCO2’s plasticization effect on polymers, the saturation of CO2 could have an effect on the molecular motility and the foaming process [17-19]. It may lead to the differences in the cell morphology of foams saturated for different time. Silicone rubber sheets with same ingredients and pre-curing time (6 min) were saturated at 50oC, 10 MPa for different time (1 h, 2 h, 3 h and 4 h). As shown in Figure 1, there were some differences in the cellular morphology of samples generated for different time. It seemed that cell size gradually became larger and more bubble coalescence occurred with increasing saturation time from1 h to 4 h. Figure 1. SEM photographs of silicone rubber foam saturated at 50oC, 10 MPa for different time: (a) 1 h; (b) 2 h; (c) 3 h; (d) 4 h After that, image analysis was carried out on a series of foamed samples generated for different time to obtain the trend of cell size distribution. The cell size and its distribution were statistically analyzed and shown in Figure 2. When the saturation time was 1 h, cell size distribution was the narrowest and the diameter of most cells was approximately between 30~40 μm. Hence, the silicone rubber foam owned the good uniformity of cell size. After the saturation Cellular Polymers, Vol. 35, No. 1, 2016 23 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou for a longer time, more and more large cells were gradually generated. The curve of cell size distribution moved to the right (large cell size zone) and the size of some large cells was even above 70 μm when saturated for 4 h. Figure 2. Statistical cell size distribution of silicone rubber foam saturated for different time Only judging from the SEM photographs, the effect of saturation time on cellular structure could not be clearly figured out. Hence, the cell density and average cell diameter of silicone rubber foams saturated for different time are calculated and listed in Table 1. It could be found that the cell density dropped from 3.76×106 to 1.75×106 cells/cm3, and average cell diameter enlarged from 37.09 to 49.44 μm when prolonging the saturation time from 1 h to 4 h. Table 1. Effect of saturation time on cell density and average cell diameter Saturation time (h) Cell density (cells/cm3) Average cell diameter (μm) 1 3.76×106 37.09 2 2.27×106 42.83 3 2.23×106 45.57 4 1.75×106 49.44 As we all know, the dissolution and the diffusion of scCO2 into silicone rubber matrix has a close connection with the saturation time, which could further affect the viscoelastic properties of the specimen. In order to find out how the 24 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide saturation time influences the silicone rubber matrix, we tested the complex viscosity of silicone rubber compounds during the saturation process. As shown in Figure 3, the viscosity of silicone rubber decreased a lot in the first hour as a result of the plasticization effect of scCO2. During the next three hours, the viscosity of the rubber matrix still decreased and the decreasing rate of η* gradually became smaller. This may because that a great amount of scCO2 was dissolved and diffused into the silicone rubber in the first hour. At this moment, the saturation degree of scCO2 in the specimen got to a high level. Then the plasticization effect of scCO2 was the strongest in this period. In the next three hours, only a very small amount of scCO2 could be dissolved and diffused into the rubber matrix in corresponding with the changes of viscosity in Figure 3. The decrease of viscosity could enhance the motility of molecules chains thus increasing the cell growth. In a result, silicone rubber foams with larger cell size and smaller cell density could be easily generated when increasing saturation time from 1 h to 4 h. Figure 3. Time dependence of complex viscosity of silicone rubber under 10 MPa at 50oC for 4 h Morphology of Open Porous Silicone Rubber Foams Open porous silicone rubber foams were successfully produced by CO2 and the cellular morphology was observed by scanning electron microscope. Figure 4 shows morphology of open porous silicone rubber foams with different precuring time (4 min and 6 min) which were saturated under 5 MPa for 1 h at Cellular Polymers, Vol. 35, No. 1, 2016 25 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou 40oC ,50oC and 60oC, respectively. The cell structure shown in Figure 4 had a remarkable difference with silicone rubber foams produced by Lee and Song [20, 21]. Most bubbles in these foams were coalesced and cell walls were broken and linked each other. The small and large cells appeared together in the open porous foams. Then the open cell content of different foamed specimens was tested so as to figure out the structural difference of these open porous foams. The testing results showed that open cell content of the specimen a-1 was 68.18%, a-2 was 72.36%. After increasing pre-curing time to 6 min, open cell content of the specimen b-1 was 54.26%, b-2 was 57.75%, b-3 was 55.98%. It indirectly reflected that the pre-curing time had an effect on cellular structure. However, it was not clear to find the specific morphology difference caused by different pre-curing time as a result of the open porous structure. Hence the next section could help us to clearly figure out how the pre-curing time affects cellular structure in detail. Figure 4. Morphology of open-celled silicone rubber foam with different pre-curing time under 5 MPa for 1 h at different temperatures: (a-1) 4 min 40oC; (a-2) 4 min 60oC; (b-1) 6 min 40oC; (b-2) 6 min 60oC; (b-3) 6 min 50oC Effect of Pre-curing Time on Cellular Morphology of Silicone Rubber Foams All silicone rubber specimens were not fully crosslinked before the foaming process in this research. So the pre-curing time could affect the crosslinked network in the rubber matrix thus acting as a vital role in the foaming process of silicone rubber. In order to figure out the relation between pre-curing time and cellular morphology, silicone rubber with different pre-curing time (6 min, 18 min, 24 min and 48 min) were foamed at 50oC, 10 MPa for 1 h. As shown 26 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide in Figure 5, there were distinct differences among the foamed specimens with different pre-curing time. When pre-curing time was 6 min, it could form uniform and well defined cells. After increasing pre-curing time to 18 min, larger cells were obviously generated but the uniformity of cell size became worse. The cellular morphology changed again while the pre-curing time of specimen was 24 min. Silicone rubber foams with pre-curing time 24 min owned many irregular shaped cells and even the shrinkage of some cells could be observed. After increasing to 48 min, the unique phenomenon was observed that there were no cells generated in the corresponding specimen. Figure 5. SEM photographs of silicone rubber foam saturated at 50oC, 10 MPa for 1 h with different pre-curing time: (a) 6 min; (b) 18 min; (c) 24 min; (d) 48 min The statistical analysis of cell size of specimens with different pre-curing time was made and shown in Figure 6. The cell size distribution became wider firstly when pre-curing time increased from 6 min to 18 min. Then it turned to get narrower while continuously increasing to 24 min. The cell size distribution of specimen with 48 min pre-curing time was not shown in Figure 6 because no cells were generated in this kind specimen. In order to figure out the effect of pre-curing time on cellular structure more accurately, cell density and average cell diameter of different specimens are calculated and shown in Table 2. The cell density decreased from 3.76×106 to 2.50×106 cells/cm3 when increasing pre-curing time from 6 to 24 min. At the same time, the average cell diameter became smaller from 37.09 to 29.09 μm. If go on increasing pre-curing time to 48 min, both the cell density and average cell diameter could not be calculated as a result of the disappearance of all Cellular Polymers, Vol. 35, No. 1, 2016 27 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou Figure 6. Statistical cell size distribution of silicone rubber foams with different precuring time cells. The calculation results in Table 2 corresponded well to the cellular morphology changes of the foamed specimens shown in Figure 5. Table 2. Effect of pre-curing time on cell density and average cell diameter Pre-curing time (min) Cell density (cells/cm3) Average cell diameter (μm) 6 3.76×106 37.09 18 2.99×106 49.73 24 2.50×106 29.09 48 / / The rheology analysis of silicone rubber compounds with different pre-curing time could help us to understand how the pre-curing time influences the structure of silicone rubber compounds (shown in Figure 7). When pre-curing 28 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide time was 6 min, there would be a very small part of curing agent that was decomposed. Then the complex viscosity (η*) of specimen was the smallest and the storage modulus (G′) exceeded the loss modulus (G′′) by a quite small amount. It demonstrated that the crosslinking of silicone rubber was inadequate and then the elasticity of the silicone rubber compounds was so small, which was benefit for the cell nucleation and growth. Hence, silicone rubber foams were generated with uniform and well defined cells. As the pre-curing time increased to 18 min, more curing agents were decomposed to form the crosslinking network in silicone rubber matrix. The viscosity of the specimen was increased with pre-curing time. Meanwhile, the elasticity was also enhanced, which was reflected in Figure 7b where the increase rate of G′ was larger than the G′′ and the gap between them was enlarged. Then the diffusion of scCO2 into rubber matrix would be restricted and the concentration of gas in the specimen decreased thus restricting cell nucleation rate [22-24]. Although the elasticity was increased, its effect on cell growth was not enough strong. In conjunction with the analysis of cellular morphology, we can make a conclusion that the effect of elasticity increase on the cell nucleation was much stronger than on the cell growth during this progress (increasing pre-curing time from 6 to 18 min). Consequently, it would lead to the formation of silicone rubber foams with large cell size and small cell density. When continuously increasing pre-curing time, most parts of the curing agent would be decomposed and the viscosity of silicone rubber compounds was increased to a high level. The elasticity of silicone rubber compounds was also enhanced a lot because the G′ continued to increase and it was much higher than the G′′, thus causing the great increase of elastic resilience ability of the specimen. Then it resulted in the shrinkage of cells, which led to the irregular shaped cells and the decrease of the cell size. When pre-curing time was increased to 48 min, the curing agent was almost completely decomposed and the chemical crosslinking network became integrated in the silicone rubber matrix. At this time, both the viscosity of silicone rubber compounds and the gap between the G′ and G′′ were the largest. On the other hand, the storage modulus of the specimen did not vary much with the frequency comparing with other specimens. It demonstrated that the silicone rubber compounds owned a very strong elasticity when increasing pre-curing time to 48 min. Then the high elastic resilience prevented the cell growth and accelerated the shrinkage of cells. In a result, there were no cells generated in the silicone rubber. According to the above research, the effect of the pre-curing time on silicone rubber foam’s structure is a complex process. When pre-curing time is not too long, cell nucleation would be affected more than cell growth. If continually increasing pre-curing time, both the cell nucleation and growth would be restricted. All these investigations could guide us to generate silicone rubber foams with specific cellular structure by controlling pre-curing time. Cellular Polymers, Vol. 35, No. 1, 2016 29 Hao Xu, Yunchuan He, Xia Liao, Tinggang Luo, Guangxian Li, Qi Yang, and Chuanjian Zhou Figure 7. Frequency dependence of (a) complex viscosity; (b) storage and loss modulus of silicone rubber compounds with various pre-curing time at 50oC Conclusions A green and structure-controlled approach for the manufacture of silicone rubber foams was reported in this research. Firstly, the effect of saturation time on the cellular structure was investigated. When prolonging the saturation time, more and more scCO2 molecules could diffuse into the silicone rubber matrix thus enhancing its plasticization effect. Hence, the viscosity of silicone rubber compounds would decrease with the saturation time. It would promote the cell growth and lead to foams with large cell size and small cell density. Open celled silicone rubber foams with different pre-curing time (4 min and 6 min) were successfully produced by CO2 at 40oC, 50oC and 60oC, 5 MPa for 1 h. Combining with the testing results of open cell content, the pre-curing time 30 Cellular Polymers, Vol. 35, No. 1, 2016 A Green and Structure-Controlled Approach to the Generation of Silicone Rubber Foams by Means of Carbon Dioxide had a stronger effect on the cellular structure than the saturation temperature. Then the effect of the pre-curing time on cellular structure was discussed in detail. Pre-curing time also has a strong effect on cellular morphology. When increasing pre-curing time in the short time range, cell nucleation would be affected more than cell growth in the foaming process. The foams with large cell size and small cell density could be generated easily. If continuously increasing pre-curing time, the viscosity and elasticity of the rubber matrix would increase at the same time. Both cell nucleation and growth would be restricted thus resulting in the formation of silicone rubber foams with small cell density and small cell size. Hence, this study not only provides us a clean and sustainable way to produce silicone rubber foams, but also guides us to control cellular morphology more effectively, which can make silicone rubber foams widely applied in many more fields. 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