Nanoporous structure of the cell walls of polycarbonate foams

Using CO2 to prepare microcellular polycarbonate foams resulted in a pore diameter of 45 nm and a pore density of 108 cm−2 on the walls of microscale cells, which created nano/micro foams with an open cell structure. In this study, the craze nucleation theory and the bubble nucleation theory of foaming were combined to explain the mechanism of the foaming-induced nanopores (microvoids) on the cell walls. In the foaming process, the strain energy was developed in the cell walls by bubble nucleation and growth. With large strain energy, a nanoporous structure of the cell walls was formed by initiation of crazing. Because the foaming temperature affected the strain energy in the cell wall, the temperature became a key factor of forming microcellular structure as well as the nanopores on the cell walls. Our experimental results showed that the diameter and density of the nanopores were determined by the competitive movements between chain stretching and relaxation. Furthermore, certain solvents, such as acetone, were found to increase the nanopore density of the walls by exploiting the plasticization effect of the solvent on the reduction of surface tension and viscosity.