Preparation of low density amorphous poly(aryletherketone) foams and the study of influence factors of the cell morphology

Abstract

Low-density foams of amorphous poly(aryletherketone) (PAEK) samples were prepared using supercritical carbon dioxide (ScCO₂) as physical blowing agent. The samples exhibited a wide range of foaming temperature than crystal PAEK, leading to a more controllable fabrication process. An unusual relationship was observed between viscoelasticity and gel content under different molding times. The influence of gel content on foaming was explained using the nucleation and cell growth theories. In addition, the effects of processing parameters, such as temperature, pressure, and pressure release rate, were investigated. By controlling the gel content and processing parameters, foams with density under 0.1 g cm⁻³ were achieved.