Structural features of biobased composite foams revealed by X-ray tomography

Polymer foams can have heterogeneous and complex internal structures, especially when material blends or particles have been integrated to create composites. It becomes even more challenging to probe and understand foam structure/properties when using non-uniform particles, such as biobased fillers. Optical or SEM imaging can only provide limited information as these are two-dimensional (2D) surface techniques. In this study, 3D X-ray tomography was applied to comprehensively analyze the structural features of biobased polyurethane foams containing porous rice hull fillers. The in-depth characterization at a wide range of length scale enabled us to quantify and obtain statistics of the unique trends in foam pore size and pore orientation corresponding to rice hull particle fraction and particle size. Rice hull particles were found to induce smaller cell formation. In addition, these biobased particles influenced cell expansion and caused cells to have less consistent orientation. Furthermore, after foam samples were subjected to cyclic compressive loading, X-ray tomography showed fractures in large (>100 μm) particles. This helps reveal the premature failing mechanism of composite foams with highly porous and coarse particles. The study elucidates novel microstructural evolution and deformation mechanisms using 3D X-ray tomography. The results offer new insights on internal structures for biobased composites and foams that are not previously possible through the conventional characterization tools.