Ultrasound-Induced Nucleation in Microcellular Polymers

In this study, microcellular Acrylonitrile-Butadiene-Styrene foams with high cell density and expansion ratio has been manufactured using ultrasound-induced nucleation technique in solid-state batch foaming process. Influence of sonication time, sonication frequency, and ultrasound power were found very crucial in designing of cellular morphology. The initial 10 s of ultrasound exposure was found to influence the foam morphology critically. Longer periods of ultrasound exposure developed foams with lower average cell size as compared to foams developed with lesser ultrasound exposure time. Higher sonication power resulted in foams with uniform morphology and higher cell densities as compared to foams developed with lower sonication intensities. Finally, the ultrasonic frequency was also found to influence the morphology intensely. Low frequency sonication resulted in foams with uniform cell distribution, whereas high frequency sonication developed bimodal microcellular type of microstructure. The results coherently demonstrate that with the advent of ultrasonic waves, the energy barrier for cell nucleation swiftly decreases which enhances the cell density in the final foamed product. (C) 2014 Wiley Periodicals, Inc.