Nanocomposite Foams for Ultra-High Temperature Applications

Opportunity  

There is a growing need to replace traditional metal foams with polymer foams due to the latter’s chemical inertness, superior acoustic properties, high strength-to-weight ratio and ease of fabrication into various forms. However, current polymeric foams often fail due to limited service temperature or mechanical property degradation. This invention presents methods to fabricate PN and its nanocomposite forms, which can withstand temperatures up to 300°C for extended periods without significant mechanical deterioration. 

Technology  

This technology involves the fabrication of nanocomposite foams using synchronised one-step gas liberation-polymerisation with precise control of density. These foams exhibit excellent thermal properties and mechanical retention upon thermal ageing. The addition of nanofillers enables tuneable morphology, enhancing the material’s versatility. 

Applications & Advantages  

Main application areas include commercial uses requiring lightweight composite structures with thermal resistance up to 300°C, io-related, filtration applications where structural porosity is highly desirable and other high-temperature applications. 

Advantages: 

• Offers precisely controlled density for specific applications.
• Provides good thermal stability among known thermoset foams.