Processing of Ultra-Lightweight Microcellular Foams from POSS-PMMA Nanocomposites

"This proposal is submitted in response to BMDO SBIR solicitation 02-006#5. Conventional processing techniques for polymer foams involve multiple steps and the blowing agent used is toxic. Those foams are mostly over 3 pcf in density and suffer from theserious problems of moisture infusion and retention that leads to structural degradation and damage. The efficiency of thermal and sound insulation is less effective because of their open connected channels. In this Phase I research we propose a noveltechnique to process ultra-lightweight microcellular foams that does not use or release any hazardous chemicals/gases. We will foam ultra-lightweight POSS-PMMA with densities ranging from 0.5 to 3 pcf. POSS-PMMA nanocomposite has low thermalconductivity as it contains Silica and PMMA. Ultra-lightweight microcellular foams processed from this nanocomposite will be thermal insulators. It will also have excellent strength and stiffness to weight ratio, barrier properties, and superior impactand damage resistant properties. Once exposed to flame or very high temperature these microcellular foams will form a ceramic layer on the exterior surfaces and protect the underneath materials. Sandwich structures can be fabricated using these POSS-PMMAnanocomposite foams by heat pressing, thereby reduce manufacturing and assembling costs. The proposed research will result in a new generation of ultra-low density, damage resistant microcellular foams