Self-Reinforced Foam Composites

Maxdem has developed a unique family of exceptionally high modulus, high strength, thermoplastic resins, designated Poly-X , based on processable rigid-rod polymer technology. With proper processing, these polymers are expected to lead to a new class of foam core materials with specific mechanical properties better than other organic foams and comptetitive with honeycomb core. The objective foams will feature low densities (6-12 lbs/ft ) in combination with high strength and stiffness. The new foams will form better bonds with surface skins (better contact area), will be more moisture resistant, and more damage tolerant than competing honeycomb cores. Thus, resulting foam core sandwich structures will show overall better mechanical properties along with reduced repair and maintenance and will find much use in weight-sensitive applications. The primary Phase I objective is to fabricate demonstration quantities of the new Poly-X foams via 3M's proprietary supercritical foaming method and demonstrate their superior properties (compression, flexure, and shear) in snadwich panels. Phase II eforts will include optimization of the foam composition for maximum processability and properties, scaleup of 3M's foaming process, evaluation of alternate foaming techniques, and more detailed testing of prototype systems.