Reinforced Polymer Foams, Articles And Coatings Prepared Therefrom and Methods of Making the Same

Abstract

A cellular foamed article is provided, including a polymeric foam material and a micro- or nano-sized reinforcement material embedded in the foam material. Also, methods of making a reinforced cellular foamed articles are provided, including preparing a dispersion comprising a reinforcement material and a polymer precursor; processing the reinforcement material so that it has a volume average length ranging from about average cross sectional diameter of from about 1 to about 500 nm and a volume average length of from about 10 nm to about 10 μm; reacting the polymer precursor to form a foamable polymer; and foaming the foamable polymer.

What is claimed is: 
     
         1 . A cellular foamed article, comprising:
 a polymeric foam material comprising cellular walls; and   a functionalized micro- or nano-sized reinforcement fiber material fully embedded in and constrained within the cellular walls of the polymeric foam material.   
     
     
         2 . The cellular foamed article of  claim 1 , wherein the reinforcement fiber material has an average cross sectional diameter of from 1 to 500 nm and a volume average length of from 10 nm to 10 μm. 
     
     
         3 . The cellular foamed article of  claim 1 , wherein the polymeric foam material comprises at least one polyurethane. 
     
     
         4 . The cellular foamed article of  claim 1 , wherein the reinforcement fiber material comprises a material selected from the group consisting of: aliphatic polyamides, polyesters, polyacrylonitriles, polyvinyl alcohols, polyolefins, polyvinyl chlorides, polyvinylidene chlorides, polyurethanes, polyfluorocarbons, phenolics, polybenzimidazoles, polyphenylenetriazoles, polyphenylene sulfides, polyoxadiazoles, polyimides, aromatic polyamides, and mixtures thereof. 
     
     
         5 . The cellular foamed article of  claim 1 , wherein the reinforcement fiber material is an aramid fiber. 
     
     
         6 . The cellular foamed article of  claim 1 , wherein the reinforcement fiber material is present in an amount of from 0.01 to 9.9 wt % based on the total weight of the foamed article. 
     
     
         7 . The cellular foamed article of  claim 6 , wherein the reinforcement fiber material is present in an amount of from 0.05 to 2.0 wt % based on the total weight of the foamed article. 
     
     
         8 . A polymer precursor dispersion for use in making a foamed cellular article, comprising:
 at least one polymer precursor comprising a polyol;   at least one blowing agent; and   a reinforcement fiber material,   wherein the reinforcement fiber material comprises from 0.01 to 9.9 wt % based on the total weight of the dispersion, and   wherein the reinforcement fiber material has been processed in the presence of the polymer precursor so that the reinforcement fiber material has an average cross sectional diameter of from 1 to 500 nm and a volume average length of from 10 nm to 10 μm.   
     
     
         9 . The polymer precursor dispersion of  claim 8 , wherein the reinforcement fiber material has a volume average length of from 10 nm to 4 μm. 
     
     
         10 . The polymer precursor dispersion of  claim 8 , wherein the reinforcement fiber material comprises a material selected from the group consisting of: aliphatic polyamides, polyesters, polyacrylonitriles, polyvinyl alcohols, polyolefins, polyvinyl chlorides, polyvinylidene chlorides, polyurethanes, polyfluorocarbons, phenolics, polybenzimidazoles, polyphenylenetriazoles, polyphenylene sulfides, polyoxadiazoles, polyimides, aromatic polyamides, and mixtures thereof. 
     
     
         11 . The polymer precursor dispersion of  claim 8 , wherein the reinforcement fiber material is an aramid fiber. 
     
     
         12 . The polymer precursor dispersion of  claim 8 , further comprising at least one surfactant and at least one catalyst. 
     
     
         13 . The polymer precursor dispersion of  claim 8 , wherein the viscosity of the dispersion at room temperature is between 100 and 100,000 centipoise. 
     
     
         14 . A foamed cellular product made from the polymer precursor dispersion of  claim 8 , wherein the reinforcement fiber material is fully embedded in and constrained within cellular walls of the foamed cellular product. 
     
     
         15 . A shaped foam article that is comprised of the foamed cellular product of  claim 14 . 
     
     
         16 . A method of making a reinforced cellular foamed article, comprising the steps of:
 preparing a dispersion comprising a reinforcement fiber material and a polymer precursor;   processing the reinforcement fiber material in the presence of the polymer precursor;   reacting the polymer precursor to form a foamable polymer; and   foaming the foamable polymer to form a reinforced cellular foamed article comprising the reinforcement fiber material fully embedded in and constrained within cellular walls of the reinforced cellular foamed article.   
     
     
         17 . The method of  claim 16 , wherein the reinforcement fiber material is processed to have an average cross sectional diameter of from 1 to 500 nm and a volume average length of from 10 nm to 10 μm. 
     
     
         18 . The method of  claim 17 , wherein the reinforcement fiber material is processed to have a volume average length of from 10 nm to 4 μm. 
     
     
         19 . The method of  claim 16 , wherein the processing step involves agitating and/or masticating the dispersion in the presence of a solid component. 
     
     
         20 . A reinforced cellular foamed article formed according to the method of  claim 16 . 
     
     
         21 . A method of making a reinforced cellular foamed article, comprising the steps of:
 preparing a dispersion comprising a polymer precursor and a precursor of a reinforcement fiber material;   forming a reinforcement fiber material in situ in the presence of the polymer precursor;   processing the reinforcement fiber material;   reacting the polymer precursor to form a foamable polymer; and   foaming the foamable polymer to form a reinforced cellular foamed article comprising the reinforcement fiber material fully embedded in and constrained within cellular walls of the reinforced cellular foamed article.   
     
     
         22 . The method of  claim 21 , wherein the reinforcement fiber material is processed to have an average cross sectional diameter of from 1 to 500 nm and a volume average length of from 10 nm to 10 μm. 
     
     
         23 . The method of  claim 22 , wherein the reinforcement fiber material is processed to have a volume average length of from about 10 nm to about 4 μm.