Ultra-lightweight paper foams: processing and properties

A methodology for producing a low density cellulose-based foam has been developed by combining a surfactant with pulp, mixing at high velocity to entrain air, and then drying in a non-restrained fashion. The structure of the foam, characterized through optical microscopy and X-ray computed tomographic microscopy, consists of pulp fibres in random orientations surrounding air bubbles along with large void spaces. Through careful design of experiments, the effect of fibre type, length distribution, surfactant, and air content on the mechanical behavior and permeability of the foam material was investigated. The results indicate that foamed cellulose materials can be produced at a strength of one-half the tensile strength of a standard handsheet, but having a relative density of only one percent. No chemical additives were used to enhance the strength of these samples as the properties of the foam material are enhanced simply through variation of the process parameters. Thus, a strong cellulose-based foam, with a density as low as 10 mg/cm3, can be fabricated using standard papermaking infrastructure and hence at low cost.