A review of the feasibility of lightening structural polymeric composites with voids without compromising mechanical properties.

High performance polymer-fiber composites are high strength, low weight materials that have many applications, many of which would benefit from a decrease in weight, without a decrease in material properties. Generally, the fibers serve as the main load carriers, while the matrix serves to distribute load and protect the fibers from the environment. Thus, it is postulated that if the volume fraction of matrix is reduced, while still ensuring complete wetting of the fibers by the matrix, the per unit weight, i.e., specific, mechanical properties could be improved. This can be done by introducing small, spherical bubbles. Given the small average inter-fiber distance and assuming that the bubbles must not interact with the surface of the reinforcements the bubble diameter would need to be less than 1 μm. Introducing bubbles this small and ensuring that they do not form, or become attached, on the surface of the reinforcement are significant challenges. Two methods to produce such bubbles and the effect of these bubbles on mechanical properties of neat resins are reviewed: the addition of hollow spherical fillers, called microballoons, and the creation of bubbles from blowing agents. Microballoons in resins are a class of materials called syntactic foams. Although commercial microballoons are too large, smaller diameters can be made and could be used to reduce the weight of a reinforced composite on the order of 10%. The use of a physical blowing agent to produce bubbles in a composite is also considered. However, traditional polymer foaming techniques may be inadequate, as nucleation on the reinforcing phase is likely, and the bubbles formed are generally too large, so the use of blowing agent wells is considered. Blowing agent wells are discontinuous regions made from copolymer micelles or immiscible polymers that act as reservoirs of blowing agent. Additionally, the use of nano-sized materials for use as heterogeneous nucleation sites and secondary reinforcement of the matrix is also considered. Bubbles made from blowing agent could reduce the weight slightly more than using hollow spheres, but the reduction would also be of the order of 10%.