Fabrication of rigid poly(lactic acid) foams via thermally induced phase separation

Abstract Rigid poly(lactic acid) (PLA) foams were prepared by thermally induced phase separation followed by solvent exchange and vacuum drying. A novel tetrahydrofuran (THF)/water solvent system was used for the induction of liquid-liquid phase separation of PLA solution at three different temperatures; 24 °C, 4 °C and −20 °C. PLA gels obtained were mechanically stabilized by replacing THF/water solvent mixture with ethanol nonsolvent. Characterization of rigid PLA foams was obtained by scanning electron microscopy, mercury intrusion porosimetry, x-ray diffractometry, infrared spectroscopy and differential scanning calorimetry analyses. Effects of fabrication parameters on the morphology and pore structure were systematically examined. The parameters investigated included; (i) polymer concentration, (ii) THF/water ratio and (iii) quench temperature. Results showed that degree of porosity and the morphology of the pores, such as the pore size and shape could be controlled by tuning the fabrication parameters. By controlling the degree of phase separation of PLA solution, foams with dual micro and nano structures were obtained.