Cellulose fibre foam templated porous epoxy composites: Wetting matters

Cellulose foams were used to produce porous epoxy-composites. The influence of fibre wetting by the resins on foam morphology and resulting compression properties was investigated. Impregnated foam morphology determined the composite structures and their mechanical properties. Fibre preforms of various densities (40–80 kg·m⁻³) were prepared by frothing surfactant stabilised fibre suspensions. The preforms, exhibiting compressive strengths of 0.02 MPa, were impregnated with three different resins (a lignin-based resin BLER/MA, and two commercial formulations, A/A and A/XB). Depending on the formation of closed- or open-cell structures in the cured foam composites, compressive strengths of up to 2 MPa (BLER/MA), 33 MPa (A/A), or 23 MPa (A/XB), and compressive moduli of up to 47 MPa (BLER/MA), 468 MPa (A/A), or 379 MPa (A/XB) were obtained. The surface area, fibre coverage homogeneity, and composite morphology were investigated in relation to wetting. A tool kit for fibre foam templated porous composite design is provided.