Expanded Polycarbonate (EPC)—A New Generation of High-Temperature Engineering Bead Foams

Bead foams serve in a wide variety of applications, from insulation and packaging to midsoles in shoes. However, the currently used materials are limited to somewhat low temperature or exhibit significant changes in modulus in the temperature range of many applications due to their glass transition. By comparison, polycarbonate (PC) exhibits almost constant mechanics for temperatures up to 130 °C. Therefore, it appears as an advantageous base material for bead foams. The aim of the publication is to provide comprehensive data on the properties of expanded PC (EPC) in comparison to already commercially available expanded polypropylene, EPP, and expanded polyethylene-terephthalate, EPET. A special focus is set on the thermo-mechanical properties as these are the most lacking features in current materials. In this frame, dynamic mechanical analysis, and tensile, bending, compression and impact tests at room temperature (RT), 80 °C, and 110 °C are conducted for the three materials of the same density. Already at RT, EPC exhibits superior mechanics compared to its peers, which becomes more pronounced toward higher temperature. This comes from the low sensitivity of properties to temperature as EPC is used below its glass transition. In summary, EPC proves to be an outstanding foam material over a broad range of temperatures for structural applications.