Analysis of the foam-forming of non-woven lightweight fibrous materials using X-ray tomography

Foam-forming has in the past predominantly been used to create two-dimensional sheet-like fibrous materials. Allowing the foam to drain freely and decay under gravity, rather than applying a vacuum to remove it rapidly, we can produce lightweight three-dimensional fibrous structures from cellulose fibres, of potential use for thermal and acoustic insulation. μCT scanning of the fibrous materials enable us to determine both void size distributions and also distributions of fibre orientations. Through image analysis and uniaxial compression testing, we find that the orientation of the fibres, rather than the size of the voids, determine the compressive strength of the material. The fibrous samples display a layering of the fibres perpendicular to the direction of drainage of the precursor liquid foam. This leads to an anisotropy of the compressive behaviour of the samples. Varying the initial liquid fraction of the foam allows for tuning of the compressive strength. We show an increase in over seven times can be achieved for samples of the same density (13 kg.m^-3).