Exceptional pore size distribution in foam-formed fibre networks

Foam forming leads to sheet structures with exceptional volume of large pores. The link between fibre network structure and foam properties is investigated by comparing pore structure with measured bubble-size distribution. In foams produced by mechanical mixing, higher rotor speed leads to smaller average bubble size, whereas the effects coming from air content and surfactant are smaller and non-systematic. A significant drop in the average bubble size is seen when mixing fibres to foam. In sheets made with foam forming, there are more large pores compared to the water formed sheets. The size of these pores is affected by the sizes of the bubbles in the foam. Overall, pore size distribution is more strongly affected by the fibre type than by small changes in bubble size distribution.