Abstract
Abstract A method is described for preparing composite foam using expandable PAN-based microspheres reinforced with continuous fibers. Composite foams were produced by mixing expanded and non-expanded microspheres in select proportions, packing the dry microspheres into a fibrous preform in a closed mold, and heating the assembly to expand and weld the microspheres and fibers together. The composite foams exhibited mechanical performance and formability that surpassed the unreinforced foams. The tensile modulus and strength were increased by 750 and 400% respectively, and showed enhanced resistance to crack propagation compared with unreinforced foam samples. The improvement in compression properties was modest by comparison (
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