Comparative Study of the Foaming Behavior of Ethylene–Vinyl Acetate Copolymer Foams Fabricated Using Chemical and Physical Foaming Processes

Abstract

Ethylene–vinyl acetate copolymer (EVA), a crucial elastomeric resin, finds extensive application in the footwear industry. Conventional chemical foaming agents, including azodicarbonamide and 4,4′-oxybis(benzenesulfonyl hydrazide), have been identified as environmentally problematic. Hence, this study explores the potential of physical foaming of EVA using supercritical nitrogen as a sustainable alternative, garnering considerable interest in both academia and industry. The EVA formulations and processing parameters were optimized and EVA foams with densities between 0.15 and 0.25 g/cm3 were produced. Key findings demonstrate that physical foaming not only reduces environmental impact but also enhances product quality by a uniform cell structure with small cell size (50–100 μm), a wide foaming temperature window (120–180 °C), and lower energy consumption. The research further elucidates the mechanisms of cell nucleation and growth within the crosslinked EVA network, highlighting the critical role of blowing agent dispersion and localized crosslinking around nucleated cells in defining the foam’s cellular morphology. These findings offer valuable insights for producing EVA foams with a more controllable cellular structure, utilizing physical foaming techniques.