While hollow glass microspheres are commonly used in syntactic foam, their abrasive and brittle properties usually result in poor processability and have adverse effects on the foam performance. Therefore, a number of attempts have been made in the industry to replace hollow glass microspheres with polymeric foamed microspheres. Among many choices, expandable thermoplastic (ETP) microspheres filled syntactic foam has shown its high potential to become a novel class of engineering materials, especially for lightweight structural applications. However, conventional processing techniques for syntactic foam usually experience difficulties such as high processing viscosity, low loading of foam fillers, and ineffective microsphere expansion. To address these emerging issues, a microwave expansion process to produce thermoset-matrix syntactic foam containing thermoplastic foam beads was developed in this thesis work. In this process, unexpanded ETP microspheres were directly foamed in uncured thermoset matrix via microwave heating. Expandable polystyrene (EPS) microspheres and epoxy resin were chosen as a model material system. The resin viscosity and specific microwave energy are found to be the two primary control parameters determining the process window. Mechanical characterization showed that the syntactic foam can outweigh neat polymer in lightweight structural applications and was effectively toughened by foamed EPS. Furthermore, the microwave expansion process was found to be capable of molding syntactic foam parts of relatively sophisticated geometry with smooth surfaces. In order to broaden its impact, the microwave expansion process was extended to produce composite EPS foam. This process converts an expandable suspension into a composite foam with a honeycomb-like barrier structure. The suspension viscosity was found to highly influence the foam morphology. Results from mechanical tests showed that the existence of the barrier structure can considerably improve the mechanical performance of the composite foam. Fire-retardation tests demonstrated that the barrier structure can effectively stop the fire path into the foam, suppress toxic smoke generation, and maintain foam structure integrity. A general formulation was developed to model the EPS expansion to optimize the microwave expansion process. A semi-analytical solution was first obtained based on the case of a single bubble expansion in an infinite matrix. The dimensionless bubble radius and pressure are defined and found to be as exponential functions of dimensionless expansion time. The semi-analytical solution can qualitatively predict the radial expansion of EPS microsphere observed in a real-time experiment. To have an accurate prediction, a numerical solution was obtained to the model that couples the nucleation and expansion of multiple bubbles in a finite matrix. The results show that the numerical solution can quantitatively predict the radial expansion of EPS. A parameter sensitivity study was performed to examine the effect of each parameter over the expansion process.

Dans le cadre des procédés de clarification d'eau de surface, les flocs formés au cours des étapes de coagulation et de floculation peuvent être séparés de l'eau traitée par décantation ou par flottation. Dans ce dernier cas, le procédé actuellement en vigueur est la flottation à air dissous et présente un certain nombre d'inconvénients. Ainsi, dans ce contexte, la présente thèse consiste à développer un matériau innovant, à la fois flottant et floculant, pour une application dans un procédé de flottation sans air. Dans un premier temps, l'élaboration de billes de polystyrène expansibles utilisant l'eau ou l'éthanol comme agent gonflant a été réalisée. D'autres billes ont ensuite été préparées en présence de 4-(chlorométhyl)styrène comme co-monomère puis la polymérisation par transfert d'atome amorcée en surface (SI-ATRP) de l'acrylamide a été effectuée avec succès. L'impossibilité d'expanser ces matériaux a ensuite conduit à l'exploration de nouvelles voies de synthèse avec la fonctionnalisation de matériaux flottants existants par des techniques de « grafting from » ou « grafting onto ». Quelle que soit la voie envisagée, la première étape a consisté à réduire les fonctions nitrile en amine primaire en présence d'hydrure d'aluminium lithium. Après fonctionnalisation par du bromure de bromoisobutyryle ou du chlorure d'acryloyle, il a été possible de venir greffer de l'acrylamide par SI-ATRP ou de l'amidon via un amorceur redox, respectivement. Les matériaux flottants/floculants obtenus ont été testés lors de flottatests. Les meilleurs résultats ont été obtenus avec les microsphères fonctionnalisées par de l'amidon anionique. Ces dernières ont permis d'abattre la turbidité de l'eau, ont ensuite été régénérées avec succès, par des bains d'acide oxalique ou de dithionite de sodium, et employées durant plusieurs cycles flottatest/régénération avec des résultats reproductibles. / At the end of clarification process, after coagulation-flocculation steps, flocs can be removed from treated water by settling or flotation. In the latter case, Dissolved Air Flotation is the currently used process. However, this method showed important drawbacks, especially an important energetic cost due to the production of air saturated water. In that context, the goal of the reported work dealt with achieving air-free flotation using innovative floating materials. First of all, the synthesis of expandable polystyrene beads using water or ethanol as blowing agent was investigated. Other beads containing both styrene and 4-(chloromethyl)styrene were prepared. Then, surface initiated atom transfer radical polymerization of acrylamide (SI-ATRP) was achieved. Unfortunately, the expansion of such materials was not possible. Therefore, the second part focused on the functionalization of Expancel beads by “grafting from” or “grafting onto” techniques. The first step consisted in reducing some nitrile functions at the surface into primary amine ones. After functionalization with bromoisobutyryl bromide, the SI-ATRP of acrylamide was performed in water at room temperature. On the other hand, the acryloyl chloride was grafted onto amine functions, and grafting of starch was achieved using a redox initiator. All materials obtained have been used for flocculation/flotation tests and demonstrated satisfactory performances in terms of turbidity removal. Beads functionalized with starch have been successfully regenerated with oxalic acid and sodium dithionite and kept appropriate efficiency during several flotation/regeneration cycles.