Incomparable hardness and modulus of biomimetic porous polyurethane films prepared by directional melt crystallization of a solvent

Porous materials with surprisingly diverse structures have been utilized in nature for many functional purposes. However, the structures and applications of porous man-made polymer materials have been limited by the use of processing techniques involving foaming agents. Herein, we demonstrate for the first time the outstanding hardness and modulus properties of an elastomer that originate from the novel processing approach applied. Polyurethane films of 100-μm thickness with biomimetic ordered porous structures were prepared using directional melt crystallization of a solvent and exhibited hardness and modulus values that were 6.8 and 4.3 times higher than those of the random pore structure, respectively. These values surpass the theoretical prediction of the typical model for porous materials, which works reasonably well for random pores but not for directional pores. Both the ordered and random pore structures exhibited similar porosities and pore sizes, which decreased with increasing solution concentration. This unexpectedly significant improvement of the hardness and modulus could open up new application areas for porous polymeric materials using this relatively novel processing technique.