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Khudaida SH, Yen SK, Su CS. The Application of Box-Behnken Design for Investigating the Supercritical CO 2 Foaming Process: A Case Study of Thermoplastic Polyurethane 85A. Molecules 2024; 29:363. [PMID: 38257276 PMCID: PMC10820427 DOI: 10.3390/molecules29020363] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/01/2023] [Revised: 01/04/2024] [Accepted: 01/08/2024] [Indexed: 01/24/2024] Open
Abstract
Thermoplastic polyurethane (TPU) is a versatile polymer with unique characteristics such as flexibility, rigidity, elasticity, and adjustable properties by controlling its soft and hard segments. To properly design and understand the TPU foaming process through supercritical CO2, a design of experiments approach, the Box-Behnken design (BBD) was adopted using commercial TPU 85A as the model compound. The effect of saturation pressure, saturation temperature, and immersion time on the mean pore size and expansion ratio were investigated. The design space for the production of TPU foam was shown, and the significance of process parameters was confirmed using the analysis of variance (ANOVA). In addition, extrapolation foaming experiments were designed and validated the feasibility of the response surface model developed via BBD. It was found that the pore size of TPU 85A foam could be controlled within 13 to 60 μm, and a stable expansion ratio could be designed up to six.
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Affiliation(s)
| | | | - Chie-Shaan Su
- Department of Chemical Engineering and Biotechnology, National Taipei University of Technology, Taipei 10608, Taiwan; (S.H.K.)
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2
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Chen B, Jiang J, Li Y, Zhou M, Wang Z, Wang L, Zhai W. Supercritical Fluid Microcellular Foaming of High-Hardness TPU via a Pressure-Quenching Process: Restricted Foam Expansion Controlled by Matrix Modulus and Thermal Degradation. MOLECULES (BASEL, SWITZERLAND) 2022; 27:molecules27248911. [PMID: 36558060 PMCID: PMC9783504 DOI: 10.3390/molecules27248911] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/22/2022] [Revised: 12/08/2022] [Accepted: 12/09/2022] [Indexed: 12/23/2022]
Abstract
High-hardness thermoplastic polyurethane (HD-TPU) presents a high matrix modulus, low-temperature durability, and remarkable abrasion resistance, and has been used in many advanced applications. However, the fabrication of microcellular HD-TPU foam is rarely reported in the literature. In this study, the foaming behavior of HD-TPU with a hardness of 75D was investigated via a pressure-quenching foaming process using CO2 as a blowing agent. Microcellular HD-TPU foam with a maximum expansion ratio of 3.9-fold, a cell size of 25.9 μm, and cell density of 7.8 × 108 cells/cm3 was prepared, where a high optimum foaming temperature of about 170 °C had to be applied with the aim of softening the polymer's matrix modulus. However, the foaming behavior of HD-TPU deteriorated when the foaming temperature further increased to 180 °C, characterized by the presence of coalesced cells, microcracks, and a high foam density of 1.0 g/cm3 even though the crystal domains still existed within the matrix. The cell morphology evolution of HD-TPU foam was investigated by adjusting the saturation time, and an obvious degradation occurred during the high-temperature saturation process. A cell growth mechanism of HD-TPU foams in degradation environments was proposed to explain this phenomenon based on the gas escape through the defective matrix.
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Affiliation(s)
- Bichi Chen
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
| | - Junjie Jiang
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China
- University of Chinese Academy of Sciences, Beijing 100049, China
| | - Yaozong Li
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
| | - Mengnan Zhou
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
| | - Zelin Wang
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
| | - Liang Wang
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
| | - Wentao Zhai
- School of Materials Science and Engineering, Sun Yat-sen University, Guangzhou 510275, China
- Correspondence: ; Tel./Fax: +86-020-8411-3428
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Lu J, Zhang H, Chen Y, Ge Y, Liu T. Effect of chain relaxation on the shrinkage behavior of TPEE foams fabricated with supercritical CO2. POLYMER 2022. [DOI: 10.1016/j.polymer.2022.125262] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/15/2022]
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4
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Wang H, Peng X, Liu F, Song X, Wang H, Geng L, Huang A. Facile preparation of super lightweight and highly elastic thermoplastic polyurethane bead blend foam with microporous segregated network structure for good interfacial adhesion. J Supercrit Fluids 2022. [DOI: 10.1016/j.supflu.2022.105568] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/24/2023]
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5
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Preparation of Microcellular Foams by Supercritical Carbon Dioxide: A Case Study of Thermoplastic Polyurethane 70A. Processes (Basel) 2021. [DOI: 10.3390/pr9091650] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
In this study, a case study to produce microcellular foam of a commercial thermoplastic polyurethane (TPU) through the supercritical carbon dioxide (CO2) foaming process is presented. To explore the feasibility of TPU in medical device and biomedical application, a soft TPU with Shore hardness value of 70A was selected as the model compound. The effects of saturation temperature and saturation pressure ranging from 90 to 140 °C and 90 to 110 bar on the expansion ratio, cell size and cell density of the TPU foam were compared and discussed. Regarding the expansion ratio, the effect of saturation temperature was considerable and an intermediate saturation temperature of 100 °C was favorable to produce TPU microcellular foam with a high expansion ratio. On the other hand, the mean pore size and cell density of TPU foam can be efficiently manipulated by adjusting the saturation pressure. A high saturation pressure was beneficial to obtain TPU foam with small mean pore size and high cell density. This case study shows that the expansion ratio of TPU microcellular foam could be designed as high as 4.4. The cell size and cell density could be controlled within 12–40 μm and 5.0 × 107–1.3 × 109 cells/cm3, respectively.
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Jiang J, Liu F, Yang X, Xiong Z, Liu H, Xu D, Zhai W. Evolution of ordered structure of TPU in high-elastic state and their influences on the autoclave foaming of TPU and inter-bead bonding of expanded TPU beads. POLYMER 2021. [DOI: 10.1016/j.polymer.2021.123872] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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7
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Effect of extrusion on the foaming behavior of thermoplastic polyurethane with different hard segments. JOURNAL OF POLYMER RESEARCH 2021. [DOI: 10.1007/s10965-021-02604-z] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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8
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Affiliation(s)
- Wentao Zhai
- School of Materials Science and Engineering, Sun Yat-Sen University, Guangzhou, Guangdong Province, China
| | - Junjie Jiang
- School of Materials Science and Engineering, Sun Yat-Sen University, Guangzhou, Guangdong Province, China
- Ningbo Key Lab of Polymer Materials, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, Zhejiang Province, China
| | - Chul B. Park
- Microcellular Plastics Manufacturing Laboratory, Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, Ontario, Canada
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9
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Compression Molding of Thermoplastic Polyurethane Foam Sheets with Beads Expanded by Supercritical CO 2 Foaming. Polymers (Basel) 2021; 13:polym13040656. [PMID: 33671823 PMCID: PMC7926550 DOI: 10.3390/polym13040656] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/18/2021] [Revised: 02/16/2021] [Accepted: 02/19/2021] [Indexed: 11/17/2022] Open
Abstract
Expanded thermoplastic polyurethane (ETPU) beads were prepared by a supercritical CO2 foaming process and compression molded to manufacture foam sheets. The effect of the cell structure of the foamed beads on the properties of the foam sheets was studied. Higher foaming pressure resulted in a greater number of cells and thus, smaller cell size, while increasing the foaming temperature at a fixed pressure lowered the viscosity to result in fewer cells and a larger cell size, increasing the expansion ratio of the ETPU. Although the processing window in which the cell structure of the ETPU beads can be maintained was very limited compared to that of steam chest molding, compression molding of ETPU beads to produce foam sheets was possible by controlling the compression pressure and temperature to obtain sintering of the bead surfaces. Properties of the foam sheets are influenced by the expansion ratio of the beads and the increase in the expansion ratio increased the foam resilience, decreased the hardness, and increased the tensile strength and elongation at break.
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Hydrogen bonding and topological network effects on optimizing thermoplastic polyurethane/organic montmorillonite nanocomposite foam. POLYMER 2021. [DOI: 10.1016/j.polymer.2020.123159] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
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Batı B, Küçük EB, Durmuş A, Nofar M. Microcellular foaming behavior of ether- and ester-based TPUs blown with supercritical CO2. JOURNAL OF POLYMER ENGINEERING 2020. [DOI: 10.1515/polyeng-2020-0014] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
The bead foaming behavior of ether- and an ester-based Tensor Processing Unit (TPU) resins were investigated in a lab-scale reactor using supercritical CO2 as the blowing agent. The samples were saturated at various saturation temperatures and the effects of hard segment crystallization during the saturation on the foaming behavior of the TPU samples were explored. The results revealed that the different HS crystallization tendencies and possible CO2 solubility differences in two TPU grades led to their different foaming behaviors. The ester-based TPU could be foamed within a wider saturation temperature range and revealed an easier cell growth and foam expansion while the ether-based TPU showed a more limited cell growth behavior and hence processing window. The effect of pre-annealing and hence the isothermally induced HS crystallization on the foaming behavior of the ether-based TPU and the influence of depressurization rate on the foaming behavior of ester-based TPU was also explored.
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Affiliation(s)
- Bige Batı
- Polymer Science and Technology Program, Institute of Science and Technology, Istanbul Technical University , Maslak , Istanbul , 34469 , Turkey
| | - Emine Büşra Küçük
- Polymer Science and Technology Program, Institute of Science and Technology, Istanbul Technical University , Maslak , Istanbul , 34469 , Turkey
| | - Ali Durmuş
- Department of Chemical Engineering, Faculty of Engineering , Istanbul University-Cerrahpasa , Avcılar , Istanbul , 34320 , Turkey
| | - Mohammadreza Nofar
- Polymer Science and Technology Program, Institute of Science and Technology, Istanbul Technical University , Maslak , Istanbul , 34469 , Turkey
- Metallurgical and Materials Engineering Department, Faculty of Chemical and Metallurgical Engineering , Istanbul Technical University , Maslak , Istanbul , 34469 , Turkey
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Nofar M, Batı B, Küçük EB, Jalali A. Effect of soft segment molecular weight on the microcellular foaming behavior of TPU using supercritical CO2. J Supercrit Fluids 2020. [DOI: 10.1016/j.supflu.2020.104816] [Citation(s) in RCA: 30] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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13
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Long Y, An J, Xie X. CO2-releasing blowing agents from modified polyethylenimines slightly consume isocyanate groups while foaming polyurethanes. ARAB J CHEM 2020. [DOI: 10.1016/j.arabjc.2018.10.007] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022] Open
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Nofar M, Büşra Küçük E, Batı B. Effect of hard segment content on the microcellular foaming behavior of TPU using supercritical CO2. J Supercrit Fluids 2019. [DOI: 10.1016/j.supflu.2019.104590] [Citation(s) in RCA: 38] [Impact Index Per Article: 7.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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16
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Chang J, Lin Y, Chen W, Tian F, Chen P, Zhao J, Li L. Structural origin for the strain rate dependence of mechanical response of fluoroelastomer F2314. ACTA ACUST UNITED AC 2019. [DOI: 10.1002/polb.24817] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Jiarui Chang
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
| | - Yuanfei Lin
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
- South China Advanced Institute for Soft Matter Science and TechnologySouth China University of Technology Guangzhou 510640 China
| | - Wei Chen
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
| | - Fucheng Tian
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
| | - Pinzhang Chen
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
| | - Jingyun Zhao
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
| | - Liangbin Li
- National Synchrotron Radiation Laboratory, CAS Key Laboratory of Soft Matter Chemistry, Anhui Provincial Engineering Laboratory of Advanced Functional Polymer FilmUniversity of Science and Technology of China Hefei 230026 China
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Standau T, Hädelt B, Schreier P, Altstädt V. Development of a Bead Foam from an Engineering Polymer with Addition of Chain Extender: Expanded Polybutylene Terephthalate. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b04799] [Citation(s) in RCA: 31] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Tobias Standau
- Lehrstuhl für Polymere Werkstoffe, University of Bayreuth, Universitätsstraße 30, 95447 Bayreuth, Germany
| | - Bianca Hädelt
- Lehrstuhl für Polymere Werkstoffe, University of Bayreuth, Universitätsstraße 30, 95447 Bayreuth, Germany
| | - Peter Schreier
- Neue Materialien Bayreuth GmbH, Gottlieb-Keim-Straße 60, 95448 Bayreuth, Germany
| | - Volker Altstädt
- Lehrstuhl für Polymere Werkstoffe, University of Bayreuth, Universitätsstraße 30, 95447 Bayreuth, Germany
- Neue Materialien Bayreuth GmbH, Gottlieb-Keim-Straße 60, 95448 Bayreuth, Germany
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Surface Response Methodology-Based Mixture Design to Study the Influence of Polyol Blend Composition on Polyurethanes' Properties. Molecules 2018; 23:molecules23081942. [PMID: 30081493 PMCID: PMC6222905 DOI: 10.3390/molecules23081942] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2018] [Revised: 07/23/2018] [Accepted: 07/25/2018] [Indexed: 11/16/2022] Open
Abstract
Polyurethanes are materials with a strong structure-property relationship. The goal of this research was to study the effect of a polyol blend composition of polyurethanes on its properties using a mixture design and setting mathematic models for each property. Water absorption, hydrolytic degradation, contact angle, tensile strength hardness and modulus were studied. Additionally, thermal stability was studied by thermogravimetric analysis. Area under the curve was used to evaluate the effect of polyol blend composition on thermal stability and kinetics of water absorption and hydrolytic degradation. Least squares were used to calculate the regression coefficients. Models for the properties were significant, and lack of fit was not (p < 0.05). Fit statistics suggest both good fitting and prediction. Water absorption, hydrolytic degradation and contact angle were mediated by the hydrophilic nature of the polyols. Tensile strength, modulus and hardness could be regulated by the PE content and the characteristics of polyols. Regression of DTG curves from thermal analysis showed improvement of thermal stability with the increase of PCL and PE. An ANOVA test of the model terms demonstrated that three component influences on bulk properties like water absorption, hydrolytic degradation, hardness, tensile strength and modulus. The PEG*PCL interaction influences on the contact angle, which is a surface property. Mixture design application allowed for an understanding of the structure-property relationship through mathematic models.
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