The morphology of rigid polyurethane foam matrix and its evolution with time during foaming - New insight by cryogenic scanning electron microscopy

A time-resolved investigation at multiple-length scales of the structure of liquid foam stabilized by albumins from pea

HYPOTHESIS

The structural details of foams made with pea albumins are affected by the pH of the initial solution and followed heat treatment.

EXPERIMENTS

An in situ, time-resolved investigation of foams prepared with pea albumins was conducted using small-angle neutron scattering (SANS) in combination with imaging and conductance measurements. Solutions were tested at pH three pH values (3, 4.5, and 8) before and after heating (90 °C for 1 and 5 min).

FINDINGS

The characteristic structures present in the foam from the nano to the meso-scale differed during drainage depending on solution pH. Foams obtained at pH 3, had the largest bubble radius and thinnest plateau border, as well as the highest extent of liquid drainage. At pH 4.5, close to the isoelectric point of the proteins, foams displayed similar bubbles' behavior to those at pH 8, but with the largest film thickness. In this case, the proteins were extensively aggregated. Heating of the solutions prior to foaming did not significantly affect the foam aging regardless of pH. The quantification of specific surface areas and film thickness over time without sample disruption shows to be a powerful approach to designing foam structures.

Injectable and in situ foaming shape-adaptive porous Bio-based polyurethane scaffold used for cartilage regeneration

Irregular articular cartilage injury is a common type of joint trauma, often resulting from intense impacts and other factors that lead to irregularly shaped wounds, the limited regenerative capacity of cartilage and the mismatched shape of the scaffods have contributed to unsatisfactory therapeutic outcomes. While injectable materials are a traditional solution to adapt to irregular cartilage defects, they have limitations, and injectable materials often lack the porous microstructures favorable for the rapid proliferation of cartilage cells. In this study, an injectable porous polyurethane scaffold named PU-BDO-Gelatin-Foam (PUBGF) was prepared. After injection into cartilage defects, PUBGF forms in situ at the site of the defect and exhibits a dynamic microstructure during the initial two weeks. This dynamic microstructure endows the scaffold with the ability to retain substances within its interior, thereby enhancing its capacity to promote chondrogenesis. Furthermore, the chondral repair efficacy of PUBGF was validated by directly injecting it into rat articular cartilage injury sites. The injectable PUBGF scaffold demonstrates a superior potential for promoting the repair of cartilage defects when compared to traditional porous polyurethane scaffolds. The substance retention ability of this injectable porous scaffold makes it a promising option for clinical applications.

Valorization of Agricultural Rice Straw as a Sustainable Feedstock for Rigid Polyurethane/Polyisocyanurate Foam Production

Agricultural rice straw (RS), often discarded as waste in farmlands, represents a vast and underutilized resource. This study explores the valorization of RS as a potential feedstock for rigid polyurethane/polyisocyanurate foam (RPUF) production. The process begins with the liquefaction of RS to create an RS-based polyol, which is then used in a modified foam formulation to prepare RPUFs. The resulting RPUF samples were comprehensively characterized according to their physical, mechanical, and thermal properties. The results demonstrated that up to 50% by weight of petroleum-based polyol can be substituted with RS-based polyol to produce a highly functional RPUF. The obtained foams exhibited a notably low apparent density of 18-24 kg/m3, exceptional thermal conductivity ranging from 0.031-0.041 W/m-K, and a high compressive strength exceeding 250 kPa. This study underlines the potential of the undervalued agricultural RS as a green alternative to petroleum-based feedstocks to produce a high-value RPUF. Additionally, the findings contribute to the sustainable utilization of abundant agricultural waste while offering an eco-friendly option for various applications, including construction materials and insulation.

Development of an Innovative Lightweight Composite Material with Thermal Insulation Properties Based on Cardoon and Polyurethane

The search for innovative and sustainable solutions to improve the energy efficiency of the construction industry has been a hot topic for researchers due to the tremendous impact of insulator materials in the thermal comfort of buildings. In the present work, an innovative lightweight composite material with thermal insulation properties was developed, for the first time, by using cardoon particles and polyurethane. The formulation of the composite material was optimized in terms of cardoon fraction and the polyol/isocyanate ratio, to achieve the best compromise between internal bond (IB) strength and thickness swelling (TS). The best performing composite was PU75-CP45, with 45 wt% of cardoon particles and 75% of isocyanate, achieving an IB of 0.41 MPa and a TS of 5.3%. Regarding insulation properties, the PU75-CP45 composite material exhibits a promising performance when compared to conventional construction industry materials by tuning its thickness. Additionally, the composite material presented very low emissions of volatile organic compounds and formaldehyde (bellow to legislation levels) and high resistance to biological degradation.

Directing the pore size of rigid polyurethane foam via controlled air entrainment

The interest in polyurethane rigid (PUR) foams as potent thermally insulating materials for a wide range of applications continues to grow as the minimization of CO2 emissions has become a global issue. Controlling the thermal insulation efficiency of PUR foams starts with the control of their morphology. Although the presence of micrometric air bubbles originating from air entrainment during the blending of the PU reactive mixture has been shown to influence the final PUR foam morphology, detailed experimental investigations on how exactly they affect the final PUR foam pore size are still lacking. To fill this gap, we use a double-syringe mixing device, which allows to control the number of air bubbles generated during a first air entrainment step, before using the same device to blend the reactive components in a sealed environment, avoiding further air entrainment. Keeping all experimental parameters constant except for the air bubble density in the reactive mixture, we can correlate changes of the final PUR foam morphology with the variation of the air bubble density in the initially liquid reactive mixture. Our results confirm recent findings which suggest the presence of two different regimes of bubble nucleation and growth depending on the presence or absence of dispersed air bubbles in the liquid reactive mixture. Our study pushes those insights further by demonstrating an inverse relation between the air bubble density in the liquid reactive mixture and the final pore volume of the PUR foam. For example, at constant chemical formulation and blending conditions, we could vary the final pore size between 400–1600 μm simply by controlling the amount of pre-dispersed air bubbles within the system. We are confident that the presented approach may not only provide a valuable model experiment to scan formulations in R&D laboratories, but it may also provide suggestions for the optimization of industrial processes.

Production and Application of Polymer Foams Employing Supercritical Carbon Dioxide

Polymeric foams have characteristics that make them attractive for different applications. However, some foaming methods rely on chemicals that are not environmentally friendly. One of the possibilities to tackle the environmental issue is to utilize supercritical carbon dioxide ScCO2 since it is a “green” solvent, thus facilitating a sustainable method of producing foams. ScCO2 is nontoxic, chemically inert, and soluble in molten plastic. It can act as a plasticizer, decreasing the viscosity of polymers according to temperature and pressure. Most foam processes can benefit from ScCO2 since the methods rely on nucleation, growth, and expansion mechanisms. Process considerations such as pretreatment, temperature, pressure, pressure drop, and diffusion time are relevant parameters for foaming. Other variables such as additives, fillers, and chain extenders also play a role in the foaming process. This review highlights the morphology, performance, and features of the foam produced with ScCO2, considering relevant aspects of replacing or introducing a novel foam. Recent findings related to foaming assisted by ScCO2 and how processing parameters influence the foam product are addressed. In addition, we discuss possible applications where foams have significant benefits. This review shows the recent progress and possibilities of ScCO2 in processing polymer foams.

Impact of Diisocyanates on Morphological and In Vitro Biological Efficacy of Eco-Friendly Castor-Oil-Based Water-Borne Polyurethane Dispersions

The search for renewable resources that can replace petroleum products is not only nerve-wracking, but also perplexing, as there is an abundance of plants that have yet to be explored. In this project, virgin castor oil was converted to polyol in two steps: epoxidation and hydroxylation. The resulting polyol was used to synthesize two series of water-borne polyurethane dispersions (WPUDs). The effects of the diisocyanates on the final product were evaluated. Isophorone diisocyanate (IPDI) and dicyclohexylmethane-4,4'-diisocyanate (H₁₂MDI) were used as the hard segment (HS) up to 72 wt%, along with 1-4 butanediol (BD) as the chain extender, for the dispersions. Fourier transform infrared spectroscopy (FTIR) confirmed the bonds required for the synthesis of the dispersions. Thermogravimetric analysis (TGA) showed the multistep degradation for both series: maximum degradation took place at 500 °C for IPDI and 600 °C for H₁₂MDI-based series. Scanning electron microscopy (SEM) showed phase-segmented morphology. Hemolytic activity was observed at biologically safe levels of up to 7.5% for H₁₂MDI-based series. Inhibition of biofilm formation showed comparable results against Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus): up to 46%. The results were also confirmed by phase contrast microscopy.

Role of Air Bubble Inclusion on Polyurethane Reaction Kinetics

In this study, we investigated the influence of mixing conditions on the foaming process of water blown polyurethane (PU) foams obtained at different mixing speeds (50, 500, 1000 and 2000 rpm). In particular, the morphological evolution during the foaming process, in terms of the bubble size and bubble density, was studied via optical observations, while the effects on the reaction kinetics were monitored using in situ FTIR spectroscopy. At the slow mixing speed (50 rpm), no air bubbles were included and the early foaming process was characterized by the formation of new bubbles (CO₂ nucleation), provided by the blowing reaction. Later on, it was observed that the coalescence affected the overall foaming process, caused by the gelling reaction, which was inhibited by the indigent mixing conditions and could not withstand the bubbles expansion. As a result, a PU foam with a coarse cellular structure and an average bubble size of 173 µm was obtained. In this case, the bubbles degeneration rate, dN/dt, was −3095 bubble·cm⁻³·s⁻¹. On the contrary, at 500 rpm, air bubbles were included into the PU reaction system (aeration) and no formation of new bubbles was observed during the foaming process. After this, the air bubbles underwent growth caused by diffusion of the CO₂ provided by the blowing reaction. As the gelling reaction was not strongly depleted as in the case at 50 rpm, the coalescence less affected the bubble growth (dN/dt = −2654 bubble·cm⁻³·s⁻¹), leading to a PU foam with an average bubble size of 94 µm. For the foams obtained at 1000 and 2000 rpm, the bubble degeneration was first affected by coalescence and then by Ostwald ripening, and a finer cellular structure was observed (with average bubble sizes of 62 µm and 63 µm for 1000 rpm and 2000 rpm, respectively). During the first foaming stage, the coalescence was less predominant in the bubble growth (with dN/dt values of −1838 bubble·cm⁻³·s⁻¹ and −1601 bubble·cm⁻³·s⁻¹, respectively) compared to 50 rpm and 500 rpm. This occurrence was ascribed to the more balanced process between the bubble expansion and the PU polymerization caused by the more suitable mixing conditions. During the late foaming stage, the Ostwald ripening was only responsible for the further bubble degeneration (with dN/dt values of −89 bubble·cm⁻³·s⁻¹ and −69 bubble·cm⁻³·s⁻¹, respectively).

Application of Colloidal Dispersions of Bioshell Calcium Oxide (BiSCaO) for Disinfection

Bioshell calcium oxide (BiSCaO) is a scallop-shell powder heated at a high temperature. BiSCaO is composed mainly of calcium oxide and exhibits broad microbicidal properties. The aim of this study is to evaluate the disinfection and decontamination abilities of BiSCaO colloidal dispersions with that of commercially available bioshell calcium hydroxide (BiSCa(OH)2) following the formation of flocculants/precipitates under strongly alkaline conditions (pH 11.5-12.2). Various concentrations of BiSCaO and BiSCa(OH)2 colloidal dispersions were prepared by mixing with Na-polyPO4 (PP) and Na-triPO4 (TP) as flocculating agents. The microbicidal activities, and the degree of flocculation/precipitation of trypan blue, albumin, chondroitin sulfate, heparin, non-anticoagulant heparin carrying polystyrene (NAC-HCPS), and low-molecular-weight heparin/protamine nanoparticles (LMWH/P NPs) were dependent on the pH, the average particle diameter, and the concentration of BiSCaO or BiSCa(OH)2 and of the phosphate compound. BiSCaO (average particle diameter: 6 μm) colloidal dispersions (0.2 wt.%) containing 0.15 wt.% PP or TP exhibited substantially stronger microbicidal activity and flocculation/precipitation under strongly alkaline conditions. These results suggest that BiSCaO colloidal dispersions together with phosphate compounds have practical applicability for disinfection.