The study of mechanical behavior and flame retardancy of castor oil phosphate-based rigid polyurethane foam composites containing expanded graphite and triethyl phosphate

A Review of Polyurethane Foams for Multi-Functional and High-Performance Applications

Polyurethane (PU) foams are cellular polymeric materials that have attracted much attention across various industries because of their versatile properties and potential for multifunctional applications. PU foams are involved in many innovations, especially in multi-functional and high-performance applications. Special attention is given to developing tailored PU foams for specific application needs. These foams have various applications including flame retardancy, sound absorption, radar absorption, EMI shielding, shape memory, and biomedical applications. The increasing demand for materials that can perform multiple functions while maintaining or enhancing their core properties has made PU foams a focal point of interest for engineers and researchers. This paper examines the challenges faced by the PU foam industry, particularly in developing multifunctional products, as well as the strategies for improving sustainability, such as producing PU foams from renewable resources and recycling existing materials.

Improving acoustic wave propagation models in highly attenuating porous materials

This article presents an improved and extended modeling approach for acoustic wave propagation in rigid porous materials, focusing on examples, such as plastic foams used for noise reduction in automotive applications. We demonstrate that the classical model (Johnson-Champoux-Allard) in the asymptotic high-frequency limit, widely employed in the literature, fails to accurately reconstruct the transmitted acoustic signal through high absorbent porous materials characterized by significant wave attenuation. The study focuses on the airborne ultrasonic frequency range (30-200 kHz). To address this limitation, we introduce new non-acoustic parameters Σ and V for viscous effects, and Σ' and V' for thermal effects, with surface and volumetric dimensions, respectively, allowing for the reconstruction of the transmitted signal and accurate modeling of the pronounced acoustic attenuation within the material. These parameters are incorporated into the expansion on skin depths of the dynamic tortuosity α(ω) and thermal tortuosity α' (ω) response functions, which describe the inertial-viscous and thermal interactions between the fluid and the solid, respectively. This novel modeling approach enables a more comprehensive study of high attenuating porous media, which are crucial for effective noise reduction. Additionally, it opens up new possibilities for characterization beyond the capabilities of current models.

Advancements in Flame-Retardant Systems for Rigid Polyurethane Foam

The amplified employment of rigid polyurethane foam (RPUF) has accentuated the importance of its flame-retardant properties in stimulating demand. Thus, a compelling research report is essential to scrutinize the recent progression in the field of the flame retardancy and smoke toxicity reduction of RPUF. This comprehensive analysis delves into the conventional and innovative trends in flame-retardant (FR) systems, comprising reactive-type FRs, additive-type FRs, inorganic nanoparticles, and protective coatings for flame resistance, and summarizes their impacts on the thermal stability, mechanical properties, and smoke toxicity suppression of the resultant foams. Nevertheless, there are still several challenges that require attention, such as the migration of additives, the insufficient interfacial compatibility between flame-retardant polyols or flame retardants and the RPUF matrix, and the complexity of achieving both flame retardancy and mechanical properties simultaneously. Moreover, future research should focus on utilizing functionalized precursors and developing biodegradable RPUF to promote sustainability and to expand the applications of polyurethane foam.

Effect of surface treatment on the technological properties of coconut fiber-reinforced plant polyurethane composites

Polymeric composites reinforced with plant fibers have numerous advantages, such as low cost, high raw material availability and good physical, mechanical and thermal properties. Thus, in recent years, they have been studied as thermal insulation substitutes for synthetic polymers in buildings. The aim of this study was to evaluate the technological properties of castor oil-based polyurethane composites reinforced with coconut fibers treated with hot water, alkaline solutions of NaOH and Ca(OH)₂ and corona discharge and without surface treatment as materials for the thermal insulation of buildings. The composites were produced by the hand lay-up method followed by compression; 10% by weight coconut fibers were used to replace the synthetic polymer. Specimens were produced, and physical, mechanical, thermal and microstructural tests were performed. The results showed that the polymer had a thermal conductivity of 0.016 W/(mK), while the composites produced with fibers treated with NaOH had a thermal conductivity of 0.028 W/(mK); therefore, these polymers are considered insulating materials (k = 0.01 to 1.0 W/(mK)). Thus, the composites produced with coconut fibers can be considered as lighter, less expensive and environmentally friendly alternatives to synthetic polymers.

Polyurethane foams from vegetable oil-based polyols: a review

Polyurethane is a versatile material that can be converted into various forms according to applications. PU foams or PUFs are the most commonly used polyurethanes. These are materials of low density and low thermal conductivity that make them highly suitable for thermal insulating applications. Most of the synthesis of PUFs is still based on the petrochemical industry. There are issues associated with the oil industry, such as environmental pollution, sustainability, and market instability. More recently, we have experienced the COVID-19 pandemic which has destroyed the global supply chain of raw materials. Such sudden disruption of the supply chain affects the global economy. To eliminate the reliance on special ingredients, it is important to find and produce alternate and domestic raw materials. Vegetable oils are organic, cost-effective, and economically viable and present in abundant amounts. The oil consists of triglycerides. It can be functionalized to provide polyol for PU foam synthesis. Herein, we review the literature on factors influencing the properties of PUFs depending on polyols from vegetable oil as well as present a glimpse of the conversion of vegetable oils into polyols for PUF synthesis.

Emerging trends in flame retardancy of rigid polyurethane foam and its composites: A review

Owing to the superior thermal insulating attributes of rigid polyurethane foam (RPUF) compared to other insulating materials (expanded and extruded polystyrene, mineral wool), it remains the most dominant insulating material and most studied polymer foam. Like other polyurethane foam, RPUF is highly flammable, necessitating the incorporation of flame retardants (FR) during production to lower combustibility, promoting its continuous use as insulation material in construction, transportation, and others. The popular approaches for correcting the high flammability of RPUF are copolymerization and blending (with FR). The second method has proven to be most effective as there are limited trade-offs in RPUF properties. Meanwhile, the high flammability of RPUF is still a significant hindrance in emerging applications (sensors, space travel, and others), and this has continuously inspired research in the flame retardancy of RPUF. In this study, properties, and preparation methods of RPUF are described, factors responsible for the high flammability of PUF are discussed, and flame retardancy of RPUF is thoroughly reviewed. Notably, most FR for RPUF are inorganic nanoparticles, lignin, intumescent FR systems of expandable graphite (EG), ammonium polyphosphate (APP), and hybridized APP or EG with other FR. These could be due to their ease of processing, low cost, and being environmentally benign. Elaborate discussion on RPUF FR mechanisms were also highlighted. Lastly, a summary and future perspectives in fireproofing RPUF are provided, which could inspire the design of new FR for RPUF.

Investigation of the Flame Retardant Properties of High-Strength Microcellular Flame Retardant/Polyurethane Composite Elastomers

Flame retardants (FRs) often reduce the mechanical properties of polymer materials, and FR/microcellular polyurethane elastomer (MPUE) composite materials have not been systemically studied. Hence, we conducted this study on FR/MPUE composites by using multiple liquid FRs and/or expandable graphite (EG). Compared with liquid flame retardants, the LOI of an expandable graphite/dimethyl methylphosphonate (EG/DMMP) (3:1) combination was significantly increased (~36.1%), and the vertical combustion grade reached V-0 without a dripping phenomenon. However, the corresponding tensile strength was decreased by 17.5%. With the incorporation of EG alone, although the corresponding LOI was not a match with that of DMMP/EG, there was no droplet phenomenon. In addition, even with 15 wt% of EG, there was no significant decline in the tensile strength. Cone calorimeter test results showed that PHRR, THR, PSPR, and TSR were significantly reduced, compared to the neat MPUE, when the EG content surpassed 10 wt%. The combustion process became more stable and thus the fire risk was highly reduced. It was found that flame retardancy and mechanical properties could be well balanced by adding EG alone. Our proposed strategy for synthesizing FR/MPUE composites with excellent flame retardancy and mechanical properties was easy, effective, low-cost and universal, which could have great practical significance in expanding the potential application fields of MPUEs.

Investigation of the relation between free volume and physico-mechanical performance in rigid polyurethane foam containing turkey feather fibers: Part 2

Rigid polyurethane foams (RPUFs) were modified with 0–15 wt.% turkey feather fibers (TFFs) produced from waste turkey feathers. One-shut free rising method was used for the production of TFFs-filled-RPUFs in a closed mold. The dependence of mechanical performance and water vapor permeability (WVP) feature of the final foams on TFFs loading was evaluated with free volume change. The free volume analysis was performed via Positron Annihilation Lifetime Spectroscopy (PALS), while the mechanical and WVP characteristics were determined with the use of the universal tester machines. PALS findings showed that the incorporation of TFFs with RPUF matrix caused the considerable diminishment in the free volume due to TFFs serving as a filling material and formation of strong secondary bonds between components. Moreover, tensile strength and extension of the foams decreased with the increasing of TFFs, which caused by the occurrence of noteworthy restriction on the spatial alignment and orientation capability of polyurethane chains due to the lack of sufficient free volume allowing the chains to move freely. As for the compression tests, all the TFFs-loaded RPUFs depicted substantially lower performance due to TFFs interfering with the ordered organization of isocyanate domains. Moreover, impact test results showed that the addition of TFFs into RPUF matrix brought about the insufficient impact energy delocalization throughout the matrix due to the restriction on the mobility of polymer chains. Additionally, the remarkable diminishment in WVP was recorded due to the reduction in the number of vacancies and constitution of keratin composed of roundly 60% of hydrophilic protein (especially cystine). All in all, this study established a strong links between free volume and characteristics of TFFs-loaded RPUFs.

Thermal Insulating Rigid Polyurethane Foams with Bio-Polyol from Rapeseed Oil Modified by Phosphorus Additive and Reactive Flame Retardants

In this article, rigid polyurethane foams obtained with the addition of a bio-polyol from rapeseed oil, were modified with the dimethyl propane phosphonate as additive flame retardant and two reactive flame retardants diethyl (hydroxymethyl)phosphonate and diethyl bis-(2-hydroxyethyl)-aminomethylphosphonate. The influence of used flame retardants on the foaming process and characteristic processing times of tested polyurethane systems were determined. The obtained foams were tested in terms of cell structure, physical and mechanical properties, as well as flammability. Modified foams had worse mechanical and thermal insulation properties, caused by lower cellular density and higher anisotropy coefficient in the cross-section parallel to the foam rise direction, compared to unmodified foam. However, the thermal conductivity of all tested foam materials was lower than 25.82 mW/m∙K. The applied modifiers effectively reduced the flammability of rigid polyurethane foams, among others, increasing the oxygen index above 21.4 vol.%, reducing the total heat released by about 41-51% and the rate of heat release by about 2-52%. A correlation between the limiting oxygen index values and both total heat released parameters from the pyrolysis combustion flow calorimetry and cone calorimetry was observed. The correlation was also visible between the value of the heat release capacity (HRC) parameter obtained from the pyrolysis combustion flow calorimetry and the maximum average rate of heat emission (MARHE) from the cone calorimeter test.

Self-Plasticized PVC Prepared by Introducing Fatty Acid to the PVC with Triglycidyl Isocyanurate as an Intermediate Bridge

The phthalate-free self-plasticization of poly(vinyl chloride) (PVC) conforms to the concept of green chemistry. In this work, phthalate-free, biocontaining, self-plasticized PVC with nonmigration (4-an-TG-X-PVC; X = R, P, or O) was prepared by covalent attachment of ricinoleic acid, palmitic acid, and oleic acid, respectively, to the PVC matrix with 4-aminothiophenol and triglycidyl isocyanurate (TGIC) as intermediate bridges. 4-Aminothiophenol and TGIC acted as the nucleophilic reagent and the thermally stable substance, respectively. The 4-an-TG-X-PVC was observed by diverse characterization methods. Specifically, Fourier transform infrared spectra, ¹H nuclear magnetic resonance, gel permeation chromatography, and migration stability tests proved the successful synthesis of 4-an-TG-X-PVC. Compared to the neat PVC, the mechanical property of 4-an-TG-X-PVC is better. The glass transition temperature (T _g) of PVC is 81.24 °C, while that of 4-an-TG-X-PVC decreased to 41.88, 31.49, and 46.91 °C. The 4-an-TG-X-PVC showed higher elongation at break and lower tensile strength than neat PVC. Simultaneously, the thermal property of 4-an-TG-X-PVC got a boost. Thermogravimetry-infrared and thermogravimetry-mass spectrometry showed that 4-an-TG-X-PVC released less HCl than neat PVC in a thermal environment. Discoloration experiments demonstrated that 4-an-TG-P-PVC had better heat stabilization and better color than 4-an-TG-O-PVC and 4-an-TG-R-PVC. This work provides a viable solution to the dependence on phthalates, reduced human health and ecological risks, and endowed PVC with improved thermal stability and nonmigration performance.

A Review of Rigid Polymeric Cellular Foams and Their Greener Tannin-Based Alternatives

This review focuses on the description of the main processes and materials used for the formulation of rigid polymer foams. Polyurethanes and their derivatives, as well as phenolic systems, are described, and their main components, foaming routes, end of life, and recycling are considered. Due to environmental concerns and the need to find bio-based alternatives for these products, special attention is given to a recent class of polymeric foams: tannin-based foams. In addition to their formulation and foaming procedures, their main structural, thermal, mechanical, and fire resistance properties are described in detail, with emphasis on their advanced applications and recycling routes. These systems have been shown to possess very interesting properties that allow them to be considered as potential substitutes for non-renewable rigid polymeric cellular foams.

A Systematic Review and Bibliometric Analysis of Flame-Retardant Rigid Polyurethane Foam from 1963 to 2021

Flame-retardant science and technology are sciences developed to prevent the occurrence of fire, meet the needs of social safety production, and protect people's lives and property. Rigid polyurethane (PU) is a polymer formed by the additional polymerization reaction of a molecule with two or more isocyanate functional groups with a polyol containing two or more reactive hydroxyl groups under a suitable catalyst and in an appropriate ratio. Rigid polyurethane foam (RPUF) is a foam-like material with a large contact area with oxygen when burning, resulting in rapid combustion. At the same time, RPUF produces a lot of toxic gases when burning and endangers human health. Improving the flame-retardant properties of RPUF is an important theme in flame-retardant science and technology. This review discusses the development of flame-retardant RPUF through the lens of bibliometrics. A total of 194 articles are analyzed, spanning from 1963 to 2021. We describe the development and focus of this theme at different stages. The various directions of this theme are discussed through keyword co-occurrence and clustering analysis. Finally, we provide reasonable perspectives about the future research direction of this theme based on the bibliometric results.

It Takes Two to Tango: Synergistic Expandable Graphite–Phosphorus Flame Retardant Combinations in Polyurethane Foams

Due to the high flammability and smoke toxicity of polyurethane foams (PUFs) during burning, distinct efficient combinations of flame retardants are demanded to improve the fire safety of PUFs in practical applications. This feature article focuses on one of the most impressive halogen-free combinations in PUFs: expandable graphite (EG) and phosphorus-based flame retardants (P-FRs). The synergistic effect of EG and P-FRs mainly superimposes the two modes of action, charring and maintaining a thermally insulating residue morphology, to bring effective flame retardancy to PUFs. Specific interactions between EG and P-FRs, including the agglutination of the fire residue consisting of expanded-graphite worms, yields an outstanding synergistic effect, making this approach the latest champion to fulfill the demanding requirements for flame-retarded PUFs. Current and future topics such as the increasing use of renewable feedstock are also discussed in this article.

Polyhydroxylated Nanosized Graphite as Multifunctional Building Block for Polyurethanes

Polyurethane nanocomposites were prepared with a nanosized high surface area graphite (HSAG) functionalized on its edges with hydroxyl groups as a building block. Edge functionalization of HSAG was obtained through reaction with KOH. The addition of OH groups was demonstrated by means of infrared (FTIR) and thermogravimetric analysis (TGA), and the Boehm titration allowed estimation of a level of about 5.0 mmol_OH/g_HSAG. Results from wide-angle X-ray diffraction (WAXD) and Raman spectroscopy suggested that functionalization of the graphene layers occurred on the edges. The evaluation of the Hansen solubility parameters of G-OH revealed a substantial increase of δ_P and δ_H parameters with respect to HSAG. In line with these findings, homogeneous and stable dispersions of G-OH in a polyol were obtained. PU were prepared by mixing a dispersion of G-OH in cis-1,4-butenediol with hexamethylene diisocyanate. A model reaction between catechol, 1,4-butanediol, and hexamethylene diisocyanate demonstrated the reactivity of hydroxylated aromatic rings with isocyanate groups. PU-based G-OH, characterized with WAXD and differential scanning calorimetry (DSC), revealed lower T_g, higher T_c, T_m, and crystallinity than PU without G-OH. These results could be due to the higher flexibility of the polymer chains, likely a consequence of the dilution of the urethane bonds by the carbon substrate. Hence, G-OH allowed the preparation of PU with a larger temperature range between T_g and T_m, with potential positive impact on material applications. The model reaction between butylisocyanate and 1-butanol revealed that HSAG and G-OH promote efficient formation of the urethane bond, even in the absence of a catalyst. The effect of high surface area carbon on the nucleophilic oxygen attack to the isocyanate group can be hypothesized. The results here reported lead us to comment that a reactive nanosized sp² carbon allotrope, such as G-OH, can be used as a multifunctional building block of PU. Indeed, G-OH is a comonomer of PU, a promoter of the polymerization reaction, and can definitely act as reinforcing filler by tuning its amount in the final nanocomposite leading to highly versatile materials. The larger temperature range between T_g and T_m, together with the presence of G-OH acting as a reinforcing agent, could allow the production of piezoresistive sensing, shape-memory PU with good mechanical features.

Fly Ash as an Eco-Friendly Filler for Rigid Polyurethane Foams Modification

There is currently a growing demand for more effective thermal insulation materials with the best performance properties. This research paper presents the investigation results on the influence of two types of filler on the structure and properties of rigid polyurethane foam composites. Fly ash as a product of coal combustion in power plants and microspheres of 5, 10, 15, and 20 wt.%, were used as rigid polyurethane foams modifiers. The results of thermal analysis, mechanical properties testing, and cellular structure investigation performed for polyurethane composites show that the addition of fly ash, up to 10 wt.%, significantly improved the majority of the tested parameters. The use of up to 20 wt.% of microspheres improves the mechanical and thermal properties and thermal stability of rigid polyurethane foams.

Inhibitory action of halogen-free fire retardants on combustion and volatile emission of bituminous components

The objective of this study is to quantitatively evaluate inhibitory action of halogen-free fire retardants (HFR) on combustion properties and volatile emission of such bituminous components as saturates, aromatics, resins, and asphaltenes (SARA). Thermogravimetry-Fourier transform infrared spectroscopy (TG-FTIR) tests were performed on SARA fractions containing matched fire retardants, respectively, and thermal kinetics parameters based on TG curves and functional and structural indices from FTIR spectra were calculated, respectively. The selected fire retardants have not affected the combustion process of SARA fractions, but the combustion temperature intervals are elevated and combustion progresses are retarded. Also, the char yields of SARA fractions are obviously increased by the matched fire retardants, improving their heat stability. The activation energy is elevated because of the added fire retardants, indicating combustion resistance of SARA fractions become larger. Additionally, the matched fire retardants inhibit the toxic gas emission in the combustion process of SARA fractions, but have few effects on gaseous product constituents. H2O and CO2 are identified as two typical released gases in various combustion phases of each SARA fraction. Finally, the added hydroxide play a role of fire retardants through cooling, dilution, adsorption, and neutralization, and the generated active oxide facilitates the expandable graphite (EG) and matrix to form densified and thick carbon layer. These suppress the volatile emission, and hinder the heat conduction and oxygen supply. Fire retardant composite exhibits the synergistic effect of fire retardancy and smoke inhibition in the combustion process of SARA fractions.

Effects of Various Types of Expandable Graphite and Blackcurrant Pomace on the Properties of Viscoelastic Polyurethane Foams

We investigated the effect of the type and amount of expandable graphite (EG) and blackcurrant pomace (BCP) on the flammability, thermal stability, mechanical properties, physical, and chemical structure of viscoelastic polyurethane foams (VEF). For this purpose, the polyurethane foams containing EG, BCP, and EG with BCP were obtained. The content of EG varied in the range of 3-15 per hundred polyols (php), while the BCP content was 30 php. Based on the obtained results, it was found that the additional introduction of BCPs into EG-containing composites allows for an additive effect in improving the functional properties of viscoelastic polyurethane foams. As a result, the composite containing 30 php of BCP and 15 php of EG with the largest particle size and expanded volume shows the largest change in the studied parameters (hardness (H) = 2.65 kPa (+16.2%), limiting oxygen index (LOI) = 26% (+44.4%), and peak heat release rate (pHRR) = 15.5 kW/m2 (-87.4%)). In addition, this composite was characterized by the highest char yield (m600 = 17.9% (+44.1%)). In turn, the change in mechanical properties is related to a change in the physical and chemical structure of the foams as indicated by scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FTIR) analysis.

Burning Behaviour of Rigid Polyurethane Foams with Histidine and Modified Graphene Oxide

Since rigid polyurethane (PU) foams are one of the most effective thermal insulation materials with widespread application, it is an urgent requirement to improve its fire retardancy and reduce the smoke emission. The current work assessed the fire behavior of PU foam with non-halogen fire retardants system, containing histidine (H) and modified graphene oxide (GO_A). For investigated system, three loadings (10, 20, and 30 wt.%) were used. The Fourier transform infrared spectroscopy (FT-IR), differential scanning calorimetry (DSC), thermogravimetric analysis, cone calorimetry (CC) and smoke density chamber tests as well as pre- and post-burning morphological evaluation using scanning electron microscope (SEM) were performed. Moreover, TGA combined with FT-IR was conducted to determine the substances, which could be evolved during the thermal decomposition of the PU with fire retardant system. The results indicated a reduction in heat release rate (HRR), maximum average rate of heat emission (MAHRE), the total heat release (THR) as well as the total smoke release (TSR), and maximum specific optical density (Ds_max) compared to the polyurethane with commercial fire retardant, namely ammonium polyphosphate (APP). A significantly improvement, especially in smoke suppression, suggested that HGO_A system may be a candidate as a fire retardant to reduce the flammability of PU foams.

Flame Retardancy of Biobased Composites-Research Development

Due to the thermal and fire sensitivity of polymer bio-composite materials, especially in the case of plant-based fillers applied for them, next to intensive research on the better mechanical performance of composites, it is extremely important to improve their reaction to fire. This is necessary due to the current widespread practical use of bio-based composites. The first part of this work relates to an overview of the most commonly used techniques and different approaches towards the increasing the fire resistance of petrochemical-based polymeric materials. The next few sections present commonly used methods of reducing the flammability of polymers and characterize the most frequently used compounds. It is highlighted that despite adverse health effects in animals and humans, some of mentioned fire retardants (such as halogenated organic derivatives e.g., hexabromocyclododecane, polybrominated diphenyl ether) are unfortunately also still in use, even for bio-composite materials. The most recent studies related to the development of the flame retardation of polymeric materials are then summarized. Particular attention is paid to the issue of flame retardation of bio-based polymer composites and the specifics of reducing the flammability of these materials. Strategies for retarding composites are discussed on examples of particular bio-polymers (such as: polylactide, polyhydroxyalkanoates or polyamide-11), as well as polymers obtained on the basis of natural raw materials (e.g., bio-based polyurethanes or bio-based epoxies). The advantages and disadvantages of these strategies, as well as the flame retardants used in them, are highlighted.

Enhanced Fire Safety of Rigid Polyurethane Foam via Synergistic Effect of Phosphorus/Nitrogen Compounds and Expandable Graphite

In order to explore highly efficient flame-retardant rigid polyurethane foam (RPUF), phosphorus/nitrogen compounds and expandable graphite (EG) were successfully incorporated into RPUF by a free one-spot method. The combustion results showed that the fire safety of the RPUF samples was remarkably improved by the addition of phosphoric/nitrogen compounds and EG. With the incorporation of 22.4 wt.% phosphorus/nitrogen compounds and 3.2 wt.% EG, the RPUF composites achieved UL-94 V-0 rating. Besides, the total heat release and total smoke release of RPUF composites were reduced by 29.6% and 32.4% respectively, compared to those of the pure RPUF sample. PO• and PO2• together with nonflammable gaseous products were evolved from phosphoric/nitrogen compounds in the gas phase, which quenched the flammable free radicals in the matrix and diluted the concentration of combustible gaseous products generated from PRUF during combustion. The compact char residues which acted as excellent physical barriers were formed by catalysis of EG and phosphoric/nitrogen compounds in the condense phase. The fire hazard of RPUF was significantly reduced by the synergistic effect of phosphorus-nitrogen compounds and EG. This work provides a promising strategy to enhance the fire safety of RPUF.

Preparation of Biomass-Based Ester End-Capped Hyperbranched Poly(ether)s via Facile One-Pot Reaction and Their Performance as Non-Toxic Plasticizers

The aim of this study was to develop a facile one-pot reaction for the synthesis of biomass-based hyperbranched poly(ether)s end-capped as acetate esters (BHE) for use as a sustainable, safe and feasible plasticizer for flexible poly(vinyl chloride) (PVC) materials. BHE is completely miscible with PVC but shows weaker plasticizing effect than dioctyl phthalate (DOP) (EΔTg value of BHE reaches 64.8%). PVC plasticized with BHE displays greater thermal stability than that of PVC or PVC plasticized with DOP materials. BHE improves the thermal stability and flexibility of PVC materials. As a plasticizer, BHE displays lower solvent extractability and greater volatilization resistance than DOP. Acute oral toxicity indicates that BHE has toxic doses of 5 g/kg, suggesting that BHE is non-toxic.

Study on the Structure-Property Dependences of Rigid PUR-PIR Foams Obtained from Marine Biomass-Based Biopolyol

The paper describes the preparation and characterization of rigid polyurethane-polyisocyanurate (PUR-PIR) foams obtained with biopolyol synthesized in the process of liquefaction of biomass from the Baltic Sea. The obtained foams differed in the content of biopolyol in polyol mixture (0–30 wt%) and the isocyanate index (I_ISO = 200, 250, and 300). The prepared foams were characterized in terms of processing parameters (processing times, synthesis temperature), physical (sol fraction content, apparent density) and chemical structure (Fourier transform infrared spectroscopy), microstructure (computer microtomography), as well as mechanical (compressive strength, dynamic mechanical analysis), and thermal properties (thermogravimetric analysis, thermal conductivity coefficient). The influence of biopolyol and I_ISO content on the above properties was determined. The addition of up to 30 wt% of biopolyol increased the reactivity of the polyol mixture, and the obtained foams showed enhanced mechanical, thermal, and insulating properties compared to foams prepared solely with petrochemical polyol. The addition of up to 30 wt% of biopolyol did not significantly affect the chemical structure and average cell size. With the increase in I_ISO, a slight decrease in processing times and mechanical properties was observed. As expected, foams with higher I_ISO exhibited a higher relative concentration of polyisocyanurate groups in their chemical structure, which was confirmed using principal component analysis (PCA).

Highly Effective Flame-Retardant Rigid Polyurethane Foams: Fabrication and Applications in Inhibition of Coal Combustion

The extemporaneous combustion of coal remains a major threat to safety in coal mines because such fire accidents result in casualties and significant property loss, as well as serious environmental pollution. This work proposed the fabrication of flame-retardant rigid polyurethane foam (RPUF) containing expandable graphite as char expander/sealant with melamine phosphosphate and 2-carboxyethyl (phenyl)phosphinic acid as char inducer and radical trapping agents. The as-prepared RPUF successfully inhibited coal combustion by forming thermally stable high graphitic content expandable intumescent char sealing over the coal. The RPUF achieved UL-94 V-0 rating in addition to significant reductions in peak heat release, total heat release, and CO and CO₂ yields. The external and the internal residual char structure was studied by X-ray photoelectron spectra, Raman spectroscopy, and real-time Fourier transform infrared spectra techniques, and a flame-retardant mode of action has been proposed. This work provides important insight into a facile fabrication of highly efficient and economical flame-retardant RPUF to inhibit the spontaneous combustion of coal.

The Use of Waste from the Production of Rapeseed Oil for Obtaining of New Polyurethane Composites

This article presents the results of research on obtaining new polyurethane materials modified by a by-product from vegetable oils industry—rapeseed cake. The chemical composition of rapeseed cake was examined. Rigid polyurethane-polyisocyanurate (RPU/PIR) foams containing a milled rapeseed cake in their composition were obtained as part of the conducted research. Biofiller was added in amount of 30 wt.% up to 60 wt.%. Effects of rapeseed cake on the foaming process, cell structure and selected properties of foams, such as apparent density, compressive strength, brittleness, flammability, absorbability, water absorption, thermal resistance and thermal conductivity are described. The foaming process of RPU/PIR foams modified by rapeseed cake was characterized by a lower reactivity, lower foaming temperature and decrease in dielectric polarization. This resulted in a slowed formation of the polyurethane matrix. Apparent density of RPU/PIR foams with biofiller was higher than in unmodified foam. Addition of rapeseed cake did not have a significant influence on the thermal conductivity of obtained materials. However, we observed a tendency for opening the cells of modified foams and obtaining a smaller cross-sectional area of cells. This led to an increase of absorbability and water absorption of obtained materials. However, an advantageous effect of using rapeseed cake in polyurethane formulations was noted. Modified RPU/PIR foams had higher compressive strength, lower brittleness and lower flammability than reference foam.

Thermal stability and flame retardancy of an epoxy resin modified with phosphoric triamide and glycidyl POSS

Phosphoric triamide (PTA) and glycidyl polyhedral oligomeric silsesquioxane (POSS) were simultaneously incorporated into the cured network of a bisphenol F epoxy resin and 4,4′-diaminodiphenyl methane (DDM) to improve the thermal stability and flame retardancy. PTA was synthesized by triethyl phosphate and DDM, and its chemical structure was confirmed by 1H nuclear magnetic resonance (NMR) and Fourier transform infrared (FTIR). The differential scanning calorimetric (DSC) results showed that the introduction of PTA and POSS slightly increased the glass transition temperature of the epoxy resin. The thermogravimetric analysis results indicated that compared with the pure, phosphoric, and silicic epoxy resins, the modified epoxy resin possessed the lowest weight loss rate and highest char residue. Its limiting oxygen index value was as high as 30.5, and the UL-94 grade reached V-1. A decomposition test was carried out to obtain sufficient char residue and investigate the condensed mechanism. The scanning electron microscopic images demonstrated that the char residue of the modified epoxy resin had a compact structure. The energy dispersive X-ray and FTIR analyses verified the synergistic effect of the phosphorus and silicon in the PTA and POSS, respectively, on the epoxy resin.

Plant polyphenol-inspired nano-engineering topological and chemical structures of commercial sponge surface for oils/organic solvents clean-up and recovery

In our study, plant polyphenol-inspired chemistry is explored to nano-engineer the topological and chemical structures of commercial melamine sponge surface for preparing superhydrophobic sponges. Briefly, tannic acid (TA, a typical plant polyphenol) is applied to induce the co-assembly of silica nanoparticles (SiO₂) and silver ions (Ag⁺) to form SiO₂@TA@Ag nanostructures on a melamine sponge surface. After further chemical fluorination, the superhydrophobic sponge with a "lotus leaf-mimic" surface is formed. Surface topological/chemical structures, superhydrophobic property and anti-combustion characteristics of the sponge are examined by a series of characterization techniques, including scanning electron microscopy, X-ray photoelectron spectroscopy, water contact angle measurements, combustion/heating test, etc. The superhydrophobic sponge presents an adsorption capacity of 69-153 times of its own weight toward various oils/organic solvents, and exhibits excellent recycling ability evidenced by over 100-cycled uses. Continuous oil/water separation apparatus is also set up through equipping the superhydrophobic sponge on a peristaltic pump, realizing the clean-up of oils and organic solvents from water continuously. Together with the facile, easy-to-scale-up and substrate non-selective features of plant polyphenol-inspired chemistry, the superhydrophobic sponge and the surface nano-engineering method would hold great promise for the effective treatment of oil spillages and organic discharges, achieving high sustainability to energy and environment.

Composites of Rigid Polyurethane Foams Reinforced with POSS

Rigid polyurethane foams (RPUFs) were successfully modified with different weight ratios (0.5 wt%, 1.5 wt% and 5 wt%) of APIB-POSS and AEAPIB-POSS. The resulting foams were evaluated by their processing parameters, morphology (Scanning Electron Microscopy analysis, SEM), mechanical properties (compressive test, three-point bending test and impact strength), viscoelastic behavior (Dynamic Mechanical Analysis, DMA), thermal properties (Thermogravimetric Analysis, TGA, and thermal conductivity) and application properties (contact angle, water absorption and dimensional analysis). The results showed that the morphology of modified foams is significantly affected by the type of the filler and filler content, which resulted in inhomogeneous, irregular, large cell shapes and further affected the physical and mechanical properties of resulting materials. RPUFs modified with APIB-POSS represent better mechanical and thermal properties compared to the RPUFs modified with AEAPIB-POSS. The results showed that the best results were obtained for RPUFs modified with 0.5 wt% of APIB-POSS. For example, in comparison with unfilled foam, compositions modified with 0.5 wt% of APIB-POSS provide greater compression strength, better flexural strength and lower water absorption.

Influence of the Characteristics of Expandable Graphite on the Morphology, Thermal Properties, Fire Behaviour and Compression Performance of a Rigid Polyurethane Foam

Three types of expandable graphite (EG) differing in particle size and expansion volume, are compared as flame retardant additives to rigid polyurethane foams (RPUFs). In this paper we discuss microstructure, thermal stability, fire behavior, and compression performance. We find that ell size distributions were less homogeneous and cell size was reduced. Furthermore, thermal conductivity increased along with EG loading. Thermogravimetric analysis (TGA) showed that EG only increased residue yield differently. The results indicate that a higher expansion of EG increased the limiting oxygen index (LOI) value, whereas a bigger particle size EG improved the rating of the vertical burning test (UL94). Results from the cone calorimeter test showed that a bigger particle size EG effectively reduced peak of heat release rate (pHRR). Furthermore, a higher expansion, led to a decrease in smoke production (TSP). The combination of both characteristics gives extraordinary results. The physical–mechanical characterization of the EG/RPUF foams revealed that their compression performance decreased slightly, mostly due to the effect of a bigger size EG.

Polyurethane Foams: Past, Present, and Future

Polymeric foams can be found virtually everywhere due to their advantageous properties compared with counterparts materials. Possibly the most important class of polymeric foams are polyurethane foams (PUFs), as their low density and thermal conductivity combined with their interesting mechanical properties make them excellent thermal and sound insulators, as well as structural and comfort materials. Despite the broad range of applications, the production of PUFs is still highly petroleum-dependent, so this industry must adapt to ever more strict regulations and rigorous consumers. In that sense, the well-established raw materials and process technologies can face a turning point in the near future, due to the need of using renewable raw materials and new process technologies, such as three-dimensional (3D) printing. In this work, the fundamental aspects of the production of PUFs are reviewed, the new challenges that the PUFs industry are expected to confront regarding process methodologies in the near future are outlined, and some alternatives are also presented. Then, the strategies for the improvement of PUFs sustainability, including recycling, and the enhancement of their properties are discussed.