Characterization of hard-segment crystalline phase of thermoplastic polyurethane in the presence of butane and glycerol monosterate and its impact on mechanical property and microcellular morphology

Toughening Self-Healing Elastomers with Chain Mobility

Enhancing fracture toughness and self-healing within soft elastomers is crucial to prolonging the operational lifetimes of soft devices. Herein, it is revealed that tuning the polymer chain mobilities of carboxylated-functionalized polyurethane through incorporating plasticizers or thermal treatment can enhance these properties. Self-healing is promoted as polymer chains gain greater mobility toward the broken interface to reassociate their bonds. Raising the temperature from 80 to 120 °C, the recovered work of fracture is increased from 2.86 to 123.7 MJ m-3. Improved fracture toughness is realized through two effects. First, strong carboxyl hydrogen bonds dissipate large energies when broken. Second, chain mobilities enable the redistribution of localized stress concentrations to allow crack blunting, enlarging the size of dissipation zones. At optimal conditions of plasticizers (3 wt.%) or temperature (40 °C) to promote chain mobilities, fracture toughness improves from 16.3 to 19.9 and 25.6 kJ m-2, respectively. Insights of fracture properties at healed soft interfaces are revealed through double cantilever beam tests. These measurements indicate that fracture mechanics play a critical role in delaying complete failure at partial self-healing. By imparting optimal polymer chain mobilities within tough and self-healing elastomers, effective prevention against damage and better recovery are realized.

Failure Analysis of Abnormal Cracking of the Track Circuit Reader Antenna Baffle for High-Speed Trains

The track circuit reader (TCR) is an important part of train control systems. This paper reports a failure of the TCR antenna baffle, which is used to prevent the TCR antenna from being struck by foreign objects. The designed service life of the baffle is 4.8 million kilometers, but serious cracking was found during routine maintenance after only 0.67 million kilometers of operation. In order to avoid the hidden danger brought by the incident to the safe operation of the train, it is necessary to conduct a complete failure analysis of the failed TCR antenna baffle. Therefore, a comprehensive investigation of the base material, cleaning agents, crack morphologies, etc., was carried out, and the failure environment of the antenna baffle was verified by experiment. The final results show that the environmental stress cracking is the root cause of the failed antenna baffle, and the multiple bubbles produced by the formed process of the antenna baffle are another important cause. According to the conclusions, the solutions to prevent the reoccurrence of such failures are proposed. After these solutions are adopted, the number of failed antenna baffles is greatly reduced, which fully proves the correctness of this analysis.

Synthesis and properties of bio-based thermoplastic poly(ether urethane) for soft actuators

In this study, bio-based thermoplastic polyurethane (TPU) for use in soft actuators is bio-based poly(ether-urethane) made using fermented corn, along with bio-derived compounds such as propane-1,3-diol (PDO) as a chain extender. Bio-based TPUs were obtained through a solvent-free one-shot synthesis method, and the effects of varying the [NCO]/[OH] molar ratio and type of isocyanates on chemical structure, thermal stability, and mechanical properties were investigated. The degree of phase separation (DPS) and state of hard segment (HS) / soft segment (SS) of TPU are important factors affecting the thermal and physical properties of the prepared film. These properties depend on the [NCO]/[OH] molar ratio and the type of isocyanates used for polymerization. The results showed that, when aromatic isocyanate was used, the degree of separation of the HS/SS was improved as the molar ratio increased. The average molecular weight and DPS as well as thermal and mechanical properties of 1-isocyanato-4-[(4-isocyanatophenyl)methyl]benzene (MDI)-based TPU samples are all higher than those of 1,1’-methylenebis(4-isocyanatocyclohexane) (H12MDI)-based TPU samples in spite of the lower HS content. These findings of this study are expected to contribute to the preparation of fused deposition modeling (FDM) 3D printing or 4D printing for shape memory polymer from bio-based TPU filaments for use in soft actuators with a shore hardness range of 59~84A.

Development of thermoplastic vulcanizates based on in situ synthesized thermoplastic polyurethane and acrylonitrile-butadiene rubber: the influence of the curing system

We prepared different thermoplastic elastomers (TPEs) using an internal mixer. We investigated the properties of thermoplastic polyurethanes (TPUs) produced from prepolymers with various isocyanate content and two different chain extenders to select the most appropriate TPU matrix for preparing thermoplastic vulcanizates (TPVs). Based on the results, we selected a prepolymer with moderate isocyanate content (10%) and the more flexible 1,6-hexanediol as a chain extender and prepared TPVs by dynamic vulcanization with in situ produced TPU. The rubber phase was acrylonitrile-butadiene rubber (NBR) with peroxidic and sulfuric curing with different accelerators. Dynamical mechanical analysis (DMA) results show that the room temperature storage modulus of the TPVs decreases due to the rubber phase. The TPU/NBR-CBS TPV with delayed action accelerator yields the highest tensile and tear strength and elongation at break. TPU/NBR-DCP made with a peroxide-based rubber blend shows similar tensile strength with significantly lower elongation at break and tear strength. The good mechanical properties of TPU/NBR-CBS can be explained by the long induction period, which allowed the rubber phase to disperse before vulcanization took place. In the TPU/NBR-DCP, the peroxide formed bonds not only in the rubber phase but also between the rubber and TPU phases, which is manifested in the high mixing torque and the result of the thermogravimetric analysis (TGA).

Facile Fabrication of Highly Sensitive Thermoplastic Polyurethane Sensors with Surface- and Interface-Impregnated 3D Conductive Networks

This research aims to develop a practical, scalable, and highly conductive flexible 3D printed piezoresistive sensor with low filler content. Here, we introduced a fused deposition modeling 3D printing combined in situ spray-coating technique to develop a conductive sensor in a single shot. The graphene suspension is sprayed over each layer during the 3D printing of the sensor, which helps develop a conductive network on the surface and at the interface of the printed system. Graphene deposited on the overall surface is often affected by nanoparticle delamination and loses its function over time. To avoid this, the prepared samples are subjected to foaming. The foaming process created a low-mass-density sensor by forming a microcellular structure, and the surface-deposited graphene is embedded well on the TPU surface. The method followed in this work reveals a stable and connected conduction path with excellent electrical resistance and resistance against harsh conditions (exposure to organic solvents). Besides, the compression sensor withstood its sensitivity over a severe compressive strain of 80% and showed a GF of 1.82 and a sensitivity of 2.316 kPa^-1. The conductive network path varied based on the infill pattern, affecting its electrical sensitivity. The wiggle pattern shows good resistance; under stretching, the pattern generated a higher current and showed a delayed conductive path disconnection than other patterns. Thus, the embedded graphene/TPU conductive sensors show good stability and promising sensitivity. Furthermore, the developed sensor is used to monitor human motion and actions.

Microstructural evidence of the toughening mechanisms of polyurethane reinforced with halloysite nanotubes under high strain-rate tensile loading

In this study, we have investigated the relationship between the spherulitic morphology and the dynamic tensile response of polyurethane reinforced with Halloysite nanotubes (HNTs). The polyurethane prepolymer is partially silane end-capped and filled with only 0.8 wt.% of acid-treated Halloysite nanotubes. The resultant nanocomposite material presents a 35% higher spall strength compared to the neat polyurethane and 21% higher fracture toughness. We show evidence that the HNTs are not the toughening phase in the nanocomposite, but rather it is their influence on the resultant spherulitic structures which alters the polymer microstructure and leads to a tougher dynamic response. Microstructural characterization is performed via Scanning Electron Microscopy, Atomic Force Microscopy and Field Emission Scanning Electron Microscopy, and crystallinity examination via X-ray diffraction. The spherulitic structures present a brittle fracture character, while the interspherulitic regions are more ductile and show large deformation. The nanocomposite presents a finer and more rigid spherulitic structure, and a more energy dissipative fracture mechanism characterized by a rougher fracture surface with highly deformed interspherulitic regions.

Influence of microstructural variations on morphology and separation properties of polybutadiene-based polyurethanes

Polybutadiene-based polyurethanes with different cis/trans/1,2-vinyl microstructure contents are synthesized. The phase morphology and physical properties of the polymers are investigated using spectroscopic analysis (FTIR and Raman), differential scanning calorimetry (DSC), X-ray scattering (WAXD and SAXS) and atomic force microscopy (AFM). In addition, their gas transport properties are determined for different gases at 4 bar and 25 °C. Thermodynamic incompatibility and steric hindrance of pendant groups are the dominant factors affecting the morphology and properties of the PUs. FTIR spectra, DSC, and SAXS analysis reveal a higher extent of phase mixing in high vinyl-content PUs. Moreover, the SAXS analysis and AFM phase images indicate smaller microdomains by increasing the vinyl content. Smaller permeable soft domains as well as the lower phase separation of the PUs with higher vinyl content create more tortuous pathways for gas molecules and deteriorate the gas permeability of the membranes.

Microcellular foaming behavior of ether- and ester-based TPUs blown with supercritical CO2

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.

Thermoplastic Dynamic Vulcanizates with In Situ Synthesized Segmented Polyurethane Matrix

The aim of this paper was the detailed investigation of the properties of one-shot bulk polymerized thermoplastic polyurethanes (TPUs) produced with different processing temperatures and the properties of thermoplastic dynamic vulcanizates (TDVs) made by utilizing such in situ synthetized TPUs as their matrix polymer. We combined TPUs and conventional crosslinked rubbers in order to create TDVs by dynamic vulcanization in an internal mixer. The rubber phase was based on three different rubber types: acrylonitrile butadiene rubber (NBR), carboxylated acrylonitrile butadiene rubber (XNBR), and epoxidized natural rubber (ENR). Our goal was to investigate the effect of different processing conditions and material combinations on the properties of the resulting TDVs with the opportunity of improving the interfacial connection between the two phases by chemically bonding the crosslinked rubber phase to the TPU matrix. Therefore, the matrix TPU was synthesized in situ during compounding from diisocyanate, diol, and polyol in parallel with the dynamic vulcanization of the rubber mixture. The mechanical properties were examined by tensile and dynamical mechanical analysis (DMTA) tests. The morphology of the resulting TDVs was studied by atomic force microscopy (AFM) and scanning electron microscopy (SEM) and the thermal properties by differential scanning calorimetry (DSC). Based on these results, the initial temperature of 125 °C is the most suitable for the production of TDVs. Based on the atomic force micrographs, it can be assumed that phase separation occurred in the TPU matrix and we managed to evenly distribute the rubber phase in the TDVs. However, based on the SEM images, these dispersed rubber particles tended to agglomerate and form a quasi-continuous secondary phase where rubber particles were held together by secondary forces (dipole–dipole and hydrogen bonding) and can be broken up reversibly by heat and/or shear. In terms of mechanical properties, the TDVs we produced are on a par with commercially available TDVs with similar hardness.

Preparation of Thermoplastic Polyurethane (TPU) Perforated Membrane via CO2 Foaming and Its Particle Separation Performance

The way in which a perforated structure is formed has attracted much interest in the porous membrane research community. This novel structure gives materials an excellent antifouling property as well as a low operating pressure and other benefits. Unfortunately, the current membrane fabrication methods usually involve multi-step processes and the use of organic solvents or additives. Our study is the first to offer a way to prepare perforated membrane by using a physical foaming technique with CO2 as the blowing agent. We selected thermoplastic polyurethane (TPU) as the base material because it is a biocompatible elastomer with excellent tensility, high abrasion resistance, and good elastic resilience. Various processing parameters, which included the saturation pressure, the foaming temperature, and the membrane thickness, were applied to adjust the TPU membrane's perforated morphology. We proposed a possible formation mechanism of the perforated membrane. The as-prepared TPU membrane had good mechanical properties with a tensile strength of about 5 MPa and an elongation at break above 100%. Such mechanical properties make this novel membrane usable as a self-standing filter device. In addition, its straight-through channel structure can separate particles and meet different separation requirements.

Preparation and Characterization of Isosorbide-Based Self-Healable Polyurethane Elastomers with Thermally Reversible Bonds

Polyurethane (PU) is a versatile polymer used in a wide range of applications. Recently, imparting PU with self-healing properties has attracted much interest to improve the product durability. The self-healing mechanism conceivably occurs through the existence of dynamic reversible bonds over a specific temperature range. The present study investigates the self-healing properties of 1,4:3,6-dianhydrohexitol-based PUs prepared from a prepolymer of poly(tetra-methylene ether glycol) and 4,4'-methylenebis(phenyl isocyanate) with different chain extenders (isosorbide or isomannide). PU with the conventional chain extender 1,4-butanediol was prepared for comparison. The urethane bonds in 1,4:3,6-dianhydrohexitol-based PUs were thermally reversible (as confirmed by the generation of isocyanate peaks observed by Fourier transform infrared spectroscopy) at mildly elevated temperatures and the PUs showed good mechanical properties. Especially the isosorbide-based polyurethane showed potential self-healing ability under mild heat treatment, as observed in reprocessing tests. It is inferred that isosorbide, bio-based bicyclic diol, can be employed as an efficient chain extender of polyurethane prepolymers to improve self-healing properties of polyurethane elastomers via reversible features of the urethane bonds.

Highly exfoliated montmorillonite clay reinforced thermoplastic polyurethane elastomer:in situpreparation and efficient strengthening

Highly exfoliated montmorillonite (MMT) clay reinforced thermoplastic polyurethane elastomers (TPUs) were prepared by an in situ solution polymerization method. By using small amount of 4,4′-methylenediphenyl diisocyanate (MDI) modified pristine clay (MDI-MMT) as fillers, the mechanical properties of TPUs were greatly improved. For example, with the addition of only 1.0 wt% of MDI-MMT, the resultant TPU/MDI-MMT nanocomposites showed approximately 36% increase in initial Young's modulus, 70% increase in tensile strength and 46% increase in ultimate elongation at break as compared with those of neat TPU. Detailed study showed that, owing to the strong covalent bonding between the MMT sheets and TPU matrix, MMT sheets were highly exfoliated during the polymerization process, and the highly exfoliated MMT sheets gave rise to the greatly improved mechanical properties and thermomechanical properties of TPU/MDI-MMT nanocomposites. The present work demonstrates that the in situ preparation of TPU/MDI-MMT nanocomposites by using MDI-MMT as fillers is a highly efficient method for reinforcing TPU.

Highly exfoliated montmorillonite (MMT) clay reinforced thermoplastic polyurethane elastomers (TPUs) were prepared by an in situ solution polymerization method.

Effect of Domain Structure of Segmented Poly(urethane-imide) Membranes with Polycaprolactone Soft Blocks on Dehydration of n-Propanol via Pervaporation

Segmented poly(urethane-imide)s (PUIs) were synthesized by polyaddition reaction and applied for preparation of membranes. Tolylene-2,4-diisocyanate, pyromellitic dianhydride, and m-phenylenediamine for chain extension were used to form hard aromatic blocks. Polycaprolactone diols with molecular weights equal to 530 and 2000 g mol-1 were chosen as soft segments. The effect of the length of soft segments on the structure, morphology, and transport properties of segmented poly(urethane-imide) membranes were studied using atomic force microscopy, small-angle and wide-angle X-ray scattering, and pervaporation experiments. It was found that a copolymer with a shorter soft segment (530 g mol-1) consists of soft domains in a hard matrix, while the introduction of polycaprolactone blocks with higher molecular weight (2000 g mol-1) leads to the formation of hard domains in a soft matrix. Additionally, the introduction of hard segments prevents crystallization of polycaprolactone. Transport properties of membranes based on segmented PUIs containing soft segments of different length were tested for pervaporation of a model mixture of propanol/water with 20 wt % H₂O content. It was found that a membrane based on segmented PUIs containing longer soft segments demonstrates higher flux (8.8 kg μm m-2 h-1) and selectivity (179) toward water in comparison with results for pure polycaprolactone reported in literature. The membrane based on segmented PUIs with 530 g mol-1 soft segment has a lower flux (5.1 kg μm m-2 h-1) and higher selectivity (437).