A case for closed-loop recycling of post-consumer PET for automotive foams

A Comparative Study on Crystallisation for Virgin and Recycled Polyethylene Terephthalate (PET): Multiscale Effects on Physico-Mechanical Properties

Poly(Ethylene Terephthalate) (PET) is one of the most used polymers for packaging applications. Modifications induced by service conditions and the means to make this matter circular have to be understood to really close the loop (from bottle to bottle for example). Physico-chemical properties, crystalline organisation, and mechanical behaviour of virgin PET (vPET) are compared with those of recycled PET (rPET). Using different combined experimental methods (Calorimetry, Small Angle X-ray Scattering [SAXS], Atomic Force Microscopy [AFM], Dynamic Mechanical Analysis [DMA], and uniaxial tensile test), it has been proven that even if there is no change in the crystallinity of PET, the crystallisation process shows some differences (size and number of spherulites). The potential impact of these differences on local mechanical characterisation is explored and tends to demonstrate the development of a homogeneous microstructure, leading to well-controlled and relevant local mechanical property characterisation. The main contribution of the present study is a better understanding of crystallisation of PET and recycled PET during forming processes such as thermoforming or Injection Stretch Blow Moulding (ISBM), during which elongation at the point of breaking can depend on the microstructure conditioned by the crystallisation process.

New Composite Materials Made from Rigid/Flexible Polyurethane Foams with Fir Sawdust: Acoustic and Thermal Behavior

The aim of this work is to obtain new materials with improved sound absorbing and thermal properties, using rigid or flexible polyurethane foam reinforced with recycled fir sawdust from wood processing as well as by optimizing their mixing ratio. In this respect, we prepared and characterized samples by mixing rigid polyurethane foam (RPUF)/flexible polyurethane foam (FPUF) with 0, 35, 40, 45, and 50 wt% fir sawdust (FS) with grains size larger than 2 mm. The samples were evaluated by cell morphology analysis, sound absorption, and thermal insulation performance. The obtained composite materials containing 50% sawdust have superior acoustic properties compared to those with 100% FPUF in the range of 420-1250 Hz. The addition of 35% and 50% FS in the FPUF matrix led to improved thermal insulation properties and decreased thermal insulation properties in the case of RPUF. The results show that the use of FS-based composites with the FPUF/RPUF matrix for sound absorption and thermal insulation applications is a desirable choice and could be applied as an alternative to conventional synthetic fiber-based materials and as a recycling method of waste wood.

Bio-Based Polyurethane Foams with Castor Oil Based Multifunctional Polyols for Improved Compressive Properties

Currently, most commercial polyols used in the production of polyurethane (PU) foam are derived from petrochemicals. To address concerns relating to environmental pollution, a sustainable resource, namely, castor oil (CO), was used in this study. To improve the production efficiency, sustainability, and compressive strength of PU foam, which is widely used as an impact-absorbing material for protective equipment, PU foam was synthesized with CO-based multifunctional polyols. CO-based polyols with high functionalities were synthesized via a facile thiol-ene click reaction method and their chemical structures were analyzed. Subsequently, a series of polyol blends of castor oil and two kinds of castor oil-based polyols with different hydroxyl values was prepared and the viscosity of the blends was analyzed. Polyurethane foams were fabricated from the polyol blends via a free-rising method. The effects of the composition of the polyol blends on the structural, morphological, mechanical, and thermal properties of the polyurethane foams were investigated. The results demonstrated that the fabrication of polyurethane foams from multifunctional polyol blends is an effective way to improve their compressive properties. We expect these findings to widen the range of applications of bio-based polyurethane foams.

Water Conservation Potential of Self-Funded Foam-Based Flexible Surface-Mounted Floatovoltaics

A potential solution to the coupled water–energy–food challenges in land use is the concept of floating photovoltaics or floatovoltaics (FPV). In this study, a new approach to FPV is investigated using a flexible crystalline silicon-based photovoltaic (PV) module backed with foam, which is less expensive than conventional pontoon-based FPV. This novel form of FPV is tested experimentally for operating temperature and performance and is analyzed for water-savings using an evaporation calculation adapted from the Penman–Monteith model. The results show that the foam-backed FPV had a lower operating temperature than conventional pontoon-based FPV, and thus a 3.5% higher energy output per unit power. Therefore, foam-based FPV provides a potentially profitable means of reducing water evaporation in the world’s at-risk bodies of fresh water. The case study of Lake Mead found that if 10% of the lake was covered with foam-backed FPV, there would be enough water conserved and electricity generated to service Las Vegas and Reno combined. At 50% coverage, the foam-backed FPV would provide over 127 TWh of clean solar electricity and 633.22 million m3 of water savings, which would provide enough electricity to retire 11% of the polluting coal-fired plants in the U.S. and provide water for over five million Americans, annually.

Crystallization-induced microcellular foaming behaviors of chain-extended polyethylene terephthalate

The microcellular foaming of chain-extended polyethylene terephthalate (CPET) by crystallization induction method was reported in this article. The crystallization behaviors of various polyethylene terephthalate (PET) samples which were affected by the combined effect of pyromellitic dianhydride, Surlyn, and CO2 were investigated. After Surlyn was added to CPET, the crystal nucleation of various CPET samples was improved, and numerous but small spherulites were generated. Two kinds of CPET samples with the content of 0 phr and 1 phr Surlyn were foamed at various temperature by batch foaming method. Changing the saturation temperature could adjust the appearance of high-temperature melting crystals which would affect the final cellular structures in various CPET foams. With the decrease of saturation temperature, the cell size decreased while cell density increased. At the saturation temperature of 265°C and 250°C, the cell density of CPET foam with Surlyn was one magnitude larger than CPET foam without Surlyn. At the saturation temperature of 247°C, the microcellular PET foams with the cell density of 109 cells cm−3 and the cell size less than 10 µm had been developed successfully.

Closed Cell Rigid Polyurethane Foams Based on Low Functionality Polyols: Research of Dimensional Stability and Standardised Performance Properties

Currently, polyurethane foam producers come across the several problems when petroleum-based polyols are replaced with low functionality biomass, or waste-based, polyols. In addition, the dilemma is intensified with regulations that require full or partial replacement of blowing agents that can cause high ozone depletion with alternatives like water, which causes the formation of CO₂. Therefore, these gases diffuse out of the foam so quickly that the polymeric cell walls cannot withstand the pressure, consequently causing huge dimensional changes at ambient temperature and humidity. Even though the theoretical stoichiometric balance is correct, the reality shows that it is not enough. Therefore, polyethylene terephthalate waste-based polyol was chosen as a low functionality polyol which was modified with high functionality sucrose-based polyol in order to obtain dimensionally stable polyurethane foams in the density range of 30-40 kg/m³. These more stable foams are characterized by linear changes no higher than 0.5%, short-term water absorption by partial immersion no higher than 0.35 kg/m², and water vapor resistance factors up to 50. In order to obtain thermally efficient polyurethane foams, conventional blowing agents and water systems were implemented, thus, assuring thermal conductivity values in the range of 0.0198-0.0204 W/(m·K) and obtaining products which conform to all the requirements for performance of sprayed and factory-made polyurethane foam standards EN 14315-1 and EN 13165.

Recent Trends of Foaming in Polymer Processing: A Review

Polymer foams have low density, good heat insulation, good sound insulation effects, high specific strength, and high corrosion resistance, and are widely used in civil and industrial applications. In this paper, the classification of polymer foams, principles of the foaming process, types of blowing agents, and raw materials of polymer foams are reviewed. The research progress of various foaming methods and the current problems and possible solutions are discussed in detail.

Structure and thermal properties of various alcoholysis products from waste poly(ethylene terephthalate)

Waste polyethylene terephthalate (PET) has been a core member in plastic polluters due to the great amount consumption in food packaging, soft-drink bottles, fibers and films. It is essential to recycle waste PET and alcoholysis is a significant way to accomplish chemical recycling. In this work, three kinds of dihydric alcohols, including neopentyl glycol (NPG), dipropylene glycol (DPG) and poly(propylene glycol) (PPG), were employed to decompose waste PET with different temperatures, catalysts, and PET. A series of alcoholysis products with different appearance were obtained. The bulk structure and thermal properties of alcoholysis products were investigated by FTIR, ¹H NMR, MALDI-TOF, DSC and TG experiments. It is found that poly(propylene glycol) may react with waste PET to generate copolymer instead of oligomer products, dimers or trimers, etc. This product possesses excellent shelf stability and present transparent appearance, which may hold a great potential application in chemical industry. Moreover, the alcoholysis activity of DPG is the lowest comparing with NPG and EG in degradation of waste PET.

Evaluation of Wastewater Treatment by Microcosms of Vertical Subsurface Wetlands in Partially Saturated Conditions Planted with Ornamental Plants and Filled with Mineral and Plastic Substrates

The current knowledge about the role terrestrial ornamental plants play in constructed wetlands (CWs) has scarcely been evaluated. Likewise, little attention has been given towards the use of new support or fill media for subsurface flow CWs, which may result in the reduction of costs when implemented on a large scale. This study evaluated, during nine months, the effect of three terrestrial ornamental plants and two substrates on the elimination of pollutants in wastewaters by using fill-and-drain vertical subsurface flow CWs (FD-CWs). Sixteen microcosms were used, nine filled with polyethylene terephthalate (PET) and nine with porous river stone (PRS). For each type of substrate, duplicates of microcosms were used, utilizing Anthurium sp., Zantedeschia aethiopica, and Spathiphyllum wallisii as vegetation and two other CWs without vegetation as controls. The environmental conditions, number of flowers, and height of the plants were registered. The results revealed that both substrates in the FD-CWs were efficient in removing pollutants. The average removal of pollutants in systems with vegetation revealed a positive effect on the reduction of the biochemical oxygen demand (55–70%), nitrates (28–44%), phosphates (25–45%), and fecal coliforms (52–65%). Meanwhile, in units without vegetation, the reduction of pollutants was nearly 40–50% less than in those with vegetation. The use of PET as a filling substrate in CWs did not affect the growth and/or the flowering of the species; therefore, its use combined with the species studied in CWs may be replicated in villages with similar wastewater problems. This may represent a reduction in implementation costs when utilizing PET recycled wastes and PRS as substrates in these systems in comparison with the typical substrates used in CWs. More studies are needed to better understand the interactions among these novel support media and the commercial terrestrial ornamental plants.