Flow Reactor Synthesis of Bio-Based Polyol from Soybean Oil for the Production of Rigid Polyurethane Foam

Harnessing Enhanced Flame Retardancy in Rigid Polyurethane Composite Foams through Hemp Seed Oil-Derived Natural Fillers

Over the past few decades, polymer composites have received significant interest and become protagonists due to their enhanced properties and wide range of applications. Herein, we examined the impact of filler and flame retardants in hemp seed oil-based rigid polyurethane foam (RPUF) composites' performance. Firstly, the hemp seed oil (HSO) was converted to a corresponding epoxy analog, followed by a ring-opening reaction to synthesize hemp bio-polyols. The hemp polyol was then reacted with diisocyanate in the presence of commercial polyols and other foaming components to produce RPUF in a single step. In addition, different fillers like microcrystalline cellulose, alkaline lignin, titanium dioxide, and melamine (as a flame retardant) were used in different wt.% ratios to fabricate composite foam. The mechanical characteristics, thermal degradation behavior, cellular morphology, apparent density, flammability, and closed-cell contents of the generated composite foams were examined. An initial screening of different fillers revealed that microcrystalline cellulose significantly improves the mechanical strength up to 318 kPa. The effect of melamine as a flame retardant in composite foam was also examined, which shows the highest compression strength of 447 kPa. Significantly better anti-flaming qualities than those of neat foam based on HSO have been reflected using 22.15 wt.% of melamine, with the lowest burning time of 4.1 s and weight loss of 1.88 wt.%. All the composite foams showed about 90% closed-cell content. The present work illustrates the assembly of a filler-based polyurethane foam composite with anti-flaming properties from bio-based feedstocks with high-performance applications.

Coconut power: a sustainable approach for the removal of Cr6+ ions using a new coconut-based polyurethane foam/activated carbon composite in a fixed-bed column

To attain efficient removal of hexavalent chromium (Cr⁶⁺) from aqueous solutions, a novel polyurethane foam-activated carbon (PUAC) adsorbent composite was developed. The composite material was synthesized by the binding of coconut shell-based activated carbon (AC) onto a coconut oil-based polyurethane matrix. To thoroughly characterize the physicochemical properties of the newly developed material, various analytical techniques including FTIR spectroscopy, SEM, XRD, BET, and TGA analyses were conducted. The removal efficiency of the PUAC composite in removing Cr⁶⁺ ions from aqueous solutions was evaluated through column experiments with the highest adsorption capacity of 28.41 mg g^-1 while taking into account variables such as bed height, flow rate, initial Cr⁶⁺ ion concentration, and pH. Experimental data were fitted using Thomas, Yoon-Nelson, and Adams-Bohart models to predict the column profiles and the results demonstrate high breakthrough and exhaustion time dependence on these variables. Among the obtained R² values of the models, a better fit was observed using the Thomas and Yoon-Nelson models, indicating their ability to effectively predict the adsorption of Cr⁶⁺ ions in a fixed bed column. Significantly, the exhausted adsorbent can be conveniently regenerated without any noteworthy loss of adsorption capability. Based on these findings, it can be concluded that this new PUAC composite material holds significant promise as a potent sorbent for wastewater treatment backed by its excellent performance, cost-effectiveness, biodegradability, and outstanding reusability.

Sunflower Oil as a Renewable Resource for Polyurethane Foams: Effects of Flame-Retardants

Currently, polyurethane (PU) manufacturers seek green alternatives for sustainable production. In this work, sunflower oil is studied as a replacement and converted to a reactive form through epoxidation and oxirane opening to produce rigid PU foams. Confirmatory tests such as Fourier-transform infrared spectroscopy (FT-IR), gel permeation chromatography (GPC), and hydroxyl value among others were performed to characterize the synthesized polyol. Despite the versatility of rigid PU foams, they are highly flammable, which makes eco-friendly flame retardants (FRs) desired. Herein, expandable graphite (EG) and dimethyl methyl phosphonate (DMMP), both non-halogenated FR, were incorporated under different concentrations to prepare rigid PU foams. Their effects on the physio-mechanical and fire-quenching properties of the sunflower oil-based PU foams were elucidated. Thermogravimetric and compression analysis showed that these foams presented appreciable compressive strength along with good thermal stability. The closed-cell contents (CCC) were around 90% for the EG-containing foams and suffered a decrease at higher concentrations of DMMP to 72%. The burning test showed a decrease in the foam's flammability as the neat foam had a burning time of 80 s whereas after the addition of 13.6 wt.% of EG and DMMP, separately, there was a decrease to 6 and 2 s, respectively. Hence, our research suggested that EG and DMMP could be a more viable alternative to halogen-based FR for PU foams. Additionally, the adoption of sunflower polyol yielded foams with results comparable to commercial ones.

Waterborne Polyurethane/Acrylic Adhesive Blends from Physaria fendleri Oil for Food Packaging Applications

Environmental concerns and the diminishing acceptability of using petrochemical polymers require innovative synthetic approaches to materials for essential polymeric technologies such as adhesives. Biobased plant oils have been suggested as replacements for petrochemical monomers in polyurethane formulations. A variety of seed oil extracts from plants contain naturally occurring functional groups such as hydroxyl and glycidyl ether, which can be utilized in polyurethane synthesis. Most studies of bioderived polyurethane adhesives occur in solventborne systems and with chemically modified oils. However, rising concerns and manufacturing limitations of volatile organic compounds in solventborne systems warrant investigation into more sustainable and alternatives that are easier to handle. In this work, we synthesized waterborne polyurethanes comprised of oil derived from Physaria fendleri seed (naturally occurring hydroxyl functionality), hexamethylene diisocyanate, toluene diisocyanate, and dimethyl propionic acid. Acrylate copolymers were synthesized via emulsion polymerization comprised of different butyl and methylmethacrylate monomer ratios. These polymers were formulated into waterborne polyurethane/acrylic adhesive blends. The resulting formulations possess a commercially comparable peel strength of >6 N and are suggested for use in resealable food packaging applications. This study demonstrates the utility of oil derived from Physaria fendleri seeds in waterborne adhesive applications, adding value with bioderived materials and increasing sustainability of polyurethane adhesives.

A study on coconut fatty acid diethanolamide-based polyurethane foams

The possibility of using coconut fatty acid diethanolamide, a derivate from coconut oil as a bio-based polyol for the synthesis of polyurethane foam was explored. The intrinsic tertiary amine moiety in this polyol (p-CFAD) endowed an auto-catalytic effect in the synthesis process of polyurethane foams, combined with a shorter cream and gelation time compared to the fossil-based polyol 3152. H-nuclear magnetic resonance (¹H-NMR) and Fourier transform infrared spectrometry (FTIR) were conducted to characterize the chemical structural features of the p-CFAD, and rheology measurement showed the shear-thinning behavior due to the branched structure. A thermal conductivity comparable to the commercial rigid polyurethane foam was achieved when 40wt% fossil-based polyol 3152 was substituted with the bio-based p-CFAD. With the increased content of the p-CFAD, a transition of the physical properties from rigid PU foam to soft PU foam was observed. Scanning electron microscopy (SEM) revealed the occurrence of the interconnected pores on the cell walls with the increase of the added p-CFAD, implying the possibility of regulating the cellular structure and foam properties via the incorporation of the p-CFAD. Results showed the feasibility of using p-CFAD as a potential polyol in the development of bio-based polyurethane foams with high performance.

Tannin polymerization: an overview

This review critically addresses the most relevant and innovative techniques for obtaining polymers from tannins.