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Handtke S, Brömstrup L, Hain J, Fischer F, Ossowski T, Hartwig S, Dröder K. Investigation of Recycled Expanded Polyamide Beads through Artificial Ageing and Mechanical Recycling as a Proof of Concept for Circular Economy. Polymers (Basel) 2024; 16:1730. [PMID: 38932080 PMCID: PMC11207465 DOI: 10.3390/polym16121730] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/15/2024] [Revised: 06/04/2024] [Accepted: 06/11/2024] [Indexed: 06/28/2024] Open
Abstract
Car manufacturers are currently challenged with increasing the sustainability of their products and production to comply with sustainability requirements and legislation. One way to enhance product sustainability is by reducing the carbon footprint of fossil-based plastic parts. Particle foams are a promising solution to achieve the goal of using lightweight parts with minimal material input. Ongoing developments involve the use of expanded particle foam beads made from engineering plastics such as polyamide (EPA). To achieve this, a simulated life cycle was carried out on virgin EPA, including mechanical recycling. The virgin material was processed into specimens using a steam-free method. One series was artificially aged to replicate automotive life cycle stresses, while the other series was not. The mechanical recycling and re-foaming of the minipellets were then carried out, resulting in an EPA particle foam with 100% recycled content. Finally, the thermal and chemical material properties were comparatively analysed. The study shows that the recycled EPA beads underwent polymer degradation during the simulated life cycle, as evidenced by their material properties. For instance, the recycled beads showed a more heterogeneous molecular weight distribution (an increase in PDI from two to three), contained carbonyl groups, and exhibited an increase in the degree of crystallization from approximately 24% to 36%.
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Affiliation(s)
- Sören Handtke
- Volkswagen AG, Berliner Ring 2, 38440 Wolfsburg, Germany
| | - Lena Brömstrup
- Institute of Joining and Welding, Technische Universität Braunschweig, Langer Kamp 8, 38106 Braunschweig, Germany
| | - Jörg Hain
- Volkswagen AG, Berliner Ring 2, 38440 Wolfsburg, Germany
| | - Fabian Fischer
- Volkswagen AG, Berliner Ring 2, 38440 Wolfsburg, Germany
| | - Tim Ossowski
- Institute of Machine Tools and Production Technology, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany
| | - Sven Hartwig
- Institute of Joining and Welding, Technische Universität Braunschweig, Langer Kamp 8, 38106 Braunschweig, Germany
| | - Klaus Dröder
- Institute of Machine Tools and Production Technology, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany
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2
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Chen CW, Ranganathan P, Mutharani B, Shiu JW, Rwei SP, Chang YH, Chiu FC. Synthesis of High-Value Bio-Based Polyamide 12,36 Microcellular Foams with Excellent Dimensional Stability and Shape Recovery Properties. Polymers (Basel) 2024; 16:159. [PMID: 38201824 PMCID: PMC10780462 DOI: 10.3390/polym16010159] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/08/2023] [Revised: 12/28/2023] [Accepted: 12/28/2023] [Indexed: 01/12/2024] Open
Abstract
The search for alternatives to petroleum-based thermoplastic polyamide elastomers (TPAEs) has recently drawn great interest. In this study, a bio-massed TPAE, PA12,36, was synthesized using 1,12-dodecanediamine (DDA) and fatty dimer acid (FDA, PripolTM1009) precursors via catalyst and solvent-free melt polycondensation. The molecular structure and molecular weight of the PA12,36 were characterized by 1H NMR, FTIR, and GPC. PA12,36 displayed a low melting temperature of 85.8 °C, an initial degradation temperature of 425 °C, and a glass-transition temperature of 30.4 °C, whereas it sustained satisfactory tensile strength (10.0 MPa) and superior strain at break (1378%). Furthermore, PA12,36 was foamed by supercritical CO2, and the cell size, cell density, and porosity were determined. The entangled long-chained FDA component generated a physically crosslinked network, which promoted the melt viscosity of PA12,36 against elongations of foam cell growth and increased foamability significantly. As a result, uniform structured cellular foams with a cell diameter of 15-24 µm and high cell density (1011 cells/cm3-1012 cells/cm3) were successfully achieved. The foaming window was widened from 76 to 81 °C, and the expansion ratio was increased from 4.8 to 9.6. Additionally, PA12,36 foam with a physically crosslinked structure presented a better creep shape recovery percentage (92-97.9%) and sturdier dimensional stability. This bio-based PA12,36 foam is a promising candidate to replace petroleum-based thermoplastic elastomer foams for engineering applications, particularly shoe soles.
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Affiliation(s)
- Chin-Wen Chen
- Department of Molecular Science and Engineering, Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, Taipei 10608, Taiwan; (C.-W.C.); (P.R.); (J.-W.S.)
| | - Palraj Ranganathan
- Department of Molecular Science and Engineering, Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, Taipei 10608, Taiwan; (C.-W.C.); (P.R.); (J.-W.S.)
| | | | - Jia-Wei Shiu
- Department of Molecular Science and Engineering, Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, Taipei 10608, Taiwan; (C.-W.C.); (P.R.); (J.-W.S.)
| | - Syang-Peng Rwei
- Department of Molecular Science and Engineering, Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, Taipei 10608, Taiwan; (C.-W.C.); (P.R.); (J.-W.S.)
| | - Yen-Hsiang Chang
- Department of General Dentistry, Chang Gung Memorial Hospital, Taoyuan 333, Taiwan;
| | - Fang-Chyou Chiu
- Department of Chemical and Materials Engineering, Chang Gung University, Taoyuan 333, Taiwan;
- Department of General Dentistry, Chang Gung Memorial Hospital, Taoyuan 333, Taiwan;
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Sun H, Pei X, Ruan H, Song F, Wang T, Wang Q, Wang C. “Partition Method”-Inspired Fabrication of Hierarchically Porous Polyetherimide via Supercritical CO 2 Foaming: Achieving Efficient Adsorption of Carbon Dioxide. Ind Eng Chem Res 2023. [DOI: 10.1021/acs.iecr.2c03803] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/22/2023]
Affiliation(s)
- Huiting Sun
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
- Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Xianqiang Pei
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
| | - Hongwei Ruan
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
- Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Fuzhi Song
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
| | - Tingmei Wang
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
- Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Qihua Wang
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
- Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Chao Wang
- Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 73000, China
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4
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Chen JR, Chen JR, Su CK. Solution Foaming–Treated 3D-Printed monolithic packing for enhanced solid phase extraction of trace metals. Talanta 2022; 241:123237. [DOI: 10.1016/j.talanta.2022.123237] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2021] [Revised: 01/06/2022] [Accepted: 01/14/2022] [Indexed: 10/19/2022]
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5
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Li S, Jiang S, Gong S, Ma S, Yang H, Pan K, Deng J. Preparation Methods, Performance Improvement Strategies, and Typical Applications of Polyamide Foams. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c03715] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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6
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Lee YH, Lee CW, Chou CH, Lin CH, Chen YH, Chen CW, Way TF, Rwei SP. Sustainable polyamide elastomers from a bio-based dimer diamine for fabricating highly expanded and facilely recyclable microcellular foams via supercritical CO2 foaming. Eur Polym J 2021. [DOI: 10.1016/j.eurpolymj.2021.110765] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
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7
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Ranganathan P, Chen CW, Tasi MC, Rwei SP, Lee YH. Biomass Thermoplastic (Co)polyamide Elastomers Synthesized from a Fatty Dimer Acid: a Sustainable Route toward a New Era of Uniform and Bimodal Foams. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c01533] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Palraj Ranganathan
- Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, No. 1, Sec. 3, Chung-Hsiao East Road., Taipei 10608, Taiwan, Republic of China
| | - Chin-Wen Chen
- Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, No. 1, Sec. 3, Chung-Hsiao East Road., Taipei 10608, Taiwan, Republic of China
| | - Ming-Chung Tasi
- Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, No. 1, Sec. 3, Chung-Hsiao East Road., Taipei 10608, Taiwan, Republic of China
| | - Syang-Peng Rwei
- Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, No. 1, Sec. 3, Chung-Hsiao East Road., Taipei 10608, Taiwan, Republic of China
| | - Yi-Huan Lee
- Institute of Organic and Polymeric Materials, Research and Development Center of Smart Textile Technology, National Taipei University of Technology, No. 1, Sec. 3, Chung-Hsiao East Road., Taipei 10608, Taiwan, Republic of China
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8
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Sarver JA, Sumey JL, Whitfield RM, Kiran E. Confined batch foaming of
semi‐crystalline
rubbery elastomers with carbon dioxide using a mold. J Appl Polym Sci 2021. [DOI: 10.1002/app.50698] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Affiliation(s)
- Joseph A. Sarver
- Department of Chemical Engineering Virginia Tech Blacksburg Virginia USA
| | - Jenna L. Sumey
- Department of Chemical Engineering University of Virginia Charlottesville Virginia USA
| | | | - Erdogan Kiran
- Department of Chemical Engineering Virginia Tech Blacksburg Virginia USA
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10
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Han S, Jiang C, Mi J, Wang Y, Chen S, Wang X. Influence of fibrillated poly(tetrafluoroethylene) on microcellular foaming of polyamide 6 in the presence of supercritical
CO
2
. J Appl Polym Sci 2021. [DOI: 10.1002/app.51258] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/01/2023]
Affiliation(s)
- Shuo Han
- School of Chemistry and Materials Engineering Beijing Technology and Business University Beijing China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing China
| | - Can Jiang
- School of Chemistry and Materials Engineering Beijing Technology and Business University Beijing China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing China
| | - Jianguo Mi
- State Key Laboratory of Organic‐Inorganic Composites Beijing University of Chemical Technology Beijing China
| | - Yaqiao Wang
- College of Materials Science and Engineering Beijing University of Chemical Technology Beijing China
| | - Shihong Chen
- School of Chemistry and Materials Engineering Beijing Technology and Business University Beijing China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing China
| | - Xiangdong Wang
- School of Chemistry and Materials Engineering Beijing Technology and Business University Beijing China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing China
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11
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Standau T, Nofar M, Dörr D, Ruckdäschel H, Altstädt V. A Review on Multifunctional Epoxy-Based Joncryl® ADR Chain Extended Thermoplastics. POLYM REV 2021. [DOI: 10.1080/15583724.2021.1918710] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/31/2022]
Affiliation(s)
- Tobias Standau
- Department of Polymer Engineering, University of Bayreuth, Bayreuth, Germany
| | - Mohammadreza Nofar
- Metallurgical and Materials Engineering, Department Faculty of Chemical and Metallurgical Engineering, Istanbul Technical University, Maslak, Istanbul, Turkey
- Polymer Science and Technology Program, Institute of Science and Technology, Istanbul Technical University, Maslak, Istanbul, Turkey
| | - Dominik Dörr
- Department of Polymer Engineering, University of Bayreuth, Bayreuth, Germany
| | - Holger Ruckdäschel
- Department of Polymer Engineering, University of Bayreuth, Bayreuth, Germany
| | - Volker Altstädt
- Department of Polymer Engineering, University of Bayreuth, Bayreuth, Germany
- Bavarian Polymer Institute and Bayreuth Institute of Macromolecular Research, University of Bayreuth, Bayreuth, Germany
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12
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Pin JM, Tuccitto AV, Shivokhin ME, Lee PC. Linking ethylene co-monomer content and stereostructure to polycrystallinity and foam density of random copolymers of polypropylene. POLYMER 2021. [DOI: 10.1016/j.polymer.2020.123123] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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13
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Sarver JA, Hassler JC, Kiran E. Linking thermophysical and rheological properties to the selection of CO2 foaming conditions of rubbery elastomers using the relative rigidity reduction path. J Supercrit Fluids 2020. [DOI: 10.1016/j.supflu.2020.105015] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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14
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Suethao S, Shah DU, Smitthipong W. Recent Progress in Processing Functionally Graded Polymer Foams. MATERIALS (BASEL, SWITZERLAND) 2020; 13:E4060. [PMID: 32933128 PMCID: PMC7560401 DOI: 10.3390/ma13184060] [Citation(s) in RCA: 21] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/11/2020] [Revised: 09/05/2020] [Accepted: 09/08/2020] [Indexed: 01/08/2023]
Abstract
Polymer foams are an important class of engineering material that are finding diverse applications, including as structural parts in automotive industry, insulation in construction, core materials for sandwich composites, and cushioning in mattresses. The vast majority of these manufactured foams are homogeneous with respect to porosity and structural properties. In contrast, while cellular materials are also ubiquitous in nature, nature mostly fabricates heterogeneous foams, e.g., cellulosic plant stems like bamboo, or a human femur bone. Foams with such engineered porosity distribution (graded density structure) have useful property gradients and are referred to as functionally graded foams. Functionally graded polymer foams are one of the key emerging innovations in polymer foam technology. They allow enhancement in properties such as energy absorption, more efficient use of material, and better design for specific applications, such as helmets and tissue restorative scaffolds. Here, following an overview of key processing parameters for polymer foams, we explore recent developments in processing functionally graded polymer foams and their emerging structures and properties. Processes can be as simple as utilizing different surface materials from which the foam forms, to as complex as using microfluidics. We also highlight principal challenges that need addressing in future research, the key one being development of viable generic processes that allow (complete) control and tailoring of porosity distribution on an application-by-application basis.
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Affiliation(s)
- Supitta Suethao
- Specialized Center of Rubber and Polymer Materials in Agriculture and Industry (RPM), Department of Materials Science, Faculty of Science, Kasetsart University, Chatuchak, Bangkok 10900, Thailand;
| | - Darshil U. Shah
- Centre for Natural Material Innovation, Department of Architecture, University of Cambridge, Cambridge CB2 1PX, UK;
| | - Wirasak Smitthipong
- Specialized Center of Rubber and Polymer Materials in Agriculture and Industry (RPM), Department of Materials Science, Faculty of Science, Kasetsart University, Chatuchak, Bangkok 10900, Thailand;
- Office of Natural Rubber Research Program, Thailand Science Research and Innovation (TSRI), Chatuchak, Bangkok 10900, Thailand
- Office of Research Integration on Target–Based Natural Rubber, National Research Council of Thailand (NRCT), Chatuchak, Bangkok 10900, Thailand
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15
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Xu D, Liu P, Wang Q. An ultrafast and clean method to manufacture poly(vinyl alcohol) bead foam products. POLYM ADVAN TECHNOL 2020. [DOI: 10.1002/pat.5076] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Affiliation(s)
- Dawei Xu
- State Key Laboratory of Polymer Materials Engineering Polymer Research Institute of Sichuan University Chengdu China
| | - Pengju Liu
- State Key Laboratory of Polymer Materials Engineering Polymer Research Institute of Sichuan University Chengdu China
| | - Qi Wang
- State Key Laboratory of Polymer Materials Engineering Polymer Research Institute of Sichuan University Chengdu China
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16
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Han S, Jiang C, Yu K, Mi J, Chen S, Wang X. Influence of crystallization on microcellular foaming behavior of polyamide 6 in a supercritical CO
2
‐assisted route. J Appl Polym Sci 2020. [DOI: 10.1002/app.49183] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Shuo Han
- School of Materials and Mechanical EngineeringBeijing Technology and Business University Beijing People's Republic of China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing People's Republic of China
| | - Can Jiang
- School of Materials and Mechanical EngineeringBeijing Technology and Business University Beijing People's Republic of China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing People's Republic of China
| | - Kesong Yu
- School of Materials and Mechanical EngineeringBeijing Technology and Business University Beijing People's Republic of China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing People's Republic of China
| | - Jianguo Mi
- State Key Laboratory of Organic‐Inorganic CompositesBeijing University of Chemical Technology Beijing People's Republic of China
| | - Shihong Chen
- School of Materials and Mechanical EngineeringBeijing Technology and Business University Beijing People's Republic of China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing People's Republic of China
| | - Xiangdong Wang
- School of Materials and Mechanical EngineeringBeijing Technology and Business University Beijing People's Republic of China
- Beijing Key Laboratory of Quality Evaluation Technology for Hygiene and Safety of Plastics Beijing People's Republic of China
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