Current Progress in Research into Environmentally Friendly Rigid Polyurethane Foams

Polyurethane foams are materials characterized by low density and thermal conductivity and can therefore be used as thermal insulation materials. They are synthesized from toxic and environmentally unfriendly petrochemicals called isocyanates and polyols, which react with each other to form a urethane group via the displacement of the movable hydrogen atom of the -OH group of the alcohol to the nitrogen atom of the isocyanate group. The following work describes the synthesis of polyurethane foams, focusing on using environmentally friendly materials, such as polyols derived from plant sources or modifiers, to strengthen the foam interface derived from plant precipitation containing cellulose derived from paper waste. The polyurethane foam industry is looking for new sources of materials to replace the currently used petrochemical products. The solutions described are proving to be an innovative and promising area capable of changing the face of current PU foam synthesis.

Preparation of light-colored bio-based particles by isocyanate-modified lignins and its application for tetracycline adsorption

A practical method for the preparation of lignin derivatives-light-colored bio-based particles (LC-BP) via the modification of hexamethylene diisocyanate (HDI) is presented in this work. In the mixed EtOH/H2O system, the change of solvent polarity induced the self-assembly of the lignosulfonate (LS) with the hydrophobic chromophores encapsulated inside the particles. The color of LS was reduced by the polymerization between the isocyanate groups (-N=C=O) of HDI and hydroxy groups of LS. Compared with the typical lignin-based adsorbent preparation process in the past, this is a simple, direct, and efficient preparation method and the synthetic LC-BP has good chemical stability and resistance to heat, acid and alkali. This effectively solves the problem that LS has high water solubility and is difficult to use directly for wastewater treatment. To investigate the properties, the synthetic LC-BP was characterized by SEM, specific surface area, L*a*b* (CIELAB) color space, FT-IR, XPS, and TGA. The results showed that the LC-BP exhibited obvious advantages in color reduction with a low CIE-L* value. The LC-BP exhibits a scale-like intercalation structure, which makes it a promising candidate for adsorbing tetracycline (TC) from wastewater. The conditions of pH, adsorbent dosages, adsorption time, and initial TC concentration were investigated, and the adsorption performance of LC-BP for TC was significantly better than that of conventional polyurethane particles (PP). The adsorption fitted the Langmuir model and there were hydrogen bonding, π-π conjugated binding, and electrostatic attraction during the absorption process. The adsorption capacity was up to 53.1 mg/g, and the removal rate was 67 %. The utilization of LC-BP, a low-cost, effective, and renewable resource derived from natural biomass, holds immense practical and economic potential in wastewater treatment.

Lignocellulose Biomass Liquefaction: Process and Applications Development as Polyurethane Foams

One of the main strategies for sustainable human society progress is the development of efficient strategies to limit waste production and maximize renewable resource utilization. In this context, this review highlights the opportunity to transform vegetable biomass residues into valuable commercial products. Biomass conversion entails the depolymerization of lignocellulosic biomass towards biopolyols and the synthesis and characterization of the valuable products obtained by using them. The influence of the reaction parameters in both acid and basic catalysis is highlighted, respectively the influence of microwaves on the liquefaction reaction versus conventional heating. Following the depolymerization reaction, polyols are employed to produce polyurethane foams. As a special characteristic, the addition of flame-retardant properties was emphasized. Another interesting topic is the biodegradability of these products, considering the negative consequences that waste accumulation has on the environment.

Casein/Apricot Filler in the Production of Flame-Retardant Polyurethane Composites

Polyurethane (PUR) composites reinforced with 1, 2, and 5 wt.% of apricot filler modified with casein were synthesized in the following study. The impact of 1, 2, and 5 wt.% of casein/apricot filler on the cellular structure and physico-mechanical performances of reinforced PUR composites were determined. It was found that the incorporation of 1 and 2 wt.% of casein/apricot filler resulted in the production of PUR composites with improved selected physical, thermal, and mechanical properties, while the addition of 5 wt.% of casein/apricot filler led to some deterioration of their physico-mechanical performance. The best results were obtained for PUR composites reinforced with 2 wt.% of casein/apricot filler. Those composites were characterized by a uniform structure and a high content of closed cells. Compared with the reference foam, the incorporation of 2 wt.% of casein/apricot filler resulted in improvement in compressive strength, flexural strength, impact strength, and dynamic mechanical properties-such as glass transition temperature and storage modulus. Most importantly, PUR composites showed better fire resistance and thermal stability due to the good thermal performance of casein. The main aim of this article is to determine the influence of the natural combination of the apricot filler and casein on the mechanical properties and flammability of the obtained composites.

Ambient-Pressured Acid-Catalysed Ethylene Glycol Organosolv Process: Liquefaction Structure-Activity Relationships from Model Cellulose-Lignin Mixtures to Lignocellulosic Wood Biomass

Raising the awareness of carbon dioxide emissions, climate global warming and fossil fuel depletion has renewed the transition towards a circular economy approach, starting by addressing active bio-economic precepts that all portion amounts of wood are valorised as products. This is accomplished by minimizing residues formed (preferably no waste materials), maximizing reaction productivity yields, and optimising catalysed chemical by-products. Within framework structure determination, the present work aims at drawing a parallel between the characterisation of cellulose–lignin mixture (derived system model) liquefaction and real conversion process in the acidified ethylene glycol at moderate process conditions, i.e., 150 °C, ambient atmospheric pressure and potential bio-based solvent, for 4 h. Extended-processing liquid phase is characterized considering catalyst-transformed reactant species being produced, mainly recovered lignin-based polymer, by quantitative 31P, 13C and 1H nuclear magnetic resonance (NMR) spectroscopy, as well as the size exclusion- (SEC) or high performance liquid chromatography (HPLC) separation for higher or lower molecular weight compound compositions, respectively. Such mechanistic pathway analytics help to understand the steps in mild organosolv biopolymer fractionation, which is one of the key industrial barriers preventing a more widespread manufacturing of the biomass-derived (hydroxyl, carbonyl or carboxyl) aromatic monomers or oligomers for polycarbonates, polyesters, polyamides, polyurethanes and (epoxy) resins.

Bio-Based Polyurethane Networks Derived from Liquefied Sawdust

The utilization of forestry waste resources in the production of polyurethane resins is a promising green alternative to the use of unsustainable resources. Liquefaction of wood-based biomass gives polyols with properties depending on the reagents used. In this article, the liquefaction of forestry wastes, including sawdust, in solvents such as glycerol and polyethylene glycol was investigated. The liquefaction process was carried out at temperatures of 120, 150, and 170 °C. The resulting bio-polyols were analyzed for process efficiency, hydroxyl number, water content, viscosity, and structural features using the Fourier transform infrared spectroscopy (FTIR). The optimum liquefaction temperature was 150 °C and the time of 6 h. Comprehensive analysis of polyol properties shows high biomass conversion and hydroxyl number in the range of 238-815 mg KOH/g. This may indicate that bio-polyols may be used as a potential substitute for petrochemical polyols. During polyurethane synthesis, materials with more than 80 wt% of bio-polyol were obtained. The materials were obtained by a one-step method by hot-pressing for 15 min at 100 °C and a pressure of 5 MPa with an NCO:OH ratio of 1:1 and 1.2:1. Dynamical-mechanical analysis (DMA) showed a high modulus of elasticity in the range of 62-839 MPa which depends on the reaction conditions.

Biobased Polyurethane Composite Foams Reinforced with Plum Stones and Silanized Plum Stones

In the following study, ground plum stones and silanized ground plum stones were used as natural fillers for novel polyurethane (PUR) composite foams. The impact of 1, 2, and 5 wt.% of fillers on the cellular structure, foaming parameters, and mechanical, thermomechanical, and thermal properties of produced foams were assessed. The results showed that the silanization process leads to acquiring fillers with a smoother surface compared to unmodified filler. The results also showed that the morphology of the obtained materials is affected by the type and content of filler. Moreover, the modified PUR foams showed improved properties. For example, compared with the reference foam (PUR_REF), the foam with the addition of 1 wt.% of unmodified plum filler showed better mechanical properties, such as higher compressive strength (~8% improvement) and better flexural strength (~6% improvement). The addition of silanized plum filler improved the thermal stability and hydrophobic character of PUR foams. This work shows the relationship between the mechanical, thermal, and application properties of the obtained PUR composites depending on the modification of the filler used during synthesis.

The Degradation and Repolymerization Analysis on Solvolysis Liquefaction of Corn Stalk

One of the most effective and renewable utilization methods for lignocellulosic feedstocks is the transformation from solid materials to liquid products. In this work, corn stalk (CS) was liquified with polyethylene glycol 400 (PEG400) and glycerol as the liquefaction solvents, and sulfuric acid as the catalyst. The liquefaction conditions were optimized with the liquefaction yield of 95.39% at the reaction conditions of 150 °C and 120 min. The properties of CS and liquefaction residues (LRs) were characterized using ATR–FTIR, TG, elemental analysis and SEM. The chemical components of liquefied product (LP) were also characterized by GC–MS. The results indicated that the depolymerization and repolymerization reaction took place simultaneously in the liquefaction process. The depolymerization of CS mainly occurred at the temperature of <150 °C, and the repolymerization of biomass derivatives dominated at a higher temperature of 170 °C by the lignin derivatives repolymerization with cellulose derivatives, hemicellulose derivatives and PEG400 and self-condensation of lignin derivatives. The solvolysis liquefaction of CS could be classified into the mechanism of electrophilic substitution reaction attacked by the hydrogen cation.

Anti-flammability, mechanical and thermal properties of bio-based rigid polyurethane foams with the addition of flame retardants

Adding efficient and environmentally friendly flame retardants to polyurethane foams is the preferable way to improve their flame resistance ability. In this work, bio-based rigid polyurethane foams (RPUFs) were prepared with the addition of dicyclohexyl aluminium hypophosphate (DAH) or aluminium diethyl phosphinate (ADP) as the flame retardant. The mechanical properties, thermal degradation and flammability behavior of the obtained RPUFs were evaluated by means of compressive strength tests, thermogravimetry analysis, vertical burning test and scanning electron microscopes. The characterization results indicate that, with the same content of flame retardant, the compressive strength at the deformation of 10% for each RPUF prepared with the addition of DAH is higher than that of the foams with ADP addition, which fully meets the specifications for building insulation materials. Moreover, the average flame height of each RPUF with the addition of flame retardants is less than 250 mm, whereas the average burning time of RPUF with 15 wt% addition of DAH is only 4.4 s, far less than that (12.5 s) of the foam with the same addition amount of ADP. The RPUFs with DAH addition have the potential advantages for thermal insulation applications in various fields.

Upgrading Sustainable Polyurethane Foam Based on Greener Polyols: Succinic-Based Polyol and Mannich-Based Polyol

It is well known that the traditional synthetic polymers, such as Polyurethane foams, require raw materials that are not fully sustainable and are based on oil-feedstocks. For this reason, renewable resources such as biomass, polysaccharides and proteins are still recognized as one of the most promising approaches for substituting oil-based raw materials (mainly polyols). However, polyurethanes from renewable sources exhibit poor physical and functional performances. For this reason, the best technological solution is the production of polyurethane materials obtained through a partial replacement of the oil-based polyurethane precursors. This approach enables a good balance between the need to improve the sustainability of the polymer and the need to achieve suitable performances, to fulfill the technological requirements for specific applications. In this paper, a succinic-based polyol sample (obtained from biomass source) was synthesized, characterized and blended with cardanol-based polyol (Mannich-based polyol) to produce sustainable rigid polyurethane foams in which the oil-based polyol is totally replaced. A suitable amount of catalysts and surfactant, water as blowing reagent and poly-methylene diphenyl di-isocyanate as isocyanate source were used for the polyurethane synthesis. The resulting foams were characterized by means of infrared spectroscopy (FTIR) to control the cross-linking reactions, scanning electron microscopy (SEM) to evaluate the morphological structure and thermal gravimetric analysis (TGA) and thermal conductivity to evaluate thermal degradation behavior and thermal insulation properties.

Effects of a Phosphorus Flame Retardant System on the Mechanical and Fire Behavior of Microcellular ABS

The present work deals with the study of phosphorus flame retardant microcellular acrylonitrile–butadiene–styrene (ABS) parts and the effects of weight reduction on the fire and mechanical performance. Phosphorus-based flame retardant additives (PFR), aluminum diethylphosphinate and ammonium polyphosphate, were used as a more environmentally friendly alternative to halogenated flame retardants. A 25 wt % of such PFR system was added to the polymer using a co-rotating twin-screw extruder. Subsequently, microcellular parts with 10, 15, and 20% of nominal weight reduction were prepared using a MuCell^® injection-molding process. The results indicate that the presence of PFR particles increased the storage modulus and decreased the impact energy determined by means of dynamic-mechanical-thermal analysis and falling weight impact tests respectively. Nevertheless, the reduction of impact energy was found to be lower in ABS/PFR samples than in neat ABS with increasing weight reduction. This effect was attributed to the lower cell sizes and higher cell densities of the microcellular core of ABS/PFR parts. All ABS/PFR foams showed a self-extinguishing behavior under UL-94 burning vertical tests, independently of the weight reduction. Gradual decreases of the second peak of heat release rate and time of combustion with similar intumescent effect were observed with increasing weight reduction under cone calorimeter tests.

Effects of hydrotalcite on rigid polyurethane foam composites containing a fire retarding agent: compressive stress, combustion resistance, sound absorption, and electromagnetic shielding effectiveness

Polyether polyol, isocyanate, and a flame retardant (10 wt%), hydrotalcite (0, 1, 3, 5, 7, and 9 wt%) are used to form a rigid PU foam, while a nylon nonwoven fabric (400 g m⁻²) and a polyester aluminum foil are combined to serve as the panel. The rigid PU foam and the panel are then combined to form the rigid foam composites. The cell structure, compressive stress, combustion resistance, thermal stability, sound absorption, and electromagnetic shielding effectiveness of the rigid foam composites are evaluated, examining the effects of using hydrotalcite. When the hydrotalcite is 5 wt%, the rigid foam composites have an optimal density of 0.168 g cm⁻³, an average cell size of 0.2858 mm, a maximum compressive stress of 479.95 kpa, an optimal LOI of 29, an optimal EMSE of 45 dB, and the maximum thermal stability and sound absorption.

The synthesis of rigid polyurethane foam.

Thermal insulation and stability of polysiloxane foams containing hydroxyl-terminated polydimethylsiloxanes

An effective method was described here to improve the thermal insulation and stability of polysiloxane foam (SIF) by controlling the chain length of hydroxyl-terminated polydimethylsiloxane (OH-PDMS). A series of SIFs were prepared through foaming and cross-linking processes with different cross-linking densities. The morphology of SIF was investigated by environmental scanning electron microscopy. The results demonstrated that increasing the chain length of OH-PDMS reduced the average cell size from 932 μm to 220 μm. Cell density ranged from 4.92 × 10⁶ cells per cm³ to 1.64 × 10⁸ cells per cm³. The thermal insulation capability was significantly enhanced, and the SIF derived from the long-chain OH-PDMSs yielded a minimum thermal conductivity of 0.077 W mK⁻¹. Cell size reduction and an increase in cell density were considered to be the main factors to reduce thermal conductivity. Thermal stability, which was also improved, mainly depended on the free motion rate of the polysiloxane chains and cross-linking density of the polysiloxane networks.

The thermal insulation and stability of polysiloxane foam was improved by an easy operating method.

Renewable polyols for advanced polyurethane foams from diverse biomass resources

This review highlights recent advances in the synthesis of renewable polyols, used for making polyurethane foams, from biomass.