Improving the Insulating Capacity of Polyurethane Foams through Polyurethane Aerogel Inclusion: From Insulation to Superinsulation

A novel synthesis of polyurethane foam/polyurethane aerogel (PU_F–PU_A) composites is presented. Three different polyurethane reticulated foams which present the same density but different pore sizes (named S for small, M for medium, and L for large) have been used. After the characterization of the reference materials (either, foams, and pure aerogel), the obtained composites have been characterized in order to study the effect of the foam pore size on the final properties, so that density, shrinkage, porous structure, mechanical properties, and thermal conductivity are determined. A clear influence of the pore size on the density and shrinkage was found, and the lowest densities are those obtained from L composites (123 kg/m³). Moreover, the aerogel density and shrinkage have been significantly reduced through the employment of the polyurethane (PU) foam skeleton. Due to the enhanced mechanical properties of polyurethane aerogels, the inclusion of polyurethane aerogel into the foam skeleton helps to increase the elastic modulus of the foams from 0.03 and 0.08 MPa to 0.85 MPa, while keeping great flexibility and recovery ratios. Moreover, the synthesized PU_F–PU_A composites show an excellent insulating performance, reducing the initial thermal conductivity values from 34.1, 40.3, and 50.6 mW/(m K) at 10 °C for the foams S, M, and L, to 15.8, 16.6, and 16.1 mW/(m K), respectively. Additionally, the effect of the different heat transfer mechanisms to the total thermal conductivity is herein analyzed by using a theoretical model as well as the influence of the measurement temperature.

The effect of organofluorine additives on the morphology, thermal conductivity and mechanical properties of rigid polyurethane and polyisocyanurate foams

This study investigates the effect of liquid-type organofluorine additives (OFAs) on the morphology, thermal conductivity and mechanical properties of rigid polyurethane (PU) and polyisocyanurate (PIR) foams. Foams were characterized in terms of their morphology (density, average cell size, anisotropy ratio, open cell content), thermal conductivity and compressive as well as flexural properties. Based on the results, we observed that OFAs efficiently reduced the average cell size of both PU and PIR foams, leading to improved thermal insulating and mechanical properties.

Microstructure Measurement and Microgeometric Packing Characterization of Rigid Polyurethane Foam Defects

Streak and blister cell defects pose extensive surface problems for rigid polyurethane foams. In this study, these morphological anomalies were visually inspected using 2D optical techniques, and the cell microstructural coefficients including degree of anisotropy cell circumdiameter, and the volumetric isoperimetric quotient were calculated from the observations. A geometric regular polyhedron approximation method was developed based on relative density equations, in order to characterize the packing structures of both normal and anomalous cells. The reversely calculated cell volume constant, Cc, from polyhedron geometric voxels was compared with the empirical polyhedron cell volume value, Ch. The geometric relationship between actual cells and approximated polyhedrons was characterized by the defined volumetric isoperimetric quotient. Binary packing structures were derived from deviation comparisons between the two cell volume constants, and the assumed partial relative density ratios of the two individual packing polyhedrons. The modelling results show that normal cells have a similar packing to the Weaire-Phelan model, while anomalous cells have a dodecahedron/icosidodecahedron binary packing.

Mechanical Response of Polyethylene Foams with High Densities and Cell Sizes in the Microcellular Range

This article presents the compressive mechanical response at low strains for a collection of polyethylene foams with high densities and cell sizes in the microcellular range. The materials under study had a relative density between 0.27 and 0.92, a homogeneous and multi-structured cellular structure with a dense skin and a foamed core. The Young’s modulus and collapse stress were reduced when density did, the modulus following a linear trend and the collapse stress a quadratic tendency. For relative densities higher than 0.7, the materials showed Young’s modulus slightly above the limit given by a potential law with exponent equal to one. In addition, it has been proved that variations in the cell size did not influence the elastic properties. The advantages of using these materials for flat structural panels have been analyzed. A reduction of the weight of flat panels loaded in bending of up to 35% can be reached by using these foams in spite of the solid sheet from which the foam was produced.

Mechanical Behaviour at Low Strains of LDPE Foams with Cell Sizes in the Microcellular Range: Advantages of Using These Materials in Structural Elements

This paper presents the production method and the compressive mechanical response at low strains for a collection of polyethylene foams with high densities and cell sizes in the microcellular range. The materials were produced using an improved compression moulding technique that allows and independent control of density and cell size.

The materials had a relative density between 0.27 and 0.92, an homogeneous and multi-structured cellular structure with dense skin and foamed core and cell sizes in the range 30 to 100 microns. The Young's modulus decreased with density. For relative densities higher than 0.7, the reduced Young's modulus of the foams was higher than that of the solid. In addition, it has been proved that variations in the cell size at constant density did not influence the Young's modulus. The advantages of using these materials for the production of plastic pipes have been analysed. In comparison with a solid pipe a reduction of the weight of foamed pipes loaded in compression of up to 40% can be reached.