Phenolic Resin Foam Composites Reinforced by Acetylated Poplar Fiber with High Mechanical Properties, Low Pulverization Ratio, and Good Thermal Insulation and Flame Retardant Performance

Facile Synthesis and Properties of Highly Porous Quartz Fiber-Reinforced Phenolic Resin Composites with High Strength

Lightweight and high-strength insulation materials have important application prospects in the aerospace, metallurgical, and nuclear industries. In this study, a highly porous silica fiber reinforced phenolic resin matrix composite was prepared by vacuum impregnation and atmospheric drying using quartz fiber needled felt as reinforcement and anhydrous ethanol as a pore-making agent. The effects of curing agent content on the structure, composition, density, and thermal conductivity of the composite were studied. The mechanical properties of the composite in the xy direction and z direction were analyzed. The results showed that this process can also produce porous phenolic resin (PR) with a density as low as 0.291 g/cm3, where spherical phenolic resin particles are interconnected to form a porous network structure with a particle size of about 5.43 μm. The fiber-reinforced porous PR had low density (0.372~0.397 g/cm3) and low thermal conductivity (0.085~0.095 W/m·K). The spherical phenolic resin particles inside the composite were well combined with the fiber at the interface and uniformly distributed in the fiber lap network. The composite possessed enhanced mechanical properties with compressive strength of 3.5-5.1 MPa in the xy direction and appeared as gradual compaction rather than destruction as the strain reached 30% in the z direction. This research provides a lightweight and high-strength insulation material with a simple preparation process and excellent performance.

Mesoporous multi-shelled hollow resin nanospheres with ultralow thermal conductivity

Hollow nanostructures exhibit enclosed or semi-enclosed spaces inside and the consequent features of restricting molecular motion, which is crucial for intrinsic physicochemical properties. Herein, we developed a new configuration of hollow nanostructures with more than three layers of shells and simultaneously integrated mesopores on every shell. The novel interior configuration expresses the characteristics of periodic interfaces and abundant mesopores. Benefiting from the suppression of gas molecule convection by boundary scattering, the thermal conductivity of mesoporous multi-shelled hollow resin nanospheres reaches 0.013 W m-1 K-1 at 298 K. The designed interior mesostructural configuration of hollow nanostructures provides an ideal platform to clarify the influence of nanostructure design on intrinsic physicochemical properties and propels the development of hollow nanostructures.

Thermal degradation, visco-elastic and fire-retardant behavior of hybrid Cyrtostachys Renda/kenaf fiber-reinforced MWCNT-modified phenolic composites

Natural fibers have emerged as a potential alternate to synthetic fibers, because of their excellent performance, biodegradability, renewability and sustainability. This research has focused on investigating the thermal, visco-elastic and fire-retardant properties of different hybrid Cytostachys Renda (CR)/kenaf fiber (K) (50/0; 35/ 15, 25/25, 15/ 35, 0/50)-reinforced MWCNT (multi-walled carbon nanotubes)-modified phenolic composites. The mass% of MWCNT-modified phenolic resin was maintained 50 mass% including 0.5 mass% of MWCNT. In order to achieve homogeneous dispersion ball milling process was employed to incorporate the MWCNT into phenolic resin (powder). Thermal results from thermogravimetric analysis and differential scanning calorimetric analysis revealed that the hybrid composites (35/15; 35 mass% CR and 15 mass% K) showed higher thermal stability among the composite samples. Visco-elastic results revealed that kenaf fiber-based MWCNT-modified composites (0/50; 0 mass% CR and 50 mass% K) exhibited higher storage and loss modulus due to high modulus kenaf fiber. Fire-retardant analysis (UL-94) showed that all the composite samples met H-B self-extinguishing rating and exhibited slow burning rate according to limiting oxygen index (LOI) test. However, (15/35; 15 mass% CR and 35 mass% K) hybrid composites showed the highest time to ignition, highest fire performance index, lowest total heat release rate, average mass loss rate, average fire growth rate index and maximum average rate of heat emission. Moreover, the smoke density of all hybrid composites was found to be less than 200 which meets the federal aviation regulations (FAR) 25.853d standard. Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) was carried out to select an optimal composite sample considering the thermal, visco-elastic and fire-retardant behaviors. Through TOPSIS analysis, the hybrid (15/35; 15 mass% CR and 35 mass% K) composite sample has been selected as an optimal composite which can be used for high-temperature aircraft and automotive applications.

Lignin-Based Phenolic Foam Reinforced by Poplar Fiber and Isocyanate-Terminated Polyurethane Prepolymer

Phenolic foams (PFs) are lightweight (<200 kg/m³), high-quality, and inexpensive thermal insulation materials whose heat and fire resistance are much better than those of foam plastics such as polyurethane and polystyrene. They are especially suitable for use as insulation in chemical, petroleum, construction, and other fields that are prone to fires. However, PFs have poor mechanical properties, poor abrasion resistance, and easy pulverization. In this paper, a polyurethane prepolymer was treated with an isocyanate, and then the isocyanate-terminated polyurethane prepolymer and poplar powder were used to prepare modified lignin-based phenolic foams (PUPFs), which improved the abrasion resistance and decreased the pulverization of the foam. The foam composites were comprehensively evaluated by characterizing their chemical structures, surface morphologies, mechanical properties, thermal conductivities, and flame-retardant properties. The pulverization ratio was reduced by 43.5%, and the thermal insulation performance and flame-retardancy (LOI) were improved. Compared with other methods to obtain lignin-based phenolic foam composites with anti-pulverization and flame-retardant properties, the hybrid reinforcement of foam composites with an isocyanate-terminated polyurethane prepolymer and poplar powder offers a novel strategy for an environmentally friendly alternative to the use of woody fibers.

Synergistic impact of cellulose nanocrystals with multiple resins on thermal and mechanical behavior

The cellulose nanocrystals (CNCs) surface modified with phenolic and acrylic resins were investigated for different properties such as thermally stability and adhesive property, the mechanical properties of CNCs and interactions of the resulting materials at a micro-level are very important. Phenolic resins are of great interest due to their smooth structure, low thermal conductivity and good thermal insulation. However, the high spray rates and poor mechanical properties limit its use for external insulation of buildings. Acrylic resins are used as a matrix resin for adhesives and composites due to their adhesion, mechanical properties, and their good chemical resistance. The brittleness of acrylic resins makes them less attractive than the structural materials, being much harder. For this reason, most of the resins are modified with suitable elastomers, which act as hardeners. Therefore, treatment of these compounds is necessary. In this research paper, the effect of CNCs surface on phenolic and acrylic resins were investigated to obtain an optimized surface using three different weight (wt%) ratios of CNCs. Scanning electronic microscopy (SEM), X-rays diffraction (XRD), Thermogravimetric analysis (TGA) and Fourier transform infrared spectroscopy (FTIR) were used to characterize the structure, and investigate different properties of CNCs. Furthermore, the Zwick/Roell Z020 model was used to investigate the adhesion properties of the phenolic and acrylic resins with CNCs.