Closed Cell Rigid Polyurethane Foams Based on Low Functionality Polyols: Research of Dimensional Stability and Standardised Performance Properties

Development of Rigid Polyurethane Foams Based on Kraft Lignin Polyol Obtained by Oxyalkylation Using Propylene Carbonate

This study aimed to develop new rigid polyurethane foams (RPUFs) for thermal insulation based on kraft lignin, the main by-product of the pulp and paper industry. Crude lignin-based polyol (LBP) was obtained via the oxyalkylation of kraft lignin using propylene carbonate (PC). A design of experiments (DoE) was used to evaluate the effect of the isocyanate (NCO)-to-hydroxyl (OH)-group’s ratio, the content of crude LBP, the blowing agent (BA), and catalyst on the thermal conductivity and density of RPUFs. Statistical analysis revealed that the increase in crude LBP and BA content in the formulation decreases the thermal conductivity and density of the foams. In addition, the fact that LBP is a viscous polyol containing PC-oligomers appears to affect the cellular structure of RPUFs, and consequently reduces their mechanical and thermal properties. The main novelty of this study consisted in the careful optimization of the formulation, namely, with regard to the type of blowing agent and with the high content of crude LBP obtained from the oxyalkylation of LignoBoost kraft lignin without purification to obtain good quality RPUF that meets market requirements for insulation materials.

Properties of Rigid Polyurethane Foam Filled with Sawdust from Primary Wood Processing

In this study, the possibility of using sawdust, a by-product of primary wood processing, as a filler (WF) for rigid polyurethane (PUR) foams was investigated. The effects of the addition of 5, 10, 15 and 20% of WF particles to the polyurethane matrix on the foaming process, cell structure and selected physical-mechanical properties such as density, thermal conductivity, dimensional stability, water absorption, brittleness, compressive and bending strengths were evaluated. Based on the results, it was found that the addition of WF in the amount of up to 10% does not significantly affect the kinetics of the foam foaming process, allowing the reduction of their thermal conductivity, significantly reducing brittleness and maintaining high dimensional stability. On the other hand, such an amount of WF causes a slight decrease in the compressive strength of the foam, a decrease in its bending strength and an increase in water absorption. However, it is important that in spite of the observed decrease in the values of these parameters, the obtained results are satisfactory and consistent with the parameters of insulation materials based on rigid PUR foam, currently available on the market.

Scale-Up and Testing of Polyurethane Bio-Foams as Potential Cryogenic Insulation Materials

This article compares the properties of closed-cell PUR bio-foams produced on a laboratory scale and on an industrial scale. In the formulation used, the polyol premix contained 40 wt.% of a bio-polyol based on rapeseed oil. Selected useful properties of the foams obtained on the two scales and the use of one-step and spraying methods were compared. In the case of the spraying method, the experimental system was compared to a commercial one. Given the possibility of applying the bio-foams in insulation systems for cryogenic and liquefied natural gas (LNG) applications, a compressive strength analysis of the foams was carried out at room temperature as well as at −196 °C. It was found that the foams modified with the bio-polyol were characterized by a higher compressive strength at low temperatures than commercial foams based on a petrochemical polyol.

Polyurethane Foam Composites Reinforced with Renewable Fillers for Cryogenic Insulation

Sawdust, microcellulose and nanocellulose and their silanized forms were used to reinforce rigid polyurethane (PU) foam composites. The concentration of fillers was varied in the range of 0.5-1.5%. For rigid PU foam formulations, three polyols from recycled and renewable materials were used, among other components. Polyols were obtained from rapeseed oil, tall oil fatty acids and recycled polyethylene terephthalate. As rigid PU foam composites in literature have been described as appropriate thermal insulation material, the appliance of obtained composites for cryogenic insulation was investigated by determining the various physical-mechanical properties of composites. The physical-mechanical properties, such as the modulus of elasticity, compressive and tensile strength in both 293 K and 77 K, adhesion measurements with and without cryo-shock, apparent density, thermal conductivity coefficient, and safety coefficient were measured. The results showed that the addition of fillers did not give a significant improvement of characteristics.

Bio-Based Rigid Polyurethane Foam Composites Reinforced with Bleached Curauá Fiber

This study aims to evaluate the influence of using a bleached Curauá fiber (CF) as filler in a novel rigid polyurethane foam (RPUF) composite. The influence of 0.1, 0.5 and 1 wt.% of the reinforcements on the processing characteristics, cellular structure, mechanical, dynamic-mechanical, thermal, and flame behaviors were assessed and discussed for RPUF freely expanded. The results showed that the use of 0.5 wt.% of CF resulted in RPUF with smoother cell structure with low differences on the processing times and viscosity for the filled pre-polyol. These morphological features were responsible for the gains in mechanical properties, in both parallel and perpendicular rise directions, and better viscoelastic characteristics. Despite the gains, higher thermal conductivity and lower flammability were reported for the developed RPUF composites, related to the high content of cellulose and hemicellulose on the bleached CF chemical composition. This work shows the possibility of using a Brazilian vegetable fiber, with low exploration for the manufacturing of composite materials with improved properties. The developed RPUF presents high applicability as enhanced cores for the manufacturing of structural sandwich panels, mainly used in civil, aircraft, and marine industries.

Vacuum-Based Impregnation of Liquid Glass into Sunflower Press Cake Particles and Their Use in Bio-Based Rigid Polyurethane Foam

The study analyses rigid polyurethane (PUR) foam modified with 10-30 wt.% sunflower press cake (SFP) and liquid glass-impregnated sunflower press cake (LG-SFP) particles and their impact on performance characteristics of PUR foams-foaming behaviour, rheology, thermal conductivity, compressive strength parallel and perpendicular to the foaming directions, tensile strength, dimensional stability, short-term water absorption by partial immersion, and thermal stability. Even though the dynamic viscosity and apparent density were increased for SFP and LG-SFP formulations, thermal conductivity values improved by 17% and 10%, respectively, when 30 wt.% of particles were incorporated. The addition of SFP and LG-SFP particles resulted in the formation of more structurally and dimensionally stable PUR foams with a smaller average cell size and a greater content of closed cells. At 30 wt.% of SFP and LG-SFP particles, compressive strength increased by 114% and 46% in the perpendicular direction, respectively, and by 71% and 67% in the parallel direction, respectively, while tensile strength showed an 89% and 85% higher performance at 30 wt.% SFP and LG-SFP particles loading. Furthermore, short-term water absorption for all SFP and LG-SFP modified PUR foam formulations was almost two times lower compared to the control foam. SFP particles reduced the thermal stability of modified PUR foams, but LG-SFP particles shifted the thermal decomposition temperatures towards higher ones.

Mechanical Properties of Polyurethane Adhesive Bonds in a Mineral Wool-Based External Thermal Insulation Composite System for Timber Frame Buildings

This paper aims to provide a preliminary assessment of polyurethane adhesive applicability as an alternative to conventional cement-based adhesives used to fix thermal insulation materials to substrates concerning mineral wool-based external thermal insulation composite systems. Currently, polyurethane adhesives are only used in expanded polystyrene-based ETICS. This study discusses the suitability of polyurethane adhesive for ETICS with lamella mineral-wool for timber frame buildings. Bond strength, shear strength and shear modulus tests were conducted. In addition, microstructure and apparent density were analysed. Mechanical properties were analysed in terms of the influence of substrate type and thermal and moisture conditions, taking into account solutions typical for sheathing on timber frame (oriented strand boards (OSB), fibre-reinforced gypsum boards (FGB) and cement-bonded particleboards (CPB)), as well as limit conditions for adhesive application. It was found that PU adhesive can achieve adhesion, both to MW and OSB, and FGB and CPB at ≥80 kPa, which is considered satisfactory for PU adhesives for EPS-based ETICS. Favourable shear properties were also obtained. There was no significant effect of sheathing type on the properties considered, but the influence of temperature and relative humidity, in which the bonds were made, was spotted. The results obtained can be considered promising in further assessing the usefulness of PU adhesives for MW-based ETICS.

Characterization of changes in structural, physicochemical and mechanical properties of rigid polyurethane building insulation after thermal aging in air and seawater

The purpose of this study was the identification of qualitative and quantitative changes in the visual appearance, chemical structure, morphology and selected physicochemical and mechanical properties of the closed cell rigid PU foam while heated in air and seawater for predicting its performance and durability. Specimens were aged at constant temperatures of 40 and 80 °C for a period of 10 weeks. Aging caused a yellowing of the samples. Scanning electron microscopy (SEM) revealed that foam pores lost their regularity. Differential scanning calorimetry (DSC) showed that the glass transition temperature (Tg) increased on average by 15 and 80%, respectively for samples heated at 40 and 80 °C. Water absorption (WS) also increased over time, respectively, by a maximum of 15 and 25%. The flexural strength (σflex) and compressive (σcomp) strength showed a decreasing tendency, whereas for tensile strength (σtens), an increase was observed. The starting material was characterized by the σflex, σtens and σcomp of: 436, 413 and 284 kPa, respectively. The lowest determined σflex value was of 345 kPa, and σcomp value was of 158 kPa. The highest determined σtens equaled to 608 kPa, respectively. The changes in flexural modulus were statistically insignificant and its average value was of 4.0 MPa.

Rigid Polyurethane Foams Reinforced with POSS-Impregnated Sugar Beet Pulp Filler

Rigid polyurethane (PUR) foams were reinforced with sugar beet pulp (BP) impregnated with Aminopropylisobutyl-polyhedral oligomeric silsesquioxanes (APIB-POSS). BP filler was incorporated into PUR at different percentages—1, 2, and 5 wt.%. The impact of BP filler on morphology features, mechanical performances, and thermal stability of PUR was examined. The results revealed that the greatest improvement in physico-mechanical properties was observed at lower concentrations (1 and 2 wt.%) of BP filler. For example, when compared with neat PUR foams, the addition of 2 wt.% of BP resulted in the formation of PUR composite foams with increased compressive strength (~12%), greater flexural strength (~12%), and better impact strength (~6%). The results of thermogravimetric analysis (TGA) revealed that, due to the good thermal stability of POSS-impregnated BP filler, the reinforced PUR composite foams were characterized by better thermal stability—for example, by increasing the content of BP filler up to 5 wt.%, the mass residue measured at 600 °C increased from 29.0 to 31.9%. Moreover, the addition of each amount of filler resulted in the improvement of fire resistance of PUR composite foams, which was determined by measuring the value of heat peak release (pHRR), total heat release (THR), total smoke release (TSR), limiting oxygen index (LOI), and the amount of carbon monoxide (CO) and carbon dioxide (CO₂) released during the combustion. The greatest improvement was observed for PUR composite foams with 2 wt.% of BP filler. The results presented in the current study indicate that the addition of a proper amount of POSS-impregnated BP filler may be an effective approach to the synthesis of PUR composites with improved physico-mechanical properties. Due to the outstanding properties of PUR composite foams reinforced with POSS-impregnated BP, such developed materials may be successfully used as thermal insulation materials in the building and construction industry.

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.

The Synergistic Effect of Ionic Liquid-Modified Expandable Graphite and Intumescent Flame-Retardant on Flame-Retardant Rigid Polyurethane Foams

In this study, a nitrogen–phosphorus intumescent flame-retardant 3-(N-diphenyl phosphate) amino propyl triethoxy silane (DPES), the ionic liquid (IL) of 1-butyl-3-methyl-imidazole phosphate, and a phosphorous-containing ionic liquid-modified expandable graphite (IL-EG), were synthesized, and their molecular structures were characterized. The flame-retardant rigid polyurethane foams (RPUFs) were compounded with synergistic flame-retardant IL-EG/DPES to study the effects of the combination IL-EG and DPES on the pore structure, mechanical properties, thermal decomposition behavior and thermal decomposition mechanism of RPUF. The results showed that IL-EG/DPES had good thermal stability, and an excellent expansibility and char yield. The flame-retardant RPUF, modified with IL-EG and DPES at the ratio of 1:1, had a relatively uniform pore size, the highest compressive strength, and an excellent flame-retardant performance due to the form interwoven hydrogen bonds between IL-EG and DPES, as well as the new synergistic flame-retardant coating on the RPUF surface to restrict the transfer of gas or heat into the PU matrix.

High Functionality Bio-Polyols from Tall Oil and Rigid Polyurethane Foams Formulated Solely Using Bio-Polyols

High-quality rigid polyurethane (PU) foam thermal insulation material has been developed solely using bio-polyols synthesized from second-generation bio-based feedstock. High functionality bio-polyols were synthesized from cellulose production side stream—tall oil fatty acids by oxirane ring-opening as well as esterification reactions with different polyfunctional alcohols, such as diethylene glycol, trimethylolpropane, triethanolamine, and diethanolamine. Four different high functionality bio-polyols were combined with bio-polyol obtained from tall oil esterification with triethanolamine to develop rigid PU foam formulations applicable as thermal insulation material. The developed formulations were optimized using response surface modeling to find optimal bio-polyol and physical blowing agent: c-pentane content. The optimized bio-based rigid PU foam formulations delivered comparable thermal insulation properties to the petro-chemical alternative.