Clays as Inhibitors of Polyurethane Foams' Flammability

Polyurethanes Modified by Ionic Liquids and Their Applications

Polyurethane (PU) refers to the polymer containing carbamate groups in its molecular structure, generally obtained by the reaction of isocyanate and alcohol. Because of its flexible formulation, diverse product forms, and excellent performance, it has been widely used in mechanical engineering, electronic equipment, biomedical applications, etc. Through physical or chemical methods, ionic groups are introduced into PU, which gives PU electrical conductivity, flame-retardant, and antistatic properties, thus expanding the application fields of PU, especially in flexible devices such as sensors, actuators, and functional membranes for batteries and gas absorption. In this review, we firstly introduced the characteristics of PU in chemical and microphase structures and their related physical and chemical performance. To improve the performance of PU, ionic liquids (ILs) were applied in the processing or synthesis of PU, resulting in a new type of PU called ionic PU. In the following part of this review, we mainly summarized the fabrication methods of IL-modified PUs via physical blending and the chemical copolymerization method. Then, we summarized the research progress of the applications for IL-modified PUs in different fields, including sensors, actuators, transistors, antistatic films, etc. Finally, we discussed the future development trends and challenges faced by IL-modified PUs.

Fireproof Nanocomposite Polyurethane Foams: A Review

First introduced in 1954, polyurethane foams rapidly became popular because of light weight, high chemical stability, and outstanding sound and thermal insulation properties. Currently, polyurethane foam is widely applied in industrial and household products. Despite tremendous progress in the development of various formulations of versatile foams, their use is hindered due to high flammability. Fire retardant additives can be introduced into polyurethane foams to enhance their fireproof properties. Nanoscale materials employed as fire-retardant components of polyurethane foams have the potential to overcome this problem. Here, we review the recent (last 5 years) progress that has been made in polyurethane foam modification using nanomaterials to enhance its flame retardance. Different groups of nanomaterials and approaches for incorporating them into foam structures are covered. Special attention is given to the synergetic effects of nanomaterials with other flame-retardant additives.

Buckwheat Hulls/Perlite as an Environmentally Friendly Flame-Retardant System for Rigid Polyurethane Foams

This article presents an innovative approach to the flame retardancy of rigid polyurethane foams using natural waste in the form of buckwheat hulls in combination with an inorganic additive-perlite. A series of tests were presented in which various contents of flame-retardant additives were used. Based on the test results, it was found that the addition of the buckwheat hull/perlite system affected the physical and mechanical properties of the obtained foams, i.e., apparent density, impact strength, and compressive and flexural strength. The structure of the system had also changed, directly affecting the hydrophobic properties of the foams. In addition, it was observed that the addition of buckwheat hull/perlite modifiers improved the burning behavior of composite foams.

Influence of Surface-Modified Montmorillonite Clays on the Properties of Elastomeric Thin Layer Nanocomposites

In recent years, polyurethane nanocomposites have attracted more attention due to the massive demand for materials with increasingly exceptional mechanical, optical, electrical, and thermal properties. As nanofillers have a high surface area, the interaction between the nanofiller and the polymer matrix is an essential issue for these materials. The main aim of this study is to validate the impact of the montmorillonite nanofiller (MMT) surface structure on the properties of polyurethane thin-film nanocomposites. Despite the interest in polyurethane-montmorillonite clay nanocomposites, only a few studies have explored the impact of montmorillonite surface modification on polyurethane's material properties. For this reason, four types of polyurethane nanocomposites with up to 3% content of MMT were manufactured using the prepolymer method. The impact of montmorillonites on nanocomposites properties was tested by thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), contact angle measurement, X-ray diffraction (XRD), and optical coherence tomography (OCT). The results showed that chemical and physical interactions between the polymer matrix and functional groups on the montmorillonite surface have a considerable impact on the final properties of the materials. It was noticed that the addition of MMT changed the thermal decomposition process, increased T_2% by at least 14 °C, changed the hydrophilicity of the materials, and increased the glass transition temperature. These findings have underlined the importance of montmorillonite surface structure and interactions between nanocomposite phases for the final properties of nanocomposites.

Comprehensive Investigation of Stoichiometry–Structure–Performance Relationships in Flexible Polyurethane Foams

Polyurethane (PU) foams are versatile materials with a broad application range. Their performance is driven by the stoichiometry of polymerization reaction, which has been investigated in several works. However, the analysis was often limited only to selected properties and compared samples differing in apparent density, significantly influencing their performance. In the bigger picture, there is still a lack of comprehensive studies dealing with the stoichiometry impact on PU foams’ performance. Herein, flexible PU foams with a similar apparent density but differing in the isocyanate index (IIso) (from 0.80 to 1.20) were prepared. The stoichiometry–structure–performance relationships were investigated considering cellular and chemical structure, as well as the static and dynamic mechanical properties, thermal stability, thermal insulation, and acoustic performance. For IIso of 1.00, the biggest cell diameters of 274 µm were noted, which was 21–25% higher compared to 0.80 and 1.20 values. Increasing IIso reduced open cell content from 83.1 to 22.4%, which, combined with stiffening of structure (rise of modulus from 63 to 2787 kPa) resulting from crosslinking, limited the sound suppression ability around five times. On the other hand, it significantly strengthened the material, increasing tensile and compressive strength 4 and 13 times, respectively. Changes in the foams’ performance were also induced by the glass transition temperature shift from 6.1 to 31.7 °C, resulting from a greater extent of urethane groups’ generation and additional isocyanate reactions. Generally, the presented work provides important insights into preparing flexible PU foams and could be very useful for the future development of these materials.

Recent Advances in Development of Waste-Based Polymer Materials: A Review

Limited petroleum sources, suitable law regulations, and higher awareness within society has caused sustainable development of manufacturing and recycling of polymer blends and composites to be gaining increasing attention. This work aims to report recent advances in the manufacturing of environmentally friendly and low-cost polymer materials based on post-production and post-consumer wastes. Sustainable development of three groups of materials: wood polymer composites, polyurethane foams, and rubber recycling products were comprehensively described. Special attention was focused on examples of industrially applicable technologies developed in Poland over the last five years. Moreover, current trends and limitations in the future “green” development of waste-based polymer materials were also discussed.

Formation of an Ammonium Nitrate Fuel Oil Similar Type of Explosive under Fire Conditions: Materials Based on Selected Polymers (PUR)

Polyurethanes (PURs) are a group of polymers with the most versatile properties and the broadest spectrum of application. Their name comes from the urethane group. PURs were introduced to the market on a large-scale basis by Bayer in 1942, in the form of Perlon U and Igamid U fibers produced by gradual polyaddition of diisocyanates and polyols. The development of PURs-production technology and the multitude of applications resulted in their widespread use. This group is so extensive that polyurethanes alone accounted for about 6% of the global production of polymers (2019)—most of them in the form of foam. Therefore, polyurethane can be found in a huge number of products—some of them stored in the vicinity of ammonium nitrate (AN). In the previous two articles, we showed that polymers and AN—stored within the same building—in fire conditions may, under certain circumstances, spontaneously transform into a material of explosive properties. The aim of this article is to check whether PUR, when in contact with AN, creates additional hazards, similarly to the previously tested polymers.

Characterization and Properties of Water-Blown Rigid Polyurethane Foams Reinforced with Silane-Modified Nanosepiolites Functionalized with Graphite

In the present study, a promising flame retardant consisting of 80 wt% silane-modified nanosepiolites functionalized with 20 wt% graphite (SFG) is used to obtain a synergistic effect principally focussed on the thermal stability of water-blown rigid polyurethane (RPU) foams. Density, microcellular structure, thermal stability and thermal conductivity are examined for RPU foams reinforced with different contents of SFG (0, as reference material, 2, 4 and 6 wt%). The sample with 6 wt% SFG presents a slightly thermal stability improvement, although its cellular structure is deteriorated in comparison with the reference material. Furthermore, the influence of SFG particles on chemical reactions during the foaming process is studied by FTIR spectroscopy. The information obtained from the chemical reactions and from isocyanate consumption is used to optimize the formulation of the foam with 6 wt% SFG. Additionally, in order to determine the effects of functionalization on SFG, foams containing only silane-modified nanosepiolites, only graphite, or silane-modified nanosepiolites and graphite added separately are studied here as well. In conclusion, the inclusion of SFG in RPU foams allows the best performance to be achieved.