Thermal Conductivity and Mechanical Properties of Thermoplastic Polyurethane-/Silane-Modified Al2O3 Composite Fabricated via Melt Compounding

A review on vegetable oil-based non isocyanate polyurethane: towards a greener and sustainable production route

The transition from conventional polyurethane (PU) to non isocyanate polyurethane (NIPU) is driven mainly by safety concerns, environmental considerations, and sustainability issues associated with the current PU technology. NIPU has emerged as a promising alternative, addressing limitations related to traditional PU production. There has been increasing interest in bio-based NIPU aligning with the aspiration for green materials and processes. One important biomass resource for the development of bio-based NIPU is vegetable oil, an abundant, renewable, and relatively low cost feedstock. As such, this review aims to provide insight into the progression of NIPU derived from vegetable oils. This article highlights the synthetic and green approach to NIPU production, emphasizing the method involving the polyaddition reaction of cyclic carbonates and amines. The review includes case studies on vegetable oil-based NIPU and perspectives on their properties. Further, discussions on the potential applications and commercial importance of PU and NIPU are included. Finally, we offer perspectives on possible research directions and the future prospects of NIPU, contributing to the ongoing evolution of PU technology.

Flexible, Thermally Stable, and Ultralightweight Polyimide-CNT Aerogel Composite Films for Energy Storage Applications

Polyimide (PI) aerogels are promising in various fields of application, ranging from thermal insulators to aerospace. However, they are typically in the form of a bulk monolith, which suffers from a lack of conformability and drapability. Moreover, their electrical conductivity is limited, and they mainly display an insulative behavior. These shortcomings can limit the applications of PI aerogels in energy storage systems, which require ultralightweight flexible conductive films, which at the same time offer high thermal stability, ultralow density, and high surface area. To overcome these obstacles, the present study reports the fabrication of PI-carbon nanotube (PI-CNT) aerogel composite films with varying CNT content prepared through a sol-gel preparation method, followed by a supercritical drying procedure. Compared to pristine PI aerogels, which displayed a large shrinkage and density of 18.3% and 0.12 g cm-3, respectively, the incorporation of only 5 wt % CNTs resulted in a significant reduction of both shrinkage and density to only 11.5% and 0.10 g cm-3, respectively. This suggests the importance of CNTs in improving the dimensional stability of aerogels and creating a robust network. Further characterizations showed that incorporation of 5 wt % CNTs also resulted in the highest pore volume (1.25 cm3 g-1), highest surface area (324 m2 g-1), highest real permittivity (80), highest electrical conductivity (3 × 10-1 S m-1), and ultrahigh service temperature (575 °C). It was also shown that the aerogel films can withstand a large degree of bending, can be twisted, and can be fully rolled with no obvious cracks propagated in the structure. The combined outstanding properties of the developed aerogel composite films make them promising potential candidates for supercapacitor electrodes. Therefore, the electrochemical performance of the devices based on aerogel electrodes was further studied. The device demonstrated a high energy density of 2.6 Wh kg-1 at a power density of 303.8 W kg-1. The total capacitance after 5000 cycles was 91.8% of the initial capacitance, which indicated excellent stability and durability of the device. Overall, this work provides a facile yet effective methodology for the development of high-performance aerogel materials for energy storage applications.

Enhancing Dielectric Properties, Thermal Conductivity, and Mechanical Properties of Poly(lactic acid)-Thermoplastic Polyurethane Blend Composites by Using a SiC-BaTiO3 Hybrid Filler

A composite of polymer blends-thermoplastic polyurethane (TPU) and poly(lactic acid) (PLA)-and BaTiO3-SiC was fabricated. BaTiO3 particles were used to improve the dielectric properties of the composite materials, whereas SiC was used to enhance thermal conductivity without altering the dielectric properties; notably, SiC has a good dielectric constant. The surfaces of the filler particles, BaTiO3 and SiC particles, were activated; BaTiO3 was treated with methylene diphenyl diisocyanate (MDI) and SiC's surface was subjected to calcination and acid treatment, and hybrid fillers were prepared via solution mixing. The surface modifications were verified using Fourier transform infrared spectroscopy (the appearance of OH showed acid treatment of SiC, and the presence of NH, CH2, and OH groups indicated the functionalization of BaTiO3 particles). After the extruded products were cooled and dried, the specimens were fabricated using minimolding. The thermal stability of the final composites showed improvement. The dielectric constant improved relative to the main matrix at constant and variable frequencies, being about fivefold for 40% BaTiO3-SiC-TPU-PLA composites. Upon inclusion of 40 wt.% MDI functionalized BaTiO3-SiC particles, an improvement of 232% in thermal conductivity was attained, in comparison to neat TPU-PLA blends.

Improved thermal conductivity of polyurethane (PU)-/SiC composite fabricated via solution casting method and its mechanical model for prediction and comparison

Polymer composites having high thermal conductivity (TC) gained great interest, including the advancement of electronic devices to become more functionalized, scaled, and integrated. In view of these, herein, highly thermal conductive polyurethane (PU)-/SiC composites are fabricated via the solution casting method. Silicon carbide is used as the filler in both flexible and rigid-polyurethane matrices to enhance the value of TC for electronic applications. A novel model has also been developed based on the Coran-Patel model for analysis and comparison of TC of as-synthesized composites. Calculated thermal conductivities by the model are found to be consistent with the experimental results. The highest measured TC for flexible as well as rigid-PU composites is 0.521 and 0.542 Wm^-1K^-1 representing improvements of 106% and 87% over their pure equivalents, respectively. SEM and DSC techniques are employed to analyze the samples' morphology, and other thermal properties, respectively.

A Comprehensive Study of Polyurethane Potting Compounds Doped with Magnesium Oxide Nanoparticles

Recently, polyurethanes (PURs) have become a very promising group of materials with considerable utilization and innovation potential. This work presents a comprehensive analysis of the changes in material properties important for PUR applications in the electrical industry due to the incorporation of magnesium oxide (MgO) nanoparticles at different weight ratios. From the results of the investigations carried out, it is evident that the incorporation of MgO improves the volume (by up to +0.5 order of magnitude) and surface (+1 order of magnitude) resistivities, reduces the dielectric losses at higher temperatures (-62%), improves the thermal stability of the material, and slows the decomposition reaction of polyurethane at specific temperatures (+30 °C). In contrast, the incorporation of MgO results in a slight decrease in the dielectric strength (-15%) and a significant decrease in the mechanical strength (-37%).

Thermal Management of Serpentine Flexible Heater Based on the Orthotropic Heat Conduction Model

Flexible heaters can perfectly fit with undevelopable surfaces for heating in many practical applications such as thermotherapy, defogging/deicing systems and warming garments. Considering the requirement for stretchability in a flexible heater, certain spacing needs to be retained between serpentine heat sources for deformation which will inevitably bring critical challenges to the thermal uniformity. In order to reconcile these two conflicting aspects, a novel method is proposed by embedding the serpentine heat source in orthotropic layers to achieve comprehensive performance in stretchability and uniform heating. Such a scheme takes advantage of the ability of orthotropic material to control the heat flow distribution via orthotropic thermal conductivity. In this paper, an analytical heat conduction model with orthotropic substrate and encapsulation is calculated using Fourier cosine transform, which is validated by finite element analysis (FEA). Meanwhile, the effects of the orthotropic substrate or encapsulation with different ratios of thermal conductivity and the geometric spacing on the thermal properties are investigated, which can help guide the design and fabrication of flexible heaters to achieve the goal of uniform heating.

Mechanical and wear behaviour of PEEK, PTFE and PU: review and experimental study

Soft polymers such as polyether ether ketone (PEEK), polyurethane (PU) and polytetrafluoroethylene (PTFE) have gained significant research interest in the last few decades owing to their excellent material properties which can be harnessed to meet the demands of various applications such as biomedical implants and accessories, insulation panels to cooking utensils, inner coating material for non-stick cookware etc. In the present study, we provide a comprehensive review on the mechanical and tribological behaviour of PEEK, PU and PTFE polymers. Samples of these materials were also fabricated and the experimentally obtained tensile strength, flexural strength, wear rate and coefficient of frictions were ascertained with values reported in literature. It is highlighted that coefficient of friction of polymers were highly dependent on the surface texture of the polymer’s surface; where an uneven surface exhibited higher coefficient of friction. Perspectives for future progress are also highlighted in this paper.

Characterization of polypropylene/magnesium oxide/vapor-grown carbon fiber composites prepared by melt compounding

In this paper, we discussed the characteristics and properties of polypropylene (PP)/magnesium oxide (MgO) composites prepared by melt compounding. In addition, we also discussed the effect of adding vapor-grown carbon fiber (VGCF) to PP/MgO composite on the properties of the composites. The thermal conductivity of PP/MgO increased with MgO content. In the region of MgO content of more than 30 vol%, the thermal conductivity of PP/MgO with MgO-10 (particle size of 10 μm) is the largest by comparison of other PP/MgO with different MgO sizes. The thermal conductivity of PP/MgO became increased by adding VGCF in PP/MgO. According to the estimation of thermal conductivity using Bruggeman’s equation, no synergistic effect was observed by adding VGCF into the PP/MgO composite. The surface resistance of PP/MgO significantly decreased by adding VGCF at a content of more than 3 vol%. At VGCF content of 1 vol%, the surface resistance of the composite became large, and the value was more than 109 Ω/sq. In addition, the Non-Newtonian property of PP/MgO composite melt was enhanced by the addition of VGCF into the composite.

A Novel Branched Al2O3/Silicon Rubber Composite with Improved Thermal Conductivity and Excellent Electrical Insulation Performance

In this paper, we report a thermal conductive polymer composite that consists of silicone rubber (SR) and branched Al₂O₃ (B-Al₂O₃). Owing to the unique two-dimensional branched structure, B-Al₂O₃ particles form a continuous three-dimensional network structure by overlapping each other in the matrix, serving as a continuous heat conductive pathway. As a result, the polymer composite with a 70 wt% filler achieves a maximum thermal conductivity of 1.242 Wm⁻¹ K⁻¹, which is equivalent to a significant enhancement of 521% compared to that of a pure matrix. In addition, the composite maintains a high volume resistivity of 7.94 × 10¹⁴ Ω·cm with the loading of 70 wt%, indicating that it meets the requirements in the field of electrical insulation. Moreover, B-Al₂O₃ fillers are well dispersed (no large agglomerates) and form a strong interfacial adhesion with the matrix. Therefore, the thermal decomposition temperature, residual mass, tensile strength, modulus and modulus of toughness of composites are significantly improved simultaneously. This strategy provides new insights for the design of high-performance polymer composites with potential application in advanced thermal management in modern electronics.

Viscoelastic Behavior of Drug-Loaded Polyurethane

Drug-eluting stents are desirable platforms for local medicine delivery. However, the incorporation of drugs into polymers can influence the mechanical and physicochemical properties of said matrix, which is a topic that is still poorly understood. In fact, this is more noticeable since the apposition is most often accompanied by mechanical stresses on the polymer coating, which can induce therapeutic failure that can result in death. It is therefore necessary to better understand their behavior by examining their properties in conditions such as those in living beings. We studied polyurethane drug carriers made in-house. Diclofenac epolamine was chosen as a model hydrophilic medicine. We used thermal measurements (DMTA) and tensile tests. The aim was to establish the influence of the loading and release of the drug on the physicochemical properties of this polymer in the presence of a stagnant or circulating fluid medium, phosphate-buffered saline (PBS). For the two PU/drug loadings studied, the effect of the initial drug load was more marked. The free volume fraction and the number of pores in the samples increased with the increasing percent of the drug and with release time. The kinetic profiles were accelerated with the loading ratio and with the presence of flow. Young's modulus and ultimate stress were not significantly influenced by the release time. A relevant relationship between the tensile properties and the viscoelastic behavior of the samples was developed. Our results have implications for optimizing the performance of drug coatings for stents.

Influence of the Halloysite Nanotube (HNT) Addition on Selected Mechanical and Biological Properties of Thermoplastic Polyurethane

Halloysite nanotube (HNT) additions to the thermoplastic polyurethane (TPU) system were thoroughly evaluated in this study. The resultant composites have been designed for future personalized intervertebral disc implant applications, which requires additional technology to obtain the appropriate geometry unique to each patient. These requirements can be fulfilled using 3D printing. In this work, a technology was developed to produce filaments for fused deposition modeling (FDM). Nanocomposites were prepared using variable HNT content (1, 2, and 3 wt.%). The nanostructure of the resultant composites was confirmed using scanning transmission electron microscopy (STEM). Mechanical tests were used to measure the tensile modulus, stress, and elongation the composites and TPU matrix. Nanocomposites with 2% HNT content were able to withstand 26% increased stress and 50% increased elongation compared to pure TPU before fracturing in addition to a 13% reduction in the friction coefficient. A MTT cytotoxicity assay confirmed the cytotoxicity of all tested materials against human epidermal keratinocyte cells (HaCaT).

Synthesis of cross-linked polyurethane elastomers with the inclusion of polar-aromatic moieties (BA, PNBA and 3, 5-DNBA): Electrical and thermo-mechanical properties analysis

In this work, we used the design strategy “doped nonpolar polymers” and synthesized the polyurethane elastomers (PUEs) by doping with highly polar aromatic molecules such as benzoic acid (BA), 4(para)-nitro-benzoic acid (PNBA), and 3, 5-di-nitro-benzoic acid (3, 5-DNBA) by using the solution casting method. The effect of each molecule in three different weight percentages 2%, 4%, and 6% on electrical and thermo-mechanical properties of the material has studied. Experiments were carried out to determine electrical properties such as DC volume resistivity, dielectric constant, and loss factor. DMA and DSC measurements were done to assess thermo-mechanical properties. Also, thermal conductivity measurement was carried out and a strong nitro group and doping percentage dependent results have been observed. A comparative analysis of the effect on the said properties was done among the doped and undoped PUEs.

Improvement of thermal conductivity of rigid polyurethane foams with aluminum nitride filler

The aim of this work is the fabrication of electrically insulating composite rigid polyurethane foams with improved thermal conductivity. Therefore, this study is focused on the effect of aluminum nitride (AlN) on the thermal and electrical conductivities of rigid polyurethane foams. For this purpose, aluminum nitride/rigid polyurethane composite foams were prepared using a three-step procedure. The electrical and thermal conductivities of the foams were characterized. The thermal transitions, mechanical properties and morphology of the foams were also examined. The results reveal that AlN induces an increase of the thermal conductivity of rigid polyurethane foam of 24% which seems to be a relatively noticeable increase in polymeric foams. The low electrical conductivity of the foams is preserved.

Pozzolan Based 3D Printing Composites: From the Formulation Till the Final Application in the Precision Irrigation Field

A new eco-composite polymer for material extrusion fabrication based on fine fraction pozzolan waste was developed. In addition, the composite materials obtained were used to produce a self-watering pot with complex geometry and a permeable porous part to regulate the passage of water from the storage area to the roots of the plant. Moreover, the system was devised with a cover characterized by a UV-B barrier film. The results have shown the possibility of the 3D printing of complex geometric parts as microporous structures or thin films using a composite based on poly lactic acid (PLA) and pozzolan. The pozzolan has an effect of reinforcement for the composite and at the same time improves the cohesion between the layers of the part during printing.

Polydopamine-Modified Al2O3/Polyurethane Composites with Largely Improved Thermal and Mechanical Properties

Alumina/polyurethane composites were prepared via in situ polymerization and used as thermal interface materials (TIMs). The surface of alumina particles was modified using polydopamine (PDA) and then evaluated via Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TG), and Raman spectroscopy (Raman). Scanning electron microscope (SEM) images showed that PDA-Al2O3 has better dispersion in a polyurethane (PU) matrix than Al2O3. Compared with pure PU, the 30 wt% PDA-Al2O3/PU had 95% more Young's modulus, 128% more tensile strength, and 76% more elongation at break than the pure PU. Dynamic mechanical analysis (DMA) results showed that the storage modulus of the 30 wt% PDA-Al2O3/PU composite improved, and the glass transition temperature (Tg) shifted to higher temperatures. The thermal conductivity of the 30 wt% PDA-Al2O3/PU composite increased by 138%. Therefore, the results showed that the prepared PDA-coated alumina can simultaneously improve both the mechanical properties and thermal conductivity of PU.

Fabrication of Aliphatic Water-Soluble Polyurethane Composites with Silane Treated CaCO3

In the present study, composites of water-soluble polyurethane/calcium carbonate (CaCO₃) were prepared from a soft segment of hydroxyl-terminated polybutadiene (HTPB) and polyethylene glycol (PEG, average molecular weight = 4000) with aliphatic diisocyanates. The functionality of CaCO₃ particles was modified using aminopropyltriethoxysilane (APTES), and was confirmed by Fourier-transform infrared spectroscopy (FTIR). The solubility, hydrophilic properties, and chemical structures of the composites were analyzed by water-solubility tests, contact angle measurements, and FTIR, respectively, and the successful production of the hydrophilic water-soluble polyurethane (WSPU) structure was demonstrated. The adhesion of surface-modified CaCO₃ particles to the WSPU matrix and the thermal degradation properties of the neat WSPU and WSPU/CaCO₃ composites were studied using field emission scanning electron microscopy (FE-SEM) and thermogravimetric analysis (TGA). The results demonstrated good adhesion of the surface-modified CaCO₃ particles along with an improved thermal degradation temperature with the addition of CaCO₃ particles to the WSPU matrix.

Effect of DMPA and Molecular Weight of Polyethylene Glycol on Water-Soluble Polyurethane

In this study water-soluble polyurethane (WSPU) was synthesized from isophorone diisocyanate (IPDI), and polyethylene glycol (PEG), 2-bis(hydroxymethyl) propionic acid or dimethylolpropionic acid (DMPA), butane-1,4-diol (BD), and triethylamine (TEA) using an acetone process. The water solubility was investigated by solubilizing the polymer in water and measuring the contact angle and the results indicated that water solubility and contact angle tendency were increased as the molecular weight of the soft segment decreased, the amount of emulsifier was increased, and soft segment to hard segment ratio was lower. The contact angle of samples without emulsifier was greater than 87°, while that of with emulsifier was less than 67°, indicating a shift from highly hydrophobic to hydrophilic. The WSPU was also analyzed using Fourier transform infrared spectroscopy (FT-IR) to identify the absorption of functional groups and further checked by X-ray photoelectron spectroscopy (XPS). The molecular weight of WSPU was measured using size-exclusion chromatography (SEC). The structure of the WSPU was confirmed by nuclear magnetic resonance spectroscopy (NMR). The thermal properties of WSPU were analyzed using thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC).

Experimental Analysis on the Application of Polymer Matrix Composites Containing Al2O3 for Automotive Lamp Reflector

As automotive lamps are highly integrated, the heat generated from bulbs reduces the light quantity and lifespan of the bulbs. Numerous studies have been actively conducted worldwide on heat dissipation designs and material modifications for heat release. In this study, an analysis was carried out of the mechanical, thermal, and morphological characteristics of Polybutylene Terephthalate (PBT) and Polyamide (PA6) matrix composites containing alumina filler; further, their flowability and injection moldability were also studied. The PA6 matrix that was subjected to an addition of 60% alumina was selected as the sample. To compare the performances of the selected composites with that of the fog lamp reflector manufactured with conventional PBT, fog lamp reflectors were fabricated. When 60% alumina was added, the thermal conductivity was improved. Thus, the maximum temperature of the lamp reflector was reduced, and the heat was transferred to the surroundings; this was in contrast to the fog lamp reflector fabricated with conventional PBT.

Anisotropic Thermally Conductive Perfluoroalkoxy Composite with Low Dielectric Constant Fabricated by Aligning Boron Nitride Nanosheets via Hot Pressing

Thermal management has become a critical challenge in electronics and portable devices. To address this issue, polymer composites with high thermal conductivity (TC) and low dielectric property are urgently needed. In this work, we fabricated perfluoroalkoxy (PFA) composite with high anisotropic TC and low dielectric constant by aligning boron nitride nanosheets (BNNs) via hot pressing. We characterized the thermal stability, microstructure, in-plane and through-plane TCs, heat dissipation capability, and dielectric property of the composites. The results indicate that the BNNs–PFA composites possessed good thermal stability. When the BNNs content was higher than 10 wt %, the BNNs were well layer aligned in the PFA matrix, and the composites showed obvious anisotropic TC. The in-plane TC and through-plane TCs of 30 wt % BNNs–PFA composite were 4.65 and 1.94 W m⁻¹ K⁻¹, respectively. By using the composite in thermal management of high-power LED, we found that alignment of BNNs in composite significantly improves the heat dissipation capability of composite. In addition, the composites exhibited a low dielectric property. This study shows that hot pressing is a facile and low-cost method to fabricate bulk composite with anisotropic TC, which has wide applications in electronic packaging.

Effect of the Compounding Conditions of Polyamide 6, Carbon Fiber, and Al2O3 on the Mechanical and Thermal Properties of the Composite Polymer

Among the composite manufacturing methods, injection molding has higher time efficiency and improved processability. The production of composites via injection molding requires a pre-process to mix and pelletize the matrix polymer and reinforcement material. Herein, we studied the effect of extrusion process conditions for making pellets on the mechanical and thermal properties provided by injection molding. Polyamide 6 (PA6) was used as the base, and composites were produced by blending carbon fibers and Al₂O₃ as the filler. To determine the optimum blending ratio, the mechanical properties, thermal conductivity, and melt flow index (MI) were measured at various blending ratios. With this optimum blending ratio, pellets were produced by changing the temperature and RPM conditions, which are major process variables during compounding. Samples were fabricated by applying the same injection conditions, and the mechanical strength, MI values, and thermal properties were measured. The mechanical strength increased slightly as the temperature and RPM increased, and the MI and thermal conductivity also increased. The results of this study can be used as a basis for specifying the conditions of the mixing and compounding process such that the desired mechanical and thermal properties are obtained.

Evaluation of Thermal Properties of 3D Spacer Technical Materials in Cold Environments using 3D Printing Technology

Novel materials have been recently developed for coping with various environmental factors. Generally, to improve the thermal comfort to humans in cold environments, securing an air layer is important. Therefore, this study analyzed the thermal properties of 3D spacer technical materials, 3D printed using thermoplastic polyurethane, according to the structural changes. Four 3D spacer technical material structures were designed with varying pore size and thickness. These samples were moved into a cold climate chamber (temperature 5 ± 1 °C, relative humidity (60 ± 5)%, wind velocity ≤0.2 m/s) and placed on a heating plate set to 30 °C. The surface and internal temperatures were measured after 0, 10, 20, and 30 min and then 10 min after turning off the heating plate. When heat was continuously supplied, the 3D spacer technical material with large pores and a thick air layer showed superior insulation among the materials. However, when no heat was supplied, the air gap thickness dominantly affected thermal insulation, regardless of the pore size. Hence, increasing the air gap is more beneficial than increasing the pore size. Notably, we found that the air gap can increase insulation efficiency, which is of importance to the new concept of 3D printing an interlining.