Rigid Polyurethane Foams' Development and Optimization from Polyols Based on Depolymerized Suberin and Tall Oil Fatty Acids

The utilization of polyols derived from renewable sources presents an opportunity to enhance the sustainability of rigid polyurethane (PUR) foams, thereby contributing to the advancement of a circular bioeconomy. This study explores the development of PUR rigid foams exclusively using polyols sourced from second-generation renewable biomass feedstocks, specifically depolymerized birch bark suberin (suberinic acids) and tall oil fatty acids. The polyols achieved a total renewable material content as high as 74%, with a suberinic acid content of 37%. Response surface modeling was employed to determine the optimal bio-polyol, blowing agents, and catalyst content, hence, optimizing the bio-based foam formulations. In addition, response surface modeling was applied to rigid PUR foam formulations based on commercially available petroleum-based polyols for comparison. The results, including apparent density (~40-44 kg/m3), closed cell content (~95%), compression strength (>0.2 MPa, parallel to the foaming direction), and thermal conductivity (~0.019 W/(m·K)), demonstrated that the suberinic acids-based rigid PUR foam exhibited competitive qualities in comparison to petroleum-based polyols. Remarkably, the bio-based rigid PUR foams comprised up to 29% renewable materials. These findings highlight the potential of suberinic acid-tall oil polyols as effective candidates for developing rigid PUR foams, offering promising solutions for sustainable insulation applications.

Effect of bio-polyol molecular weight on the structure and properties of polyurethane-polyisocyanurate (PUR-PIR) foams

The increasing interest in polyurethane materials has raised the question of the environmental impact of these materials. For this reason, the scientists aim to find an extremely difficult balance between new material technologies and sustainable development. This work attempts to validate the possibility of replacing petrochemical polyols with previously synthesized bio-polyols and their impact on the structure and properties of rigid polyurethane-polyisocyanurate (PUR-PIR). To date, biobased polyols were frequently used in the manufacturing of PU, but application of bio-polyols synthesized via solvothermal liquefaction using different chains of polyethylene glycol has not been comprehensively discussed. In this work, ten sets of rigid polyurethane foams were synthesized. The influence of bio-polyols addition on foam properties was investigated by mechanical testing, thermogravimetric analysis (TGA), and cone calorimetry. The structure was determined by scanning electron microscopy (SEM) and a gas pycnometer. The tests revealed a significant extension of foam growth time, which can be explained by possible steric hindrances and the presence of less reactive secondary hydroxyl groups. Moreover, an increase average size of pores and aspect ratio was noticed. This can be interpreted by the modification of the cell growth process by the introduction of a less reactive bio-polyol with different viscosity. The analysis of foams mechanical properties showed that the normalized compressive strength increased up to 40% due to incorporation of more cross-linked structures. The thermogravimetric analysis demonstrated that the addition of bio-based polyols increased temperature of 2% (T2%) and 5% (T5%) mass degradation. On the other hand, evaluation of flammability of manufactured foams showed increase of total heat release (HRR) and smoke release (TSR) what may be caused by reduction of char layer stability. These findings add substantially to our understanding of the incorporation of bio-polyols into industrial polyurethane systems and suggest the necessity of conducting further research on these materials.

Influence of Long-Term Storage and UV Light Exposure on Characteristics of Polyurethane Foams for Cryogenic Insulation

Rigid polyurethane (PUR) foams have been the most effective insulation material used in space launchers since the beginning of cryogenic fuel use, due to their outstanding thermal and mechanical properties. In this study, spray-applied PUR foams using different ratios of amine-based catalysts were produced. Due to climate change, several restrictions have been made regarding the usage of blowing agents used for PUR foam production. Lately, hydrofluoroolefins (HFOs) have been suggested as an alternative for PUR foam production due to their low global warming potential (GWP) and ozone depletion potential (ODP), replacing the hydrofluorocarbons (HFCs) so far used. This change in blowing agents naturally altered the usage of catalysts. Reactive amine-based catalysts are less hazardous because of their low volatility and ability to react successfully with isocyanate or polyols. Spray-applied PUR foams with a potential application for cryogenic insulation were produced and tested for long-term storage, analyzing parameters such as the pH value of polyol composition, foaming kinetics (trise, tcream), etc. Athermal analysis (TG, DSC) was also applied to developed materials, as well as artificial ageing by exposing samples to UV light. It was discovered that PUR foams obtained using reactive amine-based catalysts, such as Polycat 203 and 218, have a higher integral heat capacity, but polyol mixtures containing these catalysts cannot exceed a storage time of more than 4 months. It was also observed from artificial ageing tests of PUR cryogenic insulation by exposure to UV light that the thickness of the degraded layer reached 0.8 mm (after 1000 h), but no significant destruction of cellular structure deeper in the material was observed.

Characteristics of Components and Density of Rigid Nanoclay-Filled Medium-Density Polyurethane Foams Produced in a Sealed Mould

The characteristics of rigid, nanoclay-filled, medium-density NEOpolyol-380 polyurethane foams components can be estimated when two conditions are met: (1) the foam blocks are produced in a sealed mould; and (2) the mass of the reacting mixture is kept constant. It was shown that, with an increase in filler concentration, the total mass of the filled polymeric network stays constant, but the total volume reduces; the higher the ratio of density of the exfoliated nanoclay platelets and polymer, the higher the volume reduction of the polymeric network. Experimental data of polyurethane foam block mass were acquired at concentrations η = 0%, 0.25%, 0.5%, 1%, 2%, 3% and 5% from the mass of a filled reacting mixture. Foam-density dependence in the uniform zone and in the side-sections of the produced blocks on the: (1) mass of the blocks; and (2) the concentration of the filler was analysed. The study demonstrated that the correlation of the specimens' density with the foam block mass is much higher than that of the filler concentration.

Anisotropy and Mechanical Properties of Nanoclay Filled, Medium-Density Rigid Polyurethane Foams Produced in a Sealed Mold, from Renewable Resources

Medium-density rigid polyurethane (PU) foams are often produced in sealed molds; therefore, the processes inside the mold and structure of the produced foam blocks need to be understood. The structural and mechanical anisotropy is shown to be the third variable along with (1) concentration of the nanoclay filler and (2) density, to determine the mechanical properties of the filled PU foam composites produced in a sealed mold. The varying anisotropy of the specimens hinders the accurate evaluation of the filling effect. The methodology for the estimation of the anisotropy characteristics of specimens from different locations within the nanoclay filled PU foam blocks is elaborated. A criterion, based on analysis of Poisson's ratios, is formulated for the selection of specimens with similar anisotropy characteristics. The shear and bulk moduli are estimated theoretically, dependent on the filler's concentration, using the experimentally determined constants.

Influence of Reactive Amine-Based Catalysts on Cryogenic Properties of Rigid Polyurethane Foams for Space and On-Ground Applications

Rigid polyurethane (PUR) foams have outstanding properties, and some of them are successfully used even today as cryogenic insulation. The fourth-generation blowing agent Solstice^® LBA and commercial polyols were used for the production of a low-density cryogenic PUR foam composition. A lab-scale pouring method for PUR foam preparation and up-scaling of the processes using an industrial spraying machine are described in this article. For the determination of the foam properties at cryogenic temperature, original methods, devices, and appliances were used. The properties at room and cryogenic temperatures of the developed PUR foams using a low-toxicity, bismuth-based, and low-emission amine catalyst were compared with a reference foam with a conventional tin-based additive amine catalyst. It was found that the values of important cryogenic characteristics such as adhesion strength after cryoshock and the safety coefficient of the PUR foams formed with new reactive-type amine-based catalysts and with the blowing agent Solstice^® LBA were higher than those of the foam with conventional catalysts.

New Thermo-Reflective Coatings for Applications as a Layer of Heat Insulating Materials

This paper presents new thermo-reflective coatings with different properties. Basic, anti-corrosion and self-extinguishing coatings were analyzed. The coatings were obtained with a thickness varying from 1 to 3 mm. The coatings were subjected to detailed tests assessing their physical-mechanical properties, i.e., tensile strength, abrasion, pull-off test, water absorption, vapor permeability and thermal properties, i.e., the thermal performance of the reflective coatings, thermal transmittance, thermogravimetric analysis, differential scanning calorimetry, as well as thermomechanical analysis and thermal conductivity. In addition, the possibility of using such coatings in a wide range of temperatures and during application to various materials used as a substrate, i.e., concrete, metal and rigid polyurethane foam, was tested. The thermal analysis of coatings revealed that materials are stable to temperatures above 200 °C, there are no thermal transitions in the negative temperature region and shrinking in low temperatures is minimal (less than 0.5%). From the data obtained within the framework of this study, it can be concluded that anticorrosive, basic and self-extinguishing coatings are eligible for thermo-insulation applications in temperatures up to 200 °C.

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.

Light Microscopy of Medium-Density Rigid Polyurethane Foams Filled with Nanoclay

Practical applications and mathematical modelling of the physical and mechanical properties of medium-density rigid polyurethane foams require knowledge of their structure. It is necessary to determine structural characteristics without destroying the foams and measuring each element. A methodology is described for the use of light microscopy on environmentally sustainable, medium-density rigid polyurethane foams (in the density region of ≈210–230 kg/m³), by the analysis of two types of light microscopy images: (1) Cutting surface images; and (2) Through-cutting surface images. The dimensions of structural elements of polyurethane foams, filled with the nanoclay Cloisite-30B at concentrations of 0.0%, 0.25%, 0.50%, 1.0%, 2.0%, 3.0%, and 5.0% from the mass of the filled reacting mixture, are estimated. Probability density functions of projections of bubbles’ diameters and struts’ length are determined using images in three mutually perpendicular planes. A mathematical model is developed for the restoration of the actual dimensions of bubbles’ diameters using data of cutting circles’ diameters. Intercalation and exfoliation of the filler’s Cloisite-30B mono-layers is evaluated via the basal spacing by X-ray diffraction at a 5 wt.% concentration of nanoclay.

The Effect of Manufacture Process on Mechanical Properties and Burning Behavior of Epoxy-Based Hybrid Composites

The production of hybrid layered composites allows comprehensive modification of their properties and adaptation to the final expectations. Different methods, such as hand lay-up, vacuum bagging, and resin infusion were applied to manufacture the hybrid composites. In turn, fabrics used for manufacturing composites were made of glass (G), aramid (A), carbon (C), basalt (B), and flax (F) fibers. Flexural, puncture impact behavior, and cone calorimetry tests were applied to establish the effect of the manufacturing method and the fabrics layout on the mechanical and fire behavior of epoxy-based laminates. The lowest flammability and smoke emission were noted for composites made by vacuum bagging (approximately 40% lower values of total smoke release compared with composites made by the hand lay-up method). It was demonstrated that multi-layer hybrid composites made by vacuum bagging might enhance the fire safety levels and simultaneously maintain high mechanical properties designed for, e.g., the railway and automotive industries.

Natural Oil-Based Rigid Polyurethane Foam Thermal Insulation Applicable at Cryogenic Temperatures

This paper presents research into the preparation of rigid polyurethane foams with bio-polyols from rapeseed and tall oil. Rigid polyurethane foams were designed with a cryogenic insulation application for aerospace in mind. The polyurethane systems containing non-renewable diethylene glycol (DEG) were modified by replacing it with rapeseed oil-based low functional polyol (LF), obtained by a two-step reaction of epoxidation and oxirane ring opening with 1-hexanol. It was observed that as the proportion of the LF polyol in the polyurethane system increased, so too did the apparent density of the foam material. An increase in the value of the thermal conductivity coefficient was associated with an increase in the value of apparent density. Mechanical tests showed that the rigid polyurethane foam had higher compressive strength at cryogenic temperatures compared with the values obtained at room temperature. The adhesion test indicated that the foams subjected to cryo-shock obtained similar values of adhesion strength to the materials that were not subjected to this test. The results obtained were higher than 0.1 MPa, which is a favourable value for foam materials in low-temperature applications.

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.

Properties of polyurethane foam with fourth-generation blowing agent

Climate change makes it imperative to use materials with minimum global warming potential. The fourth-generation blowing agent HCFO-1233zd-E is one of them. The use of HCFO allows the production of polyurethane foam with low thermal conductivity. Thermal conductivity, like other foam properties, depends not only on the density but also on the cellular structure of the foam. The cellular structure, in turn, depends on the technological parameters of foam production. A comparison of pouring and spray foams of the same low density has shown that the cellular structure of spray foam consists of cells with much less sizes than pouring foam. Due to the small size of cells, spray foam has a lower radiative constituent in the foam conductivity and, as a result, a lower overall thermal conductivity than pouring foam. The water absorption of spray foam, due to the fine cellular structure, also is lower than that of pouring foam. Pouring foam with bigger cells has higher compressive strength and modulus of elasticity in the foam rise direction. On the contrary, spray foam with a fine cellular structure has higher strength and modulus in the perpendicular direction. The effect of foam aging on thermal conductivity was also studied.

Polytetrafluoroethylene Films in Rigid Polyurethane Foams' Dielectric Permittivity Measurements with a One-Side Access Capacitive Sensor

As a non-metallic composite material, widely applied in industry, rigid polyurethane (PUR) foams require knowledge of their dielectric properties. In experimental determination of PUR foams' dielectric properties protection of one-side capacitive sensor's active area from adverse effects caused by the PUR foams' test objects has to be ensured. In the given study, the impact of polytetrafluoroethylene (PTFE) films, thickness 0.20 mm and 0.04 mm, in covering or simulated coating the active area of one-side access capacitive sensor' electrodes on the experimentally determined true dielectric permittivity spectra of rigid PUR foams is estimated. Penetration depth of the low frequency excitation field into PTFE and PUR foams is determined experimentally. Experiments are made in order to evaluate the difference between measurements on single PUR foams' samples and on complex samples "PUR foams + PTFE film" with two calibration modes. A modification factor and a small modification criterion are defined and values of modifications are estimated in numerical calculations. Conclusions about possible practical applications of PTFE films in dielectric permittivity measurements of rigid PUR foams with one-side access capacitive sensor are made.

A Review of Wood Biomass-Based Fatty Acids and Rosin Acids Use in Polymeric Materials

In recent decades, vegetable oils as a potential replacement for petrochemical materials have been extensively studied. Tall oil (crude tall oil, distilled tall oil, tall oil fatty acids, and rosin acids) is a good source to be turned into polymeric materials. Unlike vegetable oils, tall oil is considered as lignocellulosic plant biomass waste and is considered to be the second-generation raw material, thus it is not competing with the food and feed chain. The main purpose of this review article is to identify in what kind of polymeric materials wood biomass-based fatty acids and rosin acids have been applied and their impact on the properties.

Effect of different concentration of rapeseed oil and recycled poly (ethylene terephthalate) in polyols for rigid polyurethane foams

In this research, polyols from rapeseed oil and recycled poly(ethylene terephthalate) were synthesized by two-step continuous synthesis with a different rapeseed oil and poly(ethylene terephthalate) concentration. All rapeseed oil/poly(ethylene terephthalate) polyols showed complete compatibility with blowing agent Solkane 365/227. The resulting polyols were used to prepare rigid polyurethane foams which were characterized with various techniques for determination of their physical, mechanical and thermal insulation properties. The effect of rapeseed oil and poly(ethylene terephthalate) concentrations in polyols on the characteristics of rigid polyurethane foams was investigated. The results showed that obtained rigid polyurethane foams were suitable for thermal insulation appliance. Also, the potential use of rapeseed oil as raw material combined with poly(ethylene terephthalate) to synthesize polyols with good compatibility with blowing agent was confirmed.

Rigid polyurethane foams obtained from tall oil and filled with natural fibers: Application as a support for immobilization of lignin-degrading microorganisms

The forest biomass represents an abundant, renewable, non-food competition, and low-cost resource that can play an alternative role to petro-resources. The first topic of the research activity is focused on the use of wood and a pulp mill by-product—tall oil —as raw materials for the production of rigid polyurethane foams. The maximum content of the renewable resource in ready foams is 26%. By using biopolymers as a matrix, a natural way is to reinforce them with natural fibers. Further advantages are significant weight and cost savings and, at the same time, replacement of petrochemical raw materials. Three different natural fibers (cellulose, wood, and modified cellulose) were tested as a filler of foams. Rigid polyurethane foams was used as biomass support particles for immobilization of microorganisms. Suspension cultures of the organism with biomass support particles can promote the adhesion of cells to the porous matrix surface, and subsequently the cells become immobilized during the cultivation. This method for cell immobilization has a great potential for enhancing the production of proteins or chemicals in culture supernatants. The presence of natural fibers in the matrix promotes the enzyme production because the material not only functions as an attachment place but also supplies some nutrients to the microorganism and induces the production of ligninolytic enzymes. This paper discusses the studies into the use of tall oil as a renewable source in rigid polyurethane foam production

Synthesis and physical-mechanical properties of polyurethane-polyisocyanurate foams based on PET-waste-derived modified polyols

A series of aromatic polyester polyols (APP) were synthesized by transesterification of industrial poly(ethylene terephthalate) (PET) waste using di(ethylene glycol) in the presence or absence of glycerol, adipic acid, poly(propylene glycol), or hexanediol as functional additives. PET-waste-derived modified APP was used for the synthesis of polyurethane—polyisocyanurate (PU-PIR) foams. The isocyanurate yield of the PU-PIR foams determined by the temperature method was high (67—90%) and correlated well with the data of Fourier transform infrared measurements. The effect of chemical structure of the APP and its properties (viscosity, acid number, and hydroxyl number) on technological characteristics of the PU-PIR foams at equal/similar formulations was studied. PU-PIR foams prepared using PET-waste-derived APP were characterized by high closed cell content (more than 94%). The presence of the fragments of glycerol in the structure of APP decreased the core density and tensile strength and increased elongation at break of the resulting PU-PIR foams while the presence of the fragments of adipic acid acted vice versa.

Mechanical properties of rigid polyurethane foams at room and cryogenic temperatures

Studies on the effect of the foams’ polymeric matrix’ properties on the tension and compression properties of pour rigid polyurethane (PUR) foams, apparent core density 65—70 kg/m3, at 296 and 77 K were carried out. PUR foams were produced by the hand mixing method from polyol systems that comprised polyether, polyester polyols, and chain extenders. To produce PUR foams, crude MDI was used, and Solkane 365 mfc/227 ea was used as a blowing agent. The molecular weight per branching unit (Mc) of the polymeric matrix of PUR foams was varied in the range 300—1150. Cohesion energy densities of the blocks forming the polymeric matrix were calculated. The effect of Mc on the formation of hydrogen bonds between the urethane groups was estimated from FTIR spectroscopy data and ratio NHbonded /NHfree. It has been found that, with increasing polymeric matrix’ Mc, the tensile strength and elongation at break of PUR foams at 296 and 77 K increases, while Young’s modulus decreases. The increase in the parameter Mc promotes the decrease in the compressive strength and modulus of elasticity of PUR foams at 296 K, while compressive strength indices at 77 K are higher for the foams, whose polymeric matrix has the highest Mc. With increasing polymeric matrix’ M c, the concentration of the urethane groups bonded with hydrogen bonds increases. Structural and mechanical properties of layered spray polyurethane foams, apparent core density approx. 48 kg/m3, having two layers and polymeric matrix’ Mc = 740 were investigated.

Water-Blown Polyisocyanurate Foams From Vegetable Oil Polyols

Polyols with the hydroxyl value OHV from 290 to 318 mg KOH/g are synthesized from rapeseed, sunflower seed, flaxseed, or coconut oils by the way of their: (1) transesterification with triethanolamine or (2) amidization with diethanolamine. The influence of water as the blowing agent on the storage stability of the polyol premix system is assessed from values of the polyol premix system pH, acid value, and variations in such parameters as cream and gel time. Water-blown polyisocyanurate (PIR) foams (150 · II × 300; II—isocyanate index) characterized by good mechanical characteristics, dimensional stability at 70°C and at relative humidity RH = 95% as well as by a very low water absorbance, are obtained. The optimal physical and mechanical properties of water-blown PIR foams are achieved at the isocyanate index values 150—200. The values of the solubility parameter δ and normalized cohesion energy Ecoh.norm. for the groups and blocks, incorporated in the polymer matrix, are calculated. A detailed experimental analysis has proved that the water-blown PIR foams from vegetable oil polyols possess competitive physical and mechanical properties to those exhibited by the traditional petrochemical origin foams. The optimal physical and mechanical properties suitable for practical applications, are achieved at the isocyanate index values 150<II<200.