Soft PVC foams: Study of the gelation,fusion, and foaming processes. I. Phthalate ester plasticizers

The use of foamed plastics gains more and more interest every day. Flexible poly(vinyl chloride) (PVC) foams have excellent mechanical properties and low price, thus their application is extensive. Foams are produced from plastisols, which are based on the suspension of the PVC resin in a plasticizer. Phthalates are the most used plasticizers in flexible PVC foam formation. In this study, we have studied the influence of the phthalate ester‐type plasticizers on the foaming process and the quality of the foams obtained from the corresponding plastisols. For the plastisols prepared with the nine phthalate plasticizers considered, we have studied and discussed the complex and extensional viscosities; the thermal behavior (DSC) including the decomposition of the chemical blowing agent, and the foam production by rotational molding. In addition, we have characterized the foams obtained by thermomechanical analysis, density, and bubble size distribution. As expected, clear correlations have been obtained between the molecular weight and structure of the plasticizer with the rheological behavior of the plastisols. The knowledge of the gelation and fusion processes and evolution of the extensional viscosity of the plastisols combined with the study of the thermal decomposition of the blowing agent in each plastisol allows for better understanding of the complex dynamic behavior of these foaming systems. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Formulation and mechanical characterization of PVC plastisols based on low‐toxicity additives

New formulations of plastisols based on low‐toxicity plasticizers were proposed and characterized. Traditional phthalate plasticizers were replaced in the plastisols studied in this research by polymeric plasticizers (i.e., saturated polyesters), produced by the reaction of a diol and a carboxylic acid. The main drawback for the use of these plasticizers in formulations of PVC plastisols is a significant increase of the paste viscosity, which decreases their processability; thus, the use of additional additives to reduce viscosity is recommended. This study also includes the optimization of the processing conditions (cure temperature and time) of the proposed plastisols: complete cure was obtained at 140°C and 10 min. It is reported that the final properties of plastisols are very sensitive with respect to the processing conditions; in fact, insufficient plasticization or degradation can affect the material when processed out of the optimum conditions. The influence of the plasticizer concentration on mechanical and optical properties, such as tensile strength, hardness, brightness, and the like, is also reported. In summary, the proposed plastisols, with low‐toxicity plasticizers, offer a valid alternative to traditional PVC plastisols based on phthalate plasticizers. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 1881–1890, 2001     

Soft PVC foams: Study of the gelation,fusion and foaming processes. III. Mixed phthalate ester plasticizers

The foaming of PVC (poly(vinyl chloride)) plastisols is a complex combination of simultaneous processes, involving the curing and structural changes of the plastisol, the gas generation and the foam formation. Our comprehensive study of such processes and of the influence of plasticizer on the foam quality has shown that all the processes involved have to be adequately synchronized to obtain foams of the required quality. A series of plastisols prepared by mixing a high and a low compatible phthalate ester plasticizer in several proportions (100/0, 75/25, 50/50, 25/75, 0/100 ratios) has been studied and characterized (by means of rheology, calorimetry, thermal stability, thermomechanical properties, density, and foam morphology), to study the influence of the plasticizer in such processes with changing compatibility. We found expectable rheological and calorimetric behavior regarding the plastisols without curing; however we experienced nonlinear (unexpected) behaviors in cases of foams and plastisols being cured. To confirm such behavior and our hypothesis regarding the possible plasticizer evaporation, the thermal stability of the plastisols, precured samples and foams have been studied by themorgravimetric analysis (TGA). According to our results it can be deduced that the plasticizer loss occurring in some cases during the production of the foams or the specimens being characterized, plays an important role in the foaming process and also influences the foam quality. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Extensional viscosity measurements and characterization of poly (vinyl chloride‐co‐vinyl acetate) plastisols and foams

The foaming of PVC‐VA [Poly (vinyl chloride‐co‐vinyl acetate)] plastisols is a complex combination of processes involving the simultaneous curing of the paste with the evolution of gases caused by the decomposition of the chemical blowing agent. The extensional viscosity is a fundamental characteristic of the material, responsible for the behavior of the system when undergoing the extensional stress produced by the released gases. Nevertheless, such changes have not been considered to the same extent as the complex viscosity evolution or the thermal processes suffered by PVC‐VA plastisols. The objective of the present work is to study the extensional viscosity of the PVC‐VA plastisols prepared with three plasticizers of similar structure, but with different curing and rheological behavior in order to investigate its influence on the quality of the foams obtained. Extensional viscosity measurements under forced prestretch conditions revealed that depending on the structure and consequently on the compatibility of the plasticizer used, each plastisol develops its properties and structure accordingly. DINCH plasticizer (Diisononyl cyclohexane‐1,2‐dicarboxylate presenting alicyclic ring) seems to be the less compatible compared with the other two studied (both presenting aromatic rings) according to its behavior during the curing and foaming processes and may not be able to withstand the pressure evolved by the released gases during the foaming process yielding foams of poorer quality. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Oligomeric isosorbide esters as alternative renewable resource plasticizers for PVC

Oligo(isosorbide adipate) (OSA), oligo(isosorbide suberate) (OSS), and isosorbide dihexanoate (SDH) were synthesized and evaluated as renewable resource alternatives to traditional phthalate plasticizers. The structure of the synthesized oligomers was confirmed by nuclear magnetic resonance spectroscopy (¹H‐ and ¹³C‐NMR), and molecular weight was determined by size exclusion chromatograph. The plasticizers were blended with poly(vinyl chloride) (PVC), and the miscibility and properties of the blends were evaluated by differential scanning calorimetry, fourier transform infrared spectroscopy, tensile testing, and thermogravimetry. Especially the blends plasticized with SDH had almost identical properties with PVC/diisooctyl phthalate (DIOP) blends. The blends containing OSA and OSS plasticizers, based on dicarboxylic acids, had somewhat lower strain at break but higher stress at break and better thermal stability compared to the PVC/DIOP or PVC/SDH blends. All the synthesized isosorbide plasticizers showed potential as alternative PVC plasticizers. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Dialkyl furan‐2,5‐dicarboxylates,epoxidized fatty acid esters and their mixtures as bio‐based plasticizers for poly(VInylchloride)

Dialkyl furan‐2,5‐dicarboxylates and epoxidized fatty acid esters (EFAE) of varying molecular weights and volatilities, as well as their mixtures, were investigated as alternative plasticizers for poly(vinylchloride) (PVC). The EFAE utilized were epoxidized soybean oil (ESO) and epoxidized fatty acid methyl ester (e‐FAME). All plasticizers were compatible with PVC, with plasticization efficiencies usually increasing with decreasing molecular weights of the plasticizers (except in the case of ESO, which was remarkably effective at plasticizing PVC, in spite of its relatively high molecular weight). In comparison with phthalate and trimellitate plasticizers, the alternatives generally yielded improved balance of flexibility and retention of mechanical properties after heat aging, with particularly outstanding results obtained using 30?50 wt % e‐FAME in mixtures with diisotridecyl 2,5‐furandicarboxylate. Although heat aging characteristics of the plasticized polymer were often related to plasticizer volatilities, e‐FAME performed better than bis(2‐ethylhexyl) 2,5‐furandicarboxylate, and bis(2‐ethylhexyl) phthalate of comparatively higher molecular weights. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42382.     

Synthesis and Evaluation of Soy Fatty Acid Ester Estolides as Bioplasticizers in Poly(Vinyl Chloride)

Plasticizers are nonvolatile organic liquids that impart flexibility to polymers. Due to environmental, health, and safety reasons, the industry is looking for bioplasticizers to replace petroleum-derived phthalates. To fulfill this need, soy fatty acid ester estolides were synthesized, characterized, and evaluated as phthalate replacements. Soybean oil was transesterified with methanol or glycerol to form lower molecular weight fatty acid esters that were epoxidized and ring opened with acetic acid and acetylated to give the final products. Ring opening and acetylation of the epoxidized oleic acid esters gave acyclic acetate fatty acid ester estolides, whereas the polyunsaturated fatty acid esters, linoleate, and linolenate gave cyclic tetrahydrofuran derivatives and cross-linked higher molecular weight materials. The cyclization mechanism to form the tetrahydrofuran derivatives was postulated. Soy fatty acid ester estolides were compounded with formulated poly(vinyl chloride), (PVC) and tested for their functional properties. The physical and functional properties of the new bioplasticizers were compared with commercial plasticizers. The elasticity of PVC compounded with experimental plasticizers and commercial phthalates was comparable. PVC compounded with fatty acid methyl ester estolide showed lower glass transition temperature and similar tensile properties compared to PVC compounded with the commercial phthalate. PVC compounded with the glyceryl fatty acid ester estolide showed a higher glass transition temperature, higher tensile properties compared to PVC compounded with the commercial phthalate.     

Synthesis and application of a natural plasticizer based on cardanol for poly(vinyl chloride)

A natural plasticizer with multifunctional groups, similar in structure to phthalates, cardanol derivatives glycidyl ether (CGE) was synthesized from cardanol by a two‐step modification process and characterized by FT‐IR, ¹HNMR, and ¹³CNMR. The resulting product was incorporated to PVC (CGE/PVC), and plasticizing effect was compared with PVC incorporated with two kinds of commercial phthalate ester plasticizers bis (2‐ethylhexyl) benzene‐1,4‐dicarboxylate (DOTP) and diisononyl phthalate (DINP). Dynamic mechanical analysis and mechanical properties testing of the plasticized PVC samples were performed in order to evaluate their flexibility, compatibility, and plasticizing efficiency. SEM was employed to produce fractured surface morphology. Thermogravimetric analysis and discoloration tests were used to characterize the thermal stabilities. Dynamic stability analysis was used to test the processability of formulations. Compared with DOTP and DINP plasticized samples, CGE/PVC has a maximum decrease of 9.27% in glass transition temperature (T_g), a maximum increase of 17.6% in the elongation at break, and a maximum increase of 31.59°C and 25.31 min in 50% weight loss (T50) and dynamic stability time, respectively. The obtained CGE also has slightly lower volatility resistance and higher exudation resistance than that of DOTP and DINP. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42465.     

Plasticizer factors influencing take-up by PVC resins

The ease with which plasticizer is combined with poly(vinyl chloride) resin is a measure of processing characteristics critical in the dry blending of suspension PVC and the gelation of plastisols. By using commercial grade plasticizers, this study developed predictive equations for the following processing parameters of dialkyl phthalates in PVC:

• Relative dry-blend rates in suspension PVC as a function of plasticizer viscosity.
• Relative initial gelation temperatures in plastisols as a function of plasticizer molecular weight and solvating strength.
• Relative final gelation temperatures in plastisols as a function of plasticizer solvating strength.

This information allows one to predict the relative processing characteristics of any dialkyl phthalate plasticizer for PVC on the basis of its chemical and physical properties.     

Revisiting analysis of phthalate plasticizers concentration in poly(vinyl chloride)

The method of the efficient analysis of di(2‐diethylhexyl) phthalate, tri(2‐ethylhexyl) trimellitate, di(2‐ethylhexyl) terephthalate, and other phthalate plasticizers concentrations in plasticized poly(vinyl chloride) (PVC) was developed. The method is based on quantitative dissolution of the PVC sample in methyl ethyl ketone with the consequent precipitation of PVC with hexane and concentration of phthalate in an organic layer. A capillary column‐based gas chromatographic technique for phthalates separation and quantification was developed and used in conjunction with the PVC and phthalates dissolution technique. The developed method of phthalate plasticizers analysis proved to be relatively fast, reproducible, and straightforward. J. VINYL ADDIT. TECHNOL., 21:197–204, 2015. © 2014 Society of Plastics Engineers     

An efficient plasticizer based on waste cooking oil: Structure and application

Recently, phthalates have been continuously banned in numerous fields by many countries. Therefore, the development of sustainable and efficient plasticizers has become particularly urgent. The waste cooking oil was used as the main raw materials in this study to synthesize an efficient plasticizer (acetylated-fatty acid methyl ester-trimellitic acid ester, AC-FAME-TAE). The structure of AC-FAME-TAE was characterized by FT-IR and ¹H NMR. The performance of the poly(vinyl chloride) (PVC) plasticized by AC-FAME-TAE was tested and compared with those of the PVC plasticized with di-2-ethylhexyl phthalate (DOP) and EFAME (epoxy fatty acid methyl ester), respectively. DSC results indicated that AC-FAME-TAE had excellent plasticizing efficiency for PVC. The mechanical properties of PVC plasticized by AC-FAME-TAE were as comparable as PVC plasticized by DOP from the results of tensile test. In addition, the PVC plasticized by AC-FAME-TAE had excellent thermal stability and solvent resistance by the results of leaching test and TGA.     

Recycling of Waste PET: Usage as Secondary Plasticizer for PVC

Postconsumer water bottle poly(ethylene terephthalate) (PET) flakes were depolymerized with ethylene glycol (EG) by the glycolysis reaction in the presence of zinc acetate as the catalyst. In the depolymerization reactions, different weight ratios of PET/EG were used. In order to obtain polyesters used as PVC plasticizers, these glycolysis products containing hydroxyl end groups were reacted with an adipic acid (AA)–containing diacid group at equivalent amounts. In order to obtain PVC plastisols, PVC was dispersed into a plasticizers' mixture composed of di-isooctyl phthalate (DOP) and polyester products by using a high-speed mixer (PVC/plasticizers, 65/35 w/w). For the preparation of plasticizer mixture polyester products were used at a weight ratio of 20%, 40%, 60% of DOP. Plasticized PVC sheets were prepared from plastisols and their glass transition temperatures (T_g), migration, and mechanical properties were determined. The results show that the polyester products obtained from glycolysis products of waste PET can be used as secondary plasticizers, with DOP for PVC.     

Castor Epoxy Fatty Acid Alkyl Ester Estolides as Bioplasticizers for Poly(Vinyl Chloride)

Epoxy fatty acid alkyl ester estolides were synthesized from castor oil to be used as biobased plasticizers for poly(vinyl chloride) (PVC) as a safer replacement for phthalate plasticizers. Initially, castor oil was transesterified with methanol or n-butanol to quantitatively yield castor fatty acid alkyl esters. Acetylation of hydroxyl function with acetic anhydride led to the formation of estolide. The unsaturation was epoxidized, resulting in a bifunctional epoxy fatty acid alkyl ester estolide. The bioplasticizers were compounded with PVC and were evaluated for their functionality and compared with commercial phthalate plasticizer diisononyl phthalate (DINP) and nonphthalate 1,2-cyclohexanoic acid diisononyl ester (DINCH). The bioplasticizers showed excellent gelation, efficiency, and compatibility, as well as plastisol viscosity and thermal properties, comparable to or better than the plastisols prepared with commercial controls DINP and DINCH. The volatility of the methyl ester was inferior to the butyl ester. Both compounds showed low water resistance properties. Further evaluation of the butyl ester under tropical conditions of high temperature and humidity confirmed limited compatibility. This indicates that the castor epoxy fatty acid ester estolides would be better suited for applications that do not come in contact with water for prolonged periods, such as flooring, artificial leather, wiring, or wall coverings.     

Preparation of novel reactive plastisol based on poly(vinyl chloride) and multifunctional acryl esters

Poly(vinyl chloride) (PVC) powder was mixed with various polyfunctional acryl monomers as plasticizers to prepare acrylate‐modified plastisols. This class of plastisol was hardened into the B stage without reaction and then cured into a harder material through crosslinking of the acrylate. The best formulation was attained after evaluation of various acrylates, PVC grades, and peroxides. Several difunctional acrylates with solubility parameters similar to that of PVC could be most conveniently used as the plasticizer. A sheet molding compound was obtained by the combination of the resultant plastisols with glass fiber by compression molding using conventional machines. It was cured into a PVC‐based fiber reinforced plastic with high performance. This class of acrylate‐modified plastisol is called reactive plastisol. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 1794–1801, 2000     

Ester‐amide based on ricinoleic acid as a novel primary plasticizer for poly(vinyl chloride)

Utilization of ricinoleic acid as a raw material for the synthesis of green plasticizer would offer an alternative to the phthalate plasticizers. Ester‐amide of ricinoleic acid was synthesized by a two‐step reaction with dibutyl amine and benzoic acid; and then utilized as primary plasticizer in PVC. Ester‐amide plasticizer was added up to 40 phr in PVC; and the prepared PVC sheets were characterized for mechanical, X‐ray diffraction, thermal, rheological, colorimetric, and exudation properties. Addition of the ester‐amide plasticizer demonstrated good incorporation and plasticizing performance in PVC. Viscosity of PVC decreased with increased addition of ester‐amide plasticizer. The dark color of the synthesized plasticizer could have constraints on its application areas; however, the prepared samples illustrated negligible weight loss in the exudation test, attributed to better compatibility between them brought about by the ester, tertiary amide and polarizable benzene ring in the ester‐amide plasticizer with the C‐Cl polar linkage in PVC. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41913.     

Plasticizers derived from cardanol: synthesis and plasticization properties for polyvinyl chloride(PVC)

Two natural plasticizers derived from cardanol (CD), cardanol acetate (CA) and epoxidized cardanol acetate (ECA), were synthesized and characterized by ¹H NMR and ¹³C NMR. The plasticizing effects of the obtained plasticizers on semi-rigid polyvinylchloride (PVC) formulations were also investigated. Two commercial phthalate ester plasticizers, dioctyl terephthalate (DOTP) and diisononyl phthalate (DINP), were used as controls. Mechanical and thermal properties, compatibility, thermal stability, microstructure, and workability were assessed by dynamic mechanical analysis (DMA), mechanical analysis, thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and dynamic stability analysis, respectively. Results indicated that the natural plasticizer ECA had overallsuperior flexibility, compatibility, thermal stability, and workability comparable to both controls. The obtained CA and ECA have lower volatility resistance and similar extraction and exudation resistance than that of DOTP and DINP. The CA was further blended with DOTP in soft PVC films. Results of DMA, TGA and mechanicalanalysis indicated that CA can serve as a secondary plasticizer to improve the related properties of soft PVC formulations. These CD derived plasticizers show promise as an alternative to fully or partially replace petroleum-based plasticizers.     

Migration of phthalate and non‐phthalate plasticizers out of plasticized PVC films into air

The aim of the present work is to provide information about the migration of phthalate and non‐phthalate plasticizers generally used in flexible polyvinyl chloride (PVC) applications. Plastisols (pastes) were prepared by mixing PVC, plasticizer, and thermal stabilizer. The plasticized PVC (p‐PVC) films are obtained by gelation at 160°C for 15 min. The p‐PVC films were heat treated at 50, 85, 100, 130, and 160°C up to 420 min to follow the mass loss to find out diffusivity of plasticizer out of films into air and to determine related activation energies. The films having di‐octyl terephthalate (DOTP) and di‐isononyl 1,2‐cyclohexanedicarboxylic acid (DINCH) exhibited the lowest mass loss in general, among the phthalate and non‐phthalate plasticizer having p‐PVC films, respectively, as confirmed by FTIR investigation. The same tendency was observed for diffusion coefficients and for the activation energies of migration. The diffusion coefficients were found to be around 3.5 × 10^?18–2.1 × 10^?17 m²/sec for the studied plasticizers in PVC at 50°C and around 4.0 × 10^?15–9.9 × 10^?14 m²/sec at 160°C. The activation energies for 85–160°C interval were determined to be between 70 and 153 kJ/mol (0.72–1.58 eV) for the plasticizers used herein those could be treated as a homologous series as deduced from the related compensation factors. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Supercritical CO2 extraction of phthalate plasticizers from PVC

Three common phthalates, namely, dioctyl phthalate, diisodecyl phthalate, and trioctyl trimellitate, were used as plasticizers for poly(vinyl chloride) (PVC) processing, and the extraction of these plasticizers were investigated using supercritical CO₂ fluids. Factors affecting the extractions of these phthalates were focused. The molecular weight of phthalates was found to dominate the level of extraction of low temperatures, whereas the content of carbonyl groups in the phthalate was a determining factor for the level of extraction of high temperatures. Negligible extraction was observed below the critical pressure of CO₂. For 32°C, the level of the extraction is insignificant below density of ca 0.7 g/cm³, above which the level of the extraction increases roughly linearly with increasing density. For temperatures above 32°C, the density of CO₂ for apparent extractions decreased with increasing temperatures. The threshold density of CO₂ for extractions was found to be independent of the amount of a given phthalate in PVC. Two extraction rates during the extraction could be determined, with a higher rate in the first hour followed by a lower rate later in the extraction for all three phthalates. The effects of the extractions of phthalates on the flexibility of PVC were also investigated as well as the effects of the extrusion conditions, which could lead to various degrees of plasticization of PVC, on the level of extractions. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 4032–4037, 2003     

Effect of biobased plasticizers on thermal,mechanical, and permanence properties of poly(vinyl chloride)

Phthalates can be replaced by other harmless and environmentally friendly plasticizers, such as isosorbide diesters (ISB), and epoxidized sunflower oil (ESO), which has been proved an efficient stabilizer for poly (vinyl chloride) (PVC) in helping to prevent degradation during processing. Formulations based on PVC with different amounts of ISB, ESO, and di‐(2‐ethylhexyl) phthalate (DEHP) from 0 to 60 parts by weight per hundred parts of resin were realized. To make PVC flexible with partial amounts of the debated phthalates as plasticizers, we use a combination of DEHP, ISB, and ESO. Effects of these two biobased plasticizers, ISB and ESO, and their mixture with DEHP on thermal stability by measuring discoloration degrees and thermal gravimetric analysis, on mechanical properties such tensile strength, elongation at break, and hardness, were characterized. Plasticizer permanence properties of PVC compounds were studied. Studies showed that processibility and flexibility were improved by the addition of a plasticizer system (ISB, ESO, and DEHP). An increase in the content of ISB and/or ESO increased thermal and mechanical properties, whereas compositions with ternary compositions of ISB/ESO/DEHP (15/15/30) exhibited the best performance properties. J. VINYL ADDIT. TECHNOL., 20:260–267, 2014. © 2014 Society of Plastics Engineers     

邻苯二甲酸二(乙二醇醚)酯绿色合成及增塑PVC性能

以邻苯二甲酸酐和低毒型乙二醇醚（乙二醇甲/乙/丁醚、二乙二醇甲/乙/丁醚）为原料,固体酸\mathrm{S}{\mathrm{O}}_{\mathrm{4}}^{\mathrm{2}-}/TiO₂为催化剂,采用直接酯化法催化合成邻苯二甲酸二(乙二醇醚)酯（酯化率?97.0%）,并利用傅里叶红外光谱（FTIR）、¹H核磁共振（¹H NMR）确定产物结构。对合成产物邻苯二甲酸二(乙二醇醚)酯的基本物性（酯含量、酸度、黏度、加热减量等）及其增塑后聚氯乙烯（PVC）制品的力学性能、热稳定性以及抗迁移性能进行测试。结果表明,邻苯二甲酸二(乙二醇醚)酯的增塑性能与其结构中乙氧基数目成正比,而与其末端烷基碳链长度呈现先增加后下降趋势。与邻苯二甲酸二辛酯（DOP）增塑后PVC制品（PVC/DOP）相比,邻苯二甲酸二(二乙二醇乙醚)酯增塑后PVC制品（PVC/DEEEP）的断裂伸长率和拉伸强度分别提高87.4%和3.4MPa,初始热分解温度（T_5%）提高21.5℃。