Flexible polyurethane foams modified with biobased polyols: Synthesis and physical‐chemical characterization

A series of flexible polyurethane foams with different polyol compositions were synthesized through the replacement of a portion of the petroleum‐based polyether polyol with biobased polyols, namely, glycerol (GLY) and hydroxylated methyl esters (HMETO). HMETO was synthesized by the alkaline transesterification of tung oil (TO; obtaining GLY as a byproduct) and the subsequent hydroxylation of the obtained methyl esters with performic acid generated in situ. FTIR spectroscopy, ¹H‐NMR, and different analytical procedures indicated that the hydroxyl content increased significantly and the molecular weight decreased with respect to those of the TO after the two reaction steps. The characterization of the obtained foams, achieved through the measurement of the characteristic reaction times, thermal and dynamic mechanical analysis, scanning electronic microscopy, and density measurements, is reported and discussed. The most important changes in the modified foams were found with the addition of GLY to the formulation; this led to an increased foam density and storage rubbery modulus, which were associated with a higher crosslinking density because of the decrease in the chain length between crosslinking points. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43831.     

Recent Advancement in Plant Oil Derived Polyol‐Based Polyurethane Foam for Future Perspective: A Review

Polyurethane foams (PUFs) are widely used materials because of their wide range of applications, particularly, thermal and sound insulation, mattresses, furniture, construction, cushioning, packaging, transportation of goods, etc. Recently, commercial PUF products fabricated from plant oil (PO)‐based polyols have gained increasing popularity, because of their low cost and eco‐friendly nature in comparison to petroleum‐based PUF. To date, insufficient reviews have been reported in the area of modification of plant oils for synthesizing polyol for foam synthesis. Due to abundant availability, low‐cost, and renewable nature of plant oils, they are being used as precursors for modern polyurethane industry use. There is a need for versatile and economical methods for conversion of plant oils such as castor oil (CO) and soybean oil (SO) into useful polyols for industry use. This review is an overview of the most recent advanced methods for the conversion of plant oils into polyol and further utilization of it for commercial PUF products. Since the last decade, many researchers have shown that plant‐polyol‐derived PUF can compete with conventional PUF. Practical Applications: Practical applications of the PO‐based polyurethane foams include thermal insulation, sound insulation, packaging, and waste water treatment.     

Water‐blown polyurethane–clay nanocomposite foams from biopolyol—effect of nanoclay on the properties

The present work deals with the development of polyurethane–clay nanocomposite foams by replacing part of the synthetic polyol with castor oil derivative. Hydroxylated castor oil was converted into diethanol amide by transamidation and the resulting polyol was formulated into water‐blown foams. Modified montmorillonite clay was used as nanofiller in different amounts viz. 0.5%, 1.0%, 2.0%, and 5.0% by total weight of the foam formulation. Rheological measurements on the polyol–clay mixtures indicated that up to 1% clay loading there is no significant change in the viscosity with shear rate and beyond 2%, shear thinning occurred. X‐ray diffraction studies further substantiated these results. The effect of the modified clay on the density, mechanical properties such as compression strength, compression modulus, and microstructure of the foams were investigated. The filler thus added had a reinforcing effect on the foam as observed in the density and compression strength measurements. Differential scanning calorimetric studies on T_g and dynamic mechanical analyses on the modulus clearly indicated that 1% clay loading and above led to exfoliation and plasticizing effect. Exfoliated nanocomposites in compositions containing 1% clay and more yielded a much higher nucleation rate than intercalated ones leading to reduced cell size as observed by optical and scanning electron microscopy. Thus, castor oil, which is readily available, relatively inexpensive, and environmentally benign nonedible oil, has been successfully used to prepare filled semirigid foams which can find application in insulation and packing. POLYM. COMPOS. 34:1306–1312, 2013. © 2013 Society of Plastics Engineers     

Organomodification of montmorillonite and its effects on the properties of poly(butylene succinate) nanocomposites

The pristine sodium montmorillonite (MMT) was organically modified with hexadecyltrimethylammonium bromide (HTAB) at different contents. The organoclay was characterized by X‐ray diffraction (XRD), Fourier transform infrared spectroscopy, energy dispersive X‐ray techniques, and thermogravimetric analysis. Then, poly(butylene succinate) (PBS) nanocomposites were prepared by melt‐mixing process using maleic anhydride‐grafted PBS (PBS‐g‐MA) as compatibilizer. It was found that the mechanical properties of PBS nanocomposites filled with organoclay were apparently higher than that of the nanocomposite filled with MMT. This is attributed to the better filler–matrix interactions between PBS and the organoclay and the better filler dispersion. This is verifiable through the XRD, scanning electron microscopy, and transmission electron microscopy. The addition of PBS‐g‐MA further improved the mechanical properties. It was also found that our laboratory synthesized organoclay modified with HTAB has provided a better reinforcing efficiency when compared with the commercial octadecylamine‐modified organoclay. Besides that the thermal properties of PBS nanocomposites were studied through differential scanning calorimetry. POLYM. ENG. SCI., 2013. © 2013 Society of Plastics Engineers     

Polyurethane foams made from liquefied bark‐based polyols

Liquefaction is known to be an effective method for converting biomass into a polyol. However, the relationships between bark liquefaction conditions and properties of the resulting foams are unclear. In this study, polyurethane foams (PUF) were made using bark‐based polyols obtained through liquefaction reactions of bark at two different temperatures (90 and 130°C). Through systematic characterization of the PUFs the influence of the liquefied bark and liquefaction conditions on foam properties could be observed. The bark‐based foams had similar foaming kinetics, thermal stability, and glass transition temperatures compared with the PEG‐based control foam. The bark‐based PUF from the polyol obtained at the higher liquefaction temperature showed comparable specific compressive strength to the PEG‐based control foam. Lastly, both bark foams exhibited a high amount of open‐cell content, with the foam made from the lower temperature liquefied polyol having poor cell morphology. This deviation from the controls in the open‐cell content may explain the lower modulus values observed in the bark PUFs due to the lack of cell membrane elastic stretching as a strengthening mechanism. These results demonstrated the influence of the bark liquefaction conditions on foam properties, thereby providing a better fundamental understanding for the practical application of bark‐based PUFs. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40599.     

Physical properties of water‐blown rigid polyurethane foams from vegetable oil‐based polyols

Fifty vegetable oil‐based polyols were characterized in terms of their hydroxyl number and their potential of replacing up to 50% of the petroleum‐based polyol in waterborne rigid polyurethane foam applications was evaluated. Polyurethane foams were prepared by reacting isocyanates with polyols containing 50% of vegetable oil‐based polyols and 50% of petroleum‐based polyol and their thermal conductivity, density, and compressive strength were determined. The vegetable oil‐based polyols included epoxidized soybean oil reacted with acetol, commercial soybean oil polyols (soyoils), polyols derived from epoxidized soybean oil and diglycerides, etc. Most of the foams made with polyols containing 50% of vegetable oil‐based polyols were inferior to foams made from 100% petroleum‐based polyol. However, foams made with polyols containing 50% hydroxy soybean oil, epoxidized soybean oil reacted with acetol, and oxidized epoxidized diglyceride of soybean oil not only had superior thermal conductivity, but also better density and compressive strength properties than had foams made from 100% petroleum polyol. Although the epoxidized soybean oil did not have any hydroxyl functional group to react with isocyanate, when used in 50 : 50 blend with the petroleum‐based polyol the resulting polyurethane foams had density versus compressive properties similar to polyurethane foams made from 100% petroleum‐based polyol. The density and compressive strength of foams were affected by the hydroxyl number of polyols, but the thermal conductivity of foams was not. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Physical properties of new polyurethanes foams from benzene polyols synthesized from erucic acid

High density triol‐based polyurethane (PU) foams were developed from aromatic triol isomers prepared from erucic acid. The triol monomers were crosslinked with 4,4′‐diphenylmethane diisocyanate (MDI) into PU foams. The foam's properties were studied by Fourier transform infrared (FTIR) spectroscopy, X‐ray diffraction (XRD), differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), scanning electron microscopy (SEM), and thermogravimetric analysis (TGA). The foams were analyzed for closed cell content and compression strength. The effect of the benzene ring in the polyol structure on the physical properties of these new PU foams was compared with high density foams made from aliphatic polyols originating from canola oil. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Hierarchical structure and properties of rigid PVC foam crosslinked by the reaction between anhydride and diisocyanate

Rigid crosslinked poly(vinyl chloride) (c‐PVC) foams by forming semi‐interpenetrating network (SIPN) structure via the reaction of phthalic anhydride (PA) and diisocyanate were prepared. The influence of PA on hierarchical structure and mechanical properties of c‐PVC foam was studied. The Fourier transform infrared spectrometer results showed that the presence of PA resulted in the formation of imide structure in the SIPN of obtained c‐PVC foams, which introduced a structural defect of SIPN. Thus, the residue (gel) from tetrahydrofuran extraction of the foams decreased with the increase of PA content. Dynamic thermal analysis showed the presence of three aggregation state structures in the c‐PVC foams, depending on the loading of PA. The addition of PA in the formulations affected cellular structure and mechanical properties of the obtained foams. Furthermore, the influence of chemical environment of anhydride compounds on the formation of imide structure in the crosslinking network of c‐PVC foams was discussed. A strategy for reducing defect of crosslinking network and improving mechanical properties was put forward. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46141.     

Biobased flexible polyurethane foams manufactured from lactide-based polyester-ether polyols for automotive applications

In this study, biobased polyester-ether polyols derived from meso-lactide and dimer acids were evaluated for flexible polyurethane foams (PUF) applications. Initially, the catalyst concentration was optimized for the biobased PUF containing 30% of biobased polyol (70% petroleum-based polyol). Then, the same formulation was used for biobased PUF synthesis containing 10%–40% of biobased polyols. The performance of biobased PUF was compared with the performance of the control foam made with 100% petroleum-based polyol. The characteristic times (cream, top of the cup, string gel, rise, tack-free) of biobased PUF were determined. The biobased PUF were evaluated for the mechanical (tensile and compressive) and morphological properties. As the wet compression set is important for automotive applications, it was measured for all biobased PUF. The thermal degradation behavior of biobased PUF was also evaluated and compared with the control foam. The effect of different hydroxyl and acid values of polyols on the mechanical properties of biobased PUF is also discussed. The miscibility of all components of PUF formulations is crucial in order to produce a foam with uniform properties. Thus, the miscibility of biobased polyols with commercial petroleum-based polyol was studied.     

The effect of different palm oil‐based bio‐polyols on foaming process and selected properties of porous polyurethanes

Rigid polyurethane foams were successfully prepared by blending up to 70 wt% of two different palm oil‐based bio‐polyols with a petrochemical polyether polyol. The bio‐polyols were synthesized by epoxidation–oxirane ring‐opening process using water (PP102) and diethylene glycol (PP147), respectively. Due to the high viscosity of both bio‐polyols the reactive mixture was heated to start the foaming reaction at about 50 °C. Under these conditions, the gelling reactions speed up as the amount of PP147 increases but slow down to a great extent when PP102 is used. The thermal conductivity of modified foams is higher and the closed cell content lower compared to reference ones, even when the bio‐foams present a lower apparent density. However, all foams exhibit reduced water absorption, excellent dimensional stability and better thermal stability at temperatures up to 400 °C than the control foam. Conversely, their mechanical and dynamic mechanical properties become poorer as the PP147 concentration increases and even more so if PP102 is used instead. PP147 foams containing up to 50% bio‐polyol could be used as a green replacement of petroleum‐based ones in applications where excellent behaviour in compression (the most affected properties) is not fundamental, with the additional advantages of reduced density and increased content of bio‐derived components. © 2017 Society of Chemical Industry     

Preparation and characterization of colloidal carbon sphere/rigid polyurethane foam composites

Sucrose decomposed under hydrothermal conditions, generating colloidal carbon spheres (CCSs) with a perfectly spherical morphology. X‐ray diffraction indicated that the main component of the CCSs was disordered carbon, and massive hydroxyl groups existed on the surface, as confirmed by Fourier transform infrared spectroscopy. CCSs were first introduced into polyurethane foams (PUFs), and CCS‐reinforced PUF (PUF/CCS) composites were synthesized. The introduction of CCSs did not increase the viscosity of polyol/CCS blends significantly. The good dispersion of CCSs and the compatibility between CCSs and polyurethane were confirmed by transmission electron microscopy measurements. The results of mechanical testing showed that PUF/CCS composites exhibited greatly improved mechanical properties in comparison with neat PUFs, and this could be ascribed to the finer cell structure of the PUF/CCS composites, which was inspected with scanning electron microscopy. Thermogravimetric analysis indicated that the effects of CCSs on the thermal stability of the foams were slight. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Synthesis and properties of reactively compatibilized polyester and polyamide blends

The functionalization of poly(butylene terephthalate) (PBT) has been accomplished in a twin screw extruder by grafting maleic anhydride (MA) using a free radical polymerization technique. The resulting PBT‐g‐MA was successfully used as a compatibilizer for the binary blends of polyester (PBT) and polyamide (PA66). Enhanced mechanical properties were achieved for the blend containing a small amount (as low as 2.5 %) of PBT‐g‐MA compared to the binary blend of unmodified PBT with PA66. Loss and storage moduli for blends containing compatibilizer were higher than those of uncompatibilized blends or their respective polymers. The grafting and compatibilization reactions were confirmed using FTIR and ¹³C NMR spectroscopy. The properties of these blends were studied in detail by varying the amount of compatibilizer, and the improved mechanical behaviour was correlated with the morphology with the help of scanning electron microscopy. Morphology studies also revealed the interfacial interaction in the blend containing grafted PBT. The improvement in the properties of these blends can be attributed to the effective interaction of grafted maleic anhydride groups with the amino group in PA66. The results indicate that PBT‐g‐MA acts as an effective compatibilizer for the immiscible blends of PBT and PA66. © 2000 Society of Chemical Industry     

Synthesis and performance of different polyurethane foams as oil sorbents

Oil sorption (g g^?1) through different polyurethane foams has been investigated in this study. Polyurethane foams were synthesized with different additives: glycerol, propylene glycol, polyethylene glycol 400, and 1‐dodecanol. All foams were applied as sorbents of diesel, motor oil, gasoline, kerosene, and crude oil. The foams were characterized using Fourier transform infrared spectroscopy, thermogravimetry and differential scanning calorimetry, compressive resistance at 10% deformation and the elastic modulus, scanning electron microscopy, and apparent density. The best performance of oil sorption was achieved with PUF‐3, which has the greatest amount of the chain extender polyethylene glycol 400 and lowest density of all the evaluated foams. The sorption capacities (g g^?1) of PUF‐3 were 16.8 (diesel), 15.7 (gasoline), 20.7 (oil motor), 25.4 (kerosene), and 29.8 (crude oil) and 100% removal of diesel from water was achieved, approximately. The foams with chain extenders and lower density values performed better as oil sorbents. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 45409.     

Physical Properties of Polyurethanes Produced from Polyols from Seed Oils: II. Foams

Rigid polyurethane (PU) foams were prepared using three North American seed oil starting materials. Polyol with terminal primary hydroxyl groups synthesized from canola oil by ozonolysis and hydrogenation based technology, commercially available soybean based polyol and crude castor oil were reacted with aromatic diphenylmethane diisocyanate to prepare the foams. Their physical and thermal properties were studied and compared using dynamic mechanical analysis and thermogravimetric analysis techniques, and their cellular structures were investigated by scanning electron microscope. The chemical diversity of the starting materials allowed the evaluation of the effect of dangling chain on the properties of the foams. The reactivity of soybean oil-derived polyols and of unrefined crude castor oil were found to be lower than that of the canola based polyol as shown by their processing parameters (cream, rising and gel times) and FTIR. Canola-PU foam demonstrated better compressive properties than Soybean-PU foam but less than Castor-PU foam. The differences in performance were found to be related to the differences in the number and position of OH-groups and dangling chains in the starting materials, and to the differences in cellular structure.     

The influence of nano-silica on the thermal conductivity of polyurethane foam

This study reports the influence of nano-silica particles (0.0–0.45 %wt) on properties of polyurethane foams (PUF) using monoglycerides, sorbitol, and glycerol as components of polyol. The morphology, density, mechanical, thermal stability, and thermal conductivity properties of samples were investigated in this study. When 0.35 %Wt of nano-silica was used to reinforce PUF, the compression strength of PUF achieved the highest value (82.49 kPa). The thermal gravimetric analysis showed that the presence of nano-silica can improve the thermal stability of PUF samples. Scanning electron microscopy studies indicated that PUF samples containing 0.3, 0.35, and 0.45 %Wt of nano-silica had more uniform cell structures than pure PUF sample. Finally, the thermal conductivity of pure PUF and PUF/nano-silica were measured at three different levels of humidity (33% RH, 57% RH and 75% RH) at 25°C. The lowest thermal conductivity value achieved was 0.034 W/mK.     

桐油基阻燃多元醇制备及其在硬质聚氨酯泡沫中应用

以桐油(TO)为基本原料,先后经过酯交换反应、磷钨酸季铵盐催化环氧化反应、环氧开环反应生成桐油基阻燃多元醇(TOBP),并将制备的TOBP与异氰酸酯(PAPI)共混通过一步发泡的方式制备得到阻燃型硬质聚氨酯泡沫(FRPUR)。采用傅立叶变换红外光谱和氢谱对产物的结构进行表征,分析结果表明,已成功制备出环氧中间体和TOBP;热重测试结果表明TO、桐油甲酯(TOME)、环氧桐油甲酯(ETOME)和TOBP的热稳定性顺序依次为TOBPETOMETOTOME。通过发泡和极限氧指数、力学强度等测试手段,考察了桐油基PUR泡沫的阻燃性能和力学性能,并与由工业级聚醚多元醇制备的FRPUR硬泡进行比较。分析测试结果表明,由TOBP制备的FRPUR具有良好的阻燃性能和力学性能。     

Melt compounding of PMMA/clay nanocomposites with styrene‐maleic anhydride copolymers: Effect of copolymer type on thermal,mechanical and dielectric properties

Poly(methyl methacrylate) (PMMA)‐clay nanocomposites (PCN) were prepared through melt blending. Styrene‐maleic anhydride copolymers (SMA) of different molecular weights and MA contents were used as compatibilizers with organically modified clay. The melt‐blended PCN materials were subsequently investigated by a series of characterization techniques, including wide‐angle X‐ray diffraction, transmission electron microscopy, differential scanning calorimetry, thermogravimetric analysis, dynamic mechanical thermal analysis, and thermal mechanical analysis. Compared with unmodified PMMA, with only 5 wt% clay loading, the modified PCN materials exhibit higher glass‐transition temperatures, higher dynamic storage moduli, and lower thermal expansion coefficients. The dielectric properties of PCNs in plate form were measured with dielectric spectroscopy. Significant increase in dielectric permitivities and losses were observed for these PCNs. POLYM. COMPOS., 2010. © 2009 Society of Plastics Engineers     

Effect of montmorillonoite modification and maleic anhydride‐grafted polypropylene on the microstructure and mechanical properties of polypropylene/montmorillonoite nanocomposites

Two types of modified montmorillonite (MMT) were achieved using octadecylamine as the modifying agent by the methods of dry process and wet route. Polypropylene (PP)/MMT nanocomposites were prepared using the melt mixing technique and employing maleic anhydride‐grafted polypropylene (PP‐MA) as the compatibilizer. The modification of montmorillonite was characterized by fourier transform infrared spectroscopy (FTIR), X‐ray diffraction (XRD), and scanning electron microscope (SEM). The effect of MMT modification and PP‐MA on the microstructure and properties of PP/MMT nanocomposites was investigated by SEM, differential scanning calorimeter (DSC), thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), and polarizing microscopy. The results show that organic montmorillonite modified by wet process (WOMMT) has a large d‐spacing increment; whereas montmorillonite modified by dry process (DOMMT) shows little d‐spacing increment. Furthermore, the mechanical properties of composites incorporating WOMMT are better than that containing DOMMT. As a third component, the addition of PP‐MA benefits the formation of exfoliated structure and the dispersion of MMT in PP matrix, and hence, enhances the physical properties of the nanocomposite. With the presence of PP‐MA, the highly dispersed MMT increases the number of spherulite crystals, enhances the melting enthalpy, improves the thermal stability, and induces the desired tiny crazes more effectively. MMT increases the storage modulus (E′) and glass‐transition temperature (T_g) of PP because of the stiffness of MMT layers, but PP‐MA decreases them owing to its high melt flow index, both of which were in favor of improving the physical properties. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 3952–3960, 2013     

Highly functional biobased polyols and their use in melamine–formaldehyde coatings

Highly functional sucrose soyate polyol (SSP) resins were synthesized by ring-opening epoxidized sucrose soyate with methanol or ethanol and were subsequently crosslinked with a melamine–formaldehyde (MF) resin in the presence of an acid catalyst or blocked acid catalyst. The biobased polyols were characterized by Fourier transform infrared spectroscopy, gel permeation chromatography, proton nuclear magnetic resonance spectroscopy, Brookfield viscosity, and matrix-assisted laser desorption/ionization time-of-flight mass spectrometry. The thermal properties of the biobased MF coatings were studied using differential scanning calorimetry and dynamic mechanical analysis. As controls, a soybean oil polyol (SBOP) with lower functionality and a commercial polyester polyol were studied for comparison. Overall, MF coatings formulated with SSPs showed superior properties to coatings formulated with SBOP and comparable properties to the commercial polyester which was attributed to the high hydroxyl functionality.     

Synthesis,characterization, and properties of acrylate‐modified tung‐oil waterborne insulation varnish

An acrylate‐modified tung‐oil waterborne insulation varnish was synthesized from tung oil, maleic anhydride, and acrylates via a Diels–Alder reaction and free‐radical polymerization, and the varnish could be solidified at a relatively low temperature with blocked hexamethylene diisocyanate as a curing agent. The resulting films were characterized by Fourier transform infrared spectroscopy, thermogravimetric analysis, and differential scanning calorimetry. The insulation properties (electrical insulation strength, volume resistivity, and surface resistivity) of the varnish films were tested, and the resistances of films to salted water were evaluated. With an increase in the maleic anhydride content, the thermal stability of the film was improved, whereas the electrical insulation strength, volume resistivity, and surface resistivity decreased. The electrical insulation strength of the film after it was immersed in the NaCl solution was lower than that in dry state, and it decreased as the immersed time was prolonged. In particular, the electrical insulation strength loss of the film increased significantly at maleic anhydride contents beyond 25 wt %. Furthermore, the hardness of the film increased with increasing methyl methacrylate/N‐butyl acrylate ratio, whereas the flexibility and adhesion of film decreased to a certain degree at the same time. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41608.