Lanthanum phenylphosphonate–based multilayered coating for reducing flammability and smoke production of flexible polyurethane foam

In the present work, lanthanum phenylphosphonate (LaPP)–based multilayered film was fabricated on the surface of flexible polyurethane (PU) foam by layer‐by‐layer self‐assembled method. The successful deposition of the coating was confirmed by scanning electron microscopy (SEM) and energy‐dispersive X‐ray (EDX). Subsequently, the thermal decomposition and burning behavior of untreated and treated PU foams were investigated by thermogravimetric analysis (TGA) and cone calorimeter, respectively. The TGA results indicated that T_max2 of treated PU foams were increased by approximately 15°C to 20°C as compared with untreated PU foam. The peak heat release rate (PHRR) and total heat release (THR) of PU‐6 (with 19.5 wt% weight gain) were 188 kW/m² and 20.3 MJ/m², with reductions of 70% and 15% as compared with those of untreated PU foam, respectively. Meanwhile, the smoke production of treated PU foam was suppressed after the construction of LaPP‐based coating.     

Preparation and characterization of biopolyol via liquefaction of rice straw

Biopolyols were prepared by the liquefaction of rice straw under the mild condition. The optimum liquefaction effect was obtained at 5 : 1 volume ratio of PEG400 to DEG, 4 : 1 liquid–solid ratio, H₂SO₄ 3%, time 2.5 h, and reaction temperature120°C. Products were characterized by FTIR and gel permeation chromatograms (GPC) measurements. The hydroxyl value and weight-average molecular weight of the biopolyol produced based on the above optimal conditions were 260 mg KOH/g polyol and 420 g mol^–1, respectively. Biopolyol obtained is suitable for the preparation of rigid polyurethane foam. This study has certain significance for the high added value use of rice straw and reducing the production cost and improvement biodegradability of polyurethane foams.     

Preparation of magnetic polyurethane rigid foam nanocomposites

Super paramagnetic Fe₃O₄@SiO₂ nanoparticle was incorporated into polyurethane rigid foams in order to prepare new corresponded magnetic nanocomposite foams via one-shot method. The core–shell-structured nanoparticles were prepared by sol–gel method and characterized by transmission electron microscopy, X-ray diffraction, as well as Fourier transform infrared spectroscopy techniques. Magnetic nanoparticles were used up to 3 % in the foam formulations and the samples prepared successfully. Thermal, mechanical, and magnetic properties of nanocomposites were studied and the results showed superior properties in comparison with pristine foams.     

Ion-exchange foam chromatography: Part I. Preparation of rigid and flexible ion-exchange foams

In order to be able to apply the principles of foam chromatography to ion-exchange processes, preparative methods for open-cell ion-exchange foams, were investigated. Homogeneous ion-exchange foams were prepared by introducing ion-exchange groups on previously prepared phenol-formaldehyde, polyurethane and polyethylene foams. The maximum capacity of the produced sulfonated phenol-formaldehyde cation-exchange foams was 1.85 meq g^-1; that of the styrene-polyurethane interpolymer anion-exchange foams was 2.2 meq g^-1. Weak carboxylic ion-exchange foams were prepared by radiation grafting of polyurethane and polyethylene foams; the maximum capacity of these foams was 4.02 meq g^-1. Heterogeneous ion-exchange foams were prepared by foaming a fine powder of a commercially available cation exchanger with the precursors of open-cell polyether-type polyurethane foam. The capacity of such a foam containing 26% ion-exchange powder was 1.0 meq g^-1. The kinetics of the cation-exchange process on the heterogeneous foams was measured with ⁸⁵Sr.     

The study of mechanical behavior and flame retardancy of castor oil phosphate-based rigid polyurethane foam composites containing expanded graphite and triethyl phosphate

The goal of this work was the synthesis of novel flame-retarded polyurethane rigid foam with a high percentage of castor oil phosphate flame-retarded polyol (COFPL) derived from renewable castor oil. Rigid flame-retarded polyurethane foams (PUFs) filled with expandable graphite (EG) and diethyl phosphate (TEP) were fabricated by cast molding. Castor oil phosphate flame-retarded polyol was derived by glycerolysis castor oil (GCO), H₂O₂, diethyl phosphate and catalyst via a three-step synthesis. Mechanical property, morphological characterization, limiting oxygen index (LOI) and thermostability analysis of PUFs were assessed by universal tester, scanning electron microscopy (SEM), oxygen index testing apparatus, cone calorimeter and thermogravimetric analysis (TGA). It has been shown that although the content of P element is only about 3%, the fire retardant incorporated in the castor oil molecule chain increased thermal stability and LOI value of polyurethane foam can reach to 24.3% without any other flame retardant. An increase in flame retardant was accompanied by an increase in EG, TEP and the cooperation of the two. Polyurethane foams synthesized from castor oil phosphate flame-retarded polyol showed higher flame retardancy than that synthesized from GCO. The EG, in addition to the castor oil phosphate, provided excellent flame retardancy. This castor oil phosphate flame-retarded polyol with diethyl phosphate as plasticizer avoided foam destroy by EG, thus improving the mechanical properties. The flame retardancy determined with two different flame-retarded systems COFPL/EG and EG/COFPL/TEP flame-retarded systems revealed increased flame retardancy in polyurethane foams, indicating EG/COFPL or EG/COFPL/TEP systems have a synergistic effect as a common flame retardant in castor oil-based PUFs. This EG/COFPL PUF exhibited a large reduction of peak of heat release rate (PHRR) compared to EG/GCO PUF. The SEM results showed that the incorporation of COFPL and EG allowed the formation of a cohesive and dense char layer, which inhibited the transfer of heat and combustible gas and thus increased the thermal stability of PUF. The enhancement in flame retardancy will expand the application range of COFPL-based polyurethane foam materials.     

Mechanical properties of polyurethane foams modified by polymer-polyols

The mechanical properties of polyurethane foams based on tolylene diisocyanate and polyether modified by polymer-polyol, which is a styrene-acrylonitrile copolymer grafted onto polyol, were studied. The breaking stress, the hardness at 40% compression, the elongation at break, and the density depend on the amount of both the hard phase in the polymer-polyol and the polymer-polyol component in the polyurethane foam composition. Samples with a density of ～30 kg/m³ were prepared to have other mechanical properties practically identical to those of standard samples with a density of ～37–47 kg/m³.     

WATER-BLOWN POLYURETHANE RIGID FOAMS MODIFIED BY CHEMICAL PLASTICATION

Water-blown polyurethane rigid foams are getting more and more attention, because the traditional blowing agent HCFC141b has already been abolished to prevent the ozone layer from destruction. However, the polyurethane rigid foams blown by water have serious defects, i.e. friability and resulting lower adhesion strength. Thus, the purpose of this study is to resolve the problems by chemical plastication. The maleate was added to polyol-premix containing water or to polyisocyanate,with both of which maleate does not react. To prove the reaction when polyol-premix and polyisocyanate were mixed, the model composite was synthesized and analyzed by IR, NMR and ESI (MS). Furthermore, a series of water-blown polyurethane rigid foams added different amount maleate were successfully prepared. By testing impact strength and adhesion strength of the foams, the actual effect of adding maleate was obtained.     

WATER-BLOWN POLYURETHANE RIGID FOAMS MODIFIED BY CHEMICAL PLASTICATION

1. INTRODUCTIONThese years, HCFC-141b may be the most used blowing agent for its useful properties. But, because of its high global warming effect leading to the destruction of the ozone layer, production of HCFC141b has been forbidden. However, there are…     

Chemical Recycling and Liquefaction of Rigid Polyurethane Foam Wastes through Microwave Assisted Glycolysis Process

Glycolysis of polyurethane rigid foams (PUFs) was performed utilizing microwave irradiation at atmospheric pressure. The effects of various metal hydroxide and acetate catalysts as well as different microwave powers were investigated. All reactions were monitored by FTIR spectroscopy. The recovered liquid product containing OH functional groups was applied as a portion of the polyol in formulation of a new polyurethane rigid foam product. The reactivity factors and densities were compared with the foam produced from totally virgin polyol.     

Sorption of iron(III) and iron(II) from acidic chloride solutions by polyether and polyester type polyurethane foams

Summary Iron(III) is sorbed by polyether type open-cell polyurethane foams from HCl solutions of 4 mol/l or higher. The capacity of the foams is around 50 mg·l^–1. The iron (III) sorbed can be eluted from the foam with 0.01 mol/l HCl or distilled water. An optimization of the sorption conditions showed that the process can be used for analytical applications. The polyurethane foam sorbents examined did not sorb iron(II). The mechanism of sorption by polyether foams seems to follow a mechanism similar to that of the extraction of iron(III) by etheric solvents.     

Glass transition and thermal degradation of rigid polyurethane foams derived from castor oil–molasses polyols

Rigid polyurethane (PU) foams having saccharide and castor oil structures in the molecular chain were prepared by reaction between reactive alcoholic hydroxyl group and isocyanate. The apparent density of PU foams was in a range from 0.05 to 0.15 g cm^?3. Thermal properties of the above polyurethane foams were studied by differential scanning calorimetry, thermogravimetry and thermal conductivity measurement. Glass transitions were observed in two steps. The low-temperature side glass transition was observed at around 220 K, regardless of castor oil content. This transition is attributed to the molecular motion of alkyl chain groups of castor oil. The high-temperature side glass transition observed in the temperature range from 350 to 390 K depends on the amount of molasses polyol content. The high-temperature side glass transition is attributed to the molecular motion of saccharides, such as sucrose, glucose, fructose as well as isocyanate phenyl rings, which act as rigid components. Thermal decomposition was observed in two steps at 570 and 620–670 K. Thermal conductivity was observed at around 0.032 J sec^?1 m^?1 K^?1. Compression strength and modulus of PU foams were obtained by mechanical test. It was confirmed that the thermal and mechanical properties of PU foams could be controlled by changing the mixing ratio of castor oil and molasses for suitable practical applications.     

Development and Validation of Novel DH-GC-ITMS Methods for the Determination of Freon F-141b in Formulated Polyol and Rigid Polyurethane Foam

Two efficient methods for the determination of 1,1-dichloro-1-fluoroethane (Freon F-141b) in formulated polyol and rigid polyurethane foam by dynamic-headspace-gas chromatography-ion trap-mass spectrometry were developed and validated. Rigid polyurethane foam was efficiently dissolved in dimethylformamide by heating at the temperature of 60 °C for 2 h.Validation was carried out in terms of limits of detection (LOD), limits of quantitation (LOQ), linearity, precision and recovery. LOD values of 4.00 g kg^–1 for rigid polyurethane foam and 0.73 g kg^–1 for formulated polyol were achieved, whereas linearity was statistically verified over one order of magnitude. Precision was evaluated testing two concentration levels. Good results were obtained both in terms of intra-day repeatability and between-day precision: RSD % lower than 4% (n = 6) at the concentration of 15 g kg^–1 were calculated for intra-day repeatability. Extraction recoveries up to 92.6±1.6 % (n = 3) were also calculated by the addition of Freon F-141b to the samples analysed. Both the methods were applied for the analysis of a number of formulated polyol and rigid polyurethane foam samples.     

GC-MS Analysis of Organic Vapours Emitted from Polyurethane Foam Insulation

Abstract

The vapours emitted by rigid polyurethane foam at 40° and 80° in dry and in humid (90% RH) air were trapped with a Tenax TA sampling tube and, after thermal desorption, analyzed by high resolution gas chromatography – mass spectrometry. The chromatograms obtained demonstrate a certain characteristic pattern. The qualitative composition of the effluent mixture is basically independent of both temperature and humidity of the foam. Over seventy compounds were identified as polyurethane foam off-gases. Among them the most numerous are hydrocarbons. The most abundant is the blowing agent, trichlorofluoromethane. The most interesting are cyclic acetals, aldehydes, cyclic ethers, alcohols, chloroform and chlorobenzene. The headspace concentration of the majority of them is below 10mg/m³, there are, however, several compounds with the concentration exceeding 100mg/m³.     

Trace analysis of chlorofluorocarbons/partially halogenated chlorofluorohydrocarbons (CFC/HCFC) in polymeric foams by headspace capillary gas chromatography with electron-capture detection or ion trap detection combined with preconcentration on a cold trap

Two headspace-methods were developed for the detection and determination of traces of CFC/HCFC in polymeric foams. These methods consist of capillary gas chromatography using an electron-capture detector (ECD method) or an ion trap detector combined with preconcentration on a cold trap (ITD method). Different CFC/HCFC such as R115, R22, R12, R142b, R114, R11, R141b and R113 were investigated in polyethylene and flexible polyurethane foams. Conditions for sample preparation (e.g. thermostating time and temperature) were optimized. Determination of the detection limits and quantitation of the amount of CFC/HCFC released from the foam were performed with gas standards prepared with the help of mass flow controllers. Quantitative analyses of the total amount of CFC/HCFC present in the foam were performed using multiple headspace extraction. Longterm studies were performed on the rate of release of some CFC/HCFC from the foams. Additionally a method for distinguishing a CFC/HCFC-contaminated foam from an old CFC/HCFC-blown foam is presented. Both methods can be used individually; however, best results are achieved by using the ECD method for screening and the ITD method for confirmation. This combination was used for routine analysis enforcing legal restrictions on the use of CFC/HCFC in foams.Abbreviations CFC chlorofluorocarbon - HCFC partially halogenated chlorofluorohydrocarbon - PUR polyurethane - PS polystyrene - PE polyethylene - MHE multiple headspace extraction - ECD electron capture detector - ITD ion trap detector - FID flame ionization detector - TCD thermal conductivity detector - MS mass spectrometry - WCOT wall coated, open tubular (column) - ppm parts per million (1:10⁶ v/v) - ppb parts per billion (1:10⁹ v/v) - ppt parts per trillion (1:10¹² v/v) - DL detection limit - RSD relative standard deviation - CO₂ carbon dioxide - R115 C₂ClF₅ - R22 CHClF₂ - R12 CCl₂F₂ - R142b C₂H₃ClF₂ - R114 C₂Cl₂F₄ - R11 CCl₃F - R141b C₂H₃ClF - R113 C₂Cl₃F₃     

Synthesis of activated carbon foams with high specific surface area using polyurethane elastomer templates for effective removal of methylene blue

Carbon foams have gained significant attention due to their tuneable properties that enable a wide range of applications including catalysis, energy storage and wastewater treatment. Novel synthesis pathways enable novel applications via yielding complex, hierarchical material structure. In this work, activated carbon foams (ACFs) were produced from waste polyurethane elastomer templates using different synthesis pathways, including a novel one-step method. Uniquely, the produced foams exhibited complex structure and contained carbon microspheres. The ACFs were synthesized by impregnating the elastomers in an acidified sucrose solution followed by direct activation using CO₂ at 1000 ℃. Different pyrolysis and activation conditions were investigated. The ACFs were characterized by a high specific surface area (S_BET) of 2172 m²/g and an enhanced pore volume of 1.08 cm³/g. Computer tomography and morphological studies revealed an inhomogeneous porous structure and the presence of numerous carbon spheres of varying sizes embedded in the porous network of the three-dimensional carbon foam. X-ray diffraction (XRD) and Raman spectroscopy indicated that the obtained carbon foam was amorphous and of turbostratic structure. Moreover, the activation process enhanced the surface of the carbon foam, making it more hydrophilic via altering pore size distribution and introducing oxygen functional groups. In equilibrium, the adsorption of methylene blue on ACF followed the Langmuir isotherm model with a maximum adsorption capacity of 592 mg/g. Based on these results, the produced ACFs have potential applications as adsorbents, catalyst support and electrode material in energy storage systems.     

Epoxy modified polyurethane rigid foams

Rigid IPN foams were prepared by sequential polymerization of polyurethane and epoxy systems. Significantly higher compressive modulus and strength were observed with the IPN foams in comparison to the corresponding polyurethane rigid foams. The IPN foams show one glass transition temperature. The single T_g indicates the very small domain size in the PU-epoxy IPN's.     

Environmentally Compatible Hybrid-Type Polyurethane Foams Containing Saccharide and Lignin Components

Semi-rigid polyurethane (PU) foams were prepared using lignin-molasses- poly(ethylene glycol) polyols. Two kinds of lignin, kraft lignin (KL) and sodium lignosulfonate (LS), were used. Both lignin and molasses polyols were mixed with various ratios and were reacted with poly(phenylene methylene) polyisocyanate (MDI) in the presence of silicone surfactant and di-n-butyltin dilaurate. A small amount of water was used as a foaming agent. The apparent density of PU foams increased with increasing lignin content. The compression strength and elastic modulus linearly increase with increasing apparent density, suggesting that mechanical properties are controllable by changing reaction conditions. The PU foams were amorphous and glass transition was detected by differential scanning calorimetry. The glass transition temperature (T_g ) maintained an almost constant value, regardless of the mixing ratio. This indicates that both the phenolic group of lignin and the glucopyranose ring of molasses act as rigid components in PU crosslinking network structures, and both groups contribute to the main chain motion to the same extent. By thermogravimetry (TG), it was confirmed that PU foams are thermally stable up to around 300 °C. By differential scanning calorimetry, T_g was observed at temperatures from 80 to 120 °C.     

Melamine,silica, and ionic liquid as a novel flame retardant for rigid polyurethane foams with enhanced flame retardancy and mechanical properties

Rigid polyurethane (PU) foams were successfully filled with different weight ratios of melamine (1 wt%, 5 wt%, 10 wt%), silica (0.1 wt%) and ionic liquid, 1-Ethyl-3-methylimidazolium chloride, [EMIM]Cl (0.3 wt%). The aim of this study was to improve the flame retardancy of PU foams and to develop the synergistic effect between melamine, silica and ionic liquid on the flame-retardant PU foams. The influence of different loadings of the fillers was examined. The results showed that in comparison with unfilled foam, all modified compositions are characterized by higher density (41–46 kg m⁻³), greater compression strength (134–148 kPa), and comparable thermal conductivity (0.023–0.026 W m⁻¹ K⁻¹). Moreover, the reaction to fire of the PU composites has been investigated by the cone calorimeter test. The results showed that the fire resistance of PU foams containing as little as 1 wt% of melamine is significantly improved. For example, the results from the cone calorimeter test showed that the incorporation of the melamine, silica and ionic liquid significantly reduced the peak of heat release rate (pHRR) by ca. 84% compared with that of unmodified PU foam. SEM results showed that incorporated fillers can form an intumescent char layer during combustion which improves the reaction to fire of the composite foams.     

Compressive response of composite ceramic particle-reinforced polyurethane foam

Quasi-static and dynamic compressive tests are undertaken on the polyurethane (PU) foam and fumed silica reinforced polyurethane (PU/SiO₂) foam experimentally. The ceramic microspheres with varying mass fractions are adopted to mix with the PU/SiO₂ foam to fabricate the composite particle-reinforced foams. The effects of strain rate and particle mass fraction are discussed to identify and quantify the compressive response, energy-absorbing characteristic, and the associated mechanisms of the composite foams. The results show the initial collapse strength and plateau stress of the foams are improved significantly by reinforcing with the ceramic microsphere within 60 wt% at quasi-static compression. The rate sensitivity is observed on all the foams, but in different patterns due to the influence of ceramic microsphere. The compressive response affected by ceramic microsphere can be attributed to the particle cluster effect and stress wave propagation. Together with the deformation, the compressive characteristic experiences non-monotonic change from the low to high strain rates. The specific energy absorption (SEA) of the foam with 41 wt% ceramic microsphere show the largest magnitude at quasi-static compression. With the increasing strain rate, the ceramic reinforced foam exhibits superior energy absorption efficiency at high strain rates to that of the pure foams.     

Ceramic Foams from a Preceramic Polymer and Polyurethanes: Preparation and Morphological Investigations

Open-cell ceramic foams were obtained from a preceramic polymer (silicone resin) and blown polyurethanes. The preceramic polymer, which is crosslinked by condensation of silanol groups, was dissolved in CH2Cl2 and added to a liquid polyol containing the surfactant and the amine catalyst. Isocyanate was then added to the mixture and the foam was obtained through a twofold blowing mechanism (physical and chemical blowing). The morphology of the expanded polyurethane, which can be flexible or semirigid, characterized the final structure of the ceramic foam. The materials obtained were pyrolyzed in a nitrogen flux at temperatures of 1000–1200°C, thus allowing for the polymer-to-ceramic transformation to occur in the preceramic polymer. The ceramic foams produced in this way consisted of an amorphous silicon oxycarbide ceramic (SiOC). They presented a density ranging from 0.1 to 0.3 g/cm3. The average pore diameter ranged from 200 to 400 m and they possessed 80 to 90% open porosity.