Novel Composite Planks Made of Shape Memory Polyurethane Foaming Material with Two-Step Foaming Process

In this study, shape memory polyurethane (SMP) foaming material is used as the main material that is incorporated with carbon fiber woven fabrics via two-step foaming method, forming sandwich-structured composite planks. The process is simple and efficient and facilitates any composition as required. The emphasis of this study is protection performances, involving puncture resistance, buffer absorption, and electromagnetic wave shielding effectiveness. The proposed soft PU foam composite planks consist of the top and bottom PU foam layers and an interlayer of carbon fiber woven fabric. Meanwhile, PU foam is incorporated with carbon staple fibers and an aluminized PET film for reinforcement requirements and electromagnetic wave shielding effectiveness, respectively. Based on the test results, the two-step foaming process can provide the PU foam composite planks with excellent buffer absorption, puncture resistance, and electromagnetic wave shielding effectiveness; therefore, the proposed composite planks contribute a novel structure composition to SMP, enabling it to be used as a protective composite. In addition, the composites contain conductive material and thus exhibit a greater diversity of functions.

Ultrahigh and Tunable Electromagnetic Interference Shielding Performance of PVDF Composite Induced by Nano-Micro Cellular Structure

Lightweight and efficient electromagnetic interference (EMI) shielding materials play a vital role in protecting high-precision electronic devices and human health. Porous PVDF/CNTs/urchin-like Ni composites with different cell sizes from nanoscale to microscale were fabricated through one-step supercritical carbon dioxide (CO2) foaming. The electrical conductivity and electromagnetic interference (EMI) shielding performance of the composites with different cell sizes were examined in detail. The results indicated that the nanoscale cell structure diminishes the EMI shielding performance of the composite, whereas the microscale cell structure with an appropriate size is beneficial for improving the EMI shielding performance. A maximum EMI shielding effectiveness (SE) of 43.4 dB was achieved by the composite foams which is about twice that of the solid composite. Furthermore, as the supercritical CO2 foaming process reduces the density of the composite by 25–50%, the EMI SSE (specific shielding effectiveness)/t(thickness) of the composite reaches 402 dB/(g/cm2), which is the highest value of polymer foam obtained to the best of the authors’ knowledge. Finally, compression tests were performed to show that the composites still maintained excellent mechanical properties after the supercritical CO2 foaming process.

Characterization and Properties of Water-Blown Rigid Polyurethane Foams Reinforced with Silane-Modified Nanosepiolites Functionalized with Graphite

In the present study, a promising flame retardant consisting of 80 wt% silane-modified nanosepiolites functionalized with 20 wt% graphite (SFG) is used to obtain a synergistic effect principally focussed on the thermal stability of water-blown rigid polyurethane (RPU) foams. Density, microcellular structure, thermal stability and thermal conductivity are examined for RPU foams reinforced with different contents of SFG (0, as reference material, 2, 4 and 6 wt%). The sample with 6 wt% SFG presents a slightly thermal stability improvement, although its cellular structure is deteriorated in comparison with the reference material. Furthermore, the influence of SFG particles on chemical reactions during the foaming process is studied by FTIR spectroscopy. The information obtained from the chemical reactions and from isocyanate consumption is used to optimize the formulation of the foam with 6 wt% SFG. Additionally, in order to determine the effects of functionalization on SFG, foams containing only silane-modified nanosepiolites, only graphite, or silane-modified nanosepiolites and graphite added separately are studied here as well. In conclusion, the inclusion of SFG in RPU foams allows the best performance to be achieved.

FOAMING AND MOISTURE CROSSLINKING OF VINYL TRIETHOXY SILANE GRAFTED ETHYLENE–PROPYLENE–DIENE TERPOLYMER

ABSTRACT Moisture crosslinking of polyolefins has attracted increasing attention because of its high efficiency, low cost, and easy processing. However, the crucial shortcoming of moisture crosslinking is that the side reaction of peroxide scorch (precrosslinking) simultaneously occurs in silane grafting. It has been recognized that making peroxide precrosslinking useful is an effective way to broaden the application of moisture crosslinking. A novel foaming process combined with moisture crosslinking is proposed. The matrix of ethylene–propylene–diene terpolymer grafted with silane vinyl triethoxysilane (EPDM-g-VTES) was prepared by melt grafting, with dicumyl peroxide as initiator. Foaming was then carried out with azodicarbonamide (AC) as the blowing agent by making use of precrosslinking. Subsequently, the EPDM-g-VTES foams were immersed in a water bath to achieve moisture crosslinking with dibutyl tin dilaurate as the catalyst. The results showed that VTES was grafted onto EPDM and the EPDM-g-VTES foams were successfully crosslinked by moisture. The EPDM-g-VTES compounds with AC obtained great cells by compression molding with the help of precrosslinking. The mechanical property of the EPDM-g-VTES foam was improved by moisture crosslinking. The moisture-cured foam with 4 wt% AC had an expansion ratio of about three times, which could bear large deformation and showed a high energy-absorption effect.

Vibration and Sound Response of Glass-Fiber-Reinforced Polyamide 6 Using Microcellular-Foaming-Process-Applied Injection Molding Process

In this study, the vibration and sound response characteristics of composites produced via injection molding applied with a microcellular foaming process (MCPs) were improved. The study was conducted using PA6 and glass fiber composites, which are representative thermoplastic engineering plastics. Two types of specimens were used: a plate specimen to confirm the basic sound and vibration characteristics, and a large roof-rack specimen from an actual vehicle with a complex shape. The frequency response function curve was calculated by conducting an impact test, and natural frequency and damping ratio were measured based on the curve. The results confirmed that, in the case of a specimen manufactured through the injection molding process to which MCPs were applied, the natural frequency was lowered, and the damping ratio decreased. The degree of change in the natural frequency and damping ratio was confirmed. To determine the cause of the change in the natural frequency and damping ratio, the mode shape at the natural frequency of each specimen was measured and the relationship was confirmed by measuring the density and the elastic modulus of the composite. In addition, the usability of the specimens to which MCPs were applied was verified by conducting impact strength and tensile strength tests.

Bio-Based Rigid Polyurethane Foams Modified with Phosphorus Flame Retardants

Rigid polyurethane foams (RPURF) containing a bio-polyol from rapeseed oil and different phosphorus-based flame retardants were obtained. Triethyl phosphate (TEP), dimethyl propane phosphonate (DMPP) and cyclic phosphonates Addforce CT 901 (20 parts per hundred polyol by weight) were used in the synthesis of RPURF. The influence of used flame retardants on foaming process, cell structure, and physical–mechanical properties as well as flammability of RPURF were examined. The addition of flame retardants influenced the parameters of the cellular structure and decreased compressive strength. All obtained foam materials had a low thermal conductivity coefficient, which allows them to be used as thermal insulation. The research results of bio-based RPURF were compared with foams obtained without bio-polyol. All modified materials had an oxygen index above 21 vol%; therefore, they can be classified as self-extinguishing materials. The analysis of parameters obtained after the cone calorimeter test showed that the modified RPURF have a lower tendency to fire development compared to the reference foams, which was particularly noticeable for the materials with the addition of DMPP.

SPECIALTY NATURAL RUBBER LATEX FOAM: FOAMABILITY STUDY AND FABRICATION PROCESS

ABSTRACT Specialty natural rubber (SpNR) latex, namely, deproteinized natural rubber (DPNR) latex and epoxidized natural rubber (ENR) latex, has been produced to meet specific product's requirements. However, SpNR is normally used in the form of block rubber to manufacture dry rubber products such as tires and automotive parts. The applications of SpNR latex into latex foam products will be diversified. Findings indicate that foamability of SpNR latex is lower compared to normal latex (LATZ) but shows longer stability time after foamed. Findings also indicate that foam collapse and foam coagulate are two main challenges in the fabrication process of SpNR latex foam. Despite these challenges, SpNR latex foam can be fabricated at different density levels. During the foaming process, additional foaming agent is required to fabricate a SpNR latex foam, which is different from fabricating a normal NR latex foam, especially at low latex foam density. Consequently, a higher level of sodium silicofluoride, used as the gelling agent, is required to set the cell structure of the foam. Findings also indicate that foam density influenced the gelling time and volume shrinkage of the SpNR latex foam. An ideal compounding, foaming, and gelling formulation to fabricate SpNR latex foam via Dunlop batch foaming process has been developed. Morphological study showed that all latex foams are open-cell structure, with lower density foam exhibiting higher porosity and mean pore size. Comparison on hysteresis behavior between DPNR and ENR latex foam indicated that ENR latex foam exhibits higher hysteresis loss ratio compared to DPNR latex foam.

Effect of rare earth nucleating agent on supercritical CO2 foaming behavior of block copolymerized polypropylene

The rare earth nucleating agent was used to modify block copolymerized polypropylene (PPB) in foaming process. The results show that the crystallization of PPB and the melting temperature of β-crystal increased gradually with increased β-crystal nucleating agent content. The total crystallinity decreased with amount of addition increasing, and the relative content of β-crystal increased first and then decreased. When β-crystal nucleating agent content was 0.4 wt%, the relative β-crystal content reached the maximum value of 95.27%, and the final crystal grain refinement significantly. The addition of rare earth β-crystal nucleating agent has a good effect on improving the uniformity of foam cells. Under the same content of β-crystal nucleating agent and pressure, the average cell diameter and expansion ratio increased with the saturation temperature increasing. After the foaming temperature reaches 155°C, the expansion ratio began to decrease, which was also consistent with the changed trend of relative β-crystal content. At the same content of temperature and relative β-crystal, as the foaming pressure increased, the cell diameter decreased gradually, and the expansion ratio increased first, and then decreased.