Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “polyurethane foam”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Valorisation of technical lignin in rigid polyurethane foam: A critical evaluation on trends, guidelines and future perspectives

Lignin is one of the most abundant aromatic natural polymers. Produced as a by-product from the biomass refinery industries, lignin remains largely underutilised in high-value industrial applications. The incorporation of lignin in rigid polyurethane foam (RPUF) has been the focus of much research, due to its potential to replace fossil fuel-based components of RPUF. However, the overall sustainability of RPUF depends on numerous factors including processability, cost-effectiveness, and retention of performance throughout the service life. To date, the incorporation of lignin has been explored either as filler particles (through direct incorporation) or as a blendable liquid polyol introduced after chemical modifications (such as oxyalkylation, functionalisation, or depolymerisation). However, the production of lignin incorporated foam with high performance through cost-effective processing is still an ongoing challenge. Herein, this review critically appraises the progress on the effective incorporation of lignin in RPUF. Firstly, this review briefly covers the essential raw materials, formulation, important properties, and sustainability aspects of RPUF for industrial applications. Secondly, it provides insights on the key parameters of lignin of relevance to incorporation into RPUF. Thirdly, it benchmarks the reported studies on incorporation of lignin in RPUF systems by evaluating their important properties and proposes potential strategies for addressing the key challenges in the incorporation of lignin in RPUF. By bridging the gaps that exist in the literature on the utilisation of lignin in RPUF this account will serve as a resource for both beginners and professionals in the polyurethane and biorefinery industries towards the successful development of lignin incorporated RPUF for industrial applications

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2000

Uncertainty Analysis of Decomposing Polyurethane Foam

Sensitivity/uncertainty analyses are necessary to determine where to allocate resources for improved predictions in support of our nation's nuclear safety mission. Yet, sensitivity/uncertainty analyses are not commonly performed on complex combustion models because the calculations are time consuming, CPU intensive, nontrivial exercises that can lead to deceptive results. To illustrate these ideas, a variety of sensitivity/uncertainty analyses were used to determine the uncertainty associated with thermal decomposition of polyurethane foam exposed to high radiative flux boundary conditions. The polyurethane used in this study is a rigid closed-cell foam used as an encapsulant. Related polyurethane binders such as Estane are used in many energetic materials of interest to the JANNAF community. The complex, finite element foam decomposition model used in this study has 25 input parameters that include chemistry, polymer structure, and thermophysical properties. The response variable was selected as the steady-state decomposition front velocity calculated as the derivative of the decomposition front location versus time. An analytical mean value sensitivity/uncertainty (MV) analysis was used to determine the standard deviation by taking numerical derivatives of the response variable with respect to each of the 25 input parameters. Since the response variable is also a derivative, the standard deviation was essentially determined from a second derivative that was extremely sensitive to numerical noise. To minimize the numerical noise, 50-micrometer element dimensions and approximately 1-msec time steps were required to obtain stable uncertainty results. As an alternative method to determine the uncertainty and sensitivity in the decomposition front velocity, surrogate response surfaces were generated for use with a constrained Latin Hypercube Sampling (LHS) technique. Two surrogate response surfaces were investigated: 1) a linear surrogate response surface (LIN) and 2) a quadratic response surface (QUAD). The LHS techniques do not require derivatives of the response variable and are subsequently relatively insensitive to numerical noise. To compare the LIN and QUAD methods to the MV method, a direct LHS analysis (DLHS) was performed using the full grid and timestep resolved finite element model. The surrogate response models (LIN and QUAD) are shown to give acceptable values of the mean and standard deviation when compared to the fully converged DLHS model.

Hobbs, Michael L.↗
NASA NTRS1990

Washing Off Polyurethane Foam Insulation

Jet of hot water removes material quickly and safely. Simple, environmentally sound technique found to remove polyurethane foam insulation from metal parts. Developed for (but not limited to) use during rebuilding of fuel system of Space Shuttle main engine, during which insulation must be removed for penetrant inspection of metal parts.

Burley, Richard K.↗
NASA NTRS2007

Piloted Ignition to Flaming in Smoldering Fire-Retarded Polyurethane Foam

Experimental results are presented on the piloted transition from smoldering to flaming in the fire-retarded polyurethane foam Pyrell . The samples are small rectangular blocks with a square cross section, vertically placed in the wall of a vertical wind tunnel. Three of the vertical sample sides are insulated and the fourth side is exposed to an upward oxidizer flow of variable oxygen concentration and to a variable radiant heat flux. The gases emitted from the smoldering reaction pass upwards through a pilot, which consists of a coiled resistance heating wire. In order to compensate for the solid-phase and gas-phase effects of the fire retardants on the piloted transition from smoldering to flaming in Pyrell, it was necessary to assist the process by increasing the power supplied to the smolder igniter and the pilot (compared to that used for non-fire retarded foam). The experiments indicate that the piloted transition from smoldering to flaming occurs when the gaseous mixture at the pilot passes the lean flammability limit. It was found that increasing the oxygen concentration or the external heat flux increases the likelihood of a piloted transition from smoldering to flaming, and generally decreases the time delay to transition. The piloted transition to flaming is observed in oxygen concentrations of 23% and above in both low-density and high-density Pyrell. Comparisons with previous experiments show that the piloted transition from smoldering to flaming is possible under a wider range of external conditions (i.e. lower oxygen concentration) than the spontaneous transition from smoldering to flaming. The results show that the fire retardants in Pyrell are very effective in preventing the piloted transition to flaming in normal air, but Pyrell is susceptible to smoldering and the piloted transition to flaming in oxygen-enriched environments. Therefore, precautions should be taken in the design of applications of Pyrell in oxygen-enriched environments to reduce to the risk of a piloted transition to flaming.

Putzeys, O.↗
DOE OSTI2020

Room Temperature Quasi-static Characterization and Constitutive Model Parametrization of Flexible Polyurethane Foams of Different Densities Loaded in Different Orientations

This report describes the efforts to characterize and model General Plastics TF6070 and EF4000 flexible polyurethane foams under room temperature, large deformation quasi-static cyclic mechanical loading conditions. Densities from three to fifteen pound per cubic foot (PCF) are examined, which correspond to relative densities of approximately 4 to 20%. These foams are open cell structured and flexible at room temperature with a glass transition transition less than -30°C, and they fully recover their original shape when unloaded (at room temperature). Uniaxial compression tests were conducted with accompanying lateral image series for Digital Image Correlation (DIC) analysis with the goal of extracting transverse strain responses. Due to difficulties with DIC analysis at large strains, lateral strains were instead extracted for each test via edge tracking. The experimental results exhibit a nonlinear elastic response and anisotropic material behavior (particularly for the lower densities). Some hysteresis is observed that is different between the first and subsequent cycles of deformation indicating both a small degree of permanent damage (reduced stiffness during reloading) and viscoelasticity. These inelastic mechanisms are not considered in the modeling and calibration in this report. This work considers only the rate independent, room temperature foam behavior. Individual foam densities were calibrated for loading in two directions, parallel and perpendicular to the foam bubble rise direction, since the mechanical behavior is different in these two directions. The Flex Foam constitutive model was used for all parameterizations despite the fact that the model is isotropic. A review of the constitutive model is given as well as necessary data reduction procedures to parameterize it for each foam density and orientation are discussed. Finally, two different parameterizations are developed that take the undeformed foam density as an input that span all densities considered. These two parameterized models represent foams loaded in the rise and transverse directions respectively. We summarize the assumptions and limitations of the parameterizations provided in this report to guide analysis choices with them. All parameterizations presented herein have the following traits, room temperature, rate independent, damage-free, and non-dissipative . Isotropy (even if they are representing anisotropic data). Supplied Sierra Solid Mechanics Flex Foam Model Inputs are in units: pounds, inches, Celsius, and seconds

36 MATERIALS SCIENCE↗
NASA NTRS2004

Transition from Forward Smoldering to Flaming in Small Polyurethane Foam Samples

Experimental observations are presented of the effect of the flow velocity and oxygen concentration, and of a thermal radiant flux, on the transition from smoldering to flaming in forward smoldering of small samples of polyurethane foam with a gas/solid interface. The experiments are part of a project studying the transition from smolder to flaming under conditions encountered in spacecraft facilities, i.e., microgravity, low velocity variable oxygen concentration flows. Because the microgravity experiments are planned for the International Space Station, the foam samples had to be limited in size for safety and launch mass reasons. The feasible sample size is too small for smolder to self propagate because of heat losses to the surrounding environment. Thus, the smolder propagation and the transition to flaming had to be assisted by reducing the heat losses to the surroundings and increasing the oxygen concentration. The experiments are conducted with small parallelepiped samples vertically placed in a wind tunnel. Three of the sample lateral-sides are maintained at elevated temperature and the fourth side is exposed to an upward flow and to a radiant flux. It is found that decreasing the flow velocity and increasing its oxygen concentration, and/or increasing the radiant flux enhances the transition to flaming, and reduces the delay time to transition. Limiting external ambient conditions for the transition to flaming are reported for the present experimental set-up. The results show that smolder propagation and the transition to flaming can occur in relatively small fuel samples if the external conditions are appropriate. The results also indicate that transition to flaming occurs in the char left behind by the smolder reaction, and it has the characteristics of a gas-phase ignition induced by the smolder reaction, which acts as the source of both gaseous fuel and heat.

Bar-Ilan, A.↗
DOE OSTI2021

The preparation and properties of polyurethane foams reinforced with bamboo fiber sources in China

Abstract Polyurethane (PU) foams reinforced with bamboo fiber sources in China, i.e. , bamboo fiber, bamboo α -cellulose fiber, and bamboo nanocellulose fiber, were prepared and their physico-mechanical properties were analyzed in this work. The bamboo fiber sources and PU foams were characterized by Fourier transform infrared spectroscopy (FTIR), Scanning electron microscope (SEM), Thermal gravimetric analysis (TGA) and universal compression testing. The results indicated that the hydroxyl groups on the fiber surfaces were enhanced by removing non-celluloses in the preparation of α -cellulose and nanocellulose. With the addition of small particle size α -cellulose and nanocellulose, the cell sizes of PU foams were reduced due to more nucleating agents being introduced. The FTIR spectra confirmed that the bamboo fiber sources were involved in the foaming reaction. The PU foams with bamboo fiber sources had a higher thermal stability than neat foam, and they were satisfactory enough to be used as insulation. PU foams reinforced with 5% bamboo fiber, 3% α -cellulose fiber and 3% nanocellulose fiber had better physico-mechanical performance than other foams. The reinforcement performance of 3% bamboo α -cellulose fiber on PU foam was comparable with that of high-cost nanocellulose. Accordingly, bamboo α -cellulose fiber was demonstrated to be a promising candidate to reinforce PU foam, which could be used in the reinforcement of foam insulation.

Qiu, Chongpeng↗
DOE OSTI2025

Properties and performance of lignin-based polyurethane foams from lignin and castor oil as synergistic bio-polyols

Lignin and castor oil with intrinsic hydroxyl groups are attractive green resources for polyurethane (PU) applications. However, lignin's heterogeneous and highly crosslinked structure, poor processability, as well as the feedstock variability, lead to inconsistent and poor performance of the final foam products. Castor oil-based polyurethane foam (PUF) has a relatively high price and density, which are big hurdles to its practical applications. Here, in this study, we hypothesized that synergistic bio-polyol mixtures composed of lignin and castor oil could balance the drawbacks from individual component. Castor oil could improve the dispersity of lignin, while lignin simultaneously addressed the issues caused by PUF prepared with castor oil, such as its high density and low thermal stability. For a comprehensive understanding of the effects of structural properties of lignin on its PUF processing and applications, various lignin fractions were isolated by co-solvent enhanced lignocellulosic fractionation (CELF) from different species, including hardwood, softwood, and herbaceous plants, and the processed lignins with different molecular weights were applied with castor oil. The lignin fractions with lower molecular weight showed good dispersity in castor oil with a high lignin content (up to 50 wt%) and completely replaced petroleum-based polyols. The produced foam with 50 wt% low-molecular-weight lignin fractions from woody biomass showed comparable/higher compressive strength (up to 20 psi) and thermal insulation performance (up to 5.69 R-value in −1 for 50 % L-Pine foam). In addition, this study revealed the relationship between lignin's structural properties and foam performance, providing insights for practical applications of lignin-based PUF.

Jeong, Soyeon [State Univ. of New York (SUNY), Syr↗
DOE OSTI2025

Use of Captured CO2 for Production of Sustainable Polyurethane Foams in Automotive Applications

Captured CO2 has been investigated as a feedstock for the production of polyurethane (PU) foams for automotive applications. Previous work has shown successful incorporation of CO2 into polyols via three distinct reaction pathways. These CO2-derived polyols, as well as several commercially available polyols with varying CO2 content, were used to produce PU foams for automotive seating and NVH (noise, vibration, and harshness) applications. Foam formulations were optimized to maximize sustainable content while maintaining manufacturability constraints and performance requirements for each end use application. PU foams were first formulated at lab scale to confirm free rise and molded foam properties, then scaled up to pilot and industrial scales to evaluate production manufacturing feasibility. Finally, CO2-derived foams were used to produce molded components for end use product validation. Life cycle assessment (LCA) was used to quantify the environmental impact of using captured CO2 and bio-renewable content into polyols and PU foams through the metrics of global warming potential and embodied energy. Tradeoffs among environmental impacts, energy usage, manufacturability, and PU foam performance from the incorporation of CO2 and bio-renewable content will be discussed.

Lee, Ellen [Ford Motor Company]↗
NASA NTRS2006

Thermal Expansion of Polyurethane Foam

Closed cell foams are often used for thermal insulation. In the case of the Space Shuttle, the External Tank uses several thermal protection systems to maintain the temperature of the cryogenic fuels. A few of these systems are polyurethane, closed cell foams. In an attempt to better understand the foam behavior on the tank, we are in the process of developing and improving thermal-mechanical models for the foams. These models will start at the microstructural level and progress to the overall structural behavior of the foams on the tank. One of the key properties for model characterization and verification is thermal expansion. Since the foam is not a material, but a structure, the modeling of the expansion is complex. It is also exacerbated by the anisoptropy of the material. During the spraying and foaming process, the cells become elongated in the rise direction and this imparts different properties in the rise direction than in the transverse directions. Our approach is to treat the foam as a two part structure consisting of the polymeric cell structure and the gas inside the cells. The polymeric skeleton has a thermal expansion of its own which is derived from the basic polymer chemistry. However, a major contributor to the thermal expansion is the volume change associated with the gas inside of the closed cells. As this gas expands it exerts pressure on the cell walls and changes the shape and size of the cells. The amount that this occurs depends on the elastic and viscoplastic properties of the polymer skeleton. The more compliant the polymeric skeleton, the more influence the gas pressure has on the expansion. An additional influence on the expansion process is that the polymeric skeleton begins to breakdown at elevated temperatures and releases additional gas species into the cell interiors, adding to the gas pressure. The fact that this is such a complex process makes thermal expansion ideal for testing the models. This report focuses on the thermal expansion tests and the response of the microstructure. A novel optical method is described which is appropriate for measuring thermal expansion at high temperatures without influencing the thermal expansion measurement. Detailed microstructural investigations will also be described which show cell expansion as a function of temperature. Finally, a phenomenological model on thermal expansion will be described.

Lerch, Bradley A.↗
DOE OSTI2024

Renewable and Biodegradable Polyurethane Foams with Aliphatic Diisocyanates

The transition to renewable plastics will require the development of substitutes with existing industrial standards and manufacturing processes. Polyurethanes (PU), versatile plastics, are traditionally dominated by aromatic diisocyanates, which are challenging to derive from renewable sources. However, for higher biocontent, it is crucial to utilize aliphatic diisocyanates, which can be sourced from renewable plant or algae waste streams. Historically, PU foams relied on aromatic diisocyanates for essential hard segments, resulting in desired physical properties. Here, we report the generation of high-performance renewable and biodegradable PU foams utilizing aliphatic diisocyanates and aromatic polyols, translating hard segments into the polyester polyol component using biosourced furan dicarboxylic acid (FDCA) monomers. We demonstrate that an FDCA-based PU is suitable for foams with performance characteristics that meet commercial tolerances and can biodegrade under backyard compost conditions. Here, this demonstrates steps toward redesigning traditional petrochemical-based polymers to accommodate new biological monomers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1979

A model of smoldering combustion applied to flexible polyurethane foams

Smoldering combustion, particularly in upholstery and bedding materials, has been proven a serious life hazard. The simplest representation of this hazard situation is one-dimensional downward propagation of a smolder wave against a buoyant upflow (cocurrent smolder); the configuration treated here is identical in all respects to this except for the presence of a forced flow replacing the buoyant one. The complex degradation chemistry of the polyurethanes is here reduced to the two major overall reactions of char formation and char oxidation. The model solutions, which are in reasonable agreement with experimental results, show the smolder process to be oxygen-limited, which leads to some very simple trends. More subtle behavior aspects determine actual propagation velocity, fraction of fuel consumed, and apparent equivalence ratio (all of which are variable). The self-insulating character of the smolder wave makes it viable in a wide-ranging set of conditions if the igniting stimulus is sufficiently long. These results have significant implications regarding the problem of smolder prevention or hindrance.

Ohlemiller, T. J.↗