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From Soybean Oil to Polyurethane Flexible Foams Ling Zhang Advisor: Chris W. Macosko Is Natural Oil an Alternative to Petroleum Oil? Date: Sept. 5 th , 2008 University of Minnesota, Minneapolis, MN

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Page 1: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

From Soybean Oil to Polyurethane Flexible Foams

Ling Zhang

Advisor: Chris W. Macosko

Is Natural Oil an Alternative to Petroleum Oil?

Date: Sept. 5th, 2008

University of Minnesota, Minneapolis, MN

Page 2: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Acknowledgements

• Financial support:

• Collaborators: Tim Abraham, Jeff Malsam, Wei Zhang & BiOH labs (Cargill); Dave Henton, Ron Herrington; Mark Listemann, Gary Johnson (Air Products)

• Advisor: Chris Macosko & Committee members

• Prof. Tom Hoye & Hoye research group, Macosko Research Group & Polymer Group

• Undergraduate researchers: Kari Tanaka, Ryan Seelbach & Scott Dixon

• Machine shop, staff and administrative assistants

• Family & Friends

Page 3: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

• Versatility– Range of products

• Elastomers, coating, adhesives, sealant • Rigid foams & Flexible foams

– Process methods• Casting, reaction injection molding, foaming, compounding…

• Research focus – Flexible foam– 40% of PU 1

– Wide range of applications– Room for innovation & challenging

Polyurethane (PU) & Research Focus

1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005

Page 4: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

PU Flexible Foam Chemistry

NCOOCNOCN

NCOOCN OCNNCO NCO

OH

OHHO

Polyol

Isocyanate (TDI)

OHH

Water

NCOOCN

O

OHHO

NCOCNO=

Hgelling reaction

O C N N C N N C

OO

HH

H

OH

+ O=C=O

blowing reaction

OO

O

O

OO C N

N C

N C

C N

C N C N

OO

HH

N C N

O

HH

N C N

O

HH

N C

O

HH

N

N C O

N C N

O

HH N C N

O

HH

N C O

H

O

N C O

O C N

O

O

H

H

H

O

Page 5: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

PU Foam Morphology

Soft Domain

Hard Domain

Distinct Tg’s

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

Cooper, S. L.; Tobolsky, A. V., J. Appl. Poly. Sci., 1966 (10):1837

Page 6: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Motivation

OH

OHHO

NCOOCN

Polyol

Isocyanate (TDI)

OHH

Water

soybean

rapeseed

castor bean

linseed

oil

soybean

rapeseed

castor bean

linseed

oil

Soybean Oil 2: ~ 52 ¢/lb

Castor Oil 3: ~ 63 ¢/lb

2 CBOT, Sept. 4th, 20083 Chemical Market Reporter

Page 7: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Polyol vs. Natural Oil

O

O

O

O

O

O

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

OH

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

Polyether polyol (petroleum-derived)

Natural oil

Page 8: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Going from Natural Oil to Polyol

O

O

O

O

O

O

O

O

O

OR 2R 3

1O3

H2O

O

O

OOH

R2'R3'

OzonolysisO

O

O

OR2'R3'

OH

Microbial Conversion

2

4

O

O

O

OR2'R3'

OH

Hydroformylation

CO, H2

H2

MeOH

H2 O2…3

O

O

O

OR2'R3'

OH

O

Epoxidation

O

O

O

OR2'

R3'

N

N

OHOH

OHOH

5

NH

OHOH

I2Halogen addition + substitution

1 Petrovic ZS et.al., Biomacromolecules, 2005(6):7132 Hou CT, Adv. Appl. Microbio., 1995(41):1

3 Petrovic ZS et.al., US Patent 6,433,121; 20024 Dow Chemicals, WO Patent 2004096744 A2; 2004

5 Garrett TM, Du XX, US Patent Appl. 20080076901; 2008

Page 9: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

We Have Natural Oil Polyols…Now What?

• Focus: flexible foam

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OH

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OH

SBOP

O

O

O

O

OH

OHO

O

Castor Oil

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

Hyperlite

Page 10: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Making the Foam

Page 11: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Not Quite Flexible ?!

1.0E+03

1.0E+04

1.0E+05

1.0E+06

1.0E+07

1.0E+08

-150 -50 50 150 250

Temperature (oC)

G' (

Pa) Hyperlite

Castor oil

SBOP

motor

transducerSerratedplates

ω

= 1 rad/s

25 °C

Page 12: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Why?!

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OH

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OHO

O

O

O

OH

OHO

O

Castor Oil

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

Hyperlite

SBOP

Page 13: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

A Partial Polyol Component — SBOP

• Adding SBOP into flexible foams

– Hydrophobicity filler– Low molecular weight crosslinker polyol?*

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OHHyperlite

* high functionality, low molecular weight

Page 14: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Partially Substituted Foams• Filler: SAN-copolymer filled polyol

• Crosslinker: Voranol® 446

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

Crosslinker

SAN

O

O

OO

OO

OO

OH

OHOH

Page 15: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Partially Substituted Foams

• X: % of base polyol (Hyperlite) being substituted• Y: substituent polyol

– SAN– Crosslinker– SBOP

• Samples– Control – 30% SAN– 10% Crosslinker– 10% SBOP– 30% SBOP

X% Y

30% SBOP

Page 16: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Notably Harder Foams – 30% SBOP

0

5

10

15

20

control 30% SAN 10%crosslinker

10% SBOP 30% SBOP

Pres

sure

(kPa

)

10% Crosslinker

1mm

Control

30% SBOP

10% SBOP

30% SAN

0.3

0.6

0.9

1.2

1.5

control 30% SAN 10%crosslinker

10% SBOP 30% SBOP

Cel

l Dia

met

er (m

m)

Page 17: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Polymer Phase is Key

25 mm

10 mm

motor

transducerSerratedplates

ω

= 1 rad/s 3

3.5

4

4.5

5

5.5

6

-120 -70 -20 30 80 130 180Temperature (oC)

log

(G',

Pa)

10% Crosslinker 30% SAN

Control

113 oC

3

3.5

4

4.5

5

5.5

6

-120 -70 -20 30 80 130 180Temperature (oC)

log

(G',

Pa)

30% SBOP

10% SBOP

Control

0

5

10

15

20

control 30% SAN 10%crosslinker

10% SBOP 30% SBOP

Pres

sure

(kPa

) G’ @ 25oC

Page 18: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

Hard Domain

Soft Domain Distinct Tg’s

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

Hard Domain

Soft Domain Distinct Tg’s

Is It the Tg of Soft Phase?

-120 -70 -20 30 80 130 180 230Temperature (oC)

Hea

t Flo

w (a

.u.)

Control

30% SAN

10% Crosslinker

10% SBOP

30% SBOPΔCp

Sample ΔCp (J/g/oC)

Control 0.33

30% SAN 0.25

10% Crosslinker 0.23

10% SBOP 0.16

30% SBOP 0.14

Serious loss of soft domain volume fraction?!

Page 19: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

19

Sept. 5th, 2008

Where Did Soft Phase Go?• Phase mixing — less phase separated• Change of domain spacing

0.02 0.03 0.04 0.05 0.06 0.07 0.08

q (Å-1)

Nor

mal

ized

Inte

nsity

(a.u

.)

Control

30% SAN

30% SBOP

10% SBOP

10% Crosslinker

• 30% SAN– Increased

phase contrast• 10% crosslinker

– Reduced phase contrast

– Increased domain spacing

• SBOP – Reduced phase

contrast– Reduced

domain spacing

Page 20: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

SAN

SAN

Crosslinker foam

SBOP foam

What Would That Look Like?

Page 21: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

21

Sept. 5th, 2008

A Closer Look30% SAN 30% SBOPControl

1 x 1 μm 25o 2 x 2 μm 90o 1 x 1 μm 10o

500 x 500 nm 1 x 1 μm 500 x 500 nm

Page 22: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

22

Sept. 5th, 2008

Partially Substituted Foams

• Potential and viable route

• SBOP makes harder foam– Different mechanism

• Change in hard domain morphology

• Partially substituted full potential

• Synthesize natural oil-based polyol– be used as the sole polyol component

500 x 500 nm 25°

500 x 500 nm 10°

Page 23: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

23

Sept. 5th, 2008

Flash Back… High Tg = Rigidity

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OH

O

O

O

OO

O

OH

OH

OH OH

OMe

OMe

OMe

OHO

O

O

O

OH

OHO

O

Castor Oil

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OH

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

Hyperlite

SBOP

Page 24: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

24

Sept. 5th, 2008

Tg —Increase Polyol Chain Length

• Before we move on — collapsed foam– Avoid surfactant issues– Isolate polymer phase for examination– Small-scale sample ~15 gram total

polyolwatercatalyst isocyanate

Heated mold (75 oC, 500psi)

~1 hr curing

Page 25: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

25

Sept. 5th, 2008

Making the Model Polyols

O

O

O

O

OH

OHO

O

Castor OilCH3 OH

CH3 OH CH3 OH

CH3 OH

O OH

OCH3

OCH3

O O

OH

m O

O

OH

O

O

m

O

OH m OH

OHOH

Page 26: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

26

Sept. 5th, 2008

Building Up the Molecular Weight

O

O

O

O OH

R

R

O

O

O

O O

R

RO OH

O OH

OO

O

O

O O

R

RO

1K

2K

4K

3K

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

OH

Polyether polyol-3K

Arcol

Page 27: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

UUNIVERSITY OF NIVERSITY OF MMINNESOTAINNESOTATTHESIS DDEFENSE

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Sept. 5th, 2008

Retention TimeRetention Time (min)

20 22 24 26 28 30

The Model Polyols

Retention Time20 22 24 26 28 30

Retention Time (min)

2K3K4K

Arcol

Methyl ricinoleate

Castor oil

1K

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Sept. 5th, 2008

Mn (ideal) Mn (VPO) Mn (GPC/Polyol)

Castor oil 930 930 --

2K 2010 2046 2322

3K 2934 2967 2978

4K 4054 3565 3400

Functionality # of bonds btwn OH (n)

2.9 27

2.44 64

2.18 94

2.17 114

( )(1 )g grot

cT TnN

= ∞ +Bicerano’s Correlation1:

A Model for Tg

1Bicerano et. al., J. Appl. Polym Sci. PartB: Polym Phys. (1996) 34: 2247

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Sept. 5th, 2008

-100 -80 -60 -40 -20 0 20 40

Temperature (oC)

Hea

t Cap

acity

(J/g

/o C)-S

hifte

dArcol

4K

3K

2K

Castor oil

The Tg of Collapsed Foams

-120 -70 -20 30 80 130 180 230

Temperature (oC)

Hea

t Cap

acity

(J/g

/o C)

Arcol

castor oil

2K

3K

4K

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Sept. 5th, 2008

How is MW Going to Change Tg ?

( )(1 )g grot

cT TnN

= ∞ +Bicerano’s Correlation1:

1Bicerano et. al., J. Appl. Polym Sci. PartB: Polym Phys. (1996) 34: 2247

0

0.1

0.2

0.3

0.4

0.5

0 0.02 0.04 0.06 0.08 0.1 0.12

1/n

0

0.1

0.2

0.3

0.4

0.5

0 0.02 0.04 0.06 0.08 0.1 0.12

1/n

0

0.1

0.2

0.3

0.4

0.5

0 0.02 0.04 0.06 0.08 0.1 0.12

1/n

PSDVBPMMA

11 ( )( )g

g rot

T cT N n

− =∞

T g(n

)

T g(

)-1

PEMA

PU flexible foam: polyether polyol

0

0.1

0.2

0.3

0.4

0 0.02 0.04 0.06 0.08 0.1 0.121/n

Arcol

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Sept. 5th, 2008

Why & why?

O

O

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OO

OH

OH

OH

Arcol

O

O

O

O O

R

RO OH

O OH

OO

O

O

O O

R

RO

2K

3K

Page 32: From Soybean Oil to Polyurethane Flexible Foams...Polyurethane (PU) & Research Focus 1 IAL consultants, 2004 End-use Market Survey on the Polyurethane Industry: 2005 T HESIS D EFENSE

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Sept. 5th, 2008

Modification to Tg Model

• For every degree drop in Tg25% more “n” (number of bonds) is required in model polyol than in

polyether polyol

• Model polyols have an advantagePlasticizing effect of the dangling chains

( )(1 )g grot

cT TnN

= ∞ +

( )(1 )

14

g g adjrot

oadj

cT T TnN

T C

= ∞ + −

≈0

0.1

0.2

0.3

0.4

0 0.01 0.02 0.03 0.04 0.051/n

Tg(n

)/Tg(

int)-

1

T g(n

)

T g(

)-1

0

0.1

0.2

0.3

0.4

0 0.01 0.02 0.03 0.04 0.051/n

Tg(n

)/Tg(

int)-

1

T g(n

)

T g(

)-1

T g(n

)

T g(

)-1

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Sept. 5th, 2008

Can We Make Flexible Foams?

1.E+06

1.E+07

1.E+08

1.E+09

1.E+10

-120 -70 -20 30 80 130 180 230

Temperature (oC)

G' (

Pa)

2K

4K

Arcol

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Sept. 5th, 2008

Summary & Future Work

• Model polyols– Great potentials as the sole polyol component in

flexible foam• Building up the MW is key• Plateau modulus higher in model polyol samples than in a

polyether polyol sample

• Future work– Foaming model polyols

• Surfactants + catalysts• Foaming dynamics phase separation

– Alternative route for natural oil polyol synthesis

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Sept. 5th, 2008

THE END

Questions and Comments

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Sept. 5th, 2008

0.E+00

2.E+04

4.E+04

6.E+04

5 10 15 20 25 30 35

HS content (wt%)

Mod

ulus

(Psi

)

control

10% crosslinker

10% SBOP

30% SBOP

If we extend Gier's theoretical prediction

range...

HS% and Modulus

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Sept. 5th, 2008

Collapsed Foam vs. Foamed Foam

1.E+02

1.E+04

1.E+06

1.E+08

-150 -50 50 150 250

Castor oil

Collapsed foam

Foamed sample

1.E+02

1.E+04

1.E+06

1.E+08

1.E+10

-150 -50 50 150 250

Temperature (oC)

G' (

Pa)

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Sept. 5th, 2008

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Sept. 5th, 2008

1.E+06

1.E+07

1.E+08

1.E+09

1.E+10

-120 -70 -20 30 80 130 180 230

Temperature (oC)

G' (

Pa)

155016001650170017501800

Wavenumber (cm-1)

3K

2K

Arcol F3022

4K

Arcol

2K

3K

4K

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

OCN NCN NC

OO

HH

H

OH

O

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H

H

N NCN NC

O

H

H

O

H