*Mica DeBolt, Beste Aydin, Alper Kiziltas and Debbie Mielewski

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1 *Mica DeBolt, Beste Aydin, Alper Kiziltas and Debbie Mielewski *Research Engineer Sustainable Biomaterials and Plastics Group SPE ACCE Conference Sept. 7-9, 2016 SLIDE 1

2 Outline Background Motivation Objectives Materials and Methods Results and Discussion Mechanical and Physical Properties Thermal Properties Morphological Properties Conclusions Acknowledgements SLIDE 2

3 Petroleum a limited resource harmful to environment SLIDE 3

Ford s Sustainability Initiatives Sustainable Foams Soy-based seat foam Castor oil foam in the IP Natural Fiber Reinforced Plastics Implementation of cellulose fiber Kenaf fiber interior door

4 Ford s Sustainability Initiatives Sustainable Foams Soy-based seat foam Castor oil foam in the IP Natural Fiber Reinforced Plastics Implementation of cellulose fiber Kenaf fiber interior door panels Wheat straw reinforced storage bin Rice hull reinforced wire harness Recycled Materials Seat fabric from recycled PET MRP incorporation in foams Under the foot the under the hood SLIDE 4

5 Oil feedstock alternatives for polyols SLIDE 5

6 CO 2 = Solution? SLIDE 6

7 CO 2 -based polyols Derived from waste CO 2 Environmental benefits CO 2 is a byproduct of: SLIDE 7

Silica is a flame retardant filler Silica has been shown to

8 Rice Husk Ash Husks used as fuel in heat generation for drying rice Silica-rich ash generated during combustion Silica is a flame retardant filler Silica has been shown to increase mechanical properties Supplied from Radici Group SLIDE 8

Cellulose Filaments Byproduct of forestry industry Renewable resource Filaments harvested without chemicals during pulping process Exceptional strength and purity, with an extraordinary

9 Cellulose Filaments Byproduct of forestry industry Renewable resource Filaments harvested without chemicals during pulping process Exceptional strength and purity, with an extraordinary high and unique aspect ratio Untreated cellulose filaments Cellulose filaments treated with a coupling agent Supplied from FPInnovation SLIDE 9

10 Micronized Rubber Powder Estimated that 1000 million tires end service life Burning = fire hazards and environmental pollution Depletion of landfill sites Supplied from Lehigh Technologies SLIDE 10

11 Motivation 2015 United Nations Climate Change Conference SLIDE 11

12 Objectives Synthesize flexible polyurethane foams using waste CO 2 -based polyols Determine potential for automotive use Tested for : Physical and mechanical properties Optical images taken with Keyence digital microscope SLIDE 12

13 Foam Formulations Component B Type of Additive Supplier Voranol 4701 Petroleum Polyol Dow Chemical Company Novomer Converge / CO 2 Polyol Novomer Inc Lumulse POE (26) GLYC Cell Opener Vantage Tegostab B4690 Surfactant Evonik Diethanolamine Cross Linker Sigma Aldrich Niax a300 Catalyst Momentive Niax A1 Catalyst Momentive Water Blowing Agent Component A Rubinate 7304 Isocyanate (MDI) Huntsman Corporation SLIDE 13

14 Addition of CO 2 -based polyol into flexible polyurethane foams SLIDE 14

15 Density (kg/m 3 ) SLIDE 15

16 Wet Compression Set (% Compression) SLIDE 16

17 Compression Modulus (MPa) SLIDE 17

18 SLIDE 18

19 SAG Factor SLIDE 19

20 Tensile Strength (kpa) Young s Modulus (MPa) SLIDE 20

21 Tear Resistance (N/mm) SLIDE 21

22 TGA Results Sample Code Residual Mass (%) Temp. at 10% ML ( C) Temp. at 50% ML ( C) % 8.8 (1.0) (4.5) (1.2) % 8.9 (0.9) (2.8) (4.9) % 9.4 (0.9) (4.9) (2.7) % 9.7 (0.4) (3.7) (2.7) % 9.6 (0.3) (1.3) (1.1) % 9.3 (0.3) (2.9) (0.9) % 7.8 (1.6) (4.9) (0.2) % 10.1 (0.3) (2.6) (2.1) % 10.3 (0.2) (3.7) (1.9) % 9.7 (0.5) (4.0) (1.1) SLIDE 22

23 TGA Results Mass (%) Mass (%) Control % % % % Temparature ( C) Control % % % % Temparature ( C) SLIDE 23

24 DMA Results Storage Modulus (Pa) 1e+6 1e Control % % % % Loss Modulus (Pa) 1e Control % % % % Temperature ( C) 1e Temperature ( C) Storage Modulus (Pa) 1e+6 1e Control % % % % Loss Modulus (Pa) 1e Control % % % % Temperature ( C) 1e Temperature ( C) SLIDE 24

25 Optical Images SLIDE 25

26 Converge (top) and (bottom) mixed with petroleum polyol SLIDE 26

27 Converge and Soy SLIDE 27

28 Conclusions Improvements with CO 2 -based polyol No significant change Areas of concern SLIDE 28

29 On-going studies Addition of rice husk ash, cellulose, and micronized rubber tires into formulation Compatibility of CO 2 -based polyol with soybased polyol Decreasing wet compression set values at higher concentrations SLIDE 29

30 Acknowledgements Sustainable Biomaterials and Plastics Team Novomer Inc Lehigh Technologies FPInnovations Radici Group Hutsman International LLC Dow Chemical Company SPE ACCE SLIDE 30

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