Flexible polyurethane foams formulated with polyols derived from waste carbon dioxide

In this study, flexible polyurethane foam samples were prepared using concentrations of up to 50% of two novel polycarbonate polyols, Polyol D 251-20 and Polyol D 351-30, derived from the copolymerization of carbon dioxide (CO2) and epoxides, to determine whether the final foam products meet automotive standards for use in seating applications. In other words, CO2-based polyols were substituted for a portion of petroleum-based polyols in the foam formulations. Characterization of the foam samples was carried out by mechanical, physical, and thermal analysis. Overall, inclusion of both types of CO2-based polyol led to an increase in wet compression set, compression modulus, compression stress at various strain levels, maximum tensile strength, Young's modulus, and tear resistance properties in the flexible polyurethane foams. Density, SAG factors, and elongation properties remained relatively constant compared to petroleum-based control samples. Dynamic mechanical thermal analysis showed increasing storage modulus with increasing concentrations of CO2-based polyol at temperatures below 0 degrees C. Thermogravimetric analysis showed that the thermal stability of the foam decreases with an increase in the concentration of CO2-based polyol. Images of foam samples were taken using a Keyence VHX digital microscope. (C) 2016 Wiley Periodicals, Inc.