Thermoplastic Polyurethane Rubber Morphology

The elasticity of thermoplastic polyurethane rubbers (which are also known as thermoplastic urethanes or TPUs) is a function of their morphology which comprises hard and soft phases. The hard phases consist of hydrogen bonded clusters of chain segments, which are linked by flexible chain segments that make up the soft phase. The hard blocks, which are the minor phase, exist as separate domains within a continuous matrix of the majority soft phase, as shown schematically in Fig. 25.9. 

When a thermoplastic polyurethane elastomer is heated above the melting point of its hard blocks, the chains can flow and the polymer can be molded to a new shape. When the polymer cools, new hard blocks form, recreating the physical crosslinks. We take advantage of these properties to mold elastomeric items that do not need to be cured like conventional rubbers. Scrap moldings, sprues, etc. can be recycled directly back to the extruder, which increases the efficiency of this process. In contrast, chemically crosslinked elastomers, which are thermosetting polymers, cannot be reprocessed after they have been cured. 

Thermoplastic polyurethane elastomers are normally based on polyester prepolymers. The properties of these polymers can be systematically varied by taOoring the nature and ratio of the hard and soft segments. The stiffness of a polyurethane elastomer increases as the proportion of hard blocks increases. As the stiffness increases, the extensibility of the material decreases. 

Given the wide variety of chemical structures within the polyurethane family, it should come as no surprise that polymer scientists can tailor compositions and structures to meet a correspondingly broad range of end use requirements. In order to better understand the nature of these relationships, we have divided this section into subsections based on some of the more characteristic forms in which we encounter these materials. 

Some of the key factors that lead us to select polyurethane foam for upholstery are its durability, resilience, and controllable hardness (or softness, depending on your point of view). Vibration dampening and shock absorbance are important attributes in automobile and public transportation seating. Open cell foams are preferred for these applications because they allow for air and moisture transport, which improve the comfort of passengers who may occupy a seat continuously for several hours. This inherent breathability is also a valuable attribute in mattresses. Shock absorbance plays a key role in selecting flexible polyurethane foams for the packaging of fragile items. 

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