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A Designed Surface Modification to Disperse Silica
Powder into Polyurethane
Lianying Liu,1
Hideo Watanabe,2
Takashi Shirai,2
Masayoshi Fuji,2
Minoru Takahashi2
1
Key Laboratory of Carbon Fiber and Functional Polymers, College of Materials Science and Engineering,
Beijing University of Chemical Technology, Beijing 100029, China
2
Ceramics Research Laboratory, Nagoya Institute of Technology, Tajimi, Gifu 507-0033, Japan
Received 13 September 2011; accepted 25 December 2011
DOI 10.1002/app.36734
Published online 12 June 2012 in Wiley Online Library (wileyonlinelibrary.com).
ABSTRACT: Nanoparticles of silica powder were modi-
fied by grafting polyurethane (PU) short chains or oligom-
ers using surface-started condensation reactions of various
di- or tri-ols and di-isocyanates in step-by-step. Surface
density of NCO-groups, introduced by an autoclave
method and ready for starting of subsequent reactions,
was adjusted by amount of 3-isocyanatepropyltriethoxysi-
lane (ICPTES). Length of grafted oligomers was deter-
mined by reaction steps. TG/DTA measurements
demonstrated a gradual increase of NCO-groups density
with the amount of modifier input. FTIR spectra and ther-
mal weight loss analyses confirmed the occurrence of reac-
tion in each step and the growth of grafted oligomer. SEM
images of particles dispersed in N, N-dimethylacetamide
or in prepolymer of PU indicated an improved dispersion.
Moreover, when as-modified particles were incorporated
in PU prepolymer, the resultant hybrid films displayed an
enhanced optical property, thermal stability, and Vicker’s
hardness, suggesting a better dispersion of modified par-
ticles. VC 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 126:
E522–E529, 2012
Key words: silica nanoparticle; surface modification;
dispersion; polyurethane
INTRODUCTION
Polymer/silica nanocomposite materials have
attracted both academic and industrial interest for
several decades because of their unique synergistic
properties, advantages of availability and inexpen-
siveness, and potential applications in various
fields.1–9
However, a well-defined dispersion of
silica powder nanoparticles (NPs) in polymer matri-
ces is still a pursuing issue, as the enough strong
interactions at interface between polymer matrices
and inorganic NPs is intrinsically hard to achieve.10
Up to now, extensive research works have been
done to mitigate the self-aggregation of inorganic NPs
derived from Vander Waals attractions, and thus to
improve the compatibility of inorganic NPs with an
organic phase.11–13
Among them, surface initiated con-
trol/living radical polymerizations10,14–16
are consid-
ered to be effective techniques to firmly control pa-
rameters including graft density, molecular weight,
and chemical composition of graft and matrix poly-
mers, etc.17–19
to enhance the dispersion of inorganic
NPs.19
Usually, dense and long grafted chains were
prerequisite to achieve complete isolation of NPs in
homo- or block-polymer matrices19
to take full advant-
age of large specific surface/interface area of NPs.
Sometimes, particles grafted with relative sparse and
short chains also brought about an effective disper-
sion, and their self-assembly into highly anisotropic
structures led to a pronounced enhancements in me-
chanical property of resultant nanocomposites.10,17,19
In addition, condensation reactions initiated from
a solid surface provide an alternative to covalently
immobilize linear or branched functional copolymer
chains on particles, and hence to facilitate the disper-
sion of inorganic NPs. Some of investigations on sur-
face-started condensation polymerization have been
performed to create highly advanced organic/inor-
ganic nanocomposites,20
for example, Chen et al.21
prepared polyurethane (PU)/silica hybrid nanocom-
posites by incorporation of inorganic nanosized
silica building blocks into PU matrix via a two step
functionalized reaction including encapsulation of 3-
aminopropyltriethoxysilane (APTS) and tether of PU
shell on silica surface. In previous works, elaborate
control of grafting of PU chains onto silica powder
particles, such as manipulation of surface density,
grafted chain length, and structure, by condensation
reactions started from particle surface, was seldom
involved in, and a better dispersion of silica powder
in matrix of PU is still needed.
It is known that PU can be manufactured by con-
densation polymerization of di-isocyanates and di- or
tri- hydroxyl compounds (di-ols or tri-ols). The
employment of multifunctional monomers would
Correspondence to: M. Fuji (fuji@nitech.ac.jp).
Journal of Applied Polymer Science, Vol. 126, E522–E529 (2012)
VC 2012 Wiley Periodicals, Inc.
make the grafting of PU on particle surface more com-
plex in comparison with the grafting of homopoly-
mers such as polystyrene (PSt), or poly(methyl meth-
acrylate) (PMMA) by free radical polymerizations.
Especially, when surface condensation reactions start
from large aggregated silica particles, rather than from
individual NPs dispersed homogeneously in a good
solvent or media, it is not easy to achieve dense and
long linear grafted chains because of high reactivity of
multifunctional monomers. Furthermore, the dispers-
ing behavior of as-grafted NPs in PU is supposed to be
dissimilar to that of silica NPs attached homopolymer
in analogous matrices of homopolymer, block copoly-
mer16
or miscible blends of polymers19
Accordingly,
further investigations on the grafting of PU on particle
surface by condensation reaction to disassociate silica
power in PU are demanded.
In our group, surface designed reactions were pro-
posed to shield silica particle surface with densely
grafted functional polymers to achieve a good disper-
sion in polyimide (PI) or in slurry.22,23
Herein, with
the aim to improve the dispersibility of silica powder
in PU matrix, oligomer, or short-chain of PU was
devised to incorporate onto particles by an autoclave
method under supercritical hexane using 3-isocyana-
tepropyltriethoxysilane (ICPTES) as a modifier agent,
and followed by graft condensation reactions of sur-
face-coupled isocyanate groups (NCOA) with di-, tri-
ols, and di-isocyanate, as shown in Scheme 1. Surface
density of initial functional groups (NCOA), which
indicated the surface grafting density of oligomers on
silica particles, was adjusted by modifier agent input
and evaluated by TG/DTA measurements. Graft
chain length of PU oligomers, demonstrated by FTIR
spectra analysis, and TG/DTA measurements, was
thought to be manipulated by further grafting reac-
tions of di- or tri-ols, and di-isocyanate in step by
step. Furthermore, hybrid thin films with modified
silica particles dispersed in PU were prepared by a
controlled roller coating and thermal curing, and their
optical properties, thermal, and mechanical properties
were examined.
EXPERIMENTAL
Materials
Silica powder (Aerosil OX 50, average particle size
of 40 nm, specific surface area 50 m2
/g, supplied by
Nippon Aerosil) was dried at 130
C in a vacuum
oven for at least 48 h and stored at room tempera-
ture (RT) with a relative humidity (RH) of 34%.
Modifier agent ICPTES (Shin-Etsu Silicone, KBE
9007, 99.7%, purchased from Shin-Etsu Chemical),
poly-ols including polyethylene glycol (PEG, MW ¼
400, 2000, 99%), triethylene glycol (TEG, MW ¼
150.17, 99.8%), diethanolamine (DEOA, MW ¼
105.14, 99.8%), tris-(hydroxymethyl)aminomethane
(TOAM, MW ¼ 121.14, 99.8%), and 4,4-Diphenylme-
thane diisocyanate (MDI, 99.7%), etc., from Shin-
Etsu Chemical, were used without further purifica-
tion. Solvents such as N, N-dimethylacetamide
(DMAc) and acetone, etc., were used as received.
Modification of silica particles with ICPTES
The chemical reaction of ICPTES with hydroxyl
groups of silica (density of OHA groups: 2.8/nm2
)
was carried out using an autoclave method as
described previously.22
The amount of modifier
applied was referred to mole ratio of NCO-group to
silanol groups (NCOA/OH in moles) on silica sur-
face. The surface density of modifier, noted as sur-
face density of NCO-groups (dM, NCOA nm2
) on
particles, was determined with weight loss data
from TG/DTA analysis and calculated according to
the following equation23
:
dMðNCOÀ=nm2
Þ ¼
ðDWCH À DWOHÞNA
MWSN2
where DWCH is the weight loss ratio of modified
silica particle, DWOH is that of pristine one, NA is the
Avogadro number, MW is the molecular weight of
modified group (84), and SN2 is the specific surface
area of silica powder used (50 m2
/g).
Surface grafting by condensation reactions
In a 100 mL, 4-neck bottom flask equipped with con-
denser, thermometer and N2 inlet, the modified par-
ticles (SiANCO) were suspended into DMAc with
aids of a magnetic stirrer, and then di- or tri-ols, or
MDI was introduced into the suspension in step by
step. The condensation reaction was performed usu-
ally under a small N2 flow at 25
C for 3 h.
After cycles of reaction of diisocyanate and poly-
ols, particle surface was coated with oligomers of
PU. Sample produced in each step was isolated by
centrifugation, washed with DMAc, and acetone for
at least 3 cycles, and then dried under vacuum.
Preparation of hybrid films
Pristine or surface-modified silica particles (5 wt %)
were ultrasonically dispersed in 2 mL of a mixture
Scheme 1 Representation of surface modification of silica
NPs with ICPTES, and further reactions with di-, tri-ol, or
di-isocyanate.
DISPERSING SILCA POWDER INTO POLYURETHANE E523
Journal of Applied Polymer Science DOI 10.1002/app
of PEG400 (3 Â 10À3
mol), MDI (3 Â 10À3
mol) and
DMAc. 0.05 mL or 0.5mL of the as-produced disper-
sion was coated on a piece of quartz or pyrex glass
using a K101 Control Coater (RK Print Coat Instru-
ment, UK), and then cured at 70
C for 12 h to get a
thin or thick film.
Characterization
Weight loss data: determined on a Thermo Plus
TG8120 analyzer (Rigaku, Japan) under O2 atmos-
phere with a flow rate of 500 mL/min, heating rate
of 10
C/min, from room temperature to 700
C.
Grafted chains analysis: done on a FTIR 6200 spec-
trometer (Jasco, Japan) using KBr pellets.
Morphology of particles: observed on a JSM-7000F
Scanning Electron Microscope (SEM, Jeol, Japan),
under an accelerating voltage of 10 kV. Samples
were prepared by dropping suspension of silica par-
ticles in DMAc on a small piece of cover glass and
evaporating at room temperature, or by spin-coating
the mixture of silica particles, PEG, MDI, and DMAc
on a glass and then drying under vacuum at 70
C
for 8 h. Before SEM observation, samples were
coated with osmium (OsO4).
Particle size and its distribution: evaluated by
Zetasizer Nano Series (Malvern Instrument) in a sol-
vent of DMAc.
Transmittance of hybrid films: measured on a
UV–VIS–NIR spectrophotometer, UV3150 (Shi-
madzu, Japan) in wavelength range of 190–900 nm.
Vicker hardness of hybrid film: estimated on a
HMV-2T micro-hardness tester (Shimadzu, Japan),
and for each sample, at least four points was meas-
ured to get an average value.
RESULTS AND DISCUSSION
Surface-initiated condensation reactions and
structure analysis
An autoclave method was used to allow the surface
AOH groups react efficiently with silane coupling
agent22,23
due to AOH groups in silica powder are
not easy to be fully exposed on surface. Surface den-
sity of NCO-groups (dM) introduced firstly onto par-
ticle, approximating the graft density of PU oligomer
or short chain in subsequent process, could be con-
trolled by varying ICPTES input in system and eval-
uated by TG/DTA analysis. As plotted in Figure 1,
Figure 1 Surface density of NCO-groups on silica par-
ticles modified with various ratio of NCO-/OH.
Figure 2 FTIR spectra analysis of silica particles and materials, 0: pristine particles, 1: Si-NCO particles, 2,4,6 (a) particles
produced after reaction with PEG (a) or DEOA (b), 3,5 (a) particles produced after further reaction with MDI. 7(a), 5(b):
MDI, 8(a): PEG, 6(b) DEOA.
E524 LIU ET AL.
Journal of Applied Polymer Science DOI 10.1002/app
dM improved along with increase of modifier
amount, confirming the successful incorporation of
NCO-groups on particle surface. When mole ratio of
NCOA/OH was increased up to 12.2, surface den-
sity of about 1.14 NCO-groups/nm2
was achieved,
and then a slight change of coupling of NCO-groups
displayed at a higher mole ratio of NCOA/OH.
In the present experiments, values of dM were
lower than that achieved previously22,23
and far less
than theoretical one of 2.8-OH/nm2
.23
This case
would cause some difficulties in detecting the pres-
ence of NCO-groups by FTIR analysis (Figure 2,
curve 1). The aggregation of silica particles in pow-
der (could be at around 600–1700 nm, evaluated by
dynamic light scattering, DLS) might screen some
free AOH groups on surface and limit their reaction
with modifier of ICPTES, leading to a low coupling
degree of NCO-groups. In addition, the possible
reaction of NCO-groups of ICPTES with OH-groups
on particle surface might also be negative to the cou-
pling of NCO-groups.
When poly-ols such as PEG or DEOA were
charged into reaction system to start condensation
reaction with pristine particles, and MDI was added
in subsequent step, the obtained particles showed no
distinct FTIR absorptions and marked weigh loss
differing from those of pristine particles. In system
contained particle with NCO-groups coupled on sur-
face in a density of 1.14/nm2
, FTIR analysis indi-
cated that in the first step, with poly-ols such as
PEG or DEOA charged, no significant variations was
discerned (Figure 2, curve 2). While, with MDI seg-
ments incorporated onto particle surface, characteris-
tic absorption of NCO-group at 2279 cmÀ1
was
observed clearly (Figure 2, curves a3 and b3). This
phenomenon implied that more NCO- groups could
be combined because of the possible reaction of MDI
with surface free AOH groups freshly exposed due
to a gradually improved dispersion. The above
results further verified the successful introduction of
original NCO-groups, and revealed that it was
enough to start condensation reactions from particles
surface with NCO-groups in a low density, allowing
to graft sparse and enough long polymer chains on
surface to improve the dispersion of particles.
As seen in Figure 2, absorption at 1720 cmÀ1
could
be assigned to AC¼¼O group come forth with the
addition of MDI. Absorption at 1650 cmÀ1
could be
ascribed to amide groups ACOANHA, and absorp-
tions at 1705, 1632 cmÀ1
could be attributed to car-
bonyl groups of urethano units (ANHCOOA).
Absorptions at 1600, 1560, 1514, 1423 cmÀ1
were aro-
matic characteristic peaks. When reaction with PEG
or DEOA occurred again, the characteristic absorp-
tion of NCOA at 2279 cmÀ1
was disappeared almost
completely (Figure 2, curves a4 and b4), and absorp-
tions arising from ACH2 symmetric stretching vibra-
tion at 2890 cmÀ1
, NAH stretching vibration at about
3300 cmÀ1
were detected apparently. Similar
Figure 3 (a) Typical TG curves of silica particles: pristine
particles (1), Si-NCO particles (2), modified silica particles
after reaction with TEG (3), and then with MDI repeatedly
at 0
C (4) or 25
C (5) for 5 steps. (b) Condensation reaction
of SiANCO particles with PEG (1) or DEOA (2), and then
with MDI in multisteps, WSi-NCO ¼ 0.2 g, MPEG or DEOA ¼
MMDI ¼ 3 Â 10À3
mol, VDMAc ¼ 30 mL.
TABLE I
Grafting of Short Chains or Oligomers Through Condensation Reactions in Multisteps
Composition of
grafted chains
Si-NCO-
TEG
Si-NCO-
PEG400
Si-NCO-
PEG2000
Si-NCO-TEG-
MDI-TEG-MDI-TEG
Si-NCO-
TOAM
Si-NCO-
DEOA
Si-NCO-DEOA-
MDI-DEOA
Weight loss% À3.83 À4.32 À5.15 À5.26 À4.74 À4.94 À9.15
Reaction time: 6 h; temperature: 0
C; WSi-NCO ¼ 0.2 g; Mols ¼ MMDI ¼ 3 Â 10À3
mol; VDMAc ¼ 30 mL.
DISPERSING SILCA POWDER INTO POLYURETHANE E525
Journal of Applied Polymer Science DOI 10.1002/app
observations were presented after repeated reaction
with PEG and MDI in cycles (Figure 2, curves a5
and a6). The above described FTIR analysis demon-
strated the occurrence of grafting condensation reac-
tion and implied the growth of grafting chains in
each step.
Typical TD/DTA measurements under an O2
atmosphere indicated that started from surface
NCO-groups, condensation reactions with TEG and
then MDI repeatedly led to a gradual increase of
weight loss [Figure 3(a)], suggesting a growth of
grafted chains. This phenomenon was further con-
firmed by weight loss data against reaction steps
[Figure 3(b)] with various di-ols selected as a
monomer.
It could be noted that from Figure 3(a), curve 4 and
5, the loading amount of PU oligomers obtained at
reaction temperature of 25
C, was much greater than
that achieved at 0
C, and TG curve of resultant sample
appeared two distinct regions of weight loss started
from about 200 and 330
C, respectively, analogous to a
typical TG curve of PU as reported.24
It is known that
PU is commonly composed of hard and soft segments.
The first region was related to thermal degradation of
hard segment of grafted chains due to low thermal sta-
bility of urethane groups,25
while the second region
was associated to the soft segment decomposition.26
Weight losses for the first and second regions were 27
and 34%, respectively. Using weight loss at each region
as an approximately quantitative indication25
of hard
Figure 4 SEM images of pristine (a, b) and modified (c, d, weight loss 4.5%) particles dispersed in DMAc or in prepoly-
mer of PU, and pristine (e) or modified (f) particle size distribution by intensity in DMAc. [Color figure can be viewed in
the online issue, which is available at wileyonlinelibrary.com.]
E526 LIU ET AL.
Journal of Applied Polymer Science DOI 10.1002/app
and soft segment content in grafted PU chains, one
could find that the content ratio of hard and soft seg-
ment was close to feed mole ratio of MDI to TEG (2/3)
in reactions.
Moreover, compared with reactions occurred at a
lower temperature, or reactions performed only one
or two steps, samples generated at a higher tempera-
ture and for more than three steps displayed
extremely great weight loss percents, which might
not be reasonably attributed to the lengthened graft-
ing chains. Some free oligomer might be generated
accompanying the growth of grafted chains and re-
sponsible for this exaggeration in weight losses,
because of high reactivity of isocynate and its com-
plexity in reaction with poly-ols.27,28
To alleviate the formation of free oligomer, reac-
tions were carried out in low temperature for long
time, and various types of poly-ols were selected to
deal with particles. As summarized in Table I, using
a diol having a high molecular weight, long chains
could be attached onto particle surface, as indicated
by the increased weight loss. Multi-step reactions
could also be favorable for the lengthening of teth-
ered chains. Especially, the employment of CBn-type
poly-ols permitted the covalent incorporation of
branched oligomer on particle surface, which would
be advantageous to make grafted chains spread into
a larger area as it moved away from a curved sur-
face, and result in a broader grafted chain/matrix
interface and favorable grafted chain/matrix interac-
tions. On the other hand, more functional groups
introduced onto particle surface by application of
CBn-type polyols could give more possibility to inter-
act with groups in PU matrix, and thus be positive to
the dispersion of particles.
Dispersion of modified particles
When pristine silica particles were dispersed in
DMAc, compact aggregate was observed from SEM
image [Figure 4(a)], even DMAc is a solvent in
which silica particles could be eletrostatically stabi-
lized.29
Also, it was seen that at a low magnification,
pristine silica particles could not be homogeneously
dispersed in prepolymer of PU [Figure 4(b)], and at
a high magnification, great assemblies of silica parti-
cle were found [Figure 4(b), inserted]. When silica
particles were subjected to surface grafting modifica-
tion, large aggregation was disappeared, only some
particles still congregated [Figure 4(c)]. At a low
magnification, almost uniform dispersion of modi-
fied particles could be observed [Figure 4(d)], and
separated particles in prepolymer of PU were pre-
sented [Figure 4(d), inserted]. These observations
indicated that the grafting of polymer chains indeed
improved the dispersion of particles in DMAc and
prepolymer of PU, and this effect became greater in
prepolymer of PU due to stronger interactions
between functional groups. DLS measurement fur-
ther confirmed the decrease in particle size and its
distribution [Figure 4(e,f)].
Properties of hybrid films
When pristine particles were impregnated in prepol-
ymer of PU, the prepared film had a transmittance
of around 35–70% in wavelength of 300–900 nm
using a piece of pyrex glass as reference (Figure 5,
curve 1). When modified particles were immersed in
prepolymer of PU, the hybrid film showed a trans-
mittance of about 45–80% (Figure 5, curve 2), or 50–
88% (Figure 5, curve 3). Silica particles immobilized
longer oligomer on surfaces (indicated by the greater
Figure 5 Transmittance of hybrid films impregnated with
pristine particle (1, 5), and modified particles (2, surface
attached with PEG400 segment, weight loss 4.4%; 3, 4, sur-
face grafted with PU oligomer composing of TEG and
MDI segments, weight loss 5.6%).
Figure 6 TG curves of hybrid films contained pristine (1),
modified particles attached PEG400 segment (2, weight
loss 4.4%) or PU oligomer composing of PEG400 and MDI
segments (3, weight loss 6.3%).
DISPERSING SILCA POWDER INTO POLYURETHANE E527
Journal of Applied Polymer Science DOI 10.1002/app
weight loss %) were more favorable for preparing a
transparent hybrid film. Using a piece of quartz
glass as reference, the transmittance of hybrid film
was improved from 60–80% (Figure 5, curve 5) to
58–90% (Figure 5, curve 4), closing to the transmit-
tance (%80–90%, 300–900 nm) of PU film synthesized
with PEG and MDI under similar conditions. This
enhanced transmittance of hybrid films also evi-
denced the improvement in particles dispersion.
On the other hand, Figure 5 shows that in wave-
length range of 190–300 nm, hybrid films appeared
marked absorptions, which could be attributed to ar-
omatic and carbonyl structures of PU, and the pres-
ence of particle attached PU oligomer seemed to
strengthen this UV absorption. This phenomenon
might be reasonable because of stronger interaction
of modified particles with PU prepolymer, which
might afford stretched grafted oligomers into matrix
and hence make a contribution to UV absorption.
TG/DTA measurements on hybrid films indicated
that with modified particles (presenting greater
weight loss) dispersed in matrix of PU prepolymer,
the as-prepared hybrid films exhibited a higher start-
ing thermal decomposition temperature (Td) (Figure
6, curve 3), while film contained particles providing
lower weight loss showed no significant divergence
in Td with that one impregnated pristine particles
(Figure 6, curves 2 and 1). The end residue of hybrid
film after a TG/DTA run (Figure 6, curve 3) seemed
to be somewhat greater than silica content (5 wt %),
which might be ascribed to the trapping of polymer
moiety in inorganic matrix.30
The aforementioned
thermal behaviors suggested an improvement of
thermal stability through incorporation of modified
particles. The covalently anchored functional groups
on particle would cause more surface binding sites
with matrix, thus enhancing interfacial interaction
with matrix and compatibility with organic phase,
and resulting in a greater thermal stability.
Vicker’s hardness of prepared hybrid films meas-
ured by a micro-controlled tester further proved the
compatibility enhancement derived from good disper-
sion of modified particles. As shown in Table II, with
particles giving greater weight loss, the resultant
hybrid film demonstrated an extremely high hardness.
As reported by Smith and Bedrov,17
dense and
long polymer brushes were not always necessary for
achievement of well-defined dispersion and profound
improvement of properties of composite containing
inorganic NPs. Here, our results provided another
example to confirm this point by introducing sparse
and long grafted chains to particles surface. Probable
reactions of functional groups and stronger interactions
between the grafted oligomer and prepolymer of PU
could contribute to the dispersion.
CONCLUSIONS
Using surface-emanated condensation reactions of
di- or tri-ols with di-isocyanates in steps, dispersion
of silica powder in PU was improved greatly, which
was demonstrated by SEM observations, DLS meas-
urements and improvements in properties of hybrid
films. As for the modification of silica particles, the
graft density could be controlled by amount of
modifier agent used in planting NCO-groups onto
surface, and composition, length of grafted chains
could be devised by selecting types of di- or tri-ols
and reaction steps.
Reactions occurred between functional groups on
particles surface and matrix of PU, and strong inter-
actions between modified particles and matrix could
be advantageous to the improvement of dispersion
of particles and properties of hybrid films, in despite
of that the density and length of grafted chains were
not so high.
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TABLE II
Vicker’s Hardness of Hybrid Films
Si NPs Pristine
Si-NCO-
PEG400
Si-NCO-PEG400-
MDI -PEG400-
MDI-PEG400
Weight
loss%
– À4.3 À6.5
Average
hardness
(loading)
24 (98.07 mN) 71 (245.2 mN) 554 (1.961 N)a
Formulation of hybrid film: Si NPs: 5 wt %, Mols, MMDI:
3 Â 10À3
mol, V: 2 mL.
a
Time: 10 s.
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DISPERSING SILCA POWDER INTO POLYURETHANE E529
Journal of Applied Polymer Science DOI 10.1002/app

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A Designed Surface Modification to Disperse Silica Powder into Polyurethane

  • 1. A Designed Surface Modification to Disperse Silica Powder into Polyurethane Lianying Liu,1 Hideo Watanabe,2 Takashi Shirai,2 Masayoshi Fuji,2 Minoru Takahashi2 1 Key Laboratory of Carbon Fiber and Functional Polymers, College of Materials Science and Engineering, Beijing University of Chemical Technology, Beijing 100029, China 2 Ceramics Research Laboratory, Nagoya Institute of Technology, Tajimi, Gifu 507-0033, Japan Received 13 September 2011; accepted 25 December 2011 DOI 10.1002/app.36734 Published online 12 June 2012 in Wiley Online Library (wileyonlinelibrary.com). ABSTRACT: Nanoparticles of silica powder were modi- fied by grafting polyurethane (PU) short chains or oligom- ers using surface-started condensation reactions of various di- or tri-ols and di-isocyanates in step-by-step. Surface density of NCO-groups, introduced by an autoclave method and ready for starting of subsequent reactions, was adjusted by amount of 3-isocyanatepropyltriethoxysi- lane (ICPTES). Length of grafted oligomers was deter- mined by reaction steps. TG/DTA measurements demonstrated a gradual increase of NCO-groups density with the amount of modifier input. FTIR spectra and ther- mal weight loss analyses confirmed the occurrence of reac- tion in each step and the growth of grafted oligomer. SEM images of particles dispersed in N, N-dimethylacetamide or in prepolymer of PU indicated an improved dispersion. Moreover, when as-modified particles were incorporated in PU prepolymer, the resultant hybrid films displayed an enhanced optical property, thermal stability, and Vicker’s hardness, suggesting a better dispersion of modified par- ticles. VC 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 126: E522–E529, 2012 Key words: silica nanoparticle; surface modification; dispersion; polyurethane INTRODUCTION Polymer/silica nanocomposite materials have attracted both academic and industrial interest for several decades because of their unique synergistic properties, advantages of availability and inexpen- siveness, and potential applications in various fields.1–9 However, a well-defined dispersion of silica powder nanoparticles (NPs) in polymer matri- ces is still a pursuing issue, as the enough strong interactions at interface between polymer matrices and inorganic NPs is intrinsically hard to achieve.10 Up to now, extensive research works have been done to mitigate the self-aggregation of inorganic NPs derived from Vander Waals attractions, and thus to improve the compatibility of inorganic NPs with an organic phase.11–13 Among them, surface initiated con- trol/living radical polymerizations10,14–16 are consid- ered to be effective techniques to firmly control pa- rameters including graft density, molecular weight, and chemical composition of graft and matrix poly- mers, etc.17–19 to enhance the dispersion of inorganic NPs.19 Usually, dense and long grafted chains were prerequisite to achieve complete isolation of NPs in homo- or block-polymer matrices19 to take full advant- age of large specific surface/interface area of NPs. Sometimes, particles grafted with relative sparse and short chains also brought about an effective disper- sion, and their self-assembly into highly anisotropic structures led to a pronounced enhancements in me- chanical property of resultant nanocomposites.10,17,19 In addition, condensation reactions initiated from a solid surface provide an alternative to covalently immobilize linear or branched functional copolymer chains on particles, and hence to facilitate the disper- sion of inorganic NPs. Some of investigations on sur- face-started condensation polymerization have been performed to create highly advanced organic/inor- ganic nanocomposites,20 for example, Chen et al.21 prepared polyurethane (PU)/silica hybrid nanocom- posites by incorporation of inorganic nanosized silica building blocks into PU matrix via a two step functionalized reaction including encapsulation of 3- aminopropyltriethoxysilane (APTS) and tether of PU shell on silica surface. In previous works, elaborate control of grafting of PU chains onto silica powder particles, such as manipulation of surface density, grafted chain length, and structure, by condensation reactions started from particle surface, was seldom involved in, and a better dispersion of silica powder in matrix of PU is still needed. It is known that PU can be manufactured by con- densation polymerization of di-isocyanates and di- or tri- hydroxyl compounds (di-ols or tri-ols). The employment of multifunctional monomers would Correspondence to: M. Fuji (fuji@nitech.ac.jp). Journal of Applied Polymer Science, Vol. 126, E522–E529 (2012) VC 2012 Wiley Periodicals, Inc.
  • 2. make the grafting of PU on particle surface more com- plex in comparison with the grafting of homopoly- mers such as polystyrene (PSt), or poly(methyl meth- acrylate) (PMMA) by free radical polymerizations. Especially, when surface condensation reactions start from large aggregated silica particles, rather than from individual NPs dispersed homogeneously in a good solvent or media, it is not easy to achieve dense and long linear grafted chains because of high reactivity of multifunctional monomers. Furthermore, the dispers- ing behavior of as-grafted NPs in PU is supposed to be dissimilar to that of silica NPs attached homopolymer in analogous matrices of homopolymer, block copoly- mer16 or miscible blends of polymers19 Accordingly, further investigations on the grafting of PU on particle surface by condensation reaction to disassociate silica power in PU are demanded. In our group, surface designed reactions were pro- posed to shield silica particle surface with densely grafted functional polymers to achieve a good disper- sion in polyimide (PI) or in slurry.22,23 Herein, with the aim to improve the dispersibility of silica powder in PU matrix, oligomer, or short-chain of PU was devised to incorporate onto particles by an autoclave method under supercritical hexane using 3-isocyana- tepropyltriethoxysilane (ICPTES) as a modifier agent, and followed by graft condensation reactions of sur- face-coupled isocyanate groups (NCOA) with di-, tri- ols, and di-isocyanate, as shown in Scheme 1. Surface density of initial functional groups (NCOA), which indicated the surface grafting density of oligomers on silica particles, was adjusted by modifier agent input and evaluated by TG/DTA measurements. Graft chain length of PU oligomers, demonstrated by FTIR spectra analysis, and TG/DTA measurements, was thought to be manipulated by further grafting reac- tions of di- or tri-ols, and di-isocyanate in step by step. Furthermore, hybrid thin films with modified silica particles dispersed in PU were prepared by a controlled roller coating and thermal curing, and their optical properties, thermal, and mechanical properties were examined. EXPERIMENTAL Materials Silica powder (Aerosil OX 50, average particle size of 40 nm, specific surface area 50 m2 /g, supplied by Nippon Aerosil) was dried at 130 C in a vacuum oven for at least 48 h and stored at room tempera- ture (RT) with a relative humidity (RH) of 34%. Modifier agent ICPTES (Shin-Etsu Silicone, KBE 9007, 99.7%, purchased from Shin-Etsu Chemical), poly-ols including polyethylene glycol (PEG, MW ¼ 400, 2000, 99%), triethylene glycol (TEG, MW ¼ 150.17, 99.8%), diethanolamine (DEOA, MW ¼ 105.14, 99.8%), tris-(hydroxymethyl)aminomethane (TOAM, MW ¼ 121.14, 99.8%), and 4,4-Diphenylme- thane diisocyanate (MDI, 99.7%), etc., from Shin- Etsu Chemical, were used without further purifica- tion. Solvents such as N, N-dimethylacetamide (DMAc) and acetone, etc., were used as received. Modification of silica particles with ICPTES The chemical reaction of ICPTES with hydroxyl groups of silica (density of OHA groups: 2.8/nm2 ) was carried out using an autoclave method as described previously.22 The amount of modifier applied was referred to mole ratio of NCO-group to silanol groups (NCOA/OH in moles) on silica sur- face. The surface density of modifier, noted as sur- face density of NCO-groups (dM, NCOA nm2 ) on particles, was determined with weight loss data from TG/DTA analysis and calculated according to the following equation23 : dMðNCOÀ=nm2 Þ ¼ ðDWCH À DWOHÞNA MWSN2 where DWCH is the weight loss ratio of modified silica particle, DWOH is that of pristine one, NA is the Avogadro number, MW is the molecular weight of modified group (84), and SN2 is the specific surface area of silica powder used (50 m2 /g). Surface grafting by condensation reactions In a 100 mL, 4-neck bottom flask equipped with con- denser, thermometer and N2 inlet, the modified par- ticles (SiANCO) were suspended into DMAc with aids of a magnetic stirrer, and then di- or tri-ols, or MDI was introduced into the suspension in step by step. The condensation reaction was performed usu- ally under a small N2 flow at 25 C for 3 h. After cycles of reaction of diisocyanate and poly- ols, particle surface was coated with oligomers of PU. Sample produced in each step was isolated by centrifugation, washed with DMAc, and acetone for at least 3 cycles, and then dried under vacuum. Preparation of hybrid films Pristine or surface-modified silica particles (5 wt %) were ultrasonically dispersed in 2 mL of a mixture Scheme 1 Representation of surface modification of silica NPs with ICPTES, and further reactions with di-, tri-ol, or di-isocyanate. DISPERSING SILCA POWDER INTO POLYURETHANE E523 Journal of Applied Polymer Science DOI 10.1002/app
  • 3. of PEG400 (3 Â 10À3 mol), MDI (3 Â 10À3 mol) and DMAc. 0.05 mL or 0.5mL of the as-produced disper- sion was coated on a piece of quartz or pyrex glass using a K101 Control Coater (RK Print Coat Instru- ment, UK), and then cured at 70 C for 12 h to get a thin or thick film. Characterization Weight loss data: determined on a Thermo Plus TG8120 analyzer (Rigaku, Japan) under O2 atmos- phere with a flow rate of 500 mL/min, heating rate of 10 C/min, from room temperature to 700 C. Grafted chains analysis: done on a FTIR 6200 spec- trometer (Jasco, Japan) using KBr pellets. Morphology of particles: observed on a JSM-7000F Scanning Electron Microscope (SEM, Jeol, Japan), under an accelerating voltage of 10 kV. Samples were prepared by dropping suspension of silica par- ticles in DMAc on a small piece of cover glass and evaporating at room temperature, or by spin-coating the mixture of silica particles, PEG, MDI, and DMAc on a glass and then drying under vacuum at 70 C for 8 h. Before SEM observation, samples were coated with osmium (OsO4). Particle size and its distribution: evaluated by Zetasizer Nano Series (Malvern Instrument) in a sol- vent of DMAc. Transmittance of hybrid films: measured on a UV–VIS–NIR spectrophotometer, UV3150 (Shi- madzu, Japan) in wavelength range of 190–900 nm. Vicker hardness of hybrid film: estimated on a HMV-2T micro-hardness tester (Shimadzu, Japan), and for each sample, at least four points was meas- ured to get an average value. RESULTS AND DISCUSSION Surface-initiated condensation reactions and structure analysis An autoclave method was used to allow the surface AOH groups react efficiently with silane coupling agent22,23 due to AOH groups in silica powder are not easy to be fully exposed on surface. Surface den- sity of NCO-groups (dM) introduced firstly onto par- ticle, approximating the graft density of PU oligomer or short chain in subsequent process, could be con- trolled by varying ICPTES input in system and eval- uated by TG/DTA analysis. As plotted in Figure 1, Figure 1 Surface density of NCO-groups on silica par- ticles modified with various ratio of NCO-/OH. Figure 2 FTIR spectra analysis of silica particles and materials, 0: pristine particles, 1: Si-NCO particles, 2,4,6 (a) particles produced after reaction with PEG (a) or DEOA (b), 3,5 (a) particles produced after further reaction with MDI. 7(a), 5(b): MDI, 8(a): PEG, 6(b) DEOA. E524 LIU ET AL. Journal of Applied Polymer Science DOI 10.1002/app
  • 4. dM improved along with increase of modifier amount, confirming the successful incorporation of NCO-groups on particle surface. When mole ratio of NCOA/OH was increased up to 12.2, surface den- sity of about 1.14 NCO-groups/nm2 was achieved, and then a slight change of coupling of NCO-groups displayed at a higher mole ratio of NCOA/OH. In the present experiments, values of dM were lower than that achieved previously22,23 and far less than theoretical one of 2.8-OH/nm2 .23 This case would cause some difficulties in detecting the pres- ence of NCO-groups by FTIR analysis (Figure 2, curve 1). The aggregation of silica particles in pow- der (could be at around 600–1700 nm, evaluated by dynamic light scattering, DLS) might screen some free AOH groups on surface and limit their reaction with modifier of ICPTES, leading to a low coupling degree of NCO-groups. In addition, the possible reaction of NCO-groups of ICPTES with OH-groups on particle surface might also be negative to the cou- pling of NCO-groups. When poly-ols such as PEG or DEOA were charged into reaction system to start condensation reaction with pristine particles, and MDI was added in subsequent step, the obtained particles showed no distinct FTIR absorptions and marked weigh loss differing from those of pristine particles. In system contained particle with NCO-groups coupled on sur- face in a density of 1.14/nm2 , FTIR analysis indi- cated that in the first step, with poly-ols such as PEG or DEOA charged, no significant variations was discerned (Figure 2, curve 2). While, with MDI seg- ments incorporated onto particle surface, characteris- tic absorption of NCO-group at 2279 cmÀ1 was observed clearly (Figure 2, curves a3 and b3). This phenomenon implied that more NCO- groups could be combined because of the possible reaction of MDI with surface free AOH groups freshly exposed due to a gradually improved dispersion. The above results further verified the successful introduction of original NCO-groups, and revealed that it was enough to start condensation reactions from particles surface with NCO-groups in a low density, allowing to graft sparse and enough long polymer chains on surface to improve the dispersion of particles. As seen in Figure 2, absorption at 1720 cmÀ1 could be assigned to AC¼¼O group come forth with the addition of MDI. Absorption at 1650 cmÀ1 could be ascribed to amide groups ACOANHA, and absorp- tions at 1705, 1632 cmÀ1 could be attributed to car- bonyl groups of urethano units (ANHCOOA). Absorptions at 1600, 1560, 1514, 1423 cmÀ1 were aro- matic characteristic peaks. When reaction with PEG or DEOA occurred again, the characteristic absorp- tion of NCOA at 2279 cmÀ1 was disappeared almost completely (Figure 2, curves a4 and b4), and absorp- tions arising from ACH2 symmetric stretching vibra- tion at 2890 cmÀ1 , NAH stretching vibration at about 3300 cmÀ1 were detected apparently. Similar Figure 3 (a) Typical TG curves of silica particles: pristine particles (1), Si-NCO particles (2), modified silica particles after reaction with TEG (3), and then with MDI repeatedly at 0 C (4) or 25 C (5) for 5 steps. (b) Condensation reaction of SiANCO particles with PEG (1) or DEOA (2), and then with MDI in multisteps, WSi-NCO ¼ 0.2 g, MPEG or DEOA ¼ MMDI ¼ 3 Â 10À3 mol, VDMAc ¼ 30 mL. TABLE I Grafting of Short Chains or Oligomers Through Condensation Reactions in Multisteps Composition of grafted chains Si-NCO- TEG Si-NCO- PEG400 Si-NCO- PEG2000 Si-NCO-TEG- MDI-TEG-MDI-TEG Si-NCO- TOAM Si-NCO- DEOA Si-NCO-DEOA- MDI-DEOA Weight loss% À3.83 À4.32 À5.15 À5.26 À4.74 À4.94 À9.15 Reaction time: 6 h; temperature: 0 C; WSi-NCO ¼ 0.2 g; Mols ¼ MMDI ¼ 3 Â 10À3 mol; VDMAc ¼ 30 mL. DISPERSING SILCA POWDER INTO POLYURETHANE E525 Journal of Applied Polymer Science DOI 10.1002/app
  • 5. observations were presented after repeated reaction with PEG and MDI in cycles (Figure 2, curves a5 and a6). The above described FTIR analysis demon- strated the occurrence of grafting condensation reac- tion and implied the growth of grafting chains in each step. Typical TD/DTA measurements under an O2 atmosphere indicated that started from surface NCO-groups, condensation reactions with TEG and then MDI repeatedly led to a gradual increase of weight loss [Figure 3(a)], suggesting a growth of grafted chains. This phenomenon was further con- firmed by weight loss data against reaction steps [Figure 3(b)] with various di-ols selected as a monomer. It could be noted that from Figure 3(a), curve 4 and 5, the loading amount of PU oligomers obtained at reaction temperature of 25 C, was much greater than that achieved at 0 C, and TG curve of resultant sample appeared two distinct regions of weight loss started from about 200 and 330 C, respectively, analogous to a typical TG curve of PU as reported.24 It is known that PU is commonly composed of hard and soft segments. The first region was related to thermal degradation of hard segment of grafted chains due to low thermal sta- bility of urethane groups,25 while the second region was associated to the soft segment decomposition.26 Weight losses for the first and second regions were 27 and 34%, respectively. Using weight loss at each region as an approximately quantitative indication25 of hard Figure 4 SEM images of pristine (a, b) and modified (c, d, weight loss 4.5%) particles dispersed in DMAc or in prepoly- mer of PU, and pristine (e) or modified (f) particle size distribution by intensity in DMAc. [Color figure can be viewed in the online issue, which is available at wileyonlinelibrary.com.] E526 LIU ET AL. Journal of Applied Polymer Science DOI 10.1002/app
  • 6. and soft segment content in grafted PU chains, one could find that the content ratio of hard and soft seg- ment was close to feed mole ratio of MDI to TEG (2/3) in reactions. Moreover, compared with reactions occurred at a lower temperature, or reactions performed only one or two steps, samples generated at a higher tempera- ture and for more than three steps displayed extremely great weight loss percents, which might not be reasonably attributed to the lengthened graft- ing chains. Some free oligomer might be generated accompanying the growth of grafted chains and re- sponsible for this exaggeration in weight losses, because of high reactivity of isocynate and its com- plexity in reaction with poly-ols.27,28 To alleviate the formation of free oligomer, reac- tions were carried out in low temperature for long time, and various types of poly-ols were selected to deal with particles. As summarized in Table I, using a diol having a high molecular weight, long chains could be attached onto particle surface, as indicated by the increased weight loss. Multi-step reactions could also be favorable for the lengthening of teth- ered chains. Especially, the employment of CBn-type poly-ols permitted the covalent incorporation of branched oligomer on particle surface, which would be advantageous to make grafted chains spread into a larger area as it moved away from a curved sur- face, and result in a broader grafted chain/matrix interface and favorable grafted chain/matrix interac- tions. On the other hand, more functional groups introduced onto particle surface by application of CBn-type polyols could give more possibility to inter- act with groups in PU matrix, and thus be positive to the dispersion of particles. Dispersion of modified particles When pristine silica particles were dispersed in DMAc, compact aggregate was observed from SEM image [Figure 4(a)], even DMAc is a solvent in which silica particles could be eletrostatically stabi- lized.29 Also, it was seen that at a low magnification, pristine silica particles could not be homogeneously dispersed in prepolymer of PU [Figure 4(b)], and at a high magnification, great assemblies of silica parti- cle were found [Figure 4(b), inserted]. When silica particles were subjected to surface grafting modifica- tion, large aggregation was disappeared, only some particles still congregated [Figure 4(c)]. At a low magnification, almost uniform dispersion of modi- fied particles could be observed [Figure 4(d)], and separated particles in prepolymer of PU were pre- sented [Figure 4(d), inserted]. These observations indicated that the grafting of polymer chains indeed improved the dispersion of particles in DMAc and prepolymer of PU, and this effect became greater in prepolymer of PU due to stronger interactions between functional groups. DLS measurement fur- ther confirmed the decrease in particle size and its distribution [Figure 4(e,f)]. Properties of hybrid films When pristine particles were impregnated in prepol- ymer of PU, the prepared film had a transmittance of around 35–70% in wavelength of 300–900 nm using a piece of pyrex glass as reference (Figure 5, curve 1). When modified particles were immersed in prepolymer of PU, the hybrid film showed a trans- mittance of about 45–80% (Figure 5, curve 2), or 50– 88% (Figure 5, curve 3). Silica particles immobilized longer oligomer on surfaces (indicated by the greater Figure 5 Transmittance of hybrid films impregnated with pristine particle (1, 5), and modified particles (2, surface attached with PEG400 segment, weight loss 4.4%; 3, 4, sur- face grafted with PU oligomer composing of TEG and MDI segments, weight loss 5.6%). Figure 6 TG curves of hybrid films contained pristine (1), modified particles attached PEG400 segment (2, weight loss 4.4%) or PU oligomer composing of PEG400 and MDI segments (3, weight loss 6.3%). DISPERSING SILCA POWDER INTO POLYURETHANE E527 Journal of Applied Polymer Science DOI 10.1002/app
  • 7. weight loss %) were more favorable for preparing a transparent hybrid film. Using a piece of quartz glass as reference, the transmittance of hybrid film was improved from 60–80% (Figure 5, curve 5) to 58–90% (Figure 5, curve 4), closing to the transmit- tance (%80–90%, 300–900 nm) of PU film synthesized with PEG and MDI under similar conditions. This enhanced transmittance of hybrid films also evi- denced the improvement in particles dispersion. On the other hand, Figure 5 shows that in wave- length range of 190–300 nm, hybrid films appeared marked absorptions, which could be attributed to ar- omatic and carbonyl structures of PU, and the pres- ence of particle attached PU oligomer seemed to strengthen this UV absorption. This phenomenon might be reasonable because of stronger interaction of modified particles with PU prepolymer, which might afford stretched grafted oligomers into matrix and hence make a contribution to UV absorption. TG/DTA measurements on hybrid films indicated that with modified particles (presenting greater weight loss) dispersed in matrix of PU prepolymer, the as-prepared hybrid films exhibited a higher start- ing thermal decomposition temperature (Td) (Figure 6, curve 3), while film contained particles providing lower weight loss showed no significant divergence in Td with that one impregnated pristine particles (Figure 6, curves 2 and 1). The end residue of hybrid film after a TG/DTA run (Figure 6, curve 3) seemed to be somewhat greater than silica content (5 wt %), which might be ascribed to the trapping of polymer moiety in inorganic matrix.30 The aforementioned thermal behaviors suggested an improvement of thermal stability through incorporation of modified particles. The covalently anchored functional groups on particle would cause more surface binding sites with matrix, thus enhancing interfacial interaction with matrix and compatibility with organic phase, and resulting in a greater thermal stability. Vicker’s hardness of prepared hybrid films meas- ured by a micro-controlled tester further proved the compatibility enhancement derived from good disper- sion of modified particles. As shown in Table II, with particles giving greater weight loss, the resultant hybrid film demonstrated an extremely high hardness. As reported by Smith and Bedrov,17 dense and long polymer brushes were not always necessary for achievement of well-defined dispersion and profound improvement of properties of composite containing inorganic NPs. Here, our results provided another example to confirm this point by introducing sparse and long grafted chains to particles surface. Probable reactions of functional groups and stronger interactions between the grafted oligomer and prepolymer of PU could contribute to the dispersion. CONCLUSIONS Using surface-emanated condensation reactions of di- or tri-ols with di-isocyanates in steps, dispersion of silica powder in PU was improved greatly, which was demonstrated by SEM observations, DLS meas- urements and improvements in properties of hybrid films. As for the modification of silica particles, the graft density could be controlled by amount of modifier agent used in planting NCO-groups onto surface, and composition, length of grafted chains could be devised by selecting types of di- or tri-ols and reaction steps. Reactions occurred between functional groups on particles surface and matrix of PU, and strong inter- actions between modified particles and matrix could be advantageous to the improvement of dispersion of particles and properties of hybrid films, in despite of that the density and length of grafted chains were not so high. References 1. Ueno, K.; Inaba, A.; Kondoh, M.; Watanabe, M. Langmuir 2008, 24, 5253. 2. Liu, Y. L.; Hsu, C. Y.; Hsu, K. Y. Polymer 2005, 46, 1851. 3. Kohut, A.; Ranjan, S.; Voronov, A.; Peukert, W.; Tokarev, V.; Bednarska, O.; Gevus, O.; Voronov, S. Langmuir 2006, 22, 6498. 4. Elodie, B-L.; Lang. J. Macromol Symp 2000, 151, 377. 5. Chalaye, S.; Elodie, B-L.; Putaux, J-L.; Lang J. Macromol. Symp. 2001, 169, 89. 6. Elodie, B.-L.; Lang, J.; Putaux, J. L.; Elodie, B-L.; Herrera, N. N.; Putaux, J-L.; Reculusa, S.; Perro, A.; Ravaine, S.; Mingo- taud, C.; Duguet, E. Macromol Symp 2005, 229, 32. 7. Elodie, B.-L.; Lang, J.; Putaux, J. L.; Elodie B-L.; Herrera, N. 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