Abstract
This study aims to investigate the potential of integrating natural biochar (BC) derived from eggshell waste into flexible polyurethane (FPU) foam to enhance its mechanical and acoustic performance. The study explores the impact of incorporating BC at various weight ratios (0.1, 0.3, 0.5, and 0.7 wt. %) on the properties of the FPU foam. Additionally, the effects of modifying the BC with (3-aminopropyl)trimethoxysilane (APTMS) at different ratios (10, 20, and 30 wt. %) and the influence of diverse particle sizes of BC on the thermal, mechanical, and acoustic characteristics of the FPU composite are investigated. The functional groups, morphology, and elemental composition of the developed FPU composites are analyzed using Fourier-transform infrared spectroscopy (FTIR), field-emission scanning electron microscopy (FESEM), and energy-dispersive X-ray (EDX) techniques. Characteristics such as density, gel fraction, and porosity were also assessed. The results reveal that the density of FPU foam increased by 4.32% and 7.83% while the porosity decreased to 50.22% and 47.05% with the addition of 0.1 wt. % of unmodified BC and modified BC with 20 wt. % APTMS, respectively, compared to unfilled FPU. Additionally, the gel fraction of the FPU matrix increases by 1.91% and 3.55% with the inclusion of 0.1 wt. % unmodified BC and modified BC with 20 wt. % APTMS, respectively. Furthermore, TGA analysis revealed that all FPU composites demonstrate improved thermal stability compared to unfilled FPU, reaching a peak value of 312.17°C for the FPU sample incorporating BC modified with 20 wt. % APTMS. Compression strength increased with 0.1 wt. % untreated BC but decreased at higher concentrations. Modifying BC with 20% APTMS resulted in an 8.23% increase in compressive strength compared to unfilled FPU. Acoustic analysis showed that the addition of BC improved absorption, and modified BC enhanced absorption characteristics of FPU, reaching Class D with a 20 mm thickness. BC modified with APTMS further improved acoustic properties compared to the unfilled FPU sample (Class E), with 20% modification showing the best results. These composites present promising materials for sound absorption applications and address environmental issues related to eggshell waste.