Understanding and Improving the Elastic Compressive Modulus of Fibre Reinforced Soy-Based Polyurethane Foams

Soy-based polyurethane foams (PUFs) were reinforced with fibres of different aspect ratios to improve the compressive modulus. Each of the three fibre types reinforced PUF differently. Shorter micro-crystalline cellulose fibres were found embedded inside the cell struts of PUF and reinforced them. The reinforcement was attributed to be stress transfer from the matrix to the fibre by comparing the experimental results to those predicted by micro-mechanical models for short fibre reinforced composites. The reinforced cell struts increased the overall compressive modulus of the foam. Longer glass fibres (470 microns, length) provided the best reinforcement. These fibres were found to be larger than the cell diameters. The micro-mechanical models could not predict the reinforcement provided by the longer glass fibres. The models predicted negligible reinforcement because the very low modulus PUF should not transfer load to the higher modulus fibres. However, using a finite element model, it was determined that the fibres were providing reinforcement through direct fibre interaction with each other. Intermediate length glass fibres (260 microns, length) were found to poorly reinforce the PUF and should be avoided. These fibres were too short to interact with each other and were on average too large to embed and reinforce cell struts.;In order to produce natural fibre reinforced PUFs in the future, a novel device was invented. The purpose of the device is to deliver natural fibres at a constant mass flow rate. The device was found to consistently meter individual loose natural fibre tufts at a mass flow rate of 2 grams per second. However, the device is not robust and requires further development to deliver a fine stream of natural fibre that can mix and interact with the curing polymeric components of PUF. A design plan was proposed to address the remaining issues with the device.