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<p>Flexible polyurethane (PU) foams are widely employed in cushioning and footwear applications, for durability, comfort, and stability. While cellulose nanocrystals (CNC) have been studied extensively in low-density PU systems, their role in high density flexible foams for footwear and comfort applications remains largely unexplored. This study investigates two commercial CNC slurries, Cellurods<sup>®</sup> 110&#xa0;L (particle size &lt; 88&#xa0;nm, 7.7–8.3 wt% solids) and Cellurods<sup>®</sup> 100&#xa0;L (particle size &lt; 95&#xa0;nm, 7.2–7.8% solids) introduced at 0.25-2 wt% (relative to polyol) into high density PU foam (≈ 110&#xa0;kg/m³). Type A (110&#xa0;L) exhibited 41% higher tensile and 38% higher tear strength than control, while Type B (100&#xa0;L) achieved increase of 28% and 30%, respectively before plateauing at higher loadings. FESEM–ImageJ analysis revealed increased cell density, reduced pore size, enhanced porosity and more uniform cells for Type A and partial aggregation for Type B at elevated concentrations. Thermogravimetric analysis indicated marginal thermal stabilisation in both series. Overall, the results show that CNC, particularly finer grades can reinforce high-density flexible PU foams without compromising comfort related properties. The comparative evaluation of Type A and Type B reveals that even subtle differences in nanocellulose particle characteristics influence performance, suggesting that particle size and dispersion behaviour can be used as tuneable parameters to tailor industrial foam properties for load-bearing applications such as footwear and orthotics.</p>

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Structure–property relationships in high-density flexible polyurethane foams reinforced with cellulose nanocrystals (CNC): comparative effects of particle size

  • 期刊论文

  • 发表日期：

    2026年3月23日

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  • Pradeep Aggarwal,
  • S. Maji,
  • Roli Purwar

摘要

Flexible polyurethane (PU) foams are widely employed in cushioning and footwear applications, for durability, comfort, and stability. While cellulose nanocrystals (CNC) have been studied extensively in low-density PU systems, their role in high density flexible foams for footwear and comfort applications remains largely unexplored. This study investigates two commercial CNC slurries, Cellurods® 110 L (particle size < 88 nm, 7.7–8.3 wt% solids) and Cellurods® 100 L (particle size < 95 nm, 7.2–7.8% solids) introduced at 0.25-2 wt% (relative to polyol) into high density PU foam (≈ 110 kg/m³). Type A (110 L) exhibited 41% higher tensile and 38% higher tear strength than control, while Type B (100 L) achieved increase of 28% and 30%, respectively before plateauing at higher loadings. FESEM–ImageJ analysis revealed increased cell density, reduced pore size, enhanced porosity and more uniform cells for Type A and partial aggregation for Type B at elevated concentrations. Thermogravimetric analysis indicated marginal thermal stabilisation in both series. Overall, the results show that CNC, particularly finer grades can reinforce high-density flexible PU foams without compromising comfort related properties. The comparative evaluation of Type A and Type B reveals that even subtle differences in nanocellulose particle characteristics influence performance, suggesting that particle size and dispersion behaviour can be used as tuneable parameters to tailor industrial foam properties for load-bearing applications such as footwear and orthotics.