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<p>The use of renewable Kraft lignin (KL) as a partial substitute for petroleum-based polyols has attracted significant interest in polyurethane foam (PUF) development. However, the effect of unmodified KL content on the balance among cellular structure, mechanical stability, cyclic compression behavior, and thermal properties of flexible polyurethane foam (FPUF) still requires further clarification. In this study, a series of lignin-based flexible polyurethane foams (LFPUF) with different KL contents were prepared via a one-shot method using polyethylene glycol 400 (PEG400) and hexamethylene diisocyanate (HDI). The proposed interactions between KL and PEG400, together with the reaction between hydroxyl groups and –NCO groups, contributed to the formation of lignin-containing polyurethane networks. With 15 wt% KL addition, L<sub>15%</sub>FPUF exhibited the most favorable cellular structure, with the smallest average cell size (843.5&#xa0;μm) and pore diameter (249.3&#xa0;μm). Its rebound resilience and elastic recovery rate reached 20.36% and 98.24%, respectively, which were higher than those of KL-free FPUF (13.45% and 96.97%). After 300 compression cycles at 75% strain, L<sub>15%</sub>FPUF maintained a high elastic recovery rate of 93.53% and a stable hysteresis loss of 32.71%, demonstrating good cyclic compression stability. Thermal analysis further showed that KL incorporation improved high-temperature residue retention while affecting the initial degradation behavior. This study identifies 15 wt% KL as a balanced substitution ratio for preparing LFPUF with improved cellular structure, mechanical stability, cyclic compression stability, and thermal performance, supporting its potential application in flexible cushioning materials.</p>

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Fabrication and properties of bio-based flexible polyurethane foams by substituting Kraft lignin polyol

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Xilai Yan,
  • Yuqing Tang,
  • Guangying Huang,
  • Han Han,
  • Ajoy Kanti Mondal,
  • Weijie Lin,
  • Fang Huang

摘要

The use of renewable Kraft lignin (KL) as a partial substitute for petroleum-based polyols has attracted significant interest in polyurethane foam (PUF) development. However, the effect of unmodified KL content on the balance among cellular structure, mechanical stability, cyclic compression behavior, and thermal properties of flexible polyurethane foam (FPUF) still requires further clarification. In this study, a series of lignin-based flexible polyurethane foams (LFPUF) with different KL contents were prepared via a one-shot method using polyethylene glycol 400 (PEG400) and hexamethylene diisocyanate (HDI). The proposed interactions between KL and PEG400, together with the reaction between hydroxyl groups and –NCO groups, contributed to the formation of lignin-containing polyurethane networks. With 15 wt% KL addition, L15%FPUF exhibited the most favorable cellular structure, with the smallest average cell size (843.5 μm) and pore diameter (249.3 μm). Its rebound resilience and elastic recovery rate reached 20.36% and 98.24%, respectively, which were higher than those of KL-free FPUF (13.45% and 96.97%). After 300 compression cycles at 75% strain, L15%FPUF maintained a high elastic recovery rate of 93.53% and a stable hysteresis loss of 32.71%, demonstrating good cyclic compression stability. Thermal analysis further showed that KL incorporation improved high-temperature residue retention while affecting the initial degradation behavior. This study identifies 15 wt% KL as a balanced substitution ratio for preparing LFPUF with improved cellular structure, mechanical stability, cyclic compression stability, and thermal performance, supporting its potential application in flexible cushioning materials.