Abstract
Flexible polyurethane (PUR) foams have been filled with fine PUR powder produced from PUR foam automotive scrap. For pulverization the proprietary non-extrusion and non-cryogenic Pressure Shear Pulverization (PSP) process was used. The PSP process is based on the combined action of high shear stress and compression load at ambient temperatures. Mechanical behavior of filled PUR foams have been studied at various contents (up to 30 percent per polyol component) and size fractions (from 75 to 500 microns) of the PSP powder. Demonstrations showed improvement of compressive and cushioning properties are very critical in terms of size and content of the filler. The mechanism of the reinforcement effect is proposed based on capsulation of the PUR filler into the cell struts and walls of the flexible cellular PUR matrix.
