Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach
Abstract The accumulation of polyurethane (PU) waste presents a critical environmental challenge due to the inefficiencies of traditional disposal methods like landfilling and incineration. This study introduces a sustainable approach by repurposing 99.89% pure rigid polyurethane foam granules (~ 15...
Saved in:
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2025-03-01
|
| Series: | Scientific Reports |
| Subjects: | |
| Online Access: | https://doi.org/10.1038/s41598-025-91273-9 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850039732014153728 |
|---|---|
| author | Vinoth Kumar Selvaraj Jeyanthi Subramanian S. Mouleswaran T. R. Keshav Keerthan Thangapandi Muneeswaran A. Kishore Nath M. Padmanabha Raju |
| author_facet | Vinoth Kumar Selvaraj Jeyanthi Subramanian S. Mouleswaran T. R. Keshav Keerthan Thangapandi Muneeswaran A. Kishore Nath M. Padmanabha Raju |
| author_sort | Vinoth Kumar Selvaraj |
| collection | DOAJ |
| description | Abstract The accumulation of polyurethane (PU) waste presents a critical environmental challenge due to the inefficiencies of traditional disposal methods like landfilling and incineration. This study introduces a sustainable approach by repurposing 99.89% pure rigid polyurethane foam granules (~ 150 µm) as fillers (5 wt.%) in bio-epoxy composites, complemented with 99.89% pure vermiculite particles (~ 10 µm) at varying concentrations (2–10 wt.%). Comprehensive characterization techniques, including high-resolution scanning electron microscopy (HR-SEM) and Fourier transform infrared spectroscopy (FTIR), were employed to evaluate the composites’ mechanical, thermal, electrical, acoustic, and electromagnetic interference (EMI) shielding properties. The study specifically measured EMI shielding effectiveness in the frequency range of 8–12 GHz. Among the formulations, sample S5 exhibited superior mechanical performance, with tensile strength (10.47 N/mm2), impact strength (0.006 kJ/cm2), and flexural strength (46.80 N/mm2). EMI analysis revealed a dielectric constant of 1.111 and shielding effectiveness of -35.24 dB, while sample S3 achieved optimal acoustic absorption (NRC 0.295). Thermal assessments showed the lowest thermal conductivity (0.141 W/mK) and a reduced burning rate (6.8 mm/min) for S5. These results highlight the viability of recycled PU foam-based composites in minimizing plastic waste and advancing net-zero carbon emission goals. Potential applications include battery enclosures, engine bay insulation, and cabin soundproofing in electric vehicles. This work establishes the novelty of integrating recycled materials into bio-epoxy matrices to address environmental challenges and create high-performance composites. |
| format | Article |
| id | doaj-art-4cb5e0d2a17e44679b875fadf8f39b64 |
| institution | DOAJ |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-4cb5e0d2a17e44679b875fadf8f39b642025-08-20T02:56:15ZengNature PortfolioScientific Reports2045-23222025-03-0115111910.1038/s41598-025-91273-9Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approachVinoth Kumar Selvaraj0Jeyanthi Subramanian1S. Mouleswaran2T. R. Keshav Keerthan3Thangapandi Muneeswaran4A. Kishore Nath5M. Padmanabha Raju6School of Mechanical Engineering, Vellore Institute of TechnologySchool of Mechanical Engineering, Vellore Institute of TechnologySchool of Mechanical Engineering, Vellore Institute of TechnologySchool of Mechanical Engineering, Vellore Institute of TechnologySedaxis Advanced Materials Pvt Ltd.Advanced System Laboratory, Defence Research & Development OrganisationAdvanced System Laboratory, Defence Research & Development OrganisationAbstract The accumulation of polyurethane (PU) waste presents a critical environmental challenge due to the inefficiencies of traditional disposal methods like landfilling and incineration. This study introduces a sustainable approach by repurposing 99.89% pure rigid polyurethane foam granules (~ 150 µm) as fillers (5 wt.%) in bio-epoxy composites, complemented with 99.89% pure vermiculite particles (~ 10 µm) at varying concentrations (2–10 wt.%). Comprehensive characterization techniques, including high-resolution scanning electron microscopy (HR-SEM) and Fourier transform infrared spectroscopy (FTIR), were employed to evaluate the composites’ mechanical, thermal, electrical, acoustic, and electromagnetic interference (EMI) shielding properties. The study specifically measured EMI shielding effectiveness in the frequency range of 8–12 GHz. Among the formulations, sample S5 exhibited superior mechanical performance, with tensile strength (10.47 N/mm2), impact strength (0.006 kJ/cm2), and flexural strength (46.80 N/mm2). EMI analysis revealed a dielectric constant of 1.111 and shielding effectiveness of -35.24 dB, while sample S3 achieved optimal acoustic absorption (NRC 0.295). Thermal assessments showed the lowest thermal conductivity (0.141 W/mK) and a reduced burning rate (6.8 mm/min) for S5. These results highlight the viability of recycled PU foam-based composites in minimizing plastic waste and advancing net-zero carbon emission goals. Potential applications include battery enclosures, engine bay insulation, and cabin soundproofing in electric vehicles. This work establishes the novelty of integrating recycled materials into bio-epoxy matrices to address environmental challenges and create high-performance composites.https://doi.org/10.1038/s41598-025-91273-9RecyclingSustainable compositesBio-epoxyNet-zero carbon emissionHR-SEMFTIR, TGA |
| spellingShingle | Vinoth Kumar Selvaraj Jeyanthi Subramanian S. Mouleswaran T. R. Keshav Keerthan Thangapandi Muneeswaran A. Kishore Nath M. Padmanabha Raju Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach Scientific Reports Recycling Sustainable composites Bio-epoxy Net-zero carbon emission HR-SEM FTIR, TGA |
| title | Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach |
| title_full | Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach |
| title_fullStr | Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach |
| title_full_unstemmed | Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach |
| title_short | Sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical, thermal, acoustic, and electromagnetic applications in a circular economy approach |
| title_sort | sustainable development of bioepoxy composites reinforced with recycled rigid polyurethane foam for mechanical thermal acoustic and electromagnetic applications in a circular economy approach |
| topic | Recycling Sustainable composites Bio-epoxy Net-zero carbon emission HR-SEM FTIR, TGA |
| url | https://doi.org/10.1038/s41598-025-91273-9 |
| work_keys_str_mv | AT vinothkumarselvaraj sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT jeyanthisubramanian sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT smouleswaran sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT trkeshavkeerthan sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT thangapandimuneeswaran sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT akishorenath sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach AT mpadmanabharaju sustainabledevelopmentofbioepoxycompositesreinforcedwithrecycledrigidpolyurethanefoamformechanicalthermalacousticandelectromagneticapplicationsinacirculareconomyapproach |