Influence of Flash Graphene on the acoustic, thermal, and mechanical performance of flexible polyurethane foam

In this study, flexible polyurethane foam (PUF) composites were prepared using three types of Flash Graphene (FG) produced from different feedstock material. The acoustic, thermal, and mechanical properties of foam composites containing 0.025 wt% FG were characterized. It was shown that PUF-1 and PUF-3 had higher sound absorption in the frequency range of 500-2000 Hz compared to neat PUF (baseline). PUF-3 experienced a 47% reduction in thermal expansion coefficient relative to the baseline. The tensile strength and compressive modulus of all composites increased by 16-26% and 33-37% respectively. Compression force deflection and tear strength did not change relative to the baseline. This may be explained by the relatively low flake diameter and aspect ratio of each FG which led to agglomeration and impacted load transfer between the filler and matrix. Overall, the addition of 0.025 wt% FG1 and FG3 improved acoustic, thermal, and tensile properties of PUF without diminishing compression force deflection and tear resistance. PUF reinforced with FG had similar or enhanced properties compared to PUF containing commercially available, exfoliated graphene nanoplatelets (GNP). This supports the use of FG as a relatively sustainable, low-cost alternative to exfoliated GNP or chemical vapor deposition (CVD)-grown graphene in porous polymer composites.