Nanocrystalline Cellulose Reinforcement and Constrained Expansion to Enhance Mechanical Performance of Rigid Polyurethane Foams for Sandwich Panel Applications

This study aimed to assess the mechanical and morphological properties of rigid polyurethane foams (RPUFs) reinforced with cellulose nanocrystals (CNC) at varying concentrations, exploring also effects of expansion under confinement for use in sandwich panels. RPUFs with 1%, 3%, and 5% CNC were tested, with the 3% CNC content delivering the best combination of mechanical performance and cellular structure. While the RPUF with 5% CNC showed a 78% increase in cell length, its compressive strength dropped by 55%, likely due to CNC agglomeration. Confining the RPUF during expansion improved the density by 23%, which in turn led to an approximately 90% increase in core shear stress. Flexural tests revealed that confined panels exhibited better force-displacement responses, with core shear strength rising by 55% compared to unconfined panels. These results suggest that CNC-reinforced and confined RPUFs are well-suited for structural applications requiring both strength and insulation.