Sustainable natural rubber latex foam carpets reinforced with rubberwood sawdust: Enhanced safety and comfort for elderly users

• NR foam-sawdust composites were developed for elderly-use slip-resistant carpets. • Dunlop method yielded denser foam with superior strength and lower water uptake. • Blowing agent and sawdust levels impacted porosity, COF, and compression set. • RSM models effectively predicted COF, energy absorption, and mass loss. • Optimal mix: 14 phr blowing agent, 23 phr sawdust for safe, durable carpet use. This study aimed to explore the application of natural rubber (NR) latex foam reinforced with wood sawdust for use in carpets intended for the elderly. The study compared two foam composite preparation methods: the standard Dunlop method and a modified Dunlop/blowing method. To optimize formulations and develop predictive models, Central Composite Design (CCD) and Response Surface Methodology (RSM) were employed. The resulting composites were subjected to a comprehensive series of tests examining thermal, morphological, physical, and mechanical properties, including tension, compression set, friction, and abrasion resistance. The results indicated that the Dunlop/blowing method produced foams with higher porosity and increased water absorption, while the Dunlop method yielded denser foams with greater tensile strength. Increasing blowing agent and wood sawdust content generally led to higher compression sets. The developed quadratic models effectively predicted the coefficient of friction (COF), energy absorption, and mass loss, offering valuable insights for optimizing composite performance. A peak COF of approximately 0.7 was achieved with 30 phr sawdust and 15 phr blowing agent, highlighting the importance of these factors in slip prevention. The study concludes that a composite formulation of 14 phr blowing agent and 23 phr wood sawdust strikes the best balance for COF, energy absorption, and mass loss, making it a promising candidate for carpets intended for the elderly. These findings are significant because they demonstrate the potential of tailored NR latex/sawdust composites to address the specific safety and comfort needs of elderly users.