Development of Next-Generation Sustainable Packaging Materials from Carbohydrate-Based Polyurethane Foams with Desired Mechanical and Barrier Properties

Polyurethane foams (PUFs) designed for rapid energy absorption are highly valued in impact-protection and shock-mitigation applications. However, conventional systems typically depend on viscoelastic damping or irreversible sacrificial bonds, which lead to slow recovery, progressive mechanical fatigue, and long-term biological persistence. Herein, we report three engineered carbohydrate-based closed-cell PUFs using dextrose ( D-GP-PUF ), glucose ( G-GP-PUF ), chitosan ( C-GP-PUF ), glycerol propoxylate, and diisocyanate as a cross-linker to achieve enhanced mechanical robustness and resilience. These sustainable and reusable foams possess robust mechanical strength, hydrophobicity, thermal insulation, and chemical/heat stability, making them highly promising for packaging and protective applications. Their closed-cell morphology was confirmed by SEM and demonstrates flexibility, low density, and a high compressive modulus, while the air-filled pores contribute to optimized stability. Mechanical testing reveals a minimal deformation over repeated compression cycles, underscoring exceptional durability. Thermal analyses classify D-GP-PUF as a highly stable material, and soil burial studies confirm the slow biodegradability, with the most degradation being displayed by D-GP-PUF among all. Importantly, the reduced coefficient of restitution (COR 0.7 → 0.32) highlights efficient energy absorption, aligning with impact-attenuation behavior seen in advanced hydrogel systems. Similar to the synergistic covalent–supramolecular networks, these carbohydrate-based PUFs dissipate mechanical energy while maintaining recovery and reusability, offering a rational design pathway toward sustainable, shock-absorbing materials for sports, defense, and consumer packaging sectors.