Effect of Filler Particle Size on the Mechanical and Acoustic Performance of Rigid Polyurethane Foam/Aluminosilicate Microsphere Composites

Rigid polyurethane foams (RPUFs) are widely used as lightweight thermal insulation materials. Their properties can be improved by incorporating inorganic fillers. However, the effect of filler particle size has not been sufficiently investigated. This study examines the influence of aluminosilicate microsphere diameter (80, 150, 300, and 500 μm) on the properties of RPUFs. Foams containing 10 wt.% microspheres (M) were prepared by the free-rise method. Their cellular structure, apparent density, mechanical, acoustic, thermal, and thermomechanical properties were evaluated. The addition of microspheres reduced the average cell diameter from 184 ± 29 μm for PU_0 to 147–174 μm, depending on microsphere size, and increased the apparent density from 31.3 to approximately 37 kg·m−3. The compressive strength decreased from 186 ± 6 kPa for PU_0 to 159 ± 2 kPa for PU_500M, whereas the tensile strength increased from 257 ± 14 kPa for PU_0 to 323 ± 14 kPa for PU_500M. The highest average sound absorption coefficient (0.14) was obtained for PU_300M, representing a 75% improvement over PU_0 (0.08). The composites also showed improved thermal stability and storage modulus. Among the investigated composites, PU_300M exhibited the most balanced combination of mechanical and acoustic properties.