Performance enhancements of PU composite foams reinforced with starfish particles chemically treated by silane derivatives

Polyurethane (PU) foams have excellent shock absorption and noise blocking effects and therefore are widely used as cushioning and sound-absorbing materials in the automobile industry. In this study, PU composite foams containing raw and chemically treated starfish particles were manufactured, and their effects on the morphology, sound absorption, comfort and dynamic mechanical properties were investigated. The surface of the raw starfish particles was modified with silane coupling agents to improve the interfacial compatibility between the fillers and matrix, which is key to improving the physical properties of polymer composite materials. However, excessive filler content leads to particle aggregation and subsequent PU matrix defects, necessitating the use of the optimal filler content. Cell morphology analysis of the manufactures PU composite foams revealed that their cavity and pore sizes, as well as their open porosity, were reduced, resulting in high sound scattering or reflection and improved sound absorption properties. The manufactured PU composite foams also exhibited increased sag factor, storage modulus, and loss modulus.