Design and optimization of fully (100%) cellulose-based polyurethane foams: Strategies, challenges, and solutions for
Sunanda Roy1, Jieun Lee2, Hoa Duc Pham2
1CRC for Nanocellulose Future Composites, Mechanical Engineering, Inha University, 100 Inha-Ro, Incheon, 22212, South Korea; Mechanical Engineering, ASAE, Alliance University, Bengaluru, 562106, India.
International Journal of Biological Macromolecules
|June 3, 2026
Summary
This study successfully synthesized pure cellulose-based polyurethane (PU) films and foams using hardwood pulp as a 100% bio-based polyol. This sustainable approach offers a novel pathway for high-performance, eco-friendly polyurethane materials.
Area of Science:
- Polymer Chemistry
- Sustainable Materials Science
- Biotechnology
Background:
- Polyurethanes (PUs) are vital industrial polymers traditionally derived from petroleum.
- Growing demand for sustainable materials necessitates alternatives to petroleum-based feedstocks.
- Cellulose, an abundant biopolymer, presents a potential renewable resource for PU synthesis, but challenges exist.
Purpose of the Study:
- To report the first synthesis of pure cellulose-based polyurethane (PU) using cellulose as the sole polyol.
- To explore the use of different cellulose types (CNFs, CNCs, HW pulp, LC) as bio-based polyols for PU.
- To develop novel cellulose-based PU films and foams.
Main Methods:
- Synthesis of polyurethanes using four distinct cellulose types as 100% bio-based polyols.
- Characterization of PU formation using FTIR and XPS spectroscopy.
- Thermal stability assessment via thermogravimetric analysis (TGA).
- Morphological analysis of cellulose materials before and after PU synthesis.
- Dissolution of hardwood (HW)-PU in ionic liquid for film and foam formation.
Main Results:
- Successful synthesis of pure cellulose-based PUs confirmed by FTIR and XPS.
- Hardwood (HW) pulp demonstrated the highest reactivity and resulted in the most thermally stable PU (HW-PU).
- Morphological studies provided insights into the physicochemical transformations during PU synthesis.
- HW-PU was successfully processed into soft films and foams using an ionic liquid solvent.
Conclusions:
- Hardwood pulp is a highly promising 100% bio-based polyol for synthesizing high-performance polyurethanes.
- This research establishes a novel method for creating cellulose-based PU films and foams, advancing sustainable polymer technology.
- The findings open new avenues for utilizing abundant lignocellulosic biomass in next-generation polyurethane applications.
