ABSTRACT
Traditionally, calcium carbonate is used as a filler in foam industries and studies have shown that egg-shell contains about 94 % calcium carbonate. The effect of egg-shell in flexible polyurethane foam was studied in this work. Foam with no filler was produced as a control. The egg-shell was beneficiated, characterized and used as filler in flexible polyurethane foam production with varying loads from 5w% to 15 w% at 2.5 w% interval. The effect of various particle sizes on the egg-shell was also studied. Conventional calcium carbonate was also used and the result compared against the produced egg-shell filled foam samples. The produced samples were characterized for compression set, indentation hardness, elongation at break, tensile strength, heat ageing elongation and tensile strength, support factor and density. Scanning electron microscopy (SEM) was also used to study the foam?s morphology. The result of beneficiation showed that the amount of CaCO3 increased by 1.355 % after beneficiating the egg-shell. The results indicated that 45 μm particle size egg-shell was better in most of the properties than other particle sizes tested, with values closest to the control. The highest elongation, tensile strength before and after heat ageing were obtained at 5 wt% of egg-shell. The results also showed that the egg-shell filled foams at 63 μm particle size and 5 wt% loading for tensile strength and elongation before and after heat ageing tests were higher than calcium carbonate filled foam by 1.04 %, 2.66 kN/m2, 0.82 % and 2.22 kN/m2, respectively. In all cases, the density increase with increase in filler loading and particle size. The SEM analysis showed that cell openings of the produced filled foams decreased as particle size and filler content were increased.