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In this research effort, phenol-formaldehyde-lignin (PFL) resin was prepared using phenol, formaldehyde, and lignin  via  a simple approach. The PFL-polyurethane (PFL-PU) was prepared using PU prepolymer and PFL resin. The blend components were then foamed  via  addition of Tween 80 surfactant and n-pentane as the blowing agent. Short glass fiber was reinforced in the blend sample to attain high performance composite foams. The composite foams were characterized for structure, morphology, stress-strain behavior, friability tests, and shape memory characteristics. Scanning electron microscopy showed a layered, porous, and distorted hexagonal shaped foam structure. The cell size ranges from 10 to 20 μm for PFL-PU-short glass fiber (SGF) Foam with 10–20 wt.% fiber loading. PFL-PU Foam had compression strength and strain of 48.3 MPa and 48.2%. The PFL-PU-SGF 1–20 Foam showed increase in strength from 55.1 to 101.7 MPa and decrease in strain from 57.8% to 35.8% due to filler addition. At temperature above T g  (130°C), the strain was increased up to 45.11%. The shape fixity was improved up to the addition of 10 wt.% filler where the value of 92.1% was achieved with shape recovery of 95%.

journal of polymer engineering

Fabrication of short glass fiber reinforced phenol-formaldehyde-lignin and polyurethane-based composite foam: mechanical, friability, and shape memory studies