Ecofriendly cork composite foam with enhanced surface cleaning performance

Overview

This technology develops polyurethane (PU) foam composites filled with cork flakes, creating an ecofriendly material with enhanced surface cleaning performance. By incorporating cork—a natural, renewable filler with low density, hydrophobic character, fire resistance, and elastic behavior—the resulting composite foams offer improved sustainability compared to conventional PU foams. The approach leverages existing expertise in PU foam manufacturing and cork-based products to deliver a material suited for cleaning applications across multiple industries. Cork's inherent properties contribute to better mechanical performance and hydrophobic behavior, which directly support improved cleaning effectiveness.

Technical specifications

Key features:

• Cork flakes integrated into PU foam matrix as natural filler, enhancing sustainability
• Cork's hydrophobic character improves surface cleaning performance
• Cork's elastic behavior contributes to mechanical resilience of the foam
• Cork's fire resistance adds a safety advantage to the composite material
• Two production approaches: conventional slabstock foaming and 3D printing
• 3D printing enables tailored honeycomb structures, allowing precise adjustment of foam properties such as flexibility and permeability
• Foam formulation adjustable through raw-material selection and quantity optimization
• Cork granulate size and content optimized for best cleaning behavior

Technology readiness level

The technology is at an early-to-mid stage of development. The research team has previously published work on cork/PU 3D printed foams and bio-based PU foams, establishing a validated foundation. Current efforts focus on optimizing cork flake granulometry and quantity within the foam formulation, followed by mechanical testing, air permeability evaluation, and cleaning behavior assessment. Parallel work on 3D printed cork/TPU composite filaments aims to optimize geometry for cleaning applications. The team has active collaborations with national and international foam and cork-based product manufacturers, supporting further development and validation toward commercial readiness.