Researchers from Beijing Forestry University are turning cardboard waste into an upcycled cushioning foam, which, according to its developers, proved stronger and more insulating than traditional, plastic foam-based cushioning during a series of tests.

The team sought to develop a sturdy but lightweight mailing material alternative to the commonly used molded cushioning materials that are often derived from Styrofoam.

Source: Jinsheng GouSource: Jinsheng Gou

To create their cardboard waste-derived foam, the team used a blender to break down cardboard scraps, turning it into a pulp, which was then mixed with either gelatin or polyvinyl acetate (PVA) glue. Once combined, the mixture was poured into molds which were subsequently refrigerated, then freeze-dried to create the cushioning foams.

The team reported that the paper-based foams proved suitable thermal insulators and strong energy absorbers with suggestions that they even outperformed some plastic foams.

Additionally, a heavy-duty version of wastepaper foam was also developed by combining pulp, gelatin, PVA glue and a silica-based fluid that hardens when force is applied. During testing, this iteration of wastepaper foam successfully endured hits from a hammer without being destroyed. The team suggests that this iteration of foam might be appropriate for use in force-intensive deliveries, such as parachute-free airdrops.

The cardboard-derived foam is detailed in the article, “Biodegradable Wastepaper-Based Foam with Ultrahigh Energy-Absorbing, Excellent Thermal Insulation, and Outstanding Cushioning Properties,” which appears in the journal ACS Sustainable Chemistry & Engineering.

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