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Various methods of nonwoven composite materials manufacturing are known. One such method is the well-known technique called spun-bonding. The production technology for composite nonwoven by the spun-bond method is known, but the technique of introducing an additive in the form of shredded wastes of natural origin so as to obtain a composite nonwoven fabric with interesting functional properties is new. The article describes a method of producing an innovative composite nonwoven using the spun-bond technique. As a result of incorporating various additives into the nonwoven structure, composite nonwovens with modified properties are obtained. Composite nonwovens, depending on the additive used, can be utilised as filtration material in the construction, agriculture or automotive industry.

The possibility of using animal wastes in the form of feathers for the production of various types of composites is an extremely original concept, opening to researchers a wide field for experiments and interdisciplinary scientific research. This article presents the results of studies on the thermal stability of keratin from feathers originating from various poultry slaughterhouses, as well as an example of the use of feathers for the production of thermosetting composites. The keratin protein contained in feathers, like any protein, is very sensitive to various external factors, e.g. high temperature. The scientific goal of the research presented in the article was a deep analysis of changes occurring in the structure of keratin protein in feathers during heating. The technological goal was to develop new thermosetting composites based on spun-bonded nonwovens with the addition of keratin fibres from poultry feather wastes.

Viscoelastic polyurethane (VEPUR) foams with increased thermal resistance are presented in this article. VEPUR foams were manufactured with the use of various types of flame retardant additives and keratin fibers. The structure of the modified foams was determined by spectrophotometric-(FTIR), thermal-(DSC), and thermogravimetric (TGA) analyses as well as by scanning electron microscopy (SEM). We also assessed the fire resistance, hardness, and comfort coefficient (SAG factor). It was found that the use of keratin filler and flame retardant additives changed the foams’ structure and properties as well as their burning behavior. The highest fire resistance was achieved for foams containing keratin and expanding graphite, for which the reduction in heat release rate (HRR) compared to VEPUR foams reached 75%.

Semi-rigid composites of polyurethane foams (SRPUF) modified with the addition of keratin flour from poultry feathers and flame retardant additives were manufactured. Ten percent by mass of keratin fibers was added to the foams as well as halogen-free flame retardant additives such as Fyrol PNX, expandable graphite, metal oxides, in amounts such that their total mass did not exceed 15%. Thermal and mechanical properties were tested. Water absorption, dimensional stability, apparent density and flammability of produced foams were determined. It was found that the use of keratin fibers and flame retardant additives changes the foam synthesis process, changes their structure and properties as well as their combustion process. The addition of the filler made of keratin fibers significantly limits the amount of smoke generated during foam burning. The most favorable reduction of heat and smoke release rate was observed for foams with the addition of 10% keratin fibers and 10% expandable graphite. Systems of reducing combustibility of polyurethane foams using keratin fillers are a new solution on a global scale.