Natural sub-bituminous coal as filler enhances mechanical, insulation and flame retardant properties of coir-polypropylene bio-composites.

Additives provide substantial improvement in the properties of composites. Although bio-based composites are preferred over synthetic polymer and metal-based composites, they do not have the requisite properties to meet specific needs. Hence, organic, inorganic and metallic additives are included to improve the properties of bio-based composites. Coal is a readily available resource with high thermal insulation, flame resistance and other properties. This work demonstrates the addition of 20-30% natural sub-bituminous coal as filler for coir-reinforced polypropylene (PP) composites and exhibits an increased tensile strength by 66% and flexural strength by 55% compared to the composites without any filler. Such composites are intended for insulation applications and as a replacement for gypsum-based false ceiling tiles. Various ratios of coal samples were included in the composites and their effect on mechanical, acoustic, thermal insulation, flame and water resistance have been determined. A substantial improvement in both flexural and tensile properties has been observed due to the addition of coal. However, a marginal improvement has been observed in both thermal conductivity (0.65 W/mK) and flame resistance values due to the presence of coal. Adding coal increases the intensity of noise absorption, particularly at a higher frequency, whereas water sorption of the composites tends to decrease with an increase in the coal content. The addition of coal improves and adds unique properties to composites, allowing coir-coal-PP composites to outperform commercially available gypsum-based insulation panels.