Evaluation of the Performance of Bio-Based Rigid Polyurethane Foam with High Amounts of Sunflower Press Cake Particles

In the current study, rigid polyurethane foam (PUR) was modified with 10–30 wt.% sunflower press cake (SFP) filler, and its effect on performance characteristics—i.e., rheology, characteristic foaming times, apparent density, thermal conductivity, compressive strength parallel and perpendicular to the foaming directions, tensile strength, and short-term water absorption by partial immersion—was evaluated. Microstructural and statistical analyses were implemented as well. During the study, it was determined that 10–20 wt.% SFP filler showed the greatest positive impact. For instance, the thermal conductivity value improved by 9% and 17%, respectively, while mechanical performance, i.e., compressive strength, increased by 11% and 28% in the perpendicular direction and by 43% and 67% in the parallel direction. Moreover, tensile strength showed 49% and 61% increments, respectively, at 10 wt.% and 20 wt.% SFP filler. Most importantly, SFP filler-modified PUR foams were characterised by two times lower water absorption values and improved microstructures with a reduced average cell size and increased content in closed cells.