Green and Fire Resistant Nanocellulose/Hemicellulose/Clay Foams

Lightweight polymer foams from synthetic polymers are commonly used in a wide-spread spectrum of application fields. Their intrinsic flammability coupled with restrictions on flame retardant chemicals poses a severe threat to safety. Here, fire resistant foams comprising biobased components capable of replacing petroleum-based foams are investigated. Cellulose nanofibers are combined with 2D montmorillonite nanoplatelets and a native xyloglucan hemicellulose binder, using a water-based freeze casting approach. Due to the silicate nanoplatelets, these lightweight foams self-extinguish the flame during flammability tests. The limiting oxygen index is as high as 31.5% and in the same range as the best fire-retardant synthetic foams available. In cone calorimetry, the foams display extremely low combustion rates. Smoke release is near the detection limit of the instrument. In addition, the foams are withstanding the penetration of a flame torch focused on one side of the specimen (T on surface 800 °C) and structural integrity is maintained. At the same time, the unexposed side is insulated, as demonstrated by a through-thickness temperature drop of 680 °C cm−1. The results represent a tremendous opportunity for the development of fire-safe foams combining excellent sustainability with multifunctional performance.