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Fully biobased thermal insulating aerogels with superior fire-retardant and mechanical properties

Biomass-based aerogels offer a promising potential as alternatives to plastic-based foams for thermal insulation applications. However, their inherent flammability has hindered their practical usage. In this work, we addressed this issue by employing a layer-by-layer assembly technique to deposit two oppositely charged biobased materials, namely phytic acid and chitosan, onto a fully biobased aerogel system. These aerogels were fabricated using cellulose filaments and chitosan and cross-linked with citric acid, resulting in a mechanically robust 3D structure. The synergistic effects of phytic acid and chitosan in the layer-by-layer deposited aerogels significantly enhanced their fire resistance and mechanical strength. The developed aerogel with six bilayer depositions (LBL6), showed an outstanding peak heat release rate (pHRR) of 6.0 kW.m−2, and total heat release (THR) of 0.4 MJ.m−2, substantially lower than the previously developed cellulose-based aerogels and foams. LBL6 also demonstrated immediate self-extinguishing behaviour, boasting an impressive limiting oxygen index (LOI) value of 63 %, which is the highest reported for a biobased aerogel. Furthermore, the developed aerogels exhibited a superior Young’s modulus of up to 4.5 MPa, surpassing previously developed flame-retardant aerogels. Additionally, they excelled in thermal insulation properties, with a thermal conductivity of less than 38.2 mW·m1·K1, placing them in the same range as, or even lower than, commercially available thermal insulators. Given the simplicity of the aerogel development process and the well-known advantages of a completely biobased system, our developed aerogels present a sustainable and environmentally friendly alternative to current commercial thermal insulators that are derived from petroleum-based materials.

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