New alginate foams: Box-Behnken design of their manufacturing; fire retardant and thermal insulating properties

Scalable Production of Biodegradable, Recyclable, Sustainable Cellulose-Mineral Foams via Coordination Interaction Assisted Ambient Drying

Heavy reliance on petrochemical-based plastic foams in both industry and society has led to severe plastic pollution (the so-called "white pollution"). In this work, we develop a biodegradable, recyclable, and sustainable cellulose/bentonite (Cel/BT) foam material directly from resource-abundant natural materials (i.e., lignocellulosic biomass and minerals) via ambient drying. The strong resistance to the capillary force-driven structural collapse of the preformed three-dimensional (3D) network during the ambient drying process can be ascribed to the purpose-designed cellulose-bentonite coordination interaction, which provides a practical way for the locally scalable production of foam materials with designed shapes without complex processing and intensive energy consumption. Benefiting from the strong cellulose-bentonite coordination interaction, the Cel/BT foam material demonstrates high mechanical strength and outstanding thermal stability, outperforming commercial plastic polystyrene foam. Furthermore, the Cel/BT foam presents environmental impacts much lower than those of petrochemical-based plastic foams as it can be 100% recycled in a closed-loop recycling process and easily biodegraded in the environment (natural cellulose goes back to the carbon cycle, and bentonite minerals return to the geological cycle). This study demonstrates an energy-efficient ambient drying approach for the local and scalable production of an all-natural cellulose/bentonite foam for sustainable packaging, buildings, and beyond, presenting great potential in response to "white pollution" and resource shortage.

One-Step Generation of Alginate-Based Hydrogel Foams Using CO2 for Simultaneous Foaming and Gelation

The reliable generation of hydrogel foams remains a challenge in a wide range of sectors, including food, cosmetic, agricultural, and medical applications. Using the example of calcium alginate foams, we introduce a novel foam generation method that uses CO₂ for the simultaneous foaming and pH reduction of the alginate solution to trigger gelation. We show that gelled foams of different gas fractions can be generated in a simple one-step process. We macroscopically follow the acidification using a pH-responsive indicator and investigate the role of CO₂ in foam ageing via foam stability measurements. Finally, we demonstrate the utility of interfacial rheology to provide evidence for the gelation process initiated by the dissolution of the CO₂ from the dispersed phase. Both approaches, gas-initiated gelation and interfacial rheology for its characterization, can be readily transferred to other types of gases and formulations.

Recycling alginate composites for thermal insulation

We present a new method for the total functional recycling of alginate-based composite materials made via ionotropic gelation. The original material, an alginate/fiberglass foam with thermal insulation characteristics, was produced following a patented process in which fiberglass waste is embedded into the polyanionic gel matrix, and the resulting compound is then freeze-dried. The functional recycling is carried out by disassembling the ionic matrix - which is initially formed by the interaction between a cation (e.g. calcium) and the negatively charged alginate backbone - with the use of a chelator (Ethylenediaminetetraacetic acid disodium salt) with a high affinity for the cations, thus obtaining a homogeneous solution. An ionotropic gel can then be re-formed upon deactivation of the chelating activity under mild acid conditions. We managed to maintain or improve the thermal, mechanical and acoustic performances of the original material and we successfully tested the possibility of multiple recycling cycles.

Fire behavior of innovative alginate foams

A new biosourced composite foam (AF, associating foamed alginate matrix and orange peel filler) is successfully tested for fire-retardant properties. This material having similar thermal insulating properties and density than fire-retardant polyurethane foam (FR-PUF, a commercial product) shows promising enhanced properties for flame retardancy, as assessed by different methods such as thermogravimetric analysis (TGA), pyrolysis combustion flow calorimetry (PCFC) and a newly designed apparatus called RAPACES for investigating large-scale samples. All these methods confirm the promising properties of this alternative material in terms of fire protection (pHRR, THR, EHC, time-to-ignition, flame duration or production of residue), especially for heat flux not exceeding 50 kW m^-2. At higher heat flux (i.e., 75 kW m^-2), flame retardant properties tend to decrease but maintain at a higher level than FR-PUF. The investigation of the effect of AF thickness shows that the critical thickness (CT) is close to 1.5-1.7 cm: heat diffusion and material combustion are limited to the CT layer that protects the underlying layers from combustion. A multiplicity of factors can explain this behavior, such as: (a) negligible heat conduction, (b) low heat of combustion, (c) charring formation, and (d) water release. Water being released from underlying layers, dilutes the gases emitted during the combustion of superficial layers and promotes the flame extinction.

On-Demand Microwave-Assisted Fabrication of Gelatin Foams

Ultraporous gelatin foams (porosity >94%, ρ ≈ 0.039–0.056 g/cm³) have been fabricated via microwave radiation. The resulting foam structures are unique with regard to pore morphology (i.e., closed-cell) and exhibit 100% macroporosity (pore size 332 to 1700 μm), presence of an external skin, and densities similar to aerogels. Results indicate that the primary foaming mechanism is governed by the vaporization of water that is tightly bound in secondary structures (i.e., helices, β-turns, β-sheets) that are present in dehydrated gelatin films but not present in the foams after microwave radiation (700 Watts).