Eco-friendly bamboo pulp foam enabled by chitosan and phytic acid interfacial assembly of halloysite nanotubes: Toward flame retardancy, thermal insulation, and sound absorption

Lightweight, porous cellulose foam is an attractive alternative to traditional petroleum-based products, but the intrinsic flammability impedes its use in construction. Herein, an environmentally friendly strategy for scalable fabrication of flame-retardant bamboo pulp foam (BPF) using a foam-forming technique followed by low-cost ambient drying is reported. In the process, a hierarchical structure of halloysite nanotubes (HNT) was decorated onto bamboo pulp fibers through layer-by-layer assembling of chitosan (CS) and phytic acid (PA). This modification retained the highly porous microcellular structure of the resultant BPF (92 %–98 %). It improved its compressive strength by 228.01 % at 50 % strain, endowing this foam with desired thermal insulation properties and sound absorption coefficient comparable to commercial products. More importantly, this foam possessed exceptional flame retardancy (47.05 % reduction in the total heat release and 95.24 % reduction in the total smoke production) in cone calorimetry, and it showed excellent extinguishing performance, indicating considerably enhanced fire safety. These encouraging results suggest that the flame retardant BPF has the potential to serve as a renewable and cost-effective alternative to traditional foam for applications in acoustic and thermal insulation.