Comprehensive enhancement of flame retardant starch/cellulose/diatomite composite foams via metal-organic coordination

In recent years, considerable attention has been given to the utilization of biomass for producing bio-based foams, such as starch-based foams. Despite their renewability and widespread availability, these foams still present certain drawbacks regarding their poor mechanical properties and flammability. To tackle these concerns, a metal ion cross-linking strategy was employed by incorporating calcium ions (Ca2+) solution into foamed starch/cellulose slurry. Followed by ambient drying, starch/cellulose composite foam was successfully fabricated with a remarkable enhancement in various properties. Specifically, compared to the control sample, the compressive strength and modulus increased by 26.2 % and 123.0 %, respectively. Additionally, the Ca2+ cross-linked starch/cellulose composite foam exhibited excellent heat resistance, water stability, and flame retardancy. The limiting oxygen index (LOI) reached 52 %, with a vertical combustion rating of V-0. Along with the addition of 2 phr diatomite, it demonstrated a significant enhancement on flame retardancy with a LOI of 65 %, although the apparent density of the composite foam was not low enough. This study indicated a green and simple method to obtain starch-based composite foams with enhanced comprehensive properties including thermal, water stability, mechanical, and flame retardancy, expanding their potential applications in areas such as building materials and rigid packaging.