Structurally Tailoring Clay Nanosheets to Design Emerging Macrofibers with Tunable Mechanical Properties and Thermal Behavior

Bio-derived nanomaterials are promising candidates for spinning high-performance sustainable textiles, but the inherent flammability of biomass-based fibers seriously limits their applications. There is still an urgent need to improve fiber flame retardancy while maintaining excellent mechanical performance. Here, inspired by the structural properties of layered nanoclay, we report a novel and efficient strategy to synthesize the strong, super tough, and flame-retardant nanocellulose/clay/sodium alginate (CRS) macrofibers via wet-spinning and directional drying. Benefiting from the precise modulation of arrangement and orientation of nanoclay in macrofibers, the new inorganic structure exhibits excellent mechanical and thermal functional properties. The anisotropic structure contributes to high toughness: the tensile strength was 373.3 MPa and the toughness was 26.92 MJ·m-3. Remarkably, rectorite nanosheets as a thermal and qualitative insulator significantly improve the flame retardancy of the CRS fibers with a heat release rate as low as 6.07 W/g, thermal conductivity of 90.5 mW/(m·K), and good temperature tolerance (ranging from -196 to 100 °C). This facile and high-efficiency strategy may have great scalability in manufacturing high-strength, super tough, and flame-retardant fibers for emerging biodegradable next-generation artificial fibers.