Strong silica-nanocellulose anisotropic composite foams combine low thermal conductivity and low moisture uptake

We report the fabrication of anisotropic lightweight composite foams based on commercial colloidal silica particles and TEMPO-oxidized cellulose nanofibrils (TOCNF). The unidirectional ice-templating of silica-TOCNF dispersions resulted in anisotropic foams with columnar porous structures in which the inorganic and organic components were homogeneously distributed. The facile addition of silica particles yielded a significant enhancement in mechanical strength, compared to TOCNF-only foams, and a 3.5-fold increase in toughness at a density of 20 kg m−3. The shape of the silica particles had a large effect on the mechanical properties; anisotropic silica particles were found to strengthen the foams more efficiently than spherical particles. The water uptake of the foams and the axial thermal conductivity in humid air were reduced by the addition of silica. The composite foams were super-insulating at dry conditions at room temperature, with a radial thermal conductivity value as low as 24 mW m−1 K−1, and remained lower than 35 mW m−1 K−1 up to 80% relative humidity. The combination of high strength, low thermal conductivity and manageable moisture sensitivity suggests that silica-TOCNF composite foams could be an attractive alternative to the oil-based thermal insulating materials.