Eco-Fabrication of Rigid Lignofoams with Porous Cellular Channels Coated by Polypropylene Films for Thermal Insulation Materials

This paper introduced a simple, efficient method to prepare mechanically strong lignin-based foams (lignofoams) with open-cell structures using a facile baking technique. The self-expansion of lignin occurred without any additional chemical blowing agents, foaming agents, plasticizers, or lubricants. During heating, kraft lignin softened, and the internal water, either initially adsorbed or generated in situ through the dehydration of hydroxyl groups, acted as a natural blowing agent for foaming a porous foam structure. Incorporating a small amount of polypropylene (PP) enhanced mechanical properties by coating the inner walls of open cells. The porous, softened composite was then cooled to room temperature and solidified into the self-expanded lignofoam. The resulting lignofoams exhibited tunable densities ranging from 0.21 to 0.49 g/cm3 and a maximum compressive strength of 3.6 MPa. The lignofoam also showed excellent thermal insulation properties with low thermal conductive coefficients (0.057–0.098 W/mK). These features highlight the great potential of lignofoam for a bio-based thermal insulation material for construction applications.