DEVELOPING CELLULOSE-BASED FOAMS FROM COTTON WASTE

Kundavi Thanda

doi:10.7273/000007939

Foams are lightweight, porous materials extensively used in packaging, insulation, and cushioning applications, primarily due to their low density and versatile functionality. However, most industrial foams are produced from petroleum-based polymers such as polystyrene and polyurethane, which are non-biodegradable and persist in the environment for centuries, exacerbating the global plastic pollution crisis. Concurrently, the fashion and textile industries generate millions of tons of post-consumer waste annually, much of which consists of cotton and polyester blends that are challenging to recycle due to their composite nature and chemical treatments. The accumulation of both plastic and textile waste underscores an urgent need for sustainable alternatives. This thesis aims to address these pressing issues by developing biodegradable foams from recycled cotton cellulose, thereby reducing dependence on synthetic foams and providing a novel pathway for diverting substantial amounts of textile waste from landfills. To achieve these objectives, recycled cotton cellulose was systematically processed and formulated with various functional additives, including hollow glass bubbles for enhanced fire resistance and polyester fibers for improved water repellency. A series of composite foams was produced and characterized using analytical techniques, including measurement of density, pore size distribution, morphological structure, compressive strength, thermal stability, fire resistance, water absorption, and surface hydrophobicity. Key results demonstrated that the addition of glass bubbles significantly improved the thermal stability and fire resistance of the foams, while maintaining robust mechanical properties. Additionally, the incorporation of polyester fiber, especially when combined with silane surface treatment, effectively increased water repellency and maintained structural integrity after water exposure. Most formulations exhibited equal or superior performance compared to conventional foams, even after post-treatment tests such as fire or water absorption. Overall, this research provides compelling evidence that recycled cotton cellulose can be upcycled into high-performance, environmentally friendly foams, supporting the advancement of circular materials strategies in both the foam manufacturing and textile waste management sectors.

DEVELOPING CELLULOSE-BASED FOAMS FROM COTTON WASTE

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