Innovative approach to enhance molded pulp biocomposites: unleashing the potential of silica aerogel through in-situ polymerization via vacuum impregnation Ajit Kumar Singh 1 , Seok Choi 2 , Youn Suk Lee 1 1 Department of Packaging, Yonsei University, South Korea, 2 Thermo Lab Korea Ltd., South Korea Molded pulp, derived from recycled paper, has emerged as a sustainable alternative to single-use packaging materials, addressing concerns related to non-biodegradable plastics and promoting environmental consciousness. However, challenges regarding water resistance and thermal insulation remain, particularly when compared to conventional plastic packaging. In this study, we present a novel technique utilizing vacuum impregnation (VI) to enhance the desired characteristics of molded pulp biocomposites. Leveraging the unique attributes of silica aerogel (SA), such as its nanoporous structure, high porosity, specific surface area, low density, and thermal conductivity, we aim to incorporate SA into the porous structure of recycled paper-based molded pulp packaging materials. This integration is achieved through a facile VI process using commercially available SA powders suspended in ethanol at varying weight percentages (0.1%, 0.5%, and 1.0%) to impregnate the pulp composites. The results demonstrate a significant improvement in water resistance and thermal stability for the SA-impregnated pulp biocomposites. Notably, reduced water absorption is observed through water absorptivity and Cobb 120 values, with the optimal performance achieved using sheets impregnated with 0.5% and 1.0% SA. Additionally, contact angle measurements indicate an increase in hydrophobicity, a crucial factor for effective packaging applications. These findings highlight the viability of SA impregnation using VI as a strategy for enhancing the functional attributes of molded pulp biocomposites, offering an innovative and efficient approach to achieving biodegradability and sustainability in packaging applications. Keywords: Molded pulp; Recycled paper; Vacuum impregnation; Superhydrophobicity; Thermal stability; Sustainable packaging
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