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Research advances in the functionalization of hollow plant fibers and their application as thermal insulation fillers
*Corresponding authors: E-mail addresses: lijp@caf.ac.cn (J. Li), y.lu@caf.ac.cn (Y. Lu)
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Received: ,
Accepted: ,
Abstract
Resisting cold environments remains a critical challenge for human survival. Traditional cold-weather garments, however, suffer from inadequate thermal insulation, excessive weight, and limited breathability, thereby compromising comfort. Additionally, the environmental impact of petroleum-based synthetic fibers underscores the need for sustainable alternatives. This review explores the potential of hollow plant fibers, including willow catkins, as sustainable and high-performance thermal insulation fillers. It aims to address the limitations of conventional thermal insulation materials while promoting the utilization of agricultural and forestry waste. The study systematically examines the structural characteristics of hollow plant fibers, including their unique lumen morphology, pore alignment, and natural wax coatings. It also evaluates their physical and chemical properties, with a particular focus on thermal insulation, hydrophobicity, and antimicrobial performance. Current modification techniques are critically reviewed to enhance their functional properties. Results demonstrate that hollow plant fibers exhibit exceptional thermal insulation, outperforming traditional materials such as polyester and wool. Their hydrophobic wax coatings and porous structures enable efficient moisture management, and their inherent antimicrobial properties improve hygiene. Modified fibers show enhanced durability, flame resistance, and compressibility, making them viable for applications in apparel, sportswear, and medical textiles. Innovations, such as phase-change composites and aerogels, further expand their utility in dynamic thermal regulation. In conclusion, hollow plant fibers represent a sustainable and multifunctional alternative to conventional insulation materials. This work provides a foundation for advancing eco-friendly thermal insulation solutions and the high-value utilization of biomass waste.
Keywords
Hollow plant fibers
Modification
Pore structure
Structural characteristics
Thermal insulation

1. Introduction
For millennia, human survival has been a constant struggle against external environmental conditions, among which ambient temperature stands out as the most critical factor directly affecting normal physiological activities. From the use of animal hides and leaves for cold protection in ancient times, to the adoption of cotton and linen textiles during the agricultural era, and further to the emergence of synthetic fibers following the Industrial Revolution, the evolution of thermal insulating materials has been inextricably linked to the advancement of human civilization. With the intensification of global climate change and the deepening of sustainable development principles, conventional insulating materials now face unprecedented challenges. Consequently, the pursuit of novel thermal insulating materials that combine superior performance with environmental compatibility has become a key research focus.
In the quest for more efficient thermal insulation solutions, scientists have turned their attention to fiber structures. Inspired by the unique hollow tubular architecture of polar bear hair, Cui et al. [1] successfully fabricated porous silk fibroin fibers through biomimetic design. These bioinspired fibers feature internally aligned microcavities that effectively trap stationary air. Given the extremely low thermal conductivity of air, these enclosed cavities form multiple thermal resistance barriers, significantly suppressing heat conduction and convective dissipation [2].
Waste utilization represents a crucial practice in sustainable development [3]. The substitution of raw materials with waste-derived alternatives can achieve dual benefits of enhanced efficiency and cost reduction [4-7]. Hollow plant fibers exhibit remarkable diversity and abundance [8]. However, their inherent dust particles degrade air quality, trigger respiratory allergies, and even pose fire hazards [9], leading to their conventional classification as agricultural waste. Nevertheless, their unique hollow structure and porous surface morphology enable effective air entrapment, significantly reducing heat convection and conduction, thereby demonstrating considerable potential for thermal insulation applications [10]. Compared to conventional insulating materials, hollow plant fibers combine lightweight properties with superior thermal performance. Their chemical composition further confers natural anti-mite, antibacterial, hydrophobic, and moisture-wicking properties [11], showing promise for developing functional textiles and creating new markets for thermal insulation batting.
Building upon these superior properties, hollow plant fibers demonstrate tremendous potential for the development of functional textiles and the exploration of novel thermal insulation material markets. Nevertheless, current research still lacks a comprehensive understanding of the structure-property relationship between their multiscale structural characteristics and their exceptional thermal insulation performance. Furthermore, systematic methodologies for functional modification strategies addressing their intrinsic limitations remain underdeveloped. Concurrently, the application of hollow plant fibers in thermal insulation remains in the exploratory phase. These critical scientific challenges and technical bottlenecks motivate the present review study, which aims to provide both theoretical guidance and a technical roadmap for developing next-generation sustainable high-performance thermal insulation materials.
This review systematically addresses three key research objectives: to comprehensively characterize the unique structural features and physicochemical properties of hollow plant fibers that contribute to their thermal insulation performance; to critically evaluate current modification strategies for enhancing their functional properties, including mechanical reinforcement, superhydrophobic treatment, and flame-retardant modification; and to assess their application potential as sustainable alternatives to conventional insulation materials in textiles and related fields. By focusing on these objectives, this review aims to provide a thorough understanding of the feasibility of utilizing hollow plant fibers as effective and sustainable thermal insulation materials. Through multidimensional analysis, fundamental structure-property relationships are established, and practical insights are offered for developing next-generation bio-based thermal insulation materials.
2. Botanical origins and structural diversity of hollow plant fibers
Hollow plant fibers are a type of fiber commonly found in nature, exhibiting distinct structural characteristics due to their hollow tubular cavity (Figure 1). These fibers originate from specific plant tissues, such as seeds and fruits, and function in structural support, protection, and nutrient transport during plant growth [12]. According to the source of the fiber, hollow plant fibers can be divided into seed fibers, leaf fibers, bast fibers, and fruit fibers. For example, willow catkins are the seed hair attached to the seed when the female capsule matures [13], Calotropis fiber is extracted from the sword hemp leaf [14], hemp fiber comes from the primary phloem outside the stem [15], and coconut shell fiber is located in the fruit part of the coconut [16]. Based on their structure characteristics, hollow plant fibers can be divided into unicellular fibers and multicellular fiber bundles. For example, Kapok and Calotropis fibers [17] are composed of single cells, whereas flax fiber [18] is a hollow fiber bundle formed by the tight arrangement of multiple fiber cells. As a valuable biomass resource, the natural reserves of hollow plant fibers are extraordinarily abundant. According to statistical data, approximately 284,000 poplar trees in Beijing can produce an average of 25 kg of poplar catkins per tree annually [8]. Despite their considerable abundance, these fibers are predominantly relegated to non-pulp portions and have limited application value. Consequently, they are frequently disposed of as agricultural or forestry waste, thereby underutilizing their potential as a valuable biomass resource.
Despite being treated as waste, hollow plant fibers were historically utilized as cost-effective fillers. As early as in the 18th century, Germany began utilizing Calotropis fibers as high-quality filling material for warm bedding. In the early 20th century, Chinese botanical records also documented that the Calotropis gigantea fibers could serve as raw materials for velvet production and filling, due to their low cost, low thermal conductivity, low density, and high fluffiness. In 2006, poplar catkins were designated as “German annual fiber.” However, the unique lumen structure and special chemical composition of hollow plant fibers endow them with multifunctional applications, which has garnered increasing attention in recent years [19,20]. These fibers have been widely applied in various fields, including adsorption [21], supercapacitors [22], and electromagnetic wave absorption [23].
3. Structural characteristics of hollow plant fibers
3.1. Morphological structure
Hollow plant fibers, including Willow Catkins, possess a distinct hollow lumen structure. The fiber diameters are approximately 10 times the thickness of their cell walls, resulting in a hollowness ratio reaching as high as 90% [14]. Under brief compression, hollow plant fibers retain intact cell walls, and the collapsed lumens recover readily when released. Kapok fiber is acknowledged as one of the finest natural cellulose fibers, with an average length ranging from 14.5 to 27.5 mm and a diameter of 15-35 μm (lumen diameter: 13.2-16 μm) [26]. The high aspect ratio of these fibers facilitates the formation of additional air layers between them, effectively reducing heat conduction. Furthermore, their non-crimping characteristic contributes to maintaining the structural stability of filling materials, preventing fiber aggregation and ensuring high loftiness, which enhances thermal insulation performance. Scanning electron microscopy (SEM) observations reveal that Kapok fibers exhibit a cylindrical hollow morphology, with both ends sealed: one end is bulbous, while the other tapers gradually. The fiber surface is completely covered by a wax coating, leading to a smooth texture without noticeable roughness [27]. Brunauer-Emmett-Teller (BET) multilayer adsorption analysis indicates that Kapok fibers possess a relatively large specific surface area of 2.99 m2/g [10].
3.2. Wall layer structure
The cell walls of Kapok and similar fibers are approximately 1 μm in thickness, predominantly consisting of helically arranged cellulose microfibril bands, with the helical seams filled with lignin and hemicellulose [28]. Analogous to wood fibers, hollow plant fibers feature a complex, layered cell wall structure. As depicted in Figure 2, both cross-sectional and longitudinal views distinctly reveal multiple layers: the cuticle (S), the cell wall layers (W3, W2, W1), and the inner layer (IS) [29]. The S-layer, serving as the protective outermost layer, demonstrates the highest packing density and the smallest thickness (40-70 nm). The IS-layer, slightly thicker than the S-layer, possesses a looser structure, enabling microfibrils to detach easily and disperse into the lumen. The W1-layer comprises an interwoven network of microfibrils (∼200 nm thick), whereas the W2- and W3-layers consist of axially aligned microfibrils (∼500 nm thick). The W1 and W3 layers are more densely packed compared to W2, and transition zones with low packing density exist between adjacent layers [30]. Notably, the cell walls of hollow plant fibers contain parallel, continuously open pores, with 80% of the total pore volume comprising pores ranging from 2-40 nm in diameter [10]. The presence of abundant nanopores (2-40 nm) in the cell walls, which are nearly two orders of magnitude larger than water vapor molecules (0.33 nm), creates an interconnected capillary network that enables exceptionally rapid moisture diffusion. This unique porous architecture, combined with the gradient density distribution from the dense outer cuticle to the loose inner layer, not only endows hollow plant fiber-based fabrics with superior breathability and moisture-wicking properties but also maintains structural integrity during repeated wetting-drying cycles, making them ideal for sustainable textile applications requiring both comfort and durability.
![Morphology, cell wall structure, and composition distribution model of Kapok fiber [26].](/content/184/2026/19/3/img/AJC-19-6692025-g3.png)
- Morphology, cell wall structure, and composition distribution model of Kapok fiber [26].
3.3. Molecular structure
Hollow plant fibers, exemplified by willow catkin fibers, are predominantly composed of cellulose, hemicellulose, and lignin [8], along with a minor amount of waxy substances [30]. As illustrated in Table 1, the precise composition of these components varies across different types of hollow plant fibers. Cellulose, as the primary constituent, exhibits superior thermal insulation properties due to its low thermal conductivity, making it highly suitable for heat preservation applications [31]. Additionally, certain hollow plant fibers, such as Kapok fibers, contain approximately 3% waxy substances, which play a critical role in conferring hydrophobicity, antibacterial characteristics, and pest resistance to the fibers [13,32].
Beyond chemical composition, hollow plant fibers share a conserved molecular architecture. Figure 2 illustrates the multi-assembly structure of Kapok fibers, where cellulose molecules aggregate into microfibril bundles via hydrogen bonding, aligning parallel to the fiber axis to form the structural framework. Hemicellulose, characterized by its short-branched chains, fills the interstitial spaces between microfibrils. Additionally, the hydroxyl groups on lignin’s phenyl rings form hydrogen bonds with the hydroxyl groups of cellulose glucose units, cross-linking as lignin-carbohydrate complexes (LCCs) to reinforce the fiber cell wall [26].
The organization of fibrils varies across different wall layers [33]. In the W1 layer, cellulose molecules form a network-like structure; in the W2 and W3 layers, cellulose molecules are aligned at varying angles relative to the fiber axis. This intricate arrangement significantly enhances the mechanical strength of the cell wall. Within the fibrils, cellulose molecular chains exhibit a tendency to self-assemble into crystalline regions, while the inter-fibrillar regions consist of disordered chain segments that constitute amorphous regions [34].
The molecular assembly mechanism of hollow plant fibers demonstrates nature’s sophisticated material design strategy. The oriented arrangement of cellulose microfibrils combined with the interfacial crosslinking of hemicellulose and lignin forms a multiscale reinforced architecture, while the alternating distribution of crystalline and amorphous regions achieves an optimal balance between rigidity and flexibility. This hierarchical organization, spanning from molecular-level hydrogen bonding networks to supramolecular LCCS, and finally to microscale layered wall structures, not only explains the fibers’ exceptional thermal insulation and mechanical properties but also provides a theoretical framework for biomimetic material design. By precisely controlling the alignment of cellulose microfibrils and interfacial interactions, it becomes possible to engineer sustainable materials with tailored functionalities.
4. Performance evaluation of hollow plant fibers
4.1. Thermal insulation property
Hollow plant fibers possess a remarkable thermal insulation property due to the well-developed lumen structures and abundant mesopores, which effectively immobilize air. The trapped air forms stagnant layers that act as thermal barriers, isolating the human body from cold environments and significantly reducing heat transfer via conduction. Moreover, the cellulose component within hollow plant fibers, characterized by inherently low thermal conductivity, demonstrates robust capabilities in reflecting and scattering thermal radiation. The hollow structure further amplifies these effects by increasing the surface area available for thermal radiation reflection and scattering, thereby minimizing heat loss. As illustrated in Figure 3(a), human body heat primarily dissipates through radiation and convection [37]. For batting materials positioned between fabric layers, heat transfer occurs through two media (air and fibers) via three pathways: direct air conduction, fiber-to-fiber contact conduction, and interfacial conduction at the air-fiber boundary.
The study by Chen et al. [38] highlights the superior thermal insulation potential of poplar catkins, attributing this to their high fill power and thermal resistance. Fill power, a key metric for insulation capability, indicates the volume occupied by a unit mass of fiber. Poplar catkins exhibit a high fill power of 9,340 cm3/28.35g, outperforming down (7,210 cm3/28.35g) and wool (4,588 cm3/28.35g). This is due to their fine diameter and hollow structure. Thermal resistance, another critical indicator, shows poplar catkins have an Rct value of 0.316 m2°C/W, comparable to wool (0.331 m2°C/W) and polyester (Hollofil II, 0.310 m2°C/W), though slightly lower than down (0.354 m2°C/W). Using a thermal manikin, the study found poplar catkins match the thermal insulation performance of common natural and synthetic fibers. These results position poplar catkins as a promising material for warm clothing and textile products. Cui et al. [39] conducted a systematic study on the performance of kapok/down blended wadding and found that the thermal insulation properties of the blended material improved significantly with increasing Kapok content. When the Kapok content in the blended wadding increased from 0% to 50%, the thermal conductivity of the wadding decreased from 3.79×10-2 to 3.09×10-2 W/m·°K, while the heat retention rate increased by approximately 13%. Additionally, Kapok fibers exhibited superior bulkiness (172.2 cm3/g) and compression resistance compared to down fibrils, though repeated compression led to performance degradation due to lumen collapse. The study recommended using a blend of Kapok and whole down in non-repeated compression scenarios to balance thermal insulation, resource sustainability, and antibacterial properties. Figure 3(b) illustrates the research findings regarding composite nonwovens that integrate kapok and milkweed fibers, revealing a consistent reduction in thermal conductivity as the proportion of hollow fiber content increases [40]. These findings provide an important theoretical basis for developing lightweight, high-performance bio-based composite insulation materials.
4.2. Hydrophobicity and moisture management
Hollow plant fibers exhibit a unique combination of hydrophobicity and moisture management capabilities, attributable to their distinctive structural and compositional features. Kapok fibers, as exemplary hollow plant fibers, possess a natural wax coating primarily consisting of long-chain fatty acids and alcohols [11]. The nonpolar C-C and C-H bonds within these molecular structures preclude interaction with polar solvents such as water, thereby conferring inherent water repellency on the fibers. As shown in Figure 4, atomic force microscopy (AFM) observations disclose nanoscale surface wrinkles that form a micro-nano binary structure. This structure significantly enhances the hydrophobic properties of the fibers by inhibiting water droplet adhesion. The porous hydrophobic surface generates negative capillary pressure, effectively preventing liquid water penetration [41]. Upon contact with the fiber aggregate surface, water droplets experience repulsive forces that counteract gravitational effects, enabling them to retain spherical shapes and roll off swiftly without retention.
![(a) Height image, (b) phase image, (c) 3D view, and (d) Water Contact Angle (WCA) test of the Kapok fiber surface [41].](/content/184/2026/19/3/img/AJC-19-6692025-g5.png)
- (a) Height image, (b) phase image, (c) 3D view, and (d) Water Contact Angle (WCA) test of the Kapok fiber surface [41].
Remarkably, these fibers exhibit dynamic moisture regulation characterized by rapid water release and gradual absorption. Specifically, they demonstrate exceptional rates of moisture liberation [42]. Despite their surface hydrophobicity, which inhibits water droplet spreading, the internal lumen and pore structures are capable of absorbing and retaining a limited amount of moisture. Cellulose’s polar groups form hydrogen bonds with water, enabling humidity-dependent adsorption, while surface tension effects facilitate vapor diffusion into lumens [43]. Under conditions of high relative humidity, water vapor diffuses into the hollow cavities, showcasing unique moisture-wicking and absorption capabilities. This balanced moisture regulation enables hollow plant fibers to effectively modulate microclimate humidity, thus ensuring superior wearing comfort. Particularly noteworthy is the fibers’ ability to maintain rapid moisture liberation rates while achieving gradual absorption kinetics, a combination rarely found in synthetic textiles. These fundamental insights could inspire innovative designs for smart textiles requiring simultaneous water protection and breathability, such as sportswear, medical drapes, and protective clothing.
4.3. Mechanical properties
As presented in Table 2, hollow plant fibers, such as those of Kapok and Calotropis, exhibit relatively low tensile strength and bending stiffness [43]. This limitation in mechanical performance stems from their microporous structure and thin cell walls, which may constrain their applicability in spinning processes [44,45]. The variations in mechanical properties of hollow plant fibers can be ascribed to multiple factors, including fiber microstructure, processing techniques, and environmental conditions.
The cellulose content and the degree of orientation within the fine structure significantly influence the stiffness and strength of fibers [25]. Kapok fibers, characterized by a high crystallinity orientation index (COI) of 71.5%, tend to exhibit reduced flexibility, which may result in issues such as brittleness during spinning processes [46]. The processing of hollow plant fibers also has a notable impact on their mechanical properties. Mechanical forces exerted on these fibers disproportionately affect weaker regions. For example, the spiral pattern observed in Kapok fiber cell walls indicates axial weak connections, leading to non-uniform mechanical properties along individual fibers [34]. Environmental factors further contribute to the mechanical performance of hollow plant fiber batting. Wang et al. [46] noted that the compression elasticity of Kapok fiber assemblies performs more effectively under dry conditions, and reducing environmental humidity aids in preserving the hollow structure, thereby enhancing thermal insulation performance.
4.4. Additional properties
Beyond the aforementioned properties, hollow plant fibers such as Kapok exhibit remarkable antibacterial characteristics due to their high lignin and wax content, which effectively inhibits the growth of microorganisms responsible for decay [47]. Furthermore, Willow Catkin fibers display exceptional thermal stability, as evidenced by thermogravimetric analysis (TGA) revealing a thermal degradation temperature range of 201-360°C [12].
Nonwoven fabrics produced from coconut coir, sisal, and banana fibers exhibit superior acoustic damping performance, making them widely applicable in automotive interiors. The inherently low density, large lumen, and thin-walled structure of these fibers increase the friction between sound waves and the surface, thereby effectively converting acoustic energy into mechanical and thermal energy [48]. Comparative analyses indicate that Kapok fibers provide enhanced sound absorption capabilities compared to commercial glass wool and absorbent cotton fibers at reduced thickness levels [49].
As natural fiber materials, hollow plant fibers exhibit thermal insulation performance that equals or surpasses that of synthetic fibers and animal-derived down. Their distinctive structure provides exceptional advantages in hydrophobicity, breathability, and antimicrobial properties, which are challenging to replicate with alternative fibers. From an economic standpoint, Wang et al. [50] suggested replacing duck down with Kapok fibers in cold-weather apparel, highlighting comparable thermal resistance and evaporative resistance at only one-tenth of the material cost. Collectively, these attributes establish hollow plant fibers as a revolutionary material for the development of next-generation winter clothing systems.
5. Modification for hollow plant fibers
Hollow plant fibers exhibit potential for thermal insulation due to their distinctive lumen structure. However, under long-term stress conditions in practical applications, the hollow lumen structure gradually collapses, the hydrophobic surface wax layer degrades, and the fibers demonstrate high sensitivity to sparks. These factors collectively restrict their application as thermal insulation filler materials [51]. Consequently, it is imperative to modify hollow plant fibers to fulfill the requirements of functional thermal insulation fillers. Considering the substantial chemical composition and molecular structure similarities between hollow plant fibers and cellulose fibers, modification strategies for cellulose fibers offer valuable insights and references for the modification of hollow plant fibers.
5.1. Mechanical reinforcement
Compressive elasticity represents a crucial mechanical property for filler materials. Hollow plant fibers subjected to prolonged compression experience severe structural deformation, resulting in substantial loss of entrapped air within their lumens and thereby diminishing their thermal insulation performance. Consequently, improving the long-term resilience of hollow plant fibers to extend product lifespan has become a pivotal focus in the industry.
Rapid concentrated alkali treatment of flattened Kapok fibers induces swelling in the amorphous regions of cellulose and polymorphic transitions in crystalline domains, thereby facilitating targeted molecular rearrangement. This process successfully restores the hollow structure in 83% of kapok fibers [52]. Li et al. [53] systematically investigated the effects of alkali treatment on the surface morphology and mechanical properties of Kapok fiber. The alkali-treated fibers exhibited irregular etching patterns, which enhanced the surface friction coefficients and consequently improved fiber cohesion during spinning. Initially, the tensile strength of fibers increased; however, it decreased with excessive alkali concentration due to cell wall dissolution. An optimal concentration range of 8-10 g/L was identified for achieving balanced performance. While ethanol, amines, deep eutectic solvents, and ionic liquids exhibit cellulose-swelling properties [54], their utilization in fiber mechanical reinforcement modification has been rarely documented in the literature.
The challenge of insufficient compression elasticity of hollow plant fibers hinders their commercial potential. To address this, researchers have explored various reinforcement strategies. Saxena et al. [55] significantly enhanced the elasticity of the composite material by adding 7% nano calcium carbonate as a filler to the mixed system of banana fiber and sisal fiber, achieving a maximum elastic modulus of 20.61 GPa. This approach highlights the potential of nanofillers in improving the mechanical resilience of natural fiber composites. However, such methods often focus on external additives rather than optimizing the intrinsic structure of the fibers themselves, which may limit their sustainability and cost-effectiveness.
In contrast, fewer studies have explored the development of elastic properties by leveraging the inherent structure of hollow plant fibers. Recent advancements in cellulose-based materials, however, offer promising inspiration. As shown in Figure 5, Chen et al. [56] introduced a highly elastic cellulosic material fabricated via chemical treatment and freeze-drying processes. The modification partially removed lignin and hemicellulose, softening the wood cell walls and forming a honeycomb-like structure with an internal hydrogel network. This unique architecture endowed the material with remarkable compressive elasticity, allowing it to fully recover its original shape under a compressive strain of up to 70% and maintain structural stability even after 10,000 compression/release cycles. The success of this top-down approach suggests that similar strategies could be applied to hollow plant fibers.
![Elastic enhancement of wood fiber via the ice templating method [56].](/content/184/2026/19/3/img/AJC-19-6692025-g6.png)
- Elastic enhancement of wood fiber via the ice templating method [56].
5.2. Superhydrophobic modification
5.2.1. Plasma technology
Plasma treatment (Figure 6a) is a technique that employs high-energy particles to bombard material surfaces, thereby creating 3D micro/nano-scale structures through etching [57]. When applied to inherently hydrophobic materials, plasma etching can enhance surface roughness, which in turn increases water contact angles [58]. Yao et al. [59] reported an environmentally friendly method for the rapid production of superhydrophobic cellulose-based materials. By first utilizing plasma etching to increase the roughness of bagasse fiber surfaces and subsequently depositing trisilanol butyl to reduce surface energy, the water contact angle of the fibers was significantly improved from 2.4° to 152.9°, achieving effective superhydrophobicity.
![(a) Mechanism of plasma-induced superhydrophobic modification [59]. The * denotes reactive species in an excited state, where O represents excited oxygen atoms generated in the plasma, and Cell represents the activated radicals generated on the cellulose surface. (b) Sol-gel method for preparation of superhydrophobic cellulose paper. TEOS: Tetraethyl orthosilicate [62]. (c) Growth of ZnO nanorods on cotton fabrics via microwave hydrothermal method OTMS: Octadecyltrimethoxysilane [66]. (d) Enzyme etching in conjunction with chemical vapor deposition for the fabrication of robust and eco-friendly superhydrophobic fabrics [70].](/content/184/2026/19/3/img/AJC-19-6692025-g7.png)
- (a) Mechanism of plasma-induced superhydrophobic modification [59]. The * denotes reactive species in an excited state, where O represents excited oxygen atoms generated in the plasma, and Cell represents the activated radicals generated on the cellulose surface. (b) Sol-gel method for preparation of superhydrophobic cellulose paper. TEOS: Tetraethyl orthosilicate [62]. (c) Growth of ZnO nanorods on cotton fabrics via microwave hydrothermal method OTMS: Octadecyltrimethoxysilane [66]. (d) Enzyme etching in conjunction with chemical vapor deposition for the fabrication of robust and eco-friendly superhydrophobic fabrics [70].
Compared to wet chemical modification, plasma technology not only eliminates industrial wastewater discharge but also enables automated processing, thereby gaining increasing prevalence in the textile industry. Phuong et al. [60] employed plasma etching as a pretreatment method, followed by simple dip-coating, to produce superhydrophobic cotton fibers with a water contact angle reaching up to 173°. The covalent bonds formed between the fiber surface and tetraethyl orthosilicate ensured exceptional wash durability for the treated cotton fabric. Similarly, Tao et al. [61] applied cold plasma technology to hydrophobically modify kapok fibers, exploring the correlation between microstructure and hydrophobicity. After etching, the enhanced surface roughness, characterized by grooves and cracks, expanded the fiber surface area, which improved water resistance and enhanced the capillary effect of the fabric.
5.2.2. The sol-gel method
The sol-gel method entails the hydrolysis and condensation of precursors within a solvent medium, leading to the formation of gels with various morphologies and dimensions. Upon deposition onto material surfaces and subsequent curing, these gels generate rough surfaces with low surface energy. As shown in Figure 6(b), Wang et al. [62] developed a superhydrophobic paper capable of withstanding 10 times deformation by coating cellulose fibers with a SiO2 nanoparticle film via sol-gel processing, followed by modification with hexadecyltrimethoxysilane.
Qi et al. [63] utilized sol-gel technology in conjunction with brush-coating to fabricate a superhydrophobic flame-retardant cotton fabric. The superhydrophobic coating was securely anchored to the flame retardants through hydrolyzed tetraethyl orthosilicate and polydimethylsiloxane mixtures, while the phenylphosphonate-based flame-retardant layer was covalently bonded to the fabric, thereby providing exceptional abrasion resistance. Given that silanol groups derived from hydrolyzed silanes can condense with cellulose hydroxyl groups, SiO2 coatings exhibit strong adhesion to cellulose materials [64], facilitating the transformation of hydrophobic kapok fibers into superhydrophobic ones. Expanding on this foundation, Wang et al. [65] successfully prepared a kapok-based superhydrophobic material with a water contact angle of 151° by incorporating silica nanoparticles through the sol-gel method and modifying it with dodecyltrimethoxysilane (DTMS). The durable surface modification was achieved through siloxane-hydroxyl hydrogen bonding and the physical adhesion of silica nanoparticles, which marked surpassed the hydrophobic properties of native Kapok fibers.
5.2.3. Hydrothermal method
The hydrothermal method employs high-temperature and high-pressure aqueous systems to dissolve or react precursors, thereby forming nanomaterials with low surface energy and micro/nanostructures that exhibit superhydrophobic properties. As shown in Figure 6(c), Khan et al. [66] developed a novel microwave-assisted hydrothermal approach for the growth of vertically aligned ZnO nanorods on cotton fibers, which were subsequently silanized using trimethoxy(octadecyl)silane. This two-step process successfully endowed cotton fabric with dual functionalities of superhydrophobicity and UV-blocking capabilities.
Sheng et al. [67] simplified the hydrothermal synthesis process, enabling the one-step growth of low-surface-energy TiO2 nanoparticles directly on cotton fibers. This resulted in a fabric exhibiting a water contact angle of 168°. To enhance the hydrophobicity of Kapok fibers, Tigno et al. [68] employed a hydrothermal method to immobilize TiO2 nanoparticles onto Kapok surfaces. Subsequently, the nanoparticles were chemically modified with 1H,1H,2H,2H-perfluorooctyltriethoxysilane (PTES), leading to the formation of hydrophobic TiO2-kapok nanocomposites. Scanning electron microscope (SEM) analysis revealed that the deposition of TiO2 nanoparticles significantly roughened the initially smooth fiber walls, resulting in the formation of surface wrinkles. Fourier transform infrared (FTIR) spectra explicitly showed a reduction in the hydroxyl group following the incorporation of TiO2, which indirectly corroborated the enhanced hydrophobicity of the material. The measured water contact angle of 151° provided definitive evidence of the superhydrophobic characteristics of the Kapok-based composite.
5.2.4. Chemical vapor deposition
Chemical vapor deposition (CVD) is a versatile and efficient technique for depositing superhydrophobic coatings onto various substrates. This process involves vaporizing precursors at temperatures above their boiling points to form either powder or thin-film coatings. For instance, Ma et al. [69] constructed a rough surface on cellulose substrates using CaCO3 nanoparticles, followed by CVD modification with methyltrimethoxysilane (MTMS) at 105°C for 2 h. The treated ancient paper achieved a water contact angle of 155°, demonstrating excellent superhydrophobic properties, while also enhancing its mechanical strength.
CVD provides significant cost advantages in textile applications since it does not require expensive equipment, high reaction temperatures, or organic solvents. As shown in Figure 6(d), Cheng et al. [70] employed an eco-friendly enzymatic etching method to introduce micro-roughness on cotton fibers, followed by reducing the surface energy through CVD using methyltrichlorosilane (MTCS) at 70°C. Lee et al.[71] developed a robust superhydrophobic Kapok fiber by first coating SiO2 nanoparticles with polydimethylsiloxane (PDMS) via CVD, and subsequently dip-coating them onto the fibers. The dual-scale roughness (micro/nano hierarchical structure) resulted in a contact angle of 154.6°, which is substantially higher than the native fiber’s contact angle of 119.3°.
Current superhydrophobic modification techniques for cellulose fibers involve inherent trade-offs. Plasma treatment enables rapid modification but necessitates expensive equipment. The sol-gel method provides uniform and durable coatings, yet it diminishes breathability and flexibility. Hydrothermal processing is economically advantageous but exhibits limited performance for general applications. CVD produces superior nanostructured coatings with exceptional hydrophobicity, albeit requiring precise process control. When selecting materials and modification strategies, it is crucial to achieve a balance among fiber characteristics, application requirements, and economic considerations.
5.3. Flame retardant modification
5.3.1. Gamma irradiation
Gamma rays, as a form of high-energy electromagnetic radiation characterized by short wavelengths (0.001-0.0001 mm) and high frequency, possess strong penetrating capability. Chung et al. [72] utilized gamma irradiation to develop flame-retardant Kapok fibers. Their study revealed that gamma irradiation effectively removed flammable lipid compounds from Kapok fibers while maintaining the integrity of their hollow lumen structure. Furthermore, the methoxy groups within lignin were cleaved by gamma irradiation, which enhanced lignin’s thermal stability and thereby slowed down the combustion process. During a 10-min flame resistance test conducted at 550°C in an electric furnace, the control samples were entirely reduced to white ash, whereas all gamma-irradiated samples exhibited incomplete combustion, turning black instead (Figure 7a). Within the radiation dose range of 0-1000 kGy, the flame-retardant performance was found to be directly proportional to the irradiation dose.
![(a) Kapok fibers were burnt in an electric furnace at 550°C after gamma irradiation [72]. (b) Schematic diagram of the phosphorylation of KF with PA in the presence of urea [73]. (c) Flammability test of raw KF sheet and phosphylated KF sheet [73]. (d) Preparation of PEI/APP-coated ramie fabrics using the layer-by-layer spraying technique [78].](/content/184/2026/19/3/img/AJC-19-6692025-g8.png)
- (a) Kapok fibers were burnt in an electric furnace at 550°C after gamma irradiation [72]. (b) Schematic diagram of the phosphorylation of KF with PA in the presence of urea [73]. (c) Flammability test of raw KF sheet and phosphylated KF sheet [73]. (d) Preparation of PEI/APP-coated ramie fabrics using the layer-by-layer spraying technique [78].
5.3.2. Dip-coating
The dip-coating and drying technique constitutes an efficient modification strategy, particularly well-suited for loose and short fibers. Jiang et al. [73] submerged kapok fibers in a bio-based flame-retardant solution containing phytic acid (PA), employing PA to phosphorylate the fibers under high-temperature urea treatment. The phosphate groups of phytic acid form covalent bonds with the hydroxyl groups of cellulose molecules, creating phosphate ester bonds that firmly graft phytic acid onto the cellulose (Figure 7b). Owing to its exceptionally high phosphorus content [74], PA fulfills multiple critical functions during fiber combustion: promoting cellulose degradation, catalyzing dehydration reactions, and accelerating carbonization rates [75]. These mechanisms contribute to the formation of a protective surface layer that effectively suppresses further combustion, rendering PA highly applicable for improving the flame resistance of textile fibers. In vertical burning tests, untreated Kapok fibers exhibited continuous combustion until complete consumption within 30 s, whereas phosphorylated Kapok fibers demonstrated significantly improved flame resistance with substantially reduced ignitability (Figure 7c). Comprehensive characterization through surface morphology analysis, Raman spectroscopy, thermogravimetry, and microcalorimetry revealed that phosphorylated Kapok fibers possess excellent ablative performance, with reductions of 71.2% and 78.5% in heat release capacity and total heat release, respectively. Zhang et al. [76] further validated the efficacy of this method by modifying Kapok fibers with ammonium dihydrogen phosphate inorganic salt through dip-coating, achieving comparably significant flame-retardant effects.
5.3.3. Spray-coating
The spray coating method offers operational simplicity and scalability for large-scale modification of fibers. Kwon et al. [77] developed a specialized sprayable flame retardant tailored for kapok fibers and nonwoven fabrics. This treatment demonstrates compatibility with materials used in automotive interiors, apparel, and bedding. Treated Kapok nonwovens exhibit exceptional flame resistance during combustion tests, with a burning rate of approximately 102 mm/min. Furthermore, the adjustable composition of the formulation enables the production of self-extinguishing kapok nonwovens.
As shown in Figure 7(d), Zhao et al. [78] engineered an intumescent flame-retardant coating on ramie fabric via spray-assisted layer-by-layer deposition, utilizing the cationic nature of polyethyleneimine (PEI) and the anionic characteristics of ammonium polyphosphate (APP). Upon thermal decomposition, the dehydration products of APP catalyze the carbonization of cellulose while interacting with PEI to reduce the concentration of flammable gases. This synergistic mechanism results in the formation of an expanded char layer, which effectively inhibits oxygen penetration and heat transfer.
Notably, flame retardants designed for cotton textiles show comparable applicability to hollow plant fibers such as Kapok [76]. Gao et al. [79] extended this technology by developing multifunctional cotton fabric via spray-assisted layer-by-layer assembly, thereby achieving concurrent superhydrophobicity, flame resistance, and electrical conductivity for human motion detection. Upon exposure to fire, the coating forms a robust physical barrier, showcasing superior flame-retardant properties.
A thorough analysis of the aforementioned flame-retardant modification methods highlights distinct advantages and limitations for each approach. High-energy radiation treatment provides uniform and substantial flame-retardant effects but necessitates significant energy consumption and incurs considerable costs. Additionally, this method may cause irreversible changes to the fiber structure, making it most suitable for cellulose fibers requiring exceptionally high flame-retardant performance. The dip-coating and drying method is characterized by operational simplicity and broad applicability, enabling flexible adjustment of flame-retardant types and concentrations based on specific requirements. However, this approach may negatively impact the tactile properties and softness of fibers while demonstrating limited durability in flame-retardant efficacy, rendering it appropriate for large-scale production of cellulose fibers with general flame-retardant needs. The spray coating method offers advantages for localized or specialized flame-retardant treatments; however, it is limited by relatively poor coating stability in practical applications. Each method involves unique technical and economic trade-offs that must be meticulously assessed against application-specific performance requirements and production considerations.
6. Applications of hollow plant fibers in various fields
6.1. Thermal insulation filling materials
Hollow plant fibers have recently gained attention as promising alternatives to traditional cold-weather insulation materials, owing to their exceptional combination of compression resistance, thermal insulation, moisture regulation, and anti-mite characteristics. As early as the previous century, researchers recognized their commercial potential as filling materials for jackets and quilts (Figure 8a) [80].
Jabbar et al. [81] developed a needled nonwoven thermal insulation filler using a blend of kapok fibers and recycled-PET fibers. This material is lightweight and cost-effective, with a thermal resistance comparable to that of commercially available polyester fillers. It is suitable for use in winter jackets and quilt fillings and helps to reduce environmental pollution. Pividal et al. [82] successfully developed a bi-layered needle-punched nonwoven material made from 100% raw kapok fibers using a dry heat-pressing process. The material exhibits a thermal conductivity of only 58.84×10-3 W/(m·K) and a thermal resistance as high as 253.80×10-3 m2·K/W. In thermal insulation performance tests, when the back side of the sample was placed against the inner wall of the wooden box, heat transfer was delayed by 48 min during heating to 100°C and by 75 min during cooling to ambient temperature (27±2°C). The decrement delay is a key characteristic of thermal insulation materials, indicating that the material can effectively slow down heat transfer and thus achieve excellent thermal insulation performance. Thenmozhi et al. [83] have developed quilted composites for winter jackets utilizing chicken feather/kapok-polypropylene nonwovens as sustainable commercial alternatives. The Canadian company Vegeto has successfully commercialized insulating nonwovens based on Milkweed and Kapok fibers, with adjustable thermal insulation performance ranging from 2.5 to 4.5 clo depending on the fiber composition. Likewise, Quartz Company has integrated Milkweed fibers into winter coats to improve their thermal performance.
6.2. Sportswear
The evaporation of sweat plays a crucial role in athletic performance. Hollow plant fibers, such as those derived from Milkweed, exhibit superior moisture-wicking and breathability by effectively transporting perspiration from the skin to the outer surface of garments for rapid evaporation. Zarehshi et al. [84] developed a nonwoven fabric for sportswear by carding milkweed fibers to form fiber webs, followed by needle punching to enhance fiber cohesion and structural integrity. The capillary action within the lumens of Milkweed fibers facilitates efficient liquid transport driven by surface tension, enabling more effective sweat release compared to traditional cotton fibers. Permeability tests demonstrated that milkweed-based nonwovens exhibited a 46.58% higher water vapor transmission rate compared to cotton fabrics. This significantly reduces the sticky sensation associated with sweat accumulation in cotton-based sportswear, thereby enhancing physiological comfort during physical activity.
6.3. Medical protective apparel
The inherent antibacterial characteristics of hollow plant fibers render them exceptionally well-suited for medical protective products, providing sustainable alternatives to address the global supply chain challenges associated with petroleum-based materials that have been intensified by the COVID-19 pandemic. Mula et al.[85] developed nonwoven fabrics for surgical gowns utilizing Milkweed fibers as the primary matrix, reinforced with bio-based polylactic acid/polybutylene succinate (PLA/PBS) composite fibers through meticulously optimized carding and hot-pressing processes. Performance evaluations conducted in accordance with EN 13795 standards revealed that the milkweed fiber gowns exhibited superior tensile strength compared to commercially available options while preserving excellent mechanical properties even after repeated use. The remarkable hydrophobic nature of Milkweed fibers ensures dependable protection against bloodborne pathogens and wound exudates. Moreover, the gowns fulfill the stringent requirements for air permeability and moisture vapor transmission rate in surgical applications, with adjustable thermal resistance achieved via fiber ratio optimization to ensure optimal thermophysiological comfort during extended procedures (Figure 8b).
6.4. Advanced thermal insulation materials
Aldo et al. [86] successfully developed a novel ultra-lightweight natural fiber insulation board via hot-air processing (Figure 8c). This board is primarily composed of kapok fibers and employs polylactic acid (PLA) or bicomponent fibers as binders, achieving densities as low as 10, 15, and 20 kg/m3. In terms of thermal insulation performance, the board demonstrates exceptionally efficiency, with thermal conductivities of 0.0356 W/(m·K) (using PLA) and 0.03432 W/(m·K) (using bicomponent fibers) at 20°C, both significantly lower than the 0.04075 W/(m·K) of commercial glass wool. Furthermore, the board exhibits superior water-repellent properties due to the hydrophobic wax layer on the surface of kapok fibers and its high porosity. Specifically, it achieves a short-term water absorption rate of less than 1 kg/m2 and a contact angle of up to 130°, far exceeding the performance of commercial glass wool.
Dong et al. [87] successfully fabricated a microtubule-based composite material composed of kapok fibers and hollow PET fibers. Through the application of a vacuum impregnation technique, a phase change material (PCM), consisting of myristic acid and tetradecyl alcohol (MA-TD), was effectively encapsulated within the microtubules of the Kapok fibers. Thermal property testing revealed that the PCM-encapsulated composite absorbed 76.8 J/g of latent heat within the comfortable temperature range of 24°C to 42.3°C and released 77.4 J/g of latent heat within the reverse temperature range of 29.7°C to 10.5°C. This material demonstrated both fundamental thermal insulation properties and dynamic thermal regulation capabilities, maintaining stability during repeated laundering cycles and exhibiting robust leakage resistance under continuous heating/cooling cycles, even under pressure.
He et al. [88] developed an eco-friendly wearable active-passive aerogel heater comprising calcium alginate, Kapok fiber, and carbon nanotubes (CNTs) (Figure 8d). The unique independent cavity structure of Kapok fiber substantially enhances the thermal insulation performance of the aerogel heater, demonstrating its low energy consumption and superior personal thermal management capability. Moreover, the incorporation of CNTs in the calcium alginate/Kapok fiber/CNT composite enables excellent solar radiation absorption and Joule heating, effectively warming the human body. Based on heat loss model analysis, the calcium alginate/Kapok fiber/CNT aerogel, when utilized as a wearable heater, can achieve up to 60% thermal energy savings compared to conventional building heating systems. In terms of thermal insulation properties, the material exhibits remarkably low thermal conductivity (0.024 W/(m·K)) and ultra-low density (0.027 g/cm3), significantly inhibiting heat transfer pathways and thus providing exceptional thermal insulation. Additionally, the composite material is capable of absorbing or releasing latent heat within the human comfort temperature range (24°C to 42.3°C or 29.7°C to 40.5°C), facilitating body temperature regulation and enhancing adaptability to cold environments.
Wang et al. [89] successfully developed an eco-friendly Kapok fiber/chitosan composite aerogel material through a simple yet cost-effective fabrication process that integrates wet-laid forming, immersion, and freeze-drying techniques. This material demonstrates exceptional thermal insulation properties, characterized by high porosity (98.32%–98.48%), excellent thermal resistance (0.072–0.079 m2·°C·W-1), and ultralow density (0.019–0.022 g/cm3). These attributes make it a highly promising candidate for applications in packaging and building insulation. Furthermore, the Kapok fiber/chitosan aerogel exhibits superior amphiphilicity (oil-water affinity), effective UV-blocking capability, remarkable mechanical strength, and compressible resilience, which render it particularly suitable for outdoor environments. Additionally, owing to the inherent antibacterial properties of Kapok fibers, this material holds significant potential for use in food packaging and cold-chain logistics, where it can effectively inhibit microbial growth and significantly extend shelf life.
7. Conclusion, challenges, and future perspectives
This review systematically establishes the structure-property relationships of hollow plant fibers across micro-to-macro scales, integrating agricultural and forestry waste into a novel theoretical framework for high-performance thermal insulation. It establishes fundamental theoretical foundations to guide the development of sustainable textiles and low-carbon construction materials utilizing hollow plant fibers. Theoretically, we elucidate the synergistic insulation mechanism driven by hollow lumens (>90% volume) and hierarchical pores that collectively impede heat conduction, while revealing molecular origins of inherent hydrophobicity. Experimentally, multiple data confirm that the thermal insulation performance of hollow plant fibers is similar to that of down. The thermal resistance value of Poplar Catkins is 0.316 m2°C/W, while that of down is 0.354 m2°C/W. Lightweight boards (PLA/bicomponent binders) exhibit 0.03432 W/(m·K), and Kapok aerogels attain ultralow 0.024 W/(m·K). Commercial products (2.5-4.5 clo) further validate scalability, positioning these fibers as viable lightweight alternatives.
However, transitioning from gram- to kilogram-scale production faces dual bottlenecks in green continuous manufacturing. Seasonal availability and underdeveloped collection/purification processes impede supply chain stability. Immature forming technologies, lacking integrated production lines, remain key obstacles. Future solutions must combine aerodynamic/electrostatic harvesting, water bath/microwave purification, and needle-punching/hydroentanglement stabilization.
Performance limitations impose significant constraints on practical applications. The inadequate flame retardancy and diminished hydrophobic durability of hollow plant fibers severely limit their environmental adaptability. Compounding these issues, insufficient mechanical resilience leads to lumen collapse under compressive stresses, which accelerates insulation performance degradation and markedly reduces product service life. These limitations originate fundamentally from the restricted mobility of cellulose molecular chains during the deformation recovery processes. Current modification techniques face substantial practical limitations. To achieve commercially viable solutions, future research must focus on cost-effective molecular engineering strategies capable of simultaneously improving elastic recovery, flame resistance, and hydrophobic stability at industrial scales.
Moreover, prevailing thermal/moisture resistance standards (10-35°C steady-state) inadequately replicate extreme environments. Establishing multiphysics-coupled testing platforms spanning -60-50°C with dynamic wind (0-15 m/s) and humidity gradients (10-95% RH) is critical for specialized gear design.
Environmentally, these fibers hold negative-carbon potential by upcycling waste biomass while displacing carbon-intensive glass wool/down. Yet the absence of rigorous LCA obscures their true impact. Quantifying cradle-to-grave carbon footprints remains essential to validate contributions to carbon neutrality.
Acknowledgment
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 32371797, 32101604).
CRediT authorship contribution statement
Jiawei Han: Manuscript editing and review, Manuscript preparation, Literature search; Zongying Fu: Design, Manuscript preparation; Jingpeng Li: Concepts, Design, Manuscript editing and review, Manuscript preparation, Funding acquisition. Yun Lu: Concepts, Design, Manuscript editing and review, Manuscript preparation.
Declaration of competing interest
The authors declare no competing interests.
Declaration of generative AI and AI-assisted technologies in the writing process
The authors confirm that there was no use of artificial intelligence (AI)-assisted technology for assisting in the writing or editing of the manuscript and no images were manipulated using AI.
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![Macroscopic and microscopic comparison chart of Willow Catkins, Kapok, and Calotropis fibers [10,24,25].](/content/184/2026/19/3/img/AJC-19-6692025-g2.png)
![(a) Thermal insulation mechanisms of clothing [37]. (b) The impact of fiber blending ratio on the thermal insulation of Kapok/cotton and Calotropis gigantea/cotton non-woven fabrics [40].](/content/184/2026/19/3/img/AJC-19-6692025-g4.png)
![(a) The jacket filled with Kapok fibers [50]. (b) Schematic diagram of medical protective clothing [90]. (c) Kapok-PLA sample surface section [86]. (d) Conceptual illustration of the active-cum-passive wearable heater composed of CA/Kapok fiber/CNT for personal thermal management [88].](/content/184/2026/19/3/img/AJC-19-6692025-g9.png)