Nacre-mimicking hybrids of high inorganic content (>50 wt %) tend to show low strain-to-failure. Therefore, we prepared clay nanopaper hybrid composite montmorillonite platelets in a continuous matrix of nanofibrillated cellulose (NFC) with the aim of harnessing the intrinsic toughness of fibrillar networks. Hydrocolloid mixtures were used in a filtration approach akin to paper processing. The resulting multilayered structure of the nanopaper was studied by FE-SEM, FTIR, and XRD. Uniaxial stress-strain curves measured in tension and thermal analysis were carried out by DMTA and TGA. In addition, fire retardance and oxygen permeability characteristics were measured. The continuous NFC matrix is a new concept and provides unusual ductility to the nanocomposite, allowing inorganic contents as high as 90% by weight. Clay nanopaper extends the property range of cellulose nanopaper and is of interest in self-extinguishing composites and in oxygen barrier layers.

Nanostructured materials are difficult to prepare rapidly and as large structures. The present study is thus significant because a rapid preparation procedure for large, flat, smooth, and optically transparent cellulose nanopaper structures is developed using a semiautomatic sheet former. Cellulose/inorganic hybrid nanopaper is also produced. The preparation procedure is compared with other approaches, and the nanopaper structures are tested in uniaxial tensile tests. Optical transparency and high tensile strength are demonstrated in 200 mm diameter nanopaper sheets, indicating well-dispersed nanofibrils. The preparation time is 1 h for a typical nanopaper thickness of 60 μm. In addition, the application of the nanopaper-making strategy to cellulose/inorganic hybrids demonstrates the potential for "green" processing of new types of nanostructured functional materials.