Continuous Rapid Fabrication of Ceramic Fiber Sponge Aerogels with High Thermomechanical Properties via a Green and Low-Cost Electrospinning Technique

Ceramic aerogel is an appealing fireproof and heat-insulation material, but synchronously improving its mechanical and thermal properties is a challenge. Moreover, the expensive discontinuous processing techniques inhibit the large-scale fabrication of ceramic aerogels. Here, we propose a water-based electrospinning method, based on the hydrolysis and condensation reactions of ceramic precursor salts themselves, for the continuous and rapid (0.025 m3/min) fabrication of ceramic fiber sponge aerogels with dual micronano fiber networks, which show synchronous enhanced fireproof, thermal insulation, and resilience performance. The elastic ceramic micro/nano fiber sponge aerogels contain robust silica-based microfibers as a firm skeleton and alumina-based nanofibers as elastic thermal insulation filler. The sponges have a high porosity of >99.8%, a low mass density (6.21 mg/cm3), a small thermal conductivity (0.022 W/m·K), and a large compression strength (21.15 kPa at 80% strain). The ceramic fiber sponges can effectively prevent the propagation of thermal runaway when a lithium battery experiences catastrophic thermal shock (>1000 °C) in the power battery packs. The proposed strategy is feasible for low-cost and rapid synthesizing ceramic aerogels toward effective battery thermal management.

Biomimetic Transparent Layered Tough Aerogels for Thermal Superinsulation and Triboelectric Nanogenerator

Transparent aerogels are ideal candidates for thermally insulating windows, solar thermal receivers, electronics, etc. However, they are usually prepared via energy-consuming supercritical drying and show brittleness and low tensile strength, significantly restricting their practical applications. It remains a great challenge to prepare transparent aerogels with high tensile strength and toughness. Herein, biomimetic transparent tough cellulose nanofiber-based nanocomposite aerogels with a layered nanofibrous structure are achieved by vacuum-assisted self-assembly combined with ambient pressure drying. The nacre-like layered homogeneous nanoporous structures can reduce light scattering and effectively transfer stress and prevent stress concentration under external forces. The aerogels exhibit an attractive combination of excellent transparency and hydrophobicity, high compressive and tensile strengths, high toughness, excellent machinability, thermal superinsulation, and wide working temperature range (-196 to 230 °C). It is demonstrated that they can be used for superinsulating windows of buildings and high-efficient thermal management for electronics and human bodies. In addition, a prototype of transparent flexible aerogel-based triboelectric nanogenerator is developed. This work provides a promising pathway toward transparent tough porous materials for energy saving/harvesting, thermal management, electronics, sensors, etc.

Enhancing Mesopore Volume and Thermal Insulation of Silica Aerogel via Ambient Pressure Drying-Assisted Foaming Method

Ambient pressure drying (APD) of silica aerogels has emerged as an attractive method adapting to large-scale production. Spring-back is a unique phenomenon during APD of silica aerogels with volume expansion after its shrinkage under capillary force. We attribute the intense spring-back at elevated drying temperatures to a dense structure formed on the surface and the formation of positive internal pressure. Furthermore, an APD-assisted foaming method with an in situ introduction of NH4HCO3 was proposed. NH4HCO3 decomposing at drying temperatures hastened the emergence of positive pressure, thereby increasing the expansion volume. Compared to the previous method, the porosity of silica aerogel increased from 82.2% to 92.6%, and mesopore volume from 1.79 cm3 g-1 to 4.54 cm3 g-1. By adjusting the amount of the silicon source, silica aerogels prepared by the APD-assisted foaming method generated higher volume expansion and lower thermal conductivity. After calcination to remove undecomposed ammonium salts, the hydrophobic silica aerogel with a density of 0.112 g cm-3 reached a mesopore volume of 5.07 cm3 g-1 and a thermal conductivity of 18.9 mW m-1·K-1. This strategy not only improves the thermal insulation properties, but also offers a significant advancement in tailoring silica aerogels with specific porosity and mesopore volume for various applications.

Wearable Aerogels for Personal Thermal Management and Smart Devices

Extreme climates have become frequent nowadays, causing increased heat stress in human daily life. Personal thermal management (PTM), a technology that controls the human body's microenvironment, has become a promising strategy to address heat stress. While effective in ordinary environments, traditional high-performance fibers, such as ultrafine, porous, highly thermally conductive, and phase change materials, fall short when dealing with harsh conditions or large temperature fluctuations. Aerogels, a third-generation superinsulation material, have garnered extensive attention among researchers for their thermal management applications in building energy conservation, transportation, and aerospace, attributed to their extremely low densities and thermal conductivity. While aerogels have historically faced challenges related to weak mechanical strength and limited secondary processing capacity, recent advancements have witnessed notable progress in the development of wearable aerogels for PTM. This progress underscores their potential applications within extremely harsh environments, serving as self-powered smart devices and sensors. This Review offers a timely overview of wearable aerogels and their PTM applications with a particular focus on their wearability and suitability. Finally, the discussion classifies five types of PTM applications based on aerogel function: thermal insulation, heating, cooling, adaptive regulation (involving thermal insulation, heating, and cooling), and utilization of aerogels as wearable smart devices.

Regulating microstructures of aerogels by controlling phase separation mechanism for improving specific surface area and energy harvesting

Aerogels with 3D porous structures have been attracting increasing attention among functional materials due to their advantages of being lightweight and high specific surface area. Precise control of the porous structure of aerogel is essential to improve its performance. In this work, polylactic acid (PLA) aerogels with distinctly different microstructures were fabricated by precisely controlling the phase separation behavior of the ternary solution system. Rheological and theoretical analyses have revealed that the interactions between polymer molecules, solvents and non-solvents play a crucial role in determining the nucleation and growth of poor olymer and rich polymer phases. By adjusting the non-solvent type and the solution composition, aerogels with spider network structure, bead-like connected microsphere structure, and cluster petal structure were obtained. Ideal spinodal phase separation conditions were obtained to produce aerogels with a homogeneous fiber network structure. The optimum PLA aerogel achieved an extremely porosity of 96 % and a high specific surface area of 114 m2/g, which rendered it with excellent triboelectric generation performance. Thus, this work provides fundamental insights into the precise regulation of the phase separation behavior and the structure of the aerogel, which can help boost the performance and expand the applications of PLA aerogels.

The poor reliability of thermal conductivity data in the aerogel literature: a call to action!

Aerogels are an exciting class of materials with record-breaking properties including, in some cases, ultra-low thermal conductivities. The last decade has seen a veritable explosion in aerogel research and industry R&D, leading to the synthesis of aerogels from a variety of materials for a rapidly expanding range of applications. However, both from the research side, and certainly from a market perspective, thermal insulation remains the dominant application. Unfortunately, continued progress in this area suffers from the proliferation of incorrect thermal conductivity data, with values that often are far outside of what is possible within the physical limitations. This loss of credibility in reported thermal conductivity data poses difficulties in comparing the thermal performance of different types of aerogels and other thermal superinsulators, may set back further scientific progress, and hinder technology transfer to industry and society. Here, we have compiled 519 thermal conductivity results from 87 research papers, encompassing silica, other inorganic, biopolymer and synthetic polymer aerogels, to highlight the extent of the problem. Thermal conductivity data outside of what is physically possible are common, even in high profile journals and from the world's best universities and institutes. Both steady-state and transient methods can provide accurate thermal conductivity data with proper instrumentation, suitable sample materials and experienced users, but nearly all implausible data derive from transient methods, and hot disk measurements in particular, indicating that under unfavorable circumstances, and in the context of aerogel research, transient methods are more prone to return unreliable data. Guidelines on how to acquire reliable thermal conductivity data are provided. This paper is a call to authors, reviewers, editors and readers to exercise caution and skepticism when they report, publish or interpret thermal conductivity data.

Graphical Abstract

Compendium of Safety Regulatory for Safe Applications of Aerogels

An increasing number of aerogels as nanostructured highly porous materials are entering the market in every day products, with an attractive portfolio of properties for emerging applications ranging from health care and leisure to electronics, cosmetics, energy, agriculture, food and environmental. However, the novelty in properties and forms of aerogels makes the development of a legislative framework particularly challenging for ensuring the safe development and use of nano-enabled products. The presented safety regulatory Compendium intends to share knowledge with the international aerogels community, as well as end-users and stakeholders, on the regulatory and safe handling procedures, as best safety practices, to be followed during the production process, handling, transport and end-use of aerogel-based formulations to mitigate human and environmental risks considering lack of data availability for this purpose in general.

Biopolymer-Polysiloxane Double Network Aerogels

A new series of transparent aerogels of biopolymer-polysiloxane double networks is reported. Biopolymer aerogels have attracted much attention from green and sustainable aspects but suffered from strong hydrophilicity and difficulty to make homogeneous structures in nanoscale; these drawbacks are overcome by compositing with a polysiloxane network. Alginate-polymethylsilsesquioxane aerogel has high optical transparency, water repellency, comparable superinsulation property and improved bending flexibility compared to pure polymethylsilsesquioxane aerogel. The nanoscale homogeneity is realized by separating the crosslinking steps for two networks in a sequential protocol: condensation of siloxane bonds and metal-crosslinking of biopolymer. The crosslinking order, biopolymer-first or siloxane-first, and universality/limitation of biopolymer-crosslinker pairs are discussed to construct fundamental chemistry of double network systems for their further application potentials.

Digital Light Processing 3D-Printed Silica Aerogel and as a Versatile Host Framework for High-Performance Functional Nanocomposites

Vat-photopolymerization-based 3D printing enables on-demand construction of customized objects with scalable production capacity and high precision. Herein, the sol-gel process for aerogels with digital light processing 3D printing to produce advanced functional materials possessing hierarchical pore structures and complex shapes is combined. It has revealed the temporal evolution of the photorheological behavior of acrylate-modified silica sols in an acid-base catalytic procedure, and confirmed that silica aerogels can be fabricated with very low acrylate content. The resulting aerogels are thermostable with intrinsic silica contents, skeletal densities, and physical characteristics similar to those of commercial silica aerogels yet distinct mechanical behaviors. More importantly, the printed silica aerogels can be used as a versatile nanoengineering platform to produce high-performance and multifunctional interpenetrating phase nanocomposites with complex shapes through programmable post-printing processes. Epoxy-based nanocomposites possessing excellent mechanical performance, ionogel-based conductive nanocomposites with decoupled electrical and mechanical properties, and anti-swelling hydrogel-based nanocomposites are demonstrated. The results of this study offer new guidelines for the design and fabrication of novel materials by additive manufacturing.

Mechanically Strong and Thermally Stable Chemical Cross-Linked Polyimide Aerogels for Thermal Insulator

High-performance thermal insulating materials are highly desirable in several fields, especially for thermal insulation of buildings to reduce energy consumption. Owing to the remarkable thermal stability, high porosity, low density, and outstanding mechanical features, polyimide (PI) aerogels have attracted great attention. In this work, chemical cross-linked PI (CCPI) aerogels were fabricated via freeze-drying and thermal imidization, which possess outstanding mechanical properties, good thermal stability, and excellent thermal insulation characteristics. The chemically cross-linked structure can effectively inhibit shrinkage, while retaining the structural integrity, resulting in the lower density and lower shrinkage of the materials. In this paper, completely imidized and highly cross-linked polyimide aerogels were synthesized by using p-phenylenediamine (PDA), 3,3',4,4'-biphenyltetracarboxylic dianhydride (BPDA), and the cross-linker 2,3,6,7,14,15-hexaaminotriptycene (HMT). The CCPI aerogels with excellent properties, such as covalently cross-linked chemical structure, low density (0.069 g/cm3), low volume shrinkage (10%), high decomposition temperature (Td5% = 587 °C), and low thermal conductivity (25 mW m-1K-1) are in high demand in the field of thermal insulation. This work furnishes a new method for the development of polymer-based thermal insulation materials for various prospective applications.

Bioinspired Multilayer Structures for Energy-Free Passive Heating and Thermal Regulation in Cold Environments

Passive thermal regulation has attracted increasing interest owing to its zero-energy consumption capacity, which is expected to alleviate current crises in fossil energy and global warming. In this study, a biomimetic multilayer structure (BMS) comprising a silica aerogel, a photothermal conversion material (PTCM), and a phase change material (PCM) layer is designed inspired by the physiological skin structure of polar bears for passive heating with desirable temperature and endurance. The transparent silica aerogel functions as transparent hairs and allows solar entry and prevents heat dissipation; the PTCM, a glass plate coated with black paint, acts as the black skin to convert the incident sunlight into heat; and the PCM composed of n-octadecane microcapsules stores the heat, regulating temperature and increasing endurance. Impressively, outdoor and simulated experiments indicate efficient passive heating (increment of 60 °C) of the BMS in cold environments, and endurance of 157 and 92 min is achieved compared to a single aerogel and PTCM layer, respectively. The uses of the BMS for passive heating of model houses in winter show an increase of 12.1 °C. COMSOL simulation of the BMSs in high latitudes indicates robust heating and endurance performance in a -20 °C weather. The BMS developed in this study exhibits a smart thermal regulation behavior and paves the way for passive heating in remote areas where electricity and fossil energy are unavailable in cold seasons.

Thermal Conductivity of Nanoporous Materials: Where Is the Limit?

Nowadays, our society is facing problems related to energy availability. Owing to the energy savings that insulators provide, the search for effective insulating materials is a focus of interest. Since the current insulators do not meet the increasingly strict requirements, developing materials with a greater insulating capacity is needed. Until now, several nanoporous materials have been considered as superinsulators achieving thermal conductivities below that of the air 26 mW/(m K), like nanocellular PMMA/TPU, silica aerogels, and polyurethane aerogels reaching 24.8, 10, and 12 mW/(m K), respectively. In the search for the minimum thermal conductivity, still undiscovered, the first step is understanding heat transfer in nanoporous materials. The main features leading to superinsulation are low density, nanopores, and solid interruptions hindering the phonon transfer. The second crucial condition is obtaining reliable thermal conductivity measurement techniques. This review summarizes these techniques, and data in the literature regarding the structure and thermal conductivity of two nanoporous materials, nanocellular polymers and aerogels. The key conclusion of this analysis specifies that only steady-state methods provide a reliable value for thermal conductivity of superinsulators. Finally, a theoretical discussion is performed providing a detailed background to further explore the lower limit of superinsulation to develop more efficient materials.

Direct synthesis of highly stretchable ceramic nanofibrous aerogels via 3D reaction electrospinning

Ceramic aerogels are attractive for many applications due to their ultralow density, high porosity, and multifunctionality but are limited by the typical trade-off relationship between mechanical properties and thermal stability when used in extreme environments. In this work, we design and synthesize ceramic nanofibrous aerogels with three-dimensional (3D) interwoven crimped-nanofibre structures that endow the aerogels with superior mechanical performances and high thermal stability. These ceramic aerogels are synthesized by a direct and facile route, 3D reaction electrospinning. They display robust structural stability with structure-derived mechanical ultra-stretchability up to 100% tensile strain and superior restoring capacity up to 40% tensile strain, 95% bending strain and 60% compressive strain, high thermal stability from −196 to 1400 °C, repeatable stretchability at working temperatures up to 1300 °C, and a low thermal conductivity of 0.0228 W m⁻¹ K⁻¹ in air. This work would enable the innovative design of high-performance ceramic aerogels for various applications.

Ceramic aerogels are generally brittle and often tend to structurally collapse under large external tensile strain. Here the authors synthesize large-scale stretchable ceramic aerogels with interwoven crimped nanofibers by combining electrohydrodynamic method and 3D reaction electrospinning.

Thermal Gelation for Synthesis of Surface-Modified Silica Aerogel Powders

A spherical silica aerogel powder with hydrophobic surfaces displaying a water contact angle of 147° was synthesized from a water glass-in-hexane emulsion through ambient pressure drying. Water glass droplets containing acetic acid and ethyl alcohol were stabilized in n-hexane with a surfactant. Gelation was performed by heating the droplets, followed by solvent exchange and surface modification using a hexamethyldisilazane (HMDS)/n-hexane solution. The pH of the silicic acid solution was crucial in obtaining a highly porous silica aerogel powder with a spherical morphology. The thermal conductivity, tapped density, pore volume, and BET surface area of the silica aerogel powder were 22.4 mW·m⁻¹K⁻¹, 0.07 g·cm⁻³, 4.64 cm³·g⁻¹, and 989 m²·g⁻¹, respectively. Fourier transform infrared (FT–IR) spectroscopy analysis showed that the silica granule surface was modified by Si-CH₃ groups, producing a hydrophobic aerogel.

False Morphology of Aerogels Caused by Gold Coating for SEM Imaging

The imaging of non-conducting materials by scanning electron microscopy (SEM) is most often performed after depositing few nanometers thick conductive layers on the samples. It is shown in this work, that even a 5 nm thick sputtered gold layer can dramatically alter the morphology and the surface structure of many different types of aerogels. Silica, polyimide, polyamide, calcium-alginate and cellulose aerogels were imaged in their pristine forms and after gold sputtering utilizing low voltage scanning electron microscopy (LVSEM) in order to reduce charging effects. The morphological features seen in the SEM images of the pristine samples are in excellent agreement with the structural parameters of the aerogels measured by nitrogen adsorption-desorption porosimetry. In contrast, the morphologies of the sputter coated samples are significantly distorted and feature nanostructured gold. These findings point out that extra care should be taken in order to ensure that gold sputtering does not cause morphological artifacts. Otherwise, the application of low voltage scanning electron microscopy even yields high resolution images of pristine non-conducting aerogels.

Antibacterial Activity of Linezolid against Gram-Negative Bacteria: Utilization of ε-Poly-l-Lysine Capped Silica Xerogel as an Activating Carrier

In recent times, many approaches have been developed against drug resistant Gram-negative bacteria. However, low-cost high effective materials which could broaden the spectrum of antibiotics are still needed. In this study, enhancement of linezolid spectrum, normally active against Gram-positive bacteria, was aimed for Gram-negative bacteria growth inhibition. For this purpose, a silica xerogel prepared from a low-cost precursor is used as a drug carrier owing to the advantages of its mesoporous structure, suitable pore and particle size and ultralow density. The silica xerogel is loaded with linezolid and capped with ε-poly-l-lysine. The developed nano-formulation shows a marked antibacterial activity against to Escherichia coli, Pseudomonas aeruginosa and Staphylococcus aureus. In comparison to free linezolid and ε-poly-l-lysine, the material demonstrates a synergistic effect on killing for the three tested bacteria. The results show that silica xerogels can be used as a potential drug carrier and activity enhancer. This strategy could provide the improvement of antibacterial activity spectrum of antibacterial agents like linezolid and could represent a powerful alternative to overcome antibiotic resistance in a near future.

Reaction-Spun Transparent Silica Aerogel Fibers

Aerogel fibers, the simultaneous embodiment of aerogel 3D network and fibrous geometry, have shown great advantages over natural and synthetic fibers in thermal insulation. However, as a fast gelation to ensure aerogel fiber spinning generally induces rapid local clustering of precursor particles (i.e., phase separation) and unavoidably results in nontransparency and nonuniformity in the gel state, a severe challenge remains in remedying the spinning to make transparent aerogel fibers come true. Herein, we report a reaction spinning toward highly porous silica aerogel fibers, where the Brownian motion (i.e., diffusion) of colloidal particles is hampered during spinning to allow the maintaining of the fiber shape, while a rapid gelation reaction is activated by concentrated ammonia to solidify the fiber. The aggregation degree of the primary particles can be precisely controlled by pH-dependent hydrolyzation, and thus, the final aerogel fiber can be either transparent or opaque, as dominated by Rayleigh or Mie scattering. The resulting transparent silica aerogel fibers with low density, high specific surface area, and flexibility can inherit advanced features including excellent thermal insulation, wide temperature stability, and optional hydrophobic functionalization and, thus, be suitable for wearable applications.

An overview on alumina-silica-based aerogels

Silica aerogels are remarkable materials with excellent physicochemical properties, such as high porosity and surface area, along with low density and thermal conductivity. In addition to their outstanding properties, these materials are quite interesting due to the possibility to change their chemistry according to intended applications. However, they also show some disadvantages, like low mechanical strength and poor dimensional stability under high temperatures (above 600 °C). Although these aerogels are frequently used as thermal insulators, for high temperature environments some of their properties need to be improved. The mixing with other ceramic thermally resistant phases is a viable approach. Thus, this work presents an overview on alumina-silica-based aerogels, describing their synthesis, processing and properties. The improvement on their properties will be discussed as a function of the amount of refractory phase (alumina) in the silica matrix. The introduction of the alumina phase makes them stable until 1200-1400 °C, maintaining low values of thermal conductivity at very high temperature (below 81 mW m^-1 K^-1). Finally, a brief survey on the most promising applications of these materials is presented, with several examples. In catalysis, alumina-silica aerogels have shown equivalent performance when compared to reference catalysts. In the field of thermal insulation, these materials show great potential, especially in high temperatures environments, due to their thermal dimensional stability and inherent low thermal conductivity. As adsorbents, higher stability and adsorption capacity were obtained with the incorporation of the alumina phase in silica aerogels, and these materials can be reused for repeated adsorption/desorption cycles. Indeed, a significant improvement of the aerogel performance by the synergetic effect of combining silica and alumina phases is usually obtained, supporting the expectation of the extension of their fields of application.

Superhydrophobic highly flexible doubly cross-linked aerogel/carbon nanotube composites as strain/pressure sensors

We report novel superhydrophobic highly flexible composites based on a doubly cross-linked (DCL) aerogel and carbon nanotubes (CNTs) for strain/pressure sensing. The DCL aerogel/CNT composite is prepared by radical polymerization of vinylmethyldimethoxysilane and vinyldimethylmethoxysilane, respectively, followed by hydrolytic co-polycondensation of the obtained polyvinylmethyldimethoxysilane and polyvinyldimethylmethoxysilane, combined with the incorporation of CNTs. Benefiting from the flexible methyl-rich DCL structure of the aerogel and conductive CNTs, the resultant DCL aerogel/CNT composite combines superhydrophobicity, high compressibility, high bendability, high elasticity, and strain- and pressure-sensitive conductivity. We demonstrate that the composite can be applied as a high-performance strain/pressure sensor for the detection of arterial pulse waves and joint bending with high sensitivity and high durability against humidity.

Reducing the flammability of hydrophobic silica aerogels by doping with hydroxides

In this work, we utilized Al(OH)₃ (AH) and Mg(OH)₂ (MH) as dopants to reduce the flammability of hydrophobic silica aerogels (SA) and the related thermal properties and flame retardance were investigated detailedly. The TG-DSC analyses showed the thermostability of SA in MH/SA reached 512.4 °C and that for AH/SA was just 426.1 °C, both of which were higher than that of pure SA, 399.5 °C. It was known from cone calorimeter tests that the heat release rate, peak heat release rate and total heat release of AH/SA and MH/SA decreased significantly compared to that of pure SA. The time to ignition (TTI) of MH/SA was dramatically extended, reaching 20˜38 s, which was far longer than those of pure SA (˜6 s) and AH/SA (3˜8 s). The reduction in CO concentration, CO production rate and cumulative CO production verified the decreased smoke toxicity of AH/SA and MH/SA. It was further indicated that the flame-retardant effect of AH and MH correlated with their inhibitory effect on the pyrolysis of SA, while MH showed much better flame-retardant performance than that of AH. The research outcomes provide an inspiration to reduce the flammability of SA and benefit their expansion in thermal insulation field.

An Opinion Paper on Aerogels for Biomedical and Environmental Applications

Aerogels are a special class of nanostructured materials with very high porosity and tunable physicochemical properties. Although a few types of aerogels have already reached the market in construction materials, textiles and aerospace engineering, the full potential of aerogels is still to be assessed for other technology sectors. Based on current efforts to address the material supply chain by a circular economy approach and longevity as well as quality of life with biotechnological methods, environmental and life science applications are two emerging market opportunities where the use of aerogels needs to be further explored and evaluated in a multidisciplinary approach. In this opinion paper, the relevance of the topic is put into context and the corresponding current research efforts on aerogel technology are outlined. Furthermore, key challenges to be solved in order to create materials by design, reproducible process technology and society-centered solutions specifically for the two abovementioned technology sectors are analyzed. Overall, advances in aerogel technology can yield innovative and integrated solutions for environmental and life sciences which in turn can help improve both the welfare of population and to move towards cleaner and smarter supply chain solutions.

Synthetic Polymer Aerogels in Particulate Form

Aerogels have been defined as solid colloidal or polymeric networks of nanoparticles that are expanded throughout their entire volume by a gas. They have high surface areas, low thermal conductivities, low dielectric constants, and high acoustic attenuation, all of which are very attractive properties for applications that range from thermal and acoustic insulation to dielectrics to drug delivery. However, one of the most important impediments to that potential has been that most efforts have been concentrated on monolithic aerogels, which are prone to defects and their production requires long and costly processing. An alternative approach is to consider manufacturing aerogels in particulate form. Recognizing that need, the European Commission funded “NanoHybrids”, a 3.5 years project under the Horizon 2020 framework with 12 industrial and academic partners aiming at aerogel particles from bio- and synthetic polymers. Biopolymer aerogels in particulate form have been reviewed recently. This mini-review focuses on the emerging field of particulate aerogels from synthetic polymers. That category includes mostly polyurea aerogels, but also some isolated cases of polyimide and phenolic resin aerogels. Particulate aerogels covered include powders, micro granules and spherical millimeter-size beads. For the benefit of the reader, in addition to the literature, some new results from our laboratory concerning polyurea particle aerogels are also included.

Ambient-dried highly flexible copolymer aerogels and their nanocomposites with polypyrrole for thermal insulation, separation, and pressure sensing

Highly flexible copolymer and copolymer/polypyrrole nanocomposite aerogels have been synthesized via ambient pressure drying for superinsulation, separation and pressure sensing.

Self-cross-linked melamine-formaldehyde-pectin aerogel with excellent water resistance and flame retardancy

Self-cross-linked aerogel based on pectin and melamine-formaldehyde resin (MF) was fabricated via freeze-drying method using water as solvent, where pectin is structural material meanwhile acting as acid to catalyse the cross-linking of MF. The cross-linking reaction easily occurs without additional additives, which can be significantly accelerated at elevated temperatures, with a critical value of about 55 °C. The obtained aerogel shows network microstructures as observed with SEM. With increasing pectin content, the aerogel shows significantly increased compressive modulus. The compressive modulus of M10Pe5 arrives 23.2 MPa, the specific modulus of which arrives 188 MPa cm³/g, while pure MF aerogel are too fragile to keep intact after freeze-dried. The resulting aerogel has good thermal stability, excellent water resistance (can be second dried with limited strength loss) and low flammability. This partially bio-based novel aerogel with impressive properties is promising in many applications.

Scalable Fabrication of Thermally Insulating Mechanically Resilient Hierarchically Porous Polymer Foams

The requirement of energy efficiency demands materials with superior thermal insulation properties. Inorganic aerogels are excellent thermal insulators, but are difficult to produce on a large-scale, are mechanically brittle, and their structural properties depend strongly on their density. Here, we report the scalable generation of low-density, hierarchically porous, polypropylene foams using industrial-scale foam-processing equipment, with thermal conductivity lower than that of commercially available high-performance thermal insulators such as superinsulating Styrofoam. The reduction in thermal conductivity is attributed to the restriction of air flow caused by the porous nanostructure in the cell walls of the foam. In contrast to inorganic aerogels, the mechanical properties of the foams are less sensitive to density, suggesting efficient load transfer through the skeletal structure. The scalable fabrication of hierarchically porous polymer foams opens up new perspectives for the scalable design and development of novel superinsulating materials.

Superflexible Multifunctional Polyvinylpolydimethylsiloxane-Based Aerogels as Efficient Absorbents, Thermal Superinsulators, and Strain Sensors

Aerogels are porous materials but show poor mechanical properties and limited functionality, which significantly restrict their practical applications. Preparation of highly bendable and processable aerogels with multifunctionality remains a challenge. Herein we report unprecedented superflexible aerogels based on polyvinylpolydimethylsiloxane (PVPDMS) networks, PVPDMS/polyvinylpolymethylsiloxane (PVPMS) copolymer networks, and PVPDMS/PVPMS/graphene nanocomposites by a facile radical polymerization/hydrolytic polycondensation strategy and ambient pressure drying or freeze drying. The aerogels have a doubly cross-linked organic-inorganic network structure consisting of flexible polydimethylsiloxanes and hydrocarbon chains with tunable cross-linking density, tunable pore size and bulk density. They have a high hydrophobicity and superflexibility and combine selective absorption, efficient separation of oil and water, thermal superinsulation, and strain sensing.

Transparent, Superflexible Doubly Cross-Linked Polyvinylpolymethylsiloxane Aerogel Superinsulators via Ambient Pressure Drying

Aerogels have many attractive properties but are usually costly and mechanically brittle, which always limit their practical applications. While many efforts have been made to reinforce the aerogels, most of the reinforcement efforts sacrifice the transparency or superinsulating properties. Here we report superflexible polyvinylpolymethylsiloxane, (CH₂CH(Si(CH₃)O_2/2))_n, aerogels that are facilely prepared from a single precursor vinylmethyldimethoxysilane or vinylmethyldiethoxysilane without organic cross-linkers. The method is based on consecutive processes involving radical polymerization and hydrolytic polycondensation, followed by ultralow-cost, highly scalable, ambient-pressure drying directly from alcohol as a drying medium without any modification or additional solvent exchange. The resulting aerogels and xerogels show a homogeneous, tunable, highly porous, doubly cross-linked nanostructure with the elastic polymethylsiloxane network cross-linked with flexible hydrocarbon chains. An outstanding combination of ultralow cost, high scalability, uniform pore size, high surface area, high transparency, high hydrophobicity, excellent machinability, superflexibility in compression, superflexibility in bending, and superinsulating properties has been achieved in a single aerogel or xerogel. This study represents a significant progress of porous materials and makes the practical applications of transparent flexible aerogel-based superinsulators realistic.