In situ co‐polymerization of high‐performance polybenzoxazine/silica aerogels for flame‐retardancy and thermal insulation

A high-temperature-triggered crosslinking reaction to achieve excellent intrinsic flame retardancy of organic phase change composites

The host-guest composite that integrates a porous scaffold and organic phase change materials (PCMs) features high energy density and customizable function, promising for advanced thermal storage/utilization. However, highly flammable organic PCMs are prone to severe combustion in porous structures, making it challenging for traditional flame-retardant methods to balance fire safety and latent heat. Herein, a high-temperature-triggered crosslinking reaction between the host and guest is designed using a polybenzoxazine-based aerogel (PB-1) and benzoxazine-based PCMs (C-dad). At high temperatures, the ring-opening polymerization (ROP) of C-dad can be initiated by and reacted with the phenolic groups of PB-1 to form a polybenzoxazine copolymer monolith with an improved char yield and intrinsic low flammability and without using the typical flame-retardant components. This enables the obtained composite (PB-1/C-dad) to well balance latent heat (145.3 J g-1), char yield (a char residue of 13.1% at 600 °C), and flame retardancy (a peak heat release rate of 231 W g-1), outperforming the representative flame-retardant modified polymer/organic PCM complexes reported in the literature. This thermal-triggered mechanism allows PB-1/C-dad to be repeatedly and stably used within the working temperature and activates its flame retardancy when exposed to open flames. The proposed host-guest crosslinking strategy is believed to inspire the development of inherently nonflammable phase change composites for safer thermal management.

Effect of Fiber Characteristics on the Structure and Properties of Quartz Fiber Felt Reinforced Silica-Polybenzoxazine Aerogel Composites

Fiber-reinforced aerogel composites are widely used for thermal protection. The properties of the fibers play a critical role in determining the structure and properties of the final aerogel composite. However, the effects of the fiber's characteristics on the structure and properties of the aerogel composite have rarely been studied. Herein, we prepared quartz fiber felt-reinforced silica-polybenzoxazine aerogel composite (QF/PBSAs) with different fiber diameters using a simple copolymerization process with the ambient pressure drying method. The reasons for the effects of fiber diameter on the structure and properties of the aerogel composites were investigated. The results showed that the pore structure of the aerogel composites was affected by the fiber diameter, which led to significant changes in the mechanical behavior and thermal insulation performance. At room temperature, pore structure and density were found to be the main factors influencing the thermal conductivity of the composites. At elevated temperatures, the radiative thermal conductivity (λr) plays a dominant role, and reducing the fiber diameter suppressed λr, thus decreasing the thermal conductivity. When the QF/PBSAs were exposed to a 1200 °C butane flame, the PBS aerogel was pyrolyzed, and the pyrolysis gas carried away a large amount of heat and formed a thermal barrier in the interfacial layer, at which time λr and the pyrolysis of the PBS aerogel jointly determined the backside temperature of the composites. The results of this study can provide valuable guidance for the application of polybenzoxazine aerogel composites in the field of thermal protection.

Surfactant-assisted molecular-level tunning of phenol-formaldehyde-based hard carbon microspheres for high-performance sodium-ion batteries

The phenol-formaldehyde (PF) resin is an economical precursor for spherical hard carbon (HC) anodes for sodium-ion batteries (SIBs). However, achieving precise molecular-level control of PF-based HC microspheres, particularly for optimizing ion transport microstructure, is challenging. Here, a sodium linoleate (SL)-assisted strategy is proposed to enable molecular-level engineering of PF-based HC microspheres. PF microspheres are synthesized through the polymerization of 3-aminophenol and formaldehyde, initially forming oxazine rings and then undergoing ring-opening polymerization to create a macromolecular network. SL functions as both a surfactant to control microsphere size and a catalyst to enhance ring-opening polymerization and increase polymerization of PF resin. These modifications lead to reduced microsphere diameter, increased interlayer spacing, enhanced graphitization, and significantly improved electron and ion transfer. The synthesized HC microspheres exhibit a remarkable reversible capacity of 337 mAh/g, maintaining 96.9 mAh/g even at a high current density of 5.0 A/g. Furthermore, the full cell demonstrates a high capacity of 150 mAh/g, an energy density of 125.3 Wh kg-1, an impressive initial coulombic efficiency (ICE) of 930.3% at 1 A/g, and remarkable long-term stability over 3000 cycles. This study highlights the potential of surfactant-assisted molecular-level engineering in customizing HC microspheres for advanced SIBs.

Double-Network MK Resin-Modified Silica Aerogels for High-Temperature Thermal Insulation

Polymer-reinforced SiO2 aerogel materials exhibit excellent thermal insulation, flame resistance, and mechanical properties; however, the poor thermal stability of organic components limits their application in high-temperature environments. Herein, a double-network MK/SiO2 aerogel was synthesized by direct copolymerization of a methyl-containing silicone resin (MK) and tetraethoxysilane (TEOS) under the cross-coupling of (3-aminopropyl) triethoxysilane (APTES) followed by an atmospheric drying method. The resulting MK/SiO2 aerogel, presenting a double-cross-linked MK and SiO2 network, shows a low density of 0.18 g/cm3, a high specific surface area of 716.6 m2/g, and a low thermal conductivity of 0.030 W/(m K). Especifically, the compressive strength of the MK/SiO2 aerogel (up to 3.24 MPa) is an order of magnitude higher than that of the pristine SiO2 aerogel (0.39 MPa) due to the introduction of the strong MK network and enhanced neck connections of SiO2 nanoparticles. Furthermore, the mutually supportive network endows the MK/SiO2 aerogels with significant resistance to ablation and oxidation up to 1000 °C, showing a high residual rate (89%), a high specific surface area (235.2 m2/g), and structural stability after thermal treatment under air atmosphere. These superior mechanical and thermal properties of the MK/SiO2 aerogels lead to attractive practical applications in energy transportation, thermal insulation, or aviation.

Aerogels for Thermal Protection and Their Application in Aerospace

With the continuous development of the world's aerospace industry, countries have put forward higher requirements for thermal protection materials for aerospace vehicles. As a nano porous material with ultra-low thermal conductivity, aerogel has attracted more and more attention in the thermal insulation application of aerospace vehicles. At present, the summary of aerogel used in aerospace thermal protection applications is not comprehensive. Therefore, this paper summarizes the research status of various types of aerogels for thermal protection (oxide aerogels, organic aerogels, etc.), summarizes the hot issues in the current research of various types of aerogels for thermal protection, and puts forward suggestions for the future development of various aerogels. For oxide aerogels, it is necessary to further increase their use temperature and inhibit the sintering of high-temperature resistant components. For organic aerogels, it is necessary to focus on improving the anti-ablation, thermal insulation, and mechanical properties in long-term aerobic high-temperature environments, and on this basis, find cheap raw materials to reduce costs. For carbon aerogels, it is necessary to further explore the balanced relationship between oxidation resistance, mechanics, and thermal insulation properties of materials. The purpose of this paper is to provide a reference for the further development of more efficient and reliable aerogel materials for aerospace applications in the future.

Synthesis and Application Studies of DOPO-Based Organophosphorous Derivatives to Modify the Thermal Behavior of Polybenzoxazine

The DOPO-based flame-retardant additives DOPO-HQ, DOPO-AP and DOPO-Van were synthesized in varying numbers of phenolic hydroxyl groups and amine groups. Moreover, their influence on the polymerization of a bisphenol F-based benzoxazine, as well as the thermal properties of the resulting materials, were studied. All DOPO-based derivatives influenced the polymerization temperature onset with a reduction of up to 20 °C, while thermo-mechanical properties remained high. Surprisingly, phosphorous content below 0.4 wt% significantly improved the reaction against small flames yielding an increase in the limited oxygen index by 2% and a V-0 rating in the UL-94 test. DOPO-HQ proved to be the most effective additive regarding the reaction against small flames at an astonishingly low phosphorous concentration of below 0.1 wt%, whereas DOPO-AP and DOPO-Van simultaneously lowered the polymerization temperature.