Superinsulating Polyisocyanate Based Aerogels: A Targeted Search for the Optimum Solvent System

Fabrication of High-Performance Polyisocyanurate Aerogels through Cocyclotrimerization of 4,4'-Methylene Diphenyl Diisocyanate and Its Mono-Urethane Derivatives

Aromatic polyisocyanurate (PIR) aerogels are recognized as advanced porous materials and extensively studied due to their lightweight nature, high porosity, and specific surface area, which attribute to their outstanding thermal insulation properties. The inherent thermal stability of the PIR moieties, combined with great insulating performance, renders PIR aerogels highly suitable for building insulation applications. Nevertheless, materials containing isocyanurate obtained through direct trimerization of aromatic isocyanates exhibit brittleness, resulting in inferior mechanical performance. In order to enhance the processability of the PIR aerogels, we propose a cocyclotrimerization approach involving mixtures of mono- and difunctional aromatic isocyanates. This approach is designed to develop a PIR network with decreased cross-linking density and brittleness. Herein, we developed an array of PIR aerogels from different alkyl chain-modified isocyanate mixtures. The resulting PIR aerogels exhibited high porosity (>89%), a large surface area (∼300 m2/g), superinsulating performance with ultralow thermal conductivity (∼16.8 mW m-1 K-1), notable thermal stability (Td5% ∼ 250 °C), improved mechanical performance, and intrinsic hydrophobicity without the need for postmodification. These high-performance organic aerogels hold significant promise for applications requiring superinsulating materials.

Exploring the Impact of the Synthesis Variables Involved in the Polyurethane Aerogels-like Materials Design

This research presents a novel approach to synthesising polyurethane (PUR)-based aerogels at the pilot scale, optimizing synthesis variables such as the gelation solvent, solids content, chain extender/isocyanate ratio, and dispersion mode. The solids content (2-11 wt.%) is the parameter with the most influence on the density of the aerogels, with a clear decrease in this property as the solids content decreases. On the other hand, it was demonstrated that minimizing the excess of ethylenediamine (used as chain extender) in relation to the isocyanate is a valuable consideration to improve the thermal conductivity of the aerogel. Related to the chain extender/isocyanate ratio, a compromise situation where the initial isocyanate reacts almost completely is crucial. Fourier-transform infrared spectroscopy was used to conduct such monitoring during the reaction. Once the conditions were optimised, the aerogel showing improved properties was synthesised using ethyl acetate as the gelling solvent, a 3.7 wt.% solids content, an ethylenediamine/isocyanate ratio of 0.20, and sonication as the dispersion mode, attaining a thermal conductivity of 0.030 W m-1 K-1 and a density of 0.046 g cm-3. Therefore, the synthesized aerogel emerges as a promising candidate for use in the construction and automotive industries.

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

The effect of synthesis conditions and process parameters on aerogel properties

Aerogels are remarkable nanoporous materials with unique properties such as low density, high porosity, high specific surface area, and interconnected pore networks. In addition, their ability to be synthesized from various precursors such as inorganics, organics, or hybrid, and the tunability of their properties make them very attractive for many applications such as adsorption, thermal insulation, catalysts, tissue engineering, and drug delivery. The physical and chemical properties and pore structure of aerogels are crucial in determining their application areas. Moreover, it is possible to tailor the aerogel properties to meet the specific requirements of each application. This review presents a comprehensive review of synthesis conditions and process parameters in tailoring aerogel properties. The effective parameters from the dissolution of the precursor step to the supercritical drying step, including the carbonization process for carbon aerogels, are investigated from the studies reported in the literature.

Superinsulating nanocellulose aerogels: Effect of density and nanofiber alignment

Cellulose aerogels are potential alternatives to silica aerogels with advantages in cost, sustainability and mechanical properties. However, the density dependence of thermal conductivity (λ) for cellulose aerogels remains controversial. Cellulose aerogels were produced by gas-phase pH induced gelation of TEMPO-oxidized cellulose nanofibers (CNF) and supercritical drying. Their properties are evaluated by varying the CNF concentration (5-33 mg·cm^-3) and by uniaxial compression (9-115 mg·cm^-3). The aerogels are transparent with specific surface areas of ~400 m²·g^-1, mesopore volumes of ~2 cm³·g^-1 and a power-law dependence of the E-modulus (α ~ 1.53, and the highest reported E of ~1 MPa). The dataset confirms that λ displays a traditional U-shaped density dependence with a minimum of 18 mW·m^-1·K^-1 at 0.065 g·cm^-3. For a given density, λ is ~5 mW·m^-1·K^-1 lower for compressed aerogels due to the alignment of nanofibers, confirmed by small angle X-ray scattering (SAXS).

Linking intermolecular interactions and rheological behaviour in capillary suspensions

HYPOTHESIS

Capillary suspensions feature networks of particles connected by liquid bridges, which are obtained by adding a small amount of a second immiscible liquid to a suspension. It is possible to link the network formation as well as the rheological behaviour of capillary suspensions to the intermolecular interactions of their constituents.

EXPERIMENTS AND SIMULATIONS

Through a combination of experimental and numerical methods, we present a novel approach, based on Hansen solubility parameters computed from Molecular Dynamics (MD) simulations, to rationalize and predict the rheological behaviour of capillary suspensions. We investigated the formation of capillary suspensions for various combinations of bulk and secondary liquids mixed with hydrophilic silica particles. The predictions were confirmed experimentally by rheological analysis, interfacial tension measurements and microscopy (CLSM) imaging.

FINDINGS

Numerical and experimental results show that the Hansen solubility parameters theory allows to predict the formation of capillary suspensions, whose strength exponentially decays with decreasing intermolecular interactions between the secondary liquids and the dispersed particles. High immiscibility between the bulk and secondary liquid strengthens the gel up to a critical immiscibility point, above which the strength of the gel remains mostly affected by the affinity between the secondary liquids and the dispersed particles. Furthermore, we find that hydrogen-bonding and polar interactions control the formation of capillary suspensions. This simple approach can guide the selection of adequate solvents and immiscible secondary liquids, allowing an easy formulation of new particulate-based gels.

Super-Insulating Transparent Polyisocyanurate-Polyurethane Aerogels: Analysis of Thermal Conductivity and Mechanical Properties

A family of transparent polyisocyanurate-polyurethane (PUR-PIR) aerogels with an interesting combination of physical properties were synthesized. First, their textural properties were analyzed aiming to study catalyst influence on the final porous structures and densities. Their thermal conductivities were measured at different temperatures allowing observation of a clear trend relating the initial formulation with the porous structure and reaching values as low as 12 mW/mK, the lowest found in the literature for aerogels based on this polymer matrix. Contributions to thermal conductivity were calculated, improving the understanding of the porous structure-insulating performance relationship. Moreover, their mechanical properties were studied (elastic modulus, stress at different strains and elastic behavior). The aerogels showed tunable stiffness (elastic modulus from 6.32 to 0.13 MPa) by changing the catalyst concentration and significant elasticity. Thus, super-insulating transparent PUR-PIR aerogels with tailored mechanical properties were obtained opening a wide range of potential applications in the energy, building, automotive and aeronautical sectors, among others. The exceptional insulation of silica aerogels was reached at the same time that their general brittleness was improved while keeping good transparency to visible light (85%, 650 nm). Therefore, these aerogels may constitute an alternative to silica aerogels.

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.

Polyurea Aerogels: Synthesis, Material Properties, and Applications

Polyurea is an isocyanate derivative, and comprises the basis for a well-established class of polymeric aerogels. Polyurea aerogels are prepared either via reaction of multifunctional isocyanates with multifunctional amines, via reaction of multifunctional isocyanates and water, or via reaction of multifunctional isocyanates and mineral acids. The first method is the established one for the synthesis of polyurea, the third is a relatively new method that yields polyurea doped with metal oxides in one step, while the reaction of isocyanates with water has become the most popular route to polyurea aerogels. The intense interest in polyurea aerogels can be attributed in part to the low cost of the starting materials-especially via the water method-in part to the extremely broad array of nanostructural morphologies that allow study of the nanostructure of gels as a function of synthetic conditions, and in part to the broad array of functional properties that can be achieved even within a single chemical composition by simply adjusting the synthetic parameters. In addition, polyurea aerogels based on aromatic isocyanates are typically carbonizable materials, making them highly competitive alternatives to phenolic aerogels as precursors of carbon aerogels. Several types of polyurea aerogels are already at different stages of commercialization. This article is a comprehensive review of all polyurea-based aerogels, including polyurea-crosslinked oxide and biopolymer aerogels, from a fundamental nanostructure-material properties perspective, as well as from an application perspective in thermal and acoustic insulation, oil adsorption, ballistic protection, and environmental cleanup.

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.

Mechanism of Hydration and Hydration Induced Structural Changes of Calcium Alginate Aerogel

The most relevant properties of polysaccharide aerogels in practical applications are determined by their microstructures. Hydration has a dominant role in altering the microstructures of these hydrophilic porous materials. To understand the hydration induced structural changes of monolithic Ca-alginate aerogel, produced by drying fully cross-linked gels with supercritical CO₂, the aerogel was gradually hydrated and characterized at different states of hydration by small-angle neutron scattering (SANS), liquid-state nuclear magnetic resonance (NMR) spectroscopy, and magic angle spinning (MAS) NMR spectroscopy. First, the incorporation of structural water and the formation of an extensive hydration sphere mobilize the Ca-alginate macromolecules and induce the rearrangement of the dry-state tertiary and quaternary structures. The primary fibrils of the original aerogel backbone form hydrated fibers and fascicles, resulting in the significant increase of pore size, the smoothing of the nanostructured surface, and the increase of the fractal dimension of the matrix. Because of the formation of these new superstructures in the hydrated backbone, the stiffness and the compressive strength of the aerogel significantly increase compared to its dry-state properties. Further elevation of the water content of the aerogel results in a critical hydration state. The Ca-alginate fibers of the backbone disintegrate into well-hydrated chains, which eventually form a quasi-homogeneous hydrogel-like network. Consequently, the porous structure collapses and the well-defined solid backbone ceases to exist. Even in this hydrogel-like state, the macroscopic integrity of the Ca-alginate monolith is intact. The postulated mechanism accounts for the modification of the macroscopic properties of Ca-alginate aerogel in relation to both humid and aqueous environments.

Hansen solubility parameters obtained via molecular dynamics simulations as a route to predict siloxane surfactant adsorption

HYPOTHESIS

The Hansen Solubility Parameters (HSP) derived from Molecular Dynamics (MD) simulations can be used as a fast approach to predict surfactants adsorption on a solid surface. Experiments and simulations: We focused on the specific case of siloxane-based surfactants adsorption on silicon oxide surface (SiO₂), encountered in inkjet printing processes. A simplified atomistic model of the SiO₂ surface was designed to enable the computation of its solubility parameter using MD, and to subsequently determine the interactions of the SiO₂ surface with the siloxane-based surfactant and the various solvents employed. Surfactant adsorption was characterized experimentally using contact angle goniometry, ellipsometry, XPS and AFM.

FINDINGS

Comparison of the numerical results with experiments showed that the HSP theory allows to identify the range of solvents that are likely to prevent surfactant adsorption on the SiO₂ surface. The proposed approach indicates that polar solvents, such as acetone and triacetin, which are strongly attracted to the silicon oxide surface might form a shield that prevents siloxane-based surfactants adsorption. This simple approach, can guide the selection of adequate solvents for surfaces and surfactants with specific chemical structures, providing opportunities for controlling interfacial adsorption.

Fluorescent Aerogels Based on Chemical Crosslinking between Nanocellulose and Carbon Dots for Optical Sensor

Generally produced by solvent sublimation via freeze-drying or critical point drying treatment, nanocellulose-based aerogels have attracted considerable interest in offering the features such as sustainability, available surface reactivity, lightweight, high porosity, and specific surface area. This study presents a novel strategy for the preparation of fluorescent aerogels based on covalent linkage between the natural skeleton of a cellulose nanofibril (CNF) and a fluorescent carbon dot (CD). The maximum CD grafting content on the CNF-based aerogel was 113 mg g^-1, providing bright blue fluorescence under ultraviolet radiation with a high fluorescence quantum yield of 26.2%. Besides improved mechanical properties with a 360% increase in compression strength, the covalently bonded CD nanoparticle further serves as a structural stabilizer to endow the characteristic of shape recovery in water for the fabricated fluorescent aerogel. Finally, this aerogel displays high sensitivity and selection on the recognition of NO _x and aldehyde species, which is studied for the detection of glutaraldehyde at ultralow concentrations (ppm) in water. Using the innovation of an organic solvent-free route and avoiding the toxic crosslinking reagents or fluorescent sources, the CNF/CD-based fluorescent aerogel developed in this study is a promising functional material for potential optical sensing application.

Formation of Nanofibrous Structure in Biopolymer Aerogel during Supercritical CO2 Processing: The Case of Chitosan Aerogel

Supercritical drying is widely considered as the gold standard to produce aerogels that preserve the microstructure of the gels, but we have found this is not always the case. Chitosan aerogel, one of the emerging biopolymer aerogels, was prepared by chemical cross-linking gelation, followed by solvent exchange with methanol and supercritical drying using CO₂. Small-angle X-ray scattering analysis shows that the structure of the wet gel, which consists of Gaussian chains of individual molecular strands, converts into a nanofibrous network during CO₂ processing. In situ observation reveals a drastic shrinkage of the gel in CO₂, demonstrating that physical coagulation caused by the low affinity between chitosan and CO₂ is the main structure-forming step. These results challenge the common perception of supercritical drying: it is no longer an inactive drying method, but rather an active nanostructure forming a tool to produce porous biopolymer materials with tailored structure and properties.

K-Index: A Descriptor, Predictor, and Correlator of Complex Nanomorphology to Other Material Properties

Morphology is a qualitative property of nanostructured matter and is articulated by visual inspection of micrographs. For deterministic procedures that relate nanomorphology to synthetic conditions, it is necessary to express nano- and microstructures numerically. Selecting polyurea aerogels as a model system with demonstrated potential for rich nanomorphology and guided by a statistical design-of-experiments model, we prepared a large array of materials (208) with identical chemical composition but quite different nanostructures. By reflecting on SEM imaging, it was realized that our first preverbal impression about a nanostructure is related to its openness and texture; the former is quantified by porosity ( Π), and the latter is oftentimes related to hydrophobicity, which, in turn, is quantified by the contact angle (θ) of water droplets resting on the material. Herewith, the θ-to-Π ratio is referred to as the K-index, and it was noticed that all polyurea samples of this study could be put in eight K-index groups with separate nanomorphologies ranging from caterpillar-like assemblies of nanoparticles, to thin nanofibers, to cocoon-like structures, to large bald microspheres. A first validation of the K-index as a morphology descriptor was based on compressing samples to different strains: it was observed that as the porosity decreases, the water-contact angle decreases proportionally, and thereby the K-index remains constant. The predictive power of the K-index was demonstrated with 20 polyurea aerogels prepared in 8 binary solvent systems. Subsequently, several material properties were correlated to nanomorphology through the K-index and that, in turn, provided insight about the root cause of the diversity of the nanostructure in polyurea aerogels. Finally, using response surface methodology, K-indexes and other material properties of practical interest were correlated to the monomer, water, and catalyst concentrations as well as the three Hansen solubility parameters of the sol. That enabled the synthesis of materials with up to six prescribed properties at a time, including nanomorphology, bulk density, BET surface area, elastic modulus, ultimate compressive strength, and thermal conductivity.

Application of the solubility parameter concept to assist with oral delivery of poorly water-soluble drugs – a PEARRL review

Objectives

Solubility parameters have been used for decades in various scientific fields including pharmaceutics. It is, however, still a field of active research both on a conceptual and experimental level. This work addresses the need to review solubility parameter applications in pharmaceutics of poorly water-soluble drugs.

Key findings

An overview of the different experimental and calculation methods to determine solubility parameters is provided, which covers from classical to modern approaches. In the pharmaceutical field, solubility parameters are primarily used to guide organic solvent selection, cocrystals and salt screening, lipid-based delivery, solid dispersions and nano- or microparticulate drug delivery systems. Solubility parameters have been applied for a quantitative assessment of mixtures, or they are simply used to rank excipients for a given drug.

Summary

In particular, partial solubility parameters hold great promise for aiding the development of poorly soluble drug delivery systems. This is particularly true in early-stage development, where compound availability and resources are limited. The experimental determination of solubility parameters has its merits despite being rather labour-intensive because further data can be used to continuously improve in silico predictions. Such improvements will ensure that solubility parameters will also in future guide scientists in finding suitable drug formulations.