To prepare modified silica nanospheres for emulsion polymerization, a new agglomeration-free change of dispersion media has been developed. Nanosized silica spheres were synthesized by the Stöber method and directly modified with a silane coupling agent. To prepare these particles for subsequent polymerization, the dispersion medium was changed in a two-step process from ethanol to water without agglomeration of the particles. The emulsion polymerization leads to hemispherical single-core-structured silica-polystyrene composite particles. The thickness of the polymer shell can be altered by varying the amount of styrene. The developed change of dispersion media provides nonagglomerated modified silica particles for the encapsulation with polystyrene and enables the synthesis of narrowly distributed single-core composite particles. The developed process is a promising approach for the preparation of nanoparticles for subsequent polymerization and can be scaled-up for industrial applications.

The freeze‐casting technique has been used for a variety of materials to tailor their pore structure. The growing ice crystals act as a template for the subsequent voids present in the body. While it is mostly used for inorganic oxide materials, the method is also applicable to polymers like poly(vinyl alcohol) (PVA). The synthesized materials have an aligned anisotropic pore structure which significantly influences the mechanical behavior and the thermal conductivity. Glutaraldehyde (GA) can be used as a cross‐linking agent to reduce the water solubility of the PVA samples. The composition‐dependent thermal conductivities are measured, and found to be 0.055–0.078 W m−1 K−1 parallel to the freezing direction and 0.048–0.058 W m−1 K−1 in the transverse direction. The scaffold‐like structure resembling the hydroxyapatite structures in bones yields high strength values in the axial direction well exceeding that of common unsupported building insulation materials.

We show in this paper that composites of mechanical impedance mismatch nanopowders yield competitive thermal insulation values to aerogels. The powders are connected by a polymer matrix assuring mechanical integrity. A simple calculation for the thermal boundary resistance has been conducted based on established models.

Freeze-casting consists of freezing a liquid suspension (aqueous or other), followed by sublimation of the solidified state to the gas state under reduced pressure, and subsequent sintering of the remaining scaffold to consolidate and densify the struts and walls. The structure is very porous with the pores being a replica of the solvent crystals. The technique is rather versatile and the use of a liquid solvent (water most of the time) as a pore forming agent is a strong asset. Freeze-casting has also been developed as a near net shape forming route yielding dense ceramics. In this work we report on porous composite materials synthesized via the ice templating method. Poly(vinyl alcohol) (PVA) is used as matrix and nano-silica (SiO2), nanoclay (NC) and microfibrillated cellulose (MFC) are used as fillers to improve the mechanical stability of the PVA scaffold. We show our results on the porosity and mechanical stability and consider these porous nanocomposites as potential insulation materials with low thermal conductivity and superior mechanical properties.