Porous
fiber-based ceramics have been widely applied in various
fields because of their excellent thermal insulation property and
high thermal stability property. However, designing porous fibrous
ceramics with enhanced comprehensive performances, such as low density,
low thermal conductivity, and high mechanical properties at both room
temperature and high temperature, is still a challenge and the future
development trend. Hence, based on the lightweight cuttlefish bone
that possesses a “wall-septa” structure with excellent
mechanical performance, we design and fabricate a novel porous fibrous
ceramic with the unique fiber-based dual structure of lamellas by
the directional freeze-casting method and systematically investigate
the effects of lamellar components on the microstructure and mechanical
performances of the product. For the desired cuttlefish-bone-structure-like
lamellar porous fiber-based ceramics (CLPFCs), the porous framework
formed by the overlapping of transversely arranged fibers helps to
reduce the density and thermal conductivity of the product, and the
longitudinally arranged lamellar structure replaces traditional binders
and plays an important role in improving the mechanical properties
in the direction parallel to the X–Z plane. Compared with traditional porous fibrous materials
reported in the literature, the CLPFCs with an Al2O3/SiO2 molar ratio of 1:2 in the lamellar component
exhibits prominent comprehensive performances, such as low density,
excellent thermal insulation property, and outstanding mechanical
performances at both room temperature and high temperature (3.46 MPa
at 1300 °C), indicating that the CLPFCs are a promising candidate
for applications in high-temperature thermal insulation systems.