Aerogel has been much highlighted as an emerging lightweight
thermal
insulation material, but problems such as fragility, low strength,
liquid permeability, and lack of flexibility greatly limit further
applications. In this work, a facile aramid-coating-on-aramid (ACoA)
method is demonstrated to fabricate all-aramid aerogel composite films
for thermal insulation. The method started from the bottom-up synthesis
of polymerization-induced para-aramid nanofibers
(PANF), which were easily transformed into aerogel films through the
vacuum-assisted filtration followed by the freeze-drying techniques.
Then, the heterocyclic aramid (HA) solution prepared through the low-temperature-solution
polycondensation was used as the coating to be applied onto the PANF
aerogel films, and composite films of HA/PANF aerogel were simply
achieved with HA contributed to the dense and continuous surface layer.
The bulk HA film is of superior mechanical and thermal properties
to those of the PANF film. Moreover, reliable interfacial interlocking
structures were developed beneath the outermost surface via the interpenetration
of the infiltrated HA with PANF network. The comprehensive result
was the 15 times enhanced tensile strength, 33 times enhanced fracture
toughness, the high thermal decomposition temperature, and the additional
flexibility for the foldable films of HA/PANF aerogel. The sealing
of the surface macropores greatly suppressed the surface chalking
and high water absorption. However, the survival of the tiny pores
inside the composite maintained the low enough level of the thermal
conductivity to provide effective protections against high temperature
not only in air but also under wet or even liquid conditions, suggesting
the broader applications for thermal insulation.