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.
Keywords: aerogel; coating; films; heterocyclic aramid; performance; polymerization-induced aramid nanofibers; thermal insulation.