Economical Architected Foamy Aerogel Coating for Energy Conservation and Flame Resistance

Aerogel coating (AC) is an emerging constructional material to achieve ambitions to reduce our carbon footprint. However, common ACs, which are usually formulated by straightforward filler–matrix composites, suffer from unsatisfying thermal-insulating performance due to the low porosity and polymer intrusion into the filler. These can be solved by applying an easy foaming process to the ACs, where meanwhile the intrusion issue can be relented by particles decoration on the inner surface of bubbles. Herein, an architected foamy AC by melamine polymer and silica aerogel particles is demonstrated as a proof-of-concept. The high-porosity foamy AC can achieve much lower thermal conductivity and less heat release as well as superhydrophobicity and excellent fire resistance. The coating can be air-sprayed on surfaces regardless of the materials and shapes, followed by natural drying. It provides an economical drop-in measure to enhance the energy conservation and fire safety of various buildings.