Ultrathin SiO2 aerogel papers with hierarchical scale enable high-temperature thermal insulation

Aerogel composites reinforced by fibers have found extensive applications in the field of thermal insulation and energy conservation. However, the composites are hindered by their high infrared radiation transmittance and weak interface adhesion in practical applications. Herein, we designed and prepared a novel thin composite called ‘fiber/whisker/aerogel paper’ (SWAP) with a thickness of less than 1 mm. The SWAP integrated SiC nanowhiskers (SiCnw) as opacifiers and ultrafine SiO2 fibers as reinforcement, fabricated through wet manufacturing and sol-gel process. The ‘fiber/aerogel paper’ (SAP) and SWAP exhibited low thermal conductivity at room temperature, measuring 0.025 W/(m·K) and 0.033 W/(m·K), respectively. Additionally, they exhibited low densities of 0.195 g/cm3 and 0.225 g/cm3, respectively. Notably, SWAP exhibited excellent high-temperature insulation performance, primarily due to its low infrared transmittance (50% at 3 μm). The incorporation of SiCnw and ultrafine SiO2 fibers collectively enhanced the interfacial adhesion with the aerogel matrix even amidst rigorous testing (weight loss less than 3%). SWAP also demonstrated flexibility, high thermal stability, hydrophobicity, and flame resistance. Furthermore, a comprehensive investigation into the performance variations and influencing g factors of the material was conducted under different heat treatment conditions. This research provides guidance for the application of such materials under high temperatures.