Merging flexibility with superinsulation: Machinable, nanofibrous pullulan-silica aerogel composites

Freeze-dried nanofibrous scaffolds are flexible, but typically have high thermal conductivities. Conversely, silica aerogel has an ultra-low thermal conductivity, but is brittle. Here, the impregnation of pullulan/PVA nanofiber scaffolds with hydrophobic silica aerogel decreased the thermal conductivity from 31.4 to 17.7 mW/(m·K). The compatibility between the silylated nanofibers and the silica aerogel promotes the overgrowth of silica particles onto the fiber surfaces and the fiber incorporation. The composites display improved compressive and tensile properties compared to the neat pullulan scaffold and silica aerogel. The composite's E-modulus is 234 kPa compared to 4 kPa for the pullulan scaffold and 102 kPa for the silica aerogel. The composite's tensile strength is five times higher than that of the silica aerogel. Because of its reduced brittleness, the pullulan-silica aerogel composites can be shaped using a sharp blade. The composites can sustain uniaxial compression up to 80% strain, but the decompressed composites display two times higher densities because the strain is partially irreversible. This densification reduces thermal conductivity to 16.3 mW/(m·K) and increases final compressive strength by a factor of seven. Both the as prepared and densified composites demonstrate unique material properties in terms of thermal conductivity, mechanical strength and machinability. [Display omitted] •Aerogel composites were synthesized by impregnating nanofibrous pullulan-PVA scaffolds with hydrophobic silica aerogel.•Compatibility between the silylated nanofibers and the silica aerogel promotes a superior thermo-mechanical performance.•Pullulan-silica aerogel composites display an excellent machinability and can be easily cut into different shapes.•Densifying composites further reduces thermal conductivity and increases compressive strength.