Aerogels are nanoporous materials with excellent properties, especially super thermal insulation. However, owing to their serious high brittleness, the macroscopic forms of aerogels are not sufficiently rich for the application in some fields, such as thermal insulation clothing fabric. Recently, freeze spinning and wet spinning have been attempted for the synthesis of aerogel fibers. In this study, robust fibrous silica-bacterial cellulose (BC) composite aerogels with high performance were synthesized in a novel way. Silica sol was diffused into a fiber-like matrix, which was obtained by cutting the BC hydrogel and followed by secondary shaping to form a composite wet gel fiber with a nanoscale interpenetrating network structure. The tensile strength of the resulting aerogel fibers reached up to 5.4 MPa because the quantity of BC nanofibers in the unit volume of the matrix was improved significantly by the secondary shaping process. In addition, the composite aerogel fibers had a high specific area (up to 606.9 m²/g), low density (less than 0.164 g/cm³), and outstanding hydrophobicity. Most notably, they exhibited excellent thermal insulation performance in high-temperature (210 °C) or low-temperature (−72 °C) environments. Moreover, the thermal stability of CAFs (decomposition temperature was about 330 °C) was higher than that of natural polymer fiber. A novel method was proposed herein to prepare aerogel fibers with excellent performance to meet the requirements of wearable applications.

Forming fibers for fabric insulation is difficult using aerogels, which have excellent thermal insulation performance but poor mechanical properties. A previous study proposed a novel method that could effectively improve the mechanical properties of aerogels and make them into fibers for use in fabric insulation. In this study, composite aerogel fibers (CAFs) with excellent mechanical properties and thermal insulation performance were prepared using a streamlined method. The wet bacterial cellulose (BC) matrix without freeze-drying directly was immersed in an inorganic precursor (silicate) solution, followed by initiating in situ sol-gel reaction under the action of acidic catalyst after secondary shaping. Finally, after surface modification and ambient drying of the wet composite gel, CAFs were obtained. The CAFs prepared by the simplified method still had favorable mechanical properties (tensile strength of 4.5 MPa) and excellent thermal insulation properties under extreme conditions (220 °C and −60 °C). In particular, compared with previous work, the presented CAFs preparation process is simpler and more environmentally friendly. In addition, the experimental costs were reduced. Furthermore, the obtained CAFs had high specific surface area (671.3 m²/g), excellent hydrophobicity, and low density (≤0.154 g/cm³). This streamlined method was proposed to prepare aerogel fibers with excellent performance to meet the requirements of wearable applications.

Aerogels are three-dimensional nanoporous materials with outstanding properties, especially great thermal insulation. Nevertheless, their extremely high brittleness restricts their practical application. Recently, although the mechanical properties of silica aerogels have been improved by regulating the precursor or introducing a polymer reinforcer, these preparation processes are usually tedious and time-consuming. The purpose of this study was to simplify the preparation process of these composite aerogels. A silicic acid solution treated with cation exchange resin was mixed with agarose (AG) to gel in situ, and then composite aerogels (CAs) with an interpenetrating network (IPN) structure were obtained by aging and supercritical CO₂ fluid (SCF) drying. Compared to previous works, the presented CAs preparation process is briefer and more environmentally friendly. Moreover, the CAs exhibit a high specific surface area (420.5 m²/g), low thermal conductivity (28.9 mW m⁻¹ K⁻¹), excellent thermal insulation properties, and thermal stability. These results show that these CAs can be better used in thermal insulation.

Advanced SiO₂–Al₂O₃ aerogel materials have outstanding potential in the field of thermal insulation. Nevertheless, the creation of a mechanically robust and low-cost SiO₂–Al₂O₃ aerogel material remains a considerable challenge. In this study, SiO₂–Al₂O₃ aerogel based on coal gangue, which is a type of zero-cost inorganic waste, was constructed in porous agarose aerogel beads, followed by simple chemical vapor deposition of trimethylchlorosilane to fabricate SiO₂–Al₂O₃/agarose composite aerogel beads (SCABs). The resulting SCABs exhibited a unique nanoscale interpenetrating network structure, which is lightweight and has high specific surface area (538.3 m²/g), hydrophobicity (approximately 128°), and excellent thermal stability and thermal insulation performance. Moreover, the compressive strength of the SCABs was dramatically increased by approximately a factor of ten compared to that of native SiO₂–Al₂O₃ aerogel beads. The prepared SCABs not only pave the way for the design of a novel aerogel material for use in thermal insulation without requiring expensive raw materials, but also provide an effective way to comprehensively use coal gangue.

Silica aerogels can be strengthened by forming a nanoscale interpenetrating network (IPN) comprising a silica gel skeleton and a cellulose nanofiber network. Previous studies have demonstrated the effectiveness of this method for improving the mechanical properties and drying of aerogels. However, the preparation process is generally tedious and time-consuming. This study aims to streamline the preparation process of these composite aerogels. Silica alcosols were directly diffused into cellulose wet gels with loose, web-like microstructures, and an IPN structure was gradually formed by regulating the gelation rate. Supercritical CO₂ drying followed to obtain composite aerogels. The mechanical properties were further enhanced by a simple secondary regulation process that increased the quantity of bacterial cellulose (BC) nanofibers per unit volume of the matrix. This led to the production of aerogels with excellent bendability and a high tensile strength. A maximum breaking stress and tensile modulus of 3.06 MPa and 46.07 MPa, respectively, were achieved. This method can be implemented to produce robust and bendable silica-based composite aerogels (CAs).