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<p>Conventional methods for preparing phenolic aerogels often suffer from poor mechanical properties, high production costs, and complex fabrication processes. Herein, this study reports the preparation of an ultra-high strength carbon fiber needled felt-reinforced phenolic aerogel (NCF/PRA) composite via a low-temperature (&lt; 100&#xa0;°C) hydrothermal synthesis combined with ambient pressure drying. Using the silane coupling agent KH-560 as a curing agent, the interfacial bonding strength of the material was enhanced through crosslinking reactions during polymerization. Simultaneously, a physico-chemically dual-crosslinked polymer network was formed, endowing the PRA with high mechanical strength. The as-prepared NCF/PRA composite exhibits ultra-light weight, efficient thermal insulation, good load-bearing capacity, and allows for the fabrication of large-sized samples. It achieves a specific strength as high as 110.61&#xa0;MPa/(g/cm³). The outstanding thermal insulating capability of the 30&#xa0;mm thick NCF/PRA composite was directly demonstrated by a mere 57.83&#xa0;°C on the backside, recorded under severe ablation testing (3.62&#xa0;MW/m², 2300&#xa0;°C, 30&#xa0;s). By presenting a unique method to engineer robust, cost-efficient, and environmentally benign PR aerogel composites, this research underscores their promising candidacy for future thermal protection systems.</p>

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Low-temperature hydrothermal synthesis of ultra-high-strength phenolic aerogel composites based on a physicochemical double-crosslinked network

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年2月9日

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  • Xiangyu Jin,
  • Shuai Yuan,
  • Can Wu,
  • Wei Wang,
  • Jiaxin Zheng,
  • Yu Feng,
  • Min Liu,
  • Yiwu Pan,
  • Changqing Hong,
  • Xinghong Zhang

摘要

Conventional methods for preparing phenolic aerogels often suffer from poor mechanical properties, high production costs, and complex fabrication processes. Herein, this study reports the preparation of an ultra-high strength carbon fiber needled felt-reinforced phenolic aerogel (NCF/PRA) composite via a low-temperature (< 100 °C) hydrothermal synthesis combined with ambient pressure drying. Using the silane coupling agent KH-560 as a curing agent, the interfacial bonding strength of the material was enhanced through crosslinking reactions during polymerization. Simultaneously, a physico-chemically dual-crosslinked polymer network was formed, endowing the PRA with high mechanical strength. The as-prepared NCF/PRA composite exhibits ultra-light weight, efficient thermal insulation, good load-bearing capacity, and allows for the fabrication of large-sized samples. It achieves a specific strength as high as 110.61 MPa/(g/cm³). The outstanding thermal insulating capability of the 30 mm thick NCF/PRA composite was directly demonstrated by a mere 57.83 °C on the backside, recorded under severe ablation testing (3.62 MW/m², 2300 °C, 30 s). By presenting a unique method to engineer robust, cost-efficient, and environmentally benign PR aerogel composites, this research underscores their promising candidacy for future thermal protection systems.