Key Takeaways & Executive Findings
- •• • Microfluidic spinning with DMSO sheath eliminates the dense surface layer typical of wet-spun aramid aerogel fibers, enabling a gradient all-nanostructure that balances thermal insulation and mechanical strength. • • The process leverages three mechanisms: hydrodynamic-induced concentration gradient (outer-low/inner-high), protonation-induced sol-gel transition for pore stabilization, and supercritical CO₂ drying to collapse surface macropores into smaller nanopores, yielding optimized thermal resistance. • • Raman mapping of the aramid I band at 1610 cm⁻¹ reveals a distinct radial distribution of nanostructure in GAFs versus the skin-core configuration of SAFs, providing a quantitative metric for structural control. • • The referenced study (Nat Commun, 2025, 16: 2357) reports enhanced thermal insulation and mechanical properties, addressing the mechanical weakness and wide thermal conductivity range that hinder conventional aerogel fibers in personal thermal management textiles.
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Abstract
Aerogel fibers are promising for personal thermal management textiles, but conventional wet-spun fibers suffer from a dense skin layer that compromises the balance between thermal insulation and mechanical robustness. This highlight examines a microfluidic spinning strategy that constructs gradient all-nanostructure aramid aerogel fibers (GAFs). By employing DMSO as a sheath fluid, the process induces a hydrodynamic concentration gradient, protonation-driven sol-gel transition, and supercritical drying-mediated structural inversion, yielding a porous gradient architecture distinct from traditional skin-core aerogel fibers (SAFs). Raman mapping of the aramid I band (1610 cm⁻¹) confirms the structural difference. The GAFs exhibit optimized thermal resistance and mechanical performance, addressing the trade-off that limits conventional aerogel fibers. The referenced work (Nat Commun, 2025, 16: 2357) demonstrates a viable route to high-performance aerogel fibers for next-generation thermal management, with potential for scalable manufacturing and enhanced energy efficiency in textiles.
1. Introduction
Conventional aerogel fibers for personal thermal management textiles face a persistent trade-off: achieving high thermal insulation often compromises mechanical robustness, while efforts to reinforce the fiber introduce dense skin layers that increase thermal conductivity. Wet spinning, the predominant manufacturing route, inherently produces a skin-core architecture with a dense shell and porous core, limiting the fiber's overall insulation efficiency and flexibility. The wide range of thermal conductivity observed in these fibers stems from inadequate control over the nanoporous architecture, particularly the radial distribution of pores. This bottleneck has stalled the adoption of aerogel fibers in next-generation textiles, where both thermal resistance and mechanical durability are critical.
The microfluidic spinning strategy reported by Ye's group addresses this bottleneck by constructing a gradient all-nanostructure aramid aerogel fiber (GAF). By selecting DMSO as the sheath fluid, the process eliminates the undesirable dense surface layer and induces a controlled concentration gradient through hydrodynamic effects, protonation-driven gelation, and supercritical drying. This results in a fiber with preferential outer porosity and smaller inner pores, optimizing interfacial thermal resistance while maintaining mechanical integrity. The approach demonstrates a viable pathway to overcome the structural limitations of conventional aerogel fibers, offering a scalable route for advanced thermal management applications.
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Jin Gao, Baolin Yin, Yuezhan Feng (2025). Advantages of Gradient All-Nanostructure in Aerogel Fibers for Thermal Insulation and Mechanical Properties. SCIENCE CHINA Materials. https://doi.org/10.1007/s40843-025-3379-7
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Frequently Asked Questions
What specific failure mechanisms under mechanical stress are mitigated by the gradient all-nanostructure compared to traditional skin-core aerogel fibers?
Traditional skin-core aerogel fibers (SAFs) exhibit a dense shell that concentrates stress, leading to brittle fracture and delamination under bending or tensile loading. The gradient all-nanostructure in GAFs distributes stress more uniformly across the radial dimension, as evidenced by the Raman intensity profile of the aramid I band (1610 cm⁻¹) that shows a gradual transition rather than an abrupt interface. This reduces stress concentration and enhances flexibility, though exact fatigue data are not provided in the highlight.
What are the cost and scalability implications of microfluidic spinning with DMSO sheath fluid compared to conventional wet spinning for industrial production?
Microfluidic spinning typically requires precise flow control and specialized equipment, potentially increasing capital expenditure. However, the use of DMSO as a sheath fluid is compatible with existing solution processing, and the process eliminates post-treatment steps to remove dense skin layers. The referenced work (Nat Commun, 2025, 16: 2357) does not provide cost analysis, but the continuous nature of microfluidic spinning suggests potential for scale-up, though throughput may be lower than wet spinning.
How does the thermal conductivity of GAFs compare quantitatively to SAFs and commercial insulation fibers, and what is the operating temperature range?
The highlight does not report specific thermal conductivity values. However, the referenced study (Nat Commun, 2025, 16: 2357) claims enhanced thermal insulation due to the gradient nanostructure, which increases interfacial thermal resistance. The operating temperature range for aramid aerogel fibers is typically up to 300 °C, but exact data are not provided in the highlight.
What is the long-term structural stability of the gradient nanostructure under repeated thermal cycling or humidity exposure?
The supercritical CO₂ drying step stabilizes the gradient nanostructure, but the highlight does not provide degradation rates or cycling data. Aramid nanofibers offer inherent thermal and environmental stability, but the nanoporous architecture may be susceptible to moisture-induced collapse. The referenced study likely addresses this, but the highlight does not include specific metrics.
What are the key processing parameters (e.g., DMSO flow rate, coagulation bath composition) that control the gradient profile, and how sensitive is the final performance to these parameters?
The highlight mentions DMSO sheath flow at specific angles and acidic coagulation baths for protonation, but exact flow rates and bath compositions are not disclosed. The sensitivity of the gradient profile to these parameters is critical for reproducibility; the referenced work (Nat Commun, 2025, 16: 2357) likely provides detailed optimization, but the highlight does not include these specifics.
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