Lightweight polyimide composite foams with anisotropic hierarchical pore structure for enhanced mechanical, flame retardancy and thermal insulation purposes

In this study, lightweight polyimide foam (PIF) with anisotropic pore structure were fabricated by adopting microwave-assisted foaming technique. Afterward, lightweight PIF/PI aerogel/silica aerogel (PIF/PIA/SiA) composite foams with anisotropic hierarchical pore structures was prepared by impregnation and directional freeze-drying method. The directional growth of foam pores and ice crystals endowed PIF/PIA/SiA composite foams with anisotropic skeleton structures and hierarchical porous filling structures, leading to anisotropic mechanical and thermal insulation performances. PIF/PIA/SiA composite foams presented mechanical robustness in vertical direction and mechanical flexibility in horizontal direction due to its unique pore structure. In addition, PIF/PIA/SiA composite foams showed outstanding thermal stability and flame retardancy, suggesting a promising application in the field of high temperature fire protection. The PIF/PIA/SiA composite foams exhibited superior thermal insulation performance with thermal conductivities ranging from 0.0253 to 0.0523 W/(m·K) between 25 and 300 °C. Therefore, a facile strategy was developed to fabricate PIF-based composite foams for mechanical, flame retardancy and thermal insulation applications in high-end engineering fields.