High-efficiency solution blow spinning of flexible Zr-based ceramic fibers for advanced thermal insulation applications

Elastic zirconium-based ceramic fiber products have gain particular interest due to their exceptional high-temperature resistant performance. Nonetheless, commercial high-performance Zr-based fibers are still difficult to acquire which hinders its widely application in thermal insulation scenes. Herein, large-scale fabrication of various Zr-based (ZrO₂, ZrSiO₄) ceramic fibers were achieved through solution blow spinning technology, which was endowed with merits such as cost-effectiveness, high production efficiency, reduced energy consumption, and exceptional product quality. Through high-temperature sintering to 1000 ​°C, blow spun organic fibers can be converted into Zr-based ceramic fibers with diameters ranging from 0.5 to 2 ​μm. Optimizing the crystalline structure of these fibers through high-temperature pyrolysis process enhanced their thermal resistance. Additionally, through introducing polysiloxane as the Si source, ZrSiO₄ fibers can be synthesized with markedly improved mechanical properties and high-temperature resistance. These blow-spun Zr-based fiber sponges exhibit advantageous internal pore structures, high-temperature elasticity and thermal insulation performance.