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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 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.