Morphology of cross-linked cellulose nanocrystal aerogels: cryo-templating versus pressurized gas expansion processing

Cellulose nanocrystal (CNC)-based aerogels are often produced through cryo-templating, followed by either critical point drying or freeze drying. While cryo-templating gives aerogels with a bimodal pore size distribution, better morphological control may be needed for certain applications. This work compares CNC aerogels prepared using a new processing method, called pressurized gas expansion (PGX) technology, to aerogels produced via cryo-templating. In all cases, CNCs were surface-modified with orthogonal functional groups to produce covalently cross-linked aerogels which are flexible and do not disperse in water. The aerogels were imaged by scanning electron microscopy and X-ray micro-computed tomography and further characterized by nitrogen sorption isotherms, X-ray diffraction, X-ray photoelectron spectroscopy, and compression testing. PGX aerogels appeared expanded and fibrillar at high magnification, with small mesopores and macropores less than 7 µm, but with large mound-like porous aggregates. Conversely, cryo-templated aerogels were comprised of denser CNC sheets surrounding macropores of 10–950 μm. Overall, PGX aerogels had a lower density, higher porosity, and a higher specific surface area than cryo-templated aerogels; they were also less stiff due to their morphology and reduced number of chemical cross-links. Scale-up of aerogel processing and understanding of the tunability of such methods may extend the use of CNCs in applications including insulation, separations, flexible supports, drug delivery, and template materials.