PPS Spherical Connection Points for Flexible, Hydrophobic, and Robust Porous Basalt Fiber Composites

ABSTRACT To overcome the persistent challenges of weak interfacial bonding in conventional basalt fibers (BF) and the inadequate flame retardancy of porous materials, this study presents a straightforward strategy for fabricating BF/polyphenylene sulfide (PPS) composite porous materials, wherein PPS functions as a polymeric binder to form spherical joint nodes. The methodology integrates wet‐laying and thermal treatment processes, utilizing a cost‐effective and environmentally benign BF network as the structural skeleton alongside recyclable PPS as the binding phase. The influence of BF content on the resulting composite properties was systematically examined. Results indicate that at a BF content of 70 wt%, the composite achieves optimal comprehensive performance. This includes outstanding flame retardancy, evidenced by a limiting oxygen index (LOI) of 36.9%, coupled with low thermal conductivity (3 × 10 ⁻² W/(m K)), as well as favorable hydrophobicity, oil absorption capacity, thermal stability, and corrosion resistance. These attributes render the composite highly suitable for applications in high‐temperature filtration and building fireproof insulation layers.