Silica/Alginate Hybrid Aerogel‐Coated Sustainable Textile Liners for Cold Weather Insulation

Conventional aerogel‐coated textiles typically rely on in situ gelation approaches that are challenging for scale‐up, whereas binder‐based coatings often use synthetic polymers that undermine environmental sustainability, thermal performance, and wearer comfort. Herein, industrial viable padding and dip coating process has employed to develop silica/alginate hybrid aerogel‐coated wool knitted liners, aligning with sustainability objectives. Alginate not only exhibits strong adhesion of silica aerogel particles to wool fibers but also establishes an aerogel‐like network that maintains low thermal conductivity while ensuring the integrity of the coating. The coated liners deliver a 100% increase in thermal resistance (4.65 Clo in −1 at 2.6 mm) and a 66% reduction in thermal effusivity. Thermal conductivity studies of the knitted aerogel liners find to be effective between +25 and −25 °C. Notably, they are skin‐friendly, cytocompatible, and durable after repeated laundering. This approach overcomes key limitations of developing aerogel‐coated textiles, providing a scalable, eco‐friendly route for developing high‐performance textile‐based thermal liners used in cold environments.