Patent ID: 10414894

Abstract:
A method of synthesizing aerogels and cross-linked aerogels in a single step and in a single pot without requiring any solvent exchange is described. Porous matrices are synthesized through a modification of hydrolysis condensation of alkoxides in which addition of water is minimized. The reaction occurs in an ethanol-water azeotrope mixture; the water in the azeotrope slowly hydrolyzes the alkoxide. Additionally, after gelation, the porous matrix is dried in supercritical ethanol rather than liquid CO2, which allows for elimination of solvent exchange steps. These modifications allow for the preparation of aerogel monoliths in any size in one step and in one pot and much faster than conventional procedures. In addition, the method provides for custom aerogel parts with large dimensions, as well as high volume fabrication of aerogels. The custom aerogel parts may be used in a variety of thermal insulation applications.