Patent ID: 7442357

Claim:
A kinetically controlled vapor reaction process, for synthesizing silica areogel, comprising the steps of: in a reaction container, continuously injecting a precursor reagent vapor including an ethanol and an alkoxide at an initial precursor reagent temperature between 90° F. and 185° F. and at an initial precursor reagent pressure of 20 to 120 psig, continuously injecting a catalyst reagent vapor of ethanol/ammonium hydroxide at an initial catalyst reagent temperature between 90° F. and 185° F. and at an initial catalyst reagent pressure of 20 to 120 psig, continuously injecting super saturated steam as a component of the catalyst reagent, continuously injecting a hydrophobic reagent vapor at an initial hydrophobic reagent temperature between 90° F. and 185° F. and at an initial hydrophobic reagent pressure of 20 to 120 psig, and continuously mixing vapor droplets of the precursor and the catalyst reagents in a super saturated state and under turbulent flow conditions in the reaction container, whereby the precursor and the catalyst reagents continuously nucleate in a hydrolysis/poly-condensation reaction and deposit as silica aerogel.