Patent ID: 7618608

Claim:
A method of manufacturing a silica aerogel, the method comprising the steps of: a) preparing a precursor solution chilled to a temperature of between 20°-60° F. (−6.7°-15.5° C.); b) preparing a catalyst solution chilled to a temperature of between 20°-60° F. (−6.7°-15.5° C.); c) mixing the chilled catalyst solution with the chilled precursor solution to form a mixed solution with the mixed solution having a pH of between 9.5 and 12.2; d) aging the mixed solution for a time of between 1 and 120 minutes, to form a gel and control a particle size distribution of the gel while maintaining the mixed solution at a temperature of between 34°-55° F. (1.1°-12.8° C.); e) immediately upon the mixed solution reaching a gel point at which a viscosity of the mixed solution increases to between about 5500 to about 10000 centipose, silating the gel; and f) drying the gel at a temperature of at least 122° F. (50° C.) to form the aerogel.