13b.Production of Low-Cost Aerogel Insulation by a Continuous Manufacturing Process

Low-cost, high-R value insulation can enable higher insulation levels in new construction and make feasible retrofits of existing buildings, and is highly desired for building construction. Aerogels are the lightest and the most porous man-made materials known so far, having higher R-value than most other materials, hence would be the best building insulation. However, their production and application in building construction is rather limited due to very high materials costs, and laborious and expensive manufacturing methods. DOE is seeking R&D efforts for manufacturing durable aerogel insulation using continuous, high-throughput production methods at atmospheric conditions and in practical building insulation form factors. This Small Business Innovation Research Phase I project aims to develop a novel aqueous-based ambient pressure drying (APD) process for production of low-cost aerogel insulation, which is amenable to continuous mass-production manufacturing. This effort, if successful, would result in the production of low-cost, high-R factor aerogel insulation. The Phase I work will involve optimization of the innovative synthesis process of the novel aerogel insulation. The aerogel insulation will be systematically characterized in terms of microstructure, morphology, density, surface area, porosity, thermal conductivity, and mechanical durability. Based on the characterization results, process-structure-property relations will be developed to guide future development. Prototypes of the aerogel insulation will be produced and evaluated in terms of R-value per inch of thickness. Phase I will also include a basic assessment of economics of the new technology. The prospective Phase II work would involve optimization and modification of the aerogel insulation, and design of the production line. The expected product of the present effort is a novel aqueous-based APD process for production of low-cost aerogel insulation that is amenable to continuous, mass-production manufacturing. The competitive advantage of our product is that it will have high potential of producing low-cost, high-R value aerogel insulation meeting the DOE technical and cost targets for building construction. Successful development of this technology will help to establish the U.S. technological lead in this field.