Manufacturing Process for Polymer Cross-Linked Aerogel Composite...

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Manufacturing Process for Polymer Cross-Linked Aerogel Composites Developed

Polymer cross-linked silica aerogels developed at the NASA Glenn Research Center have shown promising enhancements of mechanical properties in comparison to pure silica aerogels without compromising density or thermal conductivity. Thus, these materials may be enabling for future space exploration missions. They may also advance aeropropulsion systems that demand lighter weight, robust, dual-purpose materials for acoustic or thermal insulation and for structural elements of habitats, rovers, astronaut suits, and cryotanks. Incorporation of 3-aminopropyltriethoxysilane into the silicate sol-gel process provides functionality on the backbone of the silica aerogel that promotes grafting of various polymers (polyisocyanates, epoxides, etc.) into the structure. The intimate mixing of the polymer cross-links within the aerogel structure and the covalent bonding between the inorganic and organic phases are essential to controlling the material properties. Thus, processing variables are of central importance, and Glenn scientists have optimized many of these variables for producing the highest strength aerogels relative to bulk density using di-isocyanate as the cross-link (ref. 1). Glenn, however, does not have the facilities to scale up the aerogel process and investigate commercially viable manufacturing in their facility. Hence, they have joined forces with Aspen Aerogels to develop these processes. Although monolithic aerogel materials are technically interesting, they are difficult to produce in large quantities using supercritical extraction processing methods if the gels are rigid. Fiber-reinforcement of the cross-linked aerogels is intended to make them flexible enough to be spiral wound during processing and is an important step toward establishing scaleup and viable commercial production. During the early part of this project, Aspen Aerogels worked with Glenn to reproduce certain optimum formulations of the cross-linked aerogels in fiber composites, benchmarking density, thermal conductivity, and mechanical compression. Measured properties of the composites all came within 10 percent of that previously reported for the monolithic materials. Some of these composites are pictured in the photograph.

Polymer cross-linked aerogel composites made with four different fiber compositions. The aerogel component reproduces a formulation developed by Glenn with comparable density, mechanical properties, and thermal conductivities. The next steps for this project include substituting more environmentally friendly raw materials for safer large-scale manufacturing and developing a more streamlined process. The ultimate goal is to scale the process for producing polymer cross-linked aerogels developed on the bench to a semi-pilot scale without sacrificing properties.

Reference
1. Meador, Mary Ann B.: Structure-Property Relationships in Porous 3D Nanostructures as a Function of Preparation Conditions: Isocyanate Cross-Linked Silica Aerogels. Chem. Mater., vol. 19, no. 9, 2007, pp. 2247-2260.

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Manufacturing Process for Polymer Cross-Linked Aerogel Composite...

http://www.grc.nasa.gov/WWW/RT/2007/Str-Matl/03-RXD-meador.html

Find out more about the research of Glenns Durability and Protective Coatings Branch: http://www.grc.nasa.gov /WWW/EDB/ Glenn Contact: Dr. Mary Ann Meador, 216-433-3221, Maryann.Meador@nasa.gov Ohio Aerospace Institute (OAI) Contact: Dr. Baochau Nguyen, 216-433-2738, Baochau.N.Nguyen@nasa.gov Aspen Aerogels Contact: Dr. George L. Gould, 508-691-1136, ggould@aerogel.com Authors: Dr. Mary Ann Meador and Dr. George L. Gould LEW Number: LEW-17,685 Headquarters Program Office: Fundamental Aeronautics Program Programs/Projects: Subsonic Rotary Wing Project, Subsonic Fixed Wing Project Next article Previous article

Last updated: November 14, 2008 Responsible NASA Official: Gynelle.C.Steele@nasa.gov, 216-433-8258 Point of contact for NASA Glenn's Research & Technology reports: Cynthia.L.Dreibelbis@nasa.gov, 216-433-2912 Web page curator: Nancy.L.Obryan@nasa.gov (Wyle Information Systems, Inc.) GRC Accessibility Statement NASA Web Privacy Policy and Important Notices

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