Apparatus and method for manufacturing and packaging of high performance thermal insulator aerogels

A method of fabricating an aerogel insulator, said method comprising:

• providing a container characterized by an inner wall and an outer wall that define an internal volume between said walls, and one or more ports into said volume;
• introducing an aerogel precursor comprising a silicon alkoxide, an alcohol and a catalyst into said internal volume through said one or more ports to provide the container defining the internal volume containing the aerogel precursor;
• allowing said aerogel to polymerize;
• and
• (a) placing said container defining the internal volume containing the aerogel precursor into a supercritical drying vessel, where the supercritical drying vessel comprises one or more vents and/or valves that permit fluid flow out of said chamber and wherein said vessel comprises a port in communication with a vacuum source;
• (b) supercritical drying said aerogel precursor by heating said vessel while allowing the pressure in said vessel to increase until a supercritical temperature and pressure is reached and maintaining said supercritical temperature and pressure for a period sufficient to dry the aerogel;
• (c) returning the vessel to atmospheric pressure, and optionally to room temperature;
• (d) maintaining the heating of vessel or reheating said vessel if it has been returned to room temperature, and applying a vacuum to said port in communication with a vacuum source to degas remaining water in said aerogel and provide a dry aerogel;
• and
• (e) returning said dry aerogel to room temperature and pressure;
• during or after step (d) or after step (e) applying a partial vacuum to said container;
• and
• sealing said one or more ports into said internal volume to provide a sealed internal volume containing an aerogel at a pressure lower than atmospheric pressure.