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US 7,442,357 B2Granted
Manufacture of silica aerogel via vapor phase reaction
AssigneeKeller Companies, Inc.
InventorRobert R. Keller, Sr.
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Abstract
A kinetically controlled vapor reaction process for synthesizing silica areogel in a reaction container by injection of a precursor reagent vapor, a catalyst reagent vapor, super saturated steam as a component of the catalyst solution, and a hydrophobic reagent vapor amd continuously mixing vapor droplets of the precursor, catalyst and water reagents in a super saturated state to continuously nucleate in a hydrolysis/poly-condensation reaction and deposit as silica aerogel.
Claims23
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.
4 more elements
Dependencies are inferred from the claim text.