Flexible sheets of NASA's new polymer aerogel. A sheet this
thick would provide thermal insulation equal to about an inch (25 mm) of
foam insulation
Often called "frozen smoke", aerogels
are among the amazing materials of our time, with fifteen Guinness Book
of World Records entries to their name. However, despite their list of
extreme properties, traditional aerogels are brittle, crumbling and
fracturing easily enough to keep them out of many practical
applications. A new class of mechanically robust polymer aerogels
discovered at NASA's Glenn Research Center in Ohio may soon enable
engineering applications such as super-insulated clothing, unique
filters, refrigerators with thinner walls, and super-insulation for
buildings.
First synthesized in 1931, aerogels were the result of a bet between
two chemists. Knowing that jellies are mostly pectin gelled with water,
they challenged each other to remove the water without shrinking the
jelly. Now aerogels are among the least dense solids,
possess compressive specific strength similar to aerospace grade
graphite composite, and provide the smallest thermal conductivity for
any solid. With this array of amazing properties, why don't we see more
aerogel applications?
Mary Ann B. Meador, Ph.D., a chemist at NASA Glenn, explains that
despite these amazing properties, traditional aerogels made from silica
(silicon dioxide, or beach sand) are brittle, and break and crumble
easily. Not so when newer polymer aerogels are considered. Meador and
her team have developed a particularly encouraging form of polymer
aerogel, which is strong, flexible, and robust against folding,
creasing, crushing, and being stepped upon. Their new class of polymer
aerogels won a 2012 R&D100 award.
“The new aerogels are up to 500 times stronger than their silica
counterparts,” says Meador. “A thick piece actually can support the
weight of a car. And they can be produced in a thin form, a film so
flexible that a wide variety of commercial and industrial uses are
possible.”
So just how did Meador and her colleagues approach the problem of
synthesizing robust, flexible aerogels? Early attempts to produce
stronger and more durable aerogels focused on taking a silica aerogel,
and depositing a thin layer of a polymer on the surface of the aerogel
structures. This can be done using chemical vapor deposition, for
example, but the process is quite slow. (Such coating can also be
accomplished by putting a silica aerogel in a small container with a
pool of super glue, just as exposure to superglue vapors can reveal
fingerprints by coating their grease.) In addition, most of the
polymers that could be deposited in this manner have rather low melting
temperatures, whereas many of the potential applications require some
degree of thermal tolerance.
A new idea was called for. As the only role of the silica aerogel was
to give shape to the conformal polymer coating, why not see if a
polymer aerogel can be directly formed? Polyimides such as Kapton
generally show resistance to temperatures of 400 C (750 F) or higher,
are structurally very strong, and have high glass transition
temperatures, so were an obvious candidate for such applications.
Unfortunately, standard methods for forming aerogels ran into serious
problems. When polyimides in a dilute solution were gelled and then
subjected to supercritical drying, the gels shrank by up to 40%, leading
to unacceptably dense materials. A number of variations have been
tried, primarily based on altering the properties of the polyimides with
a range of additives, but these were unsatisfactory in various ways.
The NASA group tried a cross-linking approach, where linear
polyamides were reacted with a bridging compound to form a
three-dimensional covalent polymer. Such polymers are far more stiff
than linear polymers, rather like an I-beam compared to a solid round
rod of the same weight. They formed the gel at room temperature, and
were able to achieve virtually total coupling between the various
three-dimensional polymers. When this gel was subjected to supercritical
drying, they were able to form polymer aerogels with densities as small
as 0.14 g/cc and having 90% porosity – far from a record, but light
enough to provide useful properties such as very low thermal
conductivity.
The above micrograph of the nanocellular structure of the aerogel
shows pores averaging about ten nanometers in size. A quarter-inch (6
mm) sheet of this aerogel would provide as much insulation as three
inches of fiberglass.
The new class of polymer aerogels also have superior mechanical
properties. For example silica aerogels of a similar density have a
resistance to comperession and tensile limit more than 100 times smaller
than the new polymer aerogels.
A Smart car parked on top of a thick piece of NASA's new polymer aerogel (Photo: NASA)
Silica aerogels would crush to powder if placed under a car tire. As
seen above, the same is not true of the new polymer aerogels, even if
the car is only a Smart car. Overall, the mechanical properties are
rather like those of a synthetic rubber, save that the aerogel has the
same properties (and far smaller thermal conductivity) with only about
10 percent of the weight.
Applications in clothing as well as insulation of pipes, buildings,
water heaters, and the like are enabled by these materials. Tents and
sleeping bags can also benefit from the combination of light weight and
thermal insulation. NASA is even considering the new polymer aerogels
for use as inflatable heat shields.
The practicality of many such applications will depend on the cost of
polymer aerogel in commercial quantities. In any case, these types of
products now have another dimension of design flexibility.
Source:
NASA Glenn Research Center