Improvement of the silica aerogel strengthening process for scaling-up monolithic tile production

Previously published results have shown that washing and aging treatments (respectively in water/ethanol and water/polyethoxydisiloxane solutions) of silica gels (synthesized from polyethoxydisiloxane precursors through HF catalysis) significantly enhance both the permeability and mechanical properties of the wet gels. Unfortunately, scaling-up the process induces severe cracks during supercritical drying. This phenomenon has been related to a pore-size distribution gradient between the surface and the bulk of the gel that appears after aging of thick gels. We report efforts to optimize the aging step. Aging in less-concentrated polyethoxydisiloxane solutions yields gels with a more homogeneous pore-size distribution and has enabled us to obtain large monolithic and crack-free aerogels that remain light and transparent.