A scalable vacuum‐assisted method for production of aerogel blankets for thermal insulation

Abstract This study presents a novel proof‐of‐concept method for synthesizing aerogel on ceramic insulation blankets using a vacuum infusion sol–gel process with subsequent drying at ambient pressure, enhancing adhesion and durability and enabling coating on complex geometries. Scanning electron microscopy (SEM) analysis revealed a porous microstructure in the ceramic blankets, while the polymethylsilsesquioxane (PMSQ) aerogel exhibited a well‐defined and interconnected network. Fourier transform infrared (FTIR) spectroscopy and solid‐state nuclear magnetic resonance (NMR) analyses confirmed the presence of silica and carbon, respectively. Among the various compositions, the 10 wt.% PMSQ aerogel blanket establishes highly effective thermal stability in thermogravimetric analysis (TGA) results. Pristine ceramic and aerogel blankets were subjected to a 1300°C butane flame for high‐temperature stability tests that indicated the 10% PMSQ aerogel composite blanket presented better insulation properties and back surface temperature of approximately 170°C, the lowest among the other surface back temperatures of the other samples. Water contact angle measurements confirmed the hydrophobic properties and surface free energy (SFE) of PMSQ aerogel ceramic blankets. Optimizing surface‐free energy and surface tension is crucial for enhancing these materials’ hydrophobicity, thermal insulation, and structural integrity. The surface energy ranged from 11.19 to 0.96 mJ/m 2 , while the surface tension ranged from 48.47 to 64.97 mN/m for 10%–30% PMSQ aerogel ceramic blankets.