Cast-in-place, ambiently-dried, silica-based, high-temperature insulation

Abstract A novel sol-gel chemistry approach was developed to enable the simple integration of a cast-in-place, ambiently-dried insulation into high temperature applications. The insulation was silica-based and synthesized using methyltrimethoxysilane (MTMS) as the precursor. MTMS created a unique silica microstructure that was mechanically robust, macroporous, and superhydrophobic. To allow for casting into and around small, orthogonal features, zirconia fibers were added to increase stiffness and minimize contraction that could otherwise cause cracking during drying. Nano-sized titania powder was incorporated as an opacifier to reduce radiative heat transport. To assess relevance to high temperature thermoelectric generator technology, a comprehensive set of materials characterization experiments were conducted. The silica gel was thermally stable, retained superhydrophobicity with a water contact angle >150°, and showed a high electrical resistance >1 GΩ, regardless of heating temperature (up to 600 °C in Ar for 4 h). In addition, The silica-based thermal insulation exhibited a Young's modulus ∼3.7 MPa and a low thermal conductivity