Imagine a material whose volume consists mostly of air, but which possesses unimaginable thermal insulation properties and structural strength - this is not a science fiction scenario, but the real properties of aerogel. Aerogel is known as “solidified smoke” because of its translucent appearance, and is one of the solid materials with the lowest known thermal conductivity.

Aerogel insulation blanket is an advanced thermal insulation product based on aerogel. It breaks the performance limitations of traditional thermal insulation materials, both ultra-light, flexible, efficient thermal insulation and other core advantages, has set off changes in aerospace, petrochemical, construction and other fields.

In this paper, we will comprehensively analyze this high-end thermal insulation material from the nature of aerogel, the definition of aerogel thermal insulation blanket, manufacturing process, working principle, core features, types, application scenarios, comparison with traditional materials and common problems, etc., to provide reference for the industry selection.

What Is Aerogel?

Basic characteristics of aerogel

Aerogel is not a single substance, but a lightweight solid material with nanoporous structure, its porosity can be as high as 90% or more, and its density is only a few times that of air. This unique structure gives it the texture of “light as smoke”, and at the same time, it has excellent heat insulation, sound insulation, high temperature resistance and other properties.

As a synthetic material, the core of aerogel preparation is to remove the liquid component from the gel while retaining its three-dimensional porous skeleton structure. It is this special treatment that allows it to retain its solid form while maximizing the thermal insulation potential of the air.
 

Chemical composition of aerogels

The main component of aerogels is silicon dioxide (SiO₂), which is the same as the core composition of quartz and glass. With its excellent thermal stability and chemical inertness, silica aerogel has become the most widely used type of aerogel and the core raw material of aerogel insulation blanket.

In addition to silica, aerogels can also be prepared from alumina, carbon, polymers and other materials. The performance of different components of aerogel has its own focus, for example, carbon aerogel has excellent electrical conductivity, polymer aerogel is more flexible, can be customized according to the needs of specific scenarios.

What Is an Aerogel Insulation Blanket?

Aerogel insulation blanket is a kind of flexible thermal insulation material made of aerogel as the core thermal insulation component and composite fiber matrix. The essence is that the nanometer aerogel particles are uniformly embedded in the fiber skeleton, forming a composite product with both aerogel thermal insulation performance and fiber flexibility.

Common fiber matrix including glass fiber, synthetic fiber, etc., these fibers not only solve the pure aerogel brittle, easy to break the problem, but also make the product has the characteristics of cuttable, bendable, significantly reducing the construction difficulty.

Compared with traditional thermal insulation materials, the core advantage of aerogel thermal insulation blanket is the extremely low thermal conductivity, which can realize efficient thermal insulation under the extremely thin thickness. At the same time, it also has waterproof, high and low temperature resistance, chemical stability and other additional features, applicable to the scene far more than the traditional insulation materials.

How Is Aerogel Insulation Blanket Manufactured?

Supercritical drying method

Supercritical drying method is the traditional process for the preparation of aerogel and aerogel insulation blanket, and it is also the core method to ensure the high-end performance of the product. The first step of the process is sol-gel reaction, mixing silicon precursor with solvent and catalyst to form a gel-like substance.

After the gel is formed, it needs to undergo aging treatment to strengthen its three-dimensional skeleton structure and avoid collapse during subsequent drying. After aging, the gel is dried in supercritical carbon dioxide environment to utilize the properties of supercritical fluid to completely remove the internal liquid without destroying the skeleton.

Finally, the prepared aerogel is compounded with the fiber mats through a special process, allowing the aerogel to fill the fiber pores and forming a structurally stable aerogel insulation mat. The products produced by this process have excellent thermal insulation performance, uniform structure, minimal shrinkage and pore loss, but the cost is relatively high.

Atmospheric Pressure Drying Method

The atmospheric pressure drying method is a process developed to reduce costs and realize large-scale production, and its prelude sol-gel reaction and aging steps are basically the same as those of the supercritical drying method. The core difference lies in the drying stage, which can be completed at atmospheric pressure without relying on high-pressure equipment.

In order to avoid the capillary force generated by liquid evaporation during atmospheric pressure drying to destroy the gel structure, it is necessary to carry out surface modification treatment on the gel first. Chemicals such as silanizing reagents are usually used to change the surface tension of the gel pores so that the liquid can evaporate slowly at atmospheric pressure, reducing structural damage.

The modified gel is dried at high temperature and atmospheric pressure to remove the solvent, and then laminated with a fiber matrix to make insulation mats. The process cost is lower, higher capacity, but the product thermal conductivity is slightly higher than the supercritical drying method products, suitable for cost-sensitive, moderate performance requirements of the scene.

How Does Aerogel Insulation Blanket Work?

The excellent heat preservation performance of aerogel insulation blanket is entirely originated from its nanometer porous structure. The pore size inside the aerogel is only nanometer, much smaller than the average free range of air molecules, which can effectively trap the air molecules and greatly inhibit gas convection heat transfer.

At the same time, the nanoscale solid skeleton makes the heat conduction path become exceptionally tortuous, and the solid thermal conductivity efficiency is greatly weakened. In other words, it blocks heat transfer from both gas convection and solid conduction dimensions at the same time.

What's more, high-quality aerogel insulation blankets have hydrophobic properties that prevent moisture intrusion from damaging the insulation structure, even in high humidity environments. In high or low temperature extreme environment, its nanostructure is still stable, and can maintain excellent thermal insulation performance for a long time.

Key Properties of Aerogel Insulation Blanket

Extremely low thermal conductivity, superb thermal insulation efficiency

In the temperature range below 400 ℃, the thermal conductivity of aerogel insulation blanket is much lower than that of traditional materials such as glass wool and rock wool. This means that in achieving the same heat preservation effect, its thickness is only 1/3-1/5 of the traditional materials, which can greatly save the installation space.

Ultra-light texture, reducing the burden of carrying

Thanks to the porosity of up to 90% or more, the density of aerogel insulation blanket is extremely low, and the weight per square meter is much lighter than that of traditional insulation materials. This feature is particularly advantageous in load-sensitive scenarios such as construction and aerospace, reducing the overall structural load.

Flexible and Cuttable, Suitable for Complex Scenarios

The composite fiber matrix gives the product good flexibility and plasticity, which can be easily cut into any shape, suitable for pipelines, tanks, shaped equipment and other complex surfaces. No special tools are needed during construction, which greatly improves the installation efficiency.

Excellent mechanical strength, stable structure

Despite the light texture, the aerogel insulation blanket has a certain tensile and compressive strength, which can withstand slight collision and stretching during the construction process, avoiding problems such as breakage and peeling off during the use, and guaranteeing the stability of long-term use.

Resistant to high and low temperatures , chemically stable, with a wide range of applications

Silicone-based aerogel insulation blanket can be used continuously in temperatures ranging from -200°C to 650°C, and some special types can withstand higher temperatures. At the same time, it is insensitive to most chemicals, not easy to be corroded, and can serve for a long time in harsh industrial environments.

Hydrophobic and Moisture Resistant with Anti-corrosion Function

The hydrophobicity of aerogel insulation blanket can reach more than 98%, which can effectively block the intrusion of moisture. This not only prevents moisture from destroying the heat preservation performance, but also prevents the surface of the equipment from corrosion due to moisture, which prolongs the service life of the equipment.

Types of Aerogel Insulation Blanket

glass fiber aerogel composite insulation blanket

to nano-silica aerogel and glass fiber as the core raw material composite, is currently the most widely used type. The addition of glass fibers significantly improves the mechanical strength and high temperature resistance of the product, which is suitable for industrial pipelines, building facades and other scenarios.

It combines the high efficiency thermal insulation of silica aerogel and the stability of glass fiber, with outstanding cost performance, and is the product of choice for most industries.

Carbon Fiber Aerogel Composite Insulation blanket

With silica polymer as the main ingredient, it has better flexibility and durability, and can be bent repeatedly without breaking. Suitable for frequent disassembly and installation, or surface curvature of the equipment insulation, such as automobile exhaust pipes, precision instruments.

Ceramic fiber aerogel composite heat preservation blanket

is prepared with nano-sized aerogel particles, with extremely low thermal conductivity and heat preservation performance far exceeding that of ordinary aerogel blanket. It is mainly used in scenes with very high requirements for heat preservation, such as aerospace equipment, low-temperature superconducting devices and other high-end fields.

Pre-oxygenated filament aerogel blanket

is made of pre-oxygenated filament as matrix, compounded with silica aerogel, and heat-treated to form a porous structure. With excellent flame retardancy and high temperature resistance, it is suitable for high temperature industrial furnace, fire insulation and other special scenes.

Applications of Aerogel Insulation Blanket

Aerospace field

Aerospace equipment needs to withstand extreme temperature difference during flight, which requires very high weight and performance of insulation materials. Aerogel heat preservation blanket is widely used in the heat preservation of spacecraft compartments and aviation engine parts due to its ultra-light and efficient heat preservation characteristics.

It can reduce the weight of the equipment at the same time, provide a stable temperature environment for precision instruments, to protect the normal operation of the equipment.

Petrochemical field

Pipes, storage tanks, reactors and other equipment in petrochemical industry are often in high temperature, high pressure and high humidity environment. Aerogel insulation blanket can effectively reduce heat loss, maintain stable process temperature inside the equipment, reduce energy consumption.

Its hydrophobic anti-corrosion properties can also avoid equipment corrosion due to moisture, especially suitable for offshore oil platforms, LNG transportation pipelines and other harsh scenes.

Construction and municipal field

In high-rise buildings, old building renovation and other space-limited scenarios, the thinning advantage of aerogel insulation blanket is extremely obvious. It can be used for thermal insulation of external walls, roofs and floors, which does not take up indoor space and enhances the energy-saving effect of the building.

At the same time, it also has certain sound insulation properties, which can improve the indoor acoustic environment of the building, taking into account the needs of thermal insulation and noise reduction.

Automotive industry 

In high-performance cars and new energy vehicles, aerogel thermal insulation blanket is used for thermal insulation of exhaust pipes, battery packs and engine compartments. It can not only reduce the impact of engine heat on the cockpit, but also maintain a stable temperature for the battery pack and improve battery life.

Its lightweight characteristics can also help automobile weight reduction, enhance range and power performance.

Aerogel Insulation Blanket vs Traditional Insulation Materials

Comparison withglass wool 

Glass wool is inexpensive, easy to install, but the volume is huge, thermal insulation efficiency is general. Aerogel insulation blanket insulation efficiency is 3-5 times that of glass wool, the thickness is only 1/3, and lighter weight, hydrophobic and moisture-proof, suitable for space and performance requirements of the scene.

Comparison with Rockwool

Rockwool possesses good flame retardancy and is a commonly used material for industrial insulation, but has a high density and higher thermal conductivity than aerogel insulation blanket. Under the same thermal insulation effect, the aerogel insulation blanket is lighter in weight, thinner in thickness, and has a longer service life, so the overall cost performance is better.

Comparison with spray foam

Spray foam can fill the gaps and adapt to irregular surfaces, but it is poor in high temperature resistance and prone to aging in the long term. Aerogel insulation blanket is resistant to high and low temperatures, has strong stability, and its service life is 5-8 times that of spray foam, making it suitable for long-term service in industrial scenarios.

Summary of core advantages

Compared with traditional thermal insulation materials, the core advantages of aerogel thermal insulation blanket lie in “high efficiency, lightweight, durability and versatility”. Although the initial purchase cost is higher, but with lower energy consumption, longer service life and wider application range, the long-term comprehensive cost is lower.

Aerogel Insulation Blanket FAQs

Q1: What is the difference in thermal insulation effect between aerogel insulation blanket and traditional rock wool?

The thermal insulation performance of aerogel insulation blanket is 3-5 times that of traditional rock wool, and the thickness of aerogel insulation blanket is only 1/3-1/5 of rock wool when achieving the same thermal insulation effect. For example, to achieve the same thermal insulation effect, rock wool needs 50mm thickness, and aerogel insulation blanket only needs 10-15mm.

Q2: Can aerogel insulation blanket be used in low-temperature environments?

Yes. Aerogel insulation blanket has excellent low-temperature adaptability and can be used in ultra-low-temperature environments up to -200℃, especially suitable for LNG storage tanks, low-temperature pipelines and other deep-cooling scenarios. Its flexible structure can also avoid brittle cracking in low temperature and guarantee the stability of heat preservation.

Q3: Is it safe to handle aerogel insulation blanket during construction?

Safe. The texture of aerogel insulation blanket is soft and non-irritating, and no harmful dust or fiber will be produced when cutting, which will not harm the skin and respiratory tract of the construction personnel. You only need to wear normal gloves during construction, no special protective equipment is needed.

Q4: How long is the service life of aerogel insulation blanket?

Under the condition of correct installation and normal use, the service life of aerogel insulation blanket is 5-8 times longer than that of traditional insulation materials, up to 20-30 years. Its chemical stability is strong, not easy to aging, corrosion, can maintain long-term thermal insulation performance, without frequent replacement.

Q5：Will aerogel insulation blanket absorb water and get damp?

No, it won't. Aerogel insulation blanket has super hydrophobicity, hydrophobicity rate of more than 98%, can effectively block the intrusion of water. Even in a high humidity environment, it will not absorb water and get damp, which not only guarantees the heat preservation performance, but also prevents the equipment from corrosion.

Q6: Can I install aerogel insulation blanket on top of the existing insulation layer?

Yes. Aerogel insulation blanket is thin and flexible, and is the ideal material for the transformation of old equipment insulation. Directly superimposed on the existing insulation layer, without removing the original structure, can greatly improve the insulation effect, construction is simple and does not take up too much space.

Q7：What is the highest continuous use temperature of aerogel insulation blanket?

The maximum continuous use temperature of conventional silicone-based aerogel insulation blanket is 650℃, which can meet the high temperature requirements of most industrial scenarios. For special high-temperature scenarios, we can also customize high-temperature-resistant products, which can withstand higher temperatures.

Q8: Is aerogel insulation blanket recyclable?

Silicone-based aerogel insulation blankets are non-toxic, harmless and environmentally friendly, and can be safely disposed of or recycled. After recycling and processing, it can be used again in low and medium requirement heat preservation scenarios, which is in line with the development trend of green environment protection.

Q9：Does aerogel insulation blanket have sound insulation effect?

It has certain sound insulation effect. Although its core function is thermal insulation, the composite fiber structure can play a certain acoustic damping effect, which can attenuate part of the noise propagation. If you need to focus on sound insulation, it is recommended to use with professional sound insulation materials.

Conclusion: Why Aerogel Insulation Blanket Is the Future of Insulation

Aerogel thermal insulation blanket breaks the performance bottleneck of traditional thermal insulation materials by virtue of the excellent performance brought about by the nanoscale structure, and plays an important role in energy saving and consumption reduction, space optimization, and prolonging the life of equipment. From high-end applications in aerospace to livelihood scenarios in petrochemical and construction, it is gradually replacing traditional materials and becoming a new benchmark in the field of thermal insulation.

Whether it is the pursuit of the ultimate thermal insulation effect, optimize the construction space, or adapt to the harsh use of the environment, aerogel insulation blanket can provide customized solutions. With the continuous upgrading of the manufacturing process, its cost will be further reduced and the application scenarios will continue to expand.

If you have industrial insulation, building energy saving and other needs, you may want to consider aerogel insulation blanket, choose the type of product that is suitable for their own scenes, to achieve the double optimization of performance and cost. For more product details or selection advice, please feel free to consult our professional technical team.