Abstract: Embodiments of the present invention provide users with a system and method for manufacturing water-based hydrophobic aerogels and aerogel composites. The system and method can be carried out in a manner which is more rapid than typical ways and can be readily scalable. The method of manufacture is useful for producing water based hydrophobic aerogels and aerogel composites on a large scale with good homogeneity and consistency. Advantageously, the method of manufacture also has the benefit of a shorter processing time due to the vacuum homogenizing and mixing processes, the use of microwave assisted vacuum freeze drying for ease of synthesis of water-based hydrophobic aerogels.

Abstract: A method of preparing a silica aerogel composite is provided. The method includes providing an aqueous solution comprising a water soluble polymeric binder and a surfactant, adding a silyl-modified silica aerogel to the aqueous solution to form a mixture, and freeze-drying the mixture under reduced pressure at a temperature sufficient to sublime water in the mixture to obtain the silica aerogel composite. A silica aerogel composite is also provided.

Abstract: A method of preparing a silica aerogel composite is provided. The method includes providing an aqueous solution comprising a water soluble polymeric binder and a surfactant, adding a silyl-modified silica aerogel to the aqueous solution to form a mixture, and freeze-drying the mixture under reduced pressure at a temperature sufficient to sublime water in the mixture to obtain the silica aerogel composite. A silica aerogel composite is also provided.