{"id":4439,"date":"2026-10-23T18:16:17","date_gmt":"2026-10-23T10:16:17","guid":{"rendered":"https:\/\/anchor-aerogel.com\/aerogel-blanket-production-process\/"},"modified":"2026-10-23T18:16:52","modified_gmt":"2026-10-23T10:16:52","slug":"proceso-de-produccion-de-mantas-de-aerogel","status":"publish","type":"page","link":"https:\/\/anchor-aerogel.com\/es\/aerogel-blanket-production-process\/","title":{"rendered":"Proceso de producci\u00f3n de mantas de aerogel: c\u00f3mo se fabrican las mantas de aerogel de s\u00edlice"},"content":{"rendered":"

An aerogel blanket is not simply “aerogel powder glued onto a fabric.” Behind every roll sits a controlled chemical process \u2014 the sol\u2013gel route<\/strong> \u2014 in which a liquid silica sol is combined with a fiber felt, transformed into a wet gel, made water-repellent, and then dried in a way that preserves the aerogel’s nanoporous structure. This page walks through the aerogel blanket production process<\/strong> step by step, exactly as it runs on a modern production line.<\/p>\n

Two Production Routes: Belt Coating and Immersion<\/h2>\n

Manufacturers use two main ways to bring the sol into the fiber felt. In the belt-coating process<\/strong>, the felt moves continuously along a conveyor while the sol is metered onto its surface and allowed to gel in place. In the immersion process<\/strong>, the felt passes through a bath and is fully soaked in the sol, then rewound for gelation and aging. Both routes converge at the same critical finishing stage: supercritical CO\u2082 drying.<\/p>\n

\n\"Belt-coating\n<\/picture>
Figure 1. Belt-coating aerogel blanket production process \u2014 sol is applied to the felt on a continuous moving belt.<\/figcaption><\/figure>\n
\n\"Immersion\n<\/picture>
Figure 2. Immersion aerogel blanket production process \u2014 the felt is fully soaked in a sol\u2013gel bath before rewinding.<\/figcaption><\/figure>\n

The Process, Step by Step<\/h2>\n

1. Raw Materials: Fiber Felt and Silica Sol<\/h3>\n

The carrier is a needled fiber felt \u2014 most commonly glass fiber, and for higher-temperature grades, ceramic or pre-oxidized fiber. The aerogel precursor is a silica sol, typically prepared from a silicon alkoxide such as TEOS, mixed with a solvent and a catalyst. Felt is pre-dried before use, because residual moisture would disturb gelation later.<\/p>\n

2. Sol\u2013Gel Impregnation<\/h3>\n

The sol must penetrate the felt evenly; dry pockets become weak spots in the finished blanket. Belt coating meters the sol onto the moving felt, while immersion soaks the felt completely in a bath with guide rollers. Timing matters here \u2014 once the catalyst is added, the sol starts its journey toward gelation, so impregnation and gelation are tuned as one continuous operation.<\/p>\n

3. Gelation<\/h3>\n

Inside the felt, the sol turns into a wet gel: a three-dimensional silica network filled with liquid. This network is the skeleton of the final aerogel. Gelation time and temperature are controlled tightly, because they decide the pore structure \u2014 and the pore structure decides the thermal conductivity.<\/p>\n

4. Aging and Hydrophobic Modification<\/h3>\n

The wet gel rests in sealed tanks to strengthen its network. It is then treated with a hydrophobic agent that caps the surface silanol groups. This is what makes a quality aerogel blanket water-repellent instead of moisture-absorbing \u2014 a property that matters for decades of service on pipelines and building envelopes.<\/p>\n

5. Supercritical CO\u2082 Drying<\/h3>\n

This is the step that separates true aerogel from lookalikes. If the pore liquid were simply evaporated, surface tension would collapse the nanopores. Instead, the liquid is exchanged for liquid CO\u2082, which is then taken above its critical point (31.1 \u00b0C, 73.8 bar) and vented as a gas. With no liquid\u2013vapor interface, there is no capillary force \u2014 the pores survive, and the blanket keeps its ultra-low thermal conductivity.<\/p>\n

6. Final Drying, Rewinding and Trimming<\/h3>\n

A final oven pass removes residual solvent and moisture. The blanket is then rewound, slit to width, edged, and wound into rolls of standard lengths \u2014 ready for packing and delivery.<\/p>\n

Why Supercritical Drying Matters to Buyers<\/h2>\n

Some low-cost “aerogel” products are dried at ambient pressure. The result is technically a xerogel: denser, with higher thermal conductivity and weaker hydrophobicity. When you evaluate a supplier, ask one question \u2014 is the blanket supercritically dried?<\/em> The answer tells you more about long-term performance than any datasheet headline. You can explore blankets produced with the sol\u2013gel route in our aerogel blanket range<\/a>.<\/p>\n

Belt Coating vs. Immersion: A Quick Comparison<\/h2>\n\n\n\n\n\n\n
<\/th>\nBelt Coating<\/th>\nImmersion<\/th>\n<\/tr>\n
Sol application<\/strong><\/td>\nMetered onto felt on a moving belt<\/td>\nFelt fully soaked in a sol\u2013gel bath<\/td>\n<\/tr>\n
Line style<\/strong><\/td>\nContinuous, inline gelation<\/td>\nBatch-oriented, rewound for aging<\/td>\n<\/tr>\n
Best suited for<\/strong><\/td>\nSteady large-volume runs<\/td>\nThicker felts, deep penetration<\/td>\n<\/tr>\n
Shared core steps<\/strong><\/td>\nAging, hydrophobic modification, supercritical CO\u2082 drying, final drying<\/td>\n<\/tr>\n<\/table>\n

FAQ<\/h2>\n

How are aerogel blankets made?<\/strong>
By the sol\u2013gel process: a fiber felt is impregnated with silica sol, gelled, aged, made hydrophobic, and then dried with supercritical CO\u2082 so the nanoporous structure survives. The two common impregnation routes are belt coating and immersion.<\/p>\n

What is supercritical drying in aerogel production?<\/strong>
A drying method where the pore liquid is replaced by CO\u2082 taken above its critical point, so the liquid turns to gas without a phase boundary. Capillary forces never appear, and the aerogel’s pores do not collapse.<\/p>\n

Is every aerogel blanket supercritically dried?<\/strong>
No. Ambient-pressure-dried products (xerogels) exist and are cheaper, but they are denser and conduct more heat. Always confirm the drying route when comparing suppliers.<\/p>\n

For the science story behind aerogel, see how aerogel was invented<\/a>. Choosing a product? See our AG65 aerogel blanket<\/a> for building insulation or the AG65 Plus<\/a> for service up to 650 \u00b0C.<\/p>\n