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, 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. Radiative heat transport was reduced by adding titania powder as an opacifier. To assess relevance to high temperature thermoelectric generator technology, a comprehensive set of materials characterizations were conducted. The silica gel was thermally stable, retained superhydrophobicity with a water contact angle > 150°, and showed a high electrical resistance > 1 G ohm, regardless of heating temperature (up to 600 °C in Ar for 4 h). In addition, it exhibited a Young’s modulus ~3.7 MPa in room temperature and a low thermal conductivity < ~0.08 W/m.K before and after heat treatment. Thus, based on the simplicity of the manufacturing process and optimized material properties, we believe this technology can act as an effective cast-in-place thermal insulation (CTI) for thermoelectric generators and myriad other applications requiring improved thermal efficiency.
