This project seeks to further develop a proprietary rapid supercritical extraction (RSCE) method for aerogel fabrication. Aerogels are unique nanoporous materials with remarkable properties that make them beneficial for a number of applications such as insulating materials, windows, sensors and catalytic converters. However, aerogels are not widely available or widely used due to the complex and expensive methods currently used to produce them. The research team has developed a rapid supercritical extraction (RSCE) technique. The method utilizes a confined mold in an automated hydraulic hot press. The method is advantageous for the following reasons: (a) it can be easily automated; (b) it is relatively fast; (c) it is environmentally friendlier than other methods; (d) it minimizes the use of solvents and (e) it is potentially less expensive than other methods. This I-Corps project plans to determine whether its proprietary RSCE method is ready for application out of the laboratory and to identify any barriers to achieving this transition.

Aerogels have potential applications in a number of areas that foster sustainability. As thermal insulators in building materials aerogels can be used to improve energy efficiency. Catalytic aerogel materials could eliminate the use of rare precious metals in the cleanup of automotive exhaust. The RSCE method itself provides an environmentally friendlier method for producing aerogels and the method is suitable to scale up and large-scale production of these materials.

Project Report

This NSF I-Corps grant funded a team from Union College (Principal Investigator Ann Anderson, Entrepreneurial Lead José Madero, and Mentor BK Keramati) who participated in the 6 month I-Corps Training Program with their project "Rapid Supercritical Fabrication of Aerogels" during the spring of 2013. Aerogels are materials consisting of an intricate solid network with very small pores (primarily in the 2 to 50 nanometer range) that are filled with air. Aerogels are greater than 90% air by volume. Their pore structure results in a low-density material with high surface area and low thermal and acoustical conductivity. This combination of properties makes aerogels attractive for use in a number of application areas ranging from chemical sensors to automotive catalysts to insulation. However, existing commercial methods for making aerogels are time-consuming and expensive. With prior support from NSF, an interdisciplinary research group of students and faculty members at Union College, an undergraduate institution in Schenectady, NY, developed and patented a faster, potentially less expensive and environmentally friendlier way to manufacture aerogels. The team applied for I-Corps funding to investigate commercial opportunities for aerogels manufactured using the Union College rapid supercritical extraction method. The team participated in the I-Corps curriculum and conducted over 70 customer interviews. As a result of the program they identified a strong product-market fit for their aerogels in the daylighting and window industry. At the completion of the formal customer-discovery phase they returned to the Union College Aerogel Lab and, working with co-PI Prof. Mary Carroll and undergraduate students, developed several prototype aerogel windows (see image). The I-Corps team is pursuing a patent application. Participation in the NSF I-Corps program allowed the Union College researchers to get out of the lab and learn more about the commercial applications of their work. Involvement of undergraduate students in the I-Corps project was an excellent way to stimulate and interest students in a career in research while introducing them to the entrepreneurial mindset. The students who participated in the I-Corps project saw first-hand how fundamental research can lead to potential commercial products. Entrepreneurial Lead Madero is now enrolled in a full-time doctoral program in engineering. In October 2013, Anderson, Carroll and Keramati formed a company. The company competed for NSF STTR Phase I funding in December 2013 for the specific purpose of establishing commercial viability of the new aerogel process for developing high-performance windows for daylighting. The STTR Phase I grant was awarded, and we began the 12-month grant period in July 2014.

Agency
National Science Foundation (NSF)
Institute
Division of Industrial Innovation and Partnerships (IIP)
Type
Standard Grant (Standard)
Application #
1332456
Program Officer
Rathindra DasGupta
Project Start
Project End
Budget Start
2013-05-01
Budget End
2014-04-30
Support Year
Fiscal Year
2013
Total Cost
$50,000
Indirect Cost
Name
Union College
Department
Type
DUNS #
City
Schenectady
State
NY
Country
United States
Zip Code
12308