Large scale synthesis of resorcinol-formaldehyde aerogel

Abstract

A product includes an aerogel having a single bulk structure, the single bulk structure having at least one dimension greater than 10 millimeters. The single bulk structure includes a plurality of pores, where each pore has a largest diameter defined as a greatest distance between pore walls of the respective pore. In addition, an average of the largest diameters of a majority of the pores is within a specified range, and the plurality of pores are distributed substantially homogenously throughout the single bulk structure.

What is claimed is: 
     
         1 . A product, comprising,
 an aerogel having a single bulk structure, the single bulk structure having at least one dimension greater than 10 millimeters,   wherein the single bulk structure comprises a plurality of pores,   wherein each pore has a largest diameter defined as a greatest distance between pore walls of the respective pore,   wherein an average of the largest diameters of a majority of the pores is within a specified range,   wherein the plurality of pores are distributed substantially homogenously throughout the single bulk structure.   
     
     
         2 . The product as recited in  claim 1 , wherein an average of the largest diameters of a majority of the pores is in a range of about 500 nanometers to about 2000 nanometers. 
     
     
         3 . The product as recited in  claim 1 , wherein an average of the largest diameters of a majority of the pores is in a range of greater than 50 nanometers to about 500 nanometers. 
     
     
         4 . The product as recited in  claim 1 , wherein an average of the largest diameters of a majority of the pores is in a range of about 2 microns to about 10 microns. 
     
     
         5 . The product as recited in  claim 1 , wherein an average of the largest diameters of a majority of the pores is in a range of about 10 microns to about 30 microns. 
     
     
         6 . The product as recited in  claim 1 , wherein the single bulk structure has at least one dimension greater than 50 millimeters. 
     
     
         7 . The product as recited in  claim 1 , wherein the aerogel is a carbonized aerogel. 
     
     
         8 . The product as recited in  claim 7 , wherein the carbonized aerogel exhibits homogenous activation throughout the single bulk structure. 
     
     
         9 . The product as recited in  claim 1 , wherein the aerogel has a uniform microstructure throughout the aerogel. 
     
     
         10 . The product as recited in  claim 9 , wherein the uniform microstructure is defined as having a uniform pore structure. 
     
     
         11 . A plurality of products as recited in  claim 1  formed in sequence, wherein the products have a defect rate less than 10%. 
     
     
         12 . The plurality of products as recited in  claim 11  formed in sequence, wherein the products have a defect rate less than 5%.