MEGEL AP-100 — Silica Aerogel Powder for Paint and Coating Formulation

Overview

MEGEL AP-100 is the paint-and-coating specification within the MEGEL silica aerogel powder range — a free-flowing, hydrophobic aerogel powder engineered for formulation into thin-film thermal insulation coatings. The particle size distribution is 10–60 μm, bulk density 50–80 kg/m³, and BET surface area 700–800 m²/g — values selected to balance dispersibility in liquid coating systems against retained thermal-insulation performance in the cured film.

AP-100 is the formulation workhorse for the rapidly growing "insulating paint" market — water-based or solvent-based coatings applied at 0.5–3 mm dry film thickness that reduce heat loss from steel, concrete, and roofing substrates. At a typical 30–60% aerogel powder loading in acrylic emulsion binder, the cured film delivers thermal conductivity of 0.045–0.060 W/(m·K) — half to one-third that of conventional paint — turning a paint coat into a measurable thermal barrier.

The critical formulation constraint is dispersion energy. Aerogel particle integrity is the entire value proposition, and high-shear mixing pulverises the nanoporous structure into amorphous silica fines that lose the Knudsen-effect insulation performance. AP-100 must be dispersed on a low-shear paddle mixer for 30+ minutes at 200–400 rpm, or in a planetary disperser at reduced impeller speed. Sand mills, basket mills, and high-shear rotor-stator equipment are unsuitable.

Technical Specifications

Applications

Acrylic Insulating Paint Formulation

AP-100 at 30–50% loading in styrene-acrylic emulsion binder produces a water-based insulating paint suitable for indoor wall, ceiling, and behind-radiator applications. A typical formulation: 100 parts AP-100, 200 parts acrylic emulsion (50% solids), 8 parts wetting agent (non-ionic surfactant), 4 parts defoamer, water to viscosity. Disperse on paddle mixer 30 min at 300 rpm. Apply by roller or airless spray at 1–2 mm wet film. Cured dry film conductivity 0.045–0.055 W/(m·K) at 25°C, fire class B1, washable to interior-paint standard.

Solvent-Based Industrial Insulating Coating

AP-100 at 40–60% loading in a solvent-based silicone or polyurethane binder produces a high-performance industrial insulating coating for outdoor steel substrates — storage tank exteriors, container ISO units, military vehicle thermal-signature reduction, satellite dish backshells. The hydrophobic surface allows aerogel dispersion in non-polar solvents (xylene, mineral spirits) without polar-surface aggregation that would impair film formation. Cured film delivers 50–70% heat loss reduction from a 200°C steel surface at 2 mm dry film thickness.

Roofing Membrane Aerogel Modification

AP-100 at 15–25% loading in PMMA, polyurethane, or modified bitumen roofing membranes produces a thermal-insulating cool-roof membrane. The dual function — reflectance from membrane pigments + conductive insulation from aerogel — reduces roof-deck heat flux into building envelopes, lowering air-conditioning load. Particularly relevant for commercial roof retrofits in tropical and sub-tropical regions where roof solar gain is the dominant cooling load contributor.

Refractory Coating for Process Equipment

AP-100 at 30–40% loading in a heat-resistant silicone binder produces a refractory coating sprayed onto process equipment hot surfaces — heat exchanger headers, valve bonnets, instrument tap-offs — where rigid panel or felt insulation cannot easily fit. Cured film at 2–3 mm thickness withstands continuous 400°C service and delivers personnel-protection grade surface temperature reduction equivalent to 20 mm of conventional insulation.

Packaging & Storage

AP-100 is supplied in three standard package sizes selected by intended formulation scale:

• 5 kg PE-lined kraft bag — laboratory and pilot-scale dispersion testing
• 15 kg PE-lined paper bag — production formulation, manual dispersing
• 100 kg FIBC (big bag) — industrial coating manufacturers, pneumatic conveying

MOQ is 50 kg; 40' container loads 8–12 tonnes of AP-100 depending on package mix.

Store sealed below 40°C in dry conditions. The hydrophobic surface treatment means the powder does not aggregate in humid air — but partial-use bags should be resealed after each formulation campaign to maintain Karl Fischer moisture content <0.5%, the threshold above which the powder loses some dispersibility in non-polar solvents. Shelf life is 18 months in original sealed packaging. Handle in a closed system or with local exhaust ventilation; P100 respirator and eye protection for prolonged contact.

Related Products

• MEGEL® Silica Aerogel — parent hub
• MEGEL AP-200 — finer particle size for VIP panel core
• MEGEL AP-300 — coarser particle size for mortar additive
• MEGEL AC-100 — pre-formulated acrylic aerogel coating slurry
• MEGEL MG-650-IP — aerogel felt alternative for thicker section applications