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High strength aerogel panels

a technology of aerogels and panels, applied in the direction of chemistry apparatus and processes, synthetic resin layered products, transportation and packaging, etc., can solve the problems of affecting the application of aerogels in certain sectors of the insulation market, affecting the application of aerogels, and affecting the quality of the produ

Inactive Publication Date: 2006-11-23
ASPEN AEROGELS INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0012] Embodiments of the present invention describe structures comprising at least one fiber-reinforced aerogel layer and at least one binder layer, said binder layer comprising a silicon-containing organic material. Such structures are highly useful as thermal insulators, acoustic insulators or both. The binder layer can be used as a coating, an adhesive, or both for the fiber-reinforced aerogel composites. The unique combination of at least one binder layer and at least one fiber-reinforced aerogel layer, as described herein allows a variety of useful configurations for fiber reinforced aerogels such as but not limited to: adhesion to like and / or dissimilar surfaces, high strength coatings, molded fiber-reinforced aerogel forms, mechanically stable multi-ply structures, and a host of others.

Problems solved by technology

Since aerogels, particularly in low density form are fragile, they must be handled or processed with great care.
This presents a significant limitation for the application of aerogels in certain sectors of the insulation market.
Relatively large amounts of this toxic substance is needed for the preparation of high strength aerogel presenting many problems in large scale manufacturing.
Further studies on cellulose aerogels made according to Fund et al., shows that they have inferior thermal insulation properties compared to other aerogels such as those based on metal oxides like silica.
However, the flexural toughness of the fiber-reinforced aerogel composites tends to lower the effective stiffness of the composites such that large sections may not support their own weight when standing on edge.

Method used

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  • High strength aerogel panels
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Examples

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example 2

[0034] This example illustrates the formation of a rigid thermal insulation panel. The binder of example 1 was coated as a layer between three pieces of 1′×1′ foot fiber-reinforced PMA / silica hybrid aerogel blankets with a density of about 0.16 g / cm3. The three hybrid aerogel blankets were affixed to one another with a binder layer between every two blankets. The five-layer coupon was placed into an oven set at 75° C. for 2 hours. The resultant structure, which is in the form of a panel shows a density of about 0.17 g / cm3; thermal conductivity of about 13.9 mW / mK under ambient conditions and flexural strength at rupture of about 101 psi. The size of this rigid insulation panel is 1′×1′ foot and 2″ inches thick. This panel deforms lass than 10% under 17.5 psi compression. For much higher compression loading of 4000 psi, this panel recovery up to 90% of its original thickness within 2 hours after compression.

example 3

[0035] Ultra large size rigid aerogel insulation panels with over 90 square feet dimension can be prepared. For example, 30∴×3′ dimension and ⅛″ thick silica-PMA aerogel composite (two blankets and a binder layer as a glue) was prepared according to this approach. In theory, there is no limitation on the size of the composite prepared with the embodiments of the present invention. It is only currently limited by the space available for drying the composite sheet. Such high strength aerogel panels show good compression resistant properties (<10% under 17.5 psi, up to 98% recovery strain after 4000 psi loading). The resulting high strength aerogel panels also exhibit good flexural strength (resist 100 psi flexural pressure). The improvement of mechanical properties in this hybrid aerogels composite was achieved without sacrificing other inherent properties of aerogel such as low density and low thermal conductivity.

[0036] In one embodiment of the present invention, a shaped structure...

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Abstract

Embodiments of the present invention describe a structure comprising at least one fiber-reinforced aerogel layer and at least one binder layer, said binder layer comprising a silicon-containing organic material and where the binder layer is bonded to at least one surface of a fiber-reinforced aerogel layer.

Description

PRIORITY DOCUMENTS [0001] This application claims priority to U.S. provisional patent application identified by serial No. 60 / 631,217 (filed Nov. 24, 2004) which is hereby incorporated by reference.GOVERNMENT INTEREST [0002] There is no government interest in this application. FIELD OF INVENTION [0003] The present invention relates in general to structures formed from bonding fiber-reinforced aerogel layers to each other and / or a non-aerogel surface with a binder layer. Said binder layer can also be utilized as a coating. [0004] Aerogels, first prepared by Kistler in 1931 [S. S. Kistler, Nature, 1931, 127, 764], are a type of material structure rather than a specific material, and can be prepared by replacing the liquid solvent in a wet gel with air without substantially altering the network structure (e.g., pore characteristics) or the volume of the gel body. Supercritical and subcritical fluid extraction technologies are commonly used to extract the fluid from the gel without caus...

Claims

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Application Information

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IPC IPC(8): D04H1/00
CPCB32B5/02D04H13/002B32B7/12B32B27/16B32B27/18B32B27/20B32B27/28B32B27/283B32B27/308B32B2250/24B32B2262/0246B32B2262/0253B32B2262/0269B32B2262/0276B32B2264/102B32B2264/104B32B2307/102B32B2307/304B32B2307/558B32B2419/00B32B5/32Y10T428/249924
Inventor OU, DUAN LIGOULD, GEORGE L.
Owner ASPEN AEROGELS INC
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