Heat insulating aerogel composition

Abstract

The aerogel composition includes aerogel particles and a fiber component including one or more materials selected from the group consisting of polymer fibers and inorganic fibers. The weight ratio of the aerogel particles to the fiber component is 1:3 to 10:1. The aerogel composition further includes up to 25 wt. % of a polymer, based on the total weight of the composition.

Description

[Technical Field]

[0001] Related Applications This application claims priority to U.S. Provisional Application Nos. 63 / 407,202, filed September 16, 2022, and 63 / 484,033, filed February 9, 2023, both of which are incorporated by reference in their entireties. [Background technology]

[0002] Aerogel particles can have very low density, high porosity, and small pore sizes. Aerogels, particularly silica aerogels, exhibit low density and low thermal conductivity, making them useful as insulating materials. Aerogels can be formed by removing solvent from hydrogels, such as through supercritical drying techniques or solvent displacement combined with ambient pressure drying. Silica aerogels are typically hydrophilic but can be made hydrophobic through the use of certain treatment agents.

[0003] In the broadest sense, i.e., when considered as a "gel with air as a dispersant," aerogels are produced by drying a suitable gel. When used in this sense, the term "aerogel" includes narrower aerogels, such as xerogels and cryogels. A gel is designated as an aerogel in the narrower sense when liquid is removed from the gel starting at a temperature above the critical temperature and a pressure above the critical pressure. In contrast, when liquid is removed from the gel subcritically, e.g., with the formation of a liquid-vapor boundary phase, the resulting gel is often called a xerogel. It should be noted that gels according to the present invention are aerogels in the sense that they are gels with air as a dispersant.

[0004] Due to their excellent thermal insulating properties, aerogels are being incorporated into various types of articles, including thermal control articles (e.g., sheets, pads, or blankets) designed for applications such as construction, refrigeration, and piped transportation. One application of growing interest relates to the insulation of rechargeable batteries in electric vehicles (EVs).

[0005] U.S. Patent No. 9,399,864 discloses a wet-laid aerogel blanket made from a slurry of aerogel particles with a polymer binder. Chinese Patent No. 112430018 discloses fiber paper impregnated with aerogel held by a silica binder. Chinese Patent No. 112522949 discloses an aerogel mat in which an aerogel slurry is infused into a glass fiber mat, which is then immersed in a slurry containing a polymer hardener. Chinese Patent No. 112681009 discloses a two-ply paper system impregnated with an organic solution of silica aerogel. There remains a need for thin aerogel blankets that maintain thermal conductivity and tensile strength while reducing the amount of components, such as binders, that can degrade thermal insulation performance and contribute to flammability. Summary of the Invention

[0006] It has been found that insulating spacers for EV applications often encounter challenges related to the tendency of battery cells to expand and contract during charging and discharging over the life of the vehicle.

[0007] Therefore, there is a need for an approach that addresses at least some of the issues surrounding the insulation of rechargeable batteries in electric vehicles. Particularly desired is an insulating blanket that exhibits good thermal insulation properties and various mechanical properties. For example, it is desirable that insulating spacers be mechanically robust enough to withstand the mechanical challenges of handling (e.g., during installation) and operation, and that they are not too rigid or incompressible.

[0008] Many of the embodiments described herein relate to thermal control articles that are flexible insulating members, such as nonwoven blankets, sheets, pads, mats, etc. The articles can be manufactured by wet-laid techniques from compositions containing aerogel particles and other materials.

[0009] In some embodiments, the aerogel composition comprises aerogel particles and a fiber component comprising one or more materials selected from the group consisting of polymer fibers and inorganic fibers. The weight ratio of the aerogel particles to the fiber component is 1:3 to 10:1. The aerogel composition further comprises up to 25 wt. % of a polymer, based on the total weight of the composition.

[0010] The composition may further include materials such as IR opacifiers, flame or fire retardants, heat absorbers, processing aids, etc. Binders, water, dispersants, emulsifiers, flocculants, etc. may be included as needed in making the thermal control article.

[0011] The compositions can be used to prepare nonwoven blankets, pads, or other articles, for example, by a wet-laid process, and are believed to provide significant benefits to the final product. Accordingly, the thermal control articles described herein have excellent insulating properties, for example, reducing heat transfer from a battery cell experiencing thermal runaway to adjacent cells or other battery components. The compositions are preferably non-flammable, producing articles that pass UL94-V0 testing or other flammability / combustibility tests.

[0012] Additional benefits imparted to the final article may include increased flexibility, compressibility, resilience, tensile strength, and impact resistance. By allowing the battery case to expand and contract, these articles mitigate the effects of dimensional changes in the battery compartments (e.g., cells, modules, and packs), helping to reduce the wear and tear that this type of cycling inflicts on battery materials.

[0013] These and other features and advantages of the present invention, including various details of construction and combinations of parts, will be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular methods and devices embodying the invention are illustrative and not limiting of the invention. The principles and features of this invention can be employed in various and numerous embodiments without departing from the scope of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0014] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments of the invention set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0015] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Also, all conjunctions used should be understood in the most inclusive sense possible. Accordingly, the word "or" should be understood as having the logical definition of "or" and not the logical definition of "exclusive or," unless the context clearly requires otherwise. Furthermore, the singular forms and articles "a," "an," and "the" are intended to include the plural forms unless otherwise specified. It will be further understood that the terms "includes," "comprises," "including," and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and groups thereof. Furthermore, when an element, including a component or subsystem, is referred to and / or shown as being connected or coupled to another element, it will be understood that it may be directly connected or coupled to the other element, or intervening elements may be present.

[0016] Terms such as "first" and "second" are used herein to describe various elements, but these elements should not be limited by these terms. These terms are used only to distinguish one element from another. Thus, an element described below may be referred to as a second element, and similarly, the second element may be referred to as a first element without departing from the teachings of the present invention.

[0017] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms as defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and it will be further understood that they should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. All parts and percentages are by weight unless otherwise indicated.

[0018] The present invention generally relates to an aerogel-containing composition or thermal control article, which may be a flexible member such as a blanket, sheet, mat, or pad. In one example, the article is a flexible nonwoven blanket. The aerogel composition includes aerogel particles and a fiber component including one or more materials selected from the group consisting of polymer fibers and inorganic fibers. The weight ratio of the aerogel particles to the fiber component is 1:3 to 10:1. The aerogel composition further includes up to 25 wt. % of a polymer, based on the total weight of the composition. The composition has a thickness of 0.3 to 6 mm, a thermal conductivity of up to 32 mW / m·K at 25°C, a UL-94 rating of V0, a ​​tensile strength of 0.09 to 5 MPa, and a viscosity of 0.1 to 0.6 g / cm. 3 It has a density of

[0019] In certain implementations, the aerogel is a particulate form of silica aerogel. Any type of silica aerogel particle can be used. The aerogel can be formed as described in U.S. Patent No. 7,470,725. Suitable aerogels can be made from water glass or organic materials such as TEOS and TMOS. To reduce the radiative contribution to thermal conductivity, the aerogel particles can incorporate an IR opacifying agent such as carbon black, alumina, graphite, titanium dioxide, iron oxide, silicon carbide, zirconium dioxide, or mixtures thereof. Aerogel particles are available from a variety of sources, including ENOVA and ENTERA brands from Cabot Corporation and AEROVA brand from JIOS Aerogel.

[0020] Silica aerogel can have particle sizes ranging from 0.1 mm to 5 mm, e.g., 0.1 mm to 4 mm, 0.1 to 0.5 mm, 0.1 mm to 1 mm, 0.1 mm to 1.5 mm, or 1 mm to 4 mm. The aerogel can have a narrow or broad particle size distribution and can be in the form of a crushed powder. The diameter of the aerogel particles can be measured along the longest cross-sectional line of a given particle, or the particle size range can be determined by sieving.

[0021] Silica aerogel particles may be hydrophobic, exhibiting a water contact angle of greater than 90. Commercially available examples of such aerogels are ENOVA® brand aerogel, ENTERA® brand aerogel, and IC3110, P100, P150, and P200 aerogels, all from Cabot Corporation.

[0022] Some implementations utilize a mixture of silica aerogel and hydrophobic silica aerogel.

[0023] Aerogel particles are also commercially available as a mixture with opacifying agents such as carbon black.

[0024] In some embodiments, the aerogel particles have a porosity greater than about 60% and a density less than about 0.4 g / cc, hi other embodiments, the aerogel particles have a density of about 0.05 to about 0.15 g / cc.

[0025] The thermal conductivity of the aerogel particles may be less than about 40 mW / m·K, less than about 25 mW / m·K, or between about 12 mW / m·K and about 18 mW / m·K, or less, at 25° C. To reduce flammability, the aerogel particles may be low-calorie aerogels, such as those having a calorie content of less than 10 MJ / kg, less than 8 MJ / kg, less than 7 MJ / kg, or less than 6 MJ / kg.

[0026] Because the aerogel is preferably preformed (prepared prior to fabrication of the aerogel-containing thermal control article), any desired aerogel structure, morphology, or other properties can be selected, which properties can often persist in the final product. The amount of aerogel in the composition or thermal control element can be 15-65 wt%, e.g., 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt%.

[0027] In addition to the aerogel component, the compositions described herein further comprise one or more other materials. Often, these materials or components are selected to provide a particular function and / or property to the final article (e.g., a blanket). In some cases, the type and / or amount of material added is selected to achieve a balance or compromise between desirable and less desirable contributions that the material may make to the final product. Manufacturing parameters, end use, or other factors can be considered when selecting the type and / or amount of material used.

[0028] Among the materials that can affect the properties of the final product when added to the aerogel are fiber materials. The fiber materials may be present in an amount of 5 to 55 weight percent, e.g., 10 to 50 weight percent, 15 to 40 weight percent, 20 to 35 weight percent, or 10 to 30 weight percent, based on the total weight of the aerogel composition or thermal control article. Particular implementations utilize fiber components, including inorganic fibers and / or heat-resistant polymeric fibers. Exemplary inorganic fibers include ceramic wool, ceramic fibers, and glass fibers. Examples of polymeric fibers include polybenzimidazole (PBI), aromatic polyamide (aramid), or any combination thereof.

[0029] While ceramic fibers are typically made by a drawing process and then chopped to the desired length, ceramic "wool" (or other types of wool, such as mineral wool, sometimes called "stone" wool) is often made by spinning a melt. In general, wool tends to have longer, more tangled fibers. Individually, wool fibers may be less strong than shorter ceramic fibers (made by drawing and cutting). However, in bulk, wool can have an added effect that can improve the mechanical integrity of the composition and / or thermal control article.

[0030] Wool fibers often have diameters in the range of about 1 micron (μm) to several hundred microns, and fiber lengths in the range of about 100 μm to several hundred μm or longer, sometimes even several hundred millimeters (mm) long.

[0031] These high aspect ratio wools also have the effect of improving drainage and retention in wet laid articles by providing extra surface area for well dispersed actives to agglomerate during the coagulation process, which reduces the amount of actives that are removed with excess process water during the forming process.

[0032] The amount of ceramic wool that can be used often depends on the desired properties (e.g., tensile strength, tear resistance, impact resistance), intended use, and / or other factors. The ceramic wool can be provided in an amount ranging from 0.5 to 100 weight percent (based on the weight of the fiber component utilized to prepare the composition). In exemplary embodiments, the ceramic wool is present in an amount ranging from about 5 to about 30 weight percent. For example, the ceramic wool can be present in the fiber component in an amount of from about 10 to about 20 weight percent.

[0033] For a final product, e.g., a blanket, the ceramic wool can be present in the final product in an amount in the range of 0.25% to 4% by weight of the article, e.g., about 0.5 to about 2% by weight, such as in the range of about 0.5 to about 1.0; about 0.5 to about 1.5; about 0.5 to about 2.0% by weight; or in the range of about 1.0 to about 1.5; about 1.0 to about 2% by weight; or about 1.5 to about 2.0% by weight.

[0034] Suitable ceramic wools include aluminum (provided as Al2O3), silicon (in the form of SiO2), and iron (in Fe2O3), or any combination thereof. Some ceramic wools may also contain titania (TiO2) in addition to or instead of any of these components.

[0035] Although not a required element, the presence of zirconium can provide mechanical benefits and / or contribute to the heat resistance of the final aerogel composition and / or thermal control article (e.g., blanket). In some implementations, zirconium (typically in the form of zirconium oxide (ZrO)) is provided in a zirconium-containing wool, which can also contain other elements such as aluminum, silicon, iron, and / or titanium. Commercially, Ceramaterials (Dingmans Ferry, PA) offers two types of spun fibers: one with a higher zirconia concentration (with a heat resistance of up to 2600°F / 1400°C) and one with a lower zirconia loading (2300°F / 1400°C).

[0036] In the final product, e.g., a blanket, ceramic wool can be identified by analytical techniques such as high-resolution microscopy of uniform cross sections of a sample product, e.g., a blanket. Even after processing, ceramic wool is believed to retain a conformation that differentiates it from chopped ceramic fibers. Other techniques that may be applicable include scanning electron microscopy (SEM) using energy-dispersive X-ray (EDX) capabilities (often abbreviated as "SEM / EDX"), which can differentiate and correlate concentrations of elements typical of ceramic wool with other types of fibers.

[0037] Another type of wool that can be used to prepare the compositions described herein is mineral wool (also known in some instances as "stone" wool). Mineral wool is commercially available under the trade name "Rockwool®" mineral wool from Rockwool A / S, Knauf Insulation (Shelbyville, USA), and other suppliers. The amount of mineral wool can be the same or similar to that used for ceramic wool. However, other ranges can be used.

[0038] Mineral wool can be identified in finished articles, e.g., blankets, by techniques such as scanning electron microscopy (SEM) using energy dispersive X-ray (EDX) capabilities (often abbreviated as "SEM / EDX"), allowing elements in concentrations typical of mineral wool to be differentiated and correlated with other types of fibers.

[0039] In some embodiments, the compositions described herein contain heat-resistant polymeric materials in various forms. Some approaches utilize aramid fibers, which can be defined as "pulp" (0.1-6 mm) or short-cut fibers (>6 mm). Aramid short-cut fibers and pulp are widely available, with Dupont (under the trade name Kevlar®) being a major manufacturer worldwide. Alternatively, or in addition, longer aramid fibers cut to lengths such as 3 mm, 6 mm, or 12 mm can be used.

[0040] Another approach utilizes polybenzimidazole (PBI) fibers, which typically feature excellent heat and chemical resistance. PBI fibers have no discernible melting point and therefore will not ignite or drip when exposed to high temperatures. PBI fibers can be purchased from PBI Performance Products (Charlotte, NC). PBI fibers can be at least 0.1 mm long, e.g., 0.5-10 mm, 1-8 mm, or 2-6 mm.

[0041] Materials such as aramid or PBI fibers are believed to be particularly useful for addressing the expansion and contraction observed in battery packages that are charged or discharged under high or low temperature conditions. Allowing the battery case to expand relieves pressure on the battery compartment, reducing wear and tear on the battery materials.

[0042] While still imparting these advantageous properties, these polymeric fibers are typically used in as little amount as possible, as their addition can compromise the desired low flammability rating of the final product, e.g., the blanket.

[0043] The PBI and / or aramid fiber may be provided in an amount ranging from about 0.5 to 100 weight percent (based on the weight of the fiber component utilized to prepare the composition). In exemplary embodiments, the PBI and / or aramid fiber is present in an amount ranging from about 5 to about 30 weight percent, or from 25 to 80 weight percent. For example, the PBI and / or aramid fiber may be present in the fiber component in an amount ranging from about 10 to about 20 weight percent.

[0044] Often, fibers such as aramid or PBI are used in an amount of 0.25% to 4% (based on the weight of the aerogel composition or thermal control article), e.g., about 0.5 to about 2% by weight, such as in the range of about 0.5 to about 1.0% by weight; about 0.5 to about 1.5% by weight; about 0.5 to about 2.0% by weight; or about 1.0 to about 1.5% by weight; about 1.0 to about 2% by weight; or about 1.5 to about 2.0% by weight.

[0045] In the final product, eg, a blanket, the aramid or PBI fibers can be identified by techniques such as SEM / EDX, differentiating the polymeric structure from the surrounding inorganic environment.

[0046] Ceramic fibers are known for their good corrosion resistance as well as good oxidation resistance at high temperatures. Generally, ceramic fibers are characterized by a polycrystalline (as opposed to amorphous) structure. Some, such as refractory ceramic fibers, are particularly useful as thermal insulation materials for high-temperature applications. In some embodiments, ceramic fibers constitute the majority material (greater than 50 wt. % based on the total weight of the fiber component).

[0047] Suitable chopped ceramic fibers that can be used in the compositions described herein include one or several (two, three, four or more) inorganic oxides, such as Al2O3, BO3, Na2O, KO, CaO, and MgO. Some fibers may also include silicon oxide. Many types of ceramic fibers are commercially available, often well characterized in terms of composition, length, and / or other properties. Suitable chopped ceramic fibers include, but are not limited to, Unifrax 7000 and 6000 series fibers. In one example, the ceramic fibers are coarsely chopped high-purity alumina-silica products from Unifrax. The ceramic fibers may have a variety of diameters, e.g., 1.5 to 2.5 microns, and may be available chopped to specific lengths or in non-uniform lengths, including a mixture of shot (unfibered material) and longer fibers. In some embodiments, the ceramic fiber aggregate may contain as much as 45 to 55% shot. For purposes of this disclosure, shot, if present, is still counted as part of the fiber material in the aerogel composition or thermal control element.

[0048] Alternatively, or in addition, glass or other fibers can be used, alone or in combination with one or more of the ceramic fibers and / or ceramic wool, aramid, and / or PBI fibers described above. Exemplary glass fibers include borosilicate (B fiber), acid-resistant borosilicate (C fiber), and calcium aluminoborosilicate (E fiber), available from, for example, Lauscha Fiber International or Unifrax; and / or fibers consisting essentially of silica (Q fiber), available from, for example, Johns Manville. The glass fibers may be cut to various lengths, such as 3 mm, 6 mm, or 12 mm, or may be used as "shot." The glass fibers may have various diameters, such as 0.25 microns to 0.5 microns, 0.5 to 1.5 microns, 1.5 to 2.5 microns, 1 micron to 5 microns, or 8 microns to 12 microns, e.g., 6, 9, or 12 microns. Alternatively, or in addition, more than one type of glass fiber may be used, for example, glass fibers cut to more than one length or diameter, for example, a blend of fibers having a diameter less than 1 micron and fibers having a diameter greater than 5 microns. Silica gel fibers are made by spinning a gelled silica sol, for example, as described in U.S. Patent Application Publication No. 2020 / 0308729, the entire contents of which are incorporated herein by reference.

[0049] Other fibers that can be added to the ceramic fibers, glass fibers, ceramic wool, and / or polymeric fibers such as PBI or aramid include non-ceramic fibers such as cellulose, cotton, carbon, acrylic, polyvinyl alcohol (PVA), phenolic, polyolefin, and / or other types of fibers, as well as mixtures of such fibers.

[0050] The fibers used may be of any configuration known to those skilled in the art, for example, the fibers may be in the form of chopped fibers, microfibers, woven fibers, or nonwoven fibers.

[0051] The cross-sectional shape of the fiber can be round, polygonal, trilobal, pentapleof, octapleof, strip-shaped, fir tree, dumbbell, or other shapes. The fiber may have a consistent or varying diameter along the length of the fiber. In some embodiments, hollow fibers can be used. Furthermore, the fiber material can be smooth or crimped, and can be coiled or straight.

[0052] In some embodiments, coated fibers are used, one example being polyester fibers metallized with a metal such as aluminum.

[0053] Fibers modified with additives are also suitable, examples of which include, but are not limited to, antistatic agents such as carbon black; and / or IR opacifying agents (typically used to reduce radiation contribution to thermal conductivity) such as carbon black, titanium dioxide, alumina, iron oxide, or zirconium dioxide, silicon carbide, or mixtures of any of these.

[0054] In addition to including an IR opacifying agent, the radiative contribution to thermal conductivity can be further reduced by using blackened fibers, such as polyester fibers blackened with carbon black, or simply carbon fibers.

[0055] The amount of fiber component (either a single fiber or a blend of fibers) used depends on its density, diameter, length, etc., and can be 1% to 99% by weight, preferably 5% to 55% by weight, e.g., 10% to 50% by weight, 15% to 40% by weight, 20% to 35% by weight, or 10% to 30% by weight, based on the weight of the aerogel composition. In certain embodiments, the mass ratio of aerogel component to fiber component is within the range of 1:3 to 10:1 by weight, e.g., 1:2 to 10:1, 1:3 to 3:1, 1:2 to 2:1, 1:1 to 10:1, 1:2:1 to 9:1, 1:2 to 9:1, or 1:1 to 5:1. If the relative amount of fiber component is too high, the thermal conductivity of the aerogel composition and / or thermal control article may be too high. If the relative amount of fiber component is too low, the tensile strength of the aerogel composition and / or thermal control article may be too low.

[0056] Blends of fibers can also be used. For example, a first fiber selected to provide mechanical strength can be used in combination with a second fiber that functions to hold the aerogel and other particles, such as opacifying agents, within the blanket. The first fiber is typically a glass or ceramic fiber, while the second fiber is typically a fiber with a higher aspect ratio, but may also be a longer glass or ceramic fiber. Alternatively, or in addition, a third fiber may be included to enhance certain mechanical properties. For example, the addition of a polymer fiber as a third fiber can increase the flexibility of the aerogel blanket.

[0057] The wool and / or high-temperature polymeric fibers described herein may constitute the entire fiber component in the composition, but are often used in conjunction with glass or ceramic fibers. In many cases, the glass or ceramic fibers may actually constitute the predominant fiber material (greater than 50% by weight, based on the total weight of the fiber component) and may be considered the "primary" fiber used in the composition. In this context, the term "secondary" may apply to the ceramic wool and / or high-temperature polymeric fibers (e.g., PBI, aramid) in the composition. Alternatively, the PBI or aramid fibers may constitute the predominant fiber material. Alternatively, or in addition, blends of glass and ceramic fibers may also be used (e.g., ceramic or glass as the primary fiber and the other as the secondary fiber), and generally, any of the fibers or wools disclosed herein may be combined with one or more of the others. In certain embodiments, the weight ratio of the primary fibers to the secondary fibers is 100:1 to 1:100, e.g., 50:1 to 1:50, 35:1 to 1:35, 25:1 to 1:25, 15:1 to 1:15, 10:1 to 1:10, 7:1 to 1:7, 5:1 to 1:5, 4:1 to 1:4, 3:1 to 1:3, or 2:1 to 1:2. In certain implementations, glass or ceramic fibers are used alone or with aramid fibers in a weight ratio of 1:4 to 10:1, e.g., 1:3 to 5:1, 1:2 to 3:1, or 1:1 to 2:1. Alternatively, or in addition, different types of glass fibers, for example, glass fibers having a diameter of 5 to 10 microns, are used in combination with glass microfibers having a diameter of less than 1 micron in a weight ratio (larger diameter:smaller diameter) of 5:1 to 1:5, for example, 4:1 to 1:4, 2:1 to 1:2, or 1:5 to 1:1.5. Alternatively, or in addition, ceramic microfibers are the primary fibers and glass fibers or microfibers are the secondary fibers.Alternatively, or in addition, a combination of three or more types of fibers may be used, for example, ceramic microfibers (less than 5 microns in diameter, or less than 3 microns in diameter) in combination with two or more of glass fibers having a diameter of 5-10 microns, glass fibers having a diameter of less than 5 microns or less than 1 micron, aramid fibers, and PBI fibers. Alternatively, or in addition, the glass fibers used in making the aerogel composition or thermal control element are chopped to 6 microns or less, or 3 microns or less.

[0058] The length and diameter of the fibers, e.g., glass or ceramic fibers, can vary depending on the particular application. Thinner fibers, such as microfibers (diameter less than 5 microns or less than 1 micron), can, for example, add flexibility, while the length and / or distribution of the fibers can serve to increase the mechanical strength of the final product, e.g., a blanket. In exemplary embodiments, the fibers are cut to 3 mm, 6 mm, or 12 mm, or other commercially available lengths. Two or more different types of fibers, or fibers made from the same material but characterized by different fiber lengths, length distributions, diameters, or diameter distributions, can be used to achieve bimodal or multimodal fiber length or diameter distributions.

[0059] In some embodiments, the composition includes elastomeric particles, such as silicone particles, rubber powder, or thermoplastic microspheres. Such materials are believed to potentially improve both the reinforcement and elasticity of the final product, e.g., the blanket. The elastomeric particles may be solid, hollow, and / or resin-coated. For purposes of this description, elastomeric powders or particles are classified with other particulate components of the composition, such as opacifying agents, but not with polymeric components, such as dispersants, surfactants, coalescing aids, defoamers, and binders.

[0060] Silicone powders or particles are commercially available in a variety of average particle sizes (avg PS), for example, in the range of about 1 micron to 1 mm in diameter. As an example, suppliers such as Shin-Etsu Silicones offer suitable elastic particles under their Silicone Powder KMP series. For example, particles with an average PS of 13 μm are available under product code KMP-598, while product KMP-402 offers a PS of 30 μm.

[0061] The appropriate amount that can be used can be determined based on the desired properties, manufacturing parameters, and / or other factors. In some implementations, the silicone particles are provided in a ratio of up to 1:1 relative to the aerogel component, e.g., 1:10 to 1:1, 1:8 to 1:2, or 1:6 to 1:3.

[0062] Silicone rubber particles can be used in combination with one or more inorganic fibers and / or wool and / or heat-resistant polymer fibers described herein. For example, they can be combined with aerogel particles, one or more inorganic fibers and / or one or more ceramic wool, aramid fiber and / or PBI fiber. Alternatively, silicone particles can be used in compositions that do not contain ceramic wool or polymer fibers such as aramid or PBI.

[0063] In many embodiments, the compositions described herein include an opacifying agent, such as an infrared (IR) opacifying agent, to reduce radiative heat transfer. These materials reduce the transmission of infrared radiation and can include, for example, carbon black, mica, alumina, graphite, titanium dioxide, rutile sand, iron oxide, silicon carbide (SiC), graphite, or zirconium dioxide. Some suitable types of titanium dioxide include, for example, Tipure® (DuPont) and Altiris® (Huntsman). IR opacifying agents can be used individually or as a mixture of two or more compounds. Particle size can be selected to reflect specific wavelengths. For example, for ceramic opacifying agents such as titanium dioxide, particles less than 1 micron in size, as measured by laser diffraction, can block visible light more efficiently than IR radiation, but the thermal conductivity of the particles can increase with larger particle sizes, e.g., greater than 3 microns. In another example, silicon carbide is available in grit sizes from F230 to F2000, such as F500, F600, F800, F1000, F1200, and F1500 (Federation of European Producers of Adhesives).

[0064] The IR opacifying agent can be added in an amount selected to provide a target level of IR transmission reduction in the aerogel composition and / or thermal control article (e.g., blanket). Exemplary such levels can be, for example, up to 10%, 0.5% to 8%, 0.75% to 5%, or 1% to 3% opacifying agent based on the total weight of the aerogel composition and / or thermal control article. The range of IR wavelengths covered can be broadened by adding opacifying agents characterized by two or more different average particle sizes in a given composition.

[0065] In some embodiments, the aerogel composition and / or thermal control article (e.g., blanket) can include a flame retardant or fire retardant. Flame retardants can be, for example, alkali oxides, alkaline earth metal oxides, aluminum trihydrate, magnesium hydroxide, antimony oxide, titanium dioxide, rutile sand, melamine compounds, phosphate-based, or halogen-based compounds. In certain embodiments, the titanium dioxide particles can have a diameter of about 1.18 μm, 0.9-1.3 μm, 0.8-1.4 μm, or 0.5-4.0 μm as measured by laser diffusion spectroscopy; in some embodiments, the particle size distribution can have a d50 of about 1.0 μm + / - 0.01 μm, + / - 0.02 μm, or + / - 0.05 μm. Halogenated flame retardants include brominated flame retardants (BFRs), such as organic bromide compounds, including polymeric organic bromide compounds. In another set of embodiments, the polymeric flame retardant has a structure with a high ratio of heteroatoms to carbon atoms. For example, in some embodiments, the ratio of heteroatoms to carbon atoms may be greater than 0.5 to 1, greater than 1 to 1, or greater than 2 to 1, and in certain embodiments, the heteroatoms may be nitrogen and / or sulfur. Flame retardants and / or fire retardants can be incorporated into the aerogel compositions and / or thermal control articles at concentrations appropriate to suppress flammability or to meet specifications such as UL94-V0. Alternatively, or in addition, exemplary aerogel compositions and / or thermal control articles may exhibit a caloric content of, for example, less than 10 MJ / kg, less than 8 MJ / kg, less than 5 MJ / kg, less than 3 MJ / kg, less than 2 MJ / kg, or less than 1 MJ / kg, e.g., 0.5 MJ / kg, or between 1 MJ / kg and 5 MJ / kg.

[0066] Concentrations of fire retardants and / or flame retardants that can be used can range from 0.1 wt.% to 5.0 wt.%, 0.2 wt.% to 2.0 wt.%, and 0.3 wt.% to 1.5 wt.%, based on the weight of the aerogel composition and / or thermal control article. In certain implementations, the fire retardant or flame retardant is combined with a mixture that combines aerogel particles, such as silica aerogel.

[0067] Heat-absorbing materials can also be used. Such materials help the aerogel composition and / or thermal control article (e.g., blanket) behave not only as an insulator, slowing heat transfer, but also as a thermal capacitor, capable of storing thermal energy. Such heat-absorbing materials can include aluminum hydroxide and others known to those skilled in the art. Alternatively, or in addition, the heat-absorbing material can include a phase-change material that stores heat by undergoing a thermodynamic phase change or a change in hydration state or crystalline structure. Suitable phase-change materials include both organic and inorganic materials, such as metals, inorganic salts, and inorganic hydrated salts. The heat-absorbing material can be combined with the aerogel particles and / or hydrophobic silica aerogel, or deposited on the surfaces of the aerogel pores or otherwise impregnated into the aerogel pores.

[0068] The composition can optionally include a binder. In some circumstances, the binder can help prevent widespread dispersion or dissipation of the silica aerogel, hydrophobic silica-containing particles, and / or other particulate components of the aerogel composition and / or thermal control article in the event of catastrophic failure or explosion of the item being insulated, such as a battery. Examples of suitable binders include, but are not limited to, silicone, polyurethane, epoxy, polyvinyl alcohol, polyvinylidene fluoride, polyethylene terephthalate, polybutylene terephthalate, acrylate (acrylic) polymers, and the like. Binders comprising heat-resistant and / or flame-retardant polymers are preferred. Binders such as polyvinyl alcohol, silicone, polyurethane, styrene-butadiene polymers, or acrylate or acrylic polymers can also bind additives such as carbon black to the aerogel particles to reduce dust generation during downstream processing of the aerogel composition. Exemplary commercially available binders include Joncryl FLX5201, FLX5220, FLX5026A, and 1670 polymers manufactured by BASF, U4000, U4101, and APU 10120 polymers manufactured by Alberdingk Boley, Novacryl PSR300 polymer manufactured by Synthomer, and Styrofan 4306 polymer manufactured by BASF. The binder may be mixed with some or all of the components of the mixture, including any additives incorporated into the mixture, using an impeller or other suitable device known to those skilled in the art. Preferably, the binder does not render the aerogel blanket combustible under UL94 or other flammability test methods.

[0069] Processing aids may also be included. The processing aid selected will depend on the method and form of preparation of the aerogel composition and / or thermal control article. Suitable processing aids include, but are not limited to, antifoaming agents, surfactants, dispersing agents, and emulsifying agents.

[0070] Various commercially available defoamers are known to those skilled in the art and are suitable for use with the aerogel compositions herein. The defoamer may be a polyol or polyglycol, such as those available under the Surfynol brand from Evonik Industries. Alternative polyols include, but are not limited to, 1,3-propanediol, 1,2-butanediol, 2,3-butanediol, 1,3-butanediol, 1,4-butanediol, glycerol, trimethylolpropane, pentaerythritol, triethanolamine, and trihydroxymethylaminomethane. Alternatively, or in addition, oil-based or fatty acid-based defoamers can be used. Alternatively, or in addition, the defoamer may be a polymer-based defoamer, such as a silicone-based defoamer, such as BASF's Dehydran 1293 defoamer.

[0071] The dispersant or surfactant may be selected from, for example, ionic (anionic and cationic) surfactants and dispersants, amphoteric surfactants and dispersants, nonionic surfactants and dispersants, and high molecular weight surfactants and dispersants. Suitable anionic surfactants include alkyl sulfates and higher alkyl ether sulfates, more specifically, for example, ammonium lauryl sulfate and sodium polyoxyethylene lauryl ether sulfate. Suitable cationic surfactants include aliphatic ammonium salts and amine salts, more specifically, for example, alkyl trimethylammonium and polyoxyethylene alkylamine. The amphoteric surfactant may be, for example, a betaine type such as alkyl dimethyl betaine, or an oxide type such as alkyl dimethyl amine oxide.

[0072] Suitable nonionic dispersants include, for example, glycerol fatty acid esters, propylene glycol fatty acid esters, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylene sorbitol tetraoleate, polyoxyethylene alkyl ethers, polyoxyethylene alkylphenyl ethers, polyoxyethylene polyoxypropylene glycol, polyoxyethylene polyoxypropylene alkyl ethers, polyethylene glycol fatty acid esters, higher fatty acid alcohol esters, polyhydric alcohol fatty acid esters, polyether-modified polydimethylsiloxanes, and others.

[0073] Additional potential surfactants include AEROSOL OT (di-2-ethylhexyl sodium sulfosuccinate), BARLOX 12 (branched alkyl dimethyl amine oxide), BARLOX 12i (branched alkyl dimethyl amine oxide), TRITON 100 (octylphenoxypolyethoxy(9-10)ethanol), TWEEN surfactants such as TWEEN 100 surfactant, and BASF pluronic surfactants. Other examples of wetting agents include glycols, alkoxylated polyoxyalkylene fatty ethers such as polyoxyethylene fatty ethers, sorbitan esters, mono- and diglycerides, polyoxyethylene sorbitol esters, polymeric surfactants such as Hypermen polymeric surfactants, cocoalkyl PG dimonium chloride phosphate Na, and coamidopropyl PG dimonium chloride phosphate, phosphate esters, polyoxyethylene (POE) fatty acid esters, Renex nonionic surfactants (nonionic esters formed by the reaction of ethylene oxide with unsaturated fatty acids and heterocyclic resin acids), alcohol ethoxylates, alcohol alkoxylates, ethylene oxide / propylene oxide block copolymers, polyoxyethylene derivatives of sorbitan esters, or combinations thereof. Preferred dispersants have at least one cationic or cationizable group and an HLB ratio of 2 to 20, more preferably ethylene oxide and propylene oxide oligomers in a molar ratio of ethylene oxide mer to propylene oxide mer of 0.1:1 to 11:1.Exemplary dispersants include Jeffamine M-2070 compound (Huntsman), which is a monofunctional primary amine having a weight average molecular weight of about 2,000, a propylene oxide / ethylene oxide (EO / PO) molar ratio of 31 / 10, and an HLB value of 13.8; Jeffamine M600 compound (Huntsman), which is a monofunctional primary amine having a weight average molecular weight of about 600, a propylene oxide / ethylene oxide (EO / PO) molar ratio of 1 / 9, and an HLB value of 2; Jeffamine ED900 compound (Huntsman), which is a bifunctional primary amine having an EO / PO ratio of just over 2 and a weight average molecular weight of about 900; and Surfonamine ED900, which is a monofunctional primary amine having an EO / PO ratio of about 58 / 8, a weight average molecular weight of about 3000, and an HLB value of about 17.1. L-300 compound (Hunstman), and Surfonamine B-200 compound, which is a monofunctional primary amine having an EO / PO ratio of about 6 / 29 and a weight average molecular weight of about 2000.

[0074] While materials can often be combined in any suitable manner, techniques for incorporating some components can benefit from additional consideration. For example, with fibers, too little mixing energy can result in undispersed bundles of fibers that do not effectively improve performance, while over-dispersion (under unrestrained mixing or mixing energy) can result in self-entanglement and "balling." Too much chopping and cutting energy can result in fibers that are shorter than ideal, affecting product properties and performance. With regard to equipment, it has been found that mixing operations that rely on cutting blades with sharp leading edges can also contribute to fiber length reduction. While this can be relatively benign on short timescales, the effect is expected to accelerate over longer periods.

[0075] It has also been found that certain properties of the incorporated material can make the material more susceptible to "over-processing" effects. For example, in the case of fibers, such effects become more significant for fiber lengths greater than about 6 mm (0.25 inches) and / or for fine roughness.

[0076] Accordingly, some embodiments described herein relate to controlling some of the mixing parameters, such as the time of mixing, the energy supplied, the type of equipment, e.g., blade type, etc. In certain instances, the mixing parameters take into account the properties of the material being processed. In others, the properties of the material are evaluated and then correlated to appropriate mixing parameters. Setting appropriate mixing parameters can be done based on routine experimentation, past experience, etc.

[0077] To form the compositions described herein, the materials may be combined in any suitable manner and may involve a single step. However, often the mixing is carried out in a sequence of two or more steps using equipment known in the art. In one example, the aerogel particles and fibers are added to a solution containing processing aids such as antifoaming agents, surfactants, dispersing agents, and / or emulsifying agents.

[0078] The thermal control article can take any form known to those skilled in the art. For example, aerogel compositions such as fiber-containing blankets or pads can be made using techniques such as those described in, for example, U.S. Pat. No. 9,399,864, U.S. Patent Application Publication No. 2021 / 0363699, WO 2022 / 024085, CN 112759353, U.S. Pat. No. 11274044, CN 112681009, CN 113943171, CN 110093783, CN 112681009, JP 2015-048543, and / or U.S. Patent Application Publication No. 2020 / 0295328, all of which are incorporated by reference in their entirety.

[0079] Generally, in a "wet-laid" process, aerogel particles and optional materials are agglomerated from an aqueous slurry to form a substantially stable, homogeneous suspension of particles (flocs). Preferably, the aqueous slurry contains less than 5% by weight of organic solvent, e.g., less than 3% by weight, or less than 1% by weight of organic solvent. The flocs can be separated from the aqueous-based solvent to form a two-phase system consisting of agglomerated aerogel particles and a substantially aqueous supernatant. The flocs can float on top of the supernatant, or some of the flocs can be suspended in the supernatant. The agglomerated material can support a uniform distribution of different particles that can be used to create a blanket. This stable, consistent particle distribution can provide an aerogel blanket that exhibits a uniform composition throughout.

[0080] In one embodiment, as described in U.S. Pat. No. 9,399,864, an aqueous slurry is prepared from a mixture of silica aerogel, hydrophobic silica-containing particles, ceramic fibers, and other components (e.g., binders, opacifying agents, fire retardants, defoamers, etc.). Preferably, the relative amounts of the various components in the aqueous slurry correspond to their relative amounts in the aerogel composition. A charged compound or other emulsifying or dispersing agent is included in the slurry to create an emulsion, which is then flocculated with a flocculating agent. The resulting floc is collected on a scrim or belt and dewatered. The thickness of the aerogel composition can be adjusted by increasing or decreasing the solids content of the aqueous slurry. In some embodiments, the solids content may be 5% to 25% by weight of the aqueous slurry, e.g., 5-10%, 10-15%, 15-20%, or 20-25% by weight.

[0081] Without being bound by any particular theory, it is believed that as flocculation becomes more efficient, the aerogel particles can be packed more tightly within the blanket. The flocculating agent preferably aggregates enough solids in the mixture so that the bulk of the solids rises to the top of the aqueous mixture, leaving the aqueous medium relatively clear rather than cloudy. Preferred flocculating agents are polymeric flocculating agents, as opposed to inorganic flocculating agents. Exemplary polymeric flocculating agents include quaternary polyamines, such as polyamines, e.g., SuperFloc® 577 or 581 flocculants manufactured by Kemira, and polyacrylamides, such as Nalclear 7768, Nalclear 8187, and Nalclear 8176 polymers manufactured by Nalco, dicyandiamide resins, polydiallyldimethylammonium chloride (PDADMAC), aminosilanes, quaternary amine-functionalized silanes, silicone resins, and mixtures or emulsions of any of these. In some embodiments, the flocculating agent is in the form of a latex, or an aqueous emulsion of the flocculating agent. The flocculant may have various number average molecular weights, for example, 400 to 60,000,000, preferably 400 to 1,000,000, for example, 5,000 to 10,000, 10,000 to 100,000, 100,000 to 500,000, 500,000 to 1,000,000, 20,000 to 10,000,000, 1,000,000 to 30,000,000, or 5,000,000 to 50,000,000.

[0082] The flocculant may be used in conjunction with a flocculating polymer. The flocculant is preferably an ionic polymer, and the flocculating polymer is preferably an ionic polymer of the opposite charge. In some embodiments, the flocculating polymer is in the form of a latex or an aqueous emulsion of the flocculating polymer. The flocculating polymer may have a number average molecular weight of 400 to 1,000,000, e.g., 5,000 to 10,000, 10,000 to 500,000, 20,000 to 50,000, or 50,000 to 1,000,000. Alternatively, the flocculating polymer may have a molecular weight in the ranges described above for the flocculant. Suitable flocculating polymers include, but are not limited to, natural and synthetic latex polymers, acrylics, and polyacrylamides. Because the flocculant is preferably a charged polymer, any of the coagents listed above as flocculants can also be used as the flocculating polymer, depending on their relative charges. Importantly, only one component of the flocculation system (referred to herein as the flocculating polymer) is added to the aqueous slurry before or while the other components (aerogel, fiber, opacifier, etc.) are added, while the flocculant is added only after all other components have been combined. Preferably, the flocculant and flocculating polymer are used in amounts such that the amount of charge (i.e., the product of charge density and mass) provided by the flocculant is within 20%, e.g., within 10%, within 5%, or within 1% of the amount of charge provided by the flocculating polymer.

[0083] The total amount of flocculant and flocculating polymer should be sufficient to bind the various components of the aerogel composition, but not so great that they fill the pores of the aerogel composition and thus reduce its thermal conductivity. In fact, in certain embodiments, the flocculant and flocculating polymer may provide all of the required binding functions in the aerogel composition, eliminating the need for a binder. Using more flocculant and flocculating polymer than necessary may also undesirably affect the mechanical performance of the composition, undesirably increase its density, increase the caloric content of the aerogel composition, or reduce its flammability performance. The total weight fraction of polymers, including dispersants, binders, defoamers, flocculants, and flocculating polymers, used to make the aerogel composition may be less than 25% by weight of the total weight of materials added to the aqueous medium, i.e., the total weight of materials in the floc and supernatant excluding the aqueous medium, such as 3 to 25%, for example, 4 to 10%, 10 to 15%, 15 to 20%, or 20 to 25% by weight. If a binder is not used, its amount may be even less, for example, 3% to 15% by weight, or 8% to 17% by weight, based on the total weight of materials added to the aqueous solvent to form the aerogel composition. The same percentage of polymer may be found in the resulting aerogel composition. Similarly, the total weight of polymer, including dispersant, binder, defoamer, flocculating agent, and flocculating polymer, in the resulting aerogel composition may be less than 25% by weight, for example, 3% to 25%, such as 4% to 10% by weight, 10% to 15% by weight, 15% to 20% by weight, or 20% to 25% by weight, based on the total weight of the aerogel composition. If a binder is not used, its amount may be even less, for example, 3% to 15% by weight, or 8% to 17% by weight, based on the total weight of the aerogel composition.

[0084] To form a cohesive aerogel composition using the wet-laid method, threshold amounts of dispersant, defoamer, flocculating agent, and flocculating polymer are required. Those skilled in the art will recognize that the required amounts vary depending on the relative amounts of non-polymeric components (e.g., aerogel, fiber, opacifying agent, fire retardant, heat-absorbing material, etc.). However, excess material may be detrimental to thermal conductivity and / or flame retardancy under UL-94 and may undesirably increase density. In certain embodiments, the total amount of flocculating system (i.e., flocculating agent and flocculating polymer) and binder used to make the aerogel composition or thermal control article is 3 to 20 wt %, e.g., 4 to 16 wt %, based on the total weight of the materials in the floc and supernatant, but excluding the aqueous solvent. Similarly, the total amount of flocculating system and binder in the aerogel composition may be 3 to 20 wt %, e.g., 4 to 16 wt %, based on the total weight of the aerogel composition.

[0085] In certain embodiments, the packing density of the various components can be increased by using compression to force additional water out of the floc before drying. For example, the floc can be passed through a two-roll press or compressed between two plates or platens. Alternatively, a single roller can be passed over the floc. Compression increases the packing density of the various components by squeezing water out of the floc. In the final product, the remaining water is replaced by air during drying, reducing the interparticle porosity. Alternatively, or in addition, the aerogel composition can be compressed after drying using any of these methods. After drying, compression can be used to make the composition thinner and more dense, allowing the aerogel composition and / or thermal control element to occupy less space and improving mechanical properties. The density of the aerogel composition or thermal control element can be between 0.1 and 0.6 g / cm. 3 , e.g., 0.15 to 0.5 g / cm 3 , 0.15~0.4g / cm 3 , or 0.2 to 0.35 g / cm 3 is.

[0086] In another embodiment, the fibers, aerogel, binder, and any other desired ingredients are placed in a mold and pressed into a pad, for example, as described in EP 3835262, the entire contents of which are incorporated herein by reference. It may be necessary to heat or otherwise activate the polymeric binder within the mold. Alternatively, or in addition, the fibers, aerogel, binder, and other ingredients may be blended into a paste and extruded, for example, as in EP 3835262 and WO 2020 / 228998, the entire contents of which are incorporated herein by reference. Alternatively, the fibers, aerogel, and any other desired components can be used to fill an envelope or other cavity using techniques such as those described in CN 113785431, CN 110544809, JP 2012-145204, and / or U.S. Patent Application Publication No. 2021 / 0332932, all of which are incorporated herein by reference in their entirety. Alternatively, or in addition, the mixture can be incorporated into or combined with a polymer foam such as those described in WO 2020 / 211320, JP 2020-019925, U.S. Patent No. 10,640,629.

[0087] Thermal control articles (e.g., blankets) comprising the aerogel composition can be fabricated in a generally planar or flat form for insertion between cells of a rechargeable battery, e.g., a lithium-ion battery. In other approaches, the article can be prepared in another desired shape. For example, the thermal control article can be molded to be placed around a particular component within a battery or other device, or it can have a more complex shape.

[0088] In some embodiments, the aerogel composition is fabricated to the correct size for the thermal control article or cut to the desired size. Alternatively, or in addition, the thermal control article may include additional sheet-like materials to improve mechanical integrity, heat resistance, mechanical resilience, and / or other properties. Examples include, but are not limited to, silicone-based materials, polyvinylidene fluoride, chlorinated polyethylene, aramid materials such as Kevlar (e.g., woven mats of aramid fibers), and Kevlar nanofiber aerogels such as those described in Lyu, et al., ACS Nano 2019, 13, 2236-2245. Kevlar or other woven mats of aramid fibers may be impregnated with a shear-thickening fluid as described in U.S. Patent No. 7,825,045, the entire contents of which are incorporated herein by reference.

[0089] In some cases, an envelope can be used to prevent dust, help maintain the shape of the thermal control article, facilitate its handling or installation, etc. The material forming the envelope is preferably a flame-retardant and / or heat-resistant polymeric material, including, for example, silicone resin, polyvinylidene fluoride (PVDF), polyethylene terephthalate (PET), chlorinated polyethylene, and other similar polymers known to those skilled in the art. Alternatively, or in addition, the material for the envelope may include reinforcing fibers, such as aramid fibers, to provide puncture resistance. Reinforcing materials may be used in combination with other polymers, or the envelope may be formed entirely of such polymers, e.g., woven aramid fibers. In one embodiment, the envelope may include one or two sheets of polymer film, e.g., PET film, disposed around the two planar sides of the aerogel composition. In some embodiments, a frame, e.g., silicone rubber, may be placed around the edges of the aerogel composition and envelope to seal the envelope and facilitate handling of the resulting thermal control article.

[0090] Alternatively, or in addition, the thermal control article may include several layers of aerogel composition stacked on top of each other. Optionally, the layers may be separated by any of the materials described above in connection with the envelope. Alternatively, or in addition, the layers may be separated by foam pads or mica sheets to further improve thermal insulation performance. Alternatively, or in addition, such layers may be used on the outside of the aerogel composition laminate. In some embodiments, it may be desirable to include a thermally conductive material configured to transport heat in a controlled manner, for example, to a heat sink. The various layers may be adhered to each other by any suitable adhesive known to those skilled in the art, needled, or enveloped to maintain the laminate structure.

[0091] Alternatively, or in addition, the thermal control article may include a coating. For example, a polymer or prepolymer solution or emulsion may be sprayed, painted, cast, or otherwise coated onto one or more exterior surfaces of the aerogel composition or laminate and cured. Suitable cured polymers include polyolefins, silicones, polyvinyl alcohol, starch, polytetrafluoroethylene, phenolic, melamine, phenol formaldehyde, acrylic polymers, and other polymers known to those skilled in the art. Such coatings can provide similar functionality to the envelope described above, but with fewer materials. Alternatively, or in addition, the aerogel composition may be surface-treated, e.g., hydrophobized. The aerogel composition may be contacted with a hydrophobizing agent, such as a silane compound, a silazane compound, or a disiloxane compound. Examples of silane compounds include, for example, compounds of the formula R' x Six 4-x and an alkylhalosilane having the formula R' x Si(OR'') 4-x wherein R' is C1-C 10 Branched and straight chain alkyl or alkenyl, C3-C 10 Cycloalkyl and C6-C 10aryl, R" is a C1-C5 branched or linear alkyl, X is a halogen, preferably chlorine, and x is an integer from 1 to 3. The aerogel composition may be directly immersed in the hydrophobizing agent or exposed to the vapor of the hydrophobizing agent. Alternatively, the aerogel composition may be immersed in a mixture of the hydrophobizing agent and a suitable solvent. The temperature and pH of the treatment medium can be adjusted to manipulate the degree of treatment, as known to those skilled in the art. Exemplary treatment agents include, but are not limited to, trimethylchlorosilane, dimethyldichlorosilane, hexamethyldisilazane, hexamethyldisiloxane, and other hydrophobizing agents known to those skilled in the art. The hydrophobizing agent is preferably water-soluble and / or has a boiling point below 200°C, below 150°C, or preferably below 100°C.

[0092] The aerogel composition and / or thermal control article may have a thickness of 0.3 to 6 mm, e.g., 0.3 to 5 mm, 0.4 to 4 mm, 1 to 3 mm, or 1.5 to 2.5 mm. In some embodiments, after drying of the aerogel composition, at least some of the components in the thermal control article assembly are compressed, e.g., between rollers or platens, to reduce the final thickness of the product article. Preferably, the aerogel composition and / or thermal control article is self-supporting. That is, the aerogel composition and aggregation system of aerogel, fiber, opacifier and other particulate additives, and polymer binder can be handled and manipulated without losing cohesion. Aerogel compositions that are not self-supporting may require a backing or scrim to maintain cohesion.

[0093] The aerogel composition and / or the thermal control article can exhibit excellent thermal stability. For example, the thermal control article may shrink less than 2% after aging at 650° C. per ASTM-C356. The aerogel composition and / or the thermal control article may have a thermal conductivity at 25° C. of less than 30 mW / m·K, more preferably less than 25 mW / m·K, e.g., from 5 mW / m·K to 25 mW / m·K, or from 8 mW / m·K to 15 mW / m·K, or from 17 mW / m·K to 30 mW / m·K, or from 15 mW / m·K to 25 mW / m·K, or from 20 mW / m·K to 30 mW / m·K, per test method ASTM C518.

[0094] The aerogel composition and / or thermal control article may have a tensile strength of 0.1 to 5 MPa, for example, 0.1 to 3 MPa or 0.15 to 2 MPa.

[0095] The aerogel composition and / or thermal control article may be flexible, a property that may be measured by ASTM C1101 or another suitable technique. Manual bend testing may be particularly useful in the initial screening stages of products.

[0096] In certain implementations, the aerogel composition and / or the thermal control article has a flammability rating of non-flammable under UL94-V0.

[0097] Alternatively, or in addition, the aerogel composition and / or thermal control article may be compressible, e.g., have a compressive modulus at 50% compression of 0.1 to 100 MPa as measured by ASTM C 165-05, e.g., 0.1 to 1 MPa, 1 to 10 MPa, 5 to 30 MPa, 10 to 50 MPa, or 30 to 100 MPa.

[0098] The present invention includes the following aspects / embodiments / features in any order and / or in any combination:

[0099] 1. An aerogel composition comprising:

[0100] aerogel particles;

[0101] a fiber component comprising one or more materials selected from the group consisting of polymer fibers and inorganic fibers, wherein the weight ratio of aerogel particles to fiber component is 1:3 to 10:1; and

[0102] 3 to 25 wt. % of a polymer, based on the total weight of the composition

[0103] The composition has a thickness of 0.3 to 6 mm, a thermal conductivity of up to 32 mW / m·K at 25°C, a UL-94 rating of V0, a ​​tensile strength of 0.09 to 5 MPa, and a thermal conductivity of 0.1 to 0.6 g / cm 3 It has a density of

[0104] 2. The composition of any preceding or following embodiment / feature / aspect, wherein the aerogel particles are silica aerogel particles.

[0105] 3. The composition of any preceding or following embodiment / feature / aspect, wherein the silica aerogel particles are hydrophobic.

[0106] 4. The composition of any preceding or following embodiment / feature / aspect, wherein the composition comprises 15-65 wt.%, e.g., 20-60 wt.%, 25-55 wt.%, 30-50 wt.%, or 35-45 wt.% aerogel particles.

[0107] 5. The composition of any preceding or following embodiment / feature / aspect, wherein the aerogel particles have a particle size in the range of 0.1 mm to 5 mm, e.g., 0.1 mm to 4 mm, 0.1 mm to 1.5 mm, or 1 mm to 4 mm.

[0108] 6. The composition of any preceding or following embodiment / feature / aspect, wherein the weight ratio of aerogel particles to fiber components is 1:2 to 10:1, 1:3 to 3:1, 1:2 to 2:1, 1.2:1 to 9:1, 1:2 to 7:1, or 1:1 to 5:1.

[0109] 7. The composition of any preceding or following embodiment / feature / aspect, wherein the fiber component is present in an amount of 5-55 wt%, e.g., 10-50 wt%, 15-40 wt%, 20-35 wt%, or 10-30 wt%.

[0110] 8. The composition of any preceding or following embodiment / feature / aspect, wherein the fiber component comprises glass fiber, ceramic fiber, or both.

[0111] 9. The composition of any preceding or following embodiment / feature / aspect, wherein the fiber component comprises a blend of primary fibers and one or more secondary fibers.

[0112] 10. The composition of any preceding or following embodiment / feature / aspect, wherein the primary fibers comprise glass fibers or ceramic fibers, and the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, PBI fibers, cellulose fibers, cotton fibers, carbon fibers, acrylic fibers, polyvinyl alcohol (PVA) fibers, phenolic fibers, polyolefin fibers, and mixtures of any of the foregoing.

[0113] 11. The composition of any preceding or following embodiment / feature / aspect, wherein the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, and PBI fibers.

[0114] 12. The composition of any preceding or following embodiment / feature / aspect, wherein the primary and secondary fibers differ in at least one of aspect ratio, length, length distribution, diameter, diameter distribution, and composition.

[0115] 13. The composition of any preceding or following embodiment / feature / aspect, wherein primary fibers are present in the composition in greater proportion than secondary fibers.

[0116] 14. The composition of any preceding or following embodiment / feature / aspect, wherein the primary fibers and secondary fibers are in a weight ratio of 100:1 to 1:100, e.g., 50:1 to 1:50, 35:1 to 1:35, 25:1 to 1:25, 15:1 to 1:15, 10:1 to 1:10, 7:1 to 1:7, 5:1 to 1:5, 4:1 to 1:4, 3:1 to 1:3, or 2:1 to 1:2.

[0117] 15. The composition of any preceding or following embodiment / feature / aspect, having a thermal conductivity at 25°C of 5 mW / m·K to 32 mW / m·K, e.g., 10 mW / m·K to 30 mW / m·K, 17 mW / m·K to 25 mW / m·K, or 15 mW / m·K to 25 mW / m·K.

[0118] 16. The composition of any preceding or following embodiment / feature / aspect, further comprising an opacifying agent.

[0119] 17. The composition of any preceding or following embodiment / feature / aspect, wherein the opacifying agent is selected from the group consisting of carbon black, mica, alumina, graphite, titanium dioxide, rutile sand, iron oxide, silicon carbide (SiC), graphite, zirconium dioxide, and combinations of two or more thereof.

[0120] 18. The composition of any preceding or following embodiment / feature / aspect, wherein the opacifying agent is present in an amount of up to 10 wt%, e.g., 0.5 wt% to 8 wt%, 0.75 wt% to 5 wt%, or 1 wt% to 3 wt%.

[0121] 19. The composition of any preceding or following embodiment / feature / aspect, wherein the composition has a thickness of 0.3 to 6 mm, e.g., 0.4 to 4 mm, 1 to 3 mm, or 1.5 to 2.5 mm.

[0122] 20. The composition of any preceding or following embodiment / feature / aspect, wherein the composition has a tensile strength of 0.1 to 3 MPa, or 0.15 to 2 MPa.

[0123] 21. The composition of any preceding or following embodiment / feature / aspect, further comprising one or more of a fire retardant, a flame retardant, a heat absorbing material, or a phase change material.

[0124] 22. 0.1~0.6g / cm 3 , e.g., 0.15 to 0.5 g / cm 3 , 0.15~0.4g / cm 3 , or 0.2 to 0.35 g / cm 3 The composition of any preceding or following embodiment / feature / aspect, having a density of

[0125] 23. The composition of any preceding or following embodiment / feature / aspect, wherein the polymer comprises a surfactant, a dispersant, or both.

[0126] 24. The composition of any preceding or following embodiment / feature / aspect, wherein the surfactant or dispersant is selected from the group consisting of ionic (anionic and cationic) surfactants and dispersants, amphoteric surfactants and dispersants, nonionic surfactants and dispersants, and high molecular weight surfactants and dispersants.

[0127] 25. The composition of any preceding or following embodiment / feature / aspect, wherein the dispersant is a cationic dispersant, e.g., having an HLB ratio of 2 to 20.

[0128] 26. The composition of any preceding or following embodiment / feature / aspect, wherein the cationic dispersant comprises ethylene oxide and propylene oxide oligomers, wherein the molar ratio of ethylene oxide mer to propylene oxide mer is from 0.1:1 to 11:1.

[0129] 27. The composition of any preceding or following embodiment / feature / aspect, wherein the polymer comprises a binder.

[0130] 28. The composition of any preceding or following embodiment / feature / aspect, wherein the binder is selected from the group consisting of silicone, polyurethane, polyvinyl alcohol, polyvinylidene fluoride, polyethylene terephthalate, polybutylene terephthalate, styrene-butadiene copolymer, and acrylate (acrylic) polymer.

[0131] 29. The composition of any preceding or following embodiment / feature / aspect, wherein the binder is selected from the group consisting of acrylic polymers, silicones, polyurethanes, and combinations of two or more thereof.

[0132] 30. The composition of any preceding or following embodiment / feature / aspect, wherein the proportion of the polymer is 4 to 20 wt%, 5 to 10 wt%, 10 to 15 wt%, 15 to 20 wt%, 20 to 25 wt%, 5 wt% to 15 wt%, or 8 wt% to 17 wt%, based on the total weight of the composition.

[0133] 31. The composition of any preceding or following embodiment / feature / aspect, further comprising elastomer particles.

[0134] 32. The composition of any preceding or following embodiment / feature / aspect, wherein the polymer comprises a flocculating system comprising a flocculant and a flocculating polymer.

[0135] 33. The composition of any preceding or following embodiment / feature / aspect, wherein the flocculant is polymeric.

[0136] 34. The composition of any preceding or following embodiment / feature / aspect, wherein a) the flocculant is cationic and the flocculating polymer is anionic, or b) the flocculant is anionic and the flocculating polymer is cationic.

[0137] 35. The composition of any preceding or following embodiment / feature / aspect, wherein the polymer comprises a flocculating system comprising a flocculant and a flocculating polymer, an optional binder, a dispersant, and an optional defoamer, and wherein the total amount of flocculating system and optional binder in the composition is 3 to 20 wt%, e.g., 4 to 16 wt%.

[0138] 36. The composition of any preceding or following embodiment / feature / aspect, wherein the composition is self-supporting.

[0139] 37. A method of making a nonwoven aerogel composition, the method comprising:

[0140] mixing aerogel particles, a fiber component, at least one polymeric component, and an aqueous solvent to form an aqueous slurry, wherein the weight ratio of the aerogel particles to the fiber component is 1:3 to 10:1;

[0141] flocculating and / or coagulating the aqueous slurry to form flocs and a supernatant liquid, the flocs comprising at least a portion of the aerogel particles, the fiber component, and the polymer component;

[0142] dewatering the floc; and

[0143] The flock is dried to a thickness of 0.3 to 6 mm, a thermal conductivity of up to 32 mW / m K at 25°C, a UL-94 standard of V0, a ​​tensile strength of 0.09 to 5 MPa, and a thickness of 0.1 to 0.6 g / cm 3 forming a nonwoven fabric aerogel composition having a density of

[0144] The total amount of polymeric components in the floc and supernatant is 3 to 25% based on the total amount of material in the floc and supernatant excluding the aqueous solvent.

[0145] 38. The method of any preceding or following embodiment / feature / aspect, wherein the aqueous solvent comprises less than 5% by weight of an organic solvent, e.g., less than 3% or less than 1%.

[0146] 39. The method of any preceding or following embodiment / feature / aspect, wherein the total amount of solid material, including the polymeric component, in the aqueous slurry is 5% to 25% by weight, e.g., 5-10% by weight, 10-15% by weight, 15-20% by weight, or 20-25% by weight.

[0147] 40. The method of any preceding or following embodiment / feature / aspect, further comprising compressing the dewatered floc.

[0148] 41. The method of any preceding or following embodiment / feature / aspect, further comprising compressing the nonwoven aerogel blanket.

[0149] 42. The method of any preceding or following embodiment / feature / aspect, wherein the aerogel particles are silica aerogel particles.

[0150] 43. The method of any preceding or following embodiment / feature / aspect, wherein the silica aerogel particles are hydrophobic.

[0151] 44. The method of any preceding or following embodiment / feature / aspect, wherein the total amount of aerogel particles in the floc and supernatant liquid, excluding the aqueous solvent, is 15-65 wt %, e.g., 20-60 wt %, 25-55 wt %, 30-50 wt %, or 35-45 wt %.

[0152] 45. The method of any preceding or following embodiment / feature / aspect, wherein the aerogel particles have a particle size in the range of 0.1 mm to 5 mm, e.g., 0.1 mm to 4 mm, 0.1 mm to 1.5 mm, or 1 mm to 4 mm.

[0153] 46. ​​The method of any preceding or following embodiment / feature / aspect, wherein the weight ratio of aerogel particles to fiber components is 1:2 to 10:1, 1:3 to 3:1, 1:2 to 2:1, 1:2 to 9:1, 1:2 to 7:1, or 1:1 to 5:1.

[0154] 47. The method of any preceding or following embodiment / feature / aspect, wherein the fiber component is present in the floc and supernatant in an amount of 5-55 wt %, e.g., 10-50 wt %, 15-40 wt %, 20-35 wt %, or 10-30 wt %, excluding the aqueous solvent.

[0155] 48. The method of any preceding or following embodiment / feature / aspect, wherein the fiber component comprises glass fiber, ceramic fiber, or both.

[0156] 49. The method of any preceding or following embodiment / feature / aspect, wherein the fiber component comprises a blend of primary fibers and one or more secondary fibers.

[0157] 50. The method of any preceding or following embodiment / feature / aspect, wherein the primary fiber comprises glass fiber or ceramic fiber, and the secondary fiber is selected from the group consisting of ceramic wool, glass fiber, ceramic fiber, aramid fiber, PBI fiber, cellulose fiber, cotton fiber, carbon fiber, acrylic fiber, polyvinyl alcohol (PVA) fiber, phenolic fiber, polyolefin fiber, and mixtures of any of the foregoing.

[0158] 51. The method of any preceding or following embodiment / feature / aspect, wherein the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, and PBI fibers.

[0159] 52. The method of any preceding or following embodiment / feature / aspect, wherein the primary and secondary fibers differ in at least one of aspect ratio, length, length distribution, diameter, diameter distribution, and composition.

[0160] 53. The method of any preceding or following embodiment / feature / aspect, wherein primary fibers are present in the composition in greater proportion than secondary fibers.

[0161] 54. The method of any preceding or following embodiment / feature / aspect, wherein the primary fibers and secondary fibers are in a weight ratio of 100:1 to 1:100, e.g., 50:1 to 1:50, 35:1 to 1:35, 25:1 to 1:25, 15:1 to 1:15, 10:1 to 1:10, 7:1 to 1:7, 5:1 to 1:5, 4:1 to 1:4, 3:1 to 1:3, or 2:1 to 1:2.

[0162] 55. The method of any preceding or following embodiment / feature / aspect, wherein the nonwoven aerogel composition has a thermal conductivity at 25°C of 5 mW / m·K to 32 mW / m·K, e.g., 10 mW / m·K to 30 mW / m·K, 17 mW / m·K to 25 mW / m·K, or 15 mW / m·K to 25 mW / m·K.

[0163] 56. The method of any preceding or following embodiment / feature / aspect, wherein the mixing step further comprises including an opacifying agent in the aqueous slurry.

[0164] 57. The method of any preceding or following embodiment / feature / aspect, wherein the opacifying agent is selected from the group consisting of carbon black, mica, alumina, graphite, titanium dioxide, rutile sand, iron oxide, silicon carbide (SiC), graphite, zirconium dioxide, and combinations of two or more thereof.

[0165] 58. The method of any preceding or following embodiment / feature / aspect, wherein the opacifying agent is present in the floc and supernatant in an amount of up to 10% by weight, excluding aqueous solvent, e.g., 0.5% to 8% by weight, 0.75% to 5% by weight, or 1% to 3% by weight.

[0166] 59. The method of any preceding or following embodiment / feature / aspect, wherein the nonwoven aerogel composition has a thickness of 0.3-6 mm, e.g., 0.4-4 mm, 1-3 mm, or 1.5-2.5 mm.

[0167] 60. The method of any preceding or following embodiment / feature / aspect, wherein the nonwoven aerogel composition has a tensile strength of 0.1-3 MPa or 0.15-2 MPa.

[0168] 61. The method of any preceding or following embodiment / feature / aspect, wherein the mixing step further comprises including one or more of a fire retardant, a flame retardant, a heat absorbing material, or a phase change material in the aqueous slurry.

[0169] 62. The nonwoven aerogel composition is 0.1 g / cm 3 ~0.6g / cm 3 , e.g., 0.15 g / cm 3 ~0.5g / cm 3 , 0.15g / cm 3 ~0.4g / cm 3 , or 0.2 g / cm 3 ~0.35g / cm 3 30. The method of any preceding or following embodiment / feature / aspect, wherein the density of the

[0170] 63. The method of any preceding or following embodiment / feature / aspect, wherein the polymeric component comprises a surfactant, a dispersant, or both.

[0171] 64. The method of any preceding or following embodiment / feature / aspect, wherein the surfactant or dispersant is selected from the group consisting of ionic (anionic and cationic) surfactants and dispersants, amphoteric surfactants and dispersants, nonionic surfactants and dispersants, and high molecular weight surfactants and dispersants.

[0172] 65. The method of any preceding or following embodiment / feature / aspect, wherein the dispersant is a cationic dispersant, e.g., having an HLB ratio of 2 to 20.

[0173] 66. The method of any preceding or following embodiment / feature / aspect, wherein the cationic dispersant comprises ethylene oxide and propylene oxide oligomers in a molar ratio of ethylene oxide mer to propylene oxide mer of from 0.1:1 to 11:1.

[0174] 67. The method of any preceding or following embodiment / feature / aspect, wherein the polymeric component further comprises an antifoaming agent.

[0175] 68. The method of any preceding or following embodiment / feature / aspect, wherein the polymeric component comprises a binder.

[0176] 69. The method of any preceding or following embodiment / feature / aspect, wherein the binder is selected from the group consisting of silicone, polyurethane, polyvinyl alcohol, polyvinylidene fluoride, polyethylene terephthalate, polybutylene terephthalate, styrene-butadiene copolymer, and acrylate (acrylic) polymer.

[0177] 70. The method of any preceding or following embodiment / feature / aspect, wherein the binder is selected from the group consisting of acrylic polymers, silicones, polyurethanes, and combinations of two or more thereof.

[0178] 71. The method of any preceding or following embodiment / feature / aspect, wherein the proportion of polymeric components in the flocs and supernatant is 4-20 wt%, 5-10 wt%, 10-15 wt%, 15-20 wt%, 20-25 wt%, 5%-15 wt%, or 8-17 wt%, excluding the aqueous solvent.

[0179] 72. The method of any preceding or following embodiment / feature / aspect, wherein the mixing further comprises including elastomer particles in the aqueous slurry.

[0180] 73. The method of any preceding or following embodiment / feature / aspect, wherein one or more of the flocculating or coagulating steps comprises adding a flocculant to the aqueous slurry.

[0181] 74. The method of any preceding or following embodiment / feature / aspect, wherein the flocculant is polymeric.

[0182] 75. The method of any preceding or following embodiment / feature / aspect, wherein the polymeric component comprises a flocculating polymer, and a) the flocculant is cationic and the flocculating polymer is anionic, or b) the flocculant is anionic and the flocculating polymer is cationic.

[0183] 76. The method of any preceding or following embodiment / feature / aspect, wherein the total amount of flocculant, flocculating polymer, and optional binder in the floc and supernatant is 3 to 20 wt. %, e.g., 4 to 16 wt. %, excluding the aqueous solvent.

[0184] 77. The method of any preceding or following embodiment / feature / aspect, wherein the nonwoven aerogel composition is self-supporting.

[0185] 78. The method of any preceding or following embodiment / feature / aspect, further comprising coating a polymer or oligomer solution or emulsion onto the dried aerogel composition and curing the solution or emulsion to form a coating on the aerogel composition.

[0186] 79. The method of any preceding or following embodiment / feature / aspect, wherein the coating comprises a polyolefin, a silicone polymer, a polyvinyl alcohol, a starch, a polytetrafluoroethylene, a phenolic polymer, a melamine polymer, a phenol formaldehyde, and an acrylic polymer.

[0187] 80. The method of any preceding or following embodiment / feature / aspect, further comprising treating the aerogel composition with a hydrophobizing agent.

[0188] 81. The method of any preceding or following embodiment / feature / aspect, wherein the hydrophobizing agent is selected from a silane compound, a silazane compound, or a disiloxane compound.

[0189] 82. The method of any preceding or following embodiment / feature / aspect, wherein the hydrophobizing agent is selected from trimethylchlorosilane, dimethyldichlorosilane, hexamethyldisilazane, and hexamethyldisiloxane.

[0190] 83. An aerogel composition made by the method described in any preceding or following embodiment / feature / aspect.

[0191] 84. A thermal control article comprising the aerogel composition of any preceding or following embodiment / feature / aspect.

[0192] 85. The thermal control article of any preceding or following embodiment / feature / aspect, wherein the article is a blanket, sheet, mat, or pad.

[0193] 86. The thermal control article of any preceding or following embodiment / feature / aspect, wherein the article is a flexible nonwoven blanket.

[0194] 87. The thermal control article of any preceding or following embodiment / feature / aspect, having a non-flammable flammability rating based on UL94-V0.

[0195] 88. The thermal control article of any preceding or following embodiment / feature / aspect, having a thermal conductivity of at most 30 mW / m·K at 25°C.

[0196] 89. The thermal control article of any preceding or following embodiment / feature / aspect, having a thermal conductivity at 25°C of 5 mW / m·K to 30 mW / m·K, e.g., 17 mW / m·K to 30 mW / m·K, or 15 mW / m·K to 25 mW / m·K.

[0197] 90. The thermal control article of any preceding or following embodiment / feature / aspect, having a tensile strength of 0.09 to 5 MPa, e.g., 0.1 to 3 MPa or 0.15 to 2 MPa.

[0198] 91. The thermal control article of any preceding or following embodiment / feature / aspect, comprising multiple laminates of an aerogel composition.

[0199] 92. The thermal control article of any preceding or following embodiment / feature / aspect, further comprising one or more layers independently comprising a woven polymer mat, a foam pad, a mica sheet, or a thermally conductive material.

[0200] 93. The thermal control article of any preceding or following embodiment / feature / aspect, wherein at least one surface of the thermal control article is coated with a polymeric film.

[0201] 94. The thermal control article of any preceding or following embodiment / feature / aspect, wherein the polymer is selected from silicone polymer, polyvinylidene fluoride, polyethylene terephthalate, and chlorinated polyethylene.

[0202] 95. The thermal control article of any preceding or following embodiment / feature / aspect, wherein the polymeric film comprises reinforcing fibers.

[0203] 96. The thermal control article of any preceding or following embodiment / feature / aspect, further comprising a coating.

[0204] 97. The thermal control article of any preceding or following embodiment / feature / aspect, wherein the coating comprises a polyolefin, a silicone polymer, a polyvinyl alcohol, a starch, a polytetrafluoroethylene, a phenolic polymer, a melamine polymer, a phenol formaldehyde, and an acrylic polymer.

[0205] 98. An electric vehicle comprising a thermal control article according to any preceding or following embodiment / feature / aspect.

[0206] 99. A battery comprising a thermal control article according to any preceding or following embodiment / feature / aspect.

[0207] The invention is further described in the following non-limiting example section. [Example]

[0208] Examples 1 to 8 and Comparative Examples 1 and 2 Nonwoven blankets containing aerogel particles (except Comparative Example 1) and different particle combinations (Table 1) were made in a wet-laid process as described below. Dispersants (Barlox 12 (laurel dimethylamine oxide at 30 wt. % in the dispersion), or Jeffamine M2070, shown as B or J in Table 1 below), Nalclear 7768 polymer (Nalco), and Foamkill™ 830F defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 1 to form white (process) water in a Waring benchtop heavy-duty blender and mixed at high shear for 10 seconds to form process water. Fiberfrax® 7001 C5 ceramic fiber (Unifrax), ¼″ E-06 chopped glass fiber (Lauscha Fiber International), P200 aerogel particles (Cabot Corporation) (Examples 1-7) or a mixture of P200 aerogel (84%) and silicon carbide (16%) (Comparative Example 2), 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Sigma Aldrich) were added to a Waring heavy-duty blender in the amounts listed in Table 1. The mixture in the blender was mixed at high shear (2000 rpm) for 20 seconds to form a solid dispersion. Novacryl PSR 300 and Dow HV496 resin were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then transferred to a 5 L beaker. Superfloc® was added to destabilize the slurry system. Either 577 flocculant (50% polymer in dispersion, Kemira) or polydiallyldimethylammonium chloride (PDADMAC, 60-80 cps viscosity, 20% polymer by weight in dispersion) from Sigma Aldrich was added to the slurry to produce flocs. Typically, 2-3 grams of flocculant was added to the dispersion until a dense flocculant layer formed on top. After flocculation, the slurry was discharged through a single-layer wet-lay forming wire.The floc was held by the forming wire and evenly distributed across the forming wire. The forming wire was then passed through a vacuum to further remove water from the aerogel floc. Certain samples, as shown in Table 1, were passed through a roll press to squeeze out some of the water and compress the various components more compactly. All blankets were removed from the forming wire and placed in a drying oven at 120°C for approximately 20 minutes.

[0209] Example 8 was made in a wet-laid process as follows: 1 liter of water was mixed with the dispersant, Nalclear 7768 polymer (30 wt. % polymer emulsion, Nalco), and Foamkill™ 830F antifoam agent in the amounts shown in Table 1 in a WARING benchtop heavy-duty blender and mixed at high shear for 10 seconds. This water was combined with 12 L of water in a 5-gallon bucket to form process water. 1 liter of process water was scooped back into the WARING blender along with P200 aerogel, Fiberfrax® 7001 C5 ceramic fiber, 44 micron rutile titania sand, F600 silicon carbide, and aluminum trihydrate, as shown in Table 1. The mixture in the blender was mixed at high shear for 20 seconds to form a solid dispersion. Novacryl PSR300 and Dow HV496 resins were added to the blender as shown in Table 1 and mixed at high shear for an additional 20 seconds to create a slurry. The slurry was then transferred to a 5-gallon bucket. The slurry in the bucket was mixed with a paddle until uniform, and then PDADMAC, in the amount shown in Table 1, was added dropwise under constant mixing to flocculate the system. The slurry was then poured into a 12x12 headbox, with a forming wire suspended above a full 20-liter well. The materials were mixed in the headbox to evenly redistribute the floc and float it to the surface. The layer uniformity was confirmed, and a valve was opened to drip all the water from the headbox, retaining the floc on the forming wire. The forming wire was then passed through a vacuum to further remove water from the aerogel floc. The sample was rolled to force out some of the water and compress the various components more compactly. It was then removed from the forming wire and dried at 170°C for approximately 20 minutes.

[0210] The thickness of the samples was measured with a thickness gauge. Thermal conductivity was measured at room temperature and 140°C using a LaserComp Heat Flow Meter device according to ASTM C518; the standard deviation represents the standard deviation from the average of two readings during the measurement. Because the blanket of Comparative Example 1 was too thin for thermal conductivity measurement, a polycarbonate (PC) pad was used to support the material during the test. Thermal conductivity (TC) was calculated by measuring the following data: TC for the 11.55 mm thick PC pad alone was 196.69 mW / m·K. TC for the 12.62 mm thick PC pad and ceramic sample was 156.67 mW / m·K. TC for the ceramic sample (1.11 mm thick) was calculated using the equation: 1.11 / TC ceramic + 11.55 / TC PC = 12.62 / TC(ceramic + PC). Compressive modulus was measured in three replicates according to ASTM C165. Flammability was measured in accordance with UL94. Tensile strength (maximum load) was measured in three replicates according to ASTM D5035. The total amount of polymer species in Examples 1-3 was 12 wt.%, and for Examples 4-7 it was 21 wt.%. The total amount of polymer species in Example 8 was 17 wt.%. The total amount of polymer species in Comparative Example 2 was 26 wt.%. Excluding the dispersant and defoamer, the total amount of polymer species in Examples 1-3 and 8 was 7 wt.%, and for Examples 4-7 it was 12 wt.%. Excluding the dispersant and defoamer, the total amount of polymer species in Comparative Example 2 was 22 wt. [Table 1-1] [Table 1-2]

[0211] Example 9 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Example 9-1, which had only one type of fiber (Fiberfrax® 7001 C5 ceramic fiber), was prepared from the materials listed in Table 2. For Examples 9-2 through 9-7, the compositions further included additional (secondary) fiber material. Example 9-3, for example, used chopped glass fiber (6 mm E-glass chopped fiber with a diameter of 6 μm manufactured by Lauscha Fiber International), while the secondary fiber in Example 9-5 was Belcotex® 100 silica gel fiber (Textile Technologies Europe Ltd.).

[0212] Other blankets were prepared according to the embodiments described herein. Specifically, Examples 9-2 and 9-7 used relatively low and relatively high PBI fiber content (0.25 inch (6.35 mm) long, approximately 1.1 micron diameter, manufactured by PBI Performance Products, Inc.), respectively. Example 9-3 used aramid fiber (12 mm aramid fiber, 12 μm diameter, manufactured by Endnus New Material (Donguan) Co., Ltd.), and Example 9-6 used ceramic wool (bulk ceramic fiber, high purity, 2300°F, manufactured by Ceramaterials LLC). The materials and amounts used to prepare the blankets are shown in Table 2 below. [Table 2]

[0213] The blanket was made in a wet laid process according to the following procedure.

[0214] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 2 to form 1 liter of a white (process) aqueous concentrate in a Waring benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 10 liters of water in a 5-gallon tank. After mixing, approximately 2 liters of diluted process water was transferred to the Waring blender. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber, Unifrax, a high-purity coarsely chopped product with an average fiber diameter of 1.5-2.5 microns and a fiber index of 45-55% as measured by cone elutriation), secondary fiber material (for Examples 9-2 through 9-7), P200 aerogel particles (Cabot Corporation), 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Sigma Aldrich) were added to a WARING heavy-duty blender in the amounts listed in Table 1. The mixture in the blender was mixed at high shear (15,000 rpm) for 20 seconds to form a paste-like dispersion. An acrylic binder (Novacryl PSR 300, 60 wt.% polymer in dispersion, Synthomer) and a silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the remaining process water in the 5-gallon tank. In addition to the amounts shown in the table below, a small amount (up to 0.4-0.5 g) of Foamkill™ 830 antifoaming agent was stirred into the system to prevent further foaming. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20 wt.% polymer in dispersion) was added to the slurry to create flocs.Typically, a 4-5 gram amount of flocculant (as shown in Table 2) was added to the dispersion until a dense flocculant layer formed on top. The total amount of polymer relative to the particle and polymer components was 21-22%.

[0215] After coagulation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The sample was passed through a roll press to squeeze out some of the water and compress the various components more compactly. All blankets were removed from the forming wire and placed in a drying oven at 120°C for approximately 20 minutes. After drying, the blankets were calendered on a two-roll mill to form a thin blanket.

[0216] The blankets were evaluated for several properties. Thermal conductivity was measured using a LaserComp heat flow meter device according to ASTM C518. When samples were too thin to measure, they were supported on shims and the thermal conductivity of the resulting structure (shim + blanket) was measured. The thermal conductivity of the structure was compared to the thermal conductivity measured on the shim alone to calculate the thermal conductivity of the blanket itself.

[0217] Initial flexibility assessment was performed by hand bending, while tensile strength (maximum load) was measured according to ASTM D5035.

[0218] The results are shown in Table 3: [Table 3]

[0219] As shown in Table 2, PBI secondary fibers were shown to contribute to the tensile strength of the blanket, with a greater effect observed at higher contents.

[0220] The ceramic wool blanket exhibited tensile strength comparable to that of the blanket without secondary fibers, but its thermal conductivity was significantly better than that of Blanket 1.

[0221] Although Blanket 1 was not found to be flexible (under hand bending testing), the polymer fiber component was shown to add flexibility to the blanket product.

[0222] All blankets had acceptable thermal conductivity and were V0 rated in the UL94 flammability test.

[0223] Example 10 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with 6 mm chopped glass (Yiquedok) (Examples 10-1 and 10-2), 12 mm glass fiber (Vetrotex EC-6-12-SP fiber from Saint-Gobain, Examples 10-3 and 10-4), or glass microfiber (Microfiber B-06-F, 0.65 micron diameter, from Lauscha Fiber International, Example 10-5) in the amounts listed in Table 4.

[0224] The blanket was made in a wet laid process according to the following procedure.

[0225] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (25% polymer in dispersion, Nalco), and Foamkill™ 830 defoamer (30% polymer in dispersion, Crucible Chemical) were dispersed in water according to the formulation in Table 4 to form 1 liter of a white (process) aqueous concentrate in a Waring benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to the Waring blender. For Examples 10-1, 10-4, and 10-5, glass fiber, ENTERA EV5200 aerogel particles (0.1-1.2 mm diameter, Cabot Corporation), 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, ThermoFisher Scientific) were added to a WARING heavy-duty blender in the amounts listed in Table 4. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds. For Examples 10-2 and 10-3, the glass fiber was added and mixed for 40 seconds, followed by the addition of the aerogel, titania, and ATH, and the particles were blended for an additional 40 seconds. For all examples, the ceramic fiber, polyurethane binder (Joncryl FLX 5201 polyurethane from BASF, 30% polymer in dispersion), and silicone binder (Dowsil HV496 resin, 40% polymer in dispersion, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the remaining process water. To destabilize the slurry system, 2.25-2.75 g of a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20 wt.% polymer in dispersion) was added to the slurry to generate flocs.

[0226] After flocculation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes, then analyzed for room temperature thermal conductivity as described above; all samples had a thermal conductivity of 23–25 mW / m·K at 25 °C. After drying, the blankets were compressed between two platens to form thin blankets 1–1.2 mm thick, which were then evaluated for tensile strength as described above. The total polymer content was approximately 21 wt% of the total solids in the slurry, excluding dispersants and antifoaming agents, and 11 wt%. The density of all blankets after compression was 0.28–0.32 g / cm. 3 The resulting aerogel composition was expected to meet the criteria of the UL94-V0 standard. [Table 4]

[0227] Example 11 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with 6 mm chopped E-glass (6 micron diameter, Valmiera glass) in the amounts listed in Table 5.

[0228] The blanket was made in a wet laid process according to the following procedure.

[0229] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 antifoam (Crucible Chemical) were dispersed in water according to the formulation in Table 5 to form 1 liter of white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to the Waring blender. Glass fiber, ENTERA EV5200 aerogel particles (Cabot Corporation), 1-1.5 micron (D50) rutile titania (Fisher Scientific), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) were added to the WARING heavy-duty blender in the amounts listed in Table 5. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds for Examples 11-1 and 11-2 and for 80 seconds for Example 11-3. For all examples, the ceramic fiber, polyurethane binder (Joncryl FLX 5201 polyurethane from BASF), and silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the remaining process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20 wt. % solids) was added to the slurry in the amount shown in Table 5 to generate flocs.

[0230] After coagulation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes, then analyzed for room-temperature thermal conductivity as described above. After drying, the blankets were compressed between two platens to form thin blankets 1-1.2 mm thick and then evaluated for tensile strength as described above. The total polymer content was 21-22 wt% of the total solids in the slurry, or 11-12 wt%, excluding dispersants and antifoaming agents. The resulting aerogel compositions were expected to meet the criteria of the UL94-V0 standard. [Table 5]

[0231] Example 12 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with 12 mm glass fiber (Vetrotex EC-6-12-SP glass fiber manufactured by Saint Gobain) in the amounts listed in Table 6.

[0232] The blanket was made in a wet laid process according to the following procedure.

[0233] A dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 6 to form 1 liter of a white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to a Waring blender. Glass fiber was added to the WARING heavy-duty blender in the amount listed in Table 6. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds for Examples 12-1 and 12-2 and for 60 seconds for Example 12-3. For all examples, ENTERA EV5200 aerogel particles (Cabot Corporation), 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) were added to a WARING heavy-duty blender in the amounts listed in Table 6, and the mixture was blended at high shear for 40 seconds. Ceramic fiber, polyurethane binder (Joncryl FLX 5201 polyurethane from BASF), and silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the remaining process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma-Aldrich, viscosity 60-80 cps, 20 wt.% solids) was added to the slurry in the amount listed in Table 6 to generate flocs.

[0234] After flocculation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes, then analyzed for room temperature thermal conductivity as described above; all samples had a thermal conductivity of 23–25 mW / m·K at 25 °C. After drying, the blankets were compressed between two platens to form thin blankets 1–1.2 mm thick, which were then evaluated for tensile strength as described above. The total polymer content was approximately 21 wt% of the total solids in the slurry, excluding dispersants and defoamers, and 11 wt%. The density of all blankets after compression was 0.31–0.32 g / cm. 3 The resulting aerogel composition was expected to meet the criteria of the UL94-V0 standard. [Table 6]

[0235] Example 13 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with 12 mm glass fiber (Vetrotex EC-6-12-SP glass fiber from Saint Gobain) and aramid fiber (12 mm aramid fiber, 12 micron diameter, from Endnus New Material (Donguan) Co., Ltd.) in the amounts listed in Table 7.

[0236] The blanket was made in a wet laid process according to the following procedure.

[0237] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 6 to form 1 liter of a white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to a WARING blender. Glass fiber was added to the WARING heavy-duty blender in the amount listed in Table 7. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds. ENTERA EV5200 aerogel particles (Cabot Corporation), 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), aluminum trihydrate (ATH, Thermo Fisher Scientific), and aramid fiber were added to a WARING heavy-duty blender in the amounts listed in Table 7, and the mixture was blended at high shear for 40 seconds. Ceramic fiber, polyurethane binder (Joncryl FLX 5201 polyurethane from BASF), and silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was added to the remaining process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20 wt% solids) was added to the slurry in the amount shown in Table 7 to produce flocs.

[0238] After flocculation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120°C for approximately 20 minutes, then analyzed for room temperature thermal conductivity and tensile strength as described above. The total polymer content was approximately 14% by weight of the total solids in the slurry, excluding the dispersant and antifoaming agent, which was 4%. The density of Example 13-1 was 0.22 g / cm 3 The resulting aerogel composition was expected to meet the criteria of the UL94-V0 standard. [Table 7]

[0239] Example 14 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with one or more of 3 mm chopped E-glass (Vetrotex EC-6-3-SP glass fiber manufactured by Saint Gobain) (Examples 14-1 and 14-2), 6 mm chopped E-glass (6 micron diameter, Valmiera glass; Example 14-4), 6 mm E-glass chopped fiber with a 6 μm diameter manufactured by Lauscha International, silica gel fiber (6 mm long, 8 micron diameter, Belcotex; Example 14-3), crushed glass fiber (1 / 32" (0.79 mm), Fiber Glast), 3 mm aramid fiber (Donguang Sovetl Special Rope and Webbing Co.), and aramid pulp (Donguang Sovetl Special Rope and Webbing Co.) in the amounts listed in Table 8.

[0240] The blanket was made in a wet laid process according to the following procedure.

[0241] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formula in Table 8 to form 1 liter of white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing was performed at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to the WARING blender. The mixing order for the remaining ingredients is listed in Table 8; all mixing was performed at high shear (15,000 rpm). Examples 14-1 and 14-2 use IC3110 aerogel (0.1-0.7 mm diameter, Cabot Corporation). Examples 14-3 and 14-4 use ENTERA EV5200 aerogel manufactured by Cabot Corporation. For all examples, 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) were used, while the polymer binders were polyurethane binder (Joncryl FLX 5201 polyurethane from BASF) and silicone binder (Dowsil HV496 resin, Dow). After mixing, the resulting slurry was added to the remaining process water. To destabilize the slurry system, flocculants (Examples 14-1, 14-3, and 14-4: polydiallyldimethylammonium chloride (PDADMAC, Sigma-Aldrich, viscosity 60-80 cps, 20 wt.% solids); Example 14-2: Superfloc 581 flocculant, 50 wt.% polymer emulsion from Kemira) were added to the slurry in the amounts shown in Table 8 to generate flocs. In Example 14-2, the as-received flocculant was diluted 1:1 with deionized water (ie, to a solids content of 25%).

[0242] After coagulation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes, then analyzed for room-temperature thermal conductivity as described above. After drying, the blankets were compressed between two platens to form thin blankets 1 to 1.2 mm thick and then evaluated for tensile strength as described above. The total polymer content was 22 to 24 wt% of the total solids in the slurry, or 14 to 16 wt%, excluding dispersants and antifoaming agents. The resulting aerogel compositions were expected to meet the criteria of the UL94-V0 standard. [Table 8]

[0243] Example 15 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) was used in combination with 6 mm E-glass chopped fiber, 6 μm diameter, from Lauscha Fiber International in the amounts listed in Table 9.

[0244] The blanket was made in a wet laid process according to the following procedure.

[0245] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 9 to form a 1-liter white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. The concentrate was then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water was transferred to the Waring blender. Glass fiber, ENTERA EV5200 aerogel particles (Cabot Corporation), 44-micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) were added to the WARING heavy-duty blender in the amounts listed in Table 9. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds. The ceramic fiber, polyurethane binder (Joncryl FLX 5201 polyurethane from BASF), and silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the remaining process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20 wt% solids) was added to the slurry in the amount shown in Table 9 to generate flocs.

[0246] After coagulation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 2 mm to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes, then analyzed for room-temperature thermal conductivity as described above. After drying, the blankets were compressed between two platens to form thin blankets 1-1.2 mm thick and then evaluated for tensile strength as described above. The total polymer content was approximately 20 wt% of the total solids in the slurry, excluding dispersants and antifoaming agents, which was 11 wt%. The resulting aerogel composition was expected to meet the criteria of the UL94-V0 standard. [Table 9]

[0247] Example 16 Experiments were conducted to evaluate the properties and / or performance of several nonwoven blankets. Glass microfiber (Microfiber B-06-F from Unifrax) was used in combination with 6 mm E-glass chopped fibers with a diameter of 6 μm from Lauscha Fiber International in the amounts listed in Table 10.

[0248] The blanket was made in a wet laid process according to the following procedure.

[0249] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 defoamer (Crucible Chemical) were dispersed in water according to the formulation in Table 10 to form 3 liters (Example 16-1) or 2 liters (Example 16-2) of a white (process) aqueous dispersion in a WARING benchtop heavy-duty blender. Mixing was carried out at high shear for 10 seconds to form process water. After mixing, approximately 1.5 liters of process water was removed from the Waring blender and saved. Chopped glass fiber was added to the WARING heavy-duty blender in the amount listed in Table 10. The mixture in the blender was mixed at high shear (15,000 rpm) for 40 seconds. ENTERA EV5400 aerogel particles (0.1-0.5 mm particle size, Cabot Corporation), glass microfibers, 44 micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) were added to a blender and mixed at high shear for 40 seconds. A polyurethane binder (Joncryl FLX 5201 polyurethane, BASF) and a silicone binder (Dowsil HV496 resin, Dow) were added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which was then added to the stored process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC), Sigma-Aldrich, viscosity 60-80 cps, 20 wt.% solids) was added to the slurry in the amounts shown in Table 10 to generate flocs.

[0250] After coagulation, the slurry was discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire were then passed through a vacuum to further remove water from the aerogel floc. The samples were compressed with a heavy roller to a thickness of approximately 1.8 mm (Example 16-1) or 1 mm (Example 16-2) to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets were removed from the forming wire and placed in a drying oven at 120°C for approximately 20 minutes, then analyzed for room temperature thermal conductivity as described above. Example 16-1 was evaluated for tensile strength without further compression. After drying, Example 16-2 was compressed between two platens to form a thin blanket approximately 0.55 mm thick and then evaluated for tensile strength as described above. The total polymer content was approximately 22 wt% of the total solids in the slurry for both examples, or 12 wt%, excluding the dispersant and defoamer. The resulting aerogel composition was expected to meet the criteria of the UL94-V0 standard. [Table 10]

[0251] Example 17 Ceramic fiber (Fiberfrax® 7001 C5 ceramic fiber) is used in the amounts listed in Table 11 in combination with 6 mm E-glass chopped fiber with a diameter of 6 μm from Lauscha Fiber International.

[0252] The blanket is made in a wet laid process according to the following procedure.

[0253] Dispersant (Jeffamine M2070, Huntsman), Nalclear 71605 polymer (Nalco), and Foamkill™ 830 antifoam (Crucible Chemical) are dispersed in water according to the formula in Table 11 to form a 1-liter white (process) aqueous concentrate in a WARING benchtop heavy-duty blender. Mixing is carried out at high shear for 10 seconds to form process water. The concentrate is then diluted with approximately 3 liters of water. After mixing, approximately 1.5 liters of diluted process water is transferred to a Waring blender. Glass fiber, ENTERA EV5200 aerogel particles (Cabot Corporation), 44-micron rutile titania sand (Loudwolf), F600 silicon carbide (Sturbridge Metallurgical Services), and aluminum trihydrate (ATH, Thermo Fisher Scientific) are added to the WARING heavy-duty blender in the amounts listed in Table 11. The mixture in the blender is mixed at high shear (15,000 rpm) for 40 seconds. The ceramic fiber and epoxy binder (EPI-REZ 5003-W-55, 58% solids, Westlake) are added to the blender and mixed at high shear for an additional 20 seconds to create a slurry, which is then added to the remaining process water. To destabilize the slurry system, a flocculant (polydiallyldimethylammonium chloride (PDADMAC) from Sigma Aldrich, viscosity 60-80 cps, 20% solids by weight) is added to the slurry until flocs appear.

[0254] After coagulation, the slurry is discharged through a single-layer wet-lay forming wire to produce a 30 cm x 30 cm blanket sheet. The blanket and forming wire are then passed through a vacuum to further remove water from the aerogel floc. The sample is compressed with a heavy roller to a thickness of approximately 4 mm (Example 17-1) or 6 mm (Example 17-2) to squeeze out some of the water and flatten the blanket to a uniform surface. All blankets are removed from the forming wire and placed in a drying oven at 120 °C for approximately 20 minutes. The total polymer content is approximately 20% of the total solids in the slurry. The resulting aerogel composition is expected to have a thermal conductivity of less than 25 or 30 mW / m·K and a tensile strength of greater than 0.1 or 0.2 MPa, meeting the criteria of the UL94-V0 standard. [Table 11]

[0255] While the present invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details can be made therein without departing from the scope of the invention encompassed by the appended claims.

Claims

1. 1. An aerogel composition comprising: aerogel particles; a fiber component comprising one or more materials selected from the group consisting of polymer fibers and inorganic fibers, wherein the weight ratio of the aerogel particles to the fiber component is 1:3 to 10:1; and 3 to 25 wt. % of a polymer, based on the total weight of the composition; The composition has a thickness of 0.3 to 6 mm, a thermal conductivity of up to 32 mW / m K at 25°C, a UL-94 rating of V0, a ​​tensile strength of 0.09 to 5 MPa, and a thermal conductivity of 0.1 to 0.6 g / cm ３ The aerogel composition has a density of

2. 10. The composition of claim 1, wherein the aerogel particles are silica aerogel particles.

3. The composition of claim 2 , wherein the silica aerogel particles are hydrophobic.

4. 4. The composition of claim 1, wherein the composition comprises 15 to 65 wt. %, e.g., 20 to 60 wt. %, 25 to 55 wt. %, 30 to 50 wt. %, or 35 to 45 wt. % aerogel particles.

5. 5. The composition of claim 1, wherein the aerogel particles have a particle size in the range of 0.1 mm to 5 mm, e.g., 0.1 mm to 4 mm, 0.1 mm to 1.5 mm, or 1 mm to 4 mm.

6. 6. The composition of claim 1, wherein the weight ratio of the aerogel particles to the fiber component is from 1:2 to 10:1, from 1:3 to 3:1, from 1:2 to 2:1, from 1.2:1 to 9:1, from 1:2 to 7:1, or from 1:1 to 5:

1.

7. 7. The composition of any one of claims 1 to 6, wherein the fiber component is present in an amount of 5 to 55 wt%, e.g., 10 to 50 wt%, 15 to 40 wt%, 20 to 35 wt%, or 10 to 30 wt%.

8. The composition of any one of claims 1 to 7, wherein the fiber component comprises glass fibers, ceramic fibers, or both.

9. The composition of any one of claims 1 to 8, wherein the fiber component comprises a blend of primary fibers and one or more secondary fibers.

10. 10. The composition of claim 9, wherein the primary fibers comprise glass fibers or ceramic fibers and the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, PBI fibers, cellulose fibers, cotton fibers, carbon fibers, acrylic fibers, polyvinyl alcohol (PVA) fibers, phenolic fibers, polyolefin fibers, and mixtures of any of the foregoing.

11. 11. The composition of claim 9 or 10, wherein the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, and PBI fibers.

12. 12. The composition of any one of claims 9 to 11, wherein the primary fibers and the secondary fibers differ in at least one of aspect ratio, length, length distribution, diameter, diameter distribution, and composition.

13. The composition of any one of claims 9 to 12, wherein the primary fibers are present in the composition in a greater proportion than the secondary fibers.

14. 14. The composition of any one of claims 9 to 13, wherein the primary fibers and the secondary fibers are in a weight ratio of from 100:1 to 1:100, e.g., from 50:1 to 1:50, from 35:1 to 1:35, from 25:1 to 1:25, from 15:1 to 1:15, from 10:1 to 1:10, from 7:1 to 1:7, from 5:1 to 1:5, from 4:1 to 1:4, from 3:1 to 1:3, or from 2:1 to 1:

2.

15. 15. The composition of any one of claims 1 to 14, having a thermal conductivity at 25°C of 5 mW / m K to 32 mW / m K, e.g., 10 mW / m K to 30 mW / m K, 17 mW / m K to 25 mW / m K, or 15 mW / m K to 25 mW / m K.

16. The composition of any one of claims 1 to 15, further comprising an opacifying agent.

17. 17. The composition of claim 16, wherein the opacifying agent is selected from the group consisting of carbon black, mica, alumina, graphite, titanium dioxide, rutile sand, iron oxide, silicon carbide (SiC), graphite, zirconium dioxide, and combinations of two or more thereof.

18. 18. The composition of claim 16 or 17, wherein the opacifying agent is present in an amount of up to 10 wt%, such as from 0.5 wt% to 8 wt%, from 0.75 wt% to 5 wt%, or from 1 wt% to 3 wt%.

19. The composition of any one of claims 1 to 18, wherein the composition has a thickness of 0.3 to 6 mm, for example, 0.4 to 4 mm, 1 to 3 mm, or 1.5 to 2.5 mm.

20. The composition of any one of claims 1 to 19, wherein the composition has a tensile strength of 0.1 to 3 MPa, or 0.15 to 2 MPa.

21. The composition of any one of claims 1 to 20, further comprising one or more of a fire retardant, a flame retardant, a heat absorbing material, or a phase change material.

22. 0.1~0.6g / cm ３ , for example, 0.15 to 0.5 g / cm ３ , 0.15-0.4g / cm ３ , or 0.2 to 0.35 g / cm ３ The composition of any one of claims 1 to 21, having a density of

23. The composition of any one of claims 1 to 22, wherein the polymer comprises a surfactant, a dispersant, or both.

24. 24. The composition of claim 23, wherein the surfactant or dispersant is selected from the group consisting of ionic (anionic and cationic) surfactants and dispersants, amphoteric surfactants and dispersants, nonionic surfactants and dispersants, and high molecular weight surfactants and dispersants.

25. 25. A composition according to claim 23 or 24, wherein the dispersant is a cationic dispersant, for example having an HLB ratio of from 2 to 20.

26. 26. The composition of any one of claims 23 to 25, wherein the cationic dispersant comprises ethylene oxide and propylene oxide oligomers in a molar ratio of ethylene oxide mer to propylene oxide mer of from 0.1:1 to 11:

1.

27. The composition of any one of claims 1 to 26, wherein the polymer comprises a binder.

28. 28. The composition of claim 27, wherein the binder is selected from the group consisting of silicone, polyurethane, polyvinyl alcohol, polyvinylidene fluoride, polyethylene terephthalate, polybutylene terephthalate, styrene-butadiene copolymer, and acrylate (acrylic) polymer.

29. 29. The composition of claim 27 or 28, wherein the binder is selected from the group consisting of acrylic polymers, silicones, polyurethanes, and combinations of two or more thereof.

30. 30. The composition of any one of claims 1 to 29, wherein the proportion of the polymer is 4 to 20 wt%, 5 to 10 wt%, 10 to 15 wt%, 15 to 20 wt%, 20 to 25 wt%, 5 to 15 wt%, or 8 to 17 wt%, based on the total weight of the composition.

31. The composition of any one of claims 1 to 30, further comprising elastomer particles.

32. The composition of claim 1 , wherein the polymer comprises a flocculating system comprising a flocculant and a flocculating polymer.

33. 32. The composition of claim 31, wherein the flocculant is polymeric.

34. 33. The composition of claim 31 or 32, wherein a) the flocculant is cationic and the flocculating polymer is anionic, or b) the flocculant is anionic and the flocculating polymer is cationic.

35. 35. A composition according to any one of the preceding claims, wherein the polymer comprises a flocculating system comprising a flocculant and a flocculating polymer, an optional binder, a dispersant, and an optional defoamer, and the total amount of the flocculating system and the optional binder in the composition is from 3 to 20 wt%, for example from 4 to 16 wt%.

36. The composition of any one of claims 1 to 35, wherein the composition is self-supporting.

37. 1. A method of making a nonwoven aerogel composition, the method comprising: mixing aerogel particles, a fiber component, at least one polymeric component, and an aqueous solvent to form an aqueous slurry, wherein the weight ratio of the aerogel particles to the fiber component is from 1:3 to 10:1; flocculating and / or coagulating the aqueous slurry to form flocs and a supernatant liquid, the flocs comprising the aerogel particles, the fiber component, and at least a portion of the polymeric component; dewatering the floc; and The flock is dried and has a thickness of 0.3 to 6 mm, a thermal conductivity of up to 32 mW / m K at 25°C, a UL-94 standard of V0, a ​​tensile strength of 0.09 to 5 MPa, and a thickness of 0.1 to 0.6 g / cm ３ forming the nonwoven aerogel composition having a density of wherein the total amount of the polymeric component in the floc and the supernatant is 3 to 25% based on the total amount of material in the floc and the supernatant excluding the aqueous solvent.

38. 38. The method of claim 37, wherein the aqueous solvent comprises less than 5% by weight of organic solvent, such as less than 3% or less than 1%.

39. 39. The method of claim 37 or 38, wherein the total amount of solid material, including the polymeric component, in the aqueous slurry is from 5 wt% to 25 wt%, for example, from 5 to 10 wt%, from 10 to 15 wt%, from 15 to 20 wt%, or from 20 to 25 wt%.

40. 40. The method of any one of claims 37 to 39, further comprising the step of compressing the dewatered floc.

41. 41. The method of any one of claims 37 to 40, further comprising compressing the nonwoven aerogel blanket.

42. 42. The method of any one of claims 37 to 41, wherein the aerogel particles are silica aerogel particles.

43. 43. The method of claim 42, wherein the silica aerogel particles are hydrophobic.

44. 44. The method of any one of claims 37 to 43, wherein the total amount of aerogel particles in the flocs and the supernatant liquid is 15 to 65 wt%, e.g., 20 to 60 wt%, 25 to 55 wt%, 30 to 50 wt%, or 35 to 45 wt%, excluding the aqueous solvent.

45. 45. The method of any one of claims 37 to 44, wherein the aerogel particles have a particle size in the range of 0.1 mm to 5 mm, e.g., 0.1 mm to 4 mm, 0.1 mm to 1.5 mm, or 1 mm to 4 mm.

46. 46. ​​The method of any one of claims 37 to 45, wherein the weight ratio of the aerogel particles to the fiber component is from 1:2 to 10:1, from 1:3 to 3:1, from 1:2 to 2:1, from 1.2:1 to 9:1, from 1:2 to 7:1, or from 1:1 to 5:

1.

47. 47. The method of any one of claims 37 to 46, wherein the fiber component is present in the floc and the supernatant in an amount of 5 to 55% by weight, for example, 10 to 50% by weight, 15 to 40% by weight, 20 to 35% by weight, or 10 to 30% by weight, excluding the aqueous solvent.

48. 48. The method of any one of claims 37 to 47, wherein the fiber component comprises glass fibers, ceramic fibers, or both.

49. The method of any one of claims 37 to 48, wherein the fiber component comprises a blend of primary fibers and one or more secondary fibers.

50. 50. The method of claim 49, wherein the primary fibers comprise glass fibers or ceramic fibers and the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, PBI fibers, cellulose fibers, cotton fibers, carbon fibers, acrylic fibers, polyvinyl alcohol (PVA) fibers, phenolic fibers, polyolefin fibers, and mixtures of any of the foregoing.

51. 51. The method of claim 49 or 50, wherein the secondary fibers are selected from the group consisting of ceramic wool, glass fibers, ceramic fibers, aramid fibers, and PBI fibers.

52. 52. The method of any one of claims 49 to 51, wherein the primary fibers and the secondary fibers differ in at least one of aspect ratio, length, length distribution, diameter, diameter distribution, and composition.

53. 53. The method of any one of claims 49 to 52, wherein the primary fibers are present in the composition in greater proportion than the secondary fibers.

54. 54. The method of any one of claims 49 to 53, wherein the primary fibers and the secondary fibers are in a weight ratio of from 100:1 to 1:100, e.g., from 50:1 to 1:50, from 35:1 to 1:35, from 25:1 to 1:25, from 15:1 to 1:15, from 10:1 to 1:10, from 7:1 to 1:7, from 5:1 to 1:5, from 4:1 to 1:4, from 3:1 to 1:3, or from 2:1 to 1:

2.

55. 55. The method of any one of claims 37 to 54, wherein the nonwoven aerogel composition has a thermal conductivity at 25°C of 5 mW / m K to 32 mW / m K, e.g., 10 mW / m K to 30 mW / m K, 17 mW / m K to 25 mW / m K, or 15 mW / m K to 25 mW / m K.

56. 56. The method of any one of claims 37 to 55, wherein the step of mixing further comprises including an opacifying agent in the aqueous slurry.

57. 57. The method of claim 56, wherein the opacifying agent is selected from the group consisting of carbon black, mica, alumina, graphite, titanium dioxide, rutile sand, iron oxide, silicon carbide (SiC), graphite, zirconium dioxide, and combinations of two or more thereof.

58. 58. A method according to claim 56 or 57, wherein the opacifying agent is present in the floc and the supernatant in an amount of up to 10% by weight, excluding the aqueous solvent, such as from 0.5% to 8%, from 0.75% to 5%, or from 1% to 3%.

59. 59. The method of any one of claims 37 to 58, wherein the nonwoven aerogel composition has a thickness of 0.3 to 6 mm, e.g., 0.4 to 4 mm, 1 to 3 mm, or 1.5 to 2.5 mm.

60. 60. The method of any one of claims 37 to 59, wherein the nonwoven aerogel composition has a tensile strength of 0.1 to 3 MPa, or 0.15 to 2 MPa.

61. 61. The method of any one of claims 37 to 60, wherein the mixing step further comprises including one or more of a fire retardant, a flame retardant, a heat absorbing material, or a phase change material in the aqueous slurry.

62. The nonwoven fabric aerogel composition has a density of 0.1 g / cm ３ ~0.6g / cm ３ , for example, 0.15 g / cm ３ ~0.5g / cm ３ , 0.15 g / cm ３ ~0.4g / cm ３ , or 0.2 g / cm ３ ~0.35g / cm ３ 62. The method of any one of claims 37 to 61, wherein the composition has a density of

63. 63. The method of any one of claims 37 to 62, wherein the polymeric component comprises a surfactant, a dispersant, or both.

64. 64. The method of claim 63, wherein the surfactant or dispersant is selected from the group consisting of ionic (anionic and cationic) surfactants and dispersants, amphoteric surfactants and dispersants, nonionic surfactants and dispersants, and high molecular weight surfactants and dispersants.

65. 65. The method of claim 63 or 64, wherein the dispersant is a cationic dispersant, for example having an HLB ratio of from 2 to 20.

66. 66. The method of any one of claims 63 to 65, wherein the cationic dispersant comprises ethylene oxide and propylene oxide oligomers in a molar ratio of ethylene oxide mer to propylene oxide mer of from 0.1:1 to 11:

1.

67. 67. The method of any one of claims 37 to 66, wherein the polymeric component further comprises an antifoaming agent.

68. The method of any one of claims 37 to 67, wherein the polymeric component comprises a binder.

69. 69. The method of claim 68, wherein the binder is selected from the group consisting of silicone, polyurethane, polyvinyl alcohol, polyvinylidene fluoride, polyethylene terephthalate, polybutylene terephthalate, styrene-butadiene copolymer, and acrylate (acrylic) polymer.

70. 70. The method of claim 68 or 69, wherein the binder is selected from the group consisting of acrylic polymers, silicones, polyurethanes, and combinations of two or more thereof.

71. 71. The method of any one of claims 37 to 70, wherein the proportion of polymeric components in the floc and the supernatant liquid is 4 to 20 wt%, 5 to 10 wt%, 10 to 15 wt%, 15 to 20 wt%, 20 to 25 wt%, 5% to 15 wt%, or 8 to 17 wt%, excluding the aqueous solvent.

72. 72. The method of any one of claims 37 to 71, wherein the step of mixing further comprises including elastomer particles in the aqueous slurry.

73. 73. The method of any one of claims 37 to 72, wherein one or more of the flocculating or coagulating steps comprises adding a flocculant to the aqueous slurry.

74. 74. The method of claim 73, wherein the flocculant is polymeric.

75. 75. The method of any one of claims 37 to 74, wherein the polymeric component comprises a flocculating polymer, and a) the flocculant is cationic and the flocculating polymer is anionic, or b) the flocculant is anionic and the flocculating polymer is cationic.

76. 76. The method of claim 75, wherein the total amount of the flocculant, the flocculating polymer and the optional binder in the floc and the supernatant is 3 to 20% by weight, for example 4 to 16% by weight, excluding the aqueous solvent.

77. 77. The method of any one of claims 37 to 76, wherein the nonwoven aerogel composition is self-supporting.

78. 78. The method of any one of claims 37 to 77, further comprising coating a polymer or oligomer solution or emulsion onto the dried aerogel composition and curing the solution or emulsion to form a coating on the aerogel composition.

79. 79. The method of claim 78, wherein the coating comprises a polyolefin, a silicone polymer, a polyvinyl alcohol, a starch, a polytetrafluoroethylene, a phenolic polymer, a melamine polymer, a phenol formaldehyde, and an acrylic polymer.

80. 80. The method of any one of claims 37 to 79, further comprising treating the aerogel composition with a hydrophobizing agent.

81. 81. The method of claim 80, wherein the hydrophobizing agent is selected from a silane compound, a silazane compound, or a disiloxane compound.

82. 82. The method of claim 80 or 81, wherein the hydrophobizing agent is selected from trimethylchlorosilane, dimethyldichlorosilane, hexamethyldisilazane, and hexamethyldisiloxane.

83. 83. An aerogel composition made by the method of any one of claims 37 to 82.

84. 84. A thermal control article comprising the aerogel composition of any one of claims 1 to 37 and 83.

85. 85. The thermal control article of claim 84, wherein the article is a blanket, sheet, mat, or pad.

86. 86. The thermal control article of claim 84 or 85, wherein the article is a flexible nonwoven blanket.

87. 87. The thermal control article of any one of claims 84 to 86, having a flammability rating of non-flammable based on UL94-V0.

88. 88. The thermal control article of any one of claims 84 to 87, having a thermal conductivity of at most 30 mW / m·K at 25°C.

89. 89. The thermal control article of any one of claims 84 to 88, having a thermal conductivity at 25°C of 5 mW / m·K to 30 mW / m·K, e.g., 17 mW / m·K to 30 mW / m·K, or 15 mW / m·K to 25 mW / m·K.

90. 90. The thermal control article of any one of claims 84 to 89, having a tensile strength of from 0.09 to 5 MPa, e.g., from 0.1 to 3 MPa, or from 0.15 to 2 MPa.

91. 91. The thermal control article of any one of claims 84-90, comprising multiple laminates of the aerogel composition.

92. 92. The thermal control article of any one of claims 84-91, further comprising one or more layers independently comprising a woven polymer mat, a foam pad, a mica sheet, or a thermally conductive material.

93. The thermal control section article of any one of claims 84 to 92, wherein at least one surface of the thermal control section article is coated with a polymer film.

94. 94. The thermal control article of claim 93, wherein the polymer is selected from silicone polymers, polyvinylidene fluoride, polyethylene terephthalate, and chlorinated polyethylene.

95. 95. The thermal control article of claim 93 or 94, wherein the polymeric film comprises reinforcing fibers.

96. The thermal control article of any one of claims 84 to 95, further comprising a coating.

97. 97. The thermal control article of claim 96, wherein the coating comprises a polyolefin, a silicone polymer, a polyvinyl alcohol, a starch, a polytetrafluoroethylene, a phenolic polymer, a melamine polymer, a phenol formaldehyde, and an acrylic polymer.

98. An electric vehicle comprising the thermal control article of any one of claims 84 to 97.

99. A battery comprising the thermal control article of any one of claims 84 to 97.

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