Thin aerogel materials

Patent metadata

Field	Value
Publication number	US-11588196-B2
Application number	US-202217738852-A
Country	US
Kind code	B2
Filing date	May 6, 2022
Priority date	Jun 23, 2014
Publication date	Feb 21, 2023
Grant date	Feb 21, 2023

Abstract

The present invention provides a fiber-reinforced aerogel material which can be used as insulation in thermal battery applications. The fiber-reinforced aerogel material is highly durable, flexible, and has a thermal performance that exceeds the insulation materials currently used in thermal battery applications. The fiber-reinforced aerogel insulation material can be as thin as 1 mm less, and can have a thickness variation as low as 2% or less. Also provided is a method for improving the performance of a thermal battery by incorporating a reinforced aerogel material into the thermal battery. Further provided is a casting method for producing thin fiber-reinforced aerogel materials.

First claim

What is claimed:

1. A reinforced aerogel composition comprising:
an aerogel framework and a reinforcement material, the reinforced aerogel composition having an average thickness of 10 mm or less and a thickness variation of less than 15%.

2. The reinforced aerogel composition of claim 1 , wherein the reinforcement material comprises one or more of an open-cell foam reinforcement material, a polymeric reinforcement material, and a fiber reinforcement material.

3. The reinforced aerogel composition of claim 2 , wherein the fiber reinforcement material comprises discrete fibers, a woven material, a non-woven material, a batting, a web, a mat, a felt, or a combination thereof.

4. The reinforced aerogel composition of claim 2 , wherein the fiber reinforcement material comprises glass-based fibers.

5. The reinforced aerogel composition of claim 2 , wherein the fiber reinforcement material comprises silica-based fibers.

6. The reinforced aerogel composition of claim 5 , wherein the reinforced aerogel composition has a thermal conductivity in a range of about 12 mW/mK and about 20 mW/mK.

7. The reinforced aerogel composition of claim 2 , wherein the fiber reinforcement material comprises ceramic fibers.

8. The reinforced aerogel composition of claim 1 , wherein the average thickness is about 5 mm and the thickness variation is less than 10%.

9. The reinforced aerogel composition of claim 1 , wherein the average thickness is about 2 mm and the thickness variation is less than 6%.

10. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a thermal conductivity of about 25 mW/mK or less.

11. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a thermal conductivity of about 50 mW/mK or less.

12. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a thermal conductivity of between about 12 mW/mK and about 50 mW/mK.

13. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition includes a silica-based framework.

14. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a density in a range of about 0.60 g/cc and about 0.30 g/cc.

15. The reinforced aerogel composition of claim 1 , wherein the average thickness is 5 mm or less.

16. The reinforced aerogel composition of claim 1 , wherein the average thickness is 3 mm or less.

17. The reinforced aerogel composition of claim 1 , wherein the average thickness is 1 mm or less.

18. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition is a flexible aerogel blanket composition.

19. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a resilience of more than 50%.

20. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a resilience of more than 75%.

21. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a resilience of more than 90%.

22. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a resilience of more than 95%.

23. A battery comprising the aerogel reinforced composition of claim 1 .

24. A method of improving performance of a battery comprising incorporating the reinforced aerogel composition of claim 1 into the battery.

25. A reinforced aerogel composition comprising:
an aerogel framework and a reinforcement material, the reinforced aerogel composition having an average thickness of 5 mm or less and a thickness variation of less than 15%.

26. The reinforced aerogel composition of claim 25 , having an average thickness of 5 mm and a thickness variation of less than 10%.

27. The reinforced aerogel composition of claim 25 , having an average thickness of 5 mm and a thickness variation of less than 5%.

28. The reinforced aerogel composition of claim 25 , wherein the reinforced aerogel composition is a flexible aerogel blanket composition.

29. The reinforced aerogel composition of claim 25 , wherein the reinforced aerogel composition has a thermal conductivity of about 25 mW/mK or less.

30. The reinforced aerogel composition of claim 25 , wherein the reinforced aerogel composition has a thermal conductivity of between about 12 mW/mK and about 20 mW/mK.

31. The reinforced aerogel composition of claim 25 , wherein the aerogel framework comprises an organic aerogel.

Assignees

• Aspen Aerogels Inc

Inventors

• Evans Owen Richard
• Zafiropoulos Nicholas Anthony
• White Shannon Olga
• Dong Wenting
• Rhine Wendell E

Classifications

• H01M50/131

  characterised by physical properties, e.g. gas permeability, size or heat resistance · CPC title

• H01M50/117

  Inorganic material · CPC title

• H01M50/133 Primary

  Thickness · CPC title

• H01M50/122

  Composite material consisting of a mixture of organic and inorganic materials · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title