Thin aerogel materials

Patent metadata

Field	Value
Publication number	US-11658361-B2
Application number	US-202217738861-A
Country	US
Kind code	B2
Filing date	May 6, 2022
Priority date	Jun 23, 2014
Publication date	May 23, 2023
Grant date	May 23, 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 battery comprising an insulation material, wherein the insulation material comprises a reinforced aerogel composition, wherein the insulation material comprises a layer having an average thickness of from 1 mm to 10 mm and a thickness variation of from 5% to 15%.

2. The battery of claim 1 , wherein the reinforced aerogel composition comprises an organic aerogel.

3. The battery of claim 1 , wherein the reinforced aerogel composition comprises a silica-based framework.

4. The battery of claim 1 , wherein the reinforced aerogel composition has a thermal conductivity of between about 12 mW/mK and about 20 mW/mK.

5. The battery of claim 1 , wherein the insulation material comprises a layer having an average thickness of less than 5 mm and a thickness variation of less than 15%.

6. The battery of claim 1 , wherein the reinforced aerogel composition comprises an inorganic reinforcement material.

7. The battery of claim 1 , wherein the reinforced aerogel composition comprises an organic reinforcement material.

8. The battery of claim 1 , wherein the reinforced aerogel composition comprises a fiber reinforcement material.

9. The battery of claim 1 , wherein the insulation material has a resilience of from 50% to 95%.

10. A battery comprising an insulation sheet, wherein the insulation sheet comprises a reinforced aerogel composition, the insulation sheet having:
resilience of more than 50%; and
an average thickness of 10 mm or less and a thickness variation of less than 15%.

11. The battery of claim 10 , wherein the reinforced aerogel composition comprises an organic aerogel composition.

12. The battery of claim 10 , wherein the reinforced aerogel composition comprises silica-based framework.

13. The battery of claim 10 , wherein the insulation sheet has a thermal conductivity of between about 12 mW/mK and about 20 mW/mK.

14. The battery of claim 10 , wherein the resulting reinforced aerogel composition has an average thickness of less than 3 mm.

15. The battery of claim 10 , wherein the resulting reinforced aerogel composition has an average thickness of less than 5 mm.

16. The battery of claim 10 , wherein the reinforced aerogel composition has a resilience of more than 75%.

17. The battery of claim 10 , wherein the reinforced aerogel composition has a resilience of more than 90%.

18. The battery of claim 10 , wherein the reinforced aerogel composition has a thermal conductivity of between about 12 mW/mK and about 20 mW/mK.

19. The battery of claim 10 , wherein the reinforced aerogel composition comprises an inorganic reinforcement material.

20. The battery of claim 10 , wherein the reinforced aerogel composition comprises an organic reinforcement material.

21. The battery of claim 10 , wherein the reinforced aerogel composition comprises a fiber reinforcement material.

Assignees

• Aspen Aerogels Inc

Inventors

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

Classifications

• H01M50/133 Primary

  Thickness · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M50/131

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

• H01M50/138 Primary

  adapted for specific cells, e.g. electrochemical cells operating at high temperature · CPC title

• B01J13/0091

  Preparation of aerogels, e.g. xerogels · CPC title