Insulating composite materials comprising an inorganic aerogel and a melamine foam

Patent metadata

Field	Value
Publication number	US-11767671-B2
Application number	US-201414897982-A
Country	US
Kind code	B2
Filing date	Jun 13, 2014
Priority date	Jun 14, 2013
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

The invention relates to insulating composite materials comprising an inorganic aerogel and a melamine foam. The invention also relates to the production method of said materials, and to the use of same.

First claim

The invention claimed is:

1. A composite comprising an inorganic aerogel reinforced by an open-cell melamine foam, wherein
said composite has a thermal conductivity λ between 10 and 20 mW/m-K measured using a guarded hot plate according to NF EN 12667 at 20° C. and atmospheric pressure,
a percentage of a volume occupied by macropores, macropores being pores with a diameter greater than 10 μm, in a volume occupied by the composite in its entirety is less than 5%,
the inorganic aerogel is non-granular, and
the inorganic aerogel has a continuous three-dimensional porous structure.

2. Composite according to claim 1 , produced by a process comprising the following successive steps: a) casting an inorganic sol in a reactor in which was previously placed the open-cell melamine foam, b) gelation of the sol into a lyogel, c) drying the lyogel.

3. Composite according to claim 1 , wherein the aerogel is formed from an inorganic sol comprising between 5% and 15% by weight of inorganic material based on the total weight of the inorganic sol.

4. Composite according to claim 1 , wherein macropores whose diameter is between 50 and 250 microns comprises more than 80% of total number of macropores of said composite.

5. Composite according to claim 1 , wherein the composite has a thickness of between 2 and 50 nm.

6. Composite g to claim 1 , wherein the composite has a density between 70 kg/m 3 and 150 kg/m 3 .

7. Composite according to claim 1 , wherein the melamine foam is a melamine-formaldehyde foam having a thickness of between 2 and 50 mm, a porosity of between 95% and 99.5%, a density between 8.5 and 11.5 kg/m3, and a thermal conductivity of between 35 and 40 mW/m-K measured using a guarded hot plate according to NF EN 12667 at 20° C. and atmospheric pressure.

8. Composite according to claim 1 , wherein the inorganic aerogel comprises silica, titanium oxide, manganese oxide, calcium oxide, carbonate calcium, zirconium oxide, or mixtures thereof.

9. Composite according to claim 1 , wherein the composite does not contain any binder.

10. Composite according to claim 9 , wherein the composite does not comprise a fibrous reinforcing material.

11. Composite according to claim 1 , wherein the composite has a quantity of residual solvent by weight of the composite of less than or equal to 3% according to EN/ISO 3251.

12. Composite according to claim 1 , wherein the aerogel further comprises an opacifier.

13. A sandwich panel comprising at least one layer consisting essentially of a monolithic composite according to claim 1 .

14. A multilayer thermal insulation panel comprising at least one layer of a composite according to claim 1 .

15. Acoustic insulation comprising at least one layer of a composite according to claim 1 .

16. Composite according to claim 1 , wherein composite has a thermal conductivity λ between 12.5 and 20 mW/m-K at 20° C. and atmospheric pressure.

17. Composite according to claim 1 , wherein less than 5% of the volume occupied by the composite is occupied by pores with a diameter greater than 5 μm.

18. Composite according to claim 1 , wherein the inorganic aerogel is in the form of a single block piece.

Assignees

• Aspen Aerogels Inc

Inventors

• Bonnardel Pierre-Antoine
• Chausson Sophie
• Gerardin Emilie

Classifications

• E04B1/86

  slab-shaped · CPC title

• E04B1/80 Primary

  slab-shaped · CPC title

• C08J9/40 Primary

  Impregnation · CPC title

• C04B38/0045

  by a process involving the formation of a sol or a gel, e.g. sol-gel or precipitation processes · CPC title

• C04B28/005

  containing gelatineous or gel forming binders, e.g. gelatineous Al(OH)3, sol-gel binders · CPC title