Thin aerogel materials

Patent metadata

Field	Value
Publication number	US-11870084-B2
Application number	US-202318160369-A
Country	US
Kind code	B2
Filing date	Jan 27, 2023
Priority date	Jun 23, 2014
Publication date	Jan 9, 2024
Grant date	Jan 9, 2024

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 a thickness of from 0.75 mm to 2 mm and a thickness variation of less than 15%.

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

3. The reinforced aerogel composition of claim 1 , wherein the reinforcement material comprises a fibrous reinforcement material comprising 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 3 , wherein the fibrous reinforcement material comprises glass-based fibers.

5. The reinforced aerogel composition of claim 3 , wherein the fibrous 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 3 , wherein the fibrous reinforcement material comprises ceramic fibers.

8. The reinforced aerogel composition of claim 1 , wherein the thickness variation is less than 6%.

9. The reinforced aerogel composition of claim 1 , wherein the thickness variation is from 2% to less than 15%.

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 11 , 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 includes an organic aerogel.

15. 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.

16. The reinforced aerogel composition of claim 1 , wherein the thickness is from 1 mm to 2 mm.

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

18. The reinforced aerogel composition of claim 1 , wherein the reinforced aerogel composition has a resilience of from 50% to 95%.

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

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

Assignees

• Aspen Aerogels Inc

Inventors

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

Classifications

• 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

• H01M6/36

  containing electrolyte and made operational by physical means, e.g. thermal cells · CPC title

• H01M6/5072

  Preserving or storing cells · CPC title

• H01M50/116

  characterised by the material · CPC title