Inherently secured aerogel composites

Patent metadata

Field	Value
Publication number	US-12077891-B2
Application number	US-202117320814-A
Country	US
Kind code	B2
Filing date	May 14, 2021
Priority date	Jul 15, 2005
Publication date	Sep 3, 2024
Grant date	Sep 3, 2024

Abstract

Embodiments of the present invention describe secured fiber-reinforced aerogels and laminate structures formed therefrom. In one embodiment a laminate comprises at least one fiber-reinforced aerogel layer adjacent to at least one layer of fiber containing material wherein fibers from said at least one fiber-reinforced aerogel layer are interlaced with fibers of said at least one fiber-containing material. In another embodiment a laminate comprises at least two adjacent fiber-reinforced aerogel layers wherein fibers from at least one fiber-reinforced aerogel layer are interlaced with fibers of an adjacent fiber-reinforced aerogel layer.

First claim

The invention claimed is:

1. A method of forming an aerogel composite comprising:
providing a laminate including a plurality of layers comprising fiber material and a fiber reinforced aerogel material, at least one layer being a top layer that defines an exposed surface, and at least two of the layers being unsecured to one another; and
penetrating the laminate through the exposed surface with at least one needle, including penetrating at least one layer of fiber material embedded within a substantially continuous matrix, the matrix including aerogel thereby carrying at least some material from one of the layers to another layer to secure the laminate together without additional components.

2. The method of claim 1 , wherein the material carried from one of the layers to another layer includes at least some fiber material.

3. The method of claim 1 , wherein at least some fiber material from one of the layers is interlaced with fiber material of another of the layers.

4. The method of claim 1 , further comprising coating the laminate with a polymeric material.

5. The method of claim 1 , wherein the aerogel composite comprises additives.

6. The method of claim 5 , wherein the additives are selected from the group consisting of opacifying compounds, radiation absorbing compounds, radiation reflecting compounds, thermally conductive components, electrically conductive components, radar blocking components, and combinations thereof.

7. The method of claim 5 , wherein the additives are selected from the group consisting of B 4 C, Diatomite, Manganese ferrite, MnO, NiO, SnO, Ag 2 O, Bi 2 O 3 , TiC, WC, carbon black, titanium oxide, iron titanium oxide, zirconium silicate, zirconium oxide, iron (I) oxide, iron (III) oxide, manganese dioxide, iron titanium oxide (ilmenite), chromium oxide, silicon carbide and mixtures thereof.

8. A method of forming an aerogel composite comprising:
providing a laminate including a plurality of fiber-containing layers and a fiber reinforced aerogel material, at least one layer being a top layer that defines an exposed surface, and at least two of the layers being unsecured to one another; and
penetrating the laminate through the exposed surface with at least one needle, including penetrating at least one layer of fiber material embedded within a substantially continuous matrix, the matrix including aerogel thereby transporting fibers within the laminate to secure the laminate together without additional components.

9. The method of claim 8 , wherein the fibers transported within the laminate are interlaced with fibers of another of the fiber-containing layers.

10. The method of claim 8 , further comprising coating the laminate with a polymeric material.

11. The method of claim 8 , wherein the aerogel composite comprises additives.

12. The method of claim 11 , wherein the additives are selected from the group consisting of opacifying compounds, radiation absorbing compounds, radiation reflecting compounds, thermally conductive components, electrically conductive components, radar blocking components, and combinations thereof.

13. The method of claim 11 , wherein the additives are selected from the group consisting of B 4 C, Diatomite, Manganese ferrite, MnO, NiO, SnO, Ag 2 O, Bi 2 O 3 , TiC, WC, carbon black, titanium oxide, iron titanium oxide, zirconium silicate, zirconium oxide, iron (I) oxide, iron (III) oxide, manganese dioxide, iron titanium oxide (ilmenite), chromium oxide, silicon carbide and mixtures thereof.

14. A method of forming an aerogel composite comprising:
providing a laminate including (i) a first layer comprising a fiber material and a substantially continuous matrix, the matrix including aerogel material and (ii) a second layer comprising a fiber material, the first and second layers being unsecured to one another; and
interlacing fibers from at least one of the first and second layers with fibers from the other of the first and second layers to secure the laminate together without additional components.

15. The method of claim 14 , wherein the step of interlacing fibers includes penetrating the laminate with at least one needle.

16. The method of claim 14 , further comprising coating the laminate with a polymeric material.

17. The method of claim 14 , wherein the aerogel composite comprises additives.

18. The method of claim 17 , wherein the additives are selected from the group consisting of opacifying compounds, radiation absorbing compounds, radiation reflecting compounds, thermally conductive components, electrically conductive components, radar blocking components, and combinations thereof.

19. The method of claim 17 , wherein the additives are selected from the group consisting of B 4 C, Diatomite, Manganese ferrite, MnO, NiO, SnO, Ag 2 O, Bi 2 O 3 , TIC, WC, carbon black, titanium oxide, iron titanium oxide, zirconium silicate, zirconium oxide, iron (I) oxide, iron (III) oxide, manganese dioxide, iron titanium oxide (ilmenite), chromium oxide, silicon carbide and mixtures thereof.

Assignees

• Aspen Aerogels Inc

Inventors

• Bullock Daniel E
• Tomich Aaron R

Classifications

• B32B2305/08

  Reinforcements · CPC title

• B32B2305/026

  Porous · CPC title

• B32B2305/022

  Foam · CPC title

• B32B2262/00

  Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives · CPC title

• B32B2250/02

  2 layers · CPC title