Thermal insulation

Patent metadata

Field	Value
Publication number	US-12378379-B2
Application number	US-202017604195-A
Country	US
Kind code	B2
Filing date	Apr 16, 2020
Priority date	Apr 16, 2019
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

A method of manufacturing a thermally insulating product comprises: (a) forming a mixture comprising solvent and gel network former and optionally foaming agent; (b) dispersing a thermally insulating filler in the mixture; and (c) drying the mixture to form the thermally insulating product.

First claim

The invention claimed is:

1. A method of manufacturing a thermally insulating product, the method comprising:
(a) forming a mixture comprising a solvent and a gel network former;
(b) dispersing a thermally insulating filler in the mixture; and
(c) drying the mixture to form the thermally insulating product;
wherein the thermally insulating filler is an expanded silicate material having:
a loose bulk density, measured according to PI 200-77, of from about 15 to about 450 kg/m 3 ;
a compaction resistance, measured according to PI 306-80, of from about 3 PSI to about 350 PSI at 2″; and
a thermal conductivity, measured according to EN 12667, of from about 0.0300 W/mK to about 0.0700 W/mK.

2. The method according to claim 1 further comprising shaping the mixture prior to drying.

3. The method according to claim 1 , wherein the gel network former comprises:
(i) a binding agent;
(ii) a smectite clay mineral, bentonite, montmorillonite or hectorite; and
(iii) one or more reinforcing agents.

4. The method according to claim 1 , wherein the mixture of step (a) further comprises sodium dodecyl sulphate (SDS) or another surfactant.

5. The method according to claim 1 , wherein:
the mixture of step (a) further comprises at least one additive selected from the group consisting of an anti-mould agent, an antibacterial agent, a fire retardant, a hydrophobic agent and a thermal conductivity regulating agent.

6. The method according to claim 1 , wherein
the expanded silicate material comprises:
from about 3 wt. % to about 30 wt. % of X 2 O, X being an alkali metal;
from about 0 wt. % to about 20 wt. % of Al 2 O 3 ;
from about 50 wt. % to about 90 wt. % of SiO 2 ;
from 0 wt. % to about 10 wt. % of H 2 O; and
from 0 wt % to about 5 wt. % of B 2 O 3 ; and/or
the expanded silicate material is manufactured by:
forming a silicate mixture comprising:
at least one silicate material;
an alkali compound; and
water;
curing the silicate mixture to form a solid precursor;
crushing and/or milling the solid precursor to form a granular expandable silicate material; and
heating the granular expandable silicate material to form an expanded silicate material.

7. The method according to claim 1 , wherein the mixture of step (a) is a gel, and
wherein the method further comprises aerating the gel.

8. The method according to claim 1 , wherein drying the mixture to form the thermally insulating product comprises forming a foam, an aerogel, or another aerated matrix in which the thermally insulating filler is dispersed.

9. The method according to claim 1 , wherein drying the mixture comprises:
(i) freeze-drying the mixture;
(ii) drying the mixture at ambient conditions;
(iii) drying the mixture at an elevated temperature of up to 25° C.; or
(iv) drying the mixture at a temperature of from 25° C. to 60° C.

10. The method according to claim 1 , wherein the solvent is water or an alcohol.

11. A thermally insulating product manufactured by the method according to claim 1 .

12. The method according to claim 1 wherein the mixture of step (a) further comprises propionic acid, aluminum hydroxide, silicone oil, stearic acid, and/or graphite.

13. A method of manufacturing a thermally insulating product, the method comprising:
(a) forming a mixture comprising a solvent and a gel network former;
(b) dispersing a thermally insulating filler in the mixture; and
(c) drying the mixture to form the thermally insulating product, wherein the thermally insulating filler is an expanded natural perlite having:
a loose bulk density, measured according to PI 200-77, of from about 30 to about 60 kg/m 3 ;
a compaction resistance, measured according to PI 306-80, of from about 5 PSI to about 20 PSI at 2″; and
a thermal conductivity, measured according to EN 12667, of from about 0.055 W/mK to about 0.070 W/mK.

14. The method according to claim 13 , wherein the expanded natural perlite comprises:
from about 3.5 wt. % to about 22 wt. % of X 2 O, X being an alkali metal;
from about 5 wt. % to about 15 wt. % of Al 2 O 3 ; and
from about 60 wt. % to about 80 wt. % of SiO 2 ; and optionally
from 0.5 wt. % to about 5 wt. % of H 2 O; and
from 0 wt % to about 3.5 wt. %, of B 2 O 3 .

15. The method according to claim 14 , wherein the gel network former comprises:
(i) a binding agent;
(ii) a smectite clay mineral, bentonite, montmorillonite or hectorite; and
(iii) one or more reinforcing agents.

Assignees

• Imertech Sas

Inventors

• Kakali Glikeria
• Skaropoulou Aggeliki
• Gaki Anna
• Taxiarchou Maria
• Papakonstantinou Konstantina
• Dedeloudis Christos

Classifications

• C04B26/285

  Cellulose or derivatives thereof (C04B26/24 takes precedence) · CPC title

• F16L59/028

  Compositions for or methods of fixing a thermally insulating material · CPC title

• C08L2203/14

  used for foams · CPC title

• C08K7/26

  Silicon- containing compounds · CPC title

• C08K3/346

  Clay · CPC title