Insulating composite materials comprising an inorganic aerogel and a melamine foam

Patent metadata

Field	Value
Publication number	US-2016115685-A1
Application number	US-201414897982-A
Country	US
Kind code	A1
Filing date	Jun 13, 2014
Priority date	Jun 14, 2013
Publication date	Apr 28, 2016
Grant date	—

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

2 . Material 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 a preformed open-cell melamine foam, b) gelation of the sol into a lyogel, c) drying the lyogel.

3 . Material according to claim 2 , characterized in that said sol used in step a) comprises more than 5% by weight, preferably between 6 and 15% by weight, of inorganic material based on the total weight of the inorganic sol.

4 . Material according to claim 1 , characterized in that macropores whose diameter is between 50 and 250 microns comprises more than 80% of total macropores of said material.

5 . Material according to claim 1 , characterized in that the material has a thickness of between 2 and 50 mm.

6 . Material according to claim 1 , characterized in that the material has a density between 70 kg/m 3 and 150 kg/m 3 .

7 . Material according to claim 1 , characterized in that 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/m 3 , and a thermal conductivity of between 35 and 40 mW/m-K measured by means of guarded hot plate of NF EN 12667 at 20° C. and atmospheric pressure.

8 . Material according to claim 1 , characterized in that the inorganic aerogel is selected from silica aerogels, titanium oxide, manganese oxide, calcium oxide, carbonate calcium, zirconium oxide, or mixtures thereof.

9 . Material according to claim 1 , characterized in that the material does not contain any binder.

10 . Material according to claim 9 , characterized in that the material does not comprise a fibrous reinforcing material.

11 . Material according to claim 1 , characterized in that the material has a quantity of residual solvent by weight of the composite material of less than or equal to 3% according to EN/ISO 3251.

12 . Material according to claim 1 , characterized in that the aerogel further comprises an opacifier.

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

14 . Use of a composite material according to claim 1 or of a multilayer panel according to claim 13 as thermal insulation.

15 . Use of a composite material according to claim 1 or of a multilayer panel according to claim 13 as acoustic insulation.

Assignees

• Enersens
• Aspen Aerogels Inc

Inventors

• Bonnardel Pierre-Antoine
• Chausson Sophie
• Gerardin Emilie

Classifications

• E04B1/86

  slab-shaped · CPC title

• C08J9/40 Primary

  Impregnation · CPC title

• C08J2201/038

  Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass · CPC title

• C04B2201/32

  for the thermal conductivity, e.g. K-factors · CPC title

• C08J2361/28

  with melamine · CPC title