Aerogel blanket and method of production

Patent metadata

Field	Value
Publication number	US-2016333572-A1
Application number	US-201615218516-A
Country	US
Kind code	A1
Filing date	Jul 25, 2016
Priority date	Mar 15, 2013
Publication date	Nov 17, 2016
Grant date	—

Abstract

A method of making a nonwoven wet laid aerogel blanket is provided. The aerogel blanket can exhibit improved thermal conductivity, lower corrosivity, lower dust production and a uniform structure. The blanket can be made from an aerogel floc that is formed from a slurry of aerogel particles.

First claim

What is claimed is:

1 . A nonwoven insulation blanket comprising:
aerogel particles; fibers; and a binder, wherein the density of aerogel particles in the upper 10% of a cross section of the blanket is within +/−20% of the density of aerogel particles in the lowest 10% of the cross section.

2 . The nonwoven insulation blanket of claim 1 comprising an infrared opacifier.

3 . The nonwoven insulation blanket of claim 1 having a thermal conductivity of less 40 mW/m∘K, than less than 35 mW/m∘K or less than 30 mW/m∘K at 150° C.

4 . The nonwoven insulation blanket of claim 1 wherein the density of the blanket is less than 0.2 g/cc, less than 0.15 g/cc, less than 0.13 g/cc or less than 0.12 g/cc.

5 . The nonwoven insulation blanket of claim 1 wherein the blanket is translucent.

6 . The nonwoven insulation blanket of claim 1 wherein the blanket exhibits corrosivity of less than 5 ppm HCl by ASTM C1617.

7 . The nonwoven insulation blanket of claim 1 wherein the aerogel particles have an average diameter of less than 2.0 mm.

8 . The nonwoven insulation blanket of claim 1 wherein all of the aerogel particles have a diameter of less than 4.0 mm.

9 . The nonwoven insulation blanket of claim 1 wherein the blanket exhibits a flame spread index (ASTM E84) of less than 25 and a smoke developed index of less than 450 (ASTM E84).

10 . The nonwoven insulation blanket of claim 1 wherein the blanket exhibits shrinkage of less than 2% at 650° C. when tested using ASTM method C356.

11 . The nonwoven insulation blanket of claim 1 wherein the aerogel particles are hydrophobic and exhibit a water contact angle of greater than 90 degrees.

12 . The nonwoven insulation blanket of claim 1 wherein the aerogel particles are derived from waterglass.

13 . The nonwoven insulation blanket of claim 1 wherein the aerogel particles have a caloric content of less than 10 MJ/Kg.

14 . The nonwoven insulation blanket of claim 1 comprising a polymer comprising polyamine, polyacrylamide, dicyandiamide, or polydiallyldimethylammonium chloride.

15 . The nonwoven insulation blanket of claim 1 wherein the fibers have an average length less than 5 mm, or none of the fibers have a length greater than 5 mm.

16 . The nonwoven insulation blanket of claim 1 wherein none of the fibers have a length greater than 5 mm.

17 - 34 . (canceled)

Assignees

• Cabot Corp

Inventors

• Samanta Susnata
• Pescatore Peter F
• Thomas Bryan P

Classifications

• F16L59/028 Primary

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

• C04B26/06

  Acrylates · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title

• D04H1/413

  containing granules other than absorbent substances · CPC title

• E04B1/78 Primary

  Heat insulating elements {(E04B1/7662 takes precedence)} · CPC title