Aerogel based composites

Patent metadata

Field	Value
Publication number	US-9969856-B2
Application number	US-10562908-A
Country	US
Kind code	B2
Filing date	Apr 18, 2008
Priority date	Oct 21, 2005
Publication date	May 15, 2018
Grant date	May 15, 2018

Abstract

Composites, such as syntactic foams, are described. The composite contains at least one polymer and at least one aerogel. The aerogel is coated with a coating substance to at least substantially prevent the intrusion of the polymer into the pores of the aerogel. Methods of making the composite are also described, as well as uses of the composite.

First claim

What is claimed is:

1. A composite comprising at least one polymer as a continuous phase and aerogels in particulate form having pores, wherein the aerogels are dispersed amongst the continuous phase and said at least one polymer comprises a majority in weight percent of the composite, wherein said polymer does not substantially enter the pores of said aerogels and wherein said aerogels are coated on a surface thereof with a coating to substantially prevent intrusion of said polymer into said pores wherein the coating encapsulates from 75% to 100% of surface area of the surface of said aerogel, wherein said coating is a different coating from said continuous phase, and wherein said polymer is an organic polymer and said coating is a water-based polymer coating comprising a surfactant or wetting agent.

2. The composite of claim 1 , wherein at least a portion of said aerogels are treated with at least one treating agent to form a treated aerogel in particulate form which remains substantially porous, wherein said treating agent is present between said coating and said aerogels.

3. The composite of claim 1 , wherein said composite is a syntactic foam or an insulation material.

4. An insulated pipe comprising a pipe insulated with the syntactic foam of claim 3 .

5. The composite of claim 1 , wherein said at least one polymer is polyurethane, an epoxide resin, polypropylene, polyethylene, or any combination thereof.

6. The composite of claim 1 , wherein the aerogels comprise sol-gel derived aerogel.

7. The composite of claim 1 , wherein the aerogels comprise ormosil aerogel.

8. The composite of claim 1 , wherein said coating bridges over or blocks said pores.

9. The composite of claim 1 , wherein said water-based polymer coating comprises epoxy or nylon.

10. The composite of claim 1 , wherein the coating blocks or bridges all of the pores of said aerogel.

11. The composite of claim 1 , wherein the surfactant or wetting agent is alkyl sulfate, alkyl ether sulfate, alkyl trimethylammonium, polyoxyethylene alkyl amine, alkyl dimethyl betain, alkyl dimethyl amine oxido, glycerol fatty acid ester, propylene glycol fatty acid ester, sorbitan fatty acid ester, polyoxyethylene sorbitan fatty acid ester, tetraoleic acid polyoxyethylene sorbitol, polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene polyoxypropylene alkyl ether, polyethylene glycol fatty acid ester, fatty acid alcohol ester, polyhydric alcohol fatty acid ester, sodium diethylhexylsulfosuccinite, branched alkyldimethylamine oxide, octylphenoxypolyethoxyethanol, alkoxylate, polyoxyalkylene fatty ether, sorbitan ester, monoglyceride, diglyceride, polyoxyethylene sorbitol ester, sodium coco-PG-dimonium chloride phosphate, coamidopropyl PG-dimonium chloride phosphate, phosphate ester, polyoxyethylene fatty acid ester, alcohol alkoxylate, ethylene oxide/propylene oxide block copolymer, polyoxyethylene derivatives of sorbitan ester, or any combination thereof.

12. A coated aerogel comprising aerogel in particulate form having pores, wherein said aerogel is coated with at least one coating capable to substantially prevent intrusion of a continuous phase polymer into said pores, wherein said aerogel has a surface and an inner pore volume and wherein said coating is on the surface of said aerogel wherein the at least one coating encapsulates from 75% to 100% of surface area of the surface of said aerogel, thus closing the pores but not penetrating into the inner pore volume of the aerogel, and said coating capable to prevent said polymer from entering into the inner pore volume of the aerogel, wherein said polymer is an organic polymer and said coating is a water-based polymer coating comprising a surfactant or wetting agent wherein said coating penetrates no more than 10% beneath the surface of said aerogel, wherein said percentage is based on the average diameter of the aerogel, and wherein the surfactant or wetting agent is alkyl sulfate, alkyl ether sulfate, alkyl trimethylammonium, polyoxyethylene alkyl amine, alkyl dimethyl betain, alkyl dimethyl amine oxido, glycerol fatty acid ester, propylene glycol fatty acid ester, tetraoleic acid polyoxyethylene sorbitol, polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene polyoxypropylene alkyl ether, polyethylene glycol fatty acid ester, fatty acid alcohol ester, polyhydric alcohol fatty acid ester, sodium diethylhexylsulfosuccinite, branched alkyldimethylamine oxide, octylphenoxypolyethoxyethanol, alkoxylate, polyoxyalkylene fatty ether, monoglyceride, diglyceride, sodium coco-PG-dimonium chloride phosphate, coamidopropyl PG-dimonium chloride phosphate, phosphate ester, polyoxyethylene fatty acid ester, alcohol alkoxylate, or any combination thereof.

13. The coated aerogel of claim 12 , comprising a treating agent present between said coating and aerogel.

14. The coated aerogel of claim 12 , comprising at least two coatings, wherein a first coating comprises the water-based polymer coating, and wherein at least a second coating provides one or more functional properties to the coated aerogel, wherein the first and second coatings are different and the first coating is applied onto said aerogel and the second coating is applied over the first coating.

15. The coated aerogel of claim 12 , wherein said coating is an impregnated thin film that conforms to the internal structure of the aerogel.

16. The coated aerogel of claim 12 , wherein the aerogel comprises an ormosil aerogel.

17. The coated aerogel of claim 12 , wherein said water-based polymer coating comprises epoxy or nylon.

18. A coated aerogel comprising aerogel in particulate form having pores, wherein said aerogel is coated with at least one coating capable to substantially prevent intrusion of a continuous phase polymer into said pores, wherein said aerogel has a surface and an inner pore volume and wherein said coating is on the surface of said aerogel wherein the at least one coating encapsulates from 75% to 100% of surface area of the surface of said aerogel, thus closing the pores but not penetrating into the inner pore volume of the aerogel, and said coating capable to prevent said polymer from entering into the inner pore volume of the aerogel, wherein said polymer is an organic polymer and said coating is a water-based polymer coating comprising a surfactant or wetting agent wherein said coating is a thin film with a thickness of 100 nm or less, and wherein the surfactant or wetting agent is alkyl sulfate, alkyl ether sulfate, alkyl trimethylammonium, polyoxyethylene alkyl amine, alkyl dimethyl betain, alkyl dimethyl amine oxido, glycerol fatty acid ester, propylene glycol fatty acid ester, tetraoleic acid polyoxyethylene sorbitol, polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene polyoxypropylene alkyl ether, polyethylene glycol fatty acid ester, fatty acid alcohol ester, polyhydric alcohol fatty acid ester, sodium diethylhexylsulfosuccinite, branched alkyldimethylamine oxide, octylphenoxypolyethoxyethanol, alkoxylate, polyoxyalkylene fatty ether, monoglyceride, diglyceride, sodium coco-PG-dimonium chloride phosphate, coamidopropyl PG-dimonium chloride phosphate, phosphate ester, polyoxyethylene fatty acid ester, alcohol alkoxylate, or any combination thereof.

19. The coated aerogel of claim 18 comprising two or more additional thin films which can be the same or different material from each other.

Assignees

• Menashi Jameel
• Bauer Ulrich
• Pothmann Elmar
• Peterson Andrew A
• Wilkins Anna K
• Anton Mihai
• Doshi Dhaval A
• Dalzell William H
• Cabot Corp

Inventors

• Menashi Jameel
• Bauer Ulrich
• Pothmann Elmar
• Peterson Andrew A
• Wilkins Anna K
• Anton Mihai
• Doshi Dhaval A
• Dalzell William H

Classifications

• C08J2363/00

  Characterised by the use of epoxy resins; Derivatives of epoxy resins · CPC title

• C08J9/32 Primary

  from compositions containing microballoons, e.g. syntactic foams · CPC title

• C08K7/26

  Silicon- containing compounds · CPC title

• C08J9/0066 Primary

  Use of inorganic compounding ingredients · CPC title

• C08K9/00

  Use of pretreated ingredients · CPC title