High performance vacuum-sealed insulations

• US 20060035054A1
• Filed: 09/01/2005
• Published: 02/16/2006
• Est. Priority Date: 01/05/2004
• Status: Abandoned Application

• Current Assignee: Aspen Aerogels, Incorporated
• Original Assignee: Aspen Aerogels, Incorporated
• Inventors: Ou, Duan Li, Stepanian, Christopher J., Trifu, Roxana
• Application Number:
  US11/219,084
• Publication Number:
  US 20060035054A1
• Time in Patent Office: Days
• US Class Current: 428/76
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/518 bi-axially
• CPC Class Codes: B32B 2439/62 Boxes, cartons, cases
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/283 comprising polysiloxanes
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 9/02 comprising animal or vegetable substances , e.g. cork, bamboo, starch
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 14/302 Aerogels
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/305 : Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 14/306 : Zirconium oxide zircon C04B14/046
• CPC Class Codes: C04B 14/322 : Carbides
• CPC Class Codes: C04B 14/325 : Nitrides
• CPC Class Codes: C04B 14/38 : Fibrous materials; Whiskers
• CPC Class Codes: C04B 14/46 : Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/0683 : Polyesters, e.g. polylactides
• CPC Class Codes: C04B 2103/56 : Opacifiers
• CPC Class Codes: C04B 2111/28 : Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2201/32 : for the thermal conductivity, e.g. K-factors
• CPC Class Codes: C04B 24/2641 : Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/282 : Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/42 : Organo-silicon compounds
• CPC Class Codes: C04B 26/06 : Acrylates
• CPC Class Codes: C04B 26/16 : Polyurethanes
• CPC Class Codes: C04B 26/28 : Polysaccharides or derivatives thereof
• CPC Class Codes: C04B 26/32 : containing silicon
• CPC Class Codes: C04B 30/00 : Compositions for artificial stone, not containing binders
• CPC Class Codes: C04B 30/02 : containing fibrous materials
• CPC Class Codes: C04B 40/0089 : making use of vacuum or reduced pressure
• CPC Class Codes: F16L 59/065 : using vacuum F16L59/075 takes precedence
• CPC Class Codes: Y10T 428/239 : Complete cover or casing

Abstract

An insulating structure comprising an aerogel composite fully enclosed by an envelope and sealed at a reduced pressure, said aerogel composite comprising at least one metal oxide matrix and a fibrous material incorporated therein, and where said insulating structure can bend to at least 90° and a bending radius of less than ½ inch without any substantial fracture.

Claims

1. A structure comprising a flexible aerogel composite fully enclosed by an envelope and sealed at a reduced pressure.

2. The structure of claim 1 wherein said aerogel composite comprises at least one metal oxide matrix and a fibrous material incorporated therein,

optionally wherein said composite, and optionally said structure, is capable of bending to at least 90°

with a bending radius of less than ½

inch.

3. The structure of claim 1 wherein the aerogel composite comprises at least one organic polymer;

or

wherein an amount of at least one opacifying compound is incorporated in the aerogel composite.

4. The structure of claim 3 wherein said organic polymer is chitosan, polymethyl methacrylate, a member of the acrylate family of oligomers, trialkoxysilylterminated polydimethylsiloxane, polyoxyalkylene, polyurethane, polybutadiene, a member of the polyether family of materials or combinations thereof.

5. The structure of claim 2 wherein the metal oxide is silica, titania, zirconia, alumina, hafnia, yttria, ceria or combinations thereof;

or

wherein the aerogel composite comprises nitrides, carbides or any combination thereof;

or

wherein the fibrous material is in the form of a fibrous batting, a lofty batting, microfibers or a felt;

or

wherein the fibrous material is based on polyester, silica, carbon or a combination thereof;

or

wherein said fibrous material is coated with a polymeric or metallic compound.

6. The structure of claim 3 wherein the opacifying compound is B₄C, Diatomite, Manganese ferrite, MnO, NiO, SnO, Ag₂O, Bi₂O₃, 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, or mixtures thereof.

7. The structure of claim 1 wherein at least two plies of an aerogel composite are fully enclosed within the envelope;

or

further comprising at least one layer of fibrous material, within the envelope;

or

wherein the aerogel composite has a density between about 0.01 g/cc to about 0.40 g/cc or between about 0.07 g/cc to about 0.03 g/cc;

or

wherein the thermal conductivity of the aerogel composite within said structure at pressures between about 760 torr and about 0.2 torr and between temperatures of about 20°

C. and about −

122°

C. is between about 2.2 mW/mK and about 13.2 mW/mK;

or

wherein the thermal conductivity of the aerogel composite within said structure at pressures between about 760 torr and about 0.2 torr and between temperatures of about 38°

C. and about −

130°

C. is between about 2.85 mW/mK and about 12.7 mW/mK;

or

wherein the flexural strength of the aerogel composite is at least about 100 psi at rupture;

or

wherein the envelope is a polymeric, optionally metallized, film;

or

wherein the envelope is a mylar film.

8. The structure of claim 1 wherein said structure is in the shape of a box;

or

wherein said structure is partially or completely bent around a pipeline;

or

wherein the structure is in the shape of a panel.

9. A method of preparing a structure comprising fully enclosing a flexible aerogel composite an envelope and sealing said aerogel composite at a reduced pressure.

10. The method of claim 9 wherein said aerogel composite comprises at least one metal oxide matrix and a fibrous material incorporated therein, optionally wherein said structure can bend to at least 90°

with a bending radius of less than ½

inch.

11. The method of claim 9 wherein the aerogel composite comprises at least one organic polymer;

or

wherein an amount of at least one opacifying compound is incorporated in the aerogel composite.

12. The method of claim 11 wherein said organic polymer is chitosan, polymethyl methacrylate, a member of the acrylate family of oligomers, trialkoxysilylterminated polydimethylsiloxane, polyoxyalkylene, polyurethane, polybutadiene, a member of the polyether family of materials or combinations thereof.

13. The method of claim 10 wherein the metal oxide is silica, titania, zirconia, alumina, hafnia, yttria, ceria or combinations thereof;

or

wherein the aerogel composite comprises nitrides, carbides or any combination thereof;

or

wherein the fibrous material is in the form of a fibrous batting, a lofty batting, microfibers or a felt;

or

wherein the fibrous material is based on polyester, silica, carbon or a combination thereof;

or

wherein said fibrous material is coated with a polymeric or metallic compound.

14. The method of claim 11 wherein the opacifying compound is B₄C, Diatomite, Manganese ferrite, MnO, NiO, SnO, Ag₂O, Bi₂O₃, 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, or mixtures thereof.

15. The method of claim 9 wherein at least two plies of an aerogel composite are fully enclosed within the envelope;

or

further comprising at least one layer of fibrous material, within the envelope;

or

wherein the aerogel composite has a density between about 0.01 g/cc to about 0.40 g/cc or between about 0.07 g/cc to about 0.30 g/cc;

or

wherein the thermal conductivity of the aerogel composite within said structure at pressures between about 760 torr and about 0.2 torr and between temperatures of about 20°

C. and about −

122°

C. is between about 2.2 mW/mK and about 13.2 mW/mK;

or

wherein the thermal conductivity of the aerogel composite within said structure at pressures between about 760 torr and about 0.2 torr and between temperatures of about 38°

C. and about −

130°

C. is between about 2.85 mW/mK and about 12.7 mW/mK;

or

wherein the flexural strength of the aerogel composite is 102 psi at rupture;

or

wherein the envelope is a polymeric, optionally metallized, film;

or

wherein the envelope is a mylar film.

16. The method of claim 9 wherein said structure is in the shape of a box;

or

wherein said structure is partially or completely bent around a pipeline;

or

wherein the structure is in the shape of a panel.

17. A structure comprising a flexible aerogel composite and a reinforcing component,

wherein said composite, or said composite and component, is fully enclosed by an envelope and sealed at reduced pressure.

18. The structure of claim 17 wherein said reinforcing component is stainless steel, elemental metals such as copper or iron, and other metallic, semi-metallic and alloyed materials;

or

wherein said reinforcing component is in the form of a mesh, a screen, or chicken-wire;

or

wherein said reinforcing component is integrated into said composite;

or

wherein said reinforcing component is fully enclosed and sealed at reduced pressure.

19. A method of preparing a structure according to claim 17, said method comprising fully enclosing said composite and/or reinforcing component in an envelope and sealing at reduced pressure.

20. A pipe or pipeline, optionally for transporting liquefied natural gas, wrapped by the structure of any one of claims 17.