Aerogel containing blanket

• US 20060125158A1
• Filed: 12/15/2004
• Published: 06/15/2006
• Est. Priority Date: 12/15/2004
• Status: Active Grant

• Current Assignee: Cabot Corporation
• Original Assignee: Cabot Corporation
• Inventors: Menashi, Jameel, Massey, Robert K., Rouanet, Stephane F.
• Granted Patent: US 7,635,411 B2
• Time in Patent Office: Days
• US Class Current: 264/621
• CPC Class Codes: B32B 17/02 in the form of fibres or filaments
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/1018 with organic materials pigments or dyes C04B20/1096
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: C04B 40/006 involving the elimination of excess water from the mixture
• CPC Class Codes: D21H 13/40 vitreous, e.g. mineral wool, glass fibres
• CPC Class Codes: D21H 15/10 Composite fibres
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00
• CPC Class Codes: E04B 1/78 Heat insulating elements E04B1/7662 takes precedence
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: E06B 3/6715 specially adapted for increased thermal insulation or for controlled passage of light E06B3/66323 takes precedence; coating of glass pains C03C17/00; devices or arrangements for controlling the intensity, colour, phase, polarisation or direction of light G02F1/00
• CPC Class Codes: Y02A 30/24 : Structural elements or technologies for improving thermal insulation
• CPC Class Codes: Y02A 30/249 : Glazing, e.g. vacuum glazing
• CPC Class Codes: Y02B 80/10 : Insulation, e.g. vacuum or aerogel insulation
• CPC Class Codes: Y02B 80/22 : Glazing, e.g. vaccum glazing
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/2991 : Coated
• CPC Class Codes: Y10T 428/2998 : including synthetic resin or polymer

Abstract

A process of producing a blanket is described and can involve forming an aqueous slurry of hydrophobic aerogels, fibers, and at least one wetting agent, drying the aqueous slurry to form a substantially dried product, and calendaring the substantially dried product to form the blanket. The blanket can be used in a variety of applications, including windows.

Claims

1. A process of producing a blanket comprising:

forming an aqueous slurry of hydrophobic aerogels, fibers, and at least one wetting agent;

drying said aqueous slurry to form a dried product; and

calendaring said dried product to form said blanket.

4. The method of claim 1, wherein said at least one wetting agent comprises a sodium di-2-ethylhexylsulfosuccinite, a branched alkyldimethylamine oxide, an octylphenoxypolyethoxy (9-10) ethanol, or a combination thereof.

6. The process of claim 1, wherein said at least one wetting agent is present in an amount of from about 0.05 to about 0.4 parts by wt. per each part by wt. of said aerogel.

8. The process of claim 1, wherein a majority of said at least one wetting agent is volatilized during said drying.

11. The process of claim 1, wherein said fibers comprise natural fibers, synthetic fibers, or combinations thereof.

12. The process of claim 1, wherein said fibers comprise glass fibers, Q-fibers, polymeric fibers, short-cut bicomponent fibers, or combinations thereof.

15. The process of claim 1, wherein said drying includes filtering and compressing said aqueous slurry.

2. (canceled)

3. (canceled)

5. (canceled)

7. (canceled)

9. (canceled)

10. (canceled)

13. (canceled)

14. (canceled)

16-57. -57. (canceled)

58. A slurry comprising hydrophobic aerogels and at least one wetting agent.

62. The slurry of claim 58, further comprising fibers.

63. The slurry of claim 62, wherein said fibers comprise natural fibers, synthetic fibers, or combinations thereof.

64. The slurry of claim 62, wherein said fibers comprise glass fibers, Q-fibers, polymeric fibers, short-cut bi-component fibers, or combinations thereof.

65. The slurry of claim 58, wherein said hydrophobic aerogels are present in said aqueous slurry in an amount of from about 30% by weight to about 85% by weight and said fibers are present in said aqueous slurry in an amount of from about 15% by weight to about 70% by weight.

66. The slurry of claim 58, wherein said at least one wetting agent comprises sodium di-2-ethylhexylsulfosuccinite, a branched alkyldimethylamine oxide, an octylphenoxypolyethoxy (9-10) ethanol, or combinations thereof.

67. The slurry of claim 58, wherein said at least one wetting agent comprises at least one surface active agent, at least one dispersant, or a combination thereof.

68. The slurry of claim 58, wherein said at least one wetting agent is present in an amount of from about 0.05 to about 0.4 parts by wt. per each part by wt. of said aerogel.

59. Hydrophobic aerogels coated with at least one wetting agent.

60. Cement comprising cement and the hydrophobic aerogels of claim 59.

69. The hydrophobic aerogels of claim 59, wherein said wetting agent is present in an amount of from about 0.05 to about 0.4 parts by wt. per each part by wt. of said aerogel.

70. The hydrophobic aerogels of claim 59, wherein said at least one wetting agent comprises at least one surface active agent, at least one dispersant, or a combination thereof.

71. The hydrophobic aerogels of claim 59, wherein said at least one wetting agent comprises sodium di-2-ethylhexylsulfosuccinite, a branched alkyldimethylamine oxide, an octylphenoxypolyethoxy (9-10) ethanol, or combinations thereof.

61. (canceled)