Sprayable Aerogel Insulation

• US 20080241490A1
• Filed: 04/02/2008
• Published: 10/02/2008
• Est. Priority Date: 04/02/2007
• Status: Abandoned Application

• Current Assignee: Physical Sciences Incorporated
• Original Assignee: Physical Sciences Incorporated
• Inventors: Newman, Aron, Lauten, Fred
• Application Number:
  US12/061,631
• Publication Number:
  US 20080241490A1
• Time in Patent Office: Days
• US Class Current: 428/206
• CPC Class Codes: C04B 2111/00327 for obtaining microstructures
• CPC Class Codes: C04B 2111/2084 Thermal shock resistance
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 35/111 Fine ceramics
• CPC Class Codes: C04B 35/14 based on silica
• CPC Class Codes: C04B 35/62222 obtaining ceramic coatings coating of mortars, concrete, artificial or natural stone or ceramics C04B41/45; laminated ceramic products B32B18/00; coating metallic materials C23; coating of glass C03C17/00, applying ceramic coatings on silicon for semi-conductor purposes H01L
• CPC Class Codes: C04B 35/62665 Flame, plasma or melting treatment
• CPC Class Codes: C04B 38/0041 the particulate matter having preselected particle sizes
• CPC Class Codes: C04B 38/0064 Multimodal pore size distribution
• CPC Class Codes: C04B 38/0074 expressed as porosity percentage
• CPC Class Codes: F41B 6/006 Rail launchers
• CPC Class Codes: F42B 6/006 Projectiles for electromagnetic or plasma guns
• CPC Class Codes: Y10T 428/24893 including particulate material
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]

Abstract

An insulation structure and a method for forming an insulation structure on a surface provide both mechanical integrity and insulative capabilities in applications and environments involving extreme temperatures and compressive forces. The insulation structure includes aerogel agglomerates formed by combining ceramic particles with aerogel particles. The insulation structure may further include ceramic particles. The aerogel agglomerates and ceramic particles are thermally sprayed on a surface to form a graded or layered structure. The method for forming an insulation structure includes spray-drying and post-drying a mixture of ceramic particles, aerogel particles, water, and a binder.

Claims

1. An insulation structure comprising:

ceramic particles combined with aerogel particles.

2. The insulation structure of claim 1, wherein the combination of the aerogel particles and ceramic particles form agglomerate structures.

3. The insulation structure of claim 2, further comprising ceramic particles.

4. The insulation structure of claim 3, wherein the ceramic particles are refractory particles.

5. The insulation structure of claim 3, wherein the aerogel particles and ceramic particles form a graded structure.

6. The insulation structure of claim 5, wherein the ceramic particles are nearer to a surface than the aerogel particles.

7. The insulation structure of claim 5, wherein the insulation structure comprises:

a first layer of ceramic particles;

a second layer of ceramic particles blended with the combination of ceramic particles and aerogel particles; and

a third layer of a combination of ceramic particles and aerogel particles.

8. The insulation structure of claim 3, wherein the insulation structure is formed by thermal spraying the ceramic particles and the combination of ceramic particles and aerogel particles.

9. The insulation structure of claim 1, wherein the ceramic particles are fully-dense refractory particles.

10. The insulation structure of claim 5, wherein the insulation structure is 10-30% ceramic particles and 70-90% agglomerate structures.

11. The insulation structure of claim 1, wherein the ratio of ceramic particles to aerogel particles ranges from 1:

1 to 1;

10 by weight.

12. The insulation structure of claim 1, wherein the aerogel particles are silica aerogel particles.

13. The insulation structure of claim 1, wherein the ceramic particles are soda-lime glass spheres.

14. The insulation structure of claim 1, wherein the ceramic particles are alumina.

15. A method of forming an insulation structure on a surface, comprising:

combining aerogel particles and ceramic particles to form agglomerate structures; and

thermal spraying the agglomerate structures on a surface to form an insulation structure thereon.

16. The method of claim 15, wherein thermal spraying includes thermal spraying the agglomerate structures and ceramic particles.

17. The method of claim 15, wherein thermal spraying includes plasma spraying.

18. The method of claim 15, wherein thermal spraying includes high velocity oxy-fuel spraying.

19. The method of claim 15, wherein thermal spraying includes thermal spraying a layered structure of agglomerate structures and ceramic particles.

20. The method of claim 19, wherein thermal spraying a layered structure comprises:

thermal spraying a first layer of the ceramic particles;

thermal spraying a second layer of ceramic particles blended with the agglomerate structures; and

thermal spraying a third layer of the agglomerate structures.

21. The method of claim 17, wherein thermal spraying includes plasma spraying at a distance of 5-50 centimeters from the surface.

22. The method of claim 17, wherein thermal spraying includes plasma spraying using 200-500 amperes of current.

23. The method of claim 15, wherein combining aerogel particles and ceramic particles comprises:

mixing the aerogel particles, the ceramic particles, water, and a binder to form a mixture; and

drying the mixture to form agglomerate structures.

24. The method of claim 21, wherein drying the mixture includes spray-drying the mixture.

25. A method of forming an insulation structure on a surface, comprising:

mixing aerogel particles, ceramic particles, water, and a binder to form a mixture;

spray-drying the mixture;

post-drying the spray-dried mixture to form an agglomerate powder;

thermal spraying the post-dried agglomerate powder and ceramic particles on a surface to form a porous structure thereon;

sealing the surface of the porous structure with a polymer barrier; and

applying a carbon fabric or epoxy layer to the surface of the polymer barrier.

26. An apparatus for forming an insulation structure on a surface, comprising:

means for thermal spraying ceramic particles and agglomerates made of ceramic particles and aerogel particles on a surface.