Syntactic Foam Compositions, Pipelines Insulated with Same, and Method

• US 20110017340A1
• Filed: 12/18/2008
• Published: 01/27/2011
• Est. Priority Date: 12/21/2007
• Status: Abandoned Application

• Current Assignee: Cabot Corporation
• Original Assignee: Cabot Corporation
• Inventors: Benton, William J., Mirossay, Thomas C.
• Application Number:
  US12/747,287
• Publication Number:
  US 20110017340A1
• Time in Patent Office: Days
• US Class Current: 138/149
• CPC Class Codes: C04B 14/064 Silica aerogel
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00706 around pipelines or the like
• CPC Class Codes: C04B 26/14 Polyepoxides
• CPC Class Codes: C04B 38/0061 closed porosity
• CPC Class Codes: C04B 38/0074 expressed as porosity percentage
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C08J 2205/026 Aerogel, i.e. a supercritically dried gel
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 9/0066 Use of inorganic compounding ingredients
• CPC Class Codes: C08J 9/32 from compositions containing microballoons, e.g. syntactic foams
• CPC Class Codes: F16L 59/14 Arrangements for the insulation of pipes or pipe systems F16L59/02 - F16L59/12 take precedence
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Syntactic foams and thermal insulation as described containing epoxy resin, hollow microspheres, and dried sol-gel or fumed metal oxide for forming a thermal insulating layer on a substrate such as a pipeline. Methods for forming such thermal insulating layers are also described, which can include formulating with blowing agents for forming closed cells in the finished insulating foam.

Claims

1. A curable epoxy syntactic foam coating composition for forming a thermal insulating material, wherein the composition comprises:

a) curable epoxy resin;

b) hollow microspheres; and

c) dried sol-gel or fumed metal oxide having a particle size less than about 100 μ

m.

2. The composition of claim 1, further comprising a blowing agent.

3. The composition of claim 1, wherein said dried sol-gel is aerogel particles or xerogel particles, or a combination thereof.

4. The composition of claim 1, wherein said particles are amorphous silica aerogel particles.

5. The composition of claim 1, wherein said dried sol-gel has a particle size of less than about 20 μ

m.

6. The composition of claim 1, wherein said dried sol-gel has a particle size of less than about 10 μ

m.

7. The composition of claim 1, wherein said dried sol-gel has a particle size in the range of from 50 nm to 10 μ

m.

22. A method for forming a thermal insulating layer on a pipeline comprising applying the composition of claim 1 on pipe.

23. The method of claim 22, wherein said composition further comprises a blowing agent.

24. The method of claim 22, wherein said composition is applied as a homogenous mixture of the curable epoxy resin, hollow microspheres, dried sol-gel, and blowing agent.

25. The method of claim 22, wherein said applying is by coating, casting or extruding.

26. A method of filling voids in an article having at least one void, comprising filling at least a portion of said void with the curable epoxy syntactic foam coating composition of claim 1.

8. A cured epoxy syntactic foam composition comprising:

a) hardened epoxy resin;

b) hollow microspheres;

c) dried sol-gel or fumed metal oxide having a particle size less than about 100 μ

m; and

d) closed gas-filled cells.

9. The cured epoxy syntactic foam composition of claim 8, comprising at least 25 vol % closed cell content.

10. The cured epoxy syntactic foam composition of claim 8, comprising 5 vol % to 7 vol % hollow microspheres;

25 vol % to 30 vol % closed cell content;

20 vol % to 31 vol % epoxy resin; and

0.1 vol % to 7 vol % dried sol-gel having a particle size less than about 100 μ

m.

11. The cured epoxy syntactic foam composition of claim 8, wherein said syntactic foam composition has a thermal conductivity less than 0.150 watts/meter-°

K.

12. The cured epoxy syntactic foam composition of claim 8, wherein said dried sol-gel is aerogel particles or xerogel particles, or a combination thereof.

13. The cured epoxy syntactic foam composition of claim 8, wherein said particles are amorphous silica aerogel particles.

14. The cured epoxy syntactic foam composition of claim 8, wherein said dried sol-gel has a particle size of less than about 20 μ

m.

15. The cured epoxy syntactic foam composition of claim 8, wherein said dried sol-gel has a particle size of less than about 10 μ

m.

16. The cured epoxy syntactic foam composition of claim 8, wherein said dried sol-gel has a particle size in the range of from 50 nm to 10 μ

m.

17. An insulated pipeline, comprising:

a hollow pipe having an outer surface; and

an insulating layer that longitudinally encases said outer surface of said hollow pipe, wherein said insulating layer comprises a cured epoxy syntactic foam composition comprising hardened epoxy resin;

hollow microspheres;

dried sol-gel or fumed metal oxide having a particle size less than about 100 μ

m; and

closed gas-filled cells.

18. The insulated pipeline of claim 17, wherein said insulating layer has an average thickness greater than one inch.

19. The insulated pipeline of claim 17, wherein said insulating layer has an average thickness of about one inch to about six inches.

20. The insulating pipe of claim 17, wherein the hollow pipe has an outer diameter of at least 6 inches and a length of at least 10 feet.

21. The insulating pipe of claim 17, wherein the hollow pipe comprises a cylindrical shape.