Aerogel/PTFE composite insulating material

• US 7,118,801 B2
• Filed: 11/10/2003
• Issued: 10/10/2006
• Est. Priority Date: 11/10/2003
• Status: Active Grant

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: Gore Enterprise Holdings Incorporated
• Inventors: Farnworth, Brian, Ristic-Lehmann, Cedomila, Dutta, Anit
• Primary Examiner(s): Wu, David W.
• Assistant Examiner(s): Hu, Henry S.
• Application Number:
  US10/706,777
• Publication Number:
  US 20050100728A1
• Time in Patent Office: 1,065 Days
• Field of Search: 428/292.1, 428/220, 524/545, 264/120, 174/255
• US Class Current: 428/292.1
• CPC Class Codes: A41D 19/01529 with thermal or fire protection
• CPC Class Codes: B29C 63/08 by winding helically
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 66/001 Joining in special atmospheres
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/73113 Thermal conductivity
• CPC Class Codes: B29C 66/82661 by means of vacuum
• CPC Class Codes: B29K 2021/003 Thermoplastic elastomers
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2105/0085 Copolymers
• CPC Class Codes: B29K 2995/0015 Insulating
• CPC Class Codes: B29K 2995/0065 : Permeability to gases
• CPC Class Codes: B29K 2995/0092 : hydrophilic
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2023/225 : Insulated
• CPC Class Codes: B29L 2031/3431 : Telephones, Earphones
• CPC Class Codes: B29L 2031/4864 : Gloves
• CPC Class Codes: B32B 15/08 : of synthetic resin
• CPC Class Codes: B32B 15/20 : comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2260/00 : Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
• CPC Class Codes: B32B 2307/206 : Insulating
• CPC Class Codes: B32B 2307/304 : Insulating
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2327/18 : PTFE, i.e. polytetrafluoroethylene
• CPC Class Codes: B32B 2405/00 : Adhesive articles, e.g. adhesive tapes labels B32B2519/00
• 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 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08K 3/22 : of metals
• CPC Class Codes: C08K 3/36 : Silica
• CPC Class Codes: C08L 27/18 : Homopolymers or copolymers or tetrafluoroethene
• CPC Class Codes: F16L 59/028 : Composition or method of fixing a thermally insulating material
• CPC Class Codes: F28F 2270/00 : Thermal insulation; Thermal decoupling
• CPC Class Codes: G06F 1/203 : for portable computers, e.g. for laptops
• CPC Class Codes: H01L 23/433 : Auxiliary members in containers characterised by their shape, e.g. pistons
• CPC Class Codes: H01L 2924/00 : Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H04M 1/0214 : Foldable telephones, i.e. with body parts pivoting to an open position around an axis parallel to the plane they define in closed position combined with translation movement H04M1/0235
• CPC Class Codes: H04M 1/026 : Details of the structure or mounting of specific components
• CPC Class Codes: H05K 1/034 : containing halogen
• CPC Class Codes: H05K 1/0373 : containing additives, e.g. fillers H05K1/036 takes precedence
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/31544 : Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31725 : Of polyamide
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

A material comprising aerogel particles and a polytetrafluoroethylene (PTFE) binder is formed having a thermal conductivity of less than or equal to 25 mW/m K at atmospheric conditions. The material is moldable or formable, having little or no shedding of filler particles, and may be formed into structures such as tapes or composites, for example, by bonding the material between two outer layers. Advantageously, composites may be flexed, stretched, or bent without significant dusting or loss of insulating properties.

Claims

1. A materiel comprising

greater than or equal to about 40% wt aerogel particles and

less than or equal to about 60% wt polytetrafluoroethylene (PTFE) particle having a particle size of from about 50 nm to about 600 μ

m as a binder,

wherein the material is a powder or a putty, and the material has a thermal conductivity of less than or equal to 25 milliwatts per meter Kelvin (mW/m K) at atmospheric conditions (298.15 K and 101.3 kPa).

2. The material of claim 1 wherein the material has a thermal conductivity of less than or equal to about 20 mW/m K at atmospheric conditions (298.15 K and 101.3 kPa).

3. The material of claim 1 wherein the material has a thermal conductivity of less than or equal to about 17 mW/m K at atmospheric conditions (298.15 K and 101.3 kPa).

4. The material of claim 1 wherein the aerogel has an average pore size less than or equal to about 100 nm.

5. The material of claim 1 wherein the aerogel is present in an amount of greater than or equal to about 60% wt.

6. The material of claim 1 wherein the aerogel is present in an amount of greater than or equal to about 80% wt.

7. The material of claim 1 wherein the aerogel is formed from an inorganic oxide.

8. The material of claim 1 where the aerogel is silica aerogel.

9. The material of claim 1 further comprising at least one additional component selected from opacifiers, dies, fibers and polymers.

10. The material of claim 9 wherein the opacifier is carbon black, titanium dioxide, iron oxides, silicon carbide, molybdenum silicide, manganese oxide or polydialkylsiloxanes, wherein the alkyl groups contain 1 to 4 carbon atoms.

11. The material of claim 1 wherein the material is formable or moldable.

12. The material of claim 1 wherein the material is between two walls of a double walled container.

13. The material of claim 1 wherein the material is formed as a tape.