# US 10,500,557 B2 · Internally reinforced aerogel and uses thereof

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- Number: US 10,500,557 B2
- Document ID: US10500557B2
- Status: Granted
- Kind: B2
- Application number: 15/967,926
- Filed: 2018-05-01
- Published: 2018-10-11
- Granted: 2019-12-10
- Earliest claimed: 2015-11-03
- Assignees: Blueshift Materials, Inc.
- Applicants: Blueshift Materials, Inc.
- Inventors: Alan Sakaguchi; Garrett Poe; Michael Merwin
- Web page: https://patentgrep.com/patent/US10500557B2

## CPC

- B32B 5/18: characterised by features of a layer {of} foamed material
- B01J 13/0091: {Preparation of aerogels, e.g. xerogels}
- B32B 5/00: Layered products characterised by the non- homogeneity or physical structure {, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts}
- 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)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)}
- B32B 5/24: one layer being a fibrous or filamentary layer
- B32B 5/245: {another layer next to it being a foam layer}
- B01D 2239/0613: Woven
- B01D 2239/0618: Non-woven
- B01D 2239/0654: Support layers
- B01D 2239/10: Filtering material manufacturing
- B01D 2239/1225: Fibre length
- B01D 2239/1233: Fibre diameter
- B32B 2260/00: Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/028: Paper layer
- B32B 2260/04: Impregnation, embedding, or binder material
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0207: Elastomeric fibres
- B32B 2262/0215: Thermoplastic elastomer fibers
- B32B 2262/0223: Vinyl resin fibres
- B32B 2262/023: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2262/0238: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2262/0246: Acrylic resin fibres
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2262/04: Cellulosic plastic fibres, e.g. rayon
- B32B 2262/06: Vegetal fibres
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/067: Wood fibres
- B32B 2262/08: Animal fibres, e.g. hair, wool, silk
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/105: Ceramic fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2266/00: Composition of foam
- B32B 2266/0214: Materials belonging to B32B27/00
- B32B 2266/06: Open cell foam
- B32B 2457/00: Electrical equipment
- B32B 2509/00: Household appliances
- B32B 2605/18: Aircraft
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)

## Abstract

Internally reinforced aerogels, articles of manufacture and uses thereof are described. An internally reinforced aerogel includes an aerogel having a support at least partially penetrating the aerogel and having the aerogel penetrating the porous structure of the support.

## Claims

### Claim 1

A composite comprising:
a non-fibrous organic polymer aerogel layer having a first surface and an opposing second surface; and
a fibrous support layer having a first surface and an opposing second surface,
wherein an interface is formed between a portion of the first surface of the aerogel layer and a portion of the second surface of the support layer such that the aerogel and support layers are attached to one another, and
wherein a majority of the volume of the aerogel layer does not include the support layer.

### Claim 2 (depends on 1)

The composite of claim 1, specifically excluding any adhesives or binders wherein the fibrous support film or layer is integrated with the aerogel layer such that the support film or layer adheres to the aerogel layer without the use of an adhesive or binder.

### Claim 3 (depends on 1)

The composite of claim 1, wherein the aerogel layer is a polyimide aerogel.

### Claim 4 (depends on 1)

The composite of claim 1, wherein the aerogel layer is at most 15 mils thick.

### Claim 5 (depends on 1)

The composite of claim 1, wherein the aerogel layer is between 1.5 to 15 mils thick.

### Claim 6 (depends on 1)

The composite of claim 1, wherein the fibers in the fibrous support layer have an average filament cross sectional area of 7 to 800 μm2.

### Claim 7 (depends on 1)

The composite of claim 1, wherein the fibrous support layer is 1 mil or less in thickness.

### Claim 8 (depends on 1)

The composite of claim 1, wherein the fibrous support layer is between 0.25 and 1 mil thick.

### Claim 9 (depends on 1)

The composite of claim 1, wherein the fibrous support layer is a paper support.

### Claim 10 (depends on 1)

The composite of claim 1, wherein the fibrous support layer further comprises unidirectional fibers.

### Claim 11 (depends on 1)

The composite of claim 1, wherein the fibers in the fibrous support layer are omnidirectional fibers.

### Claim 12 (depends on 1)

The composite of claim 1, wherein the fibers in the fibrous support layer have an aspect ratio of less than 60.

### Claim 13 (depends on 1)

The composite of claim 1, wherein the fibers in the fibrous support layer have an aspect ratio of greater than 60.

### Claim 14 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises microfibers.

### Claim 15 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises natural, synthetic, semi-synthetic fibers, or combinations thereof.

### Claim 16 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises vegetable, wood, animal, mineral, biological fibers, or combinations thereof.

### Claim 17 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises rayon, bamboo, diacetate, triacetate fibers, or combinations thereof.

### Claim 18 (depends on 1)

The composite of claim 1, wherein fibrous support layer comprises metal, carbon, carbide, glass, mineral fibers, or combinations thereof.

### Claim 19 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises thermoplastic fibers, thermoset polymer fibers, or combinations thereof.

### Claim 20 (depends on 19)

The composite of claim 19, wherein the thermoplastic fiber is a fiber of polyethylene terephthalate (PET), a polycarbonate (PC) family of polymers, polybutylene terephthalate (PBT), poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate) (PCCD), glycol modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine or polyetherimide (PEI) and their derivatives, thermoplastic elastomer (TPE), terephthalic acid (TPA) elastomers, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), polyamide (PA), polysulfone sulfonate (PSS), sulfonates of polysulfones, polyether ether ketone (PEEK), polyether ketone ketone (PEKK), acrylonitrile butyldiene styrene (ABS), polyphenylene sulfide (PPS), co-polymers thereof, or blends thereof.

### Claim 21 (depends on 19)

The composite of claim 19, wherein the thermoset fiber is a fiber of polyaramid, polyimide, polybenzoxazole, polyurethane, or blends thereof.

### Claim 22 (depends on 1)

The composite of claim 1, wherein the fibrous support layer comprises vinylon, polyolefin, polyethylene or polyester fibers.

### Claim 23 (depends on 1)

The composite of claim 1, having a flex fatigue of at least 100,000 cycles to failure.

### Claim 24 (depends on 1)

The composite of claim 1, having a tensile strength of at least 15 MPa.

### Claim 25 (depends on 1)

The composite of claim 1, wherein the composite is 1.5 to 15 mils thick.

### Claim 26 (depends on 1)

The composite of claim 1, consisting of the non-fibrous aerogel layer and the fibrous support layer.

### Claim 27 (depends on 1)

The composite of claim 1, wherein the entire interface is positioned within the volume of the non-fibrous aerogel layer.

### Claim 28 (depends on 1)

The composite of claim 1, wherein the entire volume of the fibrous support layer is positioned in the volume of the non-fibrous aerogel layer.

### Claim 29 (depends on 1)

The composite of claim 1, wherein a portion of the volume of the fibrous support layer is positioned within the volume of the non-fibrous aerogel layer and a second portion of the fibrous support layer is positioned outside the volume of the non-fibrous aerogel layer.

### Claim 30 (depends on 1)

The composite of claim 1, wherein the composite is rolled-up such that the composite is in the form of a roll.