# US 11,077,487 B2 · Metal form containing dispersed aerogel particles impregnated with polymers and a method of producing the same

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,077,487 B2
- Document ID: US11077487B2
- Status: Granted
- Kind: B2
- Application number: 16/521,358
- Filed: 2019-07-24
- Published: 2019-11-14
- Granted: 2021-08-03
- Earliest claimed: 2015-10-29
- Assignees: Meta-Dry LLC
- Applicants: IP Metadry LLC
- Inventors: Michael Golfetto
- Web page: https://patentgrep.com/patent/US11077487B2

## CPC

- B22C 7/026: {by assembling preformed parts (joining of plastics, in general B29C65/00)}
- B01D 3/00: Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping ({evaporation in general, e.g. of liquids for gas phase reactions B01B1/005;} gas chromatography B01D15/08; destructive distillation C10B; preparation of alcoholic beverages by distillation C12H6/02)
- B01D 12/00: Displacing liquid, e.g. from wet solids or from dispersions of liquids or from solids in liquids, by means of another liquid
- B01J 13/0065: {containing an organic phase}
- B01J 13/0091: {Preparation of aerogels, e.g. xerogels}
- B22D 25/005: {Casting metal foams}
- B29C 35/16: Cooling {(cooling extruded material B29C48/911; cooling preforms for blow moulding B29C49/6427; cooling blown articles B29C49/66; cooling tyres during post cure inflation B29D30/0643)}
- B29C 67/202: {comprising elimination of a solid or a liquid ingredient}
- B29C 67/207: {comprising impregnating expanded particles or fragments with a binder}
- C01B 33/1585: {Dehydration into aerogels}
- C08J 9/22: After-treatment of expandable particles; Forming foamed products
- F26B 5/06: the process involving freezing
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- C08J 2205/026: Aerogel, i.e. a supercritically dried gel
- Y02P 20/54: using solvents, e.g. supercritical solvents or ionic liquids
- Y10T 428/12014: having metal particles
- Y10T 428/12049: Nonmetal component
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- 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)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- F26B: DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM (drying devices for combines A01D41/133; racks for drying fruit or vegetables A01F25/12; drying foodstuffs A23; drying hair A45D20/00; body-drying implements A47K10/00; drying household articles A47L; drying gases or vapours B01D; chemical or physical processes for dewatering or like separating liquids from solids B01D43/00; centrifugal apparatus B04; drying ceramics C04B33/30; drying yarns or fabrics in association with some other form of treatment D06C; drying frames for laundry without heating or positive air circulation, domestic laundry-or spin-driers, wringing or hot pressing laundry D06F; furnaces, kilns, ovens F27)
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite structure including a metal form. The composite structure further includes an aerogel matrix formed of an aerogel, with the aerogel matrix being nanoporous and including a plurality of aerogel pores. A polymer occupies at least a portion of the aerogel pores of the aerogel matrix. The polymer is a thermoplastic. The thermoplastic is nanoporous and includes a plurality of thermoplastic pores. The thermoplastic pores are less than 10 nanometers in size. The polymer is impregnated within the aerogel pores of the aerogel matrix. The aerogel comprises at least 20% by weight of the composite structure. The aerogel pores are less than 10 nanometers in size. The composite structure further contains filler material. The filler material may be graphene. The composite structure further contains reinforcing agents.

## Claims

### Claim 1

A composite structure comprising,
a metal form including:
an aerogel matrix formed of an aerogel, wherein the aerogel matrix is nanoporous and includes a plurality of aerogel pores, a polymer occupies at least a portion of the aerogel pores of the aerogel matrix, the polymer is a thermoplastic, and the thermoplastic is nanoporous and includes a plurality of thermoplastic pores.

### Claim 2 (depends on 1)

The composite structure of claim 1, wherein the metal in the metal form is selected from a group consisting of aluminum, bronze, copper, iron, steel, magnesium, and zinc.

### Claim 3 (depends on 1)

The composite structure of claim 1, wherein the thickness of the metal form is less than 25 mm.

### Claim 4 (depends on 1)

The composite structure of claim 1, wherein the polymer is selected from a group consisting of polystyrene, expandable styrene, or (methyl methacrylate) MMA copolymer.

### Claim 5 (depends on 1)

The composite structure of claim 1, wherein the thermoplastic pores are less than 10 nanometers in size.

### Claim 6 (depends on 1)

The composite structure of claim 1, wherein the thermoplastic is crystalline.

### Claim 7 (depends on 1)

The composite structure of claim 1, wherein the thermoplastic is semi-crystalline.

### Claim 8 (depends on 1)

The composite structure of claim 1, wherein the thermoplastic is amorphous.

### Claim 9 (depends on 1)

The composite structure of claim 1, wherein the aerogel comprises at least 20% by weight of the composite structure.

### Claim 10 (depends on 1)

The composite structure of claim 1, wherein the aerogel pores are less than 10 nanometers in size.

### Claim 11 (depends on 1)

The composite structure of claim 1, wherein the composite structure further contains filler material.

### Claim 12 (depends on 11)

The composite structure of claim 11, wherein the filler material is selected from a group consisting of graphene oxide, boron nitride, molybdenum disulfide, and tungsten disulfide.

### Claim 13 (depends on 1)

The composite structure of claim 1, wherein the composite structure further contains reinforcing agents.

### Claim 14 (depends on 1)

The composite structure of claim 1, wherein the polymer includes at least one of a acrylonitrile-butadiene-styrene (ABS), epoxy, melamine formaldehyde (MF), polyacrylonitrile (PAN), polyamide (PA), pylon, polyimide (PI), polybutadiene (PBD), polybutylene (PB), polycarbonate (PC), polyester, polyetheretherketone (PEEK), polyetherimide (PEI), polyethersulfone (PES), polyethylene (PE), polymethylpentene (PMP), polyphenylene Oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polystyrene (PS), polysulfone (PSU), polyurethane (PU), polyvinylchloride (PVC), polyvinylidene chloride (PVDC), silicone (SI), methyl methacrylate (MMA) copolymer, polymethylacryate, polymethyl methacrylate, polycyclopentadiene, poly(paraphenlene terephthalamide), cellulose, and polytetrafluoroethylene (PTFE).

### Claim 15 (depends on 11)

The composite structure of claim 11, wherein the filler material includes at least one of Graphene and Graphene oxide.