Organic, open cell foam materials, their carbonized derivatives, and methods for producing same
AssigneeAmerican Aerogel Corporation
InventorsDonald Albert, Greg Andrews, Joseph Bruno
Life of this patent
Estimating the term…
Abstract
Organic, small pore area materials (“SPMs”) are provided comprising open cell foams in unlimited sizes and shapes. These SPMs exhibit minimal shrinkage and cracking. Processes for preparing SPMs are also provided that do not require supercritical extraction. These processes comprise sol-gel polymerization of a hydroxylated aromatic in the presence of at least one suitable electrophilic linking agent and at least one suitable solvent capable of strengthening the sol-gel. Also disclosed are the carbonized derivatives of the organic SPMs.
Claims51
1-53. (canceled)
A method for preparing an organic, small pore area material, said method comprising the steps of:
- (a) forming a solution comprising a hydroxylated aromatic, an electrophilic linking agent, and a hydrogen-bonding agent;
- (b) allowing said solution to form a sol-gel;
- and,
- (c) removing substantially all of the fluid portion of said sol-gel.
A method for preparing a low density microcellular material comprising the steps of:
- (a) forming a sol-gel;
- and
- (b) removing substantially all of the fluid portion of said sol-gel by non-supercritical extraction
- wherein the material is a monolithic aerogel having a smallest dimension greater than about 3 inches;
- and is substantially free of cracks.
A method for preparing a small pore area material comprising the steps of:
- (a) forming a sol-gel;
- and
- (b) removing substantially all of the fluid portion of said sol-gel by non-supercritical extraction
- wherein the material is a monolithic aerogel having a smallest dimension greater than about 3 inches;
- and is substantially free of cracks.
(canceled)
A method for removing fluid from a sol-gel comprising the steps of:
- (a) forming a solution;
- (b) allowing said solution to form a sol-gel;
- (c) adding a low surface tension solvent to the sol-gel;
- (d) applying a pressure differential across the sol-gel;
- (e) removing substantially all of the original pore fluid portion of said sol-gel;
- and
- (f) removing the lower surface tension solvent.
A method for preparing an organic, low density microcellular material, said method comprising the steps of:
- (a) forming a solution;
- (b) allowing said solution to form a sol-gel;
- (c) adding a low surface tension solvent to the sol-gel;
- (d) applying a pressure differential across the sol-gel;
- (e) removing substantially all of the original pore fluid portion of said sol-gel;
- and
- (f) removing the lower surface tension solvent.
A method for preparing an organic, low density microcellular material, said method comprising the steps of:
- (a) forming a solution comprising a hydroxylated aromatic, an electrophilic linking agent, and a hydrogen-bonding agent;
- (b) allowing said solution to form a sol-gel;
- (c) adding a low surface tension solvent to the sol-gel;
- (d) applying a pressure differential across the sol-gel;
- (e) removing substantially all of the original pore fluid portion of said sol-gel, and
- (f) removing the low surface tension solvent.
A method for preparing an organic, small pore area material, said method comprising the steps of:
- (a) forming a solution;
- (b) allowing said solution to form a sol-gel;
- (c) adding a lower surface tension solvent to the sol-gel;
- (d) applying a pressure differential across the sol-gel;
- (e) removing substantially all of the original pore fluid portion of said sol-gel, and
- (f) removing the lower surface tension solvent.
A method for preparing an organic, small pore area material, said method comprising the steps of:
- (a) forming a solution comprising a hydroxylated aromatic, an electrophilic linking agent, and a hydrogen-bonding agent;
- (b) allowing said solution to form a sol-gel;
- (c) adding a low surface tension solvent to the sol-gel;
- (d) applying a pressure differential across the sol-gel;
- (e) removing substantially all of the original pore fluid portion of said sol-gel, and
- (f) removing the low surface tension solvent.
84-128. (canceled)
A method for preparing an organic, low density microcellular material, said method comprising the steps of:
- (a) forming a solution comprising a hydroxylated aromatic, an electrophilic linking agent, and a hydrogen-bonding agent;
- (b) allowing said solution to form a sol-gel;
- and,
- (c) removing substantially all of the fluid portion of said sol-gel.
A method for preparing a low density microcellular material, comprising the steps of:
- (a) forming a sol-gel;
- and
- (b) removing substantially all of the fluid portion of said sol-gel by non-supercritical extraction;
- wherein the material comprises a monolithic aerogel prepared using a non-critical drying process, wherein its smallest dimension is greater than about 3 inches;
- and said aerogel is substantially free of cracks.
A method for preparing a small pore area material comprising the steps of:
- (a) forming a sol-gel;
- and
- (b) removing substantially all of the fluid portion of said sol-gel by non-supercritical extraction;
- wherein the material comprises a monolithic aerogel prepared using a non-critical drying process, wherein its smallest dimension is greater than about 3 inches;
- and said aerogel is substantially free of cracks.
Dependencies are inferred from the claim text.