Ultra-thin prestressed fiber reinforced aerogel honeycomb catalyst monoliths
OwnerMatthew T. Sanderinventor
Life of this patent
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Abstract
A method for reinforcing thin panels or monoliths of aerogels, xergels, zeolites and other low density material with prestressed fibers in two of three dimensions (30, 32, 34). The utilization of internal molding and gas flow through channels (10) within the Aerogel monolith to achieve catalytic selectivity of the desired gas phase heterogeneous reaction. A method of internal molding (52) and decreased supercritical fluid drying times (72) for Aerogels by means of using gas porous molding features (60) that are compatable with the prestressed fiber reinforcing system (42).
Claims5
A method of producing a thin panel or monolith of low density material comprising:
- providing a gas permeable mold containing pretensioned reinforcing fibers running perpendicular to each other and at defined intervals, wherein the tensioning of the fibers is set at a loading to approximately eliminate the anticipated tensile loading stress of the thin panel or monolith in its intended service;
- providing a mixture of metal alkoxides, water and a catalyst;
- spraying a mold release agent onto the mold;
- pouring the mixture into the mold;
- polymerizing the mixture in the mold;
- subjecting the polymerized mixture to supercritical drying to obtain the low density material;
- and
- withdrawing the mold from the low density material to provide said thin panel or monolith.
Dependencies are inferred from the claim text.