Methods to produce gel sheets
AssigneeAspen Aerogels, Inc.
InventorsKang P. Lee, George L. Gould, William Gronemeyer, Christopher John Stepanian
Life of this patent
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Abstract
The present invention provides various methods for producing gel sheets in a continuous fashion. The embodiments of the present invention help reduce the time of producing gel sheets that is suitable for industrial manufacturing. Such gel sheets are used in manufacturing aerogel blankets used in a variety of applications including thermal and acoustic insulation.
Claims21
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously combining a sol and a gel inducing agent to form a catalyzed sol;
- providing at least a fibrous material;
- and
- forming a gel sheet by dispensing the catalyzed sol onto a moving element consisting essentially of one moving conveyor belt, as a single molding surface for said sol, at a predetermined rate effective to allow gelation to occur to the catalyzed sol on the moving element, wherein the fibrous material is combined with the catalyzed sol prior to gelation.
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously combining a sol and a gel inducing agent to form a catalyzed sol;
- providing at least a fibrous material;
- and
- forming a gel sheet by dispensing the catalyzed sol onto a moving element consisting essentially of one moving conveyor belt with edges, as a single molding surface for said sol, at a predetermined rate effective to allow gelation to occur to the catalyzed sol on the moving element, wherein the fibrous material is combined with the catalyzed sol prior to gelation.
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously combining a sol and a gel inducing agent to form a catalyzed sol;
- providing at least a fibrous batting or mat material;
- and
- forming a gel sheet by dispensing the catalyzed sol onto a moving element consisting essentially of one moving conveyor belt with edges, as a single molding surface for said sol, at a predetermined rate effective to allow gelation to occur to the catalyzed sol on the moving element, wherein the fibrous batting or mat material is combined with the catalyzed sol prior to gelation.
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously forming a gel sheet by dispensing catalyzed sol onto a moving element consisting essentially of one moving conveyor belt, as a single molding surface for said sol, at a predetermined rate;
- providing at least a fibrous material;
- combining the fibrous material with the catalyzed sol prior to gelation;
- and
- inducing gelation in the moving element by a process selected from the group consisting of (a) a chemical process, and (b) dissipating a predetermined quantity of energy from an energy source into a cross-sectional area of the sol.
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously combining a sol and a gel inducing agent to form a catalyzed sol;
- forming a gel sheet by dispensing the catalyzed sol onto a moving element consisting essentially of one moving conveyor belt, as a single molding surface for said sol, at a predetermined rate effective to allow gelation to occur to the catalyzed sol on the moving element;
- and
- rolling the formed gel sheet.
A process for continuously casting solvent filled gel sheet material, comprising:
- continuously combining a sol and a gel inducing agent to form a catalyzed sol;
- forming a gel sheet by dispensing the catalyzed sol onto a moving element consisting essentially of one moving conveyor belt, as a single molding surface for said sol, at a predetermined rate effective to allow gelation to occur to the catalyzed sol on the moving element;
- and
- drying the formed gel sheet.
Dependencies are inferred from the claim text.