# US 8,785,509 B2 · Superinsulation with nanopores

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- Number: US 8,785,509 B2
- Document ID: US8785509B2
- Status: Granted
- Kind: B2
- Application number: 12/736,709
- Filed: 2009-05-01
- Published: 2011-05-19
- Granted: 2014-07-22
- Earliest claimed: 2008-05-02
- Assignees: Industrial Science & Technology Network, Inc.
- Applicants: Arthur J. Yang
- Inventors: Arthur J. Yang
- Web page: https://patentgrep.com/patent/US8785509B2

## CPC

- C08F 12/08: Styrene
- C04B 26/10: obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B 38/103: {the foaming being obtained by the introduction of a gas other than untreated air, e.g. nitrogen}
- C08G 18/14: {Manufacture of cellular products}
- C08J 9/122: {Hydrogen, oxygen, CO2, nitrogen or noble gases}
- C04B 2111/00853: {in electrochemical cells or batteries, e.g. fuel cells}
- C04B 2111/40: Porous or lightweight materials
- C08G 2101/00: Manufacture of cellular products
- C08J 2201/032: Impregnation of a formed object with a gas
- C08J 2203/06: CO2, N2 or noble gases
- C08J 2205/042: Nanopores, i.e. the average diameter being smaller than 0,1 micrometer
- C08J 2325/00: Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J 2375/04: Polyurethanes
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- 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)

## Abstract

This invention relates to the field of thermal insulation. In particular, the invention describes superinsulation articles having a desired porosity, reduced pore size and cost-effective methods for manufacturing such articles. In one aspect of the present invention, the article may comprise a material system with at least about 20% porosity. In a further aspect of the invention, an article may comprise greater than about 25% of nanopores having a pore size no greater than about 1500 nanometers in its shortest axis.

## Claims

### Claim 1

A method for manufacturing an article comprising a polymer material system with at least 95% porosity comprising greater than 10% asymmetrical pores, comprising:
i) forming one or more gas nuclei in a polymer material; and
ii) asymmetrically expanding the one or more gas nuclei via gas foaming to form one or more gas bubbles, wherein the size of the one or more gas bubbles is no greater than 1500 nanometers in its shortest axis.

### Claim 2 (depends on 1)

The method of claim 1, wherein the formation of the one or more gas nuclei is via homogeneous nucleation or spinodal decomposition.

### Claim 3 (depends on 2)

The method of claim 2, wherein the homogenous nucleation uses supercritical CO2.

### Claim 4 (depends on 2)

The method of claim 2, wherein the spinodal decomposition uses a reactive system, wherein the reactive system is selected from the group consisting of polymerization of styrene and urethane.

### Claim 5 (depends on 1)

The method of claim 1, wherein the gas foaming is via sudden asymmetric release of pressure of a gas embedded in the polymer material under pressure sufficiently high for adequate gas solubility.

### Claim 6 (depends on 5)

The method of claim 5, wherein the high-pressure gas is embedded in the polymer material in the form of a solute or co-solvent.

### Claim 7 (depends on 1)

The method of claim 1, wherein the manufactured article comprises nanopores having a pore size no greater than 1500 nanometers in its shortest axis.

### Claim 8 (depends on 1)

The method of claim 1, wherein the manufactured article comprises greater than 25% asymmetrical pores.

### Claim 9 (depends on 1)

The method of claim 1, wherein the gas foaming asymmetrical expansion is controlled so that the asymmetrical pores are aligned in a preferred direction.

### Claim 10 (depends on 1)

The method of claim 1, wherein the asymmetrical pores are prolate or oblate.

### Claim 11 (depends on 1)

The method of claim 1, wherein the forming of the asymmetrical pore is facilitated by using an inorganic filler as a template for the formation of the one or more gas nuclei.

### Claim 12 (depends on 11)

The method of claim 11, wherein the inorganic filler is a modified clay to form a polymer-clay composite.

### Claim 13 (depends on 12)

The method of claim 12, wherein the modified clay is an exfoliated clay.

### Claim 14 (depends on 11)

The method of claim 11, wherein the inorganic filler is aligned along the machine direction in a continuous foam extrusion process.

### Claim 15 (depends on 1)

The method of claim 1, wherein the gas foaming is a continuous foam extrusion process.

### Claim 16 (depends on 1)

The method of claim 1, wherein the size of the one or more gas nuclei is controlled by a sudden depressurization.