Claims
- 1. A heat resistant aerogel insulation composite comprising
(a) an insulation base layer comprising hydrophobic aerogel particles and an aqueous binder, and (b) a thermally reflective top layer comprising a protective binder and an infrared reflecting agent.
- 2. The heat resistant aerogel insulation composite of claim 1, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0. 1-3 mm.
- 3. The heat resistant aerogel insulation composite of claim 2, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.5-2 mm.
- 4. The heat resistant aerogel insulation composite of claim 3, wherein at least about 95% of the hydrophobic aerogel particles (by weight) have a particle diameter of about 0.5-2 mm.
- 5. The heat resistant aerogel insulation composite of claim 1, wherein the hydrophobic aerogel particles comprise an opacifying agent.
- 6. The heat resistant aerogel insulation composite of claim 5, wherein the opacifying agent is titania, carbon black, or a mixture thereof.
- 7. The heat resistant aerogel insulation composite of claim 1, wherein the hydrophobic aerogel particles comprise fibers.
- 8. The heat resistant aerogel insulation composite of claim 1, wherein the hydrophobic aerogel particles are approximately spherical.
- 9. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer comprises 5-99 vol. % hydrophobic aerogel particles.
- 10. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer comprises a foaming agent.
- 11. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer comprises 1-95 vol. % of the aqueous binder.
- 12. The heat resistant aerogel insulation composite of claim 1, wherein the aqueous binder is an acrylic binder, a silicone-containing binder, a phenolic binder, or a mixture thereof.
- 13. The heat resistant aerogel insulation composite of claim 12, wherein the aqueous binder is an acrylic binder.
- 14. The heat resistant aerogel insulation composite of claim 1, wherein the aqueous binder is a foamed binder.
- 15. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer further comprises a flame retardant.
- 16. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer is about 1-10 mm thick.
- 17. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer has a thermal conductivity of about 40 mW/(m·K) or less.
- 18. The heat resistant aerogel insulation composite of claim 1, wherein the insulation base layer has a density of about 0.5 g/cm3 or less.
- 19. The heat resistant aerogel insulation composite of claim 1, wherein the protective binder is an acrylic binder, a silicone-containing binder, a phenolic binder, or a mixture thereof.
- 20. The heat resistant aerogel insulation composite of claim 19, wherein the protective binder is an acrylic binder.
- 21. The heat resistant aerogel insulation composite of claim 1, wherein the protective binder is a cross-linked binder.
- 22. The heat resistant aerogel insulation composite of claim 1, wherein the thermally reflective top layer further comprises an anti-sedimentation agent.
- 23. The heat resistant aerogel insulation composite of claim 1, wherein the infrared reflecting agent comprises metallic particles.
- 24. The heat resistant aerogel insulation composite of claim 23, wherein the metallic particles are aluminum particles.
- 25. The heat resistant aerogel insulation composite of claim 1, wherein the thermally reflective top layer further comprises a flame retardant.
- 26. The heat resistant aerogel insulation composite of claim 1, wherein the thermally reflective top layer further comprises reinforcing fibers.
- 27. The heat resistant aerogel insulation composite of claim 1, wherein the thermally reflective top layer further comprises carbon fibers.
- 28. The heat resistant aerogel insulation composition of claim 1, wherein the thermally reflective top layer is about 1 mm thick or less.
- 29. A substrate comprising the heat resistant aerogel insulation composite of claim 1.
- 30. The substrate of claim 29, wherein the substrate is a component of a motorized vehicle or device.
- 31. The substrate of claim 30, wherein the substrate is the underbody of a motorized vehicle or part thereof.
- 32. A method for preparing a heat resistant aerogel insulation composite comprising
(a) providing on a substrate an insulation base layer comprising hydrophobic aerogel particles and an aqueous binder, and (b) applying to a surface of the insulation base layer a thermally reflective top layer comprising a protective binder and an infrared reflecting agent.
- 33. The method of claim 32, wherein the insulation base layer is provided by
(a) providing a binder composition comprising an aqueous binder and a foaming agent, (b) agitating the binder composition to provide a foamed binder composition, (c) combining the foamed binder composition with the hydrophobic aerogel particles to provide an aerogel binder composition, and (d) applying the aerogel binder composition to the substrate to provide the insulation base layer.
- 34. The method of claim 32, wherein the insulation base layer is provided by
(a) providing a binder composition comprising an aqueous binder, (b) providing an aerogel composition comprising hydrophobic aerogel particles, and (c) simultaneously applying the binder composition and the aerogel composition to the substrate, wherein the binder composition is mixed with the aerogel composition to provide the insulation base layer.
- 35. The method of claim 32, wherein the insulation base layer is applied to the substrate by spraying.
- 36. The method of claim 32, wherein the top layer is applied to the surface of the insulation base layer by spraying.
- 37. The method of claim 32, wherein the top layer is applied to the surface of the insulation base layer while the insulation base layer is wet.
- 38. The method of claim 32, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.1-3 mm.
- 39. The method of claim 38, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.5-2 mm
- 40. The method of claim 39, wherein at least about 95% of the hydrophobic aerogel particles (by weight) have a particle diameter of about 0.5-2 mm.
- 41. The method of claim 32, wherein the hydrophobic aerogel particles comprise an opacifying agent.
- 42. The method of claim 41, wherein the opacifying agent is titania or carbon black.
- 43. The method of claim 32, wherein the hydrophobic aerogel particles comprise fibers.
- 44. The method of claim 32, wherein the hydrophobic aerogel particles are approximately spherical.
- 45. The method of claim 32, wherein the insulation base layer comprises 5-99 vol. % hydrophobic aerogel particles.
- 46. The method of claim 32, wherein the insulation base layer comprises a foaming agent.
- 47. The method of claim 32, wherein the insulation base layer comprises 1-95 vol. % of the aqueous binder.
- 48. The method of claim 32, wherein the aqueous binder is an acrylic binder, a silicone-containing binder, a phenolic binder, or a mixture thereof.
- 49. The method of claim 48, wherein the aqueous binder is an acrylic binder.
- 50. The method of claim 32, wherein the aqueous binder is a foamed binder.
- 51. The method of claim 32, wherein the insulation base layer further comprises a flame retardant.
- 52. The method of claim 32, wherein the insulation base layer is about 1-15 mm thick.
- 53. The method of claim 32, wherein the insulation base layer has a thermal conductivity of about 40 mW/(m·K) or less.
- 54. The method of claim 32, wherein the insulation base layer has a density of about 0.5 g/cm3 or less.
- 55. The method of claim 32, wherein the protective binder is an acrylic binder, a silicone-containing binder, a phenolic binder, or a mixture thereof.
- 56. The method of claim 55, wherein the protective binder is an acrylic binder.
- 57. The method of claim 32, wherein the protective binder is a cross-linked binder.
- 58. The method of claim 32, wherein the thermally reflective top layer further comprises an anti-sedimentation agent.
- 59. The method of claim 32, wherein the infrared reflecting agent comprises metallic particles.
- 60. The method of claim 59, wherein the metallic particles are aluminum particles.
- 61. The method of claim 32, wherein the thermally reflective top layer further comprises a flame retardant.
- 62. The method of claim 32, wherein the thermally reflective top layer is about 1 mm thick or less.
- 63. The method of claim 32, wherein the thermally reflective top layer further comprises reinforcing fibers.
- 64. The method of claim 32, wherein the thermally reflective top layer further comprises carbon fibers.
- 65. A method for preparing an aerogel binder composition comprising
(a) providing a binder composition comprising an aqueous binder and a foaming agent, (b) agitating the binder composition to provide a foamed binder composition, and (c) combining the foamed binder composition with hydrophobic aerogel particles to provide an aerogel binder composition.
- 66. The method of claim 65, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.1-3 mm.
- 67. The method of claim 66, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.5-2 mm
- 68. The method of claim 67, wherein at least about 95% of the hydrophobic aerogel particles (by weight) have a particle diameter of about 0.5-2 mm.
- 69. The method of claim 65, wherein the hydrophobic aerogel particles are approximately spherical.
- 70. The method of claim 65, wherein the aerogel binder composition comprises 5-99 vol. % hydrophobic aerogel particles.
- 71. The method of claim 65, wherein the aerogel binder composition comprises 0.1-5 wt. % of the foaming agent.
- 72. The method of claim 65, wherein the aerogel binder composition comprises 1-95 vol. % of the aqueous binder.
- 73. The method of claim 65, wherein the hydrophobic aerogel particles comprise an opacifying agent.
- 74. The method of claim 73, wherein the opacifying agent is titania or carbon black.
- 75. The method of claim 65, wherein the hydrophobic aerogel particles comprise fibers.
- 76. The method of claim 65, wherein the aqueous binder is an acrylic binder, a silicone binder, a urea-formaldehyde binder, or a mixture thereof.
- 77. The method of claim 76, wherein the aqueous binder is an acrylic binder.
- 78. The method of claim 65, wherein the aerogel binder composition has a thermal conductivity of about 40 mW/(m·K) or less.
- 79. The method of claim 65, wherein the aerogel binder composition has a density of about 0.5 g/cm3 or less.
- 80. An aerogel binder composition prepared by the method of claim 65.
- 81. A method for preparing an aerogel binder composition comprising
(a) providing a binder composition comprising an aqueous binder, (b) providing an aerogel composition comprising hydrophobic aerogel particles, and (c) simultaneously applying the binder composition and the aerogel composition to a substrate, whereupon the binder composition is mixed with the aerogel composition to provide an aerogel binder composition.
- 82. The method of claim 81, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.1-3 mm.
- 83. The method of claim 82, wherein the hydrophobic aerogel particles have an average particle diameter (by weight) of about 0.5-2 mm
- 84. The method of claim 83, wherein at least about 95% of the hydrophobic aerogel particles (by weight) have a particle diameter of about 0.5-2 mm.
- 85. The method of claim 81, wherein the hydrophobic aerogel particles are approximately spherical.
- 86. The method of claim 81, wherein the aerogel binder composition comprises 5-99 vol. % hydrophobic aerogel particles.
- 87. The method of claim 81, wherein the aerogel binder composition comprises 0.1-5 wt. % of the foaming agent.
- 88. The method of claim 81, wherein the aerogel binder composition comprises 1-95 vol. % of the aqueous binder.
- 89. The method of claim 81, wherein the hydrophobic aerogel particles comprise an opacifying agent.
- 90. The method of claim 89, wherein the opacifying agent is titania or carbon black.
- 91. The method of claim 81, wherein the hydrophobic aerogel particles comprise fibers.
- 92. The method of claim 81, wherein the aqueous binder is an acrylic binder, a silicone binder, a urea-formaldehyde binder, or a mixture thereof.
- 93. The method of claim 92, wherein the aqueous binder is an acrylic binder.
- 94. The method of claim 81, wherein the aerogel binder composition has a thermal conductivity of about 40 mW/(m·K) or less.
- 95. The method of claim 81, wherein the aerogel binder composition has a density of about 0.5 g/cm3 or less.
- 96. An aerogel binder composition prepared by the method of claim 81.
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims priority to provisional U.S. Patent Application No. 60/352,671 filed on Jan. 29, 2002 and provisional U.S. Patent Application No. 60/381,215 filed on May 15, 2002.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60352671 |
Jan 2002 |
US |
|
60381215 |
May 2002 |
US |