Faced aerogel article and a molding process therefor

Abstract

A molded article includes an aerogel layer and a surface layer which is vacuum formed to the aerogel layer. The aerogel layer provides the structural support for the article heretofore performed by chopped fiberglass. Do to the porosity of the aerogel layer, the vacuum is drawn directly through the aerogel layer such that the aerogel layer forms the mold for the surface layer which attaches thereto.

1 . A molded article comprising: 
 a gel layer; and    a surface layer vacuum formed to said gel layer.    
   
   
       2 . The molded article as recited in  claim 1 , wherein said gel layer comprises a dried aerogel layer.  
   
   
       3 . The molded article as recited in  claim 1 , wherein said gel layer comprises a xerogel layer.  
   
   
       4 . The molded article as recited in  claim 1 , wherein said gel layer comprises a cryogel layer.  
   
   
       5 . The molded article as recited in  claim 1 , wherein said gel layer comprises a supercritical dried aerogel layer.  
   
   
       6 . The molded article as recited in  claim 1 , wherein said surface layer comprises an acrylic.  
   
   
       7 . The molded article as recited in  claim 1 , wherein said surface layer comprises a plastic.  
   
   
       8 . The molded article as recited in  claim 1 , wherein said article comprises a dish shaped member.  
   
   
       9 . The molded article as recited in  claim 8 , wherein said article comprises a bathtub.  
   
   
       10 . The molded article as recited in  claim 8 , wherein said article comprises a sink.  
   
   
       11 . A method of molding an article comprising the steps of: 
 (1) molding an aerogel to a desired shape; and    (2) vacuum forming a surface layer to the aerogel after said step (1).    
   
   
       12 . A method as recited in  claim 11 , further comprising the step of: 
 drying the aerogel prior to said step (2).    
   
   
       13 . A method as recited in  claim 11 , further comprising the step of: 
 freeze-drying the aerogel prior to said step (2).    
   
   
       14 . A method as recited in  claim 10 , further comprising the step of: 
 supercritical drying of the aerogel prior to said step (2).    
   
   
       15 . A method as recited in  claim 10 , wherein said step (2) further comprises the step of: 
 drawing the vacuum through the aerogel.    
   
   
       16 . A method as recited in  claim 10 , wherein said step (2) further comprises the step of: 
 drawing the vacuum through the aerogel which forms a mold for the surface layer.    
   
   
       17 . A molded article comprising: 
 a first layer comprising a porosity which permits a vacuum to be drawn therethrough; and    a surface layer vacuum formed to said first layer.    
   
   
       18 . The molded article as recited in  claim 17 , wherein said first layer comprises a dried aerogel layer.  
   
   
       19 . The molded article as recited in  claim 17 , wherein said surface layer comprises an acrylic.  
   
   
       20 . A method of molding an article comprising the steps of: 
 (1) providing a surface layer of a desired shape;    (2) applying a gel layer to the surface layer; and    (3) curing the gel layer.    
   
   
       21 . A method as recited in  claim 20 , further comprising the step of: 
 spraying the gel layer upon the surface layer.