High strength aerogel panels

Abstract

Embodiments of the present invention describe a structure comprising at least one fiber-reinforced aerogel layer and at least one binder layer, said binder layer comprising a silicon-containing organic material and where the binder layer is bonded to at least one surface of a fiber-reinforced aerogel layer.

1 . A structure comprising: at least one fiber-reinforced aerogel layer and at least one binder layer, said binder layer comprising a silicon-containing organic material and wherein the binder layer is bonded to at least one surface of a fiber-reinforced aerogel layer.  
     
     
         2 . The structure of  claim 1  further comprising at least two fiber-reinforced aerogel layers wherein said binder layer is positioned between said two fiber-reinforced aerogel layers and bonded to at least one surface of each.  
     
     
         3 . The structure of  claim 1  wherein said structure is bonded to a non-aerogel surface such that the binder layer is simultaneously boded to the aerogel layer and the non-aerogel surface.  
     
     
         4 . The structure of  claim 1  wherein the silicon-containing organic material comprises at least one acrylic moiety.  
     
     
         5 . The structure of  claim 1  wherein the silicon-containing organic material comprises siloxane linkages.  
     
     
         6 . The structure of  claim 1  wherein the fiber reinforced aerogel layer is reinforced with a batting, a matt or a felt or a combination thereof.  
     
     
         7 . The structure of  claim 1  wherein the fiber reinforced aerogel layer comprises an inorganic component.  
     
     
         8 . The structure of  claim 7  wherein the fiber reinforced aerogel layer comprises silica.  
     
     
         9 . The structure of  claim 1  wherein the fiber reinforced aerogel layer comprises an organic component.  
     
     
         10 . The structure of  claim 9  wherein the aerogel material comprises an acrylic.  
     
     
         11 . The structure of  claim 1  wherein a chemical bond is formed between the binder layer and the fiber-reinforced aerogel layer.  
     
     
         12 . The structure of  claim 11  wherein the chemical bond is a siloxane bond.  
     
     
         13 . The structure of  claim 11  further comprising biocide compounds, anti-fungal compounds, flame retardant compounds, B 4 C, Diatomite, Manganese ferrite, MnO, NiO, SnO , Ag 2 O, Bi 2 O 3 , TiC, WC, carbon black, titanium oxide, iron titanium oxide, zirconium silicate, zirconium oxide, iron (I) oxide, iron (III) oxide, manganese dioxide, iron titanium oxide (ilmenite), chromium oxide, silicon carbide or any combination thereof.  
     
     
         14 . A method of preparing a structure comprising: 
 providing at least one layer of a fiber-reinforced aerogel material;    applying a silicon-containing organic compound on at least one surface of the aerogel layer; and    directing an amount of energy onto said silicon-containing organic layer, said energy sufficient to:    initiate polymerization of said silicon-containing organic compound thereby resulting in a binder layer, and    to initiate forming of chemical bonds between the silicon-containing organic compound and the aerogel layer.    
     
     
         15 . The method of  claim 14  wherein the binder layer comprises oligomers.  
     
     
         16 . The method of  claim 14  wherein the silicon-containing organic compound comprises at least one alkoxysilyl segment.  
     
     
         17 . The method of  claim 14  wherein the silicon-containing organic compound comprises at least one acrylic moiety.  
     
     
         18 . The method of  claim 14  wherein the fiber-reinforced aerogel layer comprises a batting, matt, felt or a combination thereof.  
     
     
         19 . The method of  claim 14  wherein the energy is. heat, electromagnetic energy, infrared energy, an x-ray energy, a microwave energy, a gamma ray energy, acoustic energy, ultrasound energy, particle beam energy, electron beam energy, beta particle energy, an alpha particle energy, or combinations thereof.  
     
     
         20 . The method of  claim 14  wherein at least one layer of fiber-reinforced aerogel comprises a batting, felt, matt or a combination thereof.  
     
     
         21 . A structure according to any one of  claims 14  to  20 .