Secured Aerogel Composites and Methods of Manufacture Thereof

Abstract

Embodiments of the present invention describe secured fiber-reinforced aerogels and laminate structures formed therefrom. In one embodiment a laminate comprises at least one fiber-reinforced aerogel layer adjacent to at least one layer of fiber-containing material wherein fibers from said at least one fiber-reinforced aerogel layer are interlaced with fibers of said at least one fiber-containing material. In another embodiment a laminate comprises at least two adjacent fiber-reinforced aerogel layers wherein fibers from at least one fiber-reinforced aerogel layer are interlaced with fibers of an adjacent fiber-reinforced aerogel layer.

1 . A laminate comprising at least one fiber-reinforced aerogel layer adjacent to at least one layer of fiber-containing material wherein fibers from said at least one fiber-reinforced aerogel layer are interlaced with fibers of said at least one fiber-containing material.  
     
     
         2 . The laminate of  claim 1  wherein the layer of fiber-containing material comprises a fiber-reinforced foam composite or fiber-reinforced polymeric composite.  
     
     
         3 . The laminate of  claim 1  wherein the layer of fiber-containing material or fiber-reinforced aerogel comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof.  
     
     
         4 . The laminate of  claim 1  further comprising a functional layer that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive.  
     
     
         5 . A laminate comprising at least two adjacent fiber-reinforced aerogel layers wherein fibers from at least one fiber-reinforced aerogel layer are interlaced with fibers of an adjacent fiber-reinforced aerogel layer.  
     
     
         6 . The laminate of  claim 5  wherein the fiber-reinforced aerogel layer comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof.  
     
     
         7 . The laminate of  claim 5  further comprising a functional layer that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive.  
     
     
         8 . A method of securing at least one fiber-reinforced aerogel layer to at least one layer of a fiber-containing material comprising: 
 a) disposing a laminate comprising at least one layer of a fiber-containing material adjacent to at least one fiber-reinforced aerogel layer where at least one layer being a top layer that defines an exposed surface; and    b) penetrating said laminate through said exposed surface with at least one felting needle thereby interlacing fibers within the laminate.    
     
     
         9 . A method of securing at least one fiber-reinforced gel composite to at least one fibrous layer comprising: 
 a) disposing a laminate comprising at least two layers of adjacent fiber reinforced aerogels where at least one layer being a top layer that defines an exposed surface; and    b) penetrating said laminate through said exposed surface with at least one felting needle thereby interlacing fibers within the laminate.    
     
     
         10 . The method of  claim 8  wherein the layer of fiber-containing material or fiber-reinforced aerogel comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof.  
     
     
         11 . The method of  claim 8  further comprising a functional layer that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive.  
     
     
         12 . A method of securing at least one fiber-reinforced gel composite to at least one fibrous layer comprising: 
 a) disposing a laminate comprising at least two layers of adjacent fiber reinforced aerogels where at least one layer being a top layer that defines an exposed surface; and    c) penetrating said laminate through said exposed surface with at least one needle and at least one yarn thereby quilting or stitch bonding the layers of the laminate.