Method of producing a metal form containing dispersed aerogel particles impregnated with polymers

Abstract

A method of producing a metal form containing dispersed aerogel particles impregnated with polymers comprising a method of impregnating an aerogel with polymers, placing the aerogel impregnated with polymers within a dissolved polymer, cooling the dissolved polymer to create a polymer form with dispersed aerogel particles impregnated with polymers, adding molten metal to the polymer form, vaporizing the polymer form, replacing the polymer form with molten metal, and cooling the molten metal to yield a metal form containing dispersed aerogel particles impregnated with polymers. Dispersing the aerogel particles impregnated with polymers within the polymer form prior to adding molten metal allows the aerogel particles to be fully dispersed throughout the metal form.

What is claimed is: 
     
         1 . A method of producing a metal form containing dispersed aerogel particles impregnated with polymers, said method comprising the steps of;
 (a) creating a mixture of polymers and aerogel particles having pores,   (b) dilating the pores of the aerogel particles,   characterized by,   (c) impregnating the aerogel particles with polymers within the mixture creating aerogel particles impregnated with polymers.   (d) dispersing the aerogel particles impregnated with polymers into a dissolved polymer creating a dispersed mixture,   (e) placing the dispersed mixture into a mold,   (f) freezing the dispersed mixture within the mold creating a polymer form containing dispersed aerogel particles impregnated with polymers,   (g) vaporizing the polymer form containing dispersed aerogel particles impregnated with polymers with molten metal, and   (h) replacing the polymer form with molten metal creating a metal form containing dispersed aerogel particles impregnated with polymers.   
     
     
         2 . The method of  claim 1 , further comprising:
 (i) cooling the metal form containing dispersed aerogel particles impregnated with polymers, and   (j) removing the metal form containing dispersed aerogel particles impregnated with polymers from the mold to yield a metal form containing dispersed aerogel particles impregnated with polymers having the shape of the mold.   
     
     
         3 . A method of producing an aerogel impregnated with polymers, said method comprising the steps of;
 (a) creating a mixture of polymers and aerogel particles having pores,   (b) dilating the pores of the aerogel particles,   characterized by,   (c) impregnating the aerogel particles with polymers within the mixture creating aerogel particles impregnated with polymers.   
     
     
         4 . The method of  claim 3 , further comprising:
 (d) placing the aerogel particles impregnated with polymers into a mold,   (e) freezing the aerogel particles impregnated with polymers within the mold,   (f) removing the aerogel particles impregnated with polymers from the mold, and   (g) subliming the aerogel particles impregnated with polymers to yield an aerogel impregnated with polymers having the shape of the mold.   
     
     
         5 . A method of producing a metal form containing dispersed aerogel particles, said method comprising the steps of;
 (a) vaporizing a polymer form containing dispersed aerogel particles with molten metal, and   (b) replacing the polymer form with molten metal creating a metal form containing dispersed aerogel particles.   
     
     
         6 . The method of  claim 5 , further comprising:
 creating a mixture of polymers and aerogel particles prior to step (a),   placing the mixture into a mold prior to step (a), and   freezing the mixture within the mold creating a polymer form containing dispersed aerogel particles prior to step (a).   
     
     
         7 . The method of  claim 5 , further comprising:
 (c) cooling the metal form containing dispersed aerogel particles, and   (d) removing the metal form containing dispersed aerogel particles from the mold to yield a metal form containing dispersed aerogel particles having the shape of the mold.