Metal form containing dispersed aerogel particles impregnated with polymers and a method of producing the same

Abstract

A composite structure including a metal form. The composite structure further includes an aerogel matrix formed of an aerogel, with the aerogel matrix being nanoporous and including a plurality of aerogel pores. A polymer occupies at least a portion of the aerogel pores of the aerogel matrix. The polymer is a thermoplastic. The thermoplastic is nanoporous and includes a plurality of thermoplastic pores. The thermoplastic pores are less than 10 nanometers in size. The polymer is impregnated within the aerogel pores of the aerogel matrix. The aerogel comprises at least 20% by weight of the composite structure. The aerogel pores are less than 10 nanometers in size. The composite structure further contains filler material. The filler material may be graphene. The composite structure further contains reinforcing agents.

What is claimed is: 
     
         1 . A composite structure comprising,
 an aerogel matrix formed of an aerogel, wherein the aerogel matrix is nanoporous and includes a plurality of aerogel pores dispersed throughout the aerogel matrix, and   a polymer occupying at least a portion of the aerogel pores.   
     
     
         2 . The composite structure of  claim 1 , wherein the polymer is selected from a group consisting of polystyrene, expandable styrene, or MMA copolymer. 
     
     
         3 . The composite structure of  claim 1 , wherein the polymer is a thermoplastic. 
     
     
         4 . The composite structure of  claim 3 , wherein the thermoplastic is nanoporous and includes a plurality of thermoplastic pores. 
     
     
         5 . The composite structure of  claim 4 , wherein the thermoplastic pores are less than 10 nanometers in size. 
     
     
         6 . The composite structure of  claim 3 , wherein the thermoplastic is crystalline. 
     
     
         7 . The composite structure of  claim 3 , wherein the thermoplastic is semi-crystalline. 
     
     
         8 . The composite structure of  claim 3 , wherein the thermoplastic is amorphous. 
     
     
         9 . The composite structure of  claim 1 , wherein the aerogel matrix comprises at least 20% by weight of the composite structure. 
     
     
         10 . The composite structure of  claim 1 , wherein the aerogel pores are less than 10 nanometers in size. 
     
     
         11 . The composite structure of  claim 1 , wherein the polymer is impregnated within the aerogel matrix. 
     
     
         12 . The composite structure of  claim 1 , wherein the composite structure further contains filler material. 
     
     
         13 . The composite structure of  claim 12 , wherein the filler material comprises graphene. 
     
     
         14 . The composite structure of  claim 1 , wherein the composite structure further contains reinforcing agents. 
     
     
         15 . A method of producing a composite structure of aerogel and thermoplastic, the method including the steps of:
 forming a first mixture including a polymer, a suspension of gel particles, and at least one solvent;   solidifying the first mixture to form a solidified mixture;   drying the solidified mixture to remove the remaining solvent.   
     
     
         16 . The method of  claim 15 , wherein solidifying the first mixture to form a solidified mixture includes cooling the mixture at a rate of greater than or equal to 0.2° C. 
     
     
         17 . The method of  claim 15 , wherein solidifying the first mixture to form a solidified mixture includes evaporating a portion of at least one of the solvents. 
     
     
         18 . The method of  claim 15 , wherein the solidified mixture is placed into a solvent bath that is at least partially miscible with at least one of the solvents in the solidified mixture, and where the polymer in the solidified mixture is insoluble in the solvent bath to precipitate a plastic phase through solvent exchange prior to drying the solidified mixture. 
     
     
         19 . The method of  claim 15 , wherein drying the solidified mixture to remove the remaining solvent includes ambient pressure drying. 
     
     
         20 . The method of  claim 15 , wherein drying the solidified mixture to remove the remaining solvent includes supercritical carbon dioxide drying. 
     
     
         21 . The method of  claim 20 , wherein drying the solidified mixture to remove the remaining solvent by supercritical fluid drying includes freeze drying the solidified mixture. 
     
     
         22 . The method of  claim 21 , wherein the freeze drying of the solidified mixture is accomplished through carbon dioxide freeze drying. 
     
     
         23 . The method of  claim 15 , wherein the mixture further includes filler material. 
     
     
         24 . The method of  claim 23 , wherein the filler material is selected from a group consisting of graphene oxide, boron nitride, Molybdenum disulfide, and Tungsten disulfide. 
     
     
         25 . The method of  claim 15 , wherein the mixture further includes reinforcing agents.