Secured Aerogel Composites and Methods of Manufacture Thereof
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.