Low density closed cell composite aerogel foam and articles including same
A composite foam is provided having silica aerogel particles dispersed in a closed cell polymeric foam. The silica aerogel particles are included in a volume fraction between 2 and 60%, and the composite foam has a thermal conductivity of 40 kW/mK or less and a density of 60 kg/m 3 or less. In another embodiment, a composite foam is provided having a perforated closed cell polymeric foam and 2-60% hydrophobic silica aerogel particles by volume with a particle size distribution of 1 to 50 μm, where the composite foam has a thermal conductivity of 30 kW/mK or less, a density of 20-45 kg/m 3 , and an air permeability of 20-40 cubic feet per minute.
1. A composite foam comprising:
silica aerogel particles dispersed in a closed cell polymeric foam,
wherein the composite foam includes the silica aerogel particles in a volume fraction between 2 and 60%, and has a thermal conductivity of 40 kW/mK or less and a density of 60 kg/m 3 or less, and is perforated with an air permeability of 5-60 cubic feet per minute.
2. The composite foam of claim 1 , wherein the density is 50 kg/m 3 or less.
3. The composite foam of claim 1 , wherein the density is 20-45 kg/m 3 .
4. The composite foam of claim 1 , wherein the density is 30-40 kg/m 3 .
5. The composite foam of claim 1 , wherein the thermal conductivity is 30 kW/mK or less.
6. The composite foam of claim 1 , wherein the silica aerogel particles are hydrophobic.
7. The composite foam of claim 6 , wherein a water absorption of the composite foam is 0.1% by volume or less.
8. The composite foam of claim 1 , wherein the composite foam has an average thickness between 1.5 to 6 mm.
9. The composite foam of claim 1 , wherein the composite foam includes perforations having a diameter of 1 mm or less.
10. The composite foam of claim 1 , wherein the silica aerogel particles are included in a volume fraction from 3-40%.
11. The composite foam of claim 1 , wherein the silica aerogel particles have a particle size distribution of 0.1-100 microns.
12. The composite foam of claim 1 , wherein the silica aerogel particles have a particle size distribution of 0.5-70 microns.
13. The composite foam of claim 1 , wherein the silica aerogel particles have a particle size distribution of 1-50 microns.
14. The composite foam of claim 1 , wherein the silica aerogel particles have a median particle size of 2-10 microns.
15. A composite foam comprising:
silica aerogel particles dispersed in a closed cell polymeric foam,
wherein the composite foam includes the silica aerogel particles in a volume fraction between 2 and 60%, and has a thermal conductivity of 40 kW/mK or less and a density of 60 kg/m 3 or less, and the silica aerogel particles have a particle size distribution of 0.5-50 microns with a d(10) in the range of 1-3 microns, a d(90) in the range of 8-30 microns, and a d(50) in the range of 2-7 microns.
16. The composite foam of claim 1 , further comprising a flame inhibiting chemical.
17. The composite foam of claim 1 , further comprising an anti-microbial agent.
18. The composite foam of claim 1 , wherein the composite foam has a face surface and a back surface, the composite foam further comprising:
a textile laminated on at least one of the face surface or the back surface.
19. A composite foam comprising:
a perforated closed cell polymeric foam; and
2-60% hydrophobic silica aerogel particles by volume having a particle size distribution of 1 to 50 μm, wherein the silica aerogel particles have a particle size distribution with a d(10) in the range of 1-3 microns, a d(90) in the range of 8-30 microns, and a d(50) in the range of 2-7 microns,
wherein the composite foam has a thermal conductivity of 30 kW/mK or less, a density of 20-45 kg/m 3 , and an air permeability of 20-40 cubic feet per minute.
20. The composite foam of claim 19 , wherein a water absorption of the composite foam is 0.1% by volume or less.
21. The composite foam of claim 19 , wherein the composite foam has an average thickness between 1.5 to 6 mm.
22. The composite foam of claim 19 , wherein the perforated closed cell polymeric foam includes perforations having a diameter of 1 mm or less.
23. The composite foam of claim 19 , wherein the composite foam has a face surface and a back surface, the composite foam further comprising:
a textile laminated on at least one of the face surface or the back surface.