Insulating structures
Described herein are insulating structures that include at least one microporous layer including a plurality of pores, a porous layer adjacent to the microporous layer, and a monolithic aerogel structure extending through the plurality of pores of the microporous layer and through at least part of the porous layer. The microporous layer filters aerogel dust from cracked or damaged aerogel within the scaffold, slowing or preventing loss of dust from the insulating structures.
1. An insulating structure comprising:
a scaffold comprising:
at least one microporous film,
wherein the at least one microporous film is not a fibrous layer including microporous fibers, and
wherein the at least one microporous film comprises an expanded fluoropolymer film, expanded polytetrafluoroethylene (ePTFE) film, expanded polyethylene (ePE) film, or expanded polypropylene (ePP) film,
at least one porous layer adjacent to the at least one microporous film, and
an aerogel structure,
wherein a portion of the aerogel structure extends through at least a portion of the at least one microporous film and also extends through at least a portion of the adjacent porous layer, and
wherein the at least one microporous film has a smaller average pore size than the porous layer.
2. The insulating structure of claim 1 , wherein the porous layer comprises a foam layer or a textile layer.
3. An insulating structure comprising:
a scaffold comprising:
at least two microporous films,
wherein the at least two microporous films are not fibrous layers including microporous fibers,
at least one porous layer, and
an aerogel structure,
wherein the at least two microporous films are adjacent to the at least one porous layer on opposite sides of the porous layer,
wherein a portion of the aerogel structure extends through at least a portion of the at least two microporous films and also extends through at least a portion of the at least one porous layer,
wherein the at least two microporous films comprise expanded polytetrafluoroethylene (ePTFE)
and wherein the at least two microporous films each have a smaller average pore size than the porous layer.
4. The insulating structure of claim 3 , wherein the ePTFE film comprises a pore size from 0.03 μm to 210 μm.
5. An insulating structure comprising:
a scaffold comprising:
at least one microporous film,
wherein the at least one microporous film is not a fibrous layer including microporous fibers,
at least one porous layer adjacent to the at least one microporous film,
wherein the porous layer comprises a foam layer or a textile layer, and
an aerogel structure,
wherein a portion of the aerogel structure extends through at least a portion of the at least one microporous film and also extends through at least a portion of the adjacent porous layer, and
wherein the at least one microporous film has a smaller average pore size than the porous layer.