IP Library › Granted Patent US 12,257,562
Granted Patent B2
US 12,257,562 · App. 18/072,436 · Granted Mar 25, 2025

Tailoring of pores in aerogels using 3D printed structures

Inventors: Swetha Chandrasekaran (Dublin, CA); Theodore F. Baumann (Discovery Bay, CA); Juergen Biener (San Leandro, CA); Patrick Campbell (Oakland, CA); James S. Oakdale (Castro Valley, CA); Marcus A. Worsley (Hayward, CA)
Assignee: Lawrence Livermore National Security, LLC
B01J13/0091B33Y10/00B33Y80/00C01B13/18C01B32/05
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Quick Facts
Patent No.
US 12,257,562
App. No.
18/072,436
Granted
Mar 25, 2025
Kind
B2
Abstract

A method includes acquiring a three-dimensional printed template created using an additive manufacturing technique, infilling the template with an aerogel precursor solution, allowing formation of a sol-gel, and converting the sol-gel to an aerogel.

Claims (22)

1. A method, comprising:

acquiring a three-dimensional printed template created using an additive manufacturing technique, wherein lengths of at least some continuous portions of the template extend an entire length of the template;

infilling the template with an aerogel precursor solution;

allowing formation of a sol-gel; and

converting the sol-gel to an aerogel.

2. The method of claim 1 , comprising removing the template.

3. The method of claim 2 , wherein the template is removed by pyrolization.

4. The method of claim 2 , wherein the template is removed by application of a solvent thereto.

5. The method of claim 2 , wherein the aerogel has defined regions with different densities upon removal of the template therefrom.

6. The method of claim 5 , wherein the defined regions of different densities correspond to pores in the aerogel defined by features of the template.

7. The method of claim 2 , wherein a pore structure of the aerogel is defined by features of the template.

8. The method of claim 7 , wherein the pore structure includes a population of micron-size pores that correspond to an inner channel for mass transport across the aerogel.

9. The method of claim 7 , wherein the pore structure includes population of nanometer-size pores that correspond to nanoscale features on the template.

10. The method of claim 2 , wherein a pore structure of the aerogel is characterized as being oriented along one direction.

11. The method of claim 2 , wherein the continuous portions of the template comprise length scales of a log-pile architecture.

12. The method of claim 2 , wherein the aerogel has inner channels corresponding to outer walls of the template around which the aerogel was formed, wherein at least some of the channels extend continuously along an entire length of the aerogel.

13. The method of claim 1 , wherein converting the sol-gel to the aerogel includes pyrolyzing the sol-gel.

14. The method of claim 1 , wherein the template remains after conversion of the sol-gel to the aerogel.

15. The method of claim 1 , wherein the aerogel is carbonaceous.

16. The method of claim 1 , wherein the aerogel includes a metal oxide.

17. The method of claim 1 , wherein the template is created using a photo-activated resist.

18. The method of claim 1 , comprising creating the template.

Assignments (2)
CONFIRMATORY LICENSE (SEE DOCUMENT FOR DETAILS) Recorded Dec 21, 2022
From: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC
To: U.S. DEPARTMENT OF ENERGY
Reel/Frame 062201/0958 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 7, 2022
From: CHANDRASEKARAN, SWETHA; BAUMANN, THEODORE F.; BIENER, JUERGEN; CAMPBELL, PATRICK; OAKDALE, JAMES S.; WORSLEY, MARCUS A.
To: LAWRENCE LIVERMORE NATIONAL SECURITY, LLC
Reel/Frame 062017/0340 →
Continuity (2)
Division 15208506 · Jul 12, 2016
Related Publication 20230106574A1 · Apr 6, 2023
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