IP Library › Granted Patent US 12,516,156
Granted Patent B2
US 12,516,156 · App. 18/352,881 · Granted Jan 6, 2026

Aerogel compositions and manufacturing thereof

Inventors: Shannon Olga White (Hudson, MA); Nicholas Anthony Zafiropoulos (Wayland, MA); Jimmy Lee Clark (Newhall, CA)
Assignee: Aspen Aerogels, Inc.
C08G73/10B32B3/04B32B3/266B32B5/10B32B5/18B32B5/32B32B27/281C08G73/1067C08K3/04C08K7/06C08L79/08F16L59/028B32B2266/0214B32B2266/0292B32B2266/04B32B2266/057B32B2266/06B32B2266/102B32B2266/126B32B2307/302B32B2307/304B32B2307/416B32B2307/546B32B2307/72B32B2605/18C08G2110/0091C08G2330/00Y10T428/233Y10T428/249953Y10T428/249986
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Quick Facts
Patent No.
US 12,516,156
App. No.
18/352,881
Granted
Jan 6, 2026
Kind
B2
Abstract

The present invention provides compositions and methods related to aerogel materials, including polyimide-based aerogels. In particular, aerogel materials optimized to have certain physical and chemical properties such as flexural and compressive strength are provided. In some embodiments, the aerogel materials can be at least partially carbonized.

Claims (34)

1 . An aerogel laminate panel comprising:

a reinforced layer comprising a polyimide aerogel and a carbon fiber batting material, the reinforced layer having a first major face and a second major face,

wherein the reinforced layer has a flexural strength in a range of about 105 psi to about 275 psi and a compressive Young's modulus in a range of about 182 psi to about 215 psi; and

a facesheet on the first major face of the reinforced layer comprising the polyimide aerogel.

2 . The aerogel laminate panel of claim 1 , wherein the facesheet is on both the first major face and the second major face, the facesheet further comprising edge seals.

3 . The aerogel laminate panel of claim 2 , further comprising a vent, wherein the vent allows gas to flow into and out of the aerogel laminate panel.

4 . The aerogel laminate panel of claim 3 , wherein the vent further comprises a particulate filter.

5 . The aerogel laminate panel of claim 1 , further comprising an additional facesheet on the second major face of the reinforced layer comprising the polyimide aerogel.

6 . The aerogel laminate panel of claim 5 , further comprising at least one edge seal connecting the facesheet and the additional facesheet.

7 . The aerogel laminate panel of claim 6 , wherein the at least one edge seal further comprises:

a vent; and

wherein the vent allows gas to flow into and out of the aerogel laminate panel.

8 . The aerogel laminate panel of claim 7 , wherein the vent further comprises a particulate filter.

9 . The aerogel laminate panel of claim 1 , further comprising an energy-reflective layer adjacent to the facesheet.

10 . The aerogel laminate panel of claim 1 , further comprising silica, or an opacifier, or both incorporated into the polyimide aerogel.

11 . The aerogel laminate panel of claim 1 , wherein the flexural strength of the reinforced layer is between about 200 psi and about 275 psi.

12 . The aerogel laminate panel of claim 1 , wherein the reinforced layer has a density between 0.01 g/cc and 0.30 g/cc and a thermal conductivity at ambient temperature and ambient pressure of between 15 mW/m-K and 30 mW/m-K.

13 . An aerogel laminate panel comprising:

a layer comprising a polyimide aerogel, the layer having a first major face and a second major face;

a facesheet on the first major face of the layer comprising the polyimide aerogel; and

a vent that allows gas to flow into and out of the layer;

wherein the layer has a flexural strength in a range of about 105 psi to about 275 psi.

14 . The aerogel laminate panel of claim 13 , wherein the facesheet is on both the first major face and the second major face, the facesheet further comprising edge seals.

15 . The aerogel laminate panel of claim 13 , wherein the vent further comprises a particulate filter.

16 . The aerogel laminate panel of claim 13 , further comprising an additional facesheet on the second major face of the layer comprising the polyimide aerogel.

17 . The aerogel laminate panel of claim 16 , further comprising at least one edge seal connecting the facesheet and the additional facesheet.

18 . The aerogel laminate panel of claim 17 , wherein the at least one edge seal includes the vent.

19 . The aerogel laminate panel of claim 18 , wherein the vent further comprises a particulate filter.

20 . The aerogel laminate panel of claim 13 , further comprising an energy-reflective layer adjacent to the facesheet.

21 . The aerogel laminate panel of claim 13 , further comprising silica, or an opacifier, or both incorporated into the polyimide aerogel.

22 . The aerogel laminate panel of claim 13 , wherein the polyimide aerogel further comprises a reinforcement material.

23 . The aerogel laminate panel of claim 22 , wherein the flexural strength of the layer is between about 200 psi and about 275 psi.

24 . The aerogel laminate panel of claim 22 , wherein the layer has a compressive Young's modulus in the range of about 182 psi to about 215 psi.

25 . The aerogel laminate panel of claim 13 , wherein the layer has a density between 0.01 g/cc and 0.30 g/cc and a thermal conductivity at ambient temperature and ambient pressure of between 15 mW/m-K and 30 mW/m-K.

Assignments (2)
SECURITY INTEREST Recorded Aug 28, 2024
From: ASPEN AEROGELS, INC.; ASPEN AEROGELS RHODE ISLAND, LLC
To: MIDCAP FUNDING IV TRUST
Reel/Frame 068792/0245 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 14, 2023
From: WHITE, SHANNON OLGA; ZAFIROPOULOS, NICHOLAS ANTHONY; CLARK, JIMMY LEE
To: ASPEN AEROGELS, INC.
Reel/Frame 064264/0215 →
Continuity (6)
Division 17360296 · Jun 28, 2021
Continuation 16371184 · Apr 1, 2019
Continuation 15419633 · Jan 30, 2017
Division 14202873 · Mar 10, 2014
Provisional Application 61774660 · Mar 8, 2013
Related Publication 20230357504A1 · Nov 9, 2023
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