Thin aerogel materials
The present invention provides a fiber-reinforced aerogel material which can be used as insulation. The fiber-reinforced aerogel material is highly durable, flexible, and has a thermal performance that exceeds the insulation materials currently used. The fiber-reinforced aerogel insulation material can be as thin as 1 mm or less, and can have a thickness variation as low as 2% or less. Also provided is a method for improving the performance of a battery by incorporating a reinforced aerogel material into the battery. Further provided is a casting method for producing thin fiber-reinforced aerogel materials.
1. A method for producing a reinforced aerogel composite, the method comprising:
combining a sol-gel solution and a reinforcement material;
applying pressure to the combined sol-gel solution and reinforcement, wherein the applied pressure defines a thickness of the combined sol-gel solution and reinforcement;
allowing the sol-gel solution to form a reinforced gel composite;
drying the reinforced gel composite to form a reinforced aerogel composite; and
wherein, responsive to the applied pressure, the reinforced aerogel composite has a thickness of from 0.75 millimeters (mm) to 10 mm and a thickness variation of less than 15%.
2. The method of claim 1 , wherein combining a sol-gel solution and a reinforcement material further comprises combining the sol-gel solution and the reinforcement material within a casting frame on a casting surface.
3. The method of claim 2 , wherein applying pressure further comprises:
placing a sheet on a side of the combined sol-gel solution and reinforcement material opposite the casting surface; and
applying pressure to the sheet.
4. The method of claim 2 , wherein the casting frame includes features to form one or more of holes, depressions, protrusions, and patterns in the reinforced aerogel composite.
5. The method of claim 1 , wherein the reinforcement material comprises an open-cell foam reinforcement material.
6. The method of claim 1 , wherein the reinforcement material comprises a fiber reinforcement material.
7. The method of claim 6 , wherein the fiber reinforcement material comprises discrete fibers, a woven material, a non-woven material, a batting, a web, a mat, a felt, or a combination thereof.
8. The method of claim 6 , wherein the fiber reinforcement material comprises glass-based fibers.
9. The method of claim 6 , wherein the fiber reinforcement material comprises silica-based fibers.
10. The method of claim 9 , wherein the reinforced aerogel composition has a thermal conductivity in a range of about 12 mW/mK and about 20.
11. The method of claim 6 , wherein the fiber reinforcement material comprises ceramic fibers.
12. The method of claim 6 , wherein the fiber reinforcement material comprises polyacrylonitrile (PAN) fibers or oxidized PAN fibers.
13. The method of claim 1 , wherein the thickness variation is less than 6%.
14. The method of claim 13 , wherein the reinforced aerogel composition has a thermal conductivity of between about 12 mW/mK and about 50 mW/mK.
15. The method of claim 1 , wherein the thickness variation is from 2% to less than 15%.
16. The method of claim 1 , wherein the reinforced aerogel composition has a thermal conductivity of about 25 mW (milliWatts)/mK (meter-Kelvin) or less.
17. The method of claim 1 , wherein the reinforced aerogel composition includes a silica-based framework.
18. The method of claim 1 , wherein the reinforced aerogel composition includes an organic aerogel.
19. The method of claim 1 , wherein the thickness is from 1 mm to 2 mm.
20. A method of forming a battery thermal insulating layer comprising:
fabricating a reinforced aerogel composite including;
combining a sol-gel solution and a reinforcement material;
applying pressure to the combined sol-gel solution and reinforcement, wherein the applied pressure defines a thickness of the combined sol-gel solution and reinforcement;
allowing the sol-gel solution to form a reinforced gel composite;
drying the reinforced gel composite to form a reinforced aerogel composite; and
wherein, responsive to the applied pressure, the reinforced aerogel composite has a thickness of from 0.75 millimeters (mm) to 10 mm and a thickness variation of less than 15%; and
incorporating the reinforced aerogel composition into a battery.