Macroporous-structured polymer aerogels
A macroporous-structured polymeric aerogel, and methods for making and using the same, having a polymeric matrix that includes macropores is disclosed.
1 . An evaporative air dried and thermally dried macroporous-structured polymeric material in the form of a film having an organic polymeric matrix with an average pore size of 100 nanometer (nm) to 800 nm, wherein at least 50% of the polymeric material's pore volume is made up of pore sizes greater than 100 nm, wherein the polymeric material is not-crosslinked, and wherein the evaporative air drying is at a temperature of 20° C. to 30° C. and the thermal drying is at a temperature of at least 50° C.
2 . The macroporous-structured polymeric material of claim 1 , wherein at least 75% of the material's pore volume is made up of pore sizes greater than 100 nm.
3 . The macroporous-structured polymeric material of claim 1 , wherein at least 95% of the material's pore volume is made up of pore sizes greater than 100 nm.
4 . The macroporous-structured polymeric organic material of claim 1 , wherein the organic polymeric matrix is a polyimide matrix.
5 . The macroporous-structured polymeric organic material of claim 1 , wherein the material is in the form of the film having a first surface and an opposing second surface,
wherein the material is attached to a support layer having a first surface and an opposing second surface such that an interface is formed between a portion of the first surface of the film and a portion of the second surface of the support layer, and
wherein a majority of the volume of the film does not include the support layer.
6 . The macroporous-structured polymeric organic material of claim 5 , wherein the support layer is a fiber support layer.
7 . The macroporous-structured polymeric organic material of claim 6 , wherein the fiber support is a woven fiber support, a knitted fiber support, a non-woven fiber support, or a paper.
8 . The macroporous-structured polymeric organic material of claim 5 , having a flex fatigue of at least 100,000 cycles to failure.
9 . The macroporous-structured polymeric organic material of claim 5 , wherein the entire interface is positioned within the volume of the polymeric organic material film.
10 . The macroporous-structured polymeric organic material of claim 5 , wherein the entire volume of the support layer is positioned within the volume of the polymeric organic material film.
11 . The macroporous-structured polymeric organic material of claim 5 , wherein a portion of the volume of the support layer is positioned within the volume of the polymeric organic material film and a second portion of the volume of the support layer is positioned outside the volume of the polymeric organic material film.
12 . The macroporous-structured polymeric organic material of claim 5 , wherein the film is rolled-up such that the film is in the form of a roll.
13 . The macroporous-structured polymeric organic material of claim 1 , consisting of the film and the support layer.
14 . The macroporous-structured polymeric organic material of claim 1 , having a tensile strength of at least 15 MPa.
15 . The macroporous-structured polymeric organic material of claim 1 , wherein the film is rolled-up such that the film is in the form of a roll.
16 . A method of making the macroporous-structured polymeric organic material of claim 1 , the method comprising:
(a) providing a monomer or a combination of monomers to a solvent to form a solution;
(b) polymerizing the monomers in the solution to form a polymer gel matrix; and
(c) subjecting the polymer gel matrix to conditions sufficient to remove liquid from the polymer gel matrix to form a material having macropores present in the matrix.
17 . An article of manufacture comprising the macroporous-structured polymeric organic material of claim 1 .
18 . The article of manufacture of claim 17 , wherein the article of manufacture is an insulating material.
19 . The article of manufacture of claim 17 , wherein the article of manufacture is a thin film, a monolith, a wafer, a blanket, a core composite material, a substrate for a radiofrequency antenna, a substrate for a sunshield, a substrate for a sunshade, or a substrate for radome.
20 . The article of manufacture of claim 17 , wherein the article of manufacture is an insulating material for an oil and/or gas pipeline, an insulating material for a liquefied natural gas pipeline, an insulating material for cryogenic fluid transfer pipeline, an insulating material for an apparel item, an insulating material for an aerospace application, an insulating material for a building, an insulating material for a car, an insulating material for an automotive application, insulation for a radiator, insulation for ducting and ventilation, insulation for air conditioning, insulation for a heating or a refrigeration application, an insulation material for a mobile air conditioning unit, insulation for a cooler, insulation for packaging, an insulation material for a vibration dampening, wire, cable insulation, or an insulation material for a medical device.
21 . The article of manufacture of claim 17 , wherein the article of manufacture is an insulation material for a consumer good.
22 . The article of manufacture of claim 17 , wherein the article of manufacture is a support for a catalyst, a support for a drug, a support for a drug delivery system, an aqueous filtration apparatus, an oil-based filtration apparatus, or a solvent-based filtration apparatus.