Inherently Secured Aerogel Composites

Abstract

Embodiments of the present invention describe secured fiber-reinforced aerogels and laminate structures formed therefrom. In one embodiment a laminate comprises at least one fiber-reinforced aerogel layer adjacent to at least one layer of fiber containing material wherein fibers from said at least one fiber-reinforced aerogel layer are interlaced with fibers of said at least one fiber-containing material. In another embodiment a laminate comprises at least two adjacent fiber-reinforced aerogel layers wherein fibers from at least one fiber-reinforced aerogel layer are interlaced with fibers of an adjacent fiber-reinforced aerogel layer.

1 . A composite comprising at least one first ply of fiber-reinforced aerogel material adjacent to at least one second ply of fiber-containing material, wherein fibers from the at least one first ply of fiber-reinforced aerogel material are interlaced with fibers from the at least one second ply of fiber-containing material. 
     
     
         2 . The composite of  claim 1  wherein the second ply of fiber-containing material comprises a fiber-reinforced foam composite or fiber-reinforced polymeric composite. 
     
     
         3 . The composite of  claim 1  wherein the first ply of fiber-reinforced aerogel material or the second ply of fiber-containing material comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof. 
     
     
         4 . The composite of  claim 1  further comprising a functional material that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive. 
     
     
         5 . The composite of  claim 1  wherein the second ply of fiber-containing material comprises a fiber-reinforced aerogel. 
     
     
         6 . The composite of  claim 5  wherein the fiber-reinforced aerogel comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof. 
     
     
         7 . The composite of  claim 5  further comprising a functional material that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive. 
     
     
         8 . The composite of  claim 1  wherein the aerogel comprises inorganic materials chosen from Silica, Titania, Zirconia, Alumina, Hathia, Yttria, Ceria, Carbides, Nitrides or combinations thereof. 
     
     
         9 . The composite of  claim 1  wherein the aerogel comprises organic materials chosen from urethanes, resorcinol formaldehydes, polyimide, polyacrylates, chitosan, polymethylmethacrylate, members of the acrylate family of oligomers, trialkoxysilyl terminated polydimethylsiloxane, polyoxyalkylene, polyurethane, polybutadiane, melamine-formaldehyde, phenol-furfural, a member of the polyether family of materials or combinations thereof. 
     
     
         10 . The composite of  claim 1  wherein the aerogel comprises at least one organic material and at least one inorganic material. 
     
     
         11 . The composite of  claim 1  wherein the fiber in the first ply of fiber-reinforced aerogel material or the second ply of fiber-containing material is chosen from wool, cotton, silk, linen, hemp, ramie, and jute, acetate, acrylic, latex, nylon, polyester, rayon, spandex, fiberglass, quartz, polyethylene, polypropylene, polybenzimidazole (PBI), polyphenylenebenzo-bisoxasole (PBO), polyetheretherketone (PEEK), polyarylate, polyacrylates, polytetrafluoroethylene (PTFE), poly-metaphenylene diamide, poly-paraphenylene terephthalamide, ultra high molecular weight polyethylene (UHMWPE), novoloid resins, polyacryolintrile(PAN), polyacrylonitrile-carbon, carbon fibers or combinations thereof. 
     
     
         12 . The composite of  claim 1  wherein fibers in the first ply of fiber-reinforced aerogel material are interlaced with fibers in the second ply of fiber-containing material by using at least one needle to interlace the fibers. 
     
     
         13 . A laminate composite comprising at least one first layer of fiber-reinforced aerogel material having a first surface and at least one second layer of fiber-containing material having a second surface; wherein the first surface of the at least one first layer of fiber-reinforced aerogel material is adjacent to the second surface of the at least one second layer of fiber-containing material; and wherein fibers from said at least one first layer of fiber-containing aerogel material are interlaced with fibers of said at least one second layer of fiber-containing material. 
     
     
         14 . The laminate composite of  claim 13  wherein the first layer of fiber-reinforced aerogel material or the second layer of fiber-containing material comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof. 
     
     
         15 . The composite of  claim 14  wherein the second layer of fiber-containing material comprises a fiber-reinforced foam composite or fiber-reinforced polymeric composite. 
     
     
         16 . The laminate composite of  claim 13  further comprising a functional material that is radiation absorbing, radiation reflecting, radar blocking, thermally conductive or electrically conductive. 
     
     
         17 . The laminate composite of  claim 13  wherein the second layer of fiber-containing material comprises a fiber-reinforced aerogel. 
     
     
         18 . The laminate composite of  claim 17  wherein the fiber-reinforced aerogel comprises a felt, batting, lofty batting, mat, woven fabric, non-woven fabric or a combination thereof. 
     
     
         19 . A laminate composite comprising at least one first layer of fiber-reinforced aerogel material having a first surface and at least one second layer of fiber-containing material having a second surface; wherein the first surface of the at least one first layer of fiber-reinforced aerogel material is adjacent to the second surface of the at least one second layer of fiber-containing material; wherein fibers from said at least one first layer of fiber-containing aerogel material are interlaced with fibers of said at least one second layer of fiber-containing material by using at least one needle to interlace the fibers.