Aerogel composites and methods for making and using them

Abstract

Composites such as self-supporting rigid composites that include aerogel have low thermal conductivity and attractive mechanical properties. Methods for preparing such composites include, for example, combining an aerogel-containing material with a binder to form a slurry and allowing the slurry to harden. At least part of the hardening process in conducted under compression.

1 . A self supporting rigid composite comprising an aerogel-containing material in particulate form, an inorganic binder, the self supporting rigid composite having:
 (a) a thermal conductivity no greater than about 30 mW/(m·K) at 23° C. and 1 atmosphere; and   (b) one or more mechanical properties selected from the group consisting of:
 (i) a compressive strength greater than about 0.1 MPa; 
 (ii) a flexural strength greater than about 0.05 MPa; and 
 (iii) an elastic modulus greater than about 0.5 MPa. 
   
     
     
         2 . (canceled) 
     
     
         3 . The self supporting rigid composite of  claim 1 , wherein the thermal conductivity is no greater than about 20 mW/m·K at 23° C. and 1 atmosphere. 
     
     
         4 . (canceled) 
     
     
         5 . The self supporting rigid composite of  claim 1 , wherein the flexural strength is greater than about 1 MPa. 
     
     
         6 . (canceled) 
     
     
         7 . The self supporting rigid composite of  claim 1 , wherein the compressive strength is greater than about 5 MPa. 
     
     
         8 . (canceled) 
     
     
         9 . The self supporting rigid composite of  claim 1 , wherein the elastic modulus is greater than about 2 MPa. 
     
     
         10 . (canceled) 
     
     
         11 . The self supporting rigid composite of  claim 1 , wherein the composite includes a cementitious binder selected from the group consisting of cement, gypsum, lime, and any combination thereof. 
     
     
         12 . (canceled) 
     
     
         13 . The self supporting rigid composite of  claim 1 , wherein the composite includes fibers having a substantially uniform length. 
     
     
         14 . (canceled) 
     
     
         15 . The self supporting rigid composite of  claim 1 , wherein interparticle air is present in the composite in an amount that is less than about 30 volume %. 
     
     
         16 . The self supporting rigid composite of  claim 1 , wherein the composite has fire and/or flame resistance or sound reflecting properties. 
     
     
         17 . (canceled) 
     
     
         18 . An article including two or more layers laminated to one another, at least one of said layers including the composite of  claim 1 . 
     
     
         19 .- 31 . (canceled) 
     
     
         32 . A mortar comprising a slurry precursor of the composite of  claim 1 . 
     
     
         33 . (canceled) 
     
     
         34 . Masonry comprising the composite of  claim 1 . 
     
     
         35 .- 58 . (canceled) 
     
     
         59 . An article comprising the composite of  claim 1 , wherein the article is selected from the group consisting of a building envelope, a fire barrier, a construction material, a pipe insulation system, a rigid panel, a cryogenic insulation system, a drywall board for interior wall surfaces in building construction, an acoustic ceiling tile, and a brick.