Polyimide aerogel insulated panel assembly

Abstract

A panel assembly that includes a core having first and second opposing major surfaces, a first laminate skin secured to the first major surface of the core, a second laminate skin secured to the second major surface of the core, and at least a first layer of polyimide aerogel incorporated into one of the first laminate skin or the second laminate skin.

What is claimed is: 
     
         1 . A method of producing an insulated panel assembly, the method comprising the steps of:
 obtaining a core having first and second opposing major surfaces,   obtaining a first ply of material,   obtaining a first layer of polyimide aerogel,   adhering the first layer of polyimide aerogel to the first ply of material to provide a first laminate skin,   obtaining a second ply of material,   obtaining a second layer of polyimide aerogel,   adhering the second layer of polyimide aerogel to the second ply of material to provide a second laminate skin,   positioning the first and second laminate skins adjacent to the first and second major surfaces of the core, respectively, to provide a panel assembly,   pressing the panel assembly, and   heating the panel assembly to provide the insulated panel assembly.   
     
     
         2 . The method of  claim 1  wherein the first laminate skin includes first and second plies that sandwich the first layer of polyimide aerogel therebetween. 
     
     
         3 . The method of  claim 2  wherein the second laminate skin includes first and second plies that sandwich the second layer of polyimide aerogel therebetween. 
     
     
         4 . The method of  claim 1  wherein the core is a honeycomb core. 
     
     
         5 . The method of  claim 4  further comprising the step of pouring a sol-gel mixture into the honeycomb core. 
     
     
         6 . The method of  claim 4  further comprising the step of infusing the honeycomb core with a polyimide aerogel. 
     
     
         7 . The method of  claim 6  wherein the step of infusing the honeycomb core with a polyimide aerogel is done by the steps of applying a polyimide aerogel producing mixture to one or more cells of the honeycomb core, and supercritically drying the mixture to produce a layer of polyimide aerogel on the one or more cells of the honeycomb core. 
     
     
         8 . The method of  claim 7  wherein only selected cells of the plurality of honeycomb cells include a polyimide aerogel coated thereon or infused therein.