U.S. patent application number 17/233688 was filed with the patent office on 2021-08-05 for method of producing a metal form containing dispersed aerogel particles impregnated with polymers.
The applicant listed for this patent is META-DRY LLC. Invention is credited to Michael Golfetto.
Application Number | 20210237145 17/233688 |
Document ID | / |
Family ID | 1000005525193 |
Filed Date | 2021-08-05 |
United States Patent
Application |
20210237145 |
Kind Code |
A1 |
Golfetto; Michael |
August 5, 2021 |
METHOD OF PRODUCING A METAL FORM CONTAINING DISPERSED AEROGEL
PARTICLES IMPREGNATED WITH POLYMERS
Abstract
A method of producing a metal form containing dispersed aerogel
particles impregnated with polymers comprising a method of
impregnating an aerogel with polymers, placing the aerogel
impregnated with polymers within a dissolved polymer, cooling the
dissolved polymer to create a polymer form with dispersed aerogel
particles impregnated with polymers, adding molten metal to the
polymer form, vaporizing the polymer form, replacing the polymer
form with molten metal, and cooling the molten metal to yield a
metal form containing dispersed aerogel particles impregnated with
polymers. Dispersing the aerogel particles impregnated with
polymers within the polymer form prior to adding molten metal
allows the aerogel particles to be fully dispersed throughout the
metal form.
Inventors: |
Golfetto; Michael;
(Farmington Hills, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
META-DRY LLC |
Farmington Hills |
MI |
US |
|
|
Family ID: |
1000005525193 |
Appl. No.: |
17/233688 |
Filed: |
April 19, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15966421 |
Apr 30, 2018 |
10981216 |
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17233688 |
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PCT/US17/30216 |
Apr 28, 2017 |
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15966421 |
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PCT/US2016/059611 |
Oct 29, 2016 |
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PCT/US17/30216 |
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62248162 |
Oct 29, 2015 |
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62248194 |
Oct 29, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 67/207 20130101;
Y10T 428/12014 20150115; B29C 67/202 20130101; B01D 12/00 20130101;
B22C 7/026 20130101; B01D 3/00 20130101; B01J 13/0091 20130101;
Y10T 428/12049 20150115; B22D 25/005 20130101; F26B 5/06 20130101;
C01B 33/1585 20130101; B29C 35/16 20130101; C08J 9/22 20130101;
Y02P 20/54 20151101; C08J 2205/026 20130101; B01J 13/0065 20130101;
B82Y 30/00 20130101 |
International
Class: |
B22C 7/02 20060101
B22C007/02; B01D 12/00 20060101 B01D012/00; C01B 33/158 20060101
C01B033/158; B29C 67/20 20060101 B29C067/20; F26B 5/06 20060101
F26B005/06; B01D 3/00 20060101 B01D003/00; B01J 13/00 20060101
B01J013/00; B22D 25/00 20060101 B22D025/00; B29C 35/16 20060101
B29C035/16; C08J 9/22 20060101 C08J009/22 |
Claims
1. A method of producing a metal form containing dispersed aerogel
particles impregnated with polymers, said method comprising the
steps of; (a) creating a mixture of polymers and aerogel particles
having pores, (b) dilating the pores of the aerogel particles,
characterized by, (c) impregnating the aerogel particles with
polymers within the mixture creating aerogel particles impregnated
with polymers. (d) dispersing the aerogel particles impregnated
with polymers into a dissolved polymer creating a dispersed
mixture, (e) placing the dispersed mixture into a mold, (f)
freezing the dispersed mixture within the mold creating a polymer
form containing dispersed aerogel particles impregnated with
polymers, (g) vaporizing the polymer form containing dispersed
aerogel particles impregnated with polymers with molten metal, and
(h) replacing the polymer form with molten metal creating a metal
form containing dispersed aerogel particles impregnated with
polymers.
2. The method of claim 1, further comprising: (i) cooling the metal
form containing dispersed aerogel particles impregnated with
polymers, and (j) removing the metal form containing dispersed
aerogel particles impregnated with polymers from the mold to yield
a metal form containing dispersed aerogel particles impregnated
with polymers having the shape of the mold.
3. A method of producing an aerogel impregnated with polymers, said
method comprising the steps of; (a) creating a mixture of polymers
and aerogel particles having pores, (b) dilating the pores of the
aerogel particles, characterized by, (c) impregnating the aerogel
particles with polymers within the mixture creating aerogel
particles impregnated with polymers.
4. The method of claim 3, further comprising: (d) placing the
aerogel particles impregnated with polymers into a mold, (e)
freezing the aerogel particles impregnated with polymers within the
mold, (f) removing the aerogel particles impregnated with polymers
from the mold, and (g) subliming the aerogel particles impregnated
with polymers to yield an aerogel impregnated with polymers having
the shape of the mold.
5. A method of producing a metal form containing dispersed aerogel
particles, said method comprising the steps of; (a) vaporizing a
polymer form containing dispersed aerogel particles with molten
metal, and (b) replacing the polymer form with molten metal
creating a metal form containing dispersed aerogel particles.
6. The method of claim 5, further comprising: creating a mixture of
polymers and aerogel particles prior to step (a), placing the
mixture into a mold prior to step (a), and freezing the mixture
within the mold creating a polymer form containing dispersed
aerogel particles prior to step (a).
7. The method of claim 5, further comprising: (c) cooling the metal
form containing dispersed aerogel particles, and (d) removing the
metal form containing dispersed aerogel particles from the mold to
yield a metal form containing dispersed aerogel particles having
the shape of the mold.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This U.S. Divisional application claims priority to U.S.
application Ser. No. 15/966,421, filed Apr. 30, 2018, which is a
continuation-in-part of International Application No.
PCT/US2017/30216, filed on Apr. 28, 2017, which is a
continuation-in-part of International Application No. PCT/US
2016/059611, filed Oct. 29, 2016, and U.S. application Ser. No.
15/956,252, filed on Apr. 18, 2018, which claim the benefit of U.S.
Provisional Application No. 62/248,162, filed on Oct. 29, 2015, and
U.S. Provisional Application No. 62/248,194, filed on Oct. 29,
2015. The entire disclosures of each of the above applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] A method of producing a metal form containing dispersed
aerogel particles impregnated with polymers.
2. Related Art
[0003] The 2008/0287561 ('561 publication) publication discloses an
aerogel that is separated into multiple aerogel particles. The
aerogel is coated with a coating substance in order to
substantially prevent intrusion of a polymer, ceramic and/or glass
matrix into the pores of the aerogel. The coated aerogel is then
dispersed or otherwise introduced into the polymer, ceramic and/or
glass matrix.
[0004] The 2009/0226700 ('700 publication) publication discloses a
method of creating a metal aerogel. The method begins by placing
aerogel particles into a mold. Molten metal is poured into the
mold. The molten metal mixes with the aerogel particles creating a
metal form with aerogel particles. The metal form is cooled in
order to solidify the molten metal. The metal form containing
aerogel particles is then removed from the mold.
SUMMARY
[0005] The current method produces a metal form containing
dispersed aerogel particles impregnated with polymers. Another
aspect of the invention includes either creating a well dispersed
metal aerogel composite and/or impregnating an aerogel with any
number of polymers.
[0006] The current method allows for aerogel particles to be
impregnated with polymers, allows for aerogel particles to be
dispersed throughout a metal form, and allows for the production of
a metal form containing dispersed aerogel particles impregnated
with polymers by creating a plastic form containing dispersed
aerogel particles, by pouring molten metal onto the plastic form,
and then by replacing the plastic form with molten metal. Unlike
the '561 publication, the current method allows for the
impregnation of aerogel with polymers. Also, unlike the '700
publication, the current method allows for aerogel particles to be
fully dispersed in desired locations within a metal form instead of
being concentrated in one region. Further, unlike both
applications, the current method produces a metal form containing
dispersed aerogel particles impregnated with polymers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Other advantages of the present invention will be readily
appreciated, as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0008] FIG. 1a is a flow chart showing a method of producing a
metal form containing dispersed aerogel particles impregnated with
polymers;
[0009] FIG. 1b is the continued flow chart from FIG. 1a showing the
method of producing the metal form containing dispersed aerogel
particles impregnated with polymers;
[0010] FIG. 1c is the continued flow chart from FIG. 1b showing the
method of producing the metal form containing dispersed aerogel
particles impregnated with polymers;
[0011] FIG. 1d is the continued flow chart from FIG. 1c showing the
method of producing the metal form containing dispersed aerogel
particles impregnated with polymers;
[0012] FIG. 1e is the continued flow chart from FIG. 1d showing the
method of producing the metal form containing dispersed aerogel
particles impregnated with polymers;
[0013] FIG. 2a is a second flow chart showing a method of producing
a metal form containing dispersed aerogel particles impregnated
with polymers;
[0014] FIG. 2b is the continued flow chart from FIG. 2a showing the
method of producing the metal form containing dispersed aerogel
particles impregnated with polymers;
[0015] FIG. 3 is a flow chart showing a method of producing an
aerogel impregnated with polymers;
[0016] FIG. 4 is a flow chart showing a method of producing a metal
form containing dispersed aerogel particles;
[0017] FIG. 5a is a flow chart showing another embodiment of a
method of producing a metal form containing dispersed aerogel
particles impregnated with polymers;
[0018] FIG. 5b is the continued flow chart from FIG. 5a showing
another embodiment of the method of producing the metal form
containing dispersed aerogel particles impregnated with
polymers;
[0019] FIG. 5c is the continued flow chart from FIG. 5b showing
another embodiment of the method of producing the metal form
containing dispersed aerogel particles impregnated with polymers;
and
[0020] FIG. 5d is the continued flow chart from FIG. 5c showing
another embodiment of the method of producing the metal form
containing dispersed aerogel particles impregnated with
polymers.
DETAILED DESCRIPTION
[0021] The following methods describe a method of producing a metal
form containing dispersed aerogel particles, a method of producing
an aerogel impregnated with polymers, and a method of producing a
metal form containing dispersed aerogel particles. An aerogel is a
synthetic material that is porous and lightweight. Aerogels are
derived from a gel where the liquid component of the gel has been
replaced with a gas. A variety of chemical compounds can be used to
make aerogel by extracting the liquid component of the gel using
supercritical drying, which allows the liquid to be slowly dried
away without causing the solid matrix of the gel to collapse from
capillary action. Gels of different compositions may be synthesized
through a number of known methods, which may include a sol-gel
process. The sol-gel process involves the production of sol, or
colloidal suspension of very small solid particles in a continuous
liquid medium, where nanostructures form the solid particles
dispersed in the liquid medium. The sol-gel process also involves
causing the nanostructures in the sol to interconnect to form a 3D
network, forming a gel. As provided herein, a gel may be a wet
solid-like material in which a solid network of interconnected
nanostructures spans the volume of a liquid medium. The continuous
phase is a solid network and the dispersed phase is a liquid.
Generally speaking, the term wet-gel and sol-gel can refer to
aerogel materials having pores that are substantially filled with
liquid particles. As provided herein, aerogels can be dry,
nanoporous, nanostructured materials containing both mesopores and
micropores. As provided her in, aerogel particles may be considered
matrices of dry materials comprising at least a 50% void space by
volume in which the solid-phase component comprises a 3D
nanostructured solid network. Thus aerogels do not have a
designated material or chemical formula, but represent a group of
materials with a certain geometric structure.
[0022] Method 100, shown in FIGS. 1a, 1b, 1c, 1d, and 1e,
illustrates a method of producing a metal form containing dispersed
aerogel particles impregnated with polymers which begins at step
102 with creating a colloidal solution herein referred to as a sol.
The sol starts the process of creating sol-gel particles. The sol
is comprised of a plurality of sol-gel precursors and at least one
solvent. The sol-gel precursors may be any organic or inorganic
material known in the art, such as, silica, metal and metalloid
oxides, metal chalcogenides, metals, metalloids, amorphous carbon,
graphitic carbon, diamond, discrete nanoscale objects, organic
polymers, biopolymers, polyurea, a polyurethane, a polyisocyanate,
a polyisocyanurate, a polyimide, a polyamide, a polybenzoxazine, a
polyacrylonitrile, a polyetheretherketone, a polyetherketoneketone,
a polybenzoxazole, a phenolic polymer, a resorcinol-formaldehyde
polymer, a melamine-formaldehyde polymer, a
resorcinol-melamine-formaldehyde polymer, a furfural-formaldehyde
polymer, an acetic-acid-based polymer, a polymer-crosslinked oxide,
a silica-polysaccharide polymer, a silica-pectin polymer, a
polysaccharide, amorphous carbon, graphitic carbon, graphene,
diamond, boron nitride, an alginate, a chitin, a chitosan, a
pectin, a gelatin, a gelan, a gum, a cellulose, a virus, a
biopolymer, an ormosil, an organic-inorganic hybrid material, a
rubber, a polybutadiene, a poly(methyl pentene), a polypentene, a
polybutene, a polyethylene, a polypropylene, a carbon nanotube, a
boron nitride nanotube, graphene, two-dimensional boron nitride,
and combinations thereof as non-limiting examples. In some
embodiments, suitable matrix materials may be reinforced with a
fiber, a fibrous batting, aligned fibers, chopped fibers, or
another suitable material. In some of these embodiments, the fiber
comprises silica, glass, carbon, a polymer, poly(acrylonitrile),
oxidized poly(acrylonitrile), poly(p-phenylene-2,6-benzobisoxazole)
(e.g., ZYLON.RTM. polyoxazole manufactured by Toyobo Corp.
(Japan)), poly(paraphenylene terephthalamide) (e.g., KEVLAR.RTM.
para-aramid manufactured by DuPont (Wilmington, Del.)), ultrahigh
molecular weight polyethylene (e.g., SPECTRA.RTM. ultrahigh
molecular weight polyethylene manufactured by Honeywell (Morris
Plains, N.J.) or DYNEEMA.RTM. ultrahigh molecular weight
polyethylene manufactured by Royal DSM (Netherlands)),
poly(hydroquinone diimidazopyridine) (e.g., M5), polyamide (e.g.,
NYLON.RTM.), natural cellulose, synthetic cellulose, silk, viscose
(e.g., rayon), a biologically-derived fiber, a
biologically-inspired fiber, a ceramic, alumina, silica, zirconia,
yttria-stabilized zirconia, hafnia, boron, metal/metalloid carbide
(e.g., silicon carbide), metal/metalloid nitride (e.g., boron
nitride), nanotubes, carbon nanotubes, carbon nanofibers, boron
nitride nanotubes, oxide nanotubes as non-limiting examples.
Metalloids include boron, silicon, germanium, arsenic, antimony,
tellurium, polonium and combinations thereof as non-limiting
examples. Metals include lithium, sodium, potassium, rubidium,
cesium, francium, beryllium, magnesium, calcium, strontium, barium,
radium, aluminum, scandium, titanium, vanadium, chromium,
manganese, iron, cobalt, nickel, copper, zinc, gallium, yttrium,
zirconium, niobium, molybdenum, technetium, ruthenium, rhodium,
palladium, silver, cadmium, indium, tin, lanthanum, cerium,
praseodymium, neodymium, promethium, samarium, europium,
gadolinium, terbium, dysprosium, holmium, erbium, thulium,
ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium,
iridium, platinum, gold, mercury, thallium, lead, bismuth,
actinium, thorium, protactinium, uranium, neptunium, plutonium,
americium, curium, berkelium, californium, einsteinium, fermium,
mendelevium, nobelium, lawrencium, the transactinide metals and
combinations thereof as non-limiting examples. Discrete nanoscale
objects include carbon nanotubes, boron nitride nanotubes, viruses,
semiconducting quantum dots, graphene, and combinations thereof as
non-limiting examples.
[0023] The solvent may be selected from the following:
2-methoxyethanol, 2,6,10,14-tetramethyl pentadecane acetic acid,
acetone, acetonitrile, acrolein, alcohols, acetic acid, amyl
alcohol, amyl acetate, aniline, aliphatic halogenated hydrocarbons,
benzene, 1-butanol, 2-butanol, 2-butanone, t-butyl alcohol,
N-butyraldehyde, N-butanol, N-butanol, sec-butanol, ie/t-butanol,
carbon tetrachloride, chlorobenzene, chloroform, chlorex, cresylic
acid, cyclohexanol, C1-C6 alcohols, cyclohexanone, cyclo-cresylic
acid, cycloaliphatic halogenated hydrocarbons, decane, decanes,
dimethylsulfoxide, Dimethylacetamide, dimethylformamide,
N,N'-dimethylformamide, 1,4-dioxane, epoxides, ethanol, ethyl
acetate, ethylene glycol, fluorinated ethers, furfural, furfural
alcohol, glycerin, glycols, heptane, Hexamethylphosphoramide,
Hexamethylphosphorous triamide, hexane, hexanes, N-hexane,
hydrocarbons, isopropanol, isopropanol, liquid hydrocarbons, liquid
SO2, methanol, methoxy ethanol, methylene chloride, Methyl-ethyl
Ketone, methyl t-butyl ether N-methyl-2-pyrrolidinone,
nitromethane, nitrobenzene, pentane, pentanol, petroleum ether,
1-propanol, 2-propanol, ft-propanol, polyols, pyridine, quinolone,
tert-butyl alcohol, tetrahydrofuran, toluene, triethyl amine water,
o-xylene, m-xylene, p-xylene. Upon the addition of sol-gel
precursors to at least one of the aforementioned solvents together,
the combination is vigorously agitated until the a homogenous sol
is created. Once the sol is created, the process moves to Step
104.
[0024] Step 104 consists of stirring a catalyst into the sol in
order to accelerate the formation of solid nanoparticle networks
containing a liquid. The catalyst activates one or more of the
solvents within the sol to create solid cohesive network of
nanoparticles suspended in the sol. The catalyst may be selected
from a group comprising of primary amines, secondary amines,
tertiary amines, triazine derivatives, organometallic compounds,
metal chelates, quaternary ammonium salts, ammonium hydroxides,
alkali metals, alkaline earth metal hydroxides, alkoxides, and
carboxylates. Once the catalyst is added and stirred into the sol
then method 100 moves to step 106.
[0025] During step 106, a polymerization agent is added to the sol
in order to create an emulsion. An emulsion, as used herein, is
defined as a mixture contained more than one liquid. The
polymerization agent may be any one of the aforementioned solvents
used in step 102, as well as other compounds such as liquid
monomers or polymers with moieties having functional groups
comprised of the following: Alkyl, Alkenyl, Alkyynyl, Phenyl, Halo.
Fluro, Chloro, Bromo, Iodo, Hydroxyl, carbonyl, Aldehyde,
Haloformyl, Carbonate ester, Carboxylate, Carboxyl, Ester, Methoxy,
Hydroperoxy, Peroxy, Ether, Hemiacetal, Hemiketal, Acetal, Ketal,
Orthoester, Methylenedioxy, Orthocarbonate ester, Carboxamide,
Amines, Imines, Imide Azide, Azo, Cyanate, Isocyanate, Nitrate,
Isonitrile, Nitrosooxy, Nitro, Nitrose, Oxime, Pyridyl, Sulfhydryl,
Sulfide, Disulfide, Sulfinyl, Sulfonyl, Sulfino, Sulfo,
Thiocyanate, Isothiocyanate, Carbonothioyl, Carbonothioyl,
Phosphino, Phosphono, Phosphate, Borono, Boronate, Borino, Borinate
or radical moieties containing single, double, triple bonds or
carboxylic acyl radical. The polymerization agent may act as a
means of crosslinking the sol's networks. The polymerization agent
can also be and additional catalysts from steps 106. The
polymerization agent may be a co-solvent that adjusts the ph of the
sol's colloidal solution. The polymerization agent may also serve
as a means for aggregation of particles having an affinity for
polar or nonpolar solvents. The polymerization agent can act to
influence the nature of the sol's nanoparticle network formation at
liquid-liquid or liquid-air interfaces, such as orienting the
formation of the solid network through the formation of micelles.
Once the emulsion is created, the method 100 continues to step
108.
[0026] During step 108, the emulsion is stirred until gelation
occurs. Gelation, as used herein, is defined as the formation of
macroscopic gel networks. The emulsion may be subjected to low
temperatures to promote gelation or gelation may occur through
chemical reactions taking place within the sol. Once gelation
occurs, wet-gel particles are said to be formed and the method 100
continues to step 110.
[0027] During step 110, a the polymerization agent can be removed
from the wet-gel particles by means such as blotting, centrifuging,
crosslinking, decanting, draining, evaporating, filtering,
polymerizing, scraping, rinsing, rubbing or washing. Removing the
polymerization agent creates wet-gel particles which contain
nanopores. Once the polymerization agent is removed, the method 100
continues to step 112.
[0028] During step 112, the wet-gel particles are dried through
ambient pressure drying, evaporation, lyophilization and or
supercritical drying. Once drying is finished, the remaining
particles will be dried aerogel particles and the method 100 can
continue to step 114.
[0029] During step 114, a polymer is placed within a first solvent
that can dissolve a preponderance the polymer creating a first
solution. The polymer can be a natural polymer or synthetic polymer
comprised of a plurality of molecular units. Some preferred
polymers may be one of cellulose, branched, unbranched,
crystalline, semicrystaline, amorphous, polyester, polyethylene,
terephthalate, polyolefin, polyacrylic acid, polymethylacrylate,
expoxy, polymethyl methacrylate, acrylonitrile butadiene styrene,
polyimides, polyamides, polycaprolactam, polylactic acid,
polybenzimidazole, polycarbonate, polyether sulfone, polyetherether
ketone, polyetherimide, polyethylene, medium-density polyethylene,
low-density polyethylene, polyphenylene oxide, polyphenylene
sulfide, polypropylene, polystyrene, polyvinyl chloride, and
polytetrafluoroethylene, or others not listed here. The first
dissolving agent may be any of the solvents list as suitable for
step 102. Once the first solution is created, the method 100 moves
to step 116.
[0030] During step 116, wet-gel particles from step 110 or dried
aerogel particles from step 112 are dispersed in a second solvent
to form a uniform dispersion of wet-gel particles in a second
solvent herein referred to as the first suspension. After the first
suspension is formed the method 100 proceeds to step 118.
[0031] During step 118, the pores of the wet-gel particles are
dilated within the first suspension, within the first mixture. The
process of dilating the pores of the aerogel particles may be
completed in a number of ways such as solvent induced swelling or
by increasing the temperature or the pressure of the wet-gel
particles. In this method, the wet-gel particles may be placed
within a pressure chamber so that the aerogel particles are
subjected to high temperature and increased pressure in order to
dilate the pores of the aerogel particles. Once the pores of the
aerogel particles are dilated, the method 100 moves to step
120.
[0032] During step 120, the wet-gel particles having dilated pores
in the first suspension are mixed vigorously with the dissolved
polymers in the first solution and agitated until a homogenous
mixture forms herein referred to as the first mixture. One the
first mixture is formed the method 100 can proceed to step 122.
[0033] During step 122, the wet-gel particles in the first mixture
are infiltrated with the dissolved polymers within the first
mixture, thus creating wet-gel particles infiltrated with polymers.
This step may take place within a pressure vessel where the
temperature and pressure within the vessel is increased in order to
allow the polymers to enter the pores of the wet-gel particles,
thereby infiltrating the wet-gel particles with polymers. Once the
infiltration step is completed then the method 100 continues to
step 124.
[0034] During step 124, the first mixture containing the wet-gel
particles infiltrated with polymers is placed into a first mold.
The mold may be of any shape or design suitable for the entire
contents of the first mixture. The method 100 continues to step
126.
[0035] During step 126, the dissolved polymer in and around the
pores of the wet-gel particles is precipitated to form wet-gel
particles impregnated with polymers. Precipitation may be induced
through evaporation, sedimentation, depressurization,
concentration, filtering, distillation or by first mixture is
subjected to low temperatures to induce freezing. The temperature
may be variable depending on the solvents and polymers used within
the first mixture. Freezing the first mixture creates a solid form
comprising wet-gel impregnated with polymers. This step may be
completed within a pressure chamber by lowering the temperature
within the pressure chamber in order to freeze the first mixture.
Once the aerogel impregnated with polymers is frozen solid then the
method 100 continues to step 128.
[0036] During step 128, the wet-gels impregnated with polymers is
removed from the first mold. The wet-gel particles impregnated with
polymers may optionally be mixed with filler material. The filler
material may comprise graphene, graphene oxide, carbon nanotubes,
cellulose nanocrystals as well as other two and three dimensional
materials. Once removed from the mold, the method 100 may proceed
to step 130.
[0037] In step 130, the wet-gels removed from the mold in steps 128
can be separated into many wet-gel particles impregnated with
polymers. Once separated, the method 100 may proceed to step
132.
[0038] In step 132, the wet-gel particles impregnated with polymers
are placed into a chemical bath. The chemical bath works as a
cleaning agent and the chemicals used may be selected from one or
more the aforementioned solvents listed as being suitable for steps
102. Once the wet-gel particles impregnated with polymers are
placed in the chemical bath, the method 100 continues to step
134.
[0039] During step 134, the first and second solvent dispersed
throughout the wet-gel particles impregnated with polymers are
replaced with a third solvent. The process of replacing may be
completed through solvent exchange which allows the third solvent
to replace a different solvent. The step of replacing the first and
second solvents with a third solvent may be completed within a
pressure chamber. This may be conducted by flushing the pressure
chamber, while the wet-gel particles impregnated with polymers are
within the pressure chamber, with the third solvent in order to
remove a preponderance of the first and second solvents and leave a
preponderance of the third solvent within the wet-gel particles,
thereby exchanging the first and second solvents with the third
solvent. The third solvent may be selected from one or more the
aforementioned solvents listed as being suitable for steps 102.
Once solvent exchanged is complete, the method 100 continues to
step 136.
[0040] Then during step 136, the third solvent is replaced with a
solidification agent through another solvent exchange process
because the freezing agent and third solvent are partially miscible
with one another. By replacing the third solvent with a
solidification agent, the wet-gel particles impregnated with
polymers in the solidification agent are solidified, creating a
solid sol-gel particle network impregnated with polymers. The
freezing agent may be selected from liquid carbon dioxide,
supercritical carbon dioxide, nitrous oxide, and supercritical
dihydrogen monoxide. The solidification agent might also allow for
the surface tension of any remaining first, second, or third
solvent to be reduced; thus, allowing for solid aerogel particles
to be produced through ambient pressure drying. In these instances,
the solidification agent is said to have a polar or nonpolar charge
similar to the surface of the wet-gel particle network, thus making
the wet-gel particle more rigid or solid through mutual repulsive
forces. Once the wet-gel particles impregnated with polymers in the
solidification agent are solidified, the method 100 continues to
step 138.
[0041] During step 138, the solidified agent is separated from the
wet-gel particles by converting the solidification agent to a gas
and separating the gas from the wet-gel particles impregnated with
polymers. This creates dried aerogel particles impregnated with
polymers and ends step 138, thus moving method 100 to step 140.
[0042] During step 140, the dried aerogel particles impregnated
with polymers are dispersed with a fourth solvent to generate a
second suspension. The fourth solvent may be selected from one or
more the aforementioned solvents listed as being suitable for steps
102. After the second suspension is formed the method 100 continues
to step 142.
[0043] During step 142 a second polymer is placed in a fifth
solvent in order to create a second solution. The second polymer
may be selected from one of described herein, the polymer can be a
natural polymer or synthetic polymer comprised of a plurality of
molecular units. Some preferred polymers may be one of cellulose,
branched, unbranched, crystalline, semicrystaline, amorphous,
polyester, polyethylene, terephthalate, polyolefin, polyacrylic
acid, polymethylacrylate, expoxy, polymethyl methacrylate,
acrylonitrile butadiene styrene, polyimides, polyamides,
polycaprolactam, polylactic acid, polybenzimidazole, polycarbonate,
polyether sulfone, polyetherether ketone, polyetherimide,
polyethylene, medium-density polyethylene, low-density
polyethylene, polyphenylene oxide, polyphenylene sulfide,
polypropylene, polystyrene, polyvinyl chloride, and
polytetrafluoroethylene, or others not listed here, co-polymers
thereof, and combinations therefore of. The fifth solvent may be
selected from one or more the aforementioned solvents listed as
being suitable for steps 102. After the second solution is formed,
step 142 ends and the method 100 continues to step 144.
[0044] During step 144, a sixth solvent may be selected from one or
more the aforementioned solvents listed as being suitable for steps
102 and mixed with at least one reinforcing agent to form a uniform
first colloidal dispersion of reinforcing agent within the sixth
solvent. The reinforcing agent in the colloidal dispersion may
include: fibers, particles, matrices, foam, mesh crosslinking
polymers, two-dimensional materials, few-layer materials often
called two-dimensional materials, or nanotubes and can be composed
of an aerogel, a zeolite, carbon, a polymer, a glass, crystals,
bimetallic glasses, a metal, inorganic elements, functional
moieties, or a combination thereof. After the first colloidal
dispersion is formed, the method 100 can proceed to step 146.
[0045] In step 146, the second solution is added to the second
suspension and first colloidal dispersion, and vigorously agitated
to form a second mixture. After the formation of the second
mixture, the method 100 can proceed to step 148.
[0046] In step 148, the viscosity of the second mixture is
increased. The viscosity may be increased as a result of at least a
portion the fourth, fifth, and or sixth solvent being removed. The
viscosity of the second mixture may further increase as a result of
change in temperature or pressure of the second mixture; or through
crosslinking and or polymerization. The viscosity of the second
mixture may also increase due to the solidification of the
dissolved polymer in the second mixture. After the viscosity of the
second mixture is increased, the method 100 can proceed to step
150.
[0047] In step 150, the second mixture is placed into a second mold
in order to form a shaped mixture. After step 150 is complete, the
method 100 can proceed to step 152.
[0048] In step 152, the fourth, fifth, and six solvents in the
second mixture are exchanged with a freezing agent. The freezing
agent may be selected from one of liquid carbon dioxide,
supercritical carbon dioxide, nitrous oxide, and supercritical
dihydrogen monoxide. The process of exchanging may take place
within a pressure vessel. This may be completed by flushing the
pressure vessel with a freezing agent, thereby replacing a
preponderance of the solvents in the second mixture with the
freezing agent. Once step 152 is complete, the method 100 continues
to step 154.
[0049] During step 154, the shaped second mixture is frozen
creating a polymer foam form containing dispersed aerogel particles
impregnated with polymers and a reinforcing agent. The aerogel
particles impregnated with polymers were dispersed throughout the
shaped mixture and surrounded the second dissolved polymer. When
then shaped mixture is frozen the second dissolved polymer freezes
and surrounds the dispersed aerogel particles impregnated with
polymers and dispersed reinforcing agents, creating a polymer foam
form containing dispersed aerogel particles impregnated with
polymers and dispersed reinforcing agents. Freezing the dissolved
polymer of step 152 can also generate nano-porous structure in the
now solid polymer from the second solution. The nanoporous polymer
creates a polymer foam form. Once the polymer foam form containing
dispersed aerogel particles impregnated with polymers and dispersed
reinforcing agents is frozen the method 100 continues to step
156.
[0050] During step 156, the polymer foam form containing dispersed
aerogel particles impregnated with polymers and dispersed
reinforcing agents is removed from the second mold. After step 156
is finished, the method 100 can proceed to step 158.
[0051] In step 158, polymer foam form from step 156 can be dried.
Drying of frozen polymer foam form containing dispersed aerogel
particles impregnated with polymers and dispersed reinforcing
agents can be accomplished by converting and remaining solid
solvents and or freezing agents, which would otherwise be liquid at
about room temperature; to a gas whereby the gas or gaseous
mixtures can be separated from the polymer foam form. Thus, result
of completing step 158 is a dried polymer foam form containing
dispersed aerogel particles impregnated with polymers and dispersed
reinforcing agents; which when achieved allows for the method of
100 to proceed to step 160.
[0052] In step 160, the dried polymer foam form containing
dispersed aerogel particles impregnated with polymers and dispersed
reinforcing agents is placed into a third mold with the desired
shape of the final product. The third mold may be the same shape as
the second mold or the third mold may be larger than the second
mold. After placing dried polymer foam form containing dispersed
aerogel particles impregnated with polymers and dispersed
reinforcing agents into the third mold, the method of 100 can
proceed to step 162.
[0053] During step 162, a refractory material is placed around the
dried polymer foam form containing dispersed aerogel particles
impregnated with polymers and dispersed reinforcing agents. After
the refractory material is placed around the polymer foam form, the
method 100 continues to step 164.
[0054] During step 164, molten metal is placed into the third mold.
The metal used may be a molten form of one or more of boron,
silicon, germanium, arsenic, antimony, tellurium, polonium,
lithium, sodium, potassium, rubidium, cesium, francium, beryllium,
magnesium, calcium, strontium, barium, radium, aluminum, scandium,
titanium, vanadium, chromium, manganese, iron, cobalt, nickel,
copper, zinc, gallium, yttrium, zirconium, niobium, molybdenum,
technetium, ruthenium, rhodium, palladium, silver, cadmium, indium,
tin, lanthanum, cerium, praseodymium, neodymium, promethium,
samarium, europium, gadolinium, terbium, dysprosium, holmium,
erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten,
rhenium, osmium, iridium, platinum, gold, mercury, thallium, lead,
bismuth, actinium, thorium, protactinium, uranium, neptunium,
plutonium, americium, curium, berkelium, californium, einsteinium,
fermium, mendelevium, nobelium, lawrencium, and transactinide
metals. Once the molten metal is placed in the third mold, the
method 100 continues to step 166.
[0055] During step 166, the molten metal begins to vaporize the
polymer foam form without substantially damaging the aerogel
particles impregnated with polymers. In some instances, the molten
metal will not damage the reinforcing agents substantially; in
other instances, the reinforcing agents can be vaporized along with
the polymer foam. In other instances, the molten metal or chemical
species resulting from the vaporized polymers, or a combination
there for of may cause chemical reactions with at least a portion
of the aerogel particles or the reinforcing agents or a combination
therefore of. The aerogel particles dispersed throughout the
polymer form remain in place while the molten metal vaporizes the
polymer form. After the molten metal vaporizes the polymer foam
form, the method 100 can proceed to step 168.
[0056] During step 168, the molten metal replaces the polymer form
after the polymer form is vaporized. The molten metal takes the
place of the polymer form and the dispersed aerogel particles
continue to remain in the desired location. In some instances, the
dispersed reinforcing agents also remain in their desired location.
Once the polymer form is replaced with molten metal, a metal form
containing dispersed aerogel particles impregnated with polymers is
created and the method 100 can proceed to step 170.
[0057] The method 100 continues to step 170 where the metal form is
cooled so that the metal may harden and form a solid metal form.
After step 170 is complete the method 100 proceeds to step 172.
[0058] During step 172, the metal form is removed from the third
mold which yields a metal form containing dispersed aerogel
particles impregnated with polymers having the shape of the third
mold. In some instances the resulting metal form can contain
dispersed aerogel particles impregnated with polymers and dispersed
reinforcing agents. The process of cooling the molten metal form
may be completed within a pressure vessel by lowering the
temperature within the pressure vessel. In other instances step 144
can be skipped and steps 146 can instead be performed by mixing
only the second solution and the second suspension. In instances
when step 144 is skipped and omitted from step 146, the resulting
second mixture of step 146 will proceed through steps 148-172
creating the desired result of the metal form containing dispersed
aerogel particles impregnated with polymers. This ends the method
100 by creating the desired result of the metal form containing
dispersed aerogel particles impregnated with polymers.
[0059] Method 200, which can be seen in FIGS. 2a and 2b,
illustrates a second method of producing a metal form containing
dispersed aerogel particles impregnated with polymers. Method 200
starts with step 202 by creating a mixture of polymers and aerogel
particles. The aerogel particles have pores in order for them to
later be impregnated with the polymers. Method 200 then continues
to step 204.
[0060] During step 204, the pores of the aerogel particles are
dilated in order to allow for impregnation. The process of dilating
the pores may be done by increasing the temperature of the aerogel
particles or by any other process that may enlarge the pores of the
aerogel particles. During step 206, the pores of the aerogel
particles are impregnated with polymers creating an aerogel
impregnated with polymers. This may be completed by first placing
the mixture of aerogel particles and polymers within a pressure
chamber. By increasing the pressure and temperature within the
pressure chamber, the pores of the aerogel particles are dilated
and the polymers are allowed to impregnate the pores of the aerogel
particles. Once step 206 is complete, the method 200 continues to
step 208.
[0061] During step 208, the aerogel particles impregnated with
polymers are placed into a mixture with a dissolved polymer
creating a dispersed mixture. The dissolved polymer may consist of
one or more of polyester, polyethylene, terephthalate, polyolefin,
polyacrylic acid, polymethylacrylate, expoxy, polymethyl
methacrylate, acrylonitrile butadiene styrene, polyimides,
polyamides, polycaprolactam, polylactic acid, polybenzimidazole,
polycarbonate, polyether sulfone, polyetherether ketone,
polyetherimide, polyethylene, polyphenylene oxide, polyphenylene
sulfide, polypropylene, polystyrene, polyvinyl chloride, and
polytetrafluoroethylene. The aerogel particles impregnated with
polymers may also be mixed with filler material. The filler
material may comprise graphene, graphene oxide, carbon nanotubes,
cellulose nanocrystals as well as other two and three dimensional
materials. The method 200 then continues to step 210.
[0062] During step 210, the dispersed mixture is placed into a mold
of a desired shape. The mold may be of any shape and size suitable
to hold the dispersed mixture. The method 200 moves to step 212
where the dispersed mixture is frozen in order to solidify the
dissolved polymers to create a polymer form containing dispersed
aerogel particles impregnated with polymers. This step may be
completed within a pressure chamber by decreasing the temperature
within the pressure chamber in order to freeze the dispersed
mixture. Next, the method 200 continues to step 214
[0063] During step 214, molten metal is placed into the mold. The
metal used may be a molten form of one or more of boron, silicon,
germanium, arsenic, antimony, tellurium, polonium, lithium, sodium,
potassium, rubidium, cesium, francium, beryllium, magnesium,
calcium, strontium, barium, radium, aluminum, scandium, titanium,
vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc,
gallium, yttrium, zirconium, niobium, molybdenum, technetium,
ruthenium, rhodium, palladium, silver, cadmium, indium, tin,
lanthanum, cerium, praseodymium, neodymium, promethium, samarium,
europium, gadolinium, terbium, dysprosium, holmium, erbium,
thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium,
osmium, iridium, platinum, gold, mercury, thallium, lead, bismuth,
actinium, thorium, protactinium, uranium, neptunium, plutonium,
americium, curium, berkelium, californium, einsteinium, fermium,
mendelevium, nobelium, lawrencium, and transactinide metals. Once
the molten metal is placed in the mold the method 200 continues to
step 216.
[0064] During step 216, the molten metal begins to vaporize the
polymer form without damaging the aerogel particles impregnated
with polymers. The aerogel particles dispersed throughout the
polymer form remain in place while the molten metal vaporizes the
polymer form. During step 218, the molten metal replaces the
polymer form after being completely vaporized. The molten metal
takes the place of the polymer form and the dispersed aerogel
particles continue to remain in the desired location. Once the
polymer form is replaced with molten metal, a metal form containing
dispersed aerogel particles impregnated with polymers is
created.
[0065] The method 200 continues to step 220 where the metal form is
cooled so that the metal may harden and form a solid metal form.
During step 222, the metal form is removed from the mold which
yields a metal form containing dispersed aerogel particles
impregnated with polymers having the shape of the mold. This ends
the method 200 by creating the desired end result of the metal form
containing dispersed aerogel particles impregnated with
polymers.
[0066] Method 300, shown in FIG. 3, illustrates a method of
producing an aerogel impregnated with polymers. Method 300 starts
with step 302 beginning with creating a mixture of polymers and
aerogel particles. The aerogel particles have pores in order for
them to later be impregnated with the polymers. Method 300 then
continues to step 304.
[0067] During step 304, the pores of the aerogel particles are
dilated in order to allow for impregnation. The process of dilating
the pores may be done by increasing the temperature of the aerogel
particles or by any other process that may enlarge the pores of the
aerogel particles. During step 306, the pores of the aerogel
particles are impregnated with polymers creating an aerogel
impregnated with polymers. This may be completed by first placing
the mixture of aerogel particles and polymers within a pressure
chamber. By increasing the pressure and temperature within the
pressure chamber, the pores of the aerogel particles are dilated
and the polymers are allowed to impregnate the pores of the aerogel
particles. Once step 306 is complete, the method 300 continues to
step 308.
[0068] During step 308, the aerogel particles impregnated with
polymers are placed into a mold of a desired shape. The mold may be
of any shape and size suitable to hold the aerogel particles
impregnated with polymers. The method 300 moves to step 310 where
the aerogel particles impregnated with polymers are frozen in order
to create a single aerogel impregnated with polymers having a
desired shape and size. This step may be completed within a
pressure chamber by decreasing the temperature within the pressure
chamber in order to freeze the aerogel particles impregnated with
polymers. Next, the method 300 continues to step 312
[0069] During step 312, the aerogel impregnated with polymers is
removed from the mold and then in step 314, the aerogel impregnated
with polymers is sublimed in order to yield and aerogel impregnated
with polymers having the shape of the mold. This ends the method
300.
[0070] Method 400, shown in FIG. 4, illustrates a method of
producing a metal form containing dispersed aerogel particles.
Method 400 starts with step 402 beginning with creating a mixture
of polymers and aerogel particles. Method 400 then continues to
step 404.
[0071] During step 404, the mixture of polymers and aerogel
particles is placed into a mold. During step 406, the mixture is
frozen within the mold creating a polymer form containing dispersed
aerogel particles. The mixture may be frozen by placing the mixture
of polymers and aerogel particles within a pressure chamber and by
lowering the temperature within the pressure chamber. The method
400 then continues to step 408.
[0072] During step 408, molten metal is placed into the mold. The
metal used may be a molten form of one or more of boron, silicon,
germanium, arsenic, antimony, tellurium, polonium, lithium, sodium,
potassium, rubidium, cesium, francium, beryllium, magnesium,
calcium, strontium, barium, radium, aluminum, scandium, titanium,
vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc,
gallium, yttrium, zirconium, niobium, molybdenum, technetium,
ruthenium, rhodium, palladium, silver, cadmium, indium, tin,
lanthanum, cerium, praseodymium, neodymium, promethium, samarium,
europium, gadolinium, terbium, dysprosium, holmium, erbium,
thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium,
osmium, iridium, platinum, gold, mercury, thallium, lead, bismuth,
actinium, thorium, protactinium, uranium, neptunium, plutonium,
americium, curium, berkelium, californium, einsteinium, fermium,
mendelevium, nobelium, lawrencium, and transactinide metals. Once
the molten metal is placed in the mold the method 400 continues to
step 410.
[0073] During step 410, the molten metal begins to vaporize the
polymer form without damaging the aerogel particles. The aerogel
particles dispersed throughout the polymer form remain in place
while the molten metal vaporizes the polymer form. During step 412,
the molten metal replaces the polymer form after being completely
vaporized. The molten metal takes the place of the polymer form and
the dispersed aerogel particles continue to remain in the desired
location. Once the polymer form is replaced with molten metal, a
metal form containing dispersed aerogel particles is created.
[0074] The method 400 continues to step 414 where the metal form is
cooled so that the metal may harden and form a solid metal form.
During step 416, the metal form is removed from the mold which
yields a metal form containing dispersed aerogel particles having
the shape of the mold. This ends the method 400 by creating the
desired end result of the metal form containing dispersed aerogel
particles.
[0075] Method 500, shown in FIGS. 5a, 5b, 5c, and 5d, illustrates
another embodiment of a method of producing a metal form containing
dispersed aerogel particles impregnated with polymers which begins
at step 502 with creating a homogenous mixture. The homogenous
mixture starts the process of creating aerogel particles. The
homogenous mixture is comprised of one or more solvents which may
be selected from the following: methyltrimethoxysilane, hexadecyl
trimethyl ammonium bromide, deionized water, ketone, aldehyde,
alkyl alkanoate, formamide, /V-methylpyrrolidone, dimethyl
sulfoxide, aliphatic halogenated hydrocarbons, cycloaliphatic
halogenated hydrocarbons, halogenated aromatic compounds,
fluorinated ethers, acetaldehyde, propionaldehyde, n-butyraldehyde,
isobutyraldehyde, 2-ethylbutyraldehyde, valeraldehyde,
isopentaldehyde, 2-methylpentaldehyde, 2-ethylhexaldehyde,
acrolein, methanol, ethanol, propanol, isopropanol, butanol,
sec-butanol, ferf-butanol, pentanol, neopentanol, amyl alcohol,
acetone, methylethyl, acetonitrile, dimethylacetamide,
N,N'-dimethylformamide, dimethylsulfoxide, ethyl acetate, amyl
acetate, cyclohexanol, cyclohexane, pentane, hexane, heptane,
alcohols, pyrrolidones, and other appropriate solvents. Upon mixing
three of the above listed solvents together, the mixture is mixed
under vigorous stirring until the mixture is homogenous creating a
homogenous mixture. Once the homogeneous mixture is created, the
process moves to Step 504.
[0076] Step 504 consists of stirring a catalyst into the homogenous
mixture in order to produce a liquid containing solid
nanoparticles. The catalyst activates one or more of the solvents
within the homogenous mixture to create solid nanoparticles
suspended in the homogeneous mixture. The catalyst may be selected
from a group comprising of primary amines, secondary amines,
tertiary amines, triazine derivatives, organometallic compounds,
metal chelates, quaternary ammonium salts, ammonium hydroxides,
alkali metals, alkaline earth metal hydroxides, alkoxides, and
carboxylates. Once the catalyst is added and stirred into the
homogenous mixture then method 500 moves to step 506.
[0077] During step 506, a hydrocarbon is added to the homogenous
mixture in order to create an emulsion. An emulsion, as used
herein, is defined as a mixture containing more than one liquid.
The hydrocarbon may be one of hexane, acetone, acetonitrile, acetic
acid, amyl alcohol, benzene, carbon tetrachloride, chlorobenzene,
chloroform, cyclo-cresylic acid, hexane, isopropyl alcohol,
di-methyl formamide, ethanol, ethyl acetate, furfural, furfural
alcohol, methanol, N-butane, N-heptane, N-hexane, and pyridine.
Once the emulsion is created, the method 500 continues to step
508.
[0078] During step 508, the emulsion is stirred until gelation
occurs. Gelation, as used herein, is defined as solidification by
freezing. The emulsion may be subjected to low temperatures to
promote gelation or gelation may occur through chemical reactions
taking place within the homogenous mixture. Once gelation occurs,
the method continues to step 510.
[0079] During step 510, a first dissolving agent is used to remove
the hydrocarbon from the emulsion. Removing the hydrocarbon from
the emulsion leaves the created aerogel particles which contain
pores. The first dissolving agent may be one of acetonitrile,
2-methoxyethanol, (2, 6, 10, 14)-tetramethyl pentadecane, acetone,
alcohols, amyl alcohol, amylacetate, aniline, N-butanol, N-butanol,
sec-butanol, ie/t-butanol, chlorex, cyclohexanol, C1-C6 alcohols
cyclohexanone, cresylic acid, dimethylsulfoxide, Dimethylacetamide,
dimethylformamide, N,N'-dimethylformamide, ethanol, furfural,
furfural alcohol, ft-propanol, pyridine, hexane, hexanes, N-hexane,
hydrocarbons, isopropanol, isopropanol, methanol, methoxyethanol,
N-Methylpyrollidone, nitrobenzene, pentanol, liquid SO2, quinolone,
and xylene. Once the hydrocarbon is removed, the method continues
to step 512.
[0080] During step 512, a polymer is placed within a second
dissolving agent to dissolve the polymer creating a dissolved
polymer. The polymer may be one of polyester, polyethylene,
terephthalate, polyolefin, polyacrylic acid, polymethylacrylate,
expoxy, polymethyl methacrylate, acrylonitrile butadiene styrene,
polyimides, polyamides, polycaprolactam, polylactic acid,
polybenzimidazole, polycarbonate, polyether sulfone, polyetherether
ketone, polyetherimide, polyethylene, medium-density polyethylene,
low-density polyethylene, polyphenylene oxide, polyphenylene
sulfide, polypropylene, polystyrene, polyvinyl chloride, and
polytetrafluoroethylene. The second dissolving agent may be similar
to the first dissolving agent or may be selected from one of
acetonitrile, 2-methoxyethanol, (2, 6, 10, 14)-tetramethyl
pentadecane, acetone, alcohols, amyl alcohol, amylacetate, aniline,
N-butanol, N-butanol, sec-butanol, ie/t-butanol, chlorex,
cyclohexanol, C1-C6 alcohols cyclohexanone, cresylic acid,
dimethylsulfoxide, dimethylacetamide, dimethylformamide,
N,N'-dimethylformamide, ethanol, furfural, furfural alcohol,
ft-propanol, pyridine, hexane, hexanes, N-hexane, hydrocarbons,
isopropanol, isopropanol, methanol, methoxyethanol,
N-Methylpyrollidone, nitrobenzene, pentanol, liquid SO2, quinolone,
and xylene. Once the dissolved polymer is created, the method moves
to step 514.
[0081] During step 514, the aerogel particles are mixed with an
alcohol and the dissolved polymer and then the mixture is mixed
under vigorous stirring to create a first mixture. The alcohol may
be one of ethanol, acetone, methanol, acetonitrile, acetic acid,
amyl alcohol, benzene, carbon tetrachloride, chlorobenzene,
chloroform, cyclo-cresylic acid, hexane, isopropyl alcohol,
di-methyl formamide, ethanol, ethyl acetate, furfural, furfural
alcohol, methanol, N-butane, N-heptane, N-hexane, and pyridine.
Upon creating the first mixture, method 500 proceeds to step 516.
The aerogel particles may be produced from the previous steps or
created from other known methods within the art.
[0082] During step 516, the pores of the aerogel particles are
dilated within the first mixture. The process of dilating the pores
of the aerogel particles may be completed in a number of ways such
as by increasing the temperature or the pressure of the aerogel
particles. In this method, the aerogel particles may be placed
within a pressure chamber so that the aerogel particles are
subjected to high temperature and increased pressure in order to
dilate the pores of the aerogel particles. Once the pores of the
aerogel particles are dilated, the method 500 moves to step
518.
[0083] During step 518, the aerogel particles having dilated pores
are impregnated with the dissolved polymers within the first
mixture creating aerogel particles impregnated with polymers. This
step may take place within a pressure vessel where the temperature
and pressure within the vessel is increased in order to allow the
polymers to enter the pores of the aerogel particles, thereby
impregnating the aerogel particles with polymers. Once the
impregnation step is completed then the method 500 continues to
step 520.
[0084] During step 520, the first mixture containing the aerogel
particles impregnated with polymers is placed into a first mold.
The mold may be of any shape or design suitable for the entire
contents of the first mixture. The method continues to step
522.
[0085] During step 522, the first mixture is subjected to low
temperatures to induce freezing. The temperature may be variable
depending on the solvents and polymers used within the first
mixture. Freezing the first mixture creates a solid form comprising
an aerogel impregnated with polymers. This step may be completed
within a pressure chamber by lowering the temperature within the
pressure chamber in order to freeze the first mixture. Once the
aerogel impregnated with polymers is frozen solid then the method
500 continues to step 524.
[0086] During step 524, the aerogel impregnated with polymers is
removed from the first mold and are separated into many aerogel
particles impregnated with polymers in step 526. The aerogel
particles impregnated with polymers may optionally be mixed with
filler material. The filler material may comprise graphene,
graphene oxide, carbon nanotubes, cellulose nanocrystals as well as
other two and three dimensional materials. In step 528, the aerogel
particles impregnated with polymers are placed into a chemical
bath. The chemical bath works as a cleaning agent and the chemicals
used may be selected from one or more of hexane, acetone,
acetonitrile, acetic acid, amyl alcohol, benzene, carbon
tetrachloride, chlorobenzene, chloroform, cyclo-cresylic acid,
hexane, isopropyl alcohol, di-methyl formamide, ethanol, ethyl
acetate, furfural, furfural alcohol, methanol, N-butane, N-heptane,
N-hexane, and pyridine. Once the aerogel particles impregnated with
polymers are placed in the chemical bath, the method 500 continues
to step 530.
[0087] During step 530, the first and second dissolving agents
dispersed throughout the aerogel particles impregnated with
polymers are replaced with a fourth solvent. The process of
replacing may be completed through solvent exchange which allows
the fourth solvent to replace a different solvent, in this case the
dissolving agents, which is miscible with the fourth solvent. The
step of replacing the first and second dissolving agents with a
fourth solvent may be completed within a pressure chamber. This may
be conducted by flushing the pressure chamber, while the aerogel
particles impregnated with polymers are within the pressure
chamber, with the fourth solvent in order to remove the first and
second dissolving agents and leave the fourth solvent within the
aerogel particles, thereby exchanging the first and second
dissolving agents with the fourth solvent. The fourth solvent may
be selected from one of one or more of hexane, acetone,
acetonitrile, acetic acid, amyl alcohol, benzene, carbon
tetrachloride, chlorobenzene, chloroform, cyclo-cresylic acid,
hexane, isopropyl alcohol, di-methyl formamide, ethanol, ethyl
acetate, furfural, furfural alcohol, methanol, N-butane, N-heptane,
N-hexane, and pyridine. Then during step 532, the fourth solvent is
replaced with a freezing agent through another solvent exchange
process because the freezing agent and fourth solvent are miscible
with one another. By replacing the fourth solvent with a freezing
agent, the aerogel particles impregnated with polymers are frozen
creating frozen aerogel particles impregnated with polymers. The
freezing agent may be selected from liquid carbon dioxide,
supercritical carbon dioxide, nitrous oxide, and supercritical
dihydrogen monoxide.
[0088] During step 534, the frozen aerogel particles impregnated
with polymers are sublimed. This creates sublimed aerogel particles
impregnated with polymers and ends step 534, thus moving method 500
to step 536.
[0089] During step 536, a second polymer is placed in a third
dissolving agent in order to create a second dissolved polymer. The
second polymer may be selected from one of polyester, polyethylene,
terephthalate, polyolefin, polyacrylic acid, polymethylacrylate,
expoxy, polymethyl methacrylate, acrylonitrile butadiene styrene,
polyimides, polyamides, polycaprolactam, polylactic acid,
polybenzimidazole, polycarbonate, polyether sulfone, polyetherether
ketone, polyetherimide, polyethylene, polyphenylene oxide,
polyphenylene sulfide, polypropylene, polystyrene, polyvinyl
chloride, and polytetrafluoroethylene. The third dissolving agent
may be similar to the first or second dissolving agent or may be
entirely new selected from one of methyltrimethoxysilane, hexadecyl
trimethyl ammonium bromide, deionized water, ketone, aldehyde,
alkyl alkanoate, formamide, /V-methylpyrrolidone, dimethyl
sulfoxide, aliphatic halogenated hydrocarbons, cycloaliphatic
halogenated hydrocarbons, halogenated aromatic compounds,
fluorinated ethers, acetaldehyde, propionaldehyde, n-butyraldehyde,
isobutyraldehyde, 2-ethylbutyraldehyde, valeraldehyde,
isopentaldehyde, 2-methylpentaldehyde, 2-ethylhexaldehyde,
acrolein, methanol, ethanol, propanol, isopropanol, butanol,
sec-butanol, ferf-butanol, pentanol, neopentanol, amyl alcohol,
acetone, methylethyl, acetonitrile, dimethylacetamide,
N,N'-dimethylformamide, dimethylsulfoxide, ethyl acetate, amyl
acetate, cyclohexanol, cyclohexane, pentane, hexane, heptane,
alcohols, and pyrrolidones. Step 536 ends and the method 500
continues to step 538.
[0090] During step 538, the sublimed aerogel particles impregnated
with polymers are mixed with the second dissolved polymer to create
a second mixture. The method 500 continues to step 538.
[0091] During step 540, the second mixture is placed into a second
mold in order to form a shaped mixture. In step 542, the third
dissolving agent is exchanged with a freezing agent. The freezing
agent may be selected from one of liquid carbon dioxide,
supercritical carbon dioxide, nitrous oxide, and supercritical
dihydrogen monoxide. The process of exchanging may take place
within a pressure vessel similar to step 530. This may be completed
by flushing the pressure vessel with a freezing agent, thereby
replacing the third dissolving agent with the freezing agent. Once
step 542 is complete, the method 500 continues to step 544.
[0092] During step 544, the shaped mixture is frozen creating a
polymer form containing dispersed aerogel particles impregnated
with polymers. The aerogel particles impregnated with polymers were
dispersed throughout the shaped mixture and surrounded the second
dissolved polymer. When then shaped mixture is frozen the second
dissolved polymer freezes and surrounds the dispersed aerogel
particles impregnated with polymers creating a polymer form
containing dispersed aerogel particles impregnated with polymers.
Once the polymer form containing dispersed aerogel particles
impregnated with polymers is frozen the method 500 continues to
step 546.
[0093] During step 546, the polymer form containing dispersed
aerogel particles impregnated with polymers is removed from the
second mold and placed into a third mold with the desired shape of
the final product. The third mold may be the same shape as the
second mold or the third mold may be larger than the second mold.
During step 548, a refractory material is placed around the polymer
form containing dispersed aerogel particles impregnated with
polymers. The method 500 continues to step 550 after the refractory
material is placed around the polymer form.
[0094] During step 550, molten metal is placed into the third mold.
The metal used may be a molten form of one or more of boron,
silicon, germanium, arsenic, antimony, tellurium, polonium,
lithium, sodium, potassium, rubidium, cesium, francium, beryllium,
magnesium, calcium, strontium, barium, radium, aluminum, scandium,
titanium, vanadium, chromium, manganese, iron, cobalt, nickel,
copper, zinc, gallium, yttrium, zirconium, niobium, molybdenum,
technetium, ruthenium, rhodium, palladium, silver, cadmium, indium,
tin, lanthanum, cerium, praseodymium, neodymium, promethium,
samarium, europium, gadolinium, terbium, dysprosium, holmium,
erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten,
rhenium, osmium, iridium, platinum, gold, mercury, thallium, lead,
bismuth, actinium, thorium, protactinium, uranium, neptunium,
plutonium, americium, curium, berkelium, californium, einsteinium,
fermium, mendelevium, nobelium, lawrencium, and transactinide
metals. Once the molten metal is placed in the third mold, the
method 500 continues to step 552.
[0095] During step 552, the molten metal begins to vaporize the
polymer form without damaging the aerogel particles impregnated
with polymers. The aerogel particles dispersed throughout the
polymer form remain in place while the molten metal vaporizes the
polymer form. During step 554, the molten metal replaces the
polymer form after being completely vaporized. The molten metal
takes the place of the polymer form and the dispersed aerogel
particles continue to remain in the desired location. Once the
polymer form is replaced with molten metal, a metal form containing
dispersed aerogel particles impregnated with polymers is
created.
[0096] The method 500 continues to step 556 where the metal form is
cooled so that the metal may harden and form a solid metal form.
During step 558, the metal form is removed from the third mold
which yields a metal form containing dispersed aerogel particles
impregnated with polymers having the shape of the third mold. The
process of cooling the molten metal form may be completed within a
pressure vessel by lowering the temperature within the pressure
vessel. This ends the method 500 by creating the desired end result
of the metal form containing dispersed aerogel particles
impregnated with polymers.
[0097] Obviously, many modifications and variations of the present
invention are possible in light of the above teachings and may be
practiced otherwise than as specifically described while within the
scope of the appended claims. These antecedent recitations should
be interpreted to cover any combination in which the inventive
novelty exercises its utility.
* * * * *