US 12,420,534 B2
Aerogel polysiloxane layer laminate structure
Bizhong Zhu, Midland, MI (US); Chi-Hao Chang, Midland, MI (US); Kaila Mattson, Midland, MI (US); Craig Gross, Midland, MI (US); Joseph Sootsman, Auburn, MI (US); and Greg Becker, Auburn, MI (US)
Assigned to Dow Silicones Corporation, Midland, MI (US)
Appl. No. 18/261,291
Filed by Dow Silicones Corporation, Midland, MI (US)
PCT Filed Feb. 22, 2022, PCT No. PCT/US2022/017195
§ 371(c)(1), (2) Date Jul. 13, 2023,
PCT Pub. No. WO2022/197405, PCT Pub. Date Sep. 22, 2022.
Claims priority of provisional application 63/162,044, filed on Mar. 17, 2021.
Prior Publication US 2024/0066843 A1, Feb. 29, 2024
Int. Cl. B32B 27/06 (2006.01); B32B 5/18 (2006.01); B32B 27/18 (2006.01); B32B 27/28 (2006.01); H01M 10/658 (2014.01)
CPC B32B 27/065 (2013.01) [B32B 5/18 (2013.01); B32B 27/18 (2013.01); B32B 27/283 (2013.01); H01M 10/658 (2015.04); B32B 2250/40 (2013.01); B32B 2264/102 (2013.01); B32B 2266/126 (2016.11); B32B 2307/304 (2013.01); B32B 2307/3065 (2013.01); B32B 2307/7376 (2023.05); B32B 2457/10 (2013.01)] 10 Claims
 
1. A process comprising preparing a laminate material comprising an aerogel layer and a polysiloxane layer distinct from the aerogel layer and in contact with the aerogel layer either directly or through an adhesive that is in direct contact with both the aerogel layer and the polysiloxane layer; where the polysiloxane layer comprises a polysiloxane and greater than 5 weight-percent and 95 weight-percent or less based on polysiloxane layer weight of fire retarding additives selected from a group consisting of metal hydroxides, mixed metal hydroxides, hydrated metal salts, and any combinations thereof dispersed throughout the polysiloxane layer; the process comprising the following steps:
(a) paring a polysiloxane layer by compounding the fire retarding additives with an uncured polysiloxane elastomer precursor to form a compounded material and then preparing sheets of the compounded material;
(b) providing aero gel layer; and
(c) laminating the polysiloxane layer to the aerogel layer by one of the following two methods:
Method 1:
(i) positioning the polysiloxane layer with one surface against a surface of the aerogel layer;
(ii) applying pressure to press the aerogel and polysiloxane layers again tone another; and
(iii) heating to trigger curing of the polysiloxane of the polysiloxane layer while in contact with the aerogel layers;
Method 2:
(i) heating the polysiloxane layer to produce a cured sheet of compounded polysiloxane elastomer as the polysiloxane layer;
(ii) disposing an adhesive onto the surface of one or both of the aerogel and polysiloxane layers;
(iii) pressing the aerogel and polysiloxane layer together with the adhesive between the aerogel and polysiloxane surfaces.