Additive manufacturing of hierarchical three- dimensional micro-architected aerogels

US11884002B2 · kind B2 · utility

Assignees

• Lawrence Livermore National Security, LLC · US
• Virginia Polytechnic Institute and State University · US

Inventors

• Marcus A. Worsley · Hayward, US
• Xiaoyu Zheng · Rockville, US
• Patrick Campbell · Oakland, US
• Eric B. Duoss · Danville, US
• James S. Oakdale · Castro Valley, US
• Christopher M. Spadaccini · Oakland, US
• Ryan Hensleigh · Colstrip, US

Key dates

• Filing date: Apr 5, 2019
• Grant date: Jan 30, 2024
• Expiry date: Mar 13, 2040

Classification

• Technology area (CPC C): Chemistry; Metallurgy
• CPC primary: C08J2333/08
• WIPO field: Other special machines
• WIPO sector: Mechanical engineering

Abstract

Disclosed here is a method for making a three-dimensional micro-architected aerogel, comprising: (a) curing a reaction mixture comprising a co-sol-gel material (e.g., graphene oxide (GO)) and at least one catalyst to obtain a crosslinked co-sol-gel (e.g., GO hydrogel); (b) providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of the crosslinked co-sol-gel (e.g., GO hydrogel); (c) curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three-dimensional structure; (d) drying the wet gel to produce a dry gel; and (e) pyrolyzing the dry gel to produce a three-dimensional micro-architected aerogel (e.g., graphene aerogel). Also disclosed is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of a crosslinked co-sol-gel.