Nano-enhanced carbon aerogels for energy-efficient roofing applications

Abstract

The Nano-Enhanced Carbon Aerogels for Energy-Efficient Roofing Applications represents an innovative integration of carbon nanomaterials, resulting in exceptional thermal performance, reduced weight, enhanced durability, and sustainability. Unlike existing patents focusing on single insulation aspects, our invention delivers a multifaceted solution that substantially contributes to energy-efficient roofing technologies, making it a valuable advancement in modern construction.

Description

[0001] Nano-Enhanced Carbon Aerogels for Energy- Efficient Roofing Applications

[0002] Field of the Invention

[0003] The field of the invention pertains to materials science and building engineering, with a specific focus on energy-efficient roofing solutions through advanced aerogel technology. This invention utilizes nano-enhanced carbon materials to significantly improve the thermal and acoustic insulation properties of roofing systems. It integrates carbon nanomaterials within an aerogel matrix to create a lightweight, high- performance insulation material. Positioned at the intersection of nanotechnology, sustainable construction, and energy efficiency, this invention addresses key challenges in the building sector, including high energy costs and environmental impact. By optimizing the insulation performance of roofing materials, it contributes to the development of sustainable urban infrastructure capable of reducing energy consumption and promoting resource conservation.

[0004] Prior Art: n the domain of nano-enhanced materials for roofing, several patents introduce innovations; however, the "Nano-Enhanced Carbon Aerogels for Energy-Efficient Roofing Applications" patent demonstrates clear superiority in thermal performance, sustainability, and multifunctionality:

[0005] • Patent CN 115073981 B: Describes a water-based nano heat-insulating coating using titanium dioxide nanoclusters and PVDF nanofiber felt. While effective in heat insulation, this approach lacks the lightweight structure and superior thermal efficiency of our carbon aerogels, which are specifically designed to reduce both structural load and installation costs by combining carbon nanomaterials with aerogels.

[0006] • Patent US9102076B2: Discusses aerogel-based composites with low thermal conductivity. These composites improve insulation but lack the energy efficiency and unique resilience of our nano-enhanced carbon aerogels. Our invention’s structural framework offers enhanced thermal resistance, moisture control, and durability, specifically for roofing applications. • Patent US20240198628A1 : Covers layered aerogel composites for diverse insulation uses. Unlike these composites, our carbon aerogels incorporate carbon nanomaterials to provide superior insulation, fire resistance, and extended lifespan, making them ideal for long-term roofing applications.

[0007] • Patent CN108484048A: Introduces a waterproof and heat-insulating mortar for building insulation. This mortar does not achieve the energy efficiency and lightweight advantages of our nano-enhanced carbon aerogels, which maximize insulation while minimizing material usage.

[0008] • Patent CN109913007B: Presents a reflective heat-insulation coating for building exteriors based on SiO2aerogels. However, this approach lacks carbon nanomaterial integration, which in our aerogels enhances UV resistance, reduces heat absorption, and improves durability.

[0009] • Patent US9827296B2: Provides an anti-fouling paint with silica aerogels aimed at biofilm prevention. While beneficial for marine applications, this patent does not address roofing or the comprehensive thermal, durability, and sustainability benefits delivered by our nano-enhanced carbon aerogels.

[0010] Description

[0011] This invention involves the development of nano-enhanced carbon aerogels engineered to maximize energy efficiency in roofing applications. Traditional roofing materials often suffer from inadequate thermal insulation, leading to increased energy demand for heating and cooling. By integrating carbon nanomaterials within the aerogel matrix, this advanced roofing material significantly improves thermal resistance while remaining lightweight. The nano-enhancements deliver exceptional thermal and acoustic insulation and increased durability against environmental factors, effectively reducing energy costs and enhancing occupant comfort.

[0012] Our invention advances the performance of roofing materials while contributing to sustainability by using lightweight, eco-friendly components. It can be seamlessly integrated into existing roofing systems, supporting energy-efficient construction practices. As the demand for energy-efficient buildings rises, traditional roofing materials often lack adequate insulation and sustainability. This nano-enhanced carbon aerogel solution overcomes these limitations, offering superior insulation that maintains comfortable indoor temperatures despite external weather changes.

[0013] This technology also provides moisture resistance and environmental resilience, extending its lifespan and reducing maintenance needs. Designed for ease of installation, it is adaptable to various applications, from residential homes to large commercial buildings, thereby supporting energy efficiency and sustainable construction practices.

[0014] The production process involves synthesizing carbon aerogels through controlled methodologies that optimize pore structure, enhancing thermal resistance while minimizing weight — making them ideally suited for roofing applications. By reflecting solar radiation and limiting heat absorption, this technology contributes to significant energy savings and can use carbon sources derived from recycled waste, supporting sustainable building practices [1],

[0015] Overview of the Drawings

[0016] Each figure clarifies the technical processes and demonstrates the benefits of using carbon aerogels for improved thermal insulation in roofing applications.

[0017] • Figure 1 : Flowchart illustrating the integration process of nano-enhanced carbon aerogels into roofing materials, focusing on their low thermal conductivity, lightweight properties, and high durability. It highlights how these features contribute to energy efficiency and sustainability, benefiting both residential and commercial roofing.

[0018] • Figure 2: A comparison of the thermal conductivity (W / m K) of insulation materials, including carbon aerogels, fiberglass, polyurethane foam, and asphalt, demonstrating the superior insulating capability of carbon aerogels.

[0019] • Figure 3: Shows cumulative energy savings (kWh) over 10 years for carbon aerogels compared to fiberglass and polyurethane foam, showcasing longterm financial benefits through reduced energy costs for heating and cooling.

[0020] • Figure 4: Comparison of initial costs ($ / m2) and payback periods (years) for various insulation materials. While carbon aerogels may require a higher initial investment, their energy efficiency yields long-term savings, underlining their economic value.

[0021] • Figure 5: Displays the R-values (thermal resistance) of different insulation materials, with carbon aerogels achieving the highest R-value, indicating their superior ability to resist heat flow.

[0022] • Figure 6: Cumulative reduction in CO2emissions over a decade for carbon aerogels compared to other insulation materials, emphasizing the environmental impact and benefits of using carbon aerogels for lower carbon footprints.

[0023] • Figure 7: Comparison of structural load and annual energy savings for insulation materials, indicating that carbon aerogels provide substantial energy savings without significantly increasing structural load, making them ideal for roofing.

[0024] References:

[0025] 1. Chen, X., et al., Designing energy-efficient buildings in urban centers through machine learning and enhanced clean water managements. Environmental Research, 2024. 260: p. 119526.

Claims

Claims1.- An aerogel material comprising a nano-enhanced carbon aerogel synthesized through a proprietary process involving the integration of carbon nanomaterials into an aerogel matrix, resulting in optimized pore structure and enhanced thermal resistance, specifically designed for energy-efficient roofing applications.2.- The production process according to claim 1 , wherein the synthesis involves:• Dispersing carbon nanomaterials uniformly within a resorcinol-formaldehyde precursor solution;• Undergoing controlled gelation to form a wet gel with embedded carbon nanomaterials;• Performing solvent exchange and aging to optimize pore structure;• Executing supercritical CO2drying to preserve the nanoporous structure;• Pyrolyzing the dried gel in an inert atmosphere to carbonize the polymer and produce the nano-enhanced carbon aerogel.3.- A method of enhancing the thermal insulation of roofing systems by integrating the nano-enhanced carbon aerogel of claim 1 into roofing materials, wherein the aerogel's low thermal conductivity reduces energy consumption for heating and cooling.4.- The nano-enhanced carbon aerogel of claim 1 , wherein the material exhibits improved mechanical strength and environmental durability due to the reinforcement provided by the carbon nanomaterials, making it resistant to UV radiation, moisture, and temperature fluctuations.

5. -The production process according to claim 2, wherein the carbon nanomaterials are sourced from recycled materials, contributing to environmental sustainability and reducing the carbon footprint of the aerogel.6.- An energy-efficient roofing system comprising:A structural roof substrate;An insulating layer of the nano-enhanced carbon aerogel of claim 1 fabricated into panels or coatings;• An external protective layer, wherein the aerogel layer significantly reduces the roof's thermal conductivity without substantially increasing its weight or structural load.7.- The use of the nano-enhanced carbon aerogel of claim 1 in roofing applications to provide both thermal and acoustic insulation, enhancing occupant comfort and energy efficiency in buildings.

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