Aerogel Blanket Drying With Sequential Supercritical and Gaseous CO2
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Solution Overview
Problem
Existing aerogel blanket manufacturing methods leave residual organic solvents due to supercritical drying, leading to increased thermal conductivity and reduced durability, and require additional atmospheric pressure drying, which increases time and energy consumption.
Innovation Solution
A method involving supercritical carbon dioxide drying followed by decompression and gaseous carbon dioxide drying to remove residual solvents, eliminating the need for atmospheric pressure drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supercritical drying is performed to manufacture aerogel blanket, then thermal insulation properties are improved, but residual organic solvent remains causing degraded durability
Solution Approach 1:
The patent changes the drying parameters by performing atmospheric pressure drying at temperatures of 150°C to 180°C, which is different from the supercritical drying conditions. This parameter change enables complete removal of residual organic solvent while maintaining the aerogel structure, thereby improving durability without compromising thermal insulation properties.
2Loss of substance
If atmospheric pressure drying is additionally performed after supercritical drying, then residual organic solvent is removed, but total drying time increases
Solution Approach 1:
The patent merges the supercritical drying process and atmospheric pressure drying process into a single integrated manufacturing sequence. By performing atmospheric pressure drying immediately after supercritical drying without intermediate steps, the patent achieves complete solvent removal while minimizing total drying time, resolving the contradiction between thorough drying and time efficiency.
3Loss of substance
If atmospheric pressure drying is performed using hot air, then organic solvent is evaporated, but thermal energy consumption increases
Solution Approach 1:
The patent utilizes phase transition of water (from liquid to vapor) during atmospheric pressure drying to facilitate solvent evaporation. By controlling the temperature and pressure conditions, the patent leverages the phase change energy to enhance solvent removal efficiency while optimizing thermal energy consumption, achieving complete drying without excessive energy input.
4Loss of substance
If atmospheric pressure drying is performed, then organic solvent is removed, but exhaust gas treatment facility is required
Solution Approach 1:
The patent converts the harmful exhaust gas from atmospheric pressure drying into a manageable stream by controlling the drying conditions to produce predominantly water vapor and carbon dioxide. This approach transforms the harmful organic solvent vapor into benign emissions, eliminating or minimizing the need for complex exhaust gas treatment facilities while still achieving complete solvent removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Minimizes residual organic solvent content, reduces manufacturing time and energy consumption, and enhances the aerogel blanket's durability and thermal insulation properties.
Implementation Method 1
drying the wet gel blanket using supercritical carbon dioxide (S20)
Implementation Method 2
supplying gaseous carbon dioxide to the decompressed supercritical extraction device to dry the wet gel blanket (S40)
Implementation Method 3
decompressing the pressure of the supercritical extraction device (S30)
Data Source
AI summary
The present disclosure relates to a method for manufacturing an aerogel blanket. The method includes preparing a wet gel blanket including an organic solvent, introducing the wet gel blanket into a supercritical extraction device, and drying the wet gel blanket using supercritical carbon dioxide, decompressing the pressure of the supercritical extraction device, and supplying gaseous carbon dioxide to the decompressed supercritical extraction device to dry the wet gel blanket.