Aerogel Blanket Structure for Flexibility Without Strength Loss
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Solution Overview
Problem
The existing manufacturing methods for silica aerogel blankets face challenges in adjusting the flexural modulus to enhance flexibility while maintaining mechanical physical properties and thermal insulation, leading to cumbersome processes and increased costs due to the use of organic solvents and ammonia generation.
Innovation Solution
A method that simultaneously performs the gelation and surface modification steps, using a hydrophobizing agent to control the aerogel structure size, resulting in a spider web shape with a reduced average aerogel structure size (D50) of 5-8 μm, which decreases the flexural modulus and increases flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the aerogel structure size is reduced to increase flexibility, then the flexural modulus decreases and flexibility improves, but the mechanical strength may be compromised
Solution Approach 1:
The patent optimizes the average aerogel structure size (D50) to a specific range of 5-8 μm, which represents a critical parameter change that simultaneously achieves flexibility improvement and mechanical strength maintenance. This precise parameter control resolves the contradiction by identifying the optimal size window where both requirements are satisfied.
Solution Approach 2:
The patent creates a composite structure where aerogel particles are aggregated or bonded to form a three-dimensional network structure. This composite approach allows the material to benefit from both the small-scale aerogel particles (providing flexibility) and the network structure (providing mechanical strength), thus resolving the contradiction between flexibility and strength.
2Reliability
If separate wet aging and surface modification steps are performed, then structure reinforcement and hydrophobicity are achieved, but the process becomes cumbersome and ammonia generation increases
Solution Approach 1:
The patent merges the wet aging and surface modification steps into a single integrated operation. By adding a hydrophobizing agent during the wet aging step, both structure reinforcement and hydrophobicity are achieved simultaneously, eliminating the need for separate steps and reducing process complexity while maintaining reliability.
Solution Approach 2:
The wet aging step is transformed into a multi-functional step that simultaneously performs structure reinforcement (through base catalyst action) and surface modification (through hydrophobizing agent action). This universal approach eliminates the need for separate dedicated steps, reducing process complexity while achieving both objectives.
3Reliability
If conventional surface modification and wet aging steps are performed separately, then functional properties are achieved, but ammonia generation blocks piping and increases purification costs
Solution Approach 1:
By combining surface modification and wet aging into one step with controlled reagent addition, the patent reduces the total amount of ammonia-generating chemicals required. The integrated process achieves the same functional properties with lower ammonia generation, preventing piping blockage and reducing purification costs.
Solution Approach 2:
The patent optimizes the concentration and timing of base catalyst and hydrophobizing agent addition to minimize ammonia generation while maintaining functional properties. By controlling these parameters in the integrated process, the harmful effects of ammonia are reduced without sacrificing reliability.
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
The approach improves the processability and workability of the aerogel blanket by reducing the flexural modulus, maintaining excellent mechanical physical properties, thermal insulation, and durability, while minimizing the use of organic solvents and ammonia generation.
Implementation Method 1
the aerogel structure includes a three-dimensional network structure formed by a plurality of aerogel particles aggregated or bonded
Implementation Method 2
A method that simultaneously performs the gelation and surface modification steps, using a hydrophobizing agent to control the aerogel structure size
Implementation Method 3
the aerogel is manufactured by preparing a hydrogel from a silica precursor such as water glass and an alkoxysilane group
Implementation Method 4
removing a liquid component inside the hydrogel without destroying a microstructure
Data Source
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AI summary
The present invention relates to an aerogel blanket including an aerogel structure and a substrate for a blanket, wherein the aerogel structure includes a three-dimensional network structure formed by a plurality of aerogel particles aggregated or bonded, and an average aerogel structure size (D50) measured by spraying 10 ml of dry powder of the aerogel structure with air at a pressure of 15 psi, and using laser diffraction of 780 nm wavelength is 5 µm to 10 µm.