Aerogel blanket manufacturing method and aerogel blanket thereby

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Solution Overview

Problem

Conventional aerogel blanket processing faces challenges such as aerogel particles separating from the blanket during processing, leading to contamination and reduced thermal efficiency, making it difficult to apply aerogel blankets in various fields due to dust scattering and increased production costs.

Innovation Solution

A method involving pre-processing steps like quilting, compression, or fusion on the blanket before aerogel formation, along with forming a cover layer to prevent particle leakage, which includes using materials like carbon nanotubes or graphene for improved heat and electricity diffusion, and applying a cover layer through molding or lamination to stabilize the aerogel blanket.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aerogel is impregnated in a fibrous blanket to create an insulation material, then thermal insulation performance is improved, but aerogel particles separate and scatter during processing

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidaerogel particle contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by performing quilting, compression, or fusion processes on the fibrous blanket before aerogel impregnation. This pre-processing creates a stabilized structure that prevents aerogel particles from separating and scattering during subsequent cutting and sewing operations, thereby eliminating particle contamination while maintaining insulation performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by combining the fibrous blanket with aerogel particles to create an aerogel-impregnated insulation material. This composite structure provides excellent thermal insulation properties while the fibrous matrix holds the aerogel particles in place, preventing their separation during processing

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If aerogel blanket is cut and sewn for product application, then adaptability to various fields is improved, but aerogel particles separate and insulation function weakens

Engineering Contradiction:

Improveapplication flexibilityVSAvoidinsulation function

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by performing quilting, compression, or fusion on the blanket before aerogel impregnation. This pre-stabilization ensures that the aerogel particles remain firmly embedded in the fibrous structure, preventing their separation during subsequent cutting and sewing operations, thereby maintaining insulation function while enabling versatile applications

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If cover material is added to prevent aerogel particle contamination, then particle scattering is reduced, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveparticle scatteringVSAvoidmanufacturing process complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by performing quilting, compression, or fusion processes on the fibrous blanket before aerogel impregnation. This pre-stabilization inherently prevents aerogel particle scattering during processing, eliminating the need for additional cover materials and keeping the manufacturing process simple and cost-effective

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the particle containment function from a separate cover layer and integrates it into the fibrous blanket structure itself through pre-processing. The quilting, compression, or fusion processes create an inherent containment mechanism within the blanket, eliminating the need for an external cover layer and reducing manufacturing complexity

Inventive Principle:

Principle #2Taking out (Extraction)

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

This method prevents aerogel particle separation and contamination, enhances workability, and reduces production costs by stabilizing the aerogel blanket's insulation performance even under repeated folding or rolling, allowing for broader industrial applications.

Implementation Method 1

using materials like carbon nanotubes or graphene for improved heat and electricity diffusion

Methodology Applied

Scientific EffectHeat diffusion: Conduction (thermal)

Data Source

PatentUS20230366144A1Aerogel blanket manufacturing method and aerogel blanket thereby

Publication Date: 2023.11.16 CHO YOUNG SOO

AI summary

Disclosed are an aerogel blanket production method and an aerogel blanket produced thereby, the aerogel blanket production method including steps of: preparing a blanket; preparing a liquid raw material for aerogel formation with which the blanket is to be impregnated; impregnating the blanket with the liquid raw material; and gelling the impregnated liquid raw material to form aerogel, wherein a step of performing pre-processing on the blanket before the gelling of the liquid raw material is completed. The step of performing pre-processing may be performed after the step of preparing the blanket but before impregnating with the liquid raw material, or may be performed when the impregnated liquid raw material is in a flowable semi-liquid state before the liquid raw material is not completely converted into aerogel.