Silica Aerogel Blanket Catalyst Composition for Solvent-Saving Hydrophobizing
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Solution Overview
Problem
The existing methods for manufacturing silica aerogel blankets are inefficient due to the need for a wet aging step and a surface modification step, which require large amounts of organic solvents and expensive surface modifiers, leading to increased costs, energy expenditure, and complexity, as well as issues with ammonia generation and waste liquid recycling.
Innovation Solution
A method using a silica sol with a catalyst composition that includes a hydrophobizing agent, a base catalyst, and water, allowing for the omission of wet aging and surface modification steps, thereby reducing solvent use and energy consumption, and enabling efficient reuse of waste liquids by controlling the base catalyst content and adjusting gelation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wet aging and surface modification steps are performed using conventional methods, then the silica aerogel blanket achieves adequate structure and hydrophobicity, but the process becomes complex and requires large amounts of organic solvents and expensive surface modifiers
Solution Approach 1:
The patent combines the wet aging step and surface modification step into a single integrated step by incorporating the hydrophobizing agent directly into the catalyst composition. This eliminates the need for separate aging and surface modification steps, reducing process complexity while maintaining the required hydrophobicity and structural quality of the silica aerogel blanket.
Solution Approach 2:
The catalyst composition is designed to perform multiple functions simultaneously: it acts as both the aging catalyst and the surface modification agent. The base catalyst promotes gelation and structural development, while the hydrophobizing agent in the same composition modifies the surface to achieve hydrophobicity, eliminating the need for separate specialized steps.
2Manufacturing precision
If wet aging and surface modification steps are performed using conventional methods, then the silica aerogel blanket achieves adequate structure and hydrophobicity, but the manufacturing cost increases due to expensive surface modifiers and large amounts of solvents
Solution Approach 1:
By merging wet aging and surface modification into one step using a single catalyst composition containing both base catalyst and hydrophobizing agent, the patent eliminates the need for separate expensive surface modifiers and reduces organic solvent consumption, thereby lowering manufacturing costs while maintaining product quality.
Solution Approach 2:
The patent optimizes the composition ratios of base catalyst, hydrophobizing agent, water, and organic solvent in the catalyst composition to achieve the desired hydrophobicity and structural quality at lower costs. By carefully controlling these parameters, the process reduces material consumption while maintaining manufacturing precision.
3Manufacturing precision
If conventional surface modification is performed, then hydrophobicity is achieved, but ammonia generation occurs which reacts with carbon dioxide to form ammonium carbonate salt, blocking piping and reducing process efficiency
Solution Approach 1:
The patent uses a base catalyst in the catalyst composition that reduces excessive ammonia generation compared to conventional methods. By optimizing the catalyst system, the harmful ammonia that would normally react with CO2 to form blocking ammonium carbonate salt is minimized, preventing piping blockages and improving process efficiency while still achieving the required hydrophobicity.
4Strength
If wet aging is performed in the presence of base catalyst solution, then structure reinforcement is achieved, but residual ammonia in waste liquid requires long purification processes and increases purification costs
Solution Approach 1:
The patent optimizes the base catalyst concentration and composition in the catalyst composition to achieve sufficient structure reinforcement with minimal residual ammonia. By carefully controlling these parameters, the aerogel structure gains adequate strength while the waste liquid contains reduced ammonia levels, shortening purification time and reducing purification costs.
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 approach simplifies the manufacturing process, reduces energy expenditure, minimizes ammonia generation, and enhances the hydrophobicity of the silica aerogel blankets, allowing for efficient reuse of waste liquids and improved productivity.
Implementation Method 1
a catalyst composition, wherein the catalyst composition includes a hydrophobizing agent, a base catalyst, water
Implementation Method 2
preparing a hydrogel from a silica precursor such as water glass and an alkoxysilane group
Implementation Method 3
surface modification step, the surface modification step uses a large amount of an organic solvent and an expensive surface modifier
Implementation Method 4
a catalyst composition includes a hydrophobizing agent, a base catalyst, water, and an organic solvent
Implementation Method 5
preparing a hydrogel from a silica precursor such as water glass and an alkoxysilane group
Data Source
AI summary
A silica sol, a silica aerogel blanket using the same, and a method for manufacturing the same, wherein a hydrophobizing agent, a base catalyst, an organic solvent, and water are included in a catalyst composition when manufacturing the silica aerogel blanket, so that a wet aging step which is performed under high-temperature conditions and increases the amount of a solvent used, and a surface modification step which uses a large amount of an organic solvent and an expensive surface modifier, resulting in a process that is complex and long and thus inhibiting economic feasibility and productivity, can be omitted.