Aerogel-Ceramic Fiber Composite for Thin High-Temperature Insulation
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Solution Overview
Problem
Existing ceramic fiber papers for high-temperature insulation vary in chemical composition, leading to different temperature resistances and significantly varying costs, with aluminum oxide-based papers being 20 times more expensive than alkaline earth silicate-based papers, necessitating a need for improved thermal insulation materials with enhanced temperature resistance at reduced costs.
Innovation Solution
Incorporating aerogel into ceramic fiber papers by preparing an aerogel composition with an aerogel powder and an organic solvent, injecting or impregnating it into the fiber paper, and partially or completely removing the solvent to form a composite article with reduced binder usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum oxide-based ceramic fiber papers are used to achieve high temperature resistance (1600°C), then temperature resistance is improved, but material cost increases significantly (20 times more expensive than alkaline earth silicate-based papers)
Solution Approach 1:
The patent creates a composite material combining aerogel particles with alkaline earth silicate-based ceramic fiber paper. This composite structure allows the base paper to provide structural integrity and basic high-temperature resistance (up to 1200°C), while the aerogel particles contribute additional thermal insulation capability and enhance temperature resistance to approximately 1400°C, achieving performance接近 to expensive aluminum oxide-based papers at lower cost
Solution Approach 2:
The patent modifies the thermal insulation parameters of the ceramic fiber paper by incorporating aerogel particles with exceptional low thermal conductivity. This parameter change in the material composition transforms the thermal performance characteristics, enabling the alkaline earth silicate-based paper to achieve temperature resistance levels previously only available in aluminum oxide-based papers
2Volume of moving object
If very thin insulating materials (thickness not exceeding 3 mm) are used to reduce space, then space utilization is improved, but achieving sufficient thermal insulation capability and fire resistance becomes more difficult
Solution Approach 1:
The patent utilizes aerogel particles, which are highly porous materials with porosity exceeding 90%, to create a composite structure that maintains excellent thermal insulation capability in thin sections. The porous structure of aerogel provides numerous air pockets that impede heat transfer, enabling thin composite articles to achieve fire resistance and thermal insulation performance that would be difficult to attain with conventional dense materials of the same thickness
Solution Approach 2:
The composite structure combines the mechanical strength and structural stability of ceramic fiber paper with the superior thermal insulation properties of aerogel particles. This synergistic combination allows the creation of thin articles that maintain both structural integrity and exceptional thermal insulation capability, meeting fire resistance requirements while minimizing thickness
3Ease of manufacture
If binder content is reduced or eliminated to lower material costs and improve fire resistance, then material cost and fire resistance are improved, but attachment of aerogel powder to fibers becomes more difficult
Solution Approach 1:
The patent employs a minimal amount of binder as an intermediary substance that facilitates the attachment of aerogel particles to ceramic fiber surfaces. This binder acts as a bonding medium that creates strong adhesion between the aerogel particles and the fiber matrix, ensuring the structural integrity of the composite article while maintaining low binder content to preserve fire resistance and minimize material costs
Solution Approach 2:
The ceramic fiber paper itself provides surface characteristics that enable self-attachment of aerogel particles through physical interlocking and surface adhesion mechanisms. The fibrous structure and surface properties of the ceramic fiber paper create natural anchoring points for aerogel particles, reducing or eliminating the need for additional binder materials while maintaining strong attachment
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 composite article achieves excellent thermal insulation and temperature resistance up to 1400°C with reduced material costs, exhibiting a burn-through time of 60 minutes and a weight loss of less than 35% during thermogravimetric analysis, while maintaining structural integrity.
Implementation Method 1
combining the fibrous article and the aerogel composition
Implementation Method 2
partially or completely removing the organic solvent to obtain the composite article
Data Source
AI summary
A method for the preparation of a composite article containing aerogel particles and ceramic fibers, as well as to a composite article obtained by this method, are described.