Aerogel Composite Coating to Prevent Cracking With Glass Fibers
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Solution Overview
Problem
The blending of glass fibers into a composite material containing aerogel particles and a binder resin results in cracking during film formation, making it difficult to produce a uniform composite material.
Innovation Solution
A method involving the discharge of a coating liquid containing aerogel particles, a binder resin, and glass fibers onto an object, followed by the removal of a liquid medium to form a composite material, using a discharge device with a specific inner diameter and potentially including a water-soluble polymer with a hydrophobic group, emulsion particles, and aggregates of aerogel particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fibers are blended into the composite material to achieve high film strength, then the film strength is improved, but cracking occurs during film formation making it difficult to form a uniform composite material
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating liquid by controlling the liquid medium content (5-50 mass%), using specific binder resins with appropriate molecular weights, and adjusting the ratio of aerogel particles to glass fibers. These parameter changes enable the coating liquid to form a uniform film without cracking while incorporating glass fibers for strength.
Solution Approach 2:
The patent creates a composite coating liquid system combining aerogel particles (for insulation), glass fibers (for strength), and binder resin (for cohesion). This composite approach allows the material to simultaneously achieve high film strength from glass fibers and uniform film formation from the synergistic interaction of all components.
2Strength
If glass fibers are added to the composite material, then the film strength is enhanced, but cracking is likely to occur during film formation
Solution Approach 1:
The binder resin acts as an intermediary material that bonds glass fibers to each other and to the aerogel particles, creating a cohesive network. This intermediary substance prevents cracking by ensuring uniform stress distribution throughout the film, allowing glass fibers to enhance strength without compromising film formation stability.
Solution Approach 2:
The patent optimizes the concentration of glass fibers, the type and amount of binder resin, and the liquid medium content to achieve a coating liquid composition that maintains reliability during film formation. Specific parameter ranges are established to prevent cracking while incorporating glass fibers for strength enhancement.
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 reduces cracking during film drying and enables the production of a composite material with high film strength and uniformity, enhancing heat insulating properties.
Implementation Method 1
a coating film formation step of discharging a coating liquid containing aerogel particles, a binder resin, glass fibers, and a liquid medium toward an object to obtain a coating film
Implementation Method 2
a removal step of removing at least a part of the liquid medium from the coating film to obtain a composite material
Implementation Method 3
the coating liquid further contains a water-soluble polymer having a hydrophobic group
Implementation Method 4
at least a part of the aerogel particles forms aggregates
Data Source
AI summary
A method for producing a composite material, the method comprising: a coating film formation step of discharging a coating liquid containing aerogel particles, a binder resin, glass fibers, and a liquid medium toward an object to obtain a coating film; and a removal step of removing at least a part of the liquid medium from the coating film to obtain a composite material.