Aerogel Composite Flexibility via Segmented Cavity Encapsulation
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Solution Overview
Problem
Aerogel monoliths are fragile and lack flexibility, while aerogel particulates provide poor insulation and are difficult to handle, and existing aerogel composites suffer from shedding and reduced insulating performance when bent or flexed, leading to undesirable convective paths.
Innovation Solution
The development of aerogel composites featuring a bonded web with a structured layer and a base layer, where the structured layer comprises troughs bonded to the base layer forming cavities, and monolithic aerogel material is contained within these cavities, enhancing flexibility and handling while maintaining high insulating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aerogel monoliths are used for thermal insulation, then high insulating performance is achieved, but flexibility and handling are poor due to fragility
Solution Approach 1:
The aerogel monolith is segmented into multiple smaller aerogel segments, each contained within an enclosure. This segmentation allows the aerogel to be more flexible and easier to handle while maintaining the high insulating performance of the monolithic structure within each segment.
Solution Approach 2:
The aerogel segments are nested within enclosures that form cavities between the structured layer and base layer. This nesting protects the fragile aerogel while allowing the overall composite to be flexible and adaptable to different shapes and configurations.
2Ease of operation
If aerogel particulates are used for thermal insulation, then handling is improved, but insulating performance deteriorates
Solution Approach 1:
The invention creates a composite material where aerogel segments (retaining monolithic insulating properties) are combined with a flexible enclosures and bonding layers. This composite structure provides both the handling ease of particulates and the insulating performance of monoliths.
3Ease of operation
If existing aerogel composites are bent or flexed, then flexibility is achieved, but shedding occurs and insulating performance reduces due to convective paths
Solution Approach 1:
The aerogel is divided into discrete segments contained within enclosures, preventing shedding when bent or flexed. Each sealed cavity maintains its insulating integrity regardless of the composite's deformation.
Solution Approach 2:
The enclosures forming the cavities are designed to be flexible, allowing the aerogel composite to be bent and flexed without compromising the sealed cavities. This flexibility prevents the formation of convective paths while maintaining insulation performance.
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 aerogel composites offer improved flexibility and reduced shedding, maintaining high thermal insulation even when flexed, by encapsulating aerogel within cavities between the structured and base layers, thus preventing convective paths and conductive paths through fibers.
Implementation Method 1
at least some of the troughs of the structured layer are melt-bonded to the base layer
Implementation Method 2
Aerogels are low density, high porosity materials making them useful in many applications, e.g., as thermal and/or acoustic insulators
Data Source
AI summary
Aerogel composites and bonded aerogel composites are described. The aerogel composites include monolithic aerogel material located in cavities between a base layer and a structured layer that is bonded to the base layer. Additional layers may be bonded to the base layer and/or the structured layer to form bonded aerogel composites.