Aerogel Composite Insulation Board Dust and Weight Reduction
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Solution Overview
Problem
Aerogel-based thermal insulation materials face challenges such as dust emission during handling and cutting, increased weight and thickness due to binding, and compromised non-burning classification due to hydrophobic groups for water repellence.
Innovation Solution
A thermal insulation board comprising at least two insulating layers bonded together, where at least one layer includes an aerogel composite material consisting of silica aerogel, polymer foam, and flame retardant, which reduces dust emission, weight, and thermal conductivity while maintaining mechanical stability and non-burning classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aerogel is used as thermal insulation material, then thermal insulation performance is improved, but dust emission occurs during handling and cutting
Solution Approach 1:
The patent combines aerogel particles with polymer foam to create a composite insulation board. The polymer foam matrix encapsulates the aerogel particles, preventing dust emission during handling and cutting while maintaining the superior thermal insulation properties of the aerogel. This composite structure resolves the contradiction by integrating the beneficial thermal properties of aerogel with the dust-free characteristics of foam materials.
2Strength
If aerogel granulates are bound together with binder, then mechanical stability is improved, but weight and thickness increase
Solution Approach 1:
The patent utilizes the inherent porous structure of aerogel particles, which have extremely low density and high insulation performance. By embedding these lightweight porous particles within a polymer foam matrix, the composite board achieves adequate mechanical stability without significantly increasing weight or thickness. The porous nature of both components allows for effective insulation with minimal mass.
3Reliability
If hydrophobic groups are added to aerogel for water repellence, then water resistance is improved, but non-burning classification is compromised
Solution Approach 1:
The patent separates the water repellence function from the aerogel material itself by relying on the hydrophobic properties of the polymer foam matrix. This extraction of the hydrophobic function to the matrix material allows the aerogel particles to maintain their intrinsic non-flammable characteristics, thus resolving the contradiction between water resistance and fire resistance.
Solution Approach 2:
The patent modifies the chemical composition parameters of the polymer foam matrix to achieve both hydrophobicity and fire resistance simultaneously. By selecting specific polymer types and formulations that inherently possess both water repellence and flame retardancy, the composite board achieves dual protection without compromising the non-burning classification.
4Object-generated harmful factors
If open-cell polymer foam is used as carrier material, then dust emission is reduced, but thermal insulation performance may be compromised
Solution Approach 1:
The patent creates a synergistic composite where aerogel particles (providing superior thermal insulation) are distributed within an open-cell polymer foam matrix (providing structural integrity and dust-free characteristics). The composite structure leverages the strengths of both materials: the aerogel delivers exceptional insulation performance while the foam matrix ensures easy handling without dust emission.
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 solution achieves reduced dust emission, lower weight and thickness, improved mechanical stability, and maintains non-burning classification, enhancing handling and installation ease while maintaining thermal insulation performance.
Implementation Method 1
The thermal insulation performance of the insulation materials is measured by their thermal conductivity. The lower the value of the thermal conductivity, the less the insulation material conducts heat and the better the thermal insulation is.
Implementation Method 2
to enable long-term applicability under wet and humid conditions typically encountered in building and construction applications, aerogels, especially silica aerogels, can include hydrophobic groups to imbue the material with water repellence
Data Source
AI summary
The present invention relates to a thermal insulation board (IB) comprising at least two insulating layers (A) bonded together. At least one of the at least two insulating layers (A) comprises at least one aerogel composite material, wherein the aerogel composite material comprises at least one silica aerogel (a1), at least one polymer foam (a2) and at least one flame retardant (a3). The present invention also relates to a thermal insulation system (IS) comprising the thermal insulation board (IB). Further, it relates to a process for the production of the thermal insulation board (IB) and to the use of the thermal insulation board (IB) and of the thermal insulation system (IS) for the thermal insulation of buildings, parts and/or elements of buildings.