Aerogel-Aerogel Composite Insulation for Thin Wall Thermal Performance
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Solution Overview
Problem
Existing thermal and sound insulation materials face challenges such as high thermal conductivity, handling issues due to fine dust, moisture sensitivity, fire risks, and limited fire resistance, while also requiring thick wall constructions that increase land use and material costs.
Innovation Solution
A composite material composed of hydrophobic aerogel granulate and a polymeric aerogel binder, with optional short glass fibers or natural fibers, offering low density, high strength, and flexible processing for effective heat and sound insulation with a thermal conductivity comparable to or better than existing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional insulation materials like rock wool or glass wool are used, then thermal insulation is achieved, but handling becomes unpleasant due to fine dust release and moisture sensitivity
Solution Approach 1:
The patent uses aerogel particles with highly porous structure (up to 95% air content) to achieve superior thermal insulation. The porous structure provides excellent insulation performance while the granular form factor eliminates handling issues associated with fibrous materials like rock wool and glass wool.
Solution Approach 2:
The patent creates a composite material by combining aerogel particles with a binder system (aqueous binder with optional organic solvent and/or melting agent). This composite approach maintains the insulating properties of aerogel while adding flexibility and ease of application through the liquid/semi-liquid binder matrix.
2Loss of energy
If aerogel particles are used for thermal insulation, then insulation performance is improved, but processing difficulty increases due to hydrophobicity
Solution Approach 1:
The patent introduces an aqueous binder as an intermediary substance that facilitates processing of hydrophobic aerogel particles. The binder acts as a medium to distribute and bond the aerogel particles, making the materialprocessable despite the hydrophobic nature of the aerogel surface.
Solution Approach 2:
The patent modifies the processing parameters by using aqueous binders with specific pH ranges (6-8) and optionally adding organic solvents or melting agents. These parameter changes enable effective bonding of hydrophobic aerogel particles while maintaining processability and forming coherent insulation structures.
3Loss of energy
If wall thickness is increased to achieve desired thermal conductivity, then insulation performance improves, but land use and material consumption increase
Solution Approach 1:
The patent employs aerogel particles with extremely high porosity (up to 95% air content), which provide superior thermal insulation performance per unit volume. This allows achieving desired thermal conductivity values with significantly reduced wall thickness compared to conventional insulation materials.
Solution Approach 2:
The patent changes the thermal conductivity parameter by using aerogel-based composite materials with conductivity values of 0.02-0.04 W/(m·K), which are significantly lower than conventional materials. This parameter improvement enables thinner insulation layers to achieve the same thermal performance.
4Loss of energy
If polymeric foams are used for thermal insulation, then insulation performance is achieved, but fire safety deteriorates due to smoke production and UV sensitivity
Solution Approach 1:
The patent uses aerogel particles with inorganic composition (silica, metal oxides, or ceramic materials) that provide excellent thermal insulation while being inherently fire-resistant and UV-stable. The porous structure delivers superior insulation performance without the fire safety issues associated with organic polymeric foams.
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 material achieves low thermal conductivity, improved mechanical reinforcement, and flexibility in shaping, enabling efficient heat and sound insulation in various applications, including building construction and air conditioning units, while avoiding the drawbacks of traditional materials.
Implementation Method 1
Aerogels have proven to be effective building materials with both thermal and acoustic insulation properties. Aerogels are highly porous solids in which up to 95% of the volume consists of pores.
Implementation Method 2
Sound insulation refers to the impediment of airborne sound propagation through sound reflection. The sound is absorbed by a panel that can itself vibrate. The refraction of sound waves also results in sound insulation.
Data Source
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AI summary
The invention relates to an aerogel-aerogel composite material for thermal and acoustic insulation, and to a method for producing same. A composite material according to the invention contains at least one hydrophobic aerogel granulate which is mixed with at least one polymeric binder. Such a material has a density in the range from 50 to 250 kg/m3 and has a U-value of 0.6 to 1 with a structural thickness of 5 cm.