Monolithic Organic Aerogel Compression for Low-Conductivity Insulation
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Solution Overview
Problem
Existing thermal insulation materials, such as flexible polyurethane foams and melamine-formaldehyde foams, have high thermal conductivity, while rigid polyurethane foams are brittle and lack flexibility and sufficient compressive strength.
Innovation Solution
A monolithic organic aerogel with a density range of 60 to 300 kg/m³ and thermal conductivity of 12 to 17.8 mW/m*K, featuring more than 30 Vol.% of pores with diameters less than 150 nm and 20 Vol.% with diameters less than 27 nm, is produced through a compression process that enhances mechanical stability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible polyurethane foams and melamine-formaldehyde foams are used for thermal insulation, then flexibility is improved, but thermal conductivity is high (above 30 mW/mK)
Solution Approach 1:
The patent combines aerogel particles (inorganic component) with a flexible polymer matrix (organic component) to create a composite material that exhibits both flexibility and low thermal conductivity. The aerogel particles provide exceptional insulation properties while the polymer matrix provides flexibility and structural continuity, resolving the contradiction between flexibility and thermal insulation performance.
Solution Approach 2:
The invention utilizes aerogel particles with highly porous structures containing numerous nanoscale pores. These pores trap air and other gases, creating effective thermal barriers that significantly reduce thermal conductivity. The porous structure of aerogel particles enables outstanding insulation properties while maintaining the flexibility of the overall foam material through the polymer matrix.
2Loss of energy
If rigid polyurethane foams are used for thermal insulation, then thermal conductivity is reduced, but mechanical flexibility and compressive strength are worsened (very brittle)
Solution Approach 1:
The patent creates a composite material where aerogel particles are dispersed in a flexible polymer matrix. This composite structure combines the low thermal conductivity of aerogel with the mechanical flexibility and compressive strength of the polymer matrix, resolving the contradiction between thermal insulation performance and mechanical properties.
Solution Approach 2:
The invention applies different materials with different properties to different scales: aerogel particles provide local nanoscale thermal barriers within the polymer matrix, while the polymer matrix provides macroscale mechanical flexibility and strength. This local differentiation of material properties resolves the contradiction between thermal insulation and mechanical performance.
3Loss of energy
If aerogel particles are incorporated into foam materials, then thermal conductivity is reduced, but mechanical stability and flexibility are improved
Solution Approach 1:
The patent develops a composite material where aerogel particles are uniformly distributed within a flexible polymer matrix. The polymer matrix binds the aerogel particles together, providing mechanical stability and flexibility while the aerogel particles provide thermal insulation. This composite structure resolves the contradiction between thermal performance and mechanical stability.
Solution Approach 2:
The polymer matrix acts as an intermediary that binds aerogel particles together, transferring mechanical loads and providing structural continuity. This intermediary material enables the aerogel particles to maintain their insulation properties while the overall material gains mechanical stability and flexibility from the polymer network.
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 resulting aerogel sheets exhibit low thermal conductivity, high compressive and flexural strength, and reduced friability, making them suitable for various insulation applications without significant loss of insulating properties during handling.
Implementation Method 1
aerogel-based insulating sheets have a thermal conductivity of below 15 milliwatt per meter Kelvin
Implementation Method 2
A molding based on a monolithic organic aerogel having a density in the range from 60 to 300 kg/m3
Data Source
AI summary
A molding based on a monolithic organic aerogel having a density in the range from 60 to 300 kg/m³ and a thermal conductivity in the range from 12 to 17.8 mW/m*K, more than 30 Vol.-% of pores with a diameter of less than 150 nm and more than 20 Vol.-% of pores with a diameter of less than 27 nm, based on the total pore volume and a process for preparing the molding by compression.