Aerogel-containing composition and insulation blanket prepared using the same
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Solution Overview
Problem
Existing aerogel-based insulation blankets face issues with substrate shrinkage and aerogel detachment during the drying process due to non-uniform aerogel distribution, leading to low mechanical strength and environmental contamination from powder dispersal.
Innovation Solution
An aerogel-containing composition is developed, comprising an aerogel, a water-soluble binder, a foaming agent, and a solvent mixture of water and a polar organic solvent, which enhances aerogel dispersibility and adhesion, preventing substrate shrinkage and aerogel detachment, while maintaining low thermal conductivity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If aerogel powder is used in insulation blankets, then low thermal conductivity is achieved, but aerogel detachment occurs during operation
Solution Approach 1:
A binder is introduced as an intermediary substance between the aerogel particles and the blanket substrate. The binder adheres to both the aerogel powder and the substrate, creating a stable composite structure that prevents aerogel detachment during operation while maintaining the low thermal conductivity of the aerogel material.
Solution Approach 2:
The patent creates a composite material system consisting of aerogel particles embedded in a binder matrix, which is then applied to the blanket substrate. This composite structure combines the thermal insulation properties of aerogel with the adhesive and structural properties of the binder, resolving the contradiction between thermal performance and material stability.
2Loss of energy
If aerogel powder is used in insulation blankets, then low thermal conductivity is achieved, but powder flying and environmental contamination occur
Solution Approach 1:
The binder serves as a mediating substance that binds aerogel particles together and to the substrate, eliminating loose powder that would otherwise fly and cause environmental contamination. This allows the system to maintain low thermal conductivity while eliminating the harmful powder flying effect.
Solution Approach 2:
The aerogel's highly porous structure is preserved within the binder matrix, maintaining the low thermal conductivity achieved through the porous architecture, while the binder confines the porous material to prevent powder dispersion and environmental contamination.
3Manufacturing precision
If aerogel is dispersed in composition, then uniform distribution is achieved, but blanket substrate shrinkage occurs during drying
Solution Approach 1:
The drying parameters are optimized to achieve uniform aerogel distribution while minimizing substrate shrinkage. This includes controlling drying temperature, humidity, and time parameters to ensure the binder sets properly without causing excessive substrate contraction, thereby maintaining both distribution uniformity and substrate shape.
Solution Approach 2:
The composite of aerogel-binder-substrate is designed to maintain dimensional stability during drying. The binder composition and its interaction with the substrate create a composite structure that resists shrinkage while allowing uniform aerogel distribution to be achieved during the drying process.
4Reliability
If complicated processes such as freeze-drying or thermal bonding are used, then aerogel blanket quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent employs a simple, inexpensive binder and straightforward application process that eliminates the need for complex, time-consuming processes like freeze-drying or thermal bonding. The binder provides sufficient adhesion and structural integrity through simple drying, significantly reducing manufacturing time and cost while maintaining acceptable blanket quality.
Solution Approach 2:
The processing parameters are simplified by using ambient or mild drying conditions instead of extreme freeze-drying or high-temperature thermal bonding. This parameter change reduces manufacturing complexity and time while the binder formulation ensures adequate quality outcomes under these milder conditions.
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 composition allows for the production of insulation blankets with low thermal conductivity and flexibility, reducing the complexity and cost of manufacturing, and minimizing environmental concerns by ensuring uniform aerogel distribution and adhesion.
Implementation Method 1
the solvent includes water and a polar organic solvent
Implementation Method 2
a water-soluble binder
Data Source
AI summary
The present disclosure provides an aerogel-containing composition including an aerogel, a water-soluble binder, a foaming agent, and a mixture of water and a polar organic solvent as a solvent, and an insulation blanket prepared using the same. In the aerogel-containing composition, the aerogel is uniformly dispersed in the composition, and when preparing a blanket, an insulation blanket having low thermal conductivity and flexibility of low density is prepared without concern of shrinkage of the substrate for a blanket and detachment of the aerogel during a drying process.