Aerogel Aluminum Composite Panel for Insulation and Flame Retardancy
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Solution Overview
Problem
Conventional aluminum composite panels face challenges in achieving adequate adiabatic and flame retardant properties, moldability, and flexibility, particularly due to limitations in flowability of flame retardant materials and high manufacturing costs, as well as issues with hygroscopicity affecting adiabatic properties over time.
Innovation Solution
A method involving the mixing of silica aerogel powder and thermoplastic resin powder at specific densities and sizes, followed by compression and heating under controlled conditions, to create an aerogel composite, which is then molded with adhesive resin and aluminum plates, ensuring improved adhesion and formability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame retardant powder is mixed with polyethylene pellets to prepare mixed paste for extrusion molding, then flame retardant properties are improved, but flowability of the mixed paste deteriorates
Solution Approach 1:
The patent changes the physical state of the flame retardant material from powder to granules with controlled size (0.5-2mm) and density (0.8-1.2g/cm³). This parameter change allows the flame retardant material to maintain flowability during extrusion while achieving adequate flame retardant properties, resolving the contradiction between flame retardancy and manufacturability.
Solution Approach 2:
The patent creates a composite structure where flame retardant granules are embedded within the polyethylene matrix. The granules are designed with specific physical properties that allow them to function as both flame retardant agents and flowable fillers, combining the benefits of flame protection with ease of extrusion molding.
2Ease of manufacture
If flame retardant powder is mixed at maximum 60 to 65 wt% to ensure flowability, then extrusion molding is feasible, but flame retardant properties cannot be enhanced further
Solution Approach 1:
By changing the form of flame retardant from powder to controlled granules and optimizing the polyethylene content to 35-60 wt%, the patent achieves both adequate flowability for extrusion and sufficient flame retardant properties. The granule morphology and size distribution enable better flow characteristics compared to fine powders.
3Temperature
If glass wool or rock wool is used as base material, then adiabatic property is improved, but weight increases and hygroscopicity causes adiabatic property decrease over time
Solution Approach 1:
The patent uses aerogel, an ultra-lightweight porous material, as the insulating base instead of traditional glass wool or rock wool. Aerogel provides superior adiabatic properties with significantly lower density, eliminating the weight penalty associated with conventional insulation materials while maintaining thermal performance.
Solution Approach 2:
The patent utilizes the porous structure of aerogel to achieve excellent thermal insulation. The nanoscale porous network of aerogel provides superior adiabatic properties compared to conventional insulation materials, while the hydrophobic treatment of the porous structure prevents moisture absorption that would degrade performance over time.
4Reliability
If conventional flame retardant materials are applied to base, then flame retardant properties are improved, but equipment and manufacturing costs increase
Solution Approach 1:
The patent combines the flame retardant function with the core insulating material by incorporating flame retardant granules directly into the aerogel-polyethylene composite during manufacturing. This integration eliminates the need for separate flame retardant coating equipment and processes, reducing manufacturing complexity and cost while maintaining effective flame protection.
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 aluminum composite panel exhibits enhanced adiabatic and flame retardant properties, reduced hygroscopicity, and excellent moldability, facilitating construction and maintaining structural integrity under high temperatures.
Implementation Method 1
an aerogel composite using a silica aerogel and a thermoplastic resin and thus having an improved adiabatic property
Implementation Method 2
improved flame retardant properties
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to an aluminum composite panel containing an aerogel, the aluminum composite panel having improved adiabatic property, flame retardancy, and moldability by having an aerogel composite using a silica aerogel and a thermoplastic resin, and to a method for manufacturing the same. The present invention provides an aluminum composite panel containing an aerogel, by molding an aerogel composite from a mixture of 1-90 wt% of a silica aerogel and 10-99 wt% of a thermoplastic resin, and then attaching aluminum plates on an upper surface and a lower surface of the aerogel composite, respectively, while an adhesive resin is coated on the upper surface and the lower surface. The aluminum composite panel containing an aerogel, manufactured according to the present invention, has a lower hygroscopic property than the conventional aluminum composite panel, due to the silica aerogel, and thus has an effect of exhibiting excellent adiabatic property and flame retardancy, retains excellent moldability, is light, and has an effect of facilitating a construction work.