Aerogel Aluminum Composite Panel for Low-Moisture Thermal Insulation
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Solution Overview
Problem
Conventional aluminum composite panels face challenges with inadequate adiabatic and flame retardant properties, high manufacturing costs, and limited moldability due to issues with flowability and flexibility, especially when using flame retardant powders and materials like glass wool or rock wool which exhibit high hygroscopicity and weight increase over time.
Innovation Solution
An aluminum composite panel is developed using a silica aerogel composite mixed with a thermoplastic resin, where the aerogel composite is formed by mixing 1 to 90 wt % silica aerogel with 10 to 99 wt % thermoplastic resin, applying an adhesive resin, and attaching aluminum plates, with specific mixing and heating processes to enhance moldability and reduce hygroscopicity.
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 parameter of the flame retardant material from powder to pellets, and changes the processing method from extrusion molding to compression molding. This parameter change resolves the flowability issue while maintaining flame retardant properties, as pellets can be directly compressed without requiring flow through extrusion channels.
Solution Approach 2:
The patent extracts the flame retardant powder from the extrusion molding process and uses it directly in compression molding. By separating the flame retardant material from the extrusion process, the patent eliminates the flowability problem while preserving the flame retardant function.
2Ease of manufacture
If flame retardant synthetic resin is used to ensure flowability during extrusion, then moldability is improved, but flame retardancy is reduced due to limited powder mixing
Solution Approach 1:
The patent changes the processing method from extrusion molding to compression molding, allowing for higher flame retardant powder content (up to 98 wt%) while maintaining good moldability. This parameter change in the manufacturing process resolves the contradiction between flame retardancy and moldability.
3Temperature
If glass wool or rock wool is used as base material, then adiabatic property is improved initially, but weight increases and adiabatic property decreases over time due to high hygroscopicity
Solution Approach 1:
The patent uses aerogel, a novel composite material with ultra-low density and exceptional hydrophobicity, to replace traditional glass wool or rock wool. This composite material provides superior adiabatic properties while maintaining stability over time due to its extremely low hygroscopicity.
Solution Approach 2:
The patent utilizes the porous structure of aerogel to achieve excellent thermal insulation while maintaining extremely low water absorption. The unique porous network structure of aerogel provides both adiabatic properties and long-term stability by preventing moisture ingress.
4Reliability
If conventional flame retarding materials are applied to base during fabrication, then flame retardant properties are improved, but equipment and manufacturing costs increase
Solution Approach 1:
The patent merges the flame retardant function directly into the core composite panel structure by using flame retardant powder as the base material itself, rather than applying it as a separate layer. This integration eliminates additional manufacturing steps and reduces equipment and manufacturing costs.
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 panel exhibits improved adiabatic and flame-retardant properties, reduced weight, and increased moldability, maintaining shape under high temperatures while maintaining low hygroscopicity, thus addressing the limitations of conventional panels.
Implementation Method 1
an aerogel composite prepared with a mixture of 1 to 90 wt % of a silica aerogel and 10 to 99 wt % of a thermoplastic resin
Implementation Method 2
having improved adiabatic properties, flame retardant properties, and moldability
Data Source
AI summary
An aluminum composite panel, containing an aerogel, includes an aerogel composite using a silica aerogel and a thermoplastic resin. A method for manufacturing the same includes providing 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.