Aerogel Particle Coating via Supercritical Jet Drying
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Solution Overview
Problem
Conventional methods for preparing aerogel particles are limited by the need for a pressurized and heated chamber, which restricts the size of the final product and makes it difficult to coat complex geometries without seams.
Innovation Solution
A method involving the use of a hot gas jet or plasma jet for supercritical drying of gel particles, allowing for the creation of aerogel particles that can be sprayed onto substrates without the need for a sealed pressure vessel, enabling coating of complex geometries without seams and eliminating size limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pressurized and heated chamber is used for supercritical drying, then aerogel particles can be produced with controlled structure, but the size of the final product is restricted and complex geometries cannot be coated without seams
Solution Approach 1:
The invention segments the aerogel production process into two distinct stages: (1) forming gel particles with controlled structure in a chamber, and (2) supercritically drying the gel particles in a fluidized bed reactor. This segmentation allows the structure control function to be performed in the chamber while the drying function enables production of larger and more complex geometries without size restrictions.
Solution Approach 2:
The invention introduces a fluidized bed reactor as an intermediary device between gel formation and final aerogel product. The fluidized bed uses a supercritical fluid (typically CO2) to penetrate and dry the gel particles, serving as a mediator that transfers the drying function away from the formation chamber, thereby eliminating the size and geometry constraints of the original chamber-based method.
2Stability of the object's composition
If a sealed pressure vessel is used for supercritical drying, then aerogel particles can be produced with controlled porosity, but it becomes difficult to coat complex geometries without seams
Solution Approach 1:
The invention transforms the static sealed chamber environment into a dynamic fluidized bed system. The gel particles are suspended and continuously moved by the supercritical fluid flow, allowing the supercritical drying agent to access all surfaces of complex geometries uniformly, enabling seamless coating while maintaining controlled porosity through fluid dynamics control.
Solution Approach 2:
The invention uses pneumatic principles by employing a fluidized bed where supercritical fluid (gas phase) flows through the gel particles, providing uniform penetration and drying. This pneumatic approach replaces the static pressure vessel method, enabling easy manufacturing of complex geometries through fluid dynamics while maintaining composition stability.
3Manufacturing precision
If traditional chamber-based methods are used, then aerogel particles can be produced with controlled structure, but size limitations are imposed on the final product
Solution Approach 1:
The invention segments the production process so that small gel particles with controlled structure are formed in a chamber, then these particles are transferred to a fluidized bed for drying. This allows the final aerogel particles to achieve larger volumes than the original gel particles while maintaining structural control during the formation stage.
Solution Approach 2:
The invention changes the physical parameters during the process: gel particles are formed with controlled structure at ambient or mild conditions, then subjected to supercritical conditions (high temperature and pressure) in the fluidized bed for drying. This parameter change enables volume expansion to larger aerogel particles while preserving structural control from the formation stage.
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
Enables the production of aerogel particles that can be used as thermal or environmental barrier coatings on various substrates, including complex geometries, without the constraints of traditional chamber-based methods, enhancing their applicability and efficiency.
Implementation Method 1
Aerogels are made using a technique called supercritical drying where a gel is heated and pressurized until the liquid component of the gel is supercritical, where a liquid and a gas exist simultaneously, and then depressurized and/or cooled into a gaseous phase
Implementation Method 2
the liquid component of the gel is supercritical, where a liquid and a gas exist simultaneously, and then depressurized and/or cooled into a gaseous phase
Implementation Method 3
a gel is heated and pressurized until the liquid component of the gel is supercritical
Implementation Method 4
a gel is heated and pressurized until the liquid component of the gel is supercritical
Implementation Method 5
The one or a plurality of aerogel particles are sprayed onto a substrate
Data Source
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AI summary
A method (200) for preparing aerogel particles (105) and a coated component (107) are provided. The coated component (107) includes a substrate (104) and a coating. The coating includes aerogel particles (105) sprayed from a hot gas jet or plasma jet (103). The method (200) includes the step of feeding one or a plurality of gel particles (101) into a hot gas jet or plasma jet (103). The one or a plurality of gel particles (101) are sufficiently small to permit supercritical drying during the time the particles are in the jet. The method (200) further includes the step of exposing the one or a plurality of gel particles (101) to the temperatures and pressures of the hot gas jet or plasma jet (103) to create the aerogel particles (105) outside of a jet emitter (102) and/or without a sealed pressure vessel.