Aerogel Sheet Impregnation Layout for Uniform Multistage Production
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Solution Overview
Problem
The manufacturing process of aerogel sheets is complex and inefficient, leading to poor workability and productivity.
Innovation Solution
An apparatus comprising a fiber sheet, fixing vessels with punched holes, an impregnation vessel with a vacuum chamber, and multiple silica precursor injection points, allowing for multistage stacking and improved impregnation of silica precursors into the fiber sheets, enhancing the impregnation process through suction force and uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the aerogel sheet is manufactured by injecting and impregnating aerogel and catalyst solution into a surface of a blanket, then the aerogel sheet can be produced, but the manufacturing process becomes complicated and productivity deteriorates
Solution Approach 1:
The manufacturing process is divided into separate functional modules: fixing vessels for holding fiber sheets, impregnation vessels for silica precursor injection, and drying vessels for water removal. This segmentation allows each module to perform its specific function efficiently while enabling parallel processing of multiple fiber sheets, thus simplifying the overall process and improving productivity.
Solution Approach 2:
Multiple fixing vessels are stacked vertically inside the impregnation vessel, creating a nested configuration. This allows multiple fiber sheets to be impregnated simultaneously in a compact arrangement, significantly improving productivity without requiring a larger facility footprint.
2Productivity
If multiple fixing vessels are stacked in multistage in the impregnation vessel, then mass production is enabled and productivity improves, but the device complexity increases
Solution Approach 1:
The impregnation vessel serves multiple functions: it holds the stacked fixing vessels, provides the environment for silica precursor injection, and facilitates the impregnation process. This multi-functionality reduces the need for separate dedicated equipment for each step, thereby improving productivity without proportionally increasing device complexity.
Solution Approach 2:
The system transitions from horizontal processing of single fiber sheets to vertical stacking of multiple fixing vessels in the impregnation vessel. This vertical arrangement enables mass production by utilizing the vertical dimension, allowing multiple impregnation operations to occur simultaneously in a compact space.
3Manufacturing precision
If the accommodation part is provided as a sealed vacuum chamber with vacuum generation, then silica precursor impregnation is improved through suction force, but the device complexity and energy consumption increase
Solution Approach 1:
A vacuum generation system is integrated into the impregnation vessel to create negative pressure, which draws the silica precursor solution into the fiber sheets through suction force. This pneumatic approach ensures uniform and thorough impregnation throughout the fiber matrix, significantly improving manufacturing precision compared to passive diffusion methods.
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
This apparatus simplifies the manufacturing process, enabling mass production of aerogel sheets with improved productivity and uniform quality by ensuring thorough and uniform impregnation of silica precursors into the fiber sheets.
Implementation Method 1
the silica precursor injection part which injects the silica precursor into the accommodation part to impregnate the silica precursor into the fiber sheet inserted into each of the fixing vessels
Implementation Method 2
The accommodation part may be provided as a sealed vacuum chamber
Implementation Method 3
the silica precursor injection part may be provided in plurality on a circumferential surface of the vacuum chamber in a height direction
Implementation Method 4
The impregnation vessel includes a vacuum generation part which discharges air in the accommodation part to the outside to allow the silica precursor to ascend through suction force
Implementation Method 5
the silica precursor injection part which injects the silica precursor into the accommodation part to impregnate the silica precursor into the fiber sheet inserted into each of the fixing vessels
Data Source
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AI summary
The present invention relates to an apparatus of manufacturing an aerogel sheet. The apparatus of manufacturing the aerogel sheet includes: a plurality of fixing vessels into which a fiber sheet is inserted; and an impregnation vessels provided with an accommodation part in which the plurality of fixing vessels are stacked in multistage and a silica precursor injection part which injects a silica precursor into the accommodation part to impregnate the silica precursor into the fiber sheet inserted into each of the fixing vessels.