Aerogel Sheet Impregnation Roller for Uniform Silica Sol Gelation
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Solution Overview
Problem
Existing apparatus for manufacturing aerogel sheets face issues with non-uniform impregnation of silica sol precursors on the blanket surface, leading to defective products due to incomplete penetration of the precursor, resulting in suboptimal quality.
Innovation Solution
An apparatus featuring a rotation roller with injection nozzles that moves along the blanket's surface, rotating and adjusting height to ensure uniform impregnation and gelation of the silica sol precursor, utilizing a supply device to mix and prepare the precursor, and including members to manage the roller's movement and height for comprehensive coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the silica sol precursor is injected to the blanket surface using conventional methods, then the manufacturing process is simple, but the impregnation uniformity is poor leading to defective products
Solution Approach 1:
The injection system is segmented into multiple injection nozzles arranged circumferentially on the rotation roller, allowing simultaneous injection at multiple locations across the blanket surface. This segmentation enables uniform distribution of silica sol precursor while maintaining a relatively simple overall apparatus structure.
Solution Approach 2:
The apparatus employs a rotation roller that moves dynamically from one end to the other end of the blanket while rotating, replacing static injection methods. This dynamic approach ensures uniform impregnation across the entire blanket surface and improves manufacturing precision without significantly increasing device complexity.
2Ease of manufacture
If the silica sol precursor is not uniformly impregnated on the blanket outer portion, then the manufacturing process is simple, but the product quality deteriorates
Solution Approach 1:
The injection nozzles are pre-positioned on the rotation roller at optimal locations before the impregnation process begins. The roller carries the nozzles along the blanket surface, ensuring preliminary and uniform distribution of silica sol precursor across the entire blanket area, thereby improving product quality while keeping the manufacturing process straightforward.
3Manufacturing precision
If a rotation roller with injection nozzles is used to impregnate the blanket, then the impregnation uniformity is improved, but the device complexity increases
Solution Approach 1:
The rotation roller serves multiple functions simultaneously: it holds the injection nozzles, moves along the blanket surface, rotates to distribute the precursor uniformly, and controls the injection process. This multi-functionality improves impregnation uniformity while avoiding the need for separate complex subsystems.
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 apparatus ensures uniform impregnation and improved quality of aerogel sheets by ensuring the silica sol precursor is evenly distributed across the blanket, enhancing the thermal insulation properties and sound absorption capabilities.
Implementation Method 1
a rotation roller moving from one end to the other end of a top surface of the blanket while rotating to put the stored silica sol precursor into the blanket
Implementation Method 2
A silica precursor solution is subjected to sol-gel polymerization reaction to from gel
Implementation Method 3
drying process is performed on the formed gel under supercritical or atmospheric conditions to obtain the aerogel
Implementation Method 4
The greatest advantage of the above-described advantages is the high heat insulation having thermal conductivity of 30 mW/m·k or less
Implementation Method 5
has physical properties such as heat insulation and sound absorption due to the unique pore structure
Data Source
AI summary
The present invention relates to an apparatus of manufacturing an aerogel sheet. The apparatus of manufacturing the aerogel sheet includes: a fixing vessel into which a blanket is inserted; and an impregnation device putting a silica sol precursor into the blanket inserted into the fixing vessel to impregnate and gelate the silica sol precursor, wherein the impregnation device includes a rotation roller moving from one end to the other end of a top surface of the blanket while rotating to put the stored silica sol precursor into the blanket and thereby to impregnate and gelate the silica sol precursor.