Aerogel Sheet Injection Method for Uniform Thickness and Durability
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Solution Overview
Problem
Aerogel sheets exhibit nonuniform thickness and poor heat insulation and durability due to existing manufacturing methods.
Innovation Solution
A method involving preparing a plate-shaped blanket, mixing silica sol with a gelling catalyst, injecting the precursor onto the blanket while moving, aging, surface modification, and supersonic drying to achieve uniform thickness and enhanced insulation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a sol-gel process is used to produce an aerogel sheet, then the aerogel sheet can be produced with low density and high porosity, but the mechanical strength is insufficient and the sheet cannot be handled without support
Solution Approach 1:
The patent applies parameter changes by controlling the drying conditions (supercritical drying vs. ambient drying) and composition parameters (crosslinking agents, catalysts, fillers) to achieve the desired balance between low density and adequate mechanical strength. By adjusting these parameters, the aerogel structure can be optimized for both lightweight properties and handling capability.
Solution Approach 2:
The patent employs composite materials by incorporating fillers (such as silica, alumina, titania) into the aerogel matrix to enhance mechanical strength while maintaining low density. The composite structure combines the lightweight properties of aerogel with the reinforcing effects of filler particles, resolving the contradiction between low density and mechanical strength.
2Device complexity
If ambient drying is used instead of supercritical drying, then equipment cost and operational complexity are reduced, but the aerogel sheet undergoes significant shrinkage and distortion
Solution Approach 1:
The patent applies parameter changes by optimizing the ambient drying conditions (temperature, humidity, drying rate) and gel composition to minimize shrinkage and distortion. By carefully controlling these parameters, the patent achieves dimensional stability comparable to supercritical drying while using simpler equipment.
Solution Approach 2:
The patent applies preliminary action by performing pre-drying treatments and controlled moisture removal steps before final drying. This preliminary control of the drying process helps prevent excessive shrinkage and distortion, maintaining manufacturing precision while using ambient drying equipment.
3Weight of moving object
If the aerogel sheet is made thinner to reduce weight, then the weight decreases, but the mechanical strength and structural integrity deteriorate
Solution Approach 1:
The patent employs composite materials by incorporating reinforcing fillers and optimizing the aerogel matrix composition to maintain structural integrity in thin sheets. The composite structure provides enhanced strength-to-weight ratio, allowing thin sheets to maintain adequate mechanical properties despite reduced thickness.
Solution Approach 2:
The patent optimizes the porous structure of the aerogel to maintain structural integrity in thin sheets. By controlling pore size, distribution, and connectivity, the patent achieves a balance between low weight (through high porosity) and sufficient mechanical strength for handling thin sheets.
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 method results in an aerogel sheet with superior heat insulation and durability, utilizing tetraethyl orthosilicate and ethanol for high-quality silica sol and gelling catalyst preparation, and a scraper for uniform thickness adjustment, leading to improved aerogel properties.
Implementation Method 1
wherein the catalyst promotes polymerization of the precursor solution to form a gel
Implementation Method 2
The gel is then dried to produce an aerogel
Data Source
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AI summary
A method for manufacturing an aerogel sheet according to the present invention includes: a step (a) of preparing a blanket having a plate shape; a step (b) of mixing silica sol with gelling catalyst to prepare a silica sol precursor; and a step (c) of injecting the silica sol precursor prepared in the step (b) to a surface of the blanket prepared in the step (a) through an injection device to gelate the silica sol precursor, wherein, in the step (c), the injection device injects the silica sol precursor while moving from one side to the other side of the surface of the blanket.