Aerogel Sheet Manufacturing Uniform Thickness Control
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Solution Overview
Problem
Aerogel sheets produced by existing methods often have nonuniform thickness and poor heat insulation and durability.
Innovation Solution
A method involving the preparation of a silica precursor by mixing silica sol and a surface modifying agent, followed by spraying onto a blanket using a conveyor belt with scrapers to adjust thickness, and subsequent gelling, aging, and supercritical drying to achieve uniform thickness and improved insulation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spraying methods are used to apply silica precursor and gelling catalyst, then the manufacturing process is simple, but the aerogel sheet has nonuniform thickness
Solution Approach 1:
The conveyor belt system applies the silica precursor and gelling catalyst in a predetermined sequence and at controlled rates before the actual gelation process. The scrapers pre-adjust the thickness of each layer being applied, ensuring uniform distribution before the chemical reaction begins, which directly resolves the thickness uniformity problem.
Solution Approach 2:
The conveyor belt acts as an intermediary device between the spraying mechanisms and the blanket substrate. It provides a controlled interface where the scrapers can mechanically regulate the thickness of applied materials, mediating between the spraying process and the final aerogel structure to achieve uniform thickness.
2Reliability
If conventional drying methods are used, then the process is simple, but the aerogel sheet has poor heat insulation and durability
Solution Approach 1:
The supercritical drying process utilizes the phase transition of carbon dioxide from supercritical state to gaseous state. By maintaining the drying medium (CO2) in a supercritical state during drying and then allowing controlled phase transition, the method prevents capillary stresses that would collapse the aerogel pores, thereby preserving the unique pore structure necessary for excellent heat insulation and durability.
Solution Approach 2:
The supercritical drying method is specifically designed to preserve the porous structure of aerogels. By avoiding conventional drying that would collapse pores, the process maintains the high porosity (90-99%) and unique pore structure that give aerogel its superior thermal insulation properties and mechanical durability.
3Productivity
If manual preparation of silica precursor and gelling catalyst is used, then the process is simple, but the manufacturing efficiency is low
Solution Approach 1:
The conveyor belt system enables continuous processing by continuously transporting the blanket through the spraying zones and subsequent processing stages. Instead of batch-wise manual preparation and application, the system maintains continuous motion and continuous application of precursors and catalysts, dramatically improving manufacturing efficiency and productivity.
Solution Approach 2:
The patent replaces manual mechanical preparation and application with an automated conveyor-based system. The mechanical spraying mechanisms mounted on the conveyor automatically apply materials at controlled rates, substituting manual operations with automated mechanical systems that increase throughput and efficiency.
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 aerogel sheets with superior thermal insulation and durability, ensuring uniform thickness and high-quality production through efficient processing and quality silica sol and gelling catalyst preparation.
Implementation Method 1
A silica precursor solution is subjected to sol-gel polymerization reaction to prepare gel
Implementation Method 2
The aerogel has a pore structure filled with air
Implementation Method 3
the conveyor belt comprises a scraper comprising a first scraper adjusting a thickness of the silica precursor sprayed to the surface of the blanket and a second scraper adjusting a thickness of the gelling catalyst sprayed to the surface of the blanket
Implementation Method 4
injecting the gelling catalyst prepared in the step (b) to the surface of the blanket in which the silica precursor is impregnated to chelate the silica precursor
Implementation Method 5
a drying process is performed on the prepared gel under supercritical or atmospheric conditions to obtain the aerogel
Data Source
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AI summary
The present invention relates to a method for manufacturing an aerogel sheet and comprises: a step (a) of preparing silica sol and a surface modifying agent to prepare a silica precursor; a step (b) of preparing a gelling catalyst; a step (c) of injecting the silica precursor prepared in the step (a) to a surface of a blanket to impregnate the silica precursor; and a step (d) of injecting the gelling catalyst prepared in the step (b) to the surface of the blanket in which the silica precursor is impregnated to gelate the silica precursor.