Aerogel Sheet Thickness Uniformity via Supercritical Drying
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Solution Overview
Problem
Aerogel sheets exhibit nonuniform thickness and poor heat insulation and durability.
Innovation Solution
A method involving steps such as immersing a blanket in silica sol, introducing a gelling catalyst, aging, surface modification, and a multi-stage drying process using carbon dioxide under controlled temperature and pressure conditions to produce an aerogel sheet with uniform thickness and enhanced insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying methods are used on aerogel sheets, then the drying process is simple and quick, but the aerogel sheet exhibits nonuniform thickness and poor durability
Solution Approach 1:
The drying process is divided into multiple sequential stages: supercritical drying phase, depressurization phase, and drying phase. Each stage has specific pressure and temperature control parameters, transforming a single complex drying operation into manageable segments that achieve uniform thickness while maintaining reasonable process complexity
Solution Approach 2:
The patent systematically changes pressure and temperature parameters throughout the drying process. Pressure transitions from supercritical levels (above 73 bar) to atmospheric levels, while temperature is maintained and adjusted at different stages. These parameter changes enable controlled solvent removal that prevents thickness nonuniformity and improves durability
2Reliability
If conventional drying methods are used on aerogel sheets, then the drying process is simple and quick, but the aerogel sheet exhibits poor heat insulation performance
Solution Approach 1:
The drying process is divided into multiple sequential stages: supercritical drying phase, depressurization phase, and drying phase. Each stage has specific pressure and temperature control parameters, transforming a single complex drying operation into manageable segments that achieve uniform thickness while maintaining reasonable process complexity
Solution Approach 2:
The patent systematically changes pressure and temperature parameters throughout the drying process. Pressure transitions from supercritical levels (above 73 bar) to atmospheric levels, while temperature is maintained and adjusted at different stages. These parameter changes enable controlled solvent removal that prevents thickness nonuniformity and improves durability
3Manufacturing precision
If a multi-stage drying process with controlled parameters is implemented, then uniform thickness and excellent heat insulation are achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The drying process is divided into multiple sequential stages: supercritical drying phase, depressurization phase, and drying phase. Each stage has specific pressure and temperature control parameters, transforming a single complex drying operation into manageable segments that achieve uniform thickness while maintaining reasonable process complexity
Solution Approach 2:
The patent systematically changes pressure and temperature parameters throughout the drying process. Pressure transitions from supercritical levels (above 73 bar) to atmospheric levels, while temperature is maintained and adjusted at different stages. These parameter changes enable controlled solvent removal that prevents thickness nonuniformity and improves durability
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 insulation and durability, achieving uniform thickness and improved heat insulation performance.
Implementation Method 1
a first drying step of injecting carbon dioxide at a rate of 70 L/min for ten minutes under environments of a temperature of 28°C and a pressure of 70 bar to dry the blanket of which the surface is modified
Implementation Method 2
A silica precursor solution is subjected to sol-gel polymerization reaction to form gel
Implementation Method 3
a third drying step of injecting carbon dioxide at a rate of 0.7 L/min for 20 minutes under a temperature of 50°C and a pressure of 150 bar to dry the blanket again
Data Source
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AI summary
The present invention relates to a method for manufacturing an aerogel sheet. The method for manufacturing an aerogel sheet includes: a step (a) of immersing a blanket in an impregnation vessel in which silica sol is stored to impregnate the silica sol; and a step (b) of injecting a gelling catalyst to a surface of the blanket in which the silica sol is impregnated to gelate the silica sol.