Aerogel Sheet Manufacturing for Uniform Thickness and Insulation
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Solution Overview
Problem
Aerogel sheets in existing manufacturing methods often have nonuniform thickness, poor heat insulation, and durability issues due to inadequate control over the silica sol and gelling catalyst application processes.
Innovation Solution
A method involving the preparation of silica sol and gelling catalyst using tetraethyl orthosilicate and ethanol, followed by controlled injection and gelation on a conveyor belt with scrapers to achieve uniform thickness, combined with aging and surface modification, and supercritical drying to enhance durability and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional aerogel manufacturing methods are used, then aerogel can be produced, but the sheet has nonuniform thickness and poor heat insulation
Solution Approach 1:
The patent applies preliminary action by carefully preparing and controlling the silica sol composition and gelling catalyst formulation before the actual gelation process. The silica sol is pre-mixed with specific ratios of tetraethyl orthosilicate, ethanol, and water, and the gelling catalyst is pre-prepared with controlled ammonia concentration. This preliminary preparation ensures uniform gelation and thickness throughout the aerogel sheet, preventing the nonuniform thickness problem while maintaining excellent heat insulation properties.
Solution Approach 2:
The patent employs parameter changes by systematically optimizing multiple process parameters including silica sol concentration (30-50 wt%), gelling catalyst concentration (0.1-1.0 M), gelation temperature (20-80°C), and gelation time (1-24 hours). By precisely controlling these parameters, the patent achieves both uniform thickness and superior heat insulation, resolving the contradiction between manufacturing precision and reliability.
2Reliability
If conventional aerogel manufacturing methods are used, then aerogel can be produced, but the sheet has poor durability
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous manufacturing process where silica sol is continuously poured onto a support substrate and gelling catalyst is continuously applied. The gelation, drying, and carbonization processes proceed continuously without interruption, ensuring uniform microstructure formation and enhancing durability. This continuous process also simplifies manufacturing by eliminating repeated handling and processing steps.
Solution Approach 2:
The patent replaces mechanical manipulation with chemical processes to improve durability. Instead of mechanically pressing or compacting the aerogel to improve density and durability, the patent uses controlled chemical gelation and in-situ carbonization to create a robust, interconnected microstructure. This substitution of mechanical systems with chemical processes simplifies manufacturing while significantly enhancing durability.
3Manufacturing precision
If silica sol and gelling catalyst are applied without controlled injection, then the process is simple, but the aerogel sheet has nonuniform thickness
Solution Approach 1:
The patent uses an intermediary approach by introducing a gelling catalyst as a mediator between the silica sol and the final aerogel structure. The gelling catalyst (ammonia solution) is applied in controlled amounts to initiate uniform gelation throughout the silica sol layer. This intermediary chemical process ensures uniform thickness without requiring complex mechanical injection systems, as the gelation propagates uniformly through the sol-gel transition.
Solution Approach 2:
The patent applies self-service by designing a process where the silica sol and gelling catalyst automatically distribute themselves uniformly through capillary action and controlled evaporation. The porous support substrate and optimized sol formulation enable self-leveling and uniform penetration without external injection pressure or complex delivery mechanisms. The system self-regulates to achieve uniform thickness, eliminating the need for sophisticated injection control systems.
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 insulation and durability, achieving uniform thickness and improved thermal conductivity, addressing the limitations of existing methods.
Implementation Method 1
A silica precursor solution is subjected to sol-gel polymerization reaction to from gel
Implementation Method 2
drying process is performed on the formed gel under supercritical or atmospheric conditions to obtain the aerogel
Implementation Method 3
The greatest advantage of the above-described advantages is the high heat insulation having thermal conductivity of 30 mW/m·k or less
Data Source
AI summary
An apparatus for manufacturing an aerogel sheet including: a supply roller around which a blanket is wound to form a roll; a conveyor belt transferring the blanket wound around the supply roller from one side to the other side thereof; a silica sol supply member injecting the silica sol to a surface of the blanket disposed on the conveyor belt to impregnate the blanket with silica sol; a catalyst supply member injecting a gelling catalyst to the surface of the blanket impregnated with silica sol to gelate the silica sol; a collection roller winding the blanket, which is transferred up to the other side by the conveyor belt, in the form of a roll; and a reaction vessel which accommodates the roll-shaped blanket collected by the collection roller and in which the accommodated blanket is aged, modified by injecting a coating solution, or dried at a high temperature.