Rotating Tray Aerogel Sheet Impregnation for Uniform Thickness
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Solution Overview
Problem
Aerogel sheets produced by existing methods have non-uniform thickness, poor heat insulation, and durability issues, making mass production challenging.
Innovation Solution
An apparatus comprising a tray device with a sealed vessel, a rotation device, a silica precursor injection device, and a surface modification device, which impregnates and modifies silica precursors into fiber sheets using partition walls and gap members to ensure uniform thickness and heat insulation, and includes a transfer device for continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional aerogel manufacturing methods are used, then aerogel sheets can be produced, but the sheets have non-uniform thickness and poor heat insulation
Solution Approach 1:
The tray device is divided into multiple compartments with partition walls, allowing independent control of silica precursor injection for each section. This segmentation enables precise thickness control across different areas of the fiber sheet, resolving the non-uniform thickness problem while maintaining consistent heat insulation quality.
Solution Approach 2:
The invention applies local quality by injecting silica precursor into specific regions through the connection part and partition walls, allowing each local area to receive precisely controlled amounts of precursor. This ensures uniform thickness and consistent heat insulation properties across the entire aerogel sheet by tailoring the treatment to each local region's requirements.
2Productivity
If mass production is attempted with existing methods, then production volume increases, but quality consistency deteriorates
Solution Approach 1:
The fiber sheet is pre-prepared and placed in the tray device before silica precursor injection. The partition walls and connection parts are pre-configured to ensure uniform distribution of precursor during mass production. This preliminary preparation maintains thickness uniformity even when production volume increases, as each sheet receives consistent treatment from the start.
Solution Approach 2:
The apparatus enables continuous production by maintaining consistent silica precursor injection through the connection part and partition walls across multiple sheets. The uniform structure ensures that each sheet undergoes the same treatment process continuously, preserving thickness uniformity and quality consistency throughout mass production runs.
3Reliability
If silica precursor is injected to improve heat insulation, then insulation performance increases, but sheet durability decreases
Solution Approach 1:
The invention applies partial action by injecting silica precursor only into specific regions defined by the partition walls and connection parts, rather than overwhelming the entire sheet. This controlled, partial injection achieves sufficient heat insulation performance while avoiding excessive precursor that would compromise sheet durability and structural integrity.
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
Enables the mass production of aerogel sheets with improved heat insulation, durability, and uniform thickness, preventing defects like sheet shaking and adherence during processing.
Implementation Method 1
a silica precursor injection device injecting a silica precursor into the tray device to impregnate the silica precursor into the fiber sheet
Implementation Method 2
A silica precursor solution is subjected to sol-gel polymerization reaction to from gel
Implementation Method 3
a surface modification device injecting a coating solution into the tray device to modify a surface of the fiber sheet in which the silica precursor is impregnated
Data Source
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AI summary
The present invention relates to an apparatus of manufacturing an aerogel sheet. The apparatus of manufacturing the aerogel sheet includes: a tray device in which a fiber sheet is accommodated; a rotation device including a rotation rod to which the tray device is fixed and a driving member rotating the rotation rod so that the tray device is disposed on an upper and lower portion of the rotation rod; an injection device injecting a silica precursor into the tray device disposed on the upper portion of the rotation rod to impregnate the silica precursor into the fiber sheet; and a surface modification device injecting a coating solution into the tray device disposed on the lower portion of the rotation rod to modify a surface of the fiber sheet in which the silica precursor is impregnated.