Aerogel Blanket Manufacturing Using Silazane Gelation
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Solution Overview
Problem
Conventional methods for manufacturing aerogel blankets are time-consuming and costly due to the multi-step process involving solvent use and separate aging and surface modification steps, which complicates the process and increases costs.
Innovation Solution
A method that combines the steps of forming a sol with a precursor material, acid catalyst, and hydrous alcohol, followed by reacting with a gaseous silazane-based compound to simultaneously perform gelation and surface modification, eliminating the need for additional solvents and separate aging, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional sol-gel method with separate aging and surface modification steps is used, then the aerogel blanket achieves good insulation performance, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the aging and surface modification steps into a single simultaneous reaction step. The silazane-based compound performs both aging (network densification) and surface modification (hydrophobicity enhancement) functions in one process, eliminating the need for separate sequential steps while maintaining the required insulation performance
Solution Approach 2:
The silazane-based compound serves multiple functions simultaneously: it acts as both an aging agent for network densification and a surface modifier for hydrophobicity enhancement. This multi-functional approach simplifies the manufacturing process by replacing multiple specialized chemicals and steps with a single versatile compound
2Reliability
If the conventional sol-gel method with multiple steps is used, then the aerogel blanket achieves good insulation performance, but the manufacturing time increases
Solution Approach 1:
The patent merges the aging and surface modification steps into one simultaneous reaction process. By using the silazane-based compound that performs both functions at the same time, the total manufacturing time is reduced while the final product maintains excellent insulation performance comparable to conventional methods
3Reliability
If the conventional sol-gel method with separate aging and surface modification steps is used, then the aerogel blanket achieves good insulation performance, but the manufacturing cost increases
Solution Approach 1:
The patent combines two separate process steps (aging and surface modification) into one simultaneous step using the silazane-based compound. This reduction in the number of steps directly lowers manufacturing costs by reducing equipment usage, energy consumption, and operational complexity while maintaining product quality
Solution Approach 2:
The silazane-based compound provides multi-functionality by serving as both the aging agent and surface modifier. This eliminates the need for separate chemicals and processing steps, thereby reducing material costs and manufacturing expenses while achieving the required insulation performance
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
This approach significantly reduces manufacturing time and costs while maintaining excellent thermal insulation performance and mechanical properties, as demonstrated by the examples showing lower thermal conductivity and improved hydrophobicity compared to conventional methods.
Implementation Method 1
reacting with a gaseous silazane-based compound to form a gel and to perform aging and surface modification reaction simultaneously
Implementation Method 2
surface modification may be caused by at least one compound from the group consisting of an alkoxy silane-based compound and an alkyl silanol-based compound generated when the gaseous silazane-based compound reacts with the hydrous alcohol
Implementation Method 3
drying the wet gel blanket to manufacture an aerogel blanket
Data Source
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AI summary
The present invention provides a method for manufacturing an aerogel blanket having improved processability by reducing manufacturing time and cost, and the method includes the steps of mixing a precursor material, an acid catalyst, and a hydrous alcohol to prepare a sol, depositing a substrate in the sol and reacting with a gaseous silazane-based compound to form a gel and to perform aging and surface modification reaction simultaneously to form a wet gel blanket, and drying the wet gel blanket to manufacture an aerogel blanket.