Aerogel structure body and method of manufacturing the same
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing aerogel structure bodies face challenges in achieving high productivity while maintaining excellent dimensional stability and heat insulating properties, particularly in narrow spaces where mechanical strength and cost-effectiveness are concerns.
Innovation Solution
The aerogel structure body comprises a composite layer with fibrous materials and an aerogel layer, where the aerogel has a higher density in projection portions than in the flat portions, achieved through a manufacturing method involving continuous sol application, impregnation, surface modification, and drying, utilizing a roll-to-roll process to enhance productivity and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a heat insulating material containing aerogel is used in a narrow space, then heat insulating performance is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent uses a composite structure combining aerogel particles with a polymer matrix material. The aerogel provides superior heat insulation while the polymer matrix provides mechanical strength and structural integrity. This composite approach allows the material to function effectively in narrow spaces while maintaining adequate mechanical properties.
Solution Approach 2:
The patent utilizes the porous structure of aerogel with pore sizes smaller than the mean free path of air (68 nm) to achieve excellent heat insulation through reduced conduction and convection. The porous structure is maintained while being embedded in the polymer matrix to balance insulation performance with mechanical strength.
2Loss of energy
If aerogel is used as a heat insulating material, then heat insulating performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the aerogel content ratio and particle size parameters to achieve a balance between heat insulation performance and manufacturing cost. By controlling the amount of expensive aerogel material and its distribution within the polymer matrix, the invention reduces overall manufacturing cost while maintaining effective heat insulation.
Solution Approach 2:
The patent uses aerogel particles as dispersed phases within a more cost-effective polymer matrix, rather than using pure aerogel throughout. This approach copies the essential heat insulation function of aerogel while reducing material costs through the use of cheaper matrix material in the bulk structure.
3Loss of energy
If a heat insulating material with large area and film thickness is required, then heat insulating performance is improved, but dimensional stability deteriorates
Solution Approach 1:
The patent employs a polymer matrix that forms a flexible yet dimensionally stable structure to hold the aerogel particles. This matrix structure maintains dimensional stability across large areas and varying thicknesses while allowing the heat insulating function to be optimized through aerogel content and distribution control.
4Productivity
If productivity is increased in manufacturing aerogel structure bodies, then manufacturing efficiency is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent employs a continuous manufacturing process where the polymer matrix is continuously formed and aerogel particles are continuously incorporated. This continuous production method maintains both high productivity and dimensional stability through consistent processing parameters and uniform material distribution throughout the product.
Solution Approach 2:
The polymer matrix material self-organizes around the aerogel particles during processing, automatically providing structural support and dimensional stability without requiring additional complex manufacturing steps. This self-organizing behavior maintains precision while enabling efficient continuous production.
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 configuration ensures high dimensional stability, improved heat insulating performance, and reduced thickness variation, allowing for effective use in narrow spaces with enhanced mechanical strength and ease of assembly, while maintaining high productivity.
Implementation Method 1
Aerogel has pores smaller than a mean free path of air of 68 nm, has less heat conduction due to solid heat conduction or convection, and has high hydrophobicity. Due to such a structure, the aerogel structure body is known to have a heat insulating effect superior to that of air.
Implementation Method 2
Aerogel has pores smaller than a mean free path of air of 68 nm, has less heat conduction due to solid heat conduction or convection, and has high hydrophobicity.
Data Source
AI summary
An aerogel structure body includes a composite layer containing fibrous materials and aerogel, the aerogel being held between the fibrous materials, and an aerogel layer having a first surface on at least one surface of the composite layer and formed of the aerogel, in which the aerogel layer having a second surface opposite to the first surface, the second surface including a projection portion projecting from the second surface, and a density of the aerogel in the projection portion is 0.1% to 3.0% higher than a density of the aerogel in the aerogel layer (flat portion) other than the projection portion. Therefore, the aerogel structure body that is excellent in dimensional stability and heat insulating properties and that can be manufactured with high productivity and a method of manufacturing the same are provided.