Compressed Aerogel Composite with Sub-50 Nm Pore Control
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Solution Overview
Problem
Existing aerogel composites are inflexible, exhibit high thermal conductivity, and lack optimal pore sizes and thickness control, limiting their effectiveness as thermal insulators.
Innovation Solution
A method involving the concurrent compression and heating of aerogel composites, using a reinforcing component like polyethylene terephthalate fibers, to achieve a majority of pores with diameters less than 50 nm and controlled thickness, enhancing thermal insulation and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aerogel composites are made with traditional methods, then they provide thermal insulation, but they are inflexible and exhibit high thermal conductivity
Solution Approach 1:
The patent applies parameter changes by modifying the pore size distribution (achieving majority pores <50 nm) and thickness (controlling to <0.6 mm) through controlled compression and heating processes. This transforms the aerogel composite from a rigid, high thermal conductivity material into a flexible, low thermal conductivity insulation material suitable for dynamic applications.
2Reliability
If aerogel composites are made with traditional methods, then they provide thermal insulation, but they lack optimal pore sizes and thickness control
Solution Approach 1:
The patent implements precise parameter control by using controlled compression to achieve specific pore size reduction (majority <50 nm) and thickness control (<0.6 mm). The heating process further refines these parameters, creating a reproducible manufacturing method that delivers consistent, optimal insulation performance.
Solution Approach 2:
The patent replaces traditional mechanical compression methods with a combined thermal-mechanical process. By applying heat alongside compression, the material achieves pore size control and thickness reduction through viscoelastic deformation rather than purely mechanical force, enabling more precise and controllable parameter adjustment.
3Reliability
If aerogel composites are compressed to reduce thickness, then they become more effective insulators, but they lose flexibility and increase thermal conductivity
Solution Approach 1:
The patent resolves this contradiction by changing the material's thermal and mechanical parameters through controlled heating during compression. The heat activates viscoelastic properties that allow the material to be compressed to thin dimensions while maintaining flexibility, achieving both improved insulation effectiveness and retained operational flexibility.
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 process results in aerogel composites with reduced thermal conductivity, improved mechanical strength, and precise thickness control, making them more effective thermal insulators compared to traditional methods.
Implementation Method 1
compressing and heating the aerogel composite
Implementation Method 2
heating the aerogel composite to a temperature above a glass transition temperature of the polyethylene, polyacrylonitrile, an oxidized polyacrylonitrile, polyethylene terephthalate, or a mixture thereof
Data Source
AI summary
The present disclosure relates to a method of producing an aerogel composite, the method includes compressing an aerogel composite, the aerogel composite including a gel dispersed about a reinforcing component. The method further includes heating the aerogel composite. The method further results in producing a compressed and heated aerogel composite, the produced aerogel composite comprising a plurality of pores, a. majority of which having a diameter less than 50 nm.