Double-Network Aerogel Composite for Stable Thermal Insulation
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Solution Overview
Problem
Existing aerogel composite articles typically rely on single aerogel materials and often include fillers and opacifying compounds, which can be unstable and require additional components, limiting their performance and stability.
Innovation Solution
The development of fiber-reinforced double-network aerogel composites, where primary and secondary aerogel network domains with different chemical compositions are covalently interconnected, eliminating the need for standalone opacifying compounds and enhancing thermal conductivity and hydrophobicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single aerogel material is used, then manufacturing simplicity is maintained, but stability and performance are insufficient
Solution Approach 1:
The patent employs a double-network aerogel composite structure where a first aerogel network (providing mechanical strength and stability) and a second aerogel network (providing thermal insulation and hydrophobicity) are covalently interconnected. This composite approach resolves the contradiction by integrating multiple materials with complementary properties, achieving both enhanced stability and functional performance while maintaining manufacturing feasibility through a systematic preparation process involving dispersion mixing and gelation.
2Temperature
If fillers and opacifying compounds are added, then thermal conductivity is improved, but device complexity and number of components increase
Solution Approach 1:
The second aerogel network in the composite structure serves multiple functions simultaneously: it provides thermal insulation (controlling thermal conductivity), ensures hydrophobicity, and contributes to the overall structural integrity. By designing the aerogel composite to be multi-functional, the patent eliminates the need for separate fillers and standalone opacifying compounds, thereby reducing device complexity while maintaining improved thermal performance.
3Reliability
If multiple components are used, then performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the preparation of multiple aerogel networks into a single integrated process. The first aerogel powder and second aerogel precursor are mixed in a dispersion medium, and both networks are formed simultaneously through controlled gelation and drying. This merging approach allows the composite structure to be created in one manufacturing step rather than requiring separate preparation and assembly operations, thus enhancing performance while controlling manufacturing complexity.
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 composite articles exhibit improved thermal conductivity at elevated temperatures and low thermal conductivity at ambient temperatures, with reduced reliance on fillers and opacifying compounds, providing enhanced stability and performance.
Implementation Method 1
adding an acidic catalyst to the result of step (ii) to catalyze hydrolysis of the secondary silane precursors
Implementation Method 2
adding a basic catalyst to the result of step (iii) to catalyze gelation of the secondary silane precursors
Implementation Method 3
The removing the organic solvent comprises supercritical drying using ethanol as the drying medium and nitrogen as the carrier gas
Data Source
AI summary
Disclosed herein are fiber-reinforced double-network aerogel composite articles and methods of manufacture. The composite articles comprise primary aerogel network domains and secondary aerogel network domains, which differ from each other in their chemical compositions, but are covalently interconnected.