Fiber-Reinforced Double-Network Aerogel for Stable Low Thermal Conductivity
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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 composite articles, comprising primary and secondary aerogel network domains with differing chemical compositions, interconnected covalently, and prepared through a specific method involving dispersion, catalysts, and supercritical drying, eliminating the need for standalone opacifying compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single aerogel material with fillers and opacifying compounds is used, then manufacturing complexity is reduced, but stability and performance are worsened
Solution Approach 1:
The patent employs a double-network composite aerogel structure where a first aerogel network (silica-based) and a second aerogel network (polymer-based) are interpenetratingly combined. This composite structure provides enhanced stability, mechanical strength, and functional performance while eliminating the need for separate fillers and opacifying compounds, as the aerogel matrices themselves provide these properties.
Solution Approach 2:
The aerogel matrices in the composite structure serve multiple functions simultaneously: they provide structural framework, thermal insulation, mechanical strength, and optical properties (including opacification). This multi-functionality eliminates the need for separate specialized additives, improving reliability while managing manufacturing complexity.
2Stability of the object's composition
If fillers and opacifying compounds are added to aerogel, then optical and mechanical properties are improved, but composition stability is worsened
Solution Approach 1:
The patent merges the functions of fillers and opacifying compounds into the aerogel matrix itself by creating a double-network structure where both aerogel phases contribute to mechanical strength, thermal performance, and optical properties. This integration eliminates composition instability associated with separate additives while maintaining enhanced performance.
3Strength
If fiber reinforcement is added to aerogel composite, then mechanical strength is improved, but manufacturing complexity is worsened
Solution Approach 1:
The patent incorporates fibers into the aerogel composite during the gelation process itself, before the aerogel structure fully forms. The fibers are mixed with the precursor solutions and become integrated into the growing aerogel network, which simplifies manufacturing compared to post-forming fiber reinforcement while achieving enhanced mechanical strength.
Solution Approach 2:
The patent creates a three-phase composite material system combining fibers, first aerogel network, and second aerogel network. This multi-phase composite provides synergistic mechanical reinforcement while the integrated formation process manages manufacturing complexity.
4Reliability
If double-network aerogel structure is created, then thermal conductivity is improved, but manufacturing process complexity is worsened
Solution Approach 1:
The patent segments the aerogel structure into two distinct but interpenetrating networks: a silica-based first aerogel network and a polymer-based second aerogel network. Each network can be optimized for specific thermal properties, and their combined structure provides superior thermal conductivity control. The segmented approach allows independent optimization of each network's formation process.
Solution Approach 2:
The patent utilizes parameter changes in the gelation process, switching from acid-catalyzed gelation for the first network to base-catalyzed gelation for the second network. This parameter switching enables controlled formation of the double-network structure with optimized thermal properties while managing process complexity through systematic parameter variation.
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 and hydrophobicity across varying temperatures, with reduced thermal conductivity and enhanced stability, eliminating the need for additional opacifying compounds and fillers.
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 or ambient pressure drying
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.