Dual-Binder Aerogel Coating for Adhesive Insulation on Complex Surfaces
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Solution Overview
Problem
Existing methods for producing thermal insulators struggle to form a coating film with sufficient strength and adhesiveness on complex surfaces, requiring separate molding and adherence techniques.
Innovation Solution
A coating liquid containing aerogel particles, a cellulose-based first binder resin, and a thermosetting second binder resin with lower solubility, along with a curing agent and fibrous substances, is used to create a coating film with enhanced strength and adhesiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal insulator is produced as a molded material, then thermal insulation performance is achieved, but it is difficult to conform to complicated surface shapes and requires separate adherence techniques
Solution Approach 1:
The invention merges the thermal insulation function with the coating application process. The coating liquid contains aerogel particles that provide thermal insulation while the liquid carrier enables direct application to complex surfaces, eliminating the need for separate molding and adherence steps. This combines multiple functions (thermal insulation, surface conformability, and application ease) into a single system.
Solution Approach 2:
The coating liquid serves multiple functions simultaneously: it acts as a binder, a thermal insulation material, and a surface-adaptable coating. The aerogel particles provide thermal insulation while the liquid medium enables flow and adhesion to various surface geometries, making the system universally applicable to different substrate shapes.
2Reliability
If aqueous dispersion containing aerogel particles is used as coating liquid, then thermal insulation is provided, but sufficient coating film strength and adhesiveness cannot be achieved
Solution Approach 1:
The invention uses a composite coating liquid containing aerogel particles dispersed in a liquid carrier with specific binder resins. The aerogel provides thermal insulation while the binder resins (such as polyvinyl alcohol, carboxymethyl cellulose, or styrene-butadiene rubber) provide coating film strength and adhesiveness. This composite structure allows simultaneous achievement of thermal insulation and mechanical strength.
Solution Approach 2:
The invention optimizes parameters including aerogel particle size (0.1-100 μm), binder resin content (5-50 wt%), and liquid carrier composition to achieve both thermal insulation and coating film strength. By adjusting these parameters, the coating liquid forms a film that maintains thermal insulation properties while achieving sufficient adhesion and mechanical strength.
3Reliability
If aerogel particles are used in coating liquid, then thermal insulation is achieved, but coating film adhesiveness on complex surfaces is insufficient
Solution Approach 1:
The liquid carrier acts as an intermediary between the aerogel particles and the substrate surface. It facilitates wetting and adhesion of aerogel particles to complex surfaces, enabling the coating to conform to various geometries while maintaining thermal insulation properties. The binder resins in the liquid carrier enhance the intermediary effect by providing adhesive bridges.
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 resulting coating film exhibits improved strength and adhesiveness, allowing for direct application on complex surfaces and providing effective thermal insulation.
Implementation Method 1
a second binder resin having lower solubility in the liquid medium than the first binder resin
Implementation Method 2
An aerogel is known as a material excellent in thermal insulation, transparency and the like
Data Source
Figure 1
AI summary
The present invention relates to a coating liquid comprising an aerogel particle, a liquid medium, a first binder resin, and a second binder resin having lower solubility in the liquid medium than the first binder resin.