Fiber-Reinforced Polymer Aerogel With Multimodal Pores for Simple Drying
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Solution Overview
Problem
Conventional fiber-reinforced aerogels lack mechanical durability and require complex and costly drying processes, such as super-critical drying, to prevent network collapse, which limits their scalability and practical applications.
Innovation Solution
A fiber-reinforced organic polymer aerogel with a multi-modal pore size distribution, featuring at least two distinct pore sizes, one below 50 nm and one above, is created using strong fibers and resorcinol formaldehyde polymers, allowing for thermal drying or evaporative air drying, reducing production costs and improving mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fiber-reinforced aerogels use traditional drying processes, then mechanical durability is improved, but production cost and complexity increase due to super-critical drying requirements
Solution Approach 1:
The patent changes the pore size distribution parameter from single-mode to multi-modal, creating a hierarchical structure with pores ranging from 1-50 nm to 50-500 nm. This structural parameter change allows the aerogel network to maintain mechanical integrity during conventional thermal drying without requiring super-critical drying equipment, thus reducing process complexity while preserving mechanical durability
Solution Approach 2:
The patent creates a composite aerogel structure combining organic polymer matrix with inorganic fiber reinforcement. This composite approach enhances mechanical durability while the specific pore size distribution enables use of simpler drying processes, resolving the contradiction between strength and process complexity
2Ease of manufacture
If single-mode pore size distribution is used in fiber-reinforced aerogels, then manufacturing is simplified, but mechanical properties deteriorate causing brittleness and adhesion problems
Solution Approach 1:
The patent transforms the pore size distribution from a single-mode uniform structure to a multi-modal hierarchical structure with at least two distinct pore size ranges. This parameter change creates a more resilient network that resists brittleness and improves fiber-aerogel adhesion, enhancing mechanical properties while maintaining manufacturability through controlled gelation processes
3Strength
If strong fiber materials are used to reinforce aerogel, then mechanical strength is improved, but aerogel matrix damage occurs due to fiber weakness in conventional silica-based aerogels
Solution Approach 1:
The patent employs a composite design where organic polymer aerogel matrices are reinforced with strong inorganic fibers. The organic polymer matrix proves more compatible and resilient than conventional silica-based aerogels, allowing strong fiber reinforcement without causing matrix damage, thus achieving enhanced mechanical strength without the harmful effects of fiber-matrix incompatibility
4Loss of energy
If high porosity is maintained in aerogels, then thermal conductivity is reduced, but mechanical durability deteriorates
Solution Approach 1:
The patent optimizes the pore size distribution parameter, creating a multi-modal structure with pores ranging from 1-50 nm to 50-500 nm. This specific pore size configuration maintains high porosity (80-95%) for low thermal conductivity while the hierarchical structure provides mechanical resilience, resolving the trade-off between thermal performance and mechanical durability
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 aerogel exhibits superior mechanical strength and thermal conductivity below 30 mW/m·K, with reduced weight loss during handling and improved scalability, maintaining good thermal properties while being more cost-effective to produce.
Implementation Method 1
Shrinkage of the gel's solid network during drying is negligible or altogether prevented due to the minimization of or resistance to the capillary forces acting on the network as the liquid is removed
Implementation Method 2
the presence of varying particle sizes in the gel can help prevent network collapse during drying
Implementation Method 3
the presence of the multi-modal pore structure can help reduce the thermal conductivity of the fiber-reinforced aerogels of the present invention to less than or equal to 30 mW/m·K at a temperature of 20° C.
Data Source
AI summary
A fiber-reinforced aerogel is disclosed. The aerogel can include a porous organic polymer matrix and fibers included in the porous organic polymer matrix. The aerogel can include a thermal conductivity of less than or equal to 60 mWIm·K at a temperature of 20° C., at least a bimodal pore size distribution with a first mode of pores having an average pore size of less than or equal to 50 nanometers (nm) and a second mode of pores having an average pore size of greater than 50 nm, and a planar shape having a thickness of 5 millimeters (mm) or less and is capable of being rolled up into a roll, wherein the fibers form a woven fiber matrix.