Flexible Aerogel Sheets via Ambient Pressure Drying
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Solution Overview
Problem
Existing methods for scaling up aerogel production are hindered by the need for expensive and technically unfeasible high-pressure vessels for drying, which limits the size and cost-effectiveness of aerogel materials.
Innovation Solution
A method involving the formation of a flexible gel layer on a flexible glass sheet, rolling the sheet into a roll, and drying it to convert the gel layer into a flexible aerogel layer, thereby creating a glass-aerogel sheet that can be used in glazing units or as a standalone insulation material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional high-pressure vessel drying is used for aerogel production, then aerogel can be produced, but the production cost increases and the size is limited
Solution Approach 1:
The invention changes the drying parameters from high-pressure vessel conditions to ambient pressure conditions. The aerogel is formed as a flexible gel layer on a flexible glass sheet, then dried at ambient pressure to convert it into a flexible aerogel layer. This parameter change eliminates the need for expensive high-pressure vessels while enabling large-scale production.
Solution Approach 2:
The invention introduces a flexible glass sheet as an intermediary substrate. The gel layer is formed on this flexible substrate, which allows the gel to be dried at ambient pressure without collapsing. The flexible glass sheet acts as a mediator that enables the transition from conventional high-pressure drying to ambient pressure drying while maintaining aerogel structure.
2Productivity
If aerogel is produced in granular or particulate form, then aerogel can be manufactured, but the production scale is limited and costs increase
Solution Approach 1:
The invention transitions from producing aerogel in granular or particulate form (0D/1D) to producing it as a continuous flexible sheet (2D). The gel layer is formed on a flexible glass sheet and dried to create a flexible aerogel layer, enabling large-scale continuous production rather than batch production of particles. This dimensional change dramatically increases productivity while reducing manufacturing costs.
3Reliability
If the gel layer is dried using conventional methods, then aerogel is produced, but the structure collapses and flexibility is lost
Solution Approach 1:
The invention uses a flexible glass sheet as a substrate that maintains its flexibility throughout the drying process. The gel layer is formed on this flexible substrate, and when dried, the resulting aerogel layer retains the flexibility of the substrate. This flexible support structure prevents structural collapse during drying that would occur with conventional rigid substrates or free-standing gel drying.
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
This method enables the production of large-size flexible aerogel sheets that can be used in various applications, including glazing units, while reducing production costs and overcoming the limitations of traditional drying methods.
Implementation Method 1
drying the flexible gel layer so as to convert it into a flexible aerogel layer
Implementation Method 2
drying the flexible gel layer so as to convert it into a flexible aerogel layer and thereby change the glass-gel sheet into a glass-aerogel sheet
Implementation Method 3
adhere the aerogel layer to the glass pane, e.g., through direct contact (e.g., so as to provide van der Waals force) or by providing a polymer lamination interlayer
Data Source
AI summary
The invention provides a method of processing glass that involves forming a flexible gel layer on a flexible glass sheet to create a glass-gel sheet; rolling-up the glass-gel sheet into the form of a roll; placing the roll in a dryer; and drying the flexible gel layer so as to form a flexible aerogel layer. Some embodiments provide a glazing unit that includes a glass-aerogel sheet located between first and second panes of the glazing unit, where the glass-aerogel sheet includes a flexible glass sheet and a flexible aerogel layer on the flexible glass sheet. In such embodiments, the first and second panes each have thicknesses that are greater than a thickness of the flexible glass sheet. Other embodiments provide a glass assembly having a flexible aerogel layer on a flexible glass sheet, with the flexible glass sheet being laminated to a glass pane.