Flexible Thermal Insulation Sheet for Thin Crack-Resistant Layers
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Solution Overview
Problem
Conventional thermal insulation materials using silica aerogel face challenges in flexibility and thinness due to high thermal conductivity of binders, leading to separation and cracking during deformation, and limitations in thinness and application in curved or narrow spaces.
Innovation Solution
A thermal insulation sheet with a base material thickness of 5 μm to 50 μm and a thermal insulation layer featuring a hydrophobic porous structure with a binder having an elongation at break of 200% or more, allowing for flexibility and easy folding or winding, while reducing the likelihood of cracking and improving thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the incorporated amount of binder is reduced to improve thermal insulation, then thermal insulation is improved, but the physical bonding force between silica aerogels is reduced and cracks are likely to occur during deformation
Solution Approach 1:
The patent changes the key parameter of binder elongation at break from conventional values (typically <100%) to 200% or more. This parameter change allows the binder to maintain adequate bonding force between silica aerogels while minimizing the incorporated amount of binder, thus achieving both improved thermal insulation and crack resistance during deformation
Solution Approach 2:
The patent employs a binder with high elongation at break (200% or more) that acts as a flexible connecting medium between silica aerogels. This flexible binder can accommodate deformation and bending of the thermal insulation material without breaking, preventing crack formation while maintaining structural integrity with minimal binder content
2Reliability
If a fibrous base material such as nonwoven fabric is used to reinforce binding between silica aerogels, then fall-off and cracks are suppressed, but rigidity increases and flexibility is lowered
Solution Approach 1:
The patent extracts and eliminates the fibrous base material (nonwoven fabric) from the thermal insulation structure. Instead of using fibers to support silica aerogels, the invention relies on a binder with 200% or more elongation at break to provide both binding force and flexibility, achieving silica aerogel stability without the rigidity and flexibility loss caused by fibrous materials
Solution Approach 2:
The patent changes the fundamental approach from using fibrous mechanical reinforcement to using a high-elongation binder. This parameter change in the binding mechanism allows the thermal insulation material to maintain silica aerogel stability while achieving the flexibility needed for bending and winding applications
3Length of stationary object
If the thickness of the thermal insulation material is reduced to achieve thinness, then thinness is achieved, but the material becomes more fragile and silica aerogel is more likely to fall off
Solution Approach 1:
The patent changes the critical parameter of binder elongation at break to 200% or more, which compensates for the reduced thickness. This high-elongation binder provides sufficient bonding force to retain silica aerogels even in thin configurations, preventing fall-off and maintaining structural integrity despite the reduced overall thickness
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 solution provides a thin, flexible thermal insulation sheet that can be easily arranged in narrow spaces, reduces cracking during deformation, and maintains effective thermal insulation, suitable for applications requiring weight reduction and flexibility.
Implementation Method 1
The porous structure has a hydrophobic site at least on a surface of the porous structure
Implementation Method 2
a binder that connects the porous structures with each other
Implementation Method 3
a porous structure that has a skeleton composed of a plurality of particles connected to each other and has pores therein
Data Source
AI summary
A thermal insulation sheet includes: a base material in the form of a sheet and having a thickness of 5 μm or more to 50 μm or less; and a thermal insulation layer arranged on at least one surface of the base material. The thermal insulation layer includes: a porous structure that has a skeleton composed of a plurality of particles connected to each other, has pores therein, and has a hydrophobic site at least on a surface out of the surface and inside of the porous structure; and a binder that connects the porous structures with each other and has an elongation at break of 200% or more.