Hybrid Aerogel Core-Shell Structure for Insulation
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Solution Overview
Problem
The integration of silica airgel granules into a setting matrix for molded parts is hindered by their high thermal conductivity, dustiness, and the risk of contamination during mechanical handling, which limits their widespread use in insulation and other applications due to safety concerns and complex scalable processes.
Innovation Solution
A core-shell structure is created by embedding carbon or silica airgel granules within a polysaccharide-based meso- and macroporous matrix, where the polysaccharide shell provides ductility and reduces thermal conductivity, and the process involves mechanical comminution and supercritical drying to produce hybrid aerogels with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If silica aerogel granules are embedded in a setting resin matrix to produce molded parts, then the structural integrity and shape stability are improved, but the thermal conductivity increases and the porous structure is lost
Solution Approach 1:
The patent uses a flexible polysaccharide gel shell to encapsulate brittle aerogel granules, maintaining the porous structure while providing mechanical stability. The shell is ductile and can deform without breaking, protecting the internal granules while allowing the overall structure to maintain its shape.
Solution Approach 2:
The patent creates a composite hybrid aerogel structure combining polysaccharide gel matrix with embedded aerogel granules. This composite approach allows the polysaccharide phase to provide structural integrity while the aerogel granules maintain their low thermal conductivity through preserved porosity.
2Ease of manufacture
If silica aerogel granules are handled mechanically for processing, then the production and shaping are enabled, but dust release and contamination risk increase
Solution Approach 1:
The patent embeds brittle aerogel granules inside a ductile polysaccharide gel matrix, creating a nested structure where the gel shell protects the internal granules. This allows mechanical handling of the composite material without the granules being exposed and generating dust, as they are contained within the flexible gel structure.
Solution Approach 2:
The flexible polysaccharide gel shell encapsulates the aerogel granules, providing a protective barrier that prevents dust release during mechanical processing while allowing the composite material to be shaped and handled easily.
3Strength
If the volume fraction of polymer phase is increased to produce molded parts, then the mechanical strength is improved, but the thermal insulation performance deteriorates
Solution Approach 1:
The patent uses a flexible polysaccharide gel shell that provides mechanical strength while maintaining porosity. The shell's ductility allows it to provide structural support without requiring high polymer volume fractions, thereby preserving the thermal insulation properties of the porous structure.
Solution Approach 2:
The patent utilizes the porous structure of the polysaccharide gel matrix to provide both mechanical strength and thermal insulation. The porosity allows the material to maintain low thermal conductivity while the gel network provides structural integrity, reducing the need for high polymer content.
4Quantity of substance
If small particle diameter aerogel granules are used to maximize packing density, then the space utilization is improved, but the exposure risk and handling difficulty increase
Solution Approach 1:
The patent embeds fine aerogel granules within a protective gel shell, creating a nested structure that allows high packing density of small particles while preventing their exposure. The flexible gel matrix contains the fine granules, eliminating dust release risks while maximizing the quantity of aerogel material that can be packed into a given volume.
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 hybrid aerogels exhibit reduced thermal conductivity, enhanced safety due to reduced dustiness, and improved mechanical handling, allowing for scalable production and biodegradability, with thermal conductivity values comparable to or better than expanded polystyrene and acoustic properties suitable for insulation.
Implementation Method 1
embedding of an aerogel or gel structure (1) into an enveloping gel structure (2)
Implementation Method 2
drying to aerogels
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Aerogel material comprising an aerogel granule of a first species in the core of the aerogel material and an outer shell of the first aerogel granule comprising a second species of aerogel and a method for producing the aerogel material.