Macroporous Polymer Aerogel Design to Reduce Drying Collapse
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Solution Overview
Problem
Conventional mesoporous and microporous aerogels face challenges such as collapse during drying, lack of mechanical durability, and complexity in manufacturing, which hinder large-scale production and application flexibility.
Innovation Solution
Development of macroporous-structured polymeric aerogels with a majority of pore volume composed of macropores (greater than 50 nm in diameter) to enhance manufacturability and mechanical properties, incorporating support materials for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mesoporous and microporous structured aerogels are used, then high porosity and high specific surface area are achieved, but the aerogels collapse during drying and lack mechanical durability
Solution Approach 1:
The patent changes the pore size parameter from mesoporous (2-50 nm) and microporous (<2 nm) structures to macroporous (>50 nm) structures. This parameter change fundamentally alters the mechanical properties while maintaining high porosity, resolving the contradiction between porosity and mechanical durability.
Solution Approach 2:
The patent creates composite aerogel structures combining macroporous frameworks with embedded mesoporous or microporous regions. This composite approach allows the macroporous structure to provide mechanical support while the smaller pores maintain high surface area and porosity characteristics.
2Area of stationary object
If mesoporous and microporous structured aerogels are used, then high specific surface area is achieved, but the drying process becomes complex and time-consuming
Solution Approach 1:
By changing the pore size parameter to macroporous (>50 nm), the drying process becomes simpler and less time-consuming while still achieving high specific surface area. The larger pores facilitate easier solvent removal without requiring complex drying protocols.
3Quantity of substance
If mesoporous and microporous structured aerogels are used, then high porosity is achieved, but the manufacturing process becomes expensive and difficult to scale
Solution Approach 1:
The patent employs parameter change by transitioning to macroporous (>50 nm) structures, which significantly simplifies the manufacturing process and enables scalable production while maintaining high porosity. The larger pore sizes allow for more straightforward processing and reduced manufacturing costs.
4Loss of energy
If conventional aerogels are used, then thermal insulation is achieved, but flexibility and compressibility are limited
Solution Approach 1:
The patent changes the pore size parameter to macroporous (>50 nm) structures, which inherently provide greater flexibility and compressibility while maintaining thermal insulation properties. The larger pores allow the material to deform more easily without structural collapse.
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 presence of macropores reduces drying-induced collapse and improves mechanical strength, flexibility, and process efficiency, enabling scalable production and diverse applications.
Implementation Method 1
A gel by definition is a sponge-like, three-dimensional solid network whose pores are filled with another non-gaseous substance
Implementation Method 2
polymerizing the monomers in the solution to form a polymer gel matrix
Implementation Method 3
drying of the gel that exhibits little or no shrinkage and internal pore collapse during drying
Implementation Method 4
A gel that dries and exhibits little or no shrinkage and internal pore collapse during drying can yield an aerogel
Implementation Method 5
maintaining thermal and acoustic insulation
Implementation Method 6
maintaining thermal and acoustic insulation
Data Source
AI summary
An evaporative air dried and thermally dried porous polymeric material in the form of a film having an organic polymeric matrix is disclosed. The porous polymeric material can include macropores having a size greater than 50 nanometers (nm), and the polymeric material is not-crosslinked.