Method and apparatus for preparing aerogel sheet
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Solution Overview
Problem
Aerogel sheets in existing manufacturing methods often have nonuniform thickness and poor heat insulation and durability.
Innovation Solution
A method involving steps of acid solution impregnation, binder solution application, silica precursor impregnation, gelling catalyst application, aging, surface modification, and multi-stage drying using specific solvents and catalysts to achieve uniform thickness and enhanced insulation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional aerogel manufacturing methods are used, then the process is simple, but the aerogel sheet has nonuniform thickness and poor heat insulation
Solution Approach 1:
The manufacturing process is divided into multiple sequential steps: fiber sheet preparation, acid solution treatment, binder solution impregnation, silica precursor impregnation, gelling catalyst application, aging, and drying. Each step addresses specific requirements for thickness uniformity and heat insulation, transforming a simple process into a segmented multi-stage process that achieves precise control over aerogel sheet properties.
2Reliability
If conventional aerogel manufacturing methods are used, then the production cost is low, but the aerogel sheet has poor durability
Solution Approach 1:
The fiber sheet undergoes preliminary treatments before aerogel formation: acid solution treatment to etch and activate the surface, followed by binder solution impregnation to enhance adhesion. These preliminary actions prepare the substrate to better withstand subsequent processing and ensure the final aerogel sheet has improved durability while maintaining production feasibility.
3Loss of energy
If conventional aerogel manufacturing methods are used, then the thermal conductivity is high, but the manufacturing process is simple
Solution Approach 1:
The process controls thermal conductivity by changing multiple parameters: acid solution concentration and treatment time to optimize surface area, binder solution composition to control pore structure, silica precursor concentration and impregnation conditions to achieve desired aerogel density, and drying conditions to preserve pore architecture. These parameter changes reduce thermal conductivity to 30 mW/m.k or less, achieving superior heat insulation through a complex but controllable process.
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 method results in aerogel sheets with improved uniform thickness, high insulation, and durability, reducing thermal conductivity and weight compared to traditional methods.
Implementation Method 1
the surface of the fiber sheet that is cleaned by using the acid solution which has a constant acidity(pH) is induced to be etched and then activated
Implementation Method 2
impregnating a binder solution into the fiber sheet that is cleaned by using the acid solution to manufacture a pre-processed fiber sheet
Implementation Method 3
A silica precursor solution is subjected to sol-gel polymerization reaction to prepare gel
Implementation Method 4
impregnating a gelling catalyst into the fiber sheet into which the silica precursor is impregnated to gelate the silica precursor
Implementation Method 5
The greatest advantage of the above-described advantages is the high heat insulation having thermal conductivity of 30 mW/m.k or less
Implementation Method 6
a drying process is performed on the prepared gel under supercritical or atmospheric conditions to obtain the aerogel
Data Source
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AI summary
The present invention relates to a method for manufacturing an aerogel sheet and comprises: a step (a) of impregnating an acid solution into a fiber sheet to clean the fiber sheet by using the acid solution and impregnating a binder solution into the fiber sheet that is cleaned by using the acid solution to manufacture a pre-processed fiber sheet; a step (b) of impregnating a silica precursor into the pre-processed fiber sheet; and a step (c) of a gelling catalyst into the fiber sheet into which the silica precursor is impregnated to gelate the silica precursor.