Microporous Insulation with Hydrophilic Surface via Organosilane Vapor

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Solution Overview

Problem

Microporous thermal insulation materials face issues with low mechanical stability, limited processing options, a dusty surface, and irreversible structure loss when exposed to water, as well as challenges with applying additional layers due to hydrophobic surfaces being repellent to water-based adhesives and coatings.

Innovation Solution

A process involving partial or full lamination of microporous thermal insulation moldings with hydrophilic layers, followed by treatment with vaporous organosilanes in a chamber under negative pressure to create a hydrophobic core with a hydrophilic surface, allowing for improved mechanical properties and compatibility with water-based applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If microporous thermal insulation materials are made hydrophobic through organosilane treatment, then water resistance is improved, but the surface becomes repellant to water-based adhesives and coatings

Engineering Contradiction:

Improvewater resistanceVSAvoidcompatibility with water-based adhesives

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies different surface treatments to different regions of the thermal insulation component. The front side receives organosilane treatment for hydrophobicity and water resistance, while the rear side maintains hydrophilic properties to accept water-based adhesives and coatings. This local differentiation resolves the contradiction by assigning opposite surface properties to opposite sides of the same component.

Inventive Principle:

Principle #3Local quality

2Strength

If microporous thermal insulation materials are encased in protective layers, then mechanical stability is improved, but processing options such as sawing, milling, and drilling are limited

Engineering Contradiction:

Improvemechanical stabilityVSAvoidprocessing options

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent separates the protective function from the core insulation material by applying a thin protective coating layer rather than encasing the entire component. This segmentation allows the core material to remain accessible for processing operations like sawing, milling, and drilling, while the surface coating provides mechanical protection where needed.

Inventive Principle:

Principle #1Segmentation

3Reliability

If high pressure autoclave treatment is used for hydrophobization, then water resistance is improved, but the structure of the core material is partially destroyed

Engineering Contradiction:

Improvewater resistanceVSAvoidstructure of core material

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent replaces the mechanical high-pressure autoclave treatment with a chemical vapor phase organosilane treatment process. This substitution achieves hydrophobization through chemical reaction at the surface without subjecting the core material to destructive high pressures, thereby maintaining the integrity of the microporous structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If the surface is made hydrophobic, then water resistance is improved, but the surface remains dusty and mechanically sensitive

Engineering Contradiction:

Improvewater resistanceVSAvoiddusty surface and mechanical sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite surface structure where an organosilane-treated hydrophobic layer is applied over the base thermal insulation material. This composite structure combines the water-repellent properties of organosilanes with the mechanical stability of the underlying material, reducing dustiness and mechanical sensitivity while maintaining hydrophobicity.

Inventive Principle:

Principle #40Composite materials

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 process results in a hydrophobic core with a hydrophilic surface that is low-dust, workable, and non-combustible, enabling the application of multiple layers and improved flexibility, suitable for various insulation applications including building and technical insulation.

Implementation Method 1

in a chamber where the pressure is less than atmospheric pressure, treated with one or more vaporous organosilanes

Methodology Applied

Scientific EffectVapor-phase deposition: Physical Vapour Deposition

Implementation Method 2

Microporous heat-insulating molded body which is hydrophobized with organosilanes

Methodology Applied

Scientific EffectHydrophobization: Hydrophobe

Data Source

PatentEP2622253B1Microporous heat-insulating molded body which is hydrophobized with organosilanes and which comprises a hydrophilic surface

Publication Date: 2015.01.21 EVONIK OPERATIONS GMBH

AI summary

The invention relates to a microporous heat-insulating molded body which is hydrophobized with organosilanes and the surface of which is a) partly or completely rigidly adhered to an open-pore hydrophilic layer, b) partly rigidly adhered to a closed-pore hydrophilic layer, or c) partly rigidly adhered to an open-pore hydrophilic layer and partly rigidly adhered to a closed-pore hydrophilic layer.