Segmented gel composites and rigid panels manufactured therefrom
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Solution Overview
Problem
Aerogels exhibit weakness and brittleness, which limits their scalability and performance in insulation applications due to high thermal conductivity and difficulty in handling, especially when trying to maintain integrity on irregular surfaces or under dynamic conditions.
Innovation Solution
The process involves segmenting non-woven fiber or open-cell foam reinforcement sheets to create a segmented reinforcement, which allows for flexible winding and unwinding without delamination, enabling the production of rigid panels with minimal defects and maintaining thermal performance by infusing gel precursors and using adhesives to form aerogel composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If aerogel is used for insulation, then thermal insulation performance is improved, but mechanical strength and handling ease deteriorate due to weakness and brittleness
Solution Approach 1:
The patent combines aerogel with fibrous reinforcement materials (such as glass fibers, mineral wool, or synthetic fibers) to create a composite structure. The aerogel provides superior thermal insulation with thermal conductivity below 0.025 W/mK, while the fibrous reinforcement network provides mechanical strength and structural integrity, resolving the contradiction between thermal performance and mechanical strength.
Solution Approach 2:
The patent employs flexible fibrous matrices and thin film structures that can conform to irregular surfaces while encapsulating the rigid aerogel particles. This flexible reinforcement structure allows the composite to bend and adapt without fracturing the brittle aerogel, improving handling ease and adaptability to various installation surfaces.
2Loss of energy
If aerogel is used for insulation, then thermal insulation performance is improved, but ease of operation deteriorates due to difficulty in handling and maintaining integrity
Solution Approach 1:
By embedding aerogel particles within a continuous fibrous matrix, the composite material gains the toughness and flexibility needed for easy handling. The fibrous reinforcement prevents aerogel particles from fracturing during cutting, bending, and installation, while maintaining the low thermal conductivity of the aerogel phase.
Solution Approach 2:
The patent modifies the physical state and structural parameters of aerogel by combining it with binders and reinforcement fibers, transforming it from a fragile monolithic structure into a flexible composite material that can be easily cut, shaped, and installed while retaining its thermal insulation properties.
3Ease of manufacture
If segmented reinforcement sheet is used, then ease of manufacture is improved through flexible winding and unwinding, but device complexity increases due to segmentation process
Solution Approach 1:
The reinforcement sheet is divided into discrete segments or strips that can be independently wound and unwound around cylindrical mandrels. This segmentation allows the flat reinforcement material to conform to curved surfaces during manufacturing without excessive tension or deformation, simplifying the winding process compared to using a single continuous rigid sheet.
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
This method allows for the efficient manufacturing of flat-panel aerogel-based boards with improved mechanical strength, reduced defects, and maintained thermal performance, suitable for building insulation, by enabling the use of lower-cost fibrous reinforcements and minimizing damage during handling.
Implementation Method 1
combining the segmented reinforcement sheet with a gel precursor, gelling the gel precursor in the combination to make a reinforced gel composite sheet
Implementation Method 2
drying the reinforced gel composite sheet to make a reinforced dried gel composite sheet, wherein the reinforced dried gel composite sheet comprises aerogel
Data Source
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AI summary
The present invention describes various methods for manufacturing gel composite sheets using segmented fiber or open-cell foam reinforcements and gel precursors. Additionally, rigid panels manufactured from the resulting gel composites are also described. The gel composites are relatively flexible enough to be wound and when unwound, can be stretched flat and made into rigid panels using adhesives.