Silica Aerogel Polyester Masterbatch for Uniform Dispersion
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Solution Overview
Problem
Polyester and silica aerogel powders are incompatible, leading to uneven mixing and poor spinnability and thermal insulation properties in silica aerogel-containing polyester fibers.
Innovation Solution
A method involving ball-milling a mixture of silica aerogel powder, dispersing agent, and liquid carrier to form a composite dispersion liquid, followed by drying and granulation with polyethylene terephthalate resin, using dispersing agents like paraffin oil or silane compounds to promote even dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silica aerogel powder and polyester material are directly mixed, then heat insulation property is provided, but uneven mixing occurs due to incompatibility between polar polyester and non-polar silica aerogel
Solution Approach 1:
The patent introduces a dispersing agent as an intermediary substance between the polar polyester material and non-polar silica aerogel powder. The dispersing agent has both polar and non-polar characteristics, allowing it to compatibilize the two incompatible materials and achieve uniform distribution of silica aerogel throughout the polyester matrix, thereby resolving the mixing uniformity problem while maintaining heat insulation properties.
Solution Approach 2:
The patent modifies the surface properties of silica aerogel powder through treatment with dispersing agents, changing its surface energy and polarity parameters. This parameter change enables the previously incompatible non-polar silica aerogel to be compatible with polar polyester, achieving both good mixing uniformity and effective heat insulation functionality.
2Temperature
If silica aerogel powder is added to polyester material, then thermal insulation function is achieved, but spinnability deteriorates due to poor compatibility and uneven distribution
Solution Approach 1:
The dispersing agent serves as a mediator that improves the interfacial compatibility between silica aerogel and polyester, reducing aggregation and ensuring uniform distribution. This uniform distribution prevents defects during the spinning process, thereby maintaining good spinnability while achieving the desired thermal insulation function in the final fiber product.
3Ease of manufacture
If dispersing agent is used to improve mixing, then spinnability improves, but manufacturing process complexity increases
Solution Approach 1:
The patent applies dispersing agents during the masterbatch preparation stage, which is a preliminary step before the actual spinning process. By achieving uniform dispersion of silica aerogel in the masterbatch beforehand, the spinning process itself becomes simpler and more reliable, as the material is already optimized for processing. This preliminary action improves spinnability without significantly complicating the main manufacturing 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 achieves evenly dispersed silica aerogel in polyester fibers, improving processability and thermal insulation properties, allowing production of high-quality silica aerogel-containing polyester products.
Implementation Method 1
The dispersing agent is dispersed in the polyethylene terephthalate resin, and the silica aerogel powder is dispersed in the polyethylene terephthalate resin
Implementation Method 2
subjecting a mixture of a silica aerogel powder, a dispersing agent, and a liquid carrier to a ball-milling treatment
Implementation Method 3
subjecting the silica aerogel-containing composite dispersion liquid to a drying treatment, so as to form a silica aerogel-containing composite powder
Data Source
AI summary
A silica aerogel-containing polyester masterbatch includes a polyethylene terephthalate resin, a silica aerogel powder, and a dispersing agent. The silica aerogel powder is dispersed in the polyethylene terephthalate resin, and is present in an amount ranging from 5 wt % to 30 wt % based on 100 wt % of the silica aerogel-containing polyester masterbatch. The dispersing agent is dispersed in the polyethylene terephthalate resin, is selected from the group consisting of a paraffin oil, a silane compound, a wax including C28-C32 straight chain monoacids, and combinations thereof, and is present in an amount ranging from 0.1 wt % to 4.0 wt % based on 100 wt % of the silica aerogel-containing polyester masterbatch. A method for preparing the silica aerogel-containing polyester masterbatch, and a silica aerogel-containing polyester fiber made from the same are also disclosed.