Siloxane Binder Composition for Crack-Free Aerogel Insulation
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Solution Overview
Problem
Current thermal insulation materials, particularly hydrophobic aerogel-based compositions, face limitations in temperature stability, viscosity issues, and require separate storage and application of components, which restrict their use in high-temperature applications and lead to cracking in dried films.
Innovation Solution
A binder composition comprising siloxane polymers, silicone resins, and hydrophilic silica aerogels with specific thermal conductivity and surface area characteristics, allowing for a one-component solution that maintains stability up to 900°C and prevents film cracking, even in high thickness coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hydrophobic aerogel is treated with silicone film forming binder material, then thermal stability is improved, but composition viscosity increases and cracks form in dried film
Solution Approach 1:
The patent uses a surface treatment intermediary (silane coupling agent or surfactant) to mediate between the hydrophobic aerogel particles and the silicone binder. This intermediary layer modifies the aerogel surface to be more compatible with the binder, preventing direct adverse interactions that cause cracking while maintaining the thermal stability provided by the aerogel structure.
Solution Approach 2:
The patent changes the surface properties parameter of the aerogel through chemical or physical treatment. By modifying the surface energy and wettability of aerogel particles, the composition achieves better rheological behavior and film formation characteristics, eliminating cracks while preserving high-temperature stability.
2Temperature
If hydrophobic aerogel is treated with silicone-based binder emulsion, then thermal insulation is improved, but components must be stored separately and applied immediately
Solution Approach 1:
The patent performs preliminary surface treatment of the aerogel particles during manufacturing to make them inherently compatible with silicone binders. This pre-modification allows the components to be pre-mixed and stored together as a stable one-component system, eliminating the need for separate storage and immediate application.
3Temperature
If hydrophobic aerogel is used in binder composition, then thermal insulation is achieved, but composition viscosity increases
Solution Approach 1:
The patent changes the surface energy parameter of aerogel particles through hydrophilic or amphoteric surface treatment. This modification improves the wetting and dispersion characteristics of aerogel in the binder matrix, reducing aggregation and lowering the overall composition viscosity while maintaining thermal insulation performance.
4Stability of the object's composition
If surface treatment of aerogel is performed to improve compatibility, then dispersion is improved, but treatment complexity increases
Solution Approach 1:
The patent modifies the surface chemistry parameter of aerogel during the sol-gel synthesis process itself, rather than requiring separate post-treatment steps. By controlling the hydrolysis and condensation conditions to produce hydrophilic or amphoteric surface groups, the aerogel achieves good dispersion stability while keeping the overall process simple and integrated.
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 composition provides long-term thermal and acoustic insulation, enabling use in higher temperature ranges without viscosity drift or cracking, and allows for a single-component application, enhancing stability and application ease.
Implementation Method 1
maintains stability up to 900°C
Implementation Method 2
hydrophilic silica aerogels with specific thermal conductivity and surface area characteristics
Implementation Method 3
provides long-term thermal and acoustic insulation
Implementation Method 4
without viscosity drift or cracking
Data Source
AI summary
The present invention relates to a composition comprising a binder comprising one or more siloxane polymers, silicone resins, silicone based elastomers, and mixtures thereof, wherein said binder optionally comprises one or more cross-linker components comprising a silane and/or a siloxane containing silicon-bonded hydrolysable groups; and a hydrophilic powder and/or gel selected from one or more amorphous, porous hydrophilic silica (s) having a thermal conductivity at 20°C and atmospheric pressure of 0.001 to 0.15 W/m⋅K and a surface area (SBET) of between 200 and 1500m2/g, one or more hydrophilic aerogel (s) and mixtures thereof, wherein the binder is a solution, an emulsion, or a dispersion in water. The invention also relates to the use of the composition as or in thermally or acoustically insulating materials and to coated substrates, products and articles made by using the composition.