Thermal insulation sheet and manufacturing method therefor

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Solution Overview

Problem

Existing thermal insulation sheets with silica aerogel or xerogel face performance drops due to silica microparticle separation, and hydrophobization and solvent removal are inefficient in thick sheets, limiting their heat insulation effectiveness.

Innovation Solution

A method involving impregnation of silica aerosol in a nonwoven fabric substrate with insoluble and soluble fibers, followed by gelling, hydrophobization using hydrochloric acid to create cavities, and drying, allowing for effective permeation and discharge of hydrophobizing agents, ensuring efficient hydrophobization and solvent removal even in thick sheets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silica aerogel or xerogel is used as heat-insulating material, then heat insulation performance is improved, but mechanical strength deteriorates and silica microparticles separate

Engineering Contradiction:

Improveheat insulation performanceVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines silica aerogel or xerogel with a binder material to form a composite heat-insulating layer. The binder material provides mechanical strength while the silica aerogel/xerogel maintains high heat insulation performance, resolving the contradiction between insulation performance and mechanical strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The binder material acts as an intermediary that holds silica microparticles together, preventing their separation during use. This mediator enables the silica microparticles to maintain their heat insulation properties without compromising structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal insulation sheet thickness is increased to 1.5 mm or more, then heat insulation effect is improved, but hydrophobization and solvent removal become inefficient

Engineering Contradiction:

Improveheat insulation effectVSAvoidhydrophobization efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent creates a porous structure within the thermal insulation sheet that allows hydrophobizing agents and solvents to penetrate deeply throughout the thickness of the material. This porous architecture enables efficient hydrophobization and solvent removal even in thick sheets (1.5 mm or more), maintaining both insulation performance and processing efficiency.

Inventive Principle:

Principle #31Porous materials

3Reliability

If thermal insulation sheet thickness is increased to 1.5 mm or more, then heat insulation effect is improved, but drying time increases

Engineering Contradiction:

Improveheat insulation effectVSAvoiddrying time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The porous structure enables rapid solvent evacuation from thick insulation sheets during drying. The interconnected pores provide efficient pathways for solvent removal, significantly reducing drying time while maintaining the required sheet thickness for effective heat insulation.

Inventive Principle:

Principle #31Porous 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

This method enables the production of thermal insulation sheets with thermal conductivity of 24 mW/m·K or less, maintaining effective heat insulation in sheets thicker than 1.5 mm, preventing performance drops and ensuring efficient hydrophobization and drying.

Implementation Method 1

an impregnation step of impregnating a silica aerosol in a nonwoven fabric substrate

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

a gelling step of gelling the silica aerosol

Methodology Applied

Scientific EffectGelation: Gel

Implementation Method 3

a hydrophobizing step of hydrophobizing the gel; the fiber that is soluble in the acidic solution being dissolved in the hydrophobizing step

Methodology Applied

Scientific EffectDissolution:

Data Source

PatentUS10920367B2Thermal insulation sheet and manufacturing method therefor

Publication Date: 2021.02.16 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A thermal insulation sheet is used that includes a fiber, a silica aerogel contained in the fiber, and a fibrous cavity. A method for manufacturing a thermal insulation sheet is used that includes: an impregnation step of impregnating a silica aerosol in a nonwoven fabric substrate containing a fiber that is insoluble in an acidic solution, and a fiber that is soluble in the acidic solution; a gelling step of gelling the silica aerosol; a hydrophobizing step of hydrophobizing the gel; and a drying step of drying the gel. The fiber that is soluble in the acidic solution is dissolved in the hydrophobizing step.