Solvent management methods for gel production
View Patent ↗Embodiments of the present invention describe a method for continuous manufacture of a gel material comprising the steps of: forming a gel sheet by dispensing a gel precursor mixture onto a moving element at a rate effective to allow gelation to occur to the gel precursor mixture on the moving element; and cooling the formed gel thereby reducing the rate of solvent evaporation therefrom.
1. A method for continuous manufacture of a gel material comprising:
(a) forming a fiber-reinforced gel sheet with thickness of at least about 0.5 mm by dispensing a fibrous structure and a gel precursor solution comprising a solvent onto a moving element at a first temperature and at a predetermined rate effective to allow gelation to occur at the first temperature to the gel precursor solution on the moving element; and
(b) cooling the formed gel sheet on the moving element at a second temperature with a cooling system not in physical contact with the sheet, wherein the second temperature is cooler than the first temperature.
2. The method of claim 1 wherein the gel precursor solution comprises metal oxides.
3. The method of claim 2 wherein the fibrous structure comprises a fibrous batting.
4. The method of claim 1 wherein the gel is cooled at a second temperatures below about 20° C.
5. The method of claim 4 wherein the gel is cooled at a second temperature between about 20° C. and about 0° C.
6. The method of claim 1 wherein the gel is cooled via a cooling system positioned adjacent to said gel.
7. The method of claim 6 wherein the cooling system comprises a structure for containing a cooling medium.
8. The method of claim 6 wherein the cooling system conveys a cooling medium.
9. The method of claim 8 wherein the cooling medium comprises a fluid, gas or both.
10. A method for continuous manufacture of a gel material comprising:
(a) forming a fiber-reinforced gel sheet with thickness of at least about 0.5 mm by dispensing a fibrous structure and a gel precursor solution comprising a solvent onto a moving element at a first temperature and at a predetermined rate effective to allow gelation to occur at the first temperature to the gel precursor solution on the moving element;
(b) cooling at least one surface of the formed gel sheet on the moving element at a second temperature with a cooling system not in physical contact with the sheet, wherein the second temperature is cooler than the first temperature; and
(c) cooling at least one other surface of the formed gel sheet on the moving element at a third temperature with a cooling system in physical contact with the sheet, wherein the third temperature is cooler than the first temperature.
11. A method for continuous manufacture of a gel material comprising:
(a) forming a gel sheet with thickness of at least about 0.5 mm by dispensing a solution comprising a metal oxide gel precursor and a solvent onto a moving element at a first temperature and at a predetermined rate effective to allow gelation to occur at the first temperature to the gel precursor solution on the moving element; and
(b) cooling at least two surfaces of the formed gel sheet on the moving element at a second temperature with a cooling system, wherein the second temperature is cooler than the first temperature.
12. The method of claim 10 wherein the fibrous structure comprises a fibrous batting.
13. The method of claim 11 wherein the gel is cooled at a second temperature below about 20° C.
14. The method of claim 13 wherein the gel is cooled at a second temperature between about 20° C. and about 0° C.
15. The method of claim 11 wherein the gel is cooled via a cooling system positioned adjacent to said gel.
16. The method of claim 15 wherein the cooling system comprises a structure for containing a cooling medium.
17. The method of claim 15 wherein the cooling system conveys a cooling medium.
18. The method of claim 17 wherein the cooling medium comprises a fluid, gas or both.