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DE-112021000020-B4 - Heat-insulating material and method for its production

DE112021000020B4DE 112021000020 B4DE112021000020 B4DE 112021000020B4DE-112021000020-B4

Abstract

Heat-insulating material (1, 2, 3), comprising: a heat-insulating layer (10, 20, 32) and a first base material (11, 21, 33) which is laminated onto the heat-insulating layer (10, 20, 32), the heat-insulating layer comprises (10, 20, 32): a porous structural body, wherein the porous structural body has a hydrophobic section on at least one of the outer and inner surfaces of the porous structural body, and the porous structural body is a silicon dioxide aerogel body in which a plurality of silicon dioxide aerogel particles are linked together to form a framework, and pores are formed between the silicon dioxide aerogel particles, Glass fibers, wherein the glass fibers are physically interwoven around the porous structural body, Carboxymethylcellulose thickener, and a silicon dioxide particle binder, wherein the silicon dioxide aerogel particles and the glass fibers are connected to each other via the silicon dioxide particle binder, where the heat-insulating layer (10, 20, 32) has a mass loss rate of 10 % or less in a thermogravimetric analysis, which is held at 500°C for 30 minutes, with the mass loss rate being measured according to the procedure described in the description, the heat-insulating layer (10, 20, 32) is impregnated with a mesh in the vicinity of a contact surface between the heat-insulating layer (10, 20, 32) and the first base material (11, 21, 33), and wherein the first base material (11, 21, 33) is a woven or nonwoven fabric made from a glass or metal fiber.

Inventors

  • Shinji Kumagai
  • Naoki Katayama
  • Shota Hayashi
  • Yutaro TAGUCHI

Assignees

  • SUMITOMO RIKO COMPANY LIMITED

Dates

Publication Date
20260513
Application Date
20210128
Priority Date
20200312

Claims (13)

  1. Thermal insulating material (1, 2, 3) comprising: a thermal insulating layer (10, 20, 32) and a first base material (11, 21, 33) laminated onto the thermal insulating layer (10, 20, 32), the thermal insulating layer (10, 20, 32) comprising: a porous structural body, wherein the porous structural body has a hydrophobic section on at least one of its outer and inner surfaces, and the porous structural body is a silicon dioxide aerogel body in which a plurality of silicon dioxide aerogel particles are interconnected to form a framework, and pores are formed between the silicon dioxide aerogel particles, glass fibers, wherein the glass fibers are physically interwoven around the porous structural body are, a carboxymethylcellulose thickener, and a silicon dioxide particle binder, wherein the silicon dioxide aerogel particles and the glass fibers are bonded together via the silicon dioxide particle binder, whereby the heat-insulating layer (10, 20, 32) exhibits a mass loss rate of 10% or less in a thermogravimetric analysis held at 500°C for 30 minutes, the mass loss rate being measured according to the method described in the description, the heat-insulating layer (10, 20, 32) is impregnated with a mesh near a contact surface between the heat-insulating layer (10, 20, 32) and the first base material (11, 21, 33), and whereby the first base material (11, 21, 33) is a woven or nonwoven fabric made from a glass or Metal fiber.
  2. Heat-insulating material (1, 2, 3) according to Claim 1 , wherein the porous structural body is pulverized.
  3. Heat-insulating material (1, 2, 3) according to Claim 1 or 2 , wherein the porous structural body has a beveled shape.
  4. Heat-insulating material (1, 2, 3) according to one of the Claims 1 until 3 , wherein the content of the porous structural body in the heat-insulating layer (10, 20, 32) is 50 parts by mass or more and 280 parts by mass or less, based on 100 parts by mass of the components excluding the porous structural body and the glass fibers.
  5. Heat-insulating material (1, 2, 3) according to one of the Claims 1 until 4 , wherein the content of the glass fibers in the heat-insulating layer (10, 20, 32) is 5 parts by mass or more and 200 parts by mass or less, based on 100 parts by mass of the components excluding the porous structural body and the glass fibers.
  6. Heat-insulating material (1, 2, 3) according to one of the Claims 1 until 5 , wherein the diameter of the optical fibers is 6.5 µm or more and 18 µm or less, and the length of the optical fibers is 3 mm or more and 25 mm or less.
  7. Heat-insulating material (1, 2, 3) according to Claim 1 , comprising the heat-insulating layer (10, 20, 32), the first base material (11, 21, 33) and a second base material (22, 34), wherein the heat-insulating layer (10, 20, 32) is arranged between the first base material (11, 21, 33) and the second base material (22, 34).
  8. Heat-insulating material (1, 2, 3) according to Claim 7 , wherein the second base material (22, 34) is a glass fabric.
  9. Heat-insulating material (1, 2, 3) according to Claim 7 or 8 , comprising a main body part (30) and a circumferential edge part (31), wherein a circumferential edge of the first base material (11, 21, 33) and a circumferential edge of the second base material terials (22, 34) each extend beyond a circumferential edge of the heat-insulating layer (10, 20, 32) such that the heat-insulating layer (10, 20, 32) is completely enclosed by the first (11, 21, 33) and the second base material (22, 34), the main body part (30) is a part in which the first base material (11, 21, 33), the second base material (22, 34) and the heat-insulating layer (10, 20, 32) are laminated together, and the circumferential edge part (31) is a part in which the first base material (11, 21, 33) and the second base material (22, 34) overlap around the heat-insulating layer (10, 20, 32).
  10. Heat-insulating material (1, 2, 3) according to Claim 9 , wherein the first base material (11, 21, 33) and the second base material (22, 34) are fused at the circumferential edge part (31).
  11. Heat-insulating material (1, 2, 3) according to Claim 9 or 10 , wherein the first base material (11, 21, 33) and the second base material (22, 34) are fixed by a fastening element (36) and the fastening element (36) is arranged on the circumferential edge part (31).
  12. Heat-insulating material (1, 2, 3) according to Claim 11 , wherein the fastening element (36) is elastic.
  13. Method for producing the heat-insulating material (1, 2, 3) according to Claim 1 , comprising: a manufacturing step for coating material for the production of a coating material for a heat-insulating layer (10, 20, 32) comprising the porous structural body, the glass fibers and a dispersion liquid in which the nanoparticles of the metal oxide are dispersed in a liquid; and an application step for applying the coating material for the heat-insulating layer (10, 20, 32) to the first base material (11, 21, 33).

Description

BACKGROUND Technical field The present invention relates to a heat-insulating material using a porous structural body, such as a silicon dioxide aerogel, and relates to a manufacturing process of the heat-insulating material. Technical background Silicon dioxide aerogel is a porous material with a pore structure in which fine silicon dioxide particles are bonded together to form a framework, with the pore size ranging from approximately 10 to 50 nm. The thermal conductivity of silicon dioxide aerogel is lower than that of air. Therefore, the development of a heat-insulating material that utilizes the high thermal insulation properties of silicon dioxide aerogel is underway. For example, patent literature 1 describes an article containing silicon dioxide aerogel bound by water-dispersible polyurethane, exhibiting a thermal conductivity of 0.025 W/m·K or less. This article uses a binder such as a urethane resin or similar to fix the silicon dioxide aerogel. However, if a conventional heat-insulating material with a urethane binder is used in a high-temperature atmosphere of approximately 500°C, the urethane binder, being an organic component, may decompose and deteriorate, leading to gas leakage or cracking, and thus preventing the binder from maintaining its shape. Furthermore, because the urethane binder is relatively soft, the heat-insulating material is prone to crushing when compressed, making it difficult to maintain its insulating structure. On the other hand, patent literature 2 to 5, for example, proposes composite materials that use an inorganic compound such as a silicate or the like as a binder. Specifically, patent literature 2 describes a composite material with silicon dioxide aerogel, an organic or inorganic binder, and glass fiber, and describes water glass (sodium silicate) as the inorganic binder. Patent literature 3 describes a heat-insulating material obtained by solidifying an aerogel with a water-soluble binder and an inorganic binder such as powdered sodium silicate or the like. Patent literature 4 describes a flexible insulating structure in which a layer of aerogel and an inorganic binder such as sodium silicate or the like is formed on a nonwoven fabric (cotton wool). Patent literature 5 describes a heat-insulating material composition containing silicon dioxide aerogel, a ceramic raw material liquid that can form crystals through a hydrothermal reaction, a surfactant and a reinforcing fiber. [Literature on the state of the art] [Patent literature] Patent literature 1: National publication of international patent application no. JP 2013 - 534 958 APatent literature 2: National publication of international patent application no. JP H11 - 513 349 APatent Literature 3: Japanese Patent Disclosure No. JP 2004 - 10 423 APatent Literature 4: Japanese Patent Disclosure No. JP 2017 - 155 402 APatent Literature 5: International Publication No. WO 2013 / 141 189 A1Patent Literature 6: American Publication No. US 2003 / 0 215 640 A1Patent literature 7: LASKOWSKI, Jessica: Synthesis and properties of aerogel-aerogel composites. Aachen, 2016. 125 pp. – Aachen, Techn. Hochsch., Diss., 2016 .Patent Literature 8: American Publication No. US 2013 / 0 091 682 A1Patent Literature 9: International Publication No. WO 2015 / 002 488 A1 SUMMARY [Problems to be solved] Depending on the application of the heat-insulating material, it may be necessary for the material to retain its shape even when used in a high-temperature atmosphere (heat resistance), as well as be resistant to crushing and cracking and retain its heat-insulating properties even when compressed (compression resistance). However, if an inorganic compound is used as a binder, the problems caused by binder degradation and decay are solved, but the resulting molded part becomes hard and brittle. Since patent references 2 to 4 describe only the use of an inorganic binder, it is difficult to improve heat resistance and compression resistance solely through this method. Patent reference 5 describes the use of a ceramic raw material liquid capable of crystal formation through hydrothermal reactions. Dehydration, heating, and pressurization of the heat-insulating material composition containing this ceramic raw material liquid promote the synthesis of ceramic crystals on the surfaces of the silicon dioxide aerogel and the reinforcing fiber. The resulting ceramic crystal acts as a binder, bonding the silicon dioxide aerogels together. According to the manufacturing process described in patent reference 5, the steps of producing the heat-insulating material composition, injecting it into a mold, dehydrating, heating, and pressurizing the resulting primary molded body are required. Therefore, the manufacturing process is labor-intensive, complex, and costly. Furthermore, producing a thin film is difficult due to the need for a mold. Furthermore, the ceramic crystal formed is a bulk crystal that has a needle-like shape, a fibrous shape, or the like, and