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KR-102963766-B1 - insulation

KR102963766B1KR 102963766 B1KR102963766 B1KR 102963766B1KR-102963766-B1

Abstract

A method for manufacturing an insulating product comprises (a) forming a mixture comprising a solvent, a gel network forming agent, and optionally a foaming agent; (b) dispersing an insulating filler in the mixture; and (c) drying the mixture to form an insulating product.

Inventors

  • 카칼리, 글리케리아
  • 스카로풀루, 악겔리키
  • 가키, 안나
  • 택시아르슈, 마리아
  • 파파콘스탄티누, 콘스탄티나
  • 데델루디스, 크리스토스

Assignees

  • 이머테크 에스아에스

Dates

Publication Date
20260512
Application Date
20200416
Priority Date
20190416

Claims (16)

  1. As a method for manufacturing an insulating product, the above method, (a) a step of forming a mixture comprising a solvent and a gel network former; (b) a step of dispersing an insulating filler in the mixture; and (c) a step of drying the mixture to form an insulating product, and The gel network forming agent includes a natural binder and/or; Gel network forming agent, (i) clay minerals; and (ii) comprising one or more reinforcing agents including a polymer, and The insulating filler is an expanded silicate material, and the expanded silicate material, (a) Loose bulk density measured according to PI 200-77 from 15 kg/ m³ to 450 kg/ m³ ; Compaction resistance measured according to PI 306-80 from 3 PSI to 350 PSI at 2"; or Having a thermal conductivity of 0.0300 W/mK to 0.0700 W/mK as measured according to EN 12667; (b) 3 wt% to 30 wt% of X₂O (X is an alkali metal); 0 to 20 wt% of Al₂O₃ ; and 50 wt% to 90 wt% of SiO2 ; and Contains 0 to 10 weight percent of H₂O ; The expanded silicate material contains less than 5 weight percent of B₂O₃ ; (c) at least one silicate material; Alkali compounds; and Forming a silicate mixture containing water; A silicate mixture is cured to form a solid precursor; A solid precursor is crushed and/or milled to form a granular expansive silicate material; Manufactured by heating a granular expandable silicate material to form an expanded silicate material; (d) Expanded natural perlite, method.
  2. A method according to claim 1, wherein the mixture further comprises a foaming agent.
  3. A method according to claim 1 or 2, further comprising the step of molding the mixture before drying.
  4. In paragraph 1 or 2, The natural binder contains cellulose or gelatin and/or; Method in which the clay mineral is a smectite clay mineral, bentonite, montmorillonite, or hectorite.
  5. In paragraph 2, a method in which the foaming agent is a surfactant.
  6. A method according to claim 1 or 2, wherein the mixture of step (a) further comprises at least one additive selected from antifungal agents, antimicrobial agents, flame retardants, hydrophobic agents, and thermal conductivity modifiers.
  7. A method according to claim 1 or 2, wherein the formed mixture is a gel or an aerated gel.
  8. A method according to claim 1 or 2, wherein the step of drying the mixture to form an insulating product comprises forming an aerated matrix, wherein an insulating filler is dispersed therein.
  9. In paragraph 1 or 2, the step of drying the mixture, (i) freeze-dry the mixture or; (ii) dry the mixture under ambient conditions; (iii) A method comprising drying the mixture at an elevated temperature.
  10. A method according to claim 1 or 2, wherein the solvent is water or alcohol.
  11. As an insulating product comprising an insulating filler dispersed in an aerated matrix, A foam containing a natural binder that has been foamed with an aerated matrix, or The aerated matrix is a clay aerogel formed from at least one reinforcing agent comprising clay minerals and a polymer, and The insulating filler is an expanded silicate material, and the expanded silicate material, (a) Loose bulk density measured according to PI 200-77 from 15 kg/ m³ to 450 kg/ m³ ; Compressibility measured according to PI 306-80 from 3 PSI to 350 PSI at 2"; or Having a thermal conductivity of 0.0300 W/mK to 0.0700 W/mK as measured according to EN 12667; (b) 3 wt% to 30 wt% of X₂O (X is an alkali metal); 0 to 20 wt% of Al₂O₃ ; and 50 wt% to 90 wt% of SiO2 ; and Contains 0 to 10 weight percent of H₂O ; The expanded silicate material contains less than 5 weight percent of B₂O₃ ; (c) Silicate material; Alkali compounds; and Forming a silicate mixture containing water; A silicate mixture is cured to form a solid precursor; A solid precursor is crushed and/or milled to form a granular expansive silicate material; Manufactured by heating a granular expandable silicate material to form an expanded silicate material; (d) expanded natural perlite, Insulation product.
  12. In claim 11, the foam is flexible foam and/or the foamed natural binder comprises foamed cellulose or foamed gelatin, and the insulating product has a thermal conductivity (λ, lambda value) measured according to EN 12667 of 0.010 W/mK to 0.040 W/mK; and/or a density of less than 0.035 g/cm³.
  13. In paragraph 11, the clay aerogel is a foamed clay aerogel, and The foamed clay aerogel is hard, and The clay mineral is a smectite clay mineral, bentonite, hectorite, or montmorillonite, and/or, An insulating product having a thermal conductivity (λ, lambda value) measured according to EN 12667 of 0.020 W/mK to 0.050 W/mK.
  14. In any one of paragraphs 11 to 13, the insulating product is an insulating board, and the insulating product is, Total intrusion volume as measured by a mercury porosimeter of 9 mL/g to 17 mL/g; and/or Having a total open porosity as measured by a mercury porosity meter of over 80%, Insulation product.
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Description

insulation The present invention relates to an insulating product and a method for manufacturing an insulating product. Commercially available insulation materials used in the production of insulation products, such as insulation boards or panels, include inorganic fibrous materials and organic foam materials. Although organic foam materials are widely used, their biggest drawback is their high flammability. When exposed to fire, these materials tend to transmit flames and release toxic gases. In contrast, inorganic fibrous materials can be sensitive to moisture, and compared to organic foam materials, they have higher density and thermal conductivity. Therefore, the production of an alternative lightweight insulation product would be desirable. According to a first embodiment, the present invention relates to a method for producing an insulating product comprising (a) forming a mixture comprising a solvent and a gel network former and optionally a foaming agent; (b) dispersing an insulating filler in the mixture; and (c) drying the mixture to form an insulating product. According to a second aspect, the present invention relates to an insulating product comprising an insulating filler dispersed in an aerated matrix, wherein, for example, the insulating filler is a granular material, for example, a porous granular material, for example, an expanded silicate material, and optionally the expanded silicate material is (a) about 15 kg/ m³ to about 450 kg/ m³ , for example, about 20 kg/ m³ to about 100 kg/ m³ , or about 30 kg/ m³ to about 60 kg/ m³ , or about 20 kg/ m³ to about 30 kg/m³, or about 20 kg/ m³ to about 40 kg/ m³ , or about 55 kg/ m³ to about 100 kg/ m³ , or about 70 kg/ m³ to about 100 kg/ m³ , preferably about 30 kg/ m³ to Loose bulk density measured according to PI 200-77 at approximately 60 kg/ m³ ; Compaction resistance measured according to PI 306-80 of about 3 PSI to about 350 PSI at 2", e.g., about 3 PSI to about 200 PSI at 2", or about 3 PSI to about 100 PSI at 2", or about 3 PSI to about 10 PSI at 2", or about 30 PSI to about 80 PSI at 2", or about 40 PSI to about 75 PSI at 2", or about 5 PSI to about 20 PSI at 2"; and/or about 0.0300 W/mK to about 0.0700 W/mK, e.g., about 0.0320 W/mK to about 0.0420 W/mK, about 0.0350 W/mK to about 0.0400 W/mK, or about (b) having a thermal conductivity measured according to EN 12667 of 0.0360 W/mK to about 0.0410 W/mK, or about 0.0320 W/mK to about 0.0340 W/mK, or about 0.042 W/mK to about 0.055 W/mK, or about 0.055 W/mK to about 0.070 W/mK; and/or having a thermal conductivity of about 3 wt% to about 30 wt%, e.g., about 3.5 wt% to about 22 wt%, or about 8 wt% to about 30 wt%, or about 13 wt% to about 22 wt% of X₂O (where X is an alkali metal such as Na or Li); about 0 wt% to about 20 wt%, e.g., about 5 wt% to about 15 wt%, or about 0 wt% to about 15 wt%, or about ( c ) comprising 5 wt% to about 9 wt% of Al₂O₃ ; and about 50 wt% to about 90 wt%, e.g., about 60 wt% to about 80 wt%, or about 50 wt% to about 80 wt%, or about 60 wt% to about 75 wt% of SiO₂ ; and optionally about 0 wt% to about 10 wt%, e.g., about 0.5 wt% to about 5 wt% of H₂O ; optionally, the expanded silicate material comprises less than about 5 wt%, e.g., less than about 3.5 wt% of B₂O₃ ; and/ or ; (c) forming a silicate mixture comprising at least one silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; grinding and/or milling the solid precursor to form a granular expandable silicate material; and heating the granular expandable silicate material to form an expanded silicate material. (d) expanded natural perlite. According to a third embodiment, the present invention provides an insulating product produced by the method according to a first embodiment. Surprisingly, it has been discovered that a lightweight insulating product can be produced by forming a mixture containing a solvent and a gel network forming agent (and optionally a foaming agent), dispersing an insulating filler in the mixture, and drying the mixture to form an insulating product. In particular, an insulating product containing an insulating filler dispersed in an aerated matrix can be produced in this manner. mixture The first step in forming an insulating product is to form a mixture comprising a solvent, a gel network forming agent, and optionally a foaming agent. Thus, the mixture typically comprises at least a solvent and a gel network forming agent, and may additionally comprise a foaming agent. The solvent is typically a liquid solvent. The solvent may be polar. For example, the solvent may include one or more of water, carboxylic acids (e.g., methanol (i.e., formic) acid or ethanoic (i.e., acetic) acid), alcohols (e.g., methanol, ethanol, propanol, or butanol), ketones (e.g., butanone (i.e., methyl ethyl ketone) or propanone (i.e., acetone)) (e.g., these may be). Alternatively, the solvent may be nonpolar. The gel network forming agent may be any substance or m