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KR-20260066762-A - Aerogel composite material and method for manufacturing the aerogel composite material

KR20260066762AKR 20260066762 AKR20260066762 AKR 20260066762AKR-20260066762-A

Abstract

The present invention relates to an aerogel composite material and a method for manufacturing the same. The aerogel composite material comprises a porous fiber material and an aerogel powder distributed within the porous fiber material. The aerogel powder is impregnated into the porous fiber material by applying an alternating electric field to the porous fiber material. As the aerogel powder is impregnated into the porous fiber material by the alternating electric field, the amount of aerogel powder impregnated is large and uniform, so the aerogel composite material has excellent thermal insulation properties, and the process is simple and the production cost is low.

Inventors

  • 리, 홍저
  • 리, 정
  • 위, 치우시아
  • 취에, 원빈

Assignees

  • 오웬스 코닝 인텔렉츄얼 캐피탈 엘엘씨

Dates

Publication Date
20260512
Application Date
20240814
Priority Date
20230907

Claims (20)

  1. porous fiber material; Aerogel powder dispersed in porous fiber material An aerogel composite material comprising, wherein the aerogel powder is impregnated into the porous fiber material by applying an alternating electric field to the porous fiber material, wherein the density of the aerogel powder is in the range of 0.01 g/cm³ to 0.5 g/cm³, and the average particle size of the aerogel powder is 500 μm or less.
  2. An aerogel composite material according to claim 1, wherein the voltage of the alternating electric field is in the range of 0.1KV to 50KV and the frequency is in the range of 1HZ to 800HZ; and the application time of the alternating electric field is in the range of 30 seconds to 5 minutes.
  3. An aerogel composite material according to claim 1, wherein the density of the aerogel powder is in the range of 0.03 g/cm³ to 0.1 g/cm³ and the average particle size of the aerogel powder is 50 μm or less.
  4. In claim 1, the porous fiber material is an aerogel composite material selected from glass fiber felt, glass fiber nonwoven fabric, glass fiber fabric, ceramic fiber felt, paper, polyurethane fiber felt, carbon fiber felt, polypropylene fiber felt, polypropylene, and glass fiber composite felt, and combinations thereof.
  5. An aerogel composite material according to claim 4, wherein the area density of the glass fiber nonwoven fabric is 20 g/m² to 500 g/m²; the thickness is 0.3 mm to 4 mm; and the air permeability is 200 L/m²/s to 3000 L/m²/s.
  6. An aerogel composite material according to claim 5, wherein the area density of the glass fiber nonwoven fabric is 50 g/m² to 150 g/m²; the thickness is 0.5 mm to 1.5 mm; and the air permeability is 500 L/m²/s to 2000 L/m²/s.
  7. An aerogel composite material according to claim 6, wherein the area density of the glass fiber nonwoven fabric is 90 g/m² to 135 g/m²; the thickness is 0.8 mm to 1.3 mm; and the air permeability is 1100 L/m²/s to 1800 L/m²/s.
  8. In paragraph 4, the polypropylene and glass fiber composite felt is manufactured by blending polypropylene fibers and glass fibers; the polypropylene and glass fiber composite felt has a density of 20 kg/m³ to 200 kg/m³ and a thickness of 1 mm to 20 mm, an aerogel composite material.
  9. In claim 8, the aerogel composite material, wherein the density of the polypropylene and glass fiber composite felt is 50 kg/m³ to 150 kg/m³ and the thickness is 3 mm to 10 mm.
  10. An aerogel composite material according to claim 1, wherein an additive that suppresses thermal radiation is added to the aerogel powder, and the additive is selected from at least one of silicon carbide, boron carbide, titanium oxide, and boron nitride; and the weight ratio of the additive to the aerogel powder is in the range of 1 wt% to 15 wt%.
  11. An aerogel composite material according to claim 10, wherein the weight ratio of the additive to the aerogel powder is in the range of 5 wt% to 12 wt%.
  12. An aerogel composite material according to claim 1, wherein the weight ratio of the aerogel powder to the aerogel composite material is in the range of 1 wt% to 50 wt%.
  13. A method for manufacturing an aerogel composite material according to any one of claims 1 to 12, wherein the method A method comprising the step of impregnating an aerogel powder into a porous fiber material by applying an alternating electric field, wherein the voltage of the alternating electric field is in the range of 0.1 KV to 200 KV; the frequency is in the range of 0.1 Hz to 800 Hz; the density of the aerogel powder is in the range of 0.01 g/cm³ to 0.5 g/cm³; and the average particle size of the aerogel powder is 500 μm or less.
  14. In paragraph 13, the method wherein the application time of the alternating electric field is in the range of 30 seconds to 5 minutes.
  15. A method according to claim 13, further comprising the steps of applying aerogel powder to the surface of a porous fiber material and/or applying the aerogel powder to a loader that receives at least a partially alternating electric field.
  16. A method according to claim 13, wherein a porous fiber material and an aerogel powder are placed between a lower electrode and an upper electrode, and the electrodes are electrically insulated from each other through a dielectric and connected to a power source so that the porous fiber material and the aerogel powder receive an alternating electric field.
  17. In claim 13, the density of the aerogel powder is in the range of 0.03 g/cm³ to 0.1 g/cm³, and the average particle size of the aerogel powder is 50 μm or less.
  18. In paragraph 13, the porous fiber material is selected from glass fiber felt, glass fiber nonwoven fabric, glass fiber fabric, ceramic fiber felt, paper, polyurethane fiber felt, carbon fiber felt, polypropylene fiber felt, polypropylene, and glass fiber composite felt, and combinations thereof.
  19. In paragraph 18, the glass fiber nonwoven fabric has an area density of 20 g/m² to 500 g/m²; a thickness of 0.3 mm to 4 mm; and an air permeability of 200 L/m²/s to 3000 L/m²/s.
  20. In claim 19, the glass fiber nonwoven fabric has an area density of 50 g/m² to 150 g/m²; a thickness of 0.5 mm to 1.5 mm; and an air permeability of 500 L/m²/s to 2000 L/m²/s.

Description

Aerogel composite material and method for manufacturing the aerogel composite material Cross-reference regarding related applications This application claims priority to Chinese patent application No. 202311152915.X filed on September 7, 2023, the entire contents of said application incorporated herein by reference. The present invention relates to the technical field of aerogels, in particular to aerogel composite materials and a method for manufacturing aerogel composite materials. Aerogel composites are new advanced materials created by combining nano-aerogel particles and fiber materials through a special process. They possess characteristics such as lightweight properties, high-efficiency thermal insulation, fire resistance, and environmental protection, and are widely used in various fields including construction, petroleum, and aerospace. Currently, aerogel composite materials are primarily manufactured using the supercritical drying method. Supercritical drying is a method that converts a sol-gel into an aerogel by utilizing the special properties of a supercritical fluid (e.g., carbon dioxide) to replace the solvent of a sol-gel pre-impregnated in a fiber material, thereby allowing the aerogel to grow in situ within the fiber material. Aerogel composite materials are manufactured (as described in Chinese patents CN100540257C and CN105906298A). The supercritical drying method requires supercritical conditions. The cost of supercritical drying equipment is high, process operation is complex, process energy consumption is very high, and there are specific constraints on precursor selection. In addition to supercritical drying, some technologies have sequentially implemented a technology for manufacturing aerogels using atmospheric drying, which converts sol-gels into aerogels under atmospheric pressure at room temperature or high temperature by performing a large amount of hydrophobic modification beforehand (e.g., Chinese patents CN103771428A, CN109806817A). Atmospheric drying has low equipment costs and low energy consumption. However, a factor limiting the industrial expansion of atmospheric drying is that only aerogel powder can be produced on a large scale, and aerogel composite materials cannot be manufactured in situ. Recently, much research has focused on manufacturing aerogel composite materials through a specialized process of re-compounding aerogel powder produced by atmospheric drying into fiber felt. The most common technical method involves forming aerogel powder into an aerogel slurry, compounding it into a fiber material via impregnation, and then evaporating the solvent (e.g., Chinese Patents CN112301732B and CN114835435A). However, the aerogel nanopore structure is damaged during the slurry formation process, leading to performance degradation; furthermore, the use of large amounts of solvent and drying equipment throughout the entire process results in high costs and increased energy consumption. There are also some solvent-free technical methods in which aerogel powder is applied to fiber felt via manual or electrostatic spraying, and the composite material is formed through an acupuncture process (CN115874348B). However, since the dispersibility of aerogel powder within fiber materials is always poor, excellent uniform characteristics of aerogel composite materials manufactured by the supercritical drying method cannot be achieved. Using secondary composite materials of aerogel powder to manufacture aerogel composite materials can significantly reduce the production cost of aerogel materials and expand their application in industrial production, but development is being hindered due to limitations in composite technology. The following drawings are incorporated as part of the present invention to aid in understanding the invention. Examples are illustrated and described in the drawings to explain the principles of the invention. In the drawing: Figure 1 is an SEM image of a vertical cross-section of an aerogel composite material according to Example 1 of the present invention. Figure 2a is an SEM image of a vertical cross-section of an aerogel composite material according to Example 2 of the present invention. FIG. 2b is an SEM image of the front surface of an aerogel composite material according to Example 2 of the present invention. FIG. 2c is an SEM image of the back surface of an aerogel composite material according to Example 2 of the present invention. FIG. 3a is an SEM image of a vertical cross-section of an aerogel composite material according to Comparative Example 1 of the present invention. FIG. 3b is an SEM image of the front surface of an aerogel composite material according to Comparative Example 1 of the present invention. FIG. 3c is an SEM image of the back surface of an aerogel composite material according to Comparative Example 1 of the present invention. Figure 4a is an SEM image of a vertical cross-section of an aerogel composite material according to Comparati