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KR-20260068099-A - Composite material containing aerogel particles

KR20260068099AKR 20260068099 AKR20260068099 AKR 20260068099AKR-20260068099-A

Abstract

The present invention relates to a composite material comprising two or more layers, wherein the layer (LA) having a thickness of 0.1 to 4 mm, mainly comprising aerogel particles having a diameter of 0.1 to 4 mm before any compression, and one adjacent binder layer (LB) having a thickness of 0.01 to 1 mm, optionally a support layer (LC) adjacent to the binder layer having a thickness of 0.01 to 3 mm, optionally a second adjacent binder layer (LB') and a support layer or cover layer (LC') on a second surface of the particle layer (LA), wherein the aerogel particle layer (LA) comprises a layer section (LA-1) having a thickness of 0.01 to 1 mm, which includes both the binder and the aerogel particles and optionally a portion of the support layer (LC) and is located adjacent to the binder layer (LB), and the aerogel particle layer (LA) further comprises a binder-free layer section (LA-2) having a thickness of 0.05 mm or more. The present invention further relates to a method for manufacturing the composite material, and to the use of the composite material according to the present invention in architecture and construction, appliances, thermologistics, cryogenic applications, automotive applications, infrastructure applications, marine applications, oil and gas applications, or as an insulating material for clothing, or as a thermal shielding material or a thermal propagation prevention material in batteries.

Inventors

  • 프리케 마르크
  • 수브라만얌 라만
  • 웨인리히 디르크

Assignees

  • 에어로젤-잇 게엠베하

Dates

Publication Date
20260513
Application Date
20240906
Priority Date
20230908

Claims (15)

  1. (a) a layer (LA) having a thickness in the range of 0.1 to 4 mm comprising aerogel particles having a diameter in the range of 0.1 to 4 mm prior to optional compression, and (b) one adjacent binder layer (LB) having a thickness in the range of 0.01 to 1 mm, (c) Optionally, a support layer (LC) adjacent to the binder layer having a thickness in the range of 0.01 to 3 mm, (d) Optionally, a second adjacent binder layer (LB') and a support layer or cover layer (LC') on the second surface of the particle layer (LA) A composite material comprising two or more layers, including, Here, the aerogel particle layer (LA) comprises a layer section (LA-1) having a thickness of 0.01 to 1 mm, which includes both a binder and aerogel particles and is located adjacent to the binder layer (LB). A composite material in which the aerogel particle layer (LA) further comprises a binder-free layer section (LA-2) having a thickness of 0.05 mm or more.
  2. A composite material according to claim 1, wherein the binder layer (LB) is adhered to more than 60% of the aerogel particles of the layer (LA) and preferably adhered to the support layer (LC).
  3. A composite material according to claim 1 or 2, wherein the binder layer (LB) and the support layer (LC) or the binder layer (LB') and (LC') are combined.
  4. In any one of claims 1 to 3, the uncompressed aerogel particles of the layer (LA) have the following features (α) to (γ): (α) Porosity of 80 - 99.6%, (β) Particle bulk density of 15 - 200 kg/㎥, (γ) Thermal conductivity of 16 - 30 mW/mK measured in a loosely packed particle layer at 10°C A composite material having one or more of the following.
  5. In any one of paragraphs 1 through 4, A composite material in which individual aerogel particles can be compressed to 5 to 98% of their original thickness without visible breakage of the aerogel particles during compression at a compression speed of 0.01 to 5 mm/sec, or exhibit a force drop of less than 1 N due to primary breakage during compression.
  6. In any one of paragraphs 1 through 5, (I) The aerogel particle size distribution is monodisperse, polydisperse, or partially monodisperse and/or, (II) A composite material in which the sphericity of individual aerogel particles ranges from 25% to 100%.
  7. In any one of paragraphs 1 to 6, the aerogel (A) 20-80 mass% silica and 20% ionic crosslinked polycarboxylate polymer, but at least 25 kg/m³ ionic crosslinked polycarboxylate polymer, or (B) 20-90 mass% silica and 10 mass% alginate, but at least 15 kg/m³ alginate, or (C) 20-85 mass% silica and 15 mass% pectin, but at least 20 kg/m³ of pectin, or (D) 20-80 mass% silica and 20 mass% CMC, but at least 25 kg/m³ CMC, or (E) 20-85 mass% silica and 7.5 mass% alginate and at least 15 kg/m³ alginate and at least 10 kg/m³ non-alginate ionic crosslinked polycarboxylate polymer A composite material that is a silica-based aerogel containing
  8. A composite material according to any one of claims 1 to 7, wherein the binder is selected from the group consisting of reactive binders based on acrylate, polyurethane, epoxy resin, silicone, or water glass or other inorganic binder systems, or from thermoplastic binders based on PE, PP, PA, TPU, PLA or other bio-based polymers, silicone, or any mixture of these binders.
  9. (i) a step of forming a binder layer (LB), (ii) a step of forming a layer (LA) comprising aerogel particles having a diameter in the range of 0.1 to 4 mm before optional compression, (iii) forming a composite material comprising layers (LA) and (LB) by applying conditions suitable for achieving stable bonding between layers (LA) and (LB) and forming a layer section (LA-1) having a thickness of 0.01 to 1 mm and containing both a binder and aerogel particles, and a binder-free layer section (LA-2) having a thickness of 0.05 mm or more. A method for manufacturing a composite material comprising two or more layers, comprising: Herein, the uncompressed aerogel particles of layer (LA) preferably have the following characteristics (α) to (γ): (α) Porosity of 80 - 99.6%; (β) Particle bulk density of 15 - 200 kg/m³; (γ) Thermal conductivity of 16 - 30 mW/mK measured in a loosely packed particle layer at 10°C A method for manufacturing a composite material having one or more of the following.
  10. In claim 9, the method of manufacturing the aerogel is a silica-based aerogel.
  11. In paragraph 9 or 10, the method (iv) A step of compressing the composite so that the aerogel is compressed to 5-98% of its original thickness, (v) Step of applying a compression rate in the range of 0.01 - 1 mm/sec A manufacturing method comprising
  12. A manufacturing method according to any one of claims 9 to 11, wherein the thickness of the composite material is in the range of 0.1 to 20 mm.
  13. A method of manufacturing according to any one of claims 9 to 12, wherein the thickness of the layer (LA) containing aerogel particles is in the range of 0.1 to 4 mm.
  14. A method of manufacturing in any one of claims 9 to 13, wherein the binder is selected from the group consisting of acrylate, polyurethane, epoxy resin, silicone, or thermoplastic binders such as PE, PP, PA, TPU, and PLA.
  15. Use of a composite material according to any one of paragraphs 1 to 8 or a composite material obtained or obtainable according to a manufacturing method according to any one of paragraphs 9 to 14 as an insulating material for building and construction, appliance, thermologistics, cryogenic applications, automotive applications, infrastructure applications, marine applications, oil and gas applications, or clothing, or as a thermal shielding material or thermal propagation prevention material in batteries.

Description

Composite material containing aerogel particles The present invention relates to a composite material comprising two or more layers, wherein, prior to optional compression, a layer (LA) having a thickness in the range of 0.1 to 4 mm, mainly comprising aerogel particles having a diameter in the range of 0.1 to 4 mm; one adjacent binder layer (LB) having a thickness in the range of 0.01 to 1 mm; optionally, a support layer or cover layer (LC) adjacent to or on a second surface of the binder layer (LB) having a thickness in the range of 0.01 to 3 mm; optionally, a second adjacent binder layer (LB') and a support layer or cover layer (LC') on a second surface of the aerogel particle layer (LA), wherein the aerogel particle layer (LA) comprises a layer section (LA-1) having a thickness of 0.01 to 1 mm, which includes both the binder and the aerogel particles and optionally a portion of the support layer (LC) and is located adjacent to the binder layer (LB); and the aerogel particle layer (LA) further comprises a thickness of 0.05 mm or more It includes a binder-free layer section (LA-2) having. The present invention further relates to a method for manufacturing said composite, and to the use of the composite according to the present invention as a thermal insulation material for architecture and construction, appliances, thermologistics, cryogenic applications, automotive applications, infrastructure applications, marine applications, oil and gas applications, or clothing, or as a thermal shielding material or thermal propagation prevention material in batteries. Aerogel materials are known from the latest technology for their super-insulating properties. Commercially available aerogel materials are used as super-insulators in construction, transportation, and the like. Currently available commercial aerogel materials are almost exclusively based on inorganic silica aerogels in the form of aerogel fiber blankets, aerogel particles, or aerogel powders. Aerogels typically require hydrophobization, such as using silane additives, to ensure sufficient resistance to water and humidity during application. Inorganic silica aerogels, particularly when dried using supercritical CO2 , and especially hydrophobized silica aerogels, suffer from weak mechanical integrity that causes dust formation and release throughout all stages of use, such as transport, installation, use, and disposal. Dust release makes the handling and integration of silica aerogels difficult. For some applications, aerogel composites or blankets of various thicknesses are required. In the case of electric vehicle (EV) batteries, thin composites or blankets with a thickness of 2 mm or less are particularly required. Aerogel blankets can be cut into thin layers, but there is a minimum thickness limit set by the fiber carrier, as layers that are too thin may cause a loss of the contained aerogel if they are not sufficiently retained within the carrier's fiber structure. Alternatively, aerogel powder composites can be formed by mixing and compressing them with fibers. One solution in this field is to encapsulate the resulting composite or blanket to prevent dust release into the area surrounding the aerogel composite, which can make handling difficult or negatively affect the function of the entire system. Otherwise, particularly in transportation applications, typical vibrations generated during use can cause dust formation and release. Independent of arbitrary encapsulation, aerogel materials can also be dislocated within blankets or composites by vibration, which can lead to material inhomogeneity and dysfunction within the composite. This is a particular issue in the case of thermal shielding for cell-to-cell applications in electric vehicle batteries, as such dysfunction can compromise electric vehicle safety in the event of a thermal runaway event. For example, EP0850206B1 describes an aerogel composite prepared from aerogel particles of small diameter (<0.5 mm) and various physical or reactive binder systems. The binder and the aerogel are mixed, and the mixture is compressed. The binder forms a continuous phase, which reduces thermal conductivity through thermal bridges. EP0854892B1 describes an aerogel sheet based on a wet process that requires drying. EP0963358B1 describes an aerogel composite based on compressed aerogel particles with a thermoplastic binder in a sandwich structure. The binder and aerogel are mixed, and the mixture is compressed. The binder forms a continuous phase, which reduces thermal conductivity through thermal bridging. WO2016053399A2 describes a thin aerogel blanket based on a typical aerogel manufacturing process based on supercritical drying using a thin aerogel blanket, which requires supercritical drying of the aerogel inside the blanket. US9097377B2 describes a thin aerogel composite based on a thin aerogel blanket encapsulated in a laminated foil layer to prevent dust emission, which requires an aerogel blanket manuf