WO-2026094170-A1 - COATING LIQUID, COMPOSITE MATERIAL, AND PRODUCTION METHOD FOR COMPOSITE MATERIAL

Abstract

The present disclosure relates to a coating liquid that contains aerogel particles, glass particles, a binder resin, and an aqueous solvent. The coating liquid makes it possible for a composite material that contains aerogel particles and a binder resin to be formed with excellent film formation properties.

Inventors

• IZUMI HIROYUKI
• MARUYAMA NAOKI

Assignees

• 株式会社レゾナック

Dates

Publication Date

20260507

Application Date

20241030

Claims (11)

1. A coating liquid containing aerogel particles, glass particles, a binder resin, and an aqueous solvent.
2. The coating liquid according to claim 1, wherein the glass particles include hollow glass particles.
3. The coating solution according to claim 1, further containing a water-soluble polymer.
4. The coating solution according to claim 3, wherein the water-soluble polymer has hydrophobic groups.
5. A composite material that is a dried product of a coating liquid according to any one of claims 1 to 4.
6. The composite material according to claim 5, having a thick film portion having a thickness of 1 mm or more.
7. A composite material containing aerogel particles, glass particles, and a binder resin.
8. The composite material according to claim 7, further containing a water-soluble polymer.
9. The composite material according to claim 7, having a thick film portion having a thickness of 1 mm or more.
10. A coating step of applying the coating liquid according to any one of claims 1 to 4 onto a support to obtain a coating film, A removal step of removing at least a portion of the aqueous solvent from the coating film to obtain a composite material containing aerogel particles, glass particles, and a binder resin, A method for manufacturing composite materials, including
11. The manufacturing method according to claim 10, wherein the composite material has a thick film portion having a thickness of 1 mm or more.

Description

Coating liquid, composite material, and method for manufacturing composite material This disclosure relates to a coating liquid, a composite material, and a method for manufacturing the composite material. Aerogel is known as a material with excellent thermal insulation properties. Furthermore, methods have been proposed for processing aerogel into granular form and using it as a constituent material for thermal insulation (for example, Patent Documents 1 and 2). Patent Document 1 proposes using granular aerogel as a filler between resin plates and other components that constitute a thermal insulation window. Patent Document 2 describes a method for producing thermal insulation (molded body) by preparing an aqueous dispersion containing aerogel particles and organic fibers, then evaporating the water to obtain an intermediate product, and further press-molding the resulting product. The following describes preferred embodiments of this disclosure in detail. However, this disclosure is not limited to the embodiments described below. In this specification, numerical ranges indicated using "~" indicate a range that includes the numerical values before and after "~" as the minimum and maximum values, respectively. "A or B" means that either A or B is included, or both are included. Unless otherwise specified, the materials exemplified in this embodiment can be used individually or in combination of two or more types. (Coating liquid) The coating liquid of this embodiment contains aerogel particles, glass particles, a binder resin, and an aqueous solvent. The coating liquid of this embodiment exhibits excellent film-forming properties. With this coating liquid, even when applied to a curved section or when the dried film thickness is 1 mm or more, it is possible to form a composite material while suppressing the occurrence of cracks. Because the coating liquid of this embodiment contains aerogel particles, the resulting composite material exhibits excellent thermal insulation properties. Therefore, the composite material formed from the coating liquid of this embodiment can be suitably used as a thermal insulation material. Furthermore, in this embodiment, the use of both aerogel particles and glass particles in the coating solution improves the fluidity of the solution compared to a case containing only aerogel particles, making it easier to form a uniform coating film. Also, in this embodiment, the use of both aerogel particles and glass particles as fillers suppresses the adsorption of the binder resin to the filler surface compared to a case where only aerogel particles are used as fillers, allowing the binder resin to function more effectively as a matrix. As a result, the coating solution of this embodiment achieves the excellent film-forming properties described above. In coatings containing aerogel particles, the aerogel particles may aggregate and form aggregates within the coating. When aerogel particles aggregate in the coating, these aggregates can act as crack initiation points, potentially leading to cracking during drying. Furthermore, aggregation of aerogel particles in the coating significantly increases the viscosity of the coating, making it difficult to form a uniform coating film. This can also lead to uneven shrinkage stress during drying, increasing the likelihood of cracking. Because the coating in this embodiment uses both aerogel particles and glass particles, aggregation of aerogel particles in the coating is suppressed, making the aforementioned problems caused by aerogel particle aggregates less likely. This is considered one of the factors contributing to its excellent film-forming properties. <Aerogel> In a narrow sense, a dry gel obtained by supercritical drying of a wet gel is called an aerogel, a dry gel obtained by drying under atmospheric pressure is called a xerogel, and a dry gel obtained by freeze-drying is called a cryogel. However, in this embodiment, a low-density dry gel obtained by any of these drying methods of a wet gel is called an "aerogel." That is, in this embodiment, "aerogel" means aerogel in a broad sense, "Gel composed of a microporous solid in which the dispersed phase is a gas." Generally, the interior of an aerogel has a mesh-like microstructure and has a cluster structure in which particulate aerogel components of about 2 to 20 nm are bound together. There are pores less than 100 nm in size between the frameworks formed by these clusters. As a result, the aerogel has a three-dimensionally fine, porous structure. The aerogel in this embodiment may be, for example, a silica aerogel with silica as the main component. Examples of silica aerogels include so-called organic-inorganic hybridized silica aerogels, which incorporate organic groups (such as methyl groups) or organic chains. Examples of aerogels in this embodiment include the following embodiments. By adopting these embodiments, it becomes easy to obtain an aerogel with excellent heat insulation, flam