CN107091392A - 绝热件及其制造方法 - Google Patents

绝热件及其制造方法 Download PDF

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CN107091392A
CN107091392A CN201710066415.2A CN201710066415A CN107091392A CN 107091392 A CN107091392 A CN 107091392A CN 201710066415 A CN201710066415 A CN 201710066415A CN 107091392 A CN107091392 A CN 107091392A
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base material
aeroge
fiber
material layer
substrate layer
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CN107091392B (zh
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久武阳
久武阳一
冈田伸二
酒谷茂昭
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Panasonic Intellectual Property Management Co Ltd
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Abstract

本发明涉及绝热件及其制造方法，提供在绝热片的表面不附着有气凝胶而能够粘贴粘接件、粘合件的绝热片。使用的绝热件包括：第一基材层，其包含气凝胶和纤维；和第二基材层，其层叠于上述第一基材层，且包含气凝胶和纤维，上述第一基材层中的气凝胶体积密度比上述第二基材层中的气凝胶体积密度高，上述第二基材层的不与上述第一基材层层叠的面的上述气凝胶比上述第二基材层的与上述第一基材层层叠的面的上述气凝胶少。

Description

绝热件及其制造方法
技术领域
本发明涉及绝热件及其制造法。尤其涉及多层构造的绝热件及其制造方法。
背景技术
近年来，伴随智能手机、平板电脑、笔记本电脑等电子设备的高功能化，来自发热部件的发热密度急剧增加，这些电子设备的绝热技术正成为必需技术。
尤其是，小型的移动设备直接与人体接触的机会多，其壳体外侧的温度上升正成为严重的问题。作为由移动设备的壳体外表面的温度上升引起的问题之一，可举出低温烫伤。低温烫伤是人体长时间暴露于比体温高的温度而产生的烫伤的一种，存在如下报告：以44℃持续6小时则会产生烫伤、每上升1℃则产生烫伤的时间变为一半。低温烫伤与普通的烫伤相比，绝大多数情况下当事者迟于察觉症状的发展，在察觉时皮肤多已受到重度的损伤。
另外，移动设备的显示元件使用液晶显示器、有机EL显示器，但这些显示元件不耐热，若来自发热部件的发热传递到这些显示元件，则成为显示器的亮度不均、寿命降低的原因，因此为了同时实现移动设备的高性能化和小型-薄型化，需要有效减少向显示元件的传热。
而且，最近，在膝上长时间使用小型笔记本电脑时产生低温烫伤的病例很多。在今后日益推进设备的小型化、移动化的状况下，将设备表面的温度抑制得低是极其重要的，就算只降低1℃。
除此之外，作为电气化产品，以电视、记录器、音响设备为首的AV设备、以空调、洗衣机为首的生活家电、以电动螺丝刀为首的电气工具，也正推进小型化、薄型化、高功能化。它们也有与人体接触的机会，因此抑制向壳体外部的热传导的必要性提高。
而且，对于住宅建筑材料，与室内空间的扩张相伴的墙壁的薄型化、配管路径的窄小化的需求正在变高。即使墙壁薄也必须维持房间的绝热性能。因此，需要防止外部的冷气、热气。关于配管，也需要绝热以防止结露。另外，在配管中流通热水的情况下，需要进行配管的绝热。
针对这些问题，作为切断热量的方法，在电子设备、家电产品中，考虑使用绝热构件以使来自设备的壳体内部的发热部件的热量不传递给壳体。另外，在住宅建筑材料领域，也考虑使用绝热构件以切断热量。而且，为了满足这些需求，对厚度薄且具有柔软性的绝热构件的要求正在提高。
作为满足该要求的绝热构件，存在在无纺布等基材中含有绝热性高的气凝胶的片状的绝热件。但是，在将基于该气凝胶而实现的绝热片用作绝热件的情况下，在片表面附着有气凝胶，无法将绝热件粘接于想要使用的地方。因此，存在图8的剖视图所示的构造(专利文献1)。采用由被覆层102覆盖气凝胶层101的表面的构造。
在先技术文献
专利文献1：日本特开2009-299893号公报
专利文献2：日本特表2001-509097号公报
然而，在上述以往的结构中，具有热传导率因被覆层102而变高，作为绝热件不优选这一问题。即，覆盖整体的被覆层102不佳。
发明内容
发明所要解决的课题
本发明是解决上述以往的问题的发明，其目的在于，提供能够在绝热片的表面局部地粘贴粘接件、粘合件的绝热片及其制造方法。
用于解决课题的方案
为了达到上述目的，使用如下绝热件，该绝热件包括：第一基材层，其包含气凝胶和第一纤维；和第二基材层，其层叠于上述第一基材层，且包含气凝胶和第二纤维，上述第一基材层中的气凝胶体积密度比上述第二基材层中的气凝胶体积密度高，上述第二基材层中的不与上述第一基材层叠的面的气凝胶比上述第二基材层的与所述第一基材层叠的面的气凝胶少。
另外，使用如下绝热件的制造方法，该制造方法包括：供给工序，仅向将包含第一纤维的第一基材层与包含第二纤维的第二基材层层叠而成的层叠体的上述第一基材层供给气凝胶溶液；和干燥工序，对上述层叠体进行干燥。
而且，使用如下绝热件的制造方法，该制造方法包括：供给工序，向包含第一纤维的第一基材层供给气凝胶溶液；层叠工序，将上述第一基材层与包含第二纤维的第二基材层层叠；以及干燥工序，对层叠得到的层叠体进行干燥。
发明效果
根据本发明的绝热件，能够在其表面局部地粘贴粘接件、粘合件。
附图说明
图1是表示本发明的实施方式1的两层绝热片的结构的图。
图2是表示本发明的实施方式1的两层绝热片的含浸方法1的图。
图3是表示本发明的实施方式1的两层绝热片的含浸方法2的图。
图4是表示本发明的实施方式1的两层绝热片的制造例的图。
图5是表示本发明的实施方式2的三层绝热片的结构的图。
图6是表示本发明的实施方式2的三层绝热片的含浸方法1的图。
图7是表示本发明的实施方式2的三层绝热片的制造例的图。
图8是表示专利文献1中的绝热件的结构的剖视图。
附图标记说明
101 气凝胶层
102 被覆层
200 绝热片
201 第一基材层
202 第二基材层
301 涂敷头
302 原料
303 涂敷嘴
401 浸渍槽
501 贴合辊
601 绝热片
901 第一基材层
具体实施方式
以下参照附图来说明本发明的实施方式。
(实施方式1)
图1是表示本发明的实施方式1的绝热件的结构的图。
在图1中，绝热片200是第一基材层201与第二基材层202的层叠体。
在图1中，第一基材层201是使气凝胶完全含浸于第一纤维间而得到的层。完全含浸的状态是指第一纤维间中所含的空气被置换为气凝胶的状态。在作为绝热件使用的情况下，希望气凝胶的体积密度是第一基材层201的总体积的90％以上。不过，在90％以下绝热性能低，但也能够用作绝热件。第一基材层901的绝热性能由气凝胶的体积密度决定。
第二基材层202是气凝胶未完全含浸于第二纤维间的层。未完全含浸的状态是指气凝胶没能够进入第二纤维间中而残留有空气的状态。希望气凝胶的体积密度为第二基材层202的30体积％以下。这是因为，若气凝胶的体积密度比30体积％高，则在第二基材层202的下表面(表面)附着有气凝胶的比例变高，粘接性能受到损害。
在第二基材层202的下侧、即第二基材层202的未面对第一基材层201的面，附着有气凝胶的面积的比例从粘接性出发优选为5％以下。虽然在比5％大的情况下也具有粘接性，但优选5％以下。在第二基材层202中，气凝胶的分布设为如下分布：在第二基材层202与第一基材层201的分界面部分最多，随着向相反侧的面行进，该气凝胶的体积密度变低。优选第二基材层202整体的气凝胶的体积密度为30体积％以下，下表面的气凝胶的面积的比例为5％以下。
在第二基材层202中，在气凝胶的附着少的下表面，能够粘贴粘接剂、粘合件、胶带(tape)这样的用于粘接的材料。由此，含有绝热性优异的气凝胶的绝热片200能够容易地应用于所需的地方。
第一基材层201的第一纤维与第二基材层202的第二纤维可以是相同种类的纤维，也可以不同的纤维。不过，如以下那样形状、视密度等不同。
将对第一基材层201与第二基材层202的特性的不同进行了记载的特性表的例子示于表1。单位面积重量表示第一基材层201的第一纤维和第二基材层202的第二纤维的单位面积重量。
【表1】
第一基材层201的第一纤维含有更多的气凝胶则绝热性能变高。即，在比较相同厚度的纤维的情况下，单位面积重量少的纤维能够含有较多的气凝胶，因此绝热性能变高。
不过，若纤维的厚度变化则单位面积重量也变化，因此考虑计算出每单位厚度的单位面积重量。在求出以单位面积重量[g/m2]/厚度[mm]计算出的视密度的情况下，第一基材层201的第一纤维优选具有0.04g/cm3以下的视密度。这是因为，若视密度为0.04g/cm3以下，则在以表示绝热性能的热传导率进行比较的情况下，第一基材层201的热传导率比空气的热传导率26mW/mK低，能够确保绝热性能。
视密度的下限值从强度方面出发优选为0.01g/cm3以上。
另一方面，第二基材层202的特性与第一基材层201的特性不同。第二基材层202的第二纤维优选使用与第一纤维相比单位面积重量多且视密度高的纤维。这是因为，若单位面积重量多，则纤维中所含的空气的量少，气凝胶无法浸入第二基材层202。考虑到绝热片200整体的绝热性能，气凝胶的含量少的第二基材层202的厚度越薄，绝热片200整体的绝热性能越高故而优选，第二基材层202的厚度为0.1mm以下时，绝热片200整体的绝热性能比空气的绝热性能高故而优选。
但是，第二基材层202的厚度即使为0.1mm以上也没有问题。每单位厚度的单位面积重量即视密度优选为0.1g/cm3以上。若视密度为0.1g/cm3以上，则进入第一基材层201中的气凝胶的量低于30体积％，因此能够将附着于第二基材层202的下表面的凝胶抑制为5％体积以下。
视密度的上限值从气凝胶的进入、导热性的观点出发优选为0.12g/cm3以下。
另外，作为与单位面积重量不同的特性，也可以对第二基材层202的第二纤维赋予疏水性。通过UV清洗、等离子清洗等对第二纤维赋予疏水性。在实施了该疏水处理的情况下，能够防止气凝胶浸入第二基材层202的内部。因此，即使将第二纤维的单位面积重量设定得低，气凝胶也因疏水处理而无法浸入，从而能够使用视密度比0.1g/cm3小的第二纤维。此时，不对第一基材层201赋予疏水性。这是因为，在对第一基材层201赋予疏水性的情况下，气凝胶无法浸入第一基材层201，不能够实现作为绝热件的用途。
至少第一基材层201的第一纤维的疏水性比第二基材层202的第二纤维的疏水性低。
对于疏水性的赋予，在将第一基材层201的第一纤维与第二基材层202的第二纤维贴合之前，对第二纤维赋予疏水性。对第二基材层202的第二纤维整体实施疏水性的赋予。尤其优选对表面均质地赋予。然后，采用贴合无纺布的制法即针刺法(Needle-punchMethod)等来将第一基材层201所使用的第一纤维与第二基材层202所使用的第二纤维贴合，由此能够生成复合体。
<第一制法>
气凝胶通过以下方式制作。混合水玻璃、四甲氧基硅烷之类的金属醇盐的凝胶原料、和水、醇等溶剂，并根据需要混合催化剂。由此，在溶剂中由凝胶原料制作湿润凝胶。然后，使内部的溶剂干燥，制作气凝胶。因此，在原料的状态下为液体。
图2是表示涂敷气凝胶的原料302并进行含浸的第一方法的剖视图。涂敷头301中填充有原料302。从涂敷嘴303排出的原料302含浸于第一基材层201的第一纤维。但是，第二基材层202的第二纤维的单位面积重量比第一基材层201的单位面积重量多，因此原料302几乎不浸渍于第二基材层202。原料302以第二基材层202的面对第一基材层201的上表面为中心而分布。因而，原料302不到达第二基材层202的下表面。最终成为上述所示的气凝胶的体积密度。
<第二制法>
图3是表示通过浸渍而含浸气凝胶的原料302的第二含浸方法的剖视图。浸渍槽401中填充有原料302。关于浸渍的部分，优选仅浸渍第一基材层201的第一纤维。对于第二基材层202，为了防止哪怕是少量的气凝胶附着于表面，优选不使第二基材层202浸渍于原料302。在浸渍完成后，自浸渍槽401取出并使之凝胶化。原料302的一部分从第一基材层201向第二基材层202移动。最终成为上述所示的气凝胶的体积密度。
<第三制法>
图4表示在使气凝胶的原料302含浸于第一基材层201后将第一基材层201与第二基材层202相贴合而制造的第三方法。涂敷头301中填充有原料302。从涂敷嘴303排出的原料302含浸于第一基材层201的第一纤维。
然后，使第一基材201的第一纤维与第二基材层202的第二纤维重合。然后，利用辊501来将第一基材201与第二基材层202接合。在贴合后，直接在该状态下进行凝胶化，由此形成第一基材层201与第二基材层202接合了的状态。实际上，在自第一基材层201渗出的原料302附着于第二基材层202的表层的状态下进行凝胶化，因此能够通过凝胶的结合力来进行结合。第一基材层201的原料302也进入第二基材层202。
其结果是，在绝热片200中，第二基材层202的气凝胶的分布为：气凝胶的含量从第二基材层202的与第一基材层201层叠的面侧朝向第二基材层202的不与第一基材层201层叠的面侧而变少。由此，上述第二基材层202的表面的气凝胶的面积为5％以下。
(实施方式2)
<构造>
图5所示的三层的绝热片601是由两个第二基材层202夹住第一基材层201而成的三层构造。在该情况下，三层的绝热片601的两面成为第二基材层202，因此粘合件、粘接剂、胶带这样的用于粘接的材料能够应用于三层的绝热片601的两面，能够应用的范围进一步扩宽。
<第四制法>
图6是表示制造该三层构造的三层的绝热片601时的、气凝胶的原料302的含浸方法的图。在涂敷原料的情况下，需要向三层的中心的第一基材层201直接含浸原料302。为此，优选将绝热片601沿着铅垂方向立起，并自侧面涂敷原料302，通过重力进行含浸。
<第五制法>
图7是表示在使气凝胶的原料302含浸于第一基材层201之后将第一基材层201与第二基材层202贴合而进行制造的方法的图。涂敷头301中填充有原料302。从涂敷嘴303排出的原料302含浸于第一基材层201。然后，能够通过由第二基材层202夹住第一基材层201而重合三层，并利用贴合辊501将该三层贴合来制造。
产业上的可利用性
本发明的绝热片是能够进行粘接剂、粘合件的粘贴且绝热性优异的气凝胶的绝热件，能够应用于需要绝热件的所有用途。

Claims (9)

1.一种绝热件，包括：
第一基材层，其包含气凝胶和第一纤维；和
第二基材层，其层叠于所述第一基材层，且包含气凝胶和第二纤维，
所述第一基材层中的气凝胶的体积密度比所述第二基材层中的气凝胶的体积密度高，
所述第二基材层中的不与所述第一基材层层叠的面的气凝胶比所述第二基材层的与所述第一基材层层叠的面的气凝胶少。
2.根据权利要求1所述的绝热件，其中，
所述第二基材层的气凝胶的分布为：气凝胶的含量从所述第二基材层的与所述第一基材层层叠的面侧朝向所述第二基材层的不与所述第一基材层层叠的面侧而变少。
3.根据权利要求1所述的绝热件，其中，
所述第一纤维的疏水性比所述第二纤维的疏水性低。
4.根据权利要求1所述的绝热件，其中，
由两个所述第二基材层夹着所述第一基材层。
5.根据权利要求1所述的绝热件，其中，
所述第一纤维的视密度比所述第二纤维的视密度低。
6.根据权利要求1所述的绝热件，其中，
所述第一纤维的视密度为0.04g/cm3以下。
7.根据权利要求1所述的绝热件，其中，
所述第二纤维的视密度为0.1g/cm3以上。
8.一种绝热件的制造方法，包括：
供给工序，仅向将包含第一纤维的第一基材层和包含第二纤维的第二基材层层叠而成的层叠体的所述第一基材层供给气凝胶溶液；和
干燥工序，对所述层叠体进行干燥。
9.一种绝热件的制造方法，包括：
供给工序，向包含第一纤维的第一基材层供给气凝胶溶液；
层叠工序，将所述第一基材层与包含第二纤维的第二基材层层叠；以及
干燥工序，对层叠得到的层叠体进行干燥。
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