CN109898332B - Heat insulation material - Google Patents

Heat insulation material Download PDF

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Publication number
CN109898332B
CN109898332B CN201811448520.3A CN201811448520A CN109898332B CN 109898332 B CN109898332 B CN 109898332B CN 201811448520 A CN201811448520 A CN 201811448520A CN 109898332 B CN109898332 B CN 109898332B
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China
Prior art keywords
resin
composite layer
coating film
nonwoven fabric
hydrophilic
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CN201811448520.3A
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Chinese (zh)
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CN109898332A (en
Inventor
日野裕久
中村太一
及川一摩
酒谷茂昭
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Panasonic Intellectual Property Management Co Ltd
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Panasonic Intellectual Property Management Co Ltd
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0059—Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/55—Epoxy resins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2262/0246—Acrylic resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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    • B32B2266/00—Composition of foam
    • B32B2266/12—Gel
    • B32B2266/126—Aerogel, i.e. a supercritically dried gel
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
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    • B32B2571/00—Protective equipment
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2400/00—Specific information on the treatment or the process itself not provided in D06M23/00-D06M23/18
    • D06M2400/02—Treating compositions in the form of solgel or aerogel
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/065—Insulating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/06—Arrangements using an air layer or vacuum

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Dispersion Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Thermal Insulation (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

The invention provides a covering structure of a heat insulating material for preventing powder falling of a silica-aerogel composite sheet. The heat insulator is provided with a composite layer in which silica-aerogel is enclosed in a nonwoven fabric, and a coating film which contains a hydrophilic resin and a lipophilic resin and covers the surface of the composite layer. The non-woven fabric is positioned on the heat insulating material of the coating film. The coating film uses the heat insulator in which the oleophilic resin is present in a plurality of island shapes in the hydrophilic resin.

Description

Heat insulation material
Technical Field
The present invention relates to a thermal insulation material. In particular, it relates to a heat insulator having a coating film on the surface thereof.
Background
In recent years, miniaturization, thinning, and high performance of mobile devices have been advanced. For mobile devices, a person often holds the mobile device for a long time. Therefore, it is important to suppress the temperature of the surface of the mobile device to be low.
Therefore, as a method for preventing the surface temperature of the mobile device from rising, there have been performed: a heat insulating material is provided directly above a heat generating component in a mobile device. Various heat insulating materials exist in the world, and silica-aerogel is a raw material having high heat insulating performance.
Silica-aerogel is known as a nanoporous body having a porosity of 90% or more. Further, it is known that the thermal insulation material is superior to conventional thermal insulation materials in terms of deterioration with age and heat resistance, and has an excellent thermal conductivity of about 15 mW/mK. However, silica-aerogel is a network structure in which fine silica particles of several 10nm order are connected in point contact, and therefore, mechanical strength is not so large. Therefore, in order to overcome its vulnerability, the following solutions are proposed: the strength is improved by combining silica-aerogel with fibers, nonwoven fabric, resin, and the like to form a sheet.
However, the network structure of the silica-aerogel of minute size is inherently fragile, and thus there is a possibility that individual particles are exfoliated from the network structure of the silica-aerogel. Then, the detached silica-aerogel particles float inside the mobile device, thereby causing malfunction of the mobile device.
In order to prevent this, a measure has been generally taken such as laminating a silica-aerogel composite sheet with a film to cover the sheet and forming the sheet into a pouch shape (hereinafter referred to as a laminated package) (patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese patent No. 6064149
Disclosure of Invention
Problems to be solved by the invention
However, the conventional method has the following technical problems. The case of performing laminated packaging to various shapes/sizes becomes custom-made, and therefore the cost becomes very high. As a result, the cost of the mobile device increases, which causes a loss of competitiveness of the product.
Accordingly, the present invention has been made to solve the problems of the prior art, and an object of the present invention is to provide a silica-aerogel-containing thermal insulation material which does not use a laminated package.
Means for solving the problems
In order to achieve the above object, a heat insulator is used which has a composite layer containing silica-aerogel in a nonwoven fabric, and a coating film which contains a hydrophilic resin and a lipophilic resin and covers the surface of the composite layer.
ADVANTAGEOUS EFFECTS OF INVENTION
As described above, in the nonwoven fabric and the cover structure of the silica-aerogel composite layer according to the present invention, the coating material is applied to the surface of the silica-aerogel composite layer, whereby the protective film can be provided to the silica-aerogel composite layer regardless of the shape of the coated portion. The film has high adhesion. Thus, a heat insulator having excellent heat insulation properties, a device using the heat insulator, and a method for forming a coating structure of the heat insulator can be provided.
Drawings
FIG. 1(a) is a sectional view of a thermal insulator formed by coating a coating material according to an embodiment,
fig. 1(b) is a plan view of the coating film of the embodiment.
Fig. 2 is a view showing the appearance of the coating film of the embodiment.
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Fig. 1(a) shows a cross section of a heat insulator 110 after application of the coating material according to the embodiment. Fig. 1(b) is a plan view of a coating film according to an embodiment. Fig. 2 shows the appearance of the coating film of the embodiment.
The thermal insulator 110 has a structure in which a coating film 111 is formed around the composite layer 102 including the nonwoven fabric 106 and the silica-aerogel 105. The fibers of the nonwoven fabric 106 exposed from the composite layer 102 are in close contact with the hydrophilic resin 112 and the reactive oleophilic resin 113 in the coating film 111.
< composite layer 102>
The composite layer 102 is a sheet in which a silica-aerogel 105 having a nano-sized porous structure is contained in a nonwoven fabric 106 having a thickness of 0.05 to 1.0 mm. The thermal conductivity is 0.01 to 0.1W/mK.
The thermal conductivity of the nonwoven fabric 106 is usually 0.030 to 0.060W/mK, which is a value obtained by substantially totaling the solid heat transfer component of the nonwoven fabric 106 and the heat transfer component of the air (nitrogen molecules) present in the voids of the nonwoven fabric.
The low thermal conductivity can be achieved by enclosing a silica-aerogel 105 as a low thermal conductivity material (generally, 0.010 to 0.015W/mK) in the voids.
Generally, the thermal conductivity of the static air at room temperature is about 0.026W/mK, and the thermal conductivity of the nonwoven fabric 106 is larger than that of the static air.
The composite layer 102 is characterized by: is a sheet whose thermal conductivity is smaller than that of the still air.
The composite layer 102 has water repellency and sound absorption properties in addition to heat insulation properties, and if the type of the nonwoven fabric 106 is selected, heat resistance and flame retardancy can be imparted.
In the present embodiment, in order to impart heat resistance and flame retardancy, an acrylic oxide is used as the nonwoven fabric 106, and in addition, a glass fiber paper may be used.
< thermal conductivity of composite layer 102>
The thermal conductivity of the composite layer 102 used in the present embodiment is in the range of 0.01 to 0.1W/m.K. As the thermal conductivity of the composite layer 102 is lower, the thermal insulation effect is improved, and the thickness of the composite layer 102 required to obtain the same thermal insulation effect can be reduced.
On the other hand, if the thermal conductivity is more than 0.1W/m · K, the heat insulating effect is lowered, and the thickness of the composite layer 102 needs to be increased to obtain a desired heat insulating effect, which is not preferable.
< thickness of composite layer 102>
The thickness of the composite layer 102 is in the range of 0.05mm to 2mm, preferably 0.5mm to 1 mm. When the thickness of the composite layer 102 is smaller than 0.05mm, the heat insulating effect in the thickness direction is reduced, and therefore, if a low thermal conductive material having a very low thermal conductivity (which cannot be present at present) is not selected, the heat transfer in the thickness direction from one surface to the other surface cannot be reduced satisfactorily.
< method for producing composite layer 102>
An example of a method for manufacturing the composite layer 102 is shown.
(1) Mixing raw materials: to a high-molar sodium silicate (aqueous silicic acid solution, Si concentration 14%), 1.4 wt% of concentrated hydrochloric acid (12N) was added as a catalyst, followed by stirring to prepare a sol solution.
(2) Impregnation: nonwoven fabric 106 (material: acrylic oxide, thickness: 0.4 μm, basis weight: 50 g/m)2And a size of 12mm square), and the sol solution is pressed into the nonwoven fabric 106 by a roller to impregnate the nonwoven fabric.
(3) The nonwoven fabric impregnated with the sol solution was sandwiched between PP films (40 μm × 2 sheets in thickness), and left at room temperature of 23 ℃ for about 20 minutes to gel the sol.
(4) Thickness limitation: after the gelation was confirmed, the impregnated nonwoven fabric 106 including the film was passed through 2-axis rolls with an interval set to 650 μm (including the film thickness), and excess gel was extruded from the nonwoven fabric 106, and the thickness was limited to 700 μm.
(5) And (5) maintenance: a gel sheet including a film was placed in a container, and the container was placed in a constant temperature and humidity chamber of 85 ℃/85 RH% for 3 hours to prevent drying, and silica particles were grown (dehydration condensation reaction of silanol) to form a porous structure.
(6) Film stripping: the sheet was taken out of the curing container, and the film was peeled off.
(7) Hydrophobization 1 (hydrochloric acid impregnation step): the gel sheet was immersed in hydrochloric acid (6 to 12 equivalents), and then left at room temperature of 23 ℃ for 1 hour, and hydrochloric acid was taken into the gel sheet.
(8) Hydrophobization 2 (siloxane treatment step): the gel sheet is immersed in a mixture of octamethyltrisiloxane as a silylating agent and 2-propanol (IPA) as an amphiphilic solvent, and is placed in a thermostatic bath at 55 ℃ to be reacted for 2 hours. When formation of the trimethylsiloxane bond started, hydrochloric acid water was discharged from the gel sheet, and liquid separation was performed 2 (the upper layer was the silylating agent, and the lower layer was hydrochloric acid water).
(9) And (3) drying: the gel sheet was transferred to a thermostatic bath at 150 ℃ and allowed to dry for 2 hours.
< application to composite layer 102>
The composite layer 102 is a composite of the nonwoven fabric 106 and the silica-aerogel 105, and is used as an object in which a part of the fibers of the nonwoven fabric 106 protrudes from the surface layer and the end portions. The method of forming the structure in which the fibers of the nonwoven fabric 106 protrude from the composite layer 102 may be any method, and is not limited.
Examples thereof include: the surface of the composite layer 102, which is produced by completing the steps (1) to (9) in the method for producing the composite layer 102, is roughened by a bonding roll, a brush, or the like, so that fibers are exposed, or the like.
Alternatively, in the process of manufacturing the gel sheet, the thickness of the silica-aerogel 105 and the thickness of the nonwoven fabric 106 are optimally set so that the fibers of the nonwoven fabric 106 are exposed, whereby the composite layer 102 having protruding fibers can be formed without cutting.
< application of coating Material >
The coating paint for coating the composite layer 102 is composed of at least a hydrophilic base paint and a thermosetting oleophilic resin 113.
The base paint is a hydrophilic paint, and a paint in which a particulate hydrophilic resin 112 is dispersed in a water solvent is the mainstream. The silica-aerogel 105 of the present embodiment has a specific structural form by being hydrophobized, and therefore, rather, has very good compatibility with the lipophilic resin, and the network structure thereof alone is destroyed by the compatibility with the lipophilic resin. Therefore, the coating material must be a hydrophilic coating material.
The hydrophilic coating needs to be well compatible with an aqueous solvent, and can be classified into a self-emulsification type having a hydrophilic functional group in the skeleton of the hydrophilic resin 112, and a forced emulsification type in which an emulsifier is used to forcibly disperse the resin. The type of the hydrophilic resin 112 used as a base may be acrylic resin, polyurethane resin, polyester resin, epoxy resin, silicone resin, fluororesin, or the like.
The characteristics of the hydrophilic resin 112 generally include the following: the acrylic resin is excellent in light resistance and weather resistance, various in monomer types, relatively inexpensive, colorless and transparent, and excellent in gloss.
Further, the polyurethane resin has a urethane bond, a urea bond, or the like in its interior, and is composed of a hard segment and a flexible soft segment which are strongly aggregated, and therefore has the following characteristics: excellent adhesion to a substrate, high coating film hardness, high elasticity, good abrasion resistance, good durability, good water resistance, good chemical resistance, and the like.
Further, as the polyester resin, a copolyester having suppressed crystallinity, or an alkyd resin having a fatty acid side chain in the polyester main chain via an ester bond can be used. Has an ester bond formed by the reaction of a carboxyl group and a hydroxyl group in the main chain skeleton, and has high adhesion to a substrate, high coating film strength and excellent heat resistance.
General problems of the coating material based on the hydrophilic resin 112 are, as compared with a general solvent-based coating material: (1) the coating film has a weak physical property because of a small molecular weight (network structure). (2) The water resistance is weak in the properties of the film based on the hydrophilic group. (3) The Tg is low and the adhesion is low because no crosslinking reaction proceeds.
Therefore, in the present embodiment, as a countermeasure against these problems, the following paint is used: the coating material is a unique coating material in which a thermosetting oleophilic resin 113 is added to a hydrophilic resin 112 and finely dispersed as islands of a "sea-island structure".
The thermosetting oleophilic resin 113 is well compatible with the fibers of the hydrophobic nonwoven fabric 106, and therefore: by performing the bonding and the thermosetting reaction, strong adhesion is exhibited. It has been found that: in order to disperse the lipophilic (hydrophobic) thermosetting oleophilic resin 113 in a small amount in the base paint of the hydrophilic resin 112, various surfactants, alcohols, and the like capable of improving the compatibility of both the hydrophilic resin 112 and the oleophilic resin 113 are effective. In particular, among various alcohols, 2-propanol (IPA) is an amphiphilic solvent which can control the particle size of the thermosetting oleophilic resin 113, and it has been found that when the particle size is small, the adhesion to the fibers of the nonwoven fabric 106 is improved.
The hydrophilic resin 112 used in the coating material in which the lipophilic resin 113 of the present embodiment is dispersed in the hydrophilic resin 112 as islands of a "sea-island structure" (hereinafter, this structure is also referred to as "sea-island structure") is preferably an aqueous acrylic resin, an aqueous urethane resin, or an aqueous polyester resin, and more preferably an aqueous polyester resin.
As the lipophilic resin 113, it was found that: suitable are reactive one-component epoxy resins. In general, when the oleophilic resin 113 is added to the aqueous coating material, a hydrophilic resin having good compatibility is generally used, but in the present embodiment, it is important that the oleophilic resin is not dissolved in the aqueous coating material in order to bond each fiber in a needle-like dot shape and reinforce the adhesion with the coating film 111 in order to improve the adhesion with the nonwoven fabric 106 protruding from the composite layer 102. Therefore, it is necessary to select a lipophilic one-component epoxy resin and finely disperse the same in an aqueous coating material in a sea-island structure.
< sea-island Structure >
The structure of the thermal insulation material 110 formed by applying the coating material is as follows: the fibers of the nonwoven fabric 106 are aggregated and bonded to the nonwoven fabric 106 in the silica-aerogel 105, and the fiber is integrated to form a structure protruding from the surface layer of the composite layer 102.
The following shape of the thermal insulator 110 was formed: the nonwoven fabric 106 is bonded to the coating film 111, and the oleophilic resin 113 is dispersed in the coating film 111 in a sea-island structure. The thickness of the coating film 111 is preferably 1 to 100 μm, and more preferably 10 to 30 μm. If the film thickness is less than 1 μm, the film strength is weak, and thus the film is easily broken. When the thickness of the film is larger than 100. mu.m, the heat insulating performance is deteriorated.
The particle size of the oleophilic resin 113 is preferably 0.1 to 50 μm, and the amount of the epoxy resin added in the coating film is preferably 5 to 50 wt%
When the particle diameter is less than 0.1. mu.m, hydrophilicity becomes strong, and thus the membrane strength is lowered. When the particle size is larger than 50 μm, the number of bonding points with the fibers of the nonwoven fabric 106 is reduced, and thus the adhesiveness is lowered.
If the amount of the epoxy resin added as the oleophilic resin 113 is less than 5 wt% in the coating film 111, the contact points with the fibers of the nonwoven fabric 106 become small, and thus the adhesiveness becomes low.
When the amount of the epoxy resin added is more than 50% by weight, the compatibility with the lipophilic silica-aerogel 105 becomes good, and therefore, the fine structure of the silica-aerogel 105 is destroyed, and as a result, the heat insulation property is deteriorated. Further, it is preferably 10 to 30% by weight.
[ examples ]
Examples of the hydrophilic resin 112 and the thermosetting lipophilic resin 113 used in the present embodiment are shown. The heat insulating material structure described in the present embodiment is not limited to these exemplified materials.
As the hydrophilic resin 112, a hydrophilic polyester resin "Plascoat Z-880" (manufactured by Kyowa Kagaku Co., Ltd.) was used. Further, "Novacure HX3941 HP" (asahi chemical co., ltd.) was used as the thermosetting lipophilic resin 113. In addition, 2-propanol (IPA) as an amphiphilic solvent was used as a compatibilizing agent.
(1) Composition example of coating material for forming sea island structure
(a) Hydrophilic resin 112: aqueous polyester resin: plascoat Z-880 (solid content 25 wt%): 100 portions of
(b) Oleophilic resin 113: one-component epoxy resin: novacure HX3941HP (imidazole ratio 1/3 wt%, epoxy ratio 2/3 wt%): 10 portions of
(c) Phase dissolving agent: 2-propanol (IPA): 10 portions of
(2) Preparation of coating materials
Each of (a) to (c) was weighed and mixed with a dispenser for 15 minutes under stirring to prepare a coating paint for forming a sea-island structure.
(3) Coating of coating paint:
the composite layer 102 having the shape in which the fibers of the nonwoven fabric 106 are exposed at the surface layer portion is printed, coated, and coated with a coating material using a printing mask and a squeegee. After the coating, heat curing is performed, thereby forming a coating film 111.
The coating film 111 is applied so as to cover the end of the composite layer 102 as well, thereby covering the entire composite layer 102. By repeatedly applying the coating material to both surfaces and end portions, the coating material can be applied to the entire surface.
When the coating area is small, the entire composite layer 102 may be immersed in the paint by an immersion method.
(4) Curing of the coating:
the composite layer 102 coated with the coating material on both surfaces was dried in a thermostatic bath at 120 ℃ for 15 minutes. This allows the particles of the epoxy resin particles as the oleophilic resin 113 to be reacted and cured while evaporating water, thereby completing the coating film 111.
(5) Shape of coating film 111:
the thickness of the coating film 111 was 30 μm, the particle size of the thermosetting lipophilic resin 113 was 5 μm, and the particle ratio of the thermosetting lipophilic resin 113 was about 20%.
< Structure and characteristics of the composite layer 102 after coating with the coating composition >
The nonwoven fabric 106 of the composite layer 102 has fibers protruding from the surface layer of the composite layer 102, and the fibers are oleophilic and compatible with the oleophilic resin 113 of the coating film 111 at the outermost layer, and exhibit excellent adhesion by undergoing a strong binding reaction.
Further, in the coating film 111, the reactive oleophilic resin 113 is dispersed like islands of a "sea-island structure" and chemically reacts with the fibers of the nonwoven fabric 106, thereby exhibiting strong adhesion.
The heat insulator 110 may cover the curved surface of the heat generating member to provide a heat insulating effect, and the base polyester resin may be flexible and exhibit high adhesion due to the above-described structure. Therefore, the composite layer 102 and the coating film 111 are not peeled off. The thermal insulator 110 can exhibit excellent thermal insulation performance. In addition, it is also possible to prevent the silica-aerogel 105 particles contained in the composite layer 102 from being exposed.
< adhesion force between composite layer 102 and coated resin film >
A coating film 111 having a width of 10mm and a thickness of 30 μm was formed on the composite layer 102, and the tensile strength was measured by a 90-degree peel method.
(a) The nonwoven fabric 106 is not present: 0.7N, (b) absence of nonwoven fabric 106: 5.5N, (c) case where the thermosetting resin does not enter in (b): 2.3N
< thermal conductivity of Heat insulator 110 >
The thermal insulation material 110 in which the composite layer 102 was coated with the coating film 111 to a thickness of 30 μm had a thermal conductivity of 0.07W/mK. It can be confirmed that: it also exhibits excellent thermal insulation properties comparable to the composite layer 102 alone.
Industrial applicability
The heat insulator of the present embodiment prevents the silica-aerogel particles from falling off, and can be applied to heat insulation applications such as mobile devices without degrading the heat insulation performance.
Description of the symbols
102 composite layer
105 silica-aerogel
106 nonwoven fabric
110 heat insulation material
111 coating film
112 hydrophilic resin
113 oleophilic resin

Claims (2)

1. A heat insulator comprising a composite layer and a coating film, wherein the composite layer is a nonwoven fabric and silica-aerogel is contained therein, the coating film is a coating layer comprising a hydrophilic resin and a lipophilic resin and covering the surface of the composite layer,
the hydrophilic resin is selected from acrylic resin, polyurethane resin, polyester resin, epoxy resin, silicone resin and fluororesin, the oleophilic resin is single-component epoxy resin,
the oleophilic resin is present in the coating film in an amount of 5 to 50 wt%,
the thickness of the coating film is 1-100 mu m,
the oleophilic resin is present in the hydrophilic resin in a plurality of islands, fibers of the nonwoven fabric exposed from the composite layer are in close contact with the oleophilic resin, and the plurality of islands have a diameter of 0.1 to 50 μm.
2. The thermal insulation of claim 1, wherein the hydrophilic resin is a hydrophilic polyester resin.
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