JP2015524491A - セグメント化ゲル複合材料およびこの複合材料から製造される剛性パネル - Google Patents
セグメント化ゲル複合材料およびこの複合材料から製造される剛性パネル Download PDFInfo
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- JP2015524491A JP2015524491A JP2015520722A JP2015520722A JP2015524491A JP 2015524491 A JP2015524491 A JP 2015524491A JP 2015520722 A JP2015520722 A JP 2015520722A JP 2015520722 A JP2015520722 A JP 2015520722A JP 2015524491 A JP2015524491 A JP 2015524491A
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- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
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Abstract
Description
例1:下記例は、本発明によるセグメント化ゲル/繊維複合材料およびエアロゲル系剛性パネルの調製および性能を示す。カッティング深さが元の厚さの90%以上となることを目標としたカスタムメイドのカッティング・ジグと、万能ナイフまたは自動回転工具とを組み合わせて使用して、対向シートが一体化された商業的に入手可能なグラスウール不織布シートを正確に長手方向にセグメント化した。この方法を用いて、36”×8”のセグメント化グラスウール・シートを、1”および2”のセグメントの両方を有するように製造した。所要量の可溶性シリカ源(すなわち加水分解テトラエトキシシランおよびその誘導体を含むゾル)と縮合触媒である水性水酸化アンモニウムとを組合せ、水平/フラットな形態を成すグラスウール不織布シートに浸透させておいた。15分間のシネレシス後、ゲル/繊維複合材料を直径6”のマンドレルに巻き付けた。このような複合材料の巻き取りは、セグメント・ギャップが巻き取り中にマンドレルとは反対に向くことを保証することによって行った。このようにすると、それぞれのセグメントに沿ってギャップが形成されるので、巻き応力が軽減された。次いで、円筒形状を成すゲル/繊維複合材料に所定の時間にわたってエ−ジングを施した。エ−ジングの際には、ロール型複合材料を水酸化アンモニウムの高温エタノール溶液、およびアルキル基とシリル基とを含有する疎水性物質(ヘキサメチルジシラザン)に曝露した。エ−ジング後、ロール型複合材料を円筒形圧力容器に移し、次いで超臨界CO2抽出を用いて乾燥させて溶媒を除去した。
例1:下記例は、本発明によるセグメント化ゲル/繊維複合材料およびエアロゲル系剛性パネルの調製および性能を示す。カッティング深さが元の厚さの90%以上となることを目標としたカスタムメイドのカッティング・ジグと、万能ナイフまたは自動回転工具とを組み合わせて使用して、対向シートが一体化された商業的に入手可能なグラスウール不織布シートを正確に長手方向にセグメント化した。この方法を用いて、36”×8”のセグメント化グラスウール・シートを、1”および2”のセグメントの両方を有するように製造した。所要量の可溶性シリカ源(すなわち加水分解テトラエトキシシランおよびその誘導体を含むゾル)と縮合触媒である水性水酸化アンモニウムとを組合せ、水平/フラットな形態を成すグラスウール不織布シートに浸透させておいた。15分間のシネレシス後、ゲル/繊維複合材料を直径6”のマンドレルに巻き付けた。このような複合材料の巻き取りは、セグメント・ギャップが巻き取り中にマンドレルとは反対に向くことを保証することによって行った。このようにすると、それぞれのセグメントに沿ってギャップが形成されるので、巻き応力が軽減された。次いで、円筒形状を成すゲル/繊維複合材料に所定の時間にわたってエ−ジングを施した。エ−ジングの際には、ロール型複合材料を水酸化アンモニウムの高温エタノール溶液、およびアルキル基とシリル基とを含有する疎水性物質(ヘキサメチルジシラザン)に曝露した。エ−ジング後、ロール型複合材料を円筒形圧力容器に移し、次いで超臨界CO2抽出を用いて乾燥させて溶媒を除去した。
Claims (28)
- 以下の工程を含む、繊維強化型ゲル複合材料を製造する方法:
セグメント化繊維強化シートまたはセグメント化オープンセル発泡シートを与え(providing)、
該シートとゲル前駆体とを組合せ、
該組合せにおける前記前駆体をゲル化して、複合材料シートを形成し、
該複合材料シートを巻き取り(rolling);そして
該複合材料シートを乾燥させて、繊維強化型ゲル複合材料シートを形成する。 - 更に、前記乾燥された複合材料シートを巻出し、該複合材料シートの少なくとも1つの面に接着剤を塗布し、そして該複合材料シートを他の平面状の(planar)材料に取り付ける(attaching)工程を含む、請求項1に記載の方法。
- 更に、以下の工程を含む、請求項1に記載のゲル複合材料を製造する方法:
少なくとも2つの主要な(major)面および複数のセグメント化断面を備える請求項1の乾燥された複合材料シートを与え、
前記複合材料の少なくとも1つの面に接着剤を塗布し;そして
前記複合材料を他の乾燥されたゲル複合材料に取り付ける。 - セグメント化繊維強化シート、セグメント化オープンセル発泡シートに、対向する(facing)層またはシートが取り付けられている、請求項1〜3のいずれか1項に記載の方法。
- 対向層が繊維を含む、請求項4に記載の方法。
- 前記繊維バッティング(batting)が不連続な繊維を含む、請求項1〜5のいずれか1項に記載の方法。
- 更に、二酸化チタン、酸化鉄、カーボンブラック、グラファイト、水酸化アルミニウム、リン酸塩、ホウ酸塩、金属ケイ酸塩、メタロセン、モリブデン酸塩、スズ酸塩、水酸化物、炭酸塩、酸化亜鉛、酸化アルミニウム、酸化アンチモン、マグネシウム亜鉛ブレンド、マグネシウム亜鉛アンチモンブレンド、炭化ケイ素、ケイ化モリブデン、酸化マンガン、鉄チタン酸化物、ケイ酸ジルコニウム、酸化ジルコニウム、酸化鉄(I)、酸化鉄(III)、二酸化マンガン、鉄チタン酸化物(イルメナイト)、酸化クロム、およびこれらの組み合わせからなる群から選択された添加剤を組み込む(incorporating)工程を含む、請求項1〜6のいずれか1項に記載の方法。
- 前記繊維に少なくとも1種のバインダーを加えるか、または少なくとも1種のバインダーを含む繊維を使用する工程を含む、請求項1〜7のいずれか1項に記載の方法。
- 前記セグメント化繊維強化シートまたは前記セグメント化オープンセル発泡シートの少なくとも1つのセグメントが剛性である、請求項1または2に記載の方法、或いは、該セグメント化ゲル複合材料の少なくとも1つのセグメントが剛性である、請求項3に記載の方法。
- 前記ゲル前駆体または繊維強化型ゲル複合材料が、ジルコニア、イットリア、ハフニア、アルミナ、チタニア、セリア、シリカ、ポリアクリレート、ポリスチレン、ポリアクリロニトリル、ポリウレタン、ポリイミド、ポリフルフラールアルコール、フェノールフルフリルアルコール、メラミンホルムアルデヒド、レゾルシノールホルムアルデヒド、クレゾールホルムアルデヒド、フェノールホルムアルデヒド、ポリビニルアルコールジアルデヒド、ポリシアヌレート、ポリアクリルアミド、種々のエポキシ、寒天、およびアガロース、およびこれらの組み合わせからなる群から選択された材料を含む、請求項1〜9のいずれか1項に記載の方法。
- 前記繊維強化シートまたは前記セグメント化繊維強化型ゲル複合材料中の繊維が、鉱物ウール、グラスウール、繊維ガラス、ポリエステル、ポリオレフィンテレフタレート、ポリ(エチレン)ナフタレート、ポリカーボネート、およびレーヨン、ナイロン、綿系ライクラ(DuPont製)、炭素系繊維、例えばグラファイト、炭素繊維のための前駆体、例えばポリアクリロニトリル(PAN)、酸化PAN、非炭化(uncarbonized)熱処理PAN(例えばSGL carbon製のもの)、繊維ガラス系材料、例えばSガラス、901ガラス、902ガラス、475ガラス、Eガラス、シリカ系繊維、例えば石英、quartzel(Saint-Gobain製)、Qフェルト(Johns Manville製)、Saffil(Saffil製)、Durablanket(Unifrax製)、および他のシリカ繊維、ポリアラミド繊維、例えばKevalr, Nomex, Sontera (全てDuPont製)、Conex (Taijin製)、ポリオレフィン、例えばTyvek(DuPont製)、Dyneema(DSM製)、Spectra(Honeywell製)、他のポリプロピレン繊維、例えばTypar、Xavan(両方ともDuPont製)、フルオロポリマー、例えばPTFE{商品名Teflon(DuPont製), Goretex(GORE製)}、炭化ケイ素繊維、例えばNicalon(COI Ceramics製)、セラミック繊維、例えばNextel(3M製)、アクリルポリマー、綿、絹、麻、皮革、スエードの繊維、PBO-Zylon繊維(Tyobo製)、液晶材料、例えばVectan(Hoechst製)、Cambrelle繊維(DuPont製)、ポリウレタン、ポリアミド、木質繊維、ホウ素、アルミニウム、鉄、ステンレス鋼繊維、および他の熱可塑性材料、例えばPEEK、PES、PEI、PEK、PPSおよびこれらの組み合わせからなる群から選択された材料を含む、請求項1〜10のいずれか1項に記載の方法。
- 前記接着剤が、カリウム水ガラス、ナトリウム水ガラス、セメント、およびアルカリ活性化アルミノケイ酸塩、ポリエチレン、カプトン、ポリウレタン、ポリエステル、天然ゴム、合成ゴム、ハイパロン、プラスチックアロイ、PTFE、ポリビニルハロゲン化物、ポリエステル、ネオプレン、アクリル、ニトリル、EPDM、EP、バイトン(viton)、ビニル、ビニルアセテート、エチレンビニルアセテート、スチレン、スチレンアクリレート、スチレンブタジエン、ポリビニルアルコール、ポリビニルクロリド、アクリルアミド、フェノール、およびこれらの組み合わせからなる群から選択される、請求項2〜11のいずれか1項に記載の方法。
- 前記強化型ゲル複合材料の熱伝導率は周囲条件で25mW/mK未満、または好ましくは16mW/mK未満である、請求項1〜12のいずれか1項に記載の方法。
- 前記複合材料の巻き取りが、前記セグメントの間に形成されたギャップが前記ロールの軸とは反対に向くように行われる、請求項1〜13のいずれか1項に記載の方法。
- セグメント化繊維強化型またはセグメント化オープンセル発泡体強化型ゲル複合材料であって、該ゲルが少なくとも1つのセグメント内で繊維全体にわたって連続しており、そして、少なくとも2つの隣接セグメント間に、該繊維または該オープンセル発泡体および該ゲルの両方に不連続性が形成された状態で、少なくとも1つのギャップが存在している、セグメント化繊維強化型またはセグメント化オープンセル発泡体強化型ゲル複合材料。
- 少なくとも2つの繊維強化型またはオープンセル発泡体強化型ゲル複合材料を含む剛性パネルであって、少なくとも1つの層が、請求項15に記載のセグメント化繊維強化型またはセグメント化オープンセル発泡体強化型ゲル複合材料を含む、剛性パネル。
- 更に、二酸化チタン、酸化鉄、カーボンブラック、グラファイト、水酸化アルミニウム、リン酸塩、ホウ酸塩、金属ケイ酸塩、メタロセン、モリブデン酸塩、スズ酸塩、水酸化物、炭酸塩、酸化亜鉛、酸化アルミニウム、酸化アンチモン、マグネシウム亜鉛ブレンド、マグネシウム亜鉛アンチモンブレンド、炭化ケイ素、ケイ化モリブデン、酸化マンガン、鉄チタン酸化物、ケイ酸ジルコニウム、酸化ジルコニウム、酸化鉄(I)、酸化鉄(III)、二酸化マンガン、鉄チタン酸化物(イルメナイト)、酸化クロム、およびこれらの組み合わせからなる群から選択された充填剤を含む、請求項15に記載のゲル複合材料または請求項16に記載の剛性パネル。
- 更に、前記繊維中に少なくとも1種のバインダーを含む、請求項15〜17のいずれか1項に記載のパネルまたは複合材料。
- セグメント化繊維強化シートまたはセグメント化オープンセル発泡シートに、対向する層またはシートが取り付けられている、請求項15〜18のいずれか1項に記載のパネルまたは複合材料。
- 対向する層が繊維を含む、請求項19に記載の複合材料。
- 前記繊維強化材が不連続な繊維を含む、請求項15〜20のいずれか1項に記載の複合材料。
- 更に、二酸化チタン、酸化鉄、カーボンブラック、グラファイト、水酸化アルミニウム、リン酸塩、ホウ酸塩、金属ケイ酸塩、メタロセン、モリブデン酸塩、スズ酸塩、水酸化物、炭酸塩、酸化亜鉛、酸化アルミニウム、酸化アンチモン、マグネシウム亜鉛ブレンド、マグネシウム亜鉛アンチモンブレンド、炭化ケイ素、ケイ化モリブデン、酸化マンガン、鉄チタン酸化物、ケイ酸ジルコニウム、酸化ジルコニウム、酸化鉄(I)、酸化鉄(III)、二酸化マンガン、鉄チタン酸化物(イルメナイト)、酸化クロム、およびこれらの組み合わせからなる群から選択された添加剤を含む、請求項15〜21のいずれか1項に記載のパネルまたは複合材料。
- 更に、前記繊維中に少なくとも1種のバインダーを含むか、または少なくとも1種のバインダーを含む繊維を使用する、請求項15〜22のいずれか1項に記載のパネルまたは複合材料。
- 前記セグメント化繊維バッティング・シートまたはセグメント化オープンセル発泡シートの少なくとも1つのセグメントが剛性である、請求項15〜23のいずれか1項に記載のパネルまたは複合材料。
- 前記ゲル前駆体、または繊維強化型ゲル複合材料またはオープンセル発泡体強化型ゲル複合材料が、ジルコニア、イットリア、ハフニア、アルミナ、チタニア、セリア、シリカ、ポリアクリレート、ポリスチレン、ポリアクリロニトリル、ポリウレタン、ポリイミド、ポリフルフラールアルコール、フェノールフルフリルアルコール、メラミンホルムアルデヒド、レゾルシノールホルムアルデヒド、クレゾールホルムアルデヒド、フェノールホルムアルデヒド、ポリビニルアルコールジアルデヒド、ポリシアヌレート、ポリアクリルアミド、種々のエポキシ、寒天、およびアガロース、およびこれらの組み合わせからなる群から選択された材料を含む、請求項15〜24のいずれか1項に記載のパネルまたは複合材料。
- 鉱物ウール、グラスウール、繊維ガラス、ポリエステル、ポリオレフィンテレフタレート、ポリ(エチレン)ナフタレート、ポリカーボネート、およびレーヨン、ナイロン、綿系ライクラ(DuPont製)、炭素系繊維、例えばグラファイト、炭素繊維のための前駆体、例えばポリアクリロニトリル(PAN)、酸化PAN、非炭化(uncarbonized)熱処理PAN(例えばSGL carbon製のもの)、繊維ガラス系材料、例えばSガラス、901ガラス、902ガラス、475ガラス、Eガラス、シリカ系繊維、例えば石英、quartzel(Saint-Gobain製)、Qフェルト(Johns Manville製)、Saffil(Saffil製)、Durablanket(Unifrax製)、および他のシリカ繊維、ポリアラミド繊維、例えばKevalr, Nomex, Sontera (全てDuPont製)、Conex (Taijin製)、ポリオレフィン、例えばTyvek(DuPont製)、Dyneema(DSM製)、Spectra(Honeywell製)、他のポリプロピレン繊維、例えばTypar、Xavan(両方ともDuPont製)、フルオロポリマー、例えばPTFE{商品名Teflon(DuPont製), Goretex(GORE製)}、炭化ケイ素繊維、例えばNicalon(COI Ceramics製)、セラミック繊維、例えばNextel(3M製)、アクリルポリマー、綿、絹、麻、皮革、スエードの繊維、PBO-Zylon繊維(Tyobo製)、液晶材料、例えばVectan(Hoechst製)、Cambrelle繊維(DuPont製)、ポリウレタン、ポリアミド、木質繊維、ホウ素、アルミニウム、鉄、ステンレス鋼繊維、および他の熱可塑性材料、例えばPEEK、PES、PEI、PEK、PPSおよびこれらの組み合わせからなる群から選択された繊維材料を含む、請求項15〜25のいずれか1項に記載のパネルまたは複合材料。
- 更に、カリウム水ガラス、ナトリウム水ガラス、セメント、およびアルカリ活性化アルミノケイ酸塩、ポリエチレン、カプトン、ポリウレタン、ポリエステル、天然ゴム、合成ゴム、ハイパロン、プラスチックアロイ、PTFE、ポリビニルハロゲン化物、ポリエステル、ネオプレン、アクリル、ニトリル、EPDM、EP、バイトン(viton)、ビニル、ビニルアセテート、エチレンビニルアセテート、スチレン、スチレンアクリレート、スチレンブタジエン、ポリビニルアルコール、ポリビニルクロリド、アクリルアミド、フェノール、およびこれらの組み合わせからなる群から選択される接着剤を含む、請求項16に記載のパネル。
- 前記乾燥した強化型ゲル複合材料の熱伝導率は周囲条件で25mW/mK未満、または好ましくは16mW/mK未満である、請求項15〜27のいずれか1項に記載のパネルまたは複合材料。
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