JP5081464B2 - 断熱材及びその製造方法 - Google Patents
断熱材及びその製造方法 Download PDFInfo
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Description
(1)BET比表面積が15〜500m 2 /gで且つ一次粒子径が0.003〜1μmであるシリカ微粒子、アルミナ微粒子、ケイ酸アルミニウム微粒子もしくはこれらの混合物を含む断熱性成形体の表面の少なくとも一部に、シート状の多孔質材料が、平均粒子径0.1〜5μmの無機粒子と、金属酸化物のゾルとを含むバインダーにより接着されていることを特徴とする断熱材。
(2)断熱性成形体が、繊維状物質及び乳白材の少なくとも一方を含有することを特徴とする上記(1)記載の断熱材
(3)多孔質材料が、無機質の繊維状物質を含有する抄造体、織布あるいは不織布であることを特徴とする上記(1)または(2)記載の断熱材。
(4)BET比表面積が15〜500m 2 /gで且つ一次粒子径が0.003〜1μmであるシリカ微粒子、アルミナ微粒子、ケイ酸アルミニウム微粒子もしくはこれらの混合物を含む断熱性成形体と、シート状の多孔質材料とを、平均粒子径0.1〜5μmの無機粒子と、金属酸化物のゾルと、溶媒とを含有するスラリー状の接着剤により接着することを特徴とする断熱材の製造方法。
(5)断熱性成形体と多孔質材料とを重ね合わせ、前記多孔質材料の上から接着剤を塗布して浸透させた後、乾燥することを特徴とする上記(4)記載の断熱材の製造方法。
(6)接着剤が、有機増粘剤を含有することを特徴とする上記(4)または(5)記載の断熱材の製造方法。
金属アルコキシド化合物は一般式「M−(OR)n(M:金属原子、R:アルキル基)」であらわされるが、水と反応して加水分解物「M−(OH)n」となり、更にこの金属アルコキシド化合物の加水分解物同士、あるいは、金属アルコキシド化合物の加水分解物と断熱性成形体、多孔質材料及び無機粒子の表面に存在するOH基とが脱水縮合して「M−O−M」となり、結合効果を発現する。従って、金属アルコキシド化合物を用いる場合は、接着剤中に加水分解に十分な量の水を含む必要がある。また、場合によっては、加水分解を促進するための塩酸や硫酸等の酸を添加する必要がある。
但し、金属アルコキシド化合物を使用する時は、断熱性成形体に過度に浸透しないように注意しなければならない。なぜならば、金属アルコキシド化合物が過度に浸透した断熱性成形体は、加熱によって大きく変形してしまうからである。この現象は、金属アルコキシド化合物の加水分解物が断熱性成形体の内部で、溶媒を包含したゲル状の硬化物を形成することが原因である。この硬化物に包含される溶媒は加熱によって蒸発するが、それに伴って硬化物自身が急激に収縮するため、結果的に断熱性成形体の変形を引き起こしてしまう。従って、金属アルコキシド化合物を使用する場合は、接着剤に、断熱性成形体への溶媒の浸透を抑制する材料を併せて含有させるか、あるいは、接着剤に含有させる金属アルコキシド化合物の量を断熱性成形体の加熱変形が生じない程度にする等の考慮が必要である。
金属アルコキシド化合物としては、ケイ素のアルコキシド(例えば、テトラエトキシシラン)が好ましい。ケイ素のアルコキシド以外にも数多くのアルコキシド化合物があるが、それらは極めて高価であり、また、種類によっては急速に脱水縮合してしまったり、常温で固体であったりするため、現実的に使用できない。
また、本発明においては、金属アルコキシド化合物の分子を予め数個程度縮合させたものや、金属原子に直接結合されたアルキル基を持つ金属アルコキシド化合物(例えばジメチルジエトキシシラン)も使用できる。前者の場合には金属アルコキシド化合物の加水分解に要する時間が短縮され、後者の場合には得られた断熱材が撥水性を示す等の利点がある。
一次粒子径が0.012μmで、BET比表面積が200m2/gであるシリカ微粒子75重量部、平均径10μmで平均繊維長6mmのシリカ繊維5重量部、および炭化ケイ素20重量部を均一になるまで混合し、この混合物を加圧成形して500mm×500mm×25mm、密度240kg/m3で、熱伝導率0.025W/m・K(100℃)の断熱性成形体を得た。
ケイ酸アルミニウムを主原料として含有する抄造体の代わりに、厚さ0.2mm、目付200g/m2のガラスクロスを用いたこと以外は実施例1と同様な処方で断熱材を作製した。
接着剤の調製において、テトラエトキシシランを添加せず、その代わりにエタノールを8重量部添加したこと以外は、実施例1と同様な処方で断熱材を作製した。
接着剤の調製において、シリカ粒子の平均粒子径を30μmにしたこと以外は、実施例1と同様な処方で断熱材を作製した。
実施例1と同様にして作製された断熱性成形体から、100mm×30mmの試験体を切り出し、支点間距離80mmで3点曲げ試験を行ったところ23Nの荷重で破断した。
接着剤の調製において、シリカ粒子を添加しないこと以外は、実施例1と同様な処方で断熱材を作製した。
接着剤の調製において、シリカ粒子及びシリカゾルを添加せず、その代わりにエタノールを8重量部添加したこと以外は、実施例1と同様な処方で断熱材を作製した。
接着剤の調製において、シリカ粒子及びテトラエトキシシランを添加せず、その代わりにエタノールを8重量部添加したこと以外は、実施例1と同様な処方で断熱材を作製した。
接着剤の調製において、エタノールを5重量部、水を77重量部とした以外は、実施例1と同様な処方で断熱材を作製した。
2 多孔質材料
3 接着剤
4 刷毛
5 ローラ
6 空気
7 断熱性成形体への接着剤の浸透部分
Claims (6)
- BET比表面積が15〜500m 2 /gで且つ一次粒子径が0.003〜1μmであるシリカ微粒子、アルミナ微粒子、ケイ酸アルミニウム微粒子もしくはこれらの混合物を含む断熱性成形体の表面の少なくとも一部に、シート状の多孔質材料が、平均粒子径0.1〜5μmの無機粒子と、金属酸化物のゾルとを含むバインダーにより接着されていることを特徴とする断熱材。
- 断熱性成形体が、繊維状物質及び乳白材の少なくとも一方を含有することを特徴とする請求項1記載の断熱材
- 多孔質材料が、無機質の繊維状物質を含有する抄造体、織布あるいは不織布であることを特徴とする請求項1または2記載の断熱材。
- BET比表面積が15〜500m 2 /gで且つ一次粒子径が0.003〜1μmであるシリカ微粒子、アルミナ微粒子、ケイ酸アルミニウム微粒子もしくはこれらの混合物を含む断熱性成形体と、シート状の多孔質材料とを、平均粒子径0.1〜5μmの無機粒子と、金属酸化物のゾルと、溶媒とを含有するスラリー状の接着剤により接着することを特徴とする断熱材の製造方法。
- 断熱性成形体と多孔質材料とを重ね合わせ、前記多孔質材料の上から接着剤を塗布して浸透させた後、乾燥することを特徴とする請求項4記載の断熱材の製造方法。
- 接着剤が、有機増粘剤を含有することを特徴とする請求項4または5記載の断熱材の製造方法。
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JP2007033484A JP5081464B2 (ja) | 2007-02-14 | 2007-02-14 | 断熱材及びその製造方法 |
CNA2008100061442A CN101245887A (zh) | 2007-02-14 | 2008-02-13 | 隔热材料及其制造方法 |
KR1020080013083A KR101330659B1 (ko) | 2007-02-14 | 2008-02-13 | 단열재 및 그 제조방법 |
US12/068,958 US20080193788A1 (en) | 2007-02-14 | 2008-02-13 | Heat insulating material and method for producing the same |
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CA2747775C (en) * | 2009-01-05 | 2016-08-16 | Unifrax I Llc | High strength biosoluble inorganic fiber insulation mat |
KR101134664B1 (ko) * | 2009-07-13 | 2012-04-09 | 나병오 | 고성능 단열재 및 이의 제조 방법 |
JP5351112B2 (ja) * | 2009-09-02 | 2013-11-27 | ニチアス株式会社 | 断熱材 |
JP5246442B2 (ja) * | 2010-02-08 | 2013-07-24 | ニチアス株式会社 | 断熱材及びその製造方法 |
JP5618561B2 (ja) * | 2010-02-12 | 2014-11-05 | イソライト工業株式会社 | 高性能断熱材及びその製造方法 |
GB201006625D0 (en) | 2010-04-21 | 2010-06-02 | Rolls Royce Plc | A method of manufacturing a ceramic matrix composite article |
CN101974314B (zh) * | 2010-09-29 | 2013-03-27 | 北京航空航天大学 | 隔热材料用二氧化硅基多孔块材及其包覆-干压成型的制备方法 |
JP5557686B2 (ja) * | 2010-10-14 | 2014-07-23 | ニチアス株式会社 | 断熱材および断熱材の製造方法 |
PL3262287T3 (pl) | 2015-02-24 | 2020-07-27 | Unifrax I Llc | Mata izolacyjna odporna na wysokie temperatury |
JP6572604B2 (ja) * | 2015-03-19 | 2019-09-11 | Toto株式会社 | 固体酸化物形燃料電池モジュール |
KR101947085B1 (ko) * | 2017-04-13 | 2019-04-29 | 한국과학기술연구원 | 탄소복합소재와 이종소재의 접착 및 분리 제어기술 |
CN108422722A (zh) * | 2018-02-02 | 2018-08-21 | 深圳前海优容科技有限公司 | 一种涂布机烘箱、二氧化硅复合绝热材料及其制备方法 |
JP7223600B2 (ja) * | 2019-02-28 | 2023-02-16 | 住友理工株式会社 | 断熱部材およびその製造方法 |
CN113939942A (zh) * | 2019-07-03 | 2022-01-14 | 东丽纤维研究所(中国)有限公司 | 一种隔热防火材料及其用途 |
CN115894057A (zh) * | 2022-07-19 | 2023-04-04 | 北京理工大学 | 一种耐高温可弯折变形陶瓷隔热材料及其制备方法 |
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US3738558A (en) * | 1970-09-02 | 1973-06-12 | Felt Products Mfg Co | Thin laminated gasket |
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JPH04310729A (ja) * | 1991-04-08 | 1992-11-02 | Nichias Corp | シート状発泡成形物の製造法 |
JPH05194008A (ja) * | 1991-06-19 | 1993-08-03 | Nichias Corp | 断熱材の製造法 |
JP2883275B2 (ja) * | 1994-06-07 | 1999-04-19 | 株式会社日板研究所 | コーティング用組成物 |
JP3981988B2 (ja) * | 1996-04-19 | 2007-09-26 | 東ソー株式会社 | 研磨焼成体及びその製造法 |
JP2000129127A (ja) * | 1998-10-23 | 2000-05-09 | Nichias Corp | 多孔質シリカ・シリコーン複合材及びその製造方法 |
JP4079849B2 (ja) * | 2002-07-24 | 2008-04-23 | 旭ファイバーグラス株式会社 | 建築用断熱複合板 |
JP2005036975A (ja) * | 2003-06-27 | 2005-02-10 | Matsushita Electric Ind Co Ltd | 断熱材と、その製造方法、及びその断熱材を使用した機器 |
KR20050117613A (ko) * | 2003-09-08 | 2005-12-15 | 삼손퍼라이트 주식회사 | 단열성이 우수한 다공질의 세라믹 성형체 제조방법 |
DE10347080A1 (de) * | 2003-10-10 | 2005-05-12 | Frenzelit Werke Gmbh & Co Kg | Flachdichtungswerkstoff in Form einer faserverstärkten Folie |
DE10355668A1 (de) * | 2003-11-28 | 2005-06-23 | Institut für Neue Materialien Gemeinnützige GmbH | Isolationsmaterial |
CA2465301C (en) * | 2004-04-28 | 2012-02-07 | John Scott Parent | Process to produce silica-filled elastomeric compounds |
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KR20080076777A (ko) | 2008-08-20 |
US20080193788A1 (en) | 2008-08-14 |
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