JP6693221B2 - Method for producing airgel composite - Google Patents

Description

  The present disclosure relates to a method for manufacturing an airgel composite, an airgel composite, a support member with an airgel composite, and a heat insulating material.

  Silica airgel is known as a material having a small thermal conductivity and a heat insulating property. Silica aerogel is useful as a functional material having excellent functionality (heat insulation, etc.), unique optical properties, and unique electrical properties. For example, an electronic substrate utilizing the ultra low dielectric constant properties of silica aerogel. It is used as a material, a heat insulating material that uses the high heat insulating property of silica airgel, and a light reflecting material that uses the ultra low refractive index of silica airgel.

  As a method for producing such a silica airgel, a supercritical drying method is known in which a gel compound (alcogel) obtained by hydrolyzing and polymerizing an alkoxysilane is dried under supercritical conditions of a dispersion medium. (For example, see Patent Document 1). In the supercritical drying method, the alcogel and the dispersion medium (solvent used for drying) are introduced into a high-pressure container, and the dispersion medium is heated to a temperature and pressure above its critical point to form a supercritical fluid. It is a method of removing the solvent. However, since the supercritical drying method requires a high-pressure process, it is necessary to invest in a special device that can withstand supercriticality, and also requires a lot of labor and time.

  Therefore, a method has been proposed in which the alcogel is dried using a general-purpose method that does not require a high-pressure process. As such a method, for example, a method of improving the strength of the obtained alcogel by using monoalkyltrialkoxysilane and tetraalkoxysilane in combination at a specific ratio as a gel raw material and drying at normal pressure is known. (For example, see Patent Document 2). However, when such atmospheric drying is adopted, the gel tends to contract due to the stress caused by the capillary force inside the alcogel.

U.S. Pat. No. 4,402,927 JP, 2011-93744, A

  As described above, while the problems of the conventional manufacturing process have been studied from various points of view, even if any of the above processes is adopted, the obtained airgel is poor in handleability and large in size. Since it is difficult, there is a problem in productivity. For example, the agglomerated airgel obtained by the above process may be broken just by touching and lifting it by hand. It is speculated that this is due to the low density of the airgel and the fact that the airgel has a pore structure in which fine particles of about 10 nm are weakly connected.

  As a method for improving such problems of conventional airgel, a method of imparting flexibility to the gel by increasing the pore size of the gel to a micrometer scale is considered. However, the airgel thus obtained has a problem that the thermal conductivity is significantly increased, and the excellent heat insulating property of the airgel is lost.

  The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a method for producing an airgel composite having excellent heat insulating properties and flexibility. Another object of the present disclosure is to provide an airgel composite having excellent heat insulation and flexibility, an airgel composite-equipped support member carrying the airgel composite, and a heat insulating material.

  The present inventor has conducted extensive studies in order to achieve the above object, and by using a silica particle dispersion liquid having a pH in a predetermined range, produces an airgel composite having excellent heat insulating properties and flexibility. I found that I could do it.

  That is, the present disclosure discloses a group consisting of a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in the molecule, and a hydrolysis product of the silicon compound. Provided is a method for producing an airgel composite, which comprises a step of drying a wet gel produced from a sol containing at least one selected from the above. According to the production method of the present disclosure, unlike the airgel obtained by the conventional technique, it is possible to produce an airgel composite having excellent heat insulating properties and flexibility.

  The sol may further contain at least one selected from the group consisting of a polysiloxane compound having a reactive group in the molecule and a hydrolysis product of the polysiloxane compound. Thereby, more excellent heat insulating property and flexibility can be achieved.

  The average primary particle diameter of the silica particles may be 1 to 500 nm. This makes it easier to improve heat insulation and flexibility.

  The silica particles may have a spherical shape. Further, the silica particles may be colloidal silica particles. Thereby, more excellent heat insulating property and flexibility can be achieved.

  The drying may be performed at a temperature below the critical point of the solvent used for drying and under atmospheric pressure. This makes it easier to obtain an airgel composite having excellent heat insulation and flexibility.

  The present disclosure also relates to a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in a molecule, and a hydrolysis product of the silicon compound. An airgel composite which is a dried product of a wet gel derived from a sol containing at least one selected from the above. Such an airgel composite has excellent heat insulation and flexibility.

  The present disclosure further provides a support member with an airgel composite, which comprises the above airgel composite and a support member carrying the airgel composite. According to the present disclosure, since the airgel composite has excellent heat insulating properties and flexibility, it is possible to exhibit excellent heat insulating properties and excellent flexibility that is difficult to achieve with conventional airgel.

  The present disclosure further provides a heat insulating material comprising the airgel composite. The heat insulating material according to the present disclosure exhibits excellent heat insulating properties and excellent flexibility that are difficult to achieve with conventional heat insulating materials, because the airgel composite has excellent heat insulating properties and flexibility. You can

  According to the present disclosure, it is possible to provide a method for producing an airgel composite having excellent heat insulation and flexibility. According to the present disclosure, it is also possible to provide an airgel composite having excellent heat insulation and flexibility, an airgel composite-equipped support member carrying the airgel composite, and a heat insulating material. That is, according to the present disclosure, it is possible to provide an airgel composite that exhibits excellent heat insulation properties, has improved handleability and can be made larger, and can improve productivity. As described above, the airgel composite having excellent heat insulation and flexibility has a possibility of being utilized in various applications. Here, an important point of the present disclosure is that it is easier to control heat insulation and flexibility than the conventional airgel. This cannot be achieved by the conventional airgel that needs to sacrifice the heat insulating property to obtain the flexibility or to sacrifice the flexibility to obtain the heat insulating property. The above "excellent in heat insulation and flexibility" does not necessarily mean that the numerical values representing both properties are high, and for example, "excellent in flexibility while maintaining good heat insulation". , "Excellent heat insulation while maintaining good flexibility" and the like.

It is a figure which represents typically the microstructure of the airgel composite which concerns on one Embodiment of this indication. It is a figure which shows the calculation method of the biaxial average primary particle diameter of a particle. It is a figure which shows typically the relationship between pH and reaction rate in the polycondensation reaction of 3-glycidoxy propyl trimethoxysilane. The surface of the airgel composite in the foil-like support member with the airgel composite obtained in Example 4 was (a) 10,000 times, (b) 50,000 times, (c) 200,000 times, and (d) 350,000 times. It is a SEM image observed at each magnification. SEM images of the surface of the airgel composite in the airgel composite-attached foil-shaped support member obtained in Example 6 observed at (a) 10,000 times, (b) 50,000 times, and (c) 200,000 times, respectively. Is.

  Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the drawings in some cases. However, the present disclosure is not limited to the following embodiments. In the present specification, the numerical range indicated by using "to" indicates a range including the numerical values before and after "to" as the minimum value and the maximum value, respectively. “A or B” may include either one of A and B, or may include both. The materials exemplified in the present embodiment can be used alone or in combination of two or more unless otherwise specified.

<Airgel composite>
The airgel composite of the present embodiment is a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in the molecule, and a hydrolysis product of the silicon compound. And a wet gel produced from a sol containing at least one selected from the group consisting of: That is, the airgel composite of the present embodiment includes a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in the molecule, and hydrolysis of the silicon compound. It may be a dry product of a wet gel derived from a sol containing at least one selected from the group consisting of products.

  In a narrow sense, a dry gel obtained by using a supercritical drying method for a wet gel is an aerogel, a dry gel obtained by drying under atmospheric pressure is a xerogel, and a dry gel obtained by freeze-drying is a cryogel. However, in the present embodiment, the obtained low-density dry gel is referred to as an aerogel, regardless of the drying method of the wet gel. That is, in the present embodiment, the aerogel means “a gel composed of a microporous solid in whithe the dispersed phase is a gas” that is an aerogel in a broad sense. To do. Generally, the inside of an airgel has a mesh-like fine structure, and has a cluster structure in which airgel particles of about 2 to 20 nm are bonded. There are pores of less than 100 nm between the skeletons formed by these clusters, and they have a three-dimensionally fine porous structure. The airgel in the present embodiment is, for example, a silica airgel containing silica as a main component. Examples of silica aerogel include so-called organic-inorganic hybridized silica aerogel in which an organic group such as a methyl group or an organic chain is introduced. Incidentally, the airgel composite of the present embodiment, for example, while silica particles are complexed in the airgel, has a cluster structure that is a feature of the airgel, three-dimensional fine porous structure. It may have an aspect.

  The airgel composite of this embodiment contains an airgel component and silica particles. It should be noted that although not necessarily meaning the same concept as this, it can be expressed that the airgel composite of the present embodiment contains silica particles as a component constituting the three-dimensional network skeleton. .. The airgel composite of this embodiment is excellent in heat insulation and flexibility as described later. In particular, since the flexibility is excellent, the handling property as the airgel composite is improved and the size can be increased, so that the productivity can be improved. It should be noted that such an airgel composite is obtained by allowing silica particles to exist in the airgel production environment. And the merit of the presence of the silica particles is not only to improve the heat insulating property and flexibility of the composite itself, but also to shorten the time of the wet gel formation step described later, or to simplify the washing and solvent replacement steps to the drying step. There is also a possibility. It should be noted that shortening of the time of this step and simplification of the step are not always required for producing an airgel composite having excellent flexibility.

  In the present embodiment, there are various composite modes of the airgel component and the silica particles. For example, the airgel component may be in the form of a film or the like, or may be in the form of particles (airgel particles). In any of the embodiments, since the airgel component has various forms and exists between the silica particles, it is presumed that flexibility is imparted to the skeleton of the composite.

  First, examples of a composite mode of the airgel component and the silica particles include a mode in which an amorphous airgel component is interposed between the silica particles. As such an aspect, specifically, for example, a mode in which silica particles are coated with a film-shaped airgel component (silicone) (a mode in which the airgel component includes the silica particles), and the airgel component serves as a binder , A mode in which the airgel component fills a plurality of silica particle gaps, a mode in which these modes are combined (a mode in which silica particles arranged in a cluster form are covered with the airgel component), and the like. Aspects can be mentioned. As described above, in the present embodiment, the airgel composite can have a three-dimensional network skeleton composed of silica particles and an airgel component (silicone), and the specific mode (form) thereof is not particularly limited.

  On the other hand, as will be described later, in the present embodiment, the airgel component may be in the form of distinct particles as shown in FIG.

  The mechanism by which such various aspects occur in the airgel composite of the present embodiment is not always clear, but the present inventor speculates that the generation rate of the airgel component in the gelation step is involved. For example, the production rate of the airgel component tends to vary by varying the number of silanol groups in the silica particles. Moreover, the production rate of the airgel component tends to vary also by varying the pH of the system.

  This suggests that the mode (size, shape, etc. of the three-dimensional network skeleton) of the airgel composite can be controlled by adjusting the size, shape, number of silanol groups, pH of the system, etc. of the silica particles. Therefore, it is considered that the density, porosity, etc. of the airgel composite can be controlled, and the heat insulation and flexibility of the airgel composite can be controlled. The three-dimensional network skeleton of the airgel composite may be composed of only one kind of the various modes described above, or may be composed of two or more kinds of modes.

  Hereinafter, the airgel composite of the present embodiment will be described with reference to FIG. 1 as an example, but the present disclosure is not limited to the aspect of FIG. 1 as described above. However, for matters common to any of the above aspects (type, size, content, etc. of silica particles), the following description can be appropriately referred to.

  FIG. 1 is a diagram schematically illustrating a microstructure of an airgel composite according to an embodiment of the present disclosure. As shown in FIG. 1, an airgel composite 10 has a three-dimensional network skeleton formed by partially connecting airgel particles 1 which are airgel components in a three-dimensional random manner via silica particles 2. And pores 3 surrounded by the skeleton. At this time, it is presumed that the silica particles 2 are present between the airgel particles 1 and function as a skeleton support that supports the three-dimensional network skeleton. Therefore, by having such a structure, it is considered that appropriate strength is imparted to the airgel while maintaining the heat insulating property and the flexibility as the airgel. In addition, in this embodiment, the airgel composite may have a three-dimensional network skeleton formed by three-dimensionally connecting silica particles at random through the airgel particles. Further, the silica particles may be covered with airgel particles. Since the airgel particles (airgel component) are composed of silicone, it is presumed that they have a high affinity for silica particles. Therefore, in this embodiment, it is considered that the silica particles were successfully introduced into the three-dimensional network skeleton of the airgel. In this respect, it is considered that the silanol groups of the silica particles also contribute to the affinity between the two.

  The airgel particles 1 are considered to be in the form of secondary particles composed of a plurality of primary particles, and are generally spherical. The average particle size (that is, the secondary particle size) of the airgel particles 1 can be, for example, 2 nm to 50 μm, but may be 5 nm to 2 μm or 10 nm to 200 nm. When the average particle size of the airgel particles 1 is 2 nm or more, it becomes easy to obtain an airgel composite having excellent flexibility, while when the average particle size is 50 μm or less, it is easy to obtain an airgel composite having excellent heat insulating properties. Become. The average particle size of the primary particles constituting the airgel particles 1 can be, for example, 0.1 nm to 5 μm from the viewpoint that secondary particles having a low-density porous structure can be easily formed. It may be 5 nm to 200 nm, or 1 nm to 20 nm.

  The silica particles 2 can be used without particular limitation, and examples thereof include amorphous silica particles. Further, the amorphous silica particles include at least one selected from the group consisting of fused silica particles, fumed silica particles and colloidal silica particles. Among these, the colloidal silica particles have high monodispersity, and it is easy to suppress aggregation in the sol. The silica particles 2 may be silica particles having a hollow structure, a porous structure, or the like.

  The shape of the silica particles 2 is not particularly limited, and examples thereof include a spherical shape, a cocoon shape, and an association type. Of these, the use of spherical particles as the silica particles 2 facilitates suppression of aggregation in the sol. The average primary particle diameter of the silica particles 2 may be, for example, 1 to 500 nm, but may be 5 to 300 nm or 20 to 100 nm. When the average primary particle diameter of the silica particles 2 is 1 nm or more, it becomes easy to impart appropriate strength to the airgel, and it becomes easy to obtain an airgel composite having excellent shrinkage resistance during drying. On the other hand, when the average primary particle diameter is 500 nm or less, solid heat conduction of the silica particles is easily suppressed, and an airgel composite having excellent heat insulating properties is easily obtained.

  It is presumed that the airgel particles 1 (airgel component) and the silica particles 2 are bonded to each other in the form of hydrogen bond, chemical bond, or a combination of these bonds. At this time, it is considered that the hydrogen bond, the chemical bond, or the combination of these bonds is formed by the silanol group of the airgel particle 1 (airgel component), the reactive group or both of them, and the silanol group of the silica particle 2. .. Therefore, when the bonding mode is a chemical bond, it is considered that it is easy to impart appropriate strength to the airgel. Considering this, as the particles to be combined with the airgel component, not only silica particles but also inorganic particles or organic particles having a silanol group on the particle surface can be used.

  In the present embodiment, the average particle size of particles (average secondary particle size of airgel particles and average primary particle size of silica particles) is determined by using a scanning electron microscope (hereinafter abbreviated as “SEM”). It can be obtained by directly observing the cross section. For example, the particle size of each airgel particle or silica particle can be obtained from the three-dimensional network skeleton based on the diameter of its cross section. The diameter here means a diameter when the cross section of the skeleton forming the three-dimensional mesh skeleton is regarded as a circle. The diameter when the cross section is regarded as a circle is the diameter of the circle when the area of the cross section is replaced with a circle having the same area. In calculating the average particle diameter, the diameter of a circle is calculated for 100 particles and the average thereof is calculated.

  The average particle size of the silica particles can be measured from the raw material. For example, the biaxial average primary particle diameter is calculated as follows from the result of observing 20 arbitrary particles by SEM. That is, taking colloidal silica particles having a solid content concentration of 5 to 40% by mass, which are usually dispersed in water, as an example, a chip obtained by cutting a wafer with a pattern wiring into 2 cm square pieces in a dispersion liquid of colloidal silica particles for about 30 seconds. After soaking, the chip is rinsed with pure water for about 30 seconds and dried by nitrogen blow. Then, the chip is placed on a sample stage for SEM observation, an accelerating voltage of 10 kV is applied, silica particles are observed at a magnification of 100,000 times, and an image is taken. Twenty silica particles are arbitrarily selected from the obtained image, and the average of the particle diameters of these particles is defined as the average particle diameter. At this time, when the selected silica particle has a shape as shown in FIG. 2, a rectangle (circumscribing rectangle L) circumscribing the silica particle 2 and having its longest side the longest is guided. Then, assuming that the long side of the circumscribed rectangle L is X and the short side is Y, the biaxial average primary particle diameter is calculated as (X + Y) / 2, and is set as the particle diameter of the particle.

  The size of the pores 3 in the airgel composite will be described in the section [Density and Porosity] below.

  The content of the airgel component contained in the airgel composite can be, for example, 4 to 25 parts by mass, or 10 to 20 parts by mass, relative to 100 parts by mass of the total amount of the airgel composite. When the content is 4 parts by mass or more, it becomes easy to impart appropriate strength, and when the content is 25 parts by mass or less, it becomes easy to obtain good heat insulating property.

  The content of the silica particles contained in the airgel composite can be, for example, 1 to 25 parts by mass with respect to 100 parts by mass of the total amount of the airgel composite, but may be 3 to 15 parts by mass. When the content is 1 part by mass or more, it becomes easy to impart appropriate strength to the airgel composite, and when the content is 25 parts by mass or less, solid heat conduction of the silica particles is easily suppressed.

  In addition to these airgel components and silica particles, the airgel composite may further contain other components such as carbon graphite, aluminum compounds, magnesium compounds, silver compounds and titanium compounds for the purpose of suppressing heat radiation. The content of the other components is not particularly limited, but from the viewpoint of sufficiently securing the desired effect of the airgel composite, it may be, for example, 1 to 5 parts by mass based on 100 parts by mass of the airgel composite. it can.

The number of silanol groups per 1 g of the silica particles according to the present embodiment may be, for example, 10 × 10 ^{18 to} 1000 × 10 ¹⁸ or 50 × 10 ^{18 to} 800 × 10 ¹⁸ / g. , 100 × 10 ^{18 to} 700 × 10 ¹⁸ pieces / g.

[Sol]
As described above, the sol according to the present embodiment includes a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in the molecule, and a hydrolyzed product of the silicon compound. At least one selected from the group consisting of decomposition products (hereinafter, these may be collectively referred to as “silicon compound and the like”).

(Silica particle dispersion)
The silica particles in the silica particle dispersion may be the silica particles described above. The pH of the silica particle dispersion liquid is, for example, 8.0 or less from the viewpoint that the hydrolysis reaction of the silicon compound and the polysiloxane compound described later easily proceeds and the number of crosslinking points in the three-dimensional crosslinking reaction easily increases. It may be 7.5 or less, or 6.5 or less. The pH of the silica particle dispersion is, for example, 0.5 or more, 1.5 or more, and 2.5 or more from the viewpoint that the three-dimensional crosslinking reaction easily proceeds in a short time. It may be.

  Here, the pH of the silica particle dispersion liquid can be measured with a pH meter (for example, manufactured by Denki Kagaku Keiki Co., Ltd., model number: PHL-40). The pH measurement values include standard buffer solutions (phthalate pH buffer solution pH: 4.01 (25 ° C), neutral phosphate pH buffer solution pH: 6.86 (25 ° C), borate pH buffer solution). After performing three-point calibration using a liquid pH: 9.18 (25 ° C.), the electrode is put into the dispersion liquid and the value after being stabilized for 2 minutes or more is adopted.

  The present inventors presume the reason why the upper limit of the pH of the silica particle dispersion is preferably in the above range as follows. Hereinafter, the polycondensation reaction of 3-glycidoxypropyltrimethoxysilane will be described as an example.

  FIG. 3 is a diagram schematically showing the relationship between pH and reaction rate in the polycondensation reaction of 3-glycidoxypropyltrimethoxysilane. In FIG. 3, the horizontal axis represents pH and the vertical axis represents log k (k is a reaction rate constant). However, the plots and approximate curves in FIG. 3 are based on predicted values and do not necessarily indicate actual measured values.

  As shown in FIG. 3, it is considered that when the pH of the system is high, the polycondensation rate of 3-glycidoxypropyltrimethoxysilane is significantly increased. That is, it is considered that when the pH of the silica particle dispersion liquid is high, the pH of the system is also increased, and the polycondensation rate of the silane component is remarkably increased. On the other hand, when the pH of the silica particle dispersion is appropriately low, the pH of the system is also appropriately decreased, and the polycondensation rate of the silane component is considered to be appropriately low. Therefore, it is considered that when the pH of the silica particle dispersion is appropriately low, gelation is less likely to occur in the stage before the wet gel is generated, and a good wet gel is easily produced.

  The degree of association of the silica particles in the silica particle dispersion liquid may be, for example, 2.0 or less, or 1.8 or less, from the viewpoint that the three-dimensional crosslinking reaction easily proceeds in a short time. It may be 7 or less. When the degree of association is in such a range, it is considered that the specific surface area of the particles is appropriately increased, the contact area with the silane component is increased, and the above effect is easily obtained. The degree of association of the silica particles in the above-mentioned silica particle dispersion is, for example, 1. It may be 0 or more, 1.2 or more, or 1.3 or more. When the degree of association is in such a range, it is considered that the above effect is easily obtained because the specific surface area of the particles is appropriately reduced.

  Here, in the present specification, the degree of association of the silica particles in the silica particle dispersion is a ratio of the average particle diameter of the secondary particles of the silica particles in the silica particle dispersion and the biaxial average primary particle diameter of the silica particles. (Average particle diameter of secondary particles / biaxial average primary particle diameter). The average particle size of the secondary particles of the silica particles is a value obtained by measuring the silica particle dispersion with a particle size distribution meter using a dynamic light scattering method. The biaxial average primary particle diameter is a value obtained by the method described above.

(Silicon compound etc.)
The number of silicon atoms in the molecule of the silicon compound can be, for example, 1 or 2. The silicon compound having a hydrolyzable functional group in the molecule is not particularly limited, and examples thereof include alkyl silicon alkoxide. The alkyl silicon alkoxide may have three or less hydrolyzable functional groups from the viewpoint of improving water resistance. Examples of such alkyl silicon alkoxides include methyltrimethoxysilane, dimethyldimethoxysilane and ethyltrimethoxysilane. Here, examples of the hydrolyzable functional group include an alkoxy group such as a methoxy group and an ethoxy group.

  Moreover, the number of hydrolyzable functional groups is 3 or less, and vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, and 3-glycidoxypropyl, which are silicon compounds having a reactive group in the molecule. Methyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-acryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropylmethyldimethoxysilane, N-phenyl -3-Aminopropyltrimethoxysilane, N-2- (aminoethyl) -3-aminopropylmethyldimethoxysilane and the like can also be used.

  Furthermore, bistrimethoxysilylmethane, bistrimethoxysilylethane, bistrimethoxysilylhexane, and the like, which are silicon compounds having 3 or less hydrolyzable functional groups at the molecular ends, can also be used.

  These silicon compounds and the like may be used alone or in combination of two or more.

  In producing the airgel composite of the present embodiment, the sol containing the above silicon compound or the like is selected from the group consisting of a polysiloxane compound having a reactive group in the molecule and a hydrolysis product of the polysiloxane compound. At least one (hereinafter, these may be collectively referred to as “polysiloxane compound and the like”).

  The reactive group in the polysiloxane compound or the like is not particularly limited, but may be a group that reacts with the same reactive group or a group that reacts with another reactive group, such as an alkoxy group, a silanol group, and a hydroxy group. Examples thereof include an alkyl group, an epoxy group, a polyether group, a mercapto group, a carboxyl group and a phenol group. These polysiloxane compounds having a reactive group may be used alone or in combination of two or more. Examples of the reactive group include an alkoxy group, a silanol group, a hydroxyalkyl group, and a polyether group from the viewpoint of improving the flexibility of the airgel composite. Among these, the alkoxy group or the hydroxyalkyl group is a sol. The compatibility of can be further improved. Further, from the viewpoint of improving the reactivity of the polysiloxane compound and reducing the thermal conductivity of the airgel composite, the number of carbon atoms of the alkoxy group and the hydroxyalkyl group may be, for example, 1 to 6, but the airgel composite. It may be 2 to 4 from the viewpoint of further improving the flexibility.

  Examples of the polysiloxane compound having a hydroxyalkyl group in the molecule include those having a structure represented by the following general formula (4). By using the polysiloxane compound having the structure represented by the following general formula (4), the structure represented by the general formula (1) described below can be introduced into the skeleton of the airgel composite.

In formula (4), R ₉ represents a hydroxyalkyl group, R ₁₀ represents an alkylene group, R ₁₁ and R ₁₂ each independently represent an alkyl group or an aryl group, and n represents an integer of 1 to 50. Here, examples of the aryl group include a phenyl group and a substituted phenyl group. Moreover, examples of the substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, and a cyano group. In formula (4), two R _{9 s} may be the same or different, and similarly two R _{10 s} may be the same or different. Further, in the formula (4), two or more R _11's may be the same or different, and similarly two or more R ₁₂ 's may be the same or different.

By using a wet gel produced from a sol containing the polysiloxane compound having the above structure, a flexible airgel composite having low thermal conductivity can be obtained more easily. From such a viewpoint, in the formula (4), examples of R ₉ include a hydroxyalkyl group having 1 to 6 carbon atoms, and examples of the hydroxyalkyl group include a hydroxyethyl group and a hydroxypropyl group. Further, in the formula (4), examples of R ₁₀ include alkylene groups having 1 to 6 carbon atoms, and examples of the alkylene groups include ethylene group and propylene group. In formula (4), R ₁₁ and R ₁₂ each independently include an alkyl group having 1 to 6 carbon atoms, a phenyl group, and the like, and the alkyl group includes a methyl group and the like. Further, in the formula (4), n may be, for example, 2 to 30, but may be 5 to 20.

  As the polysiloxane compound having the structure represented by the general formula (4), a commercially available product can be used, and compounds such as X-22-160AS, KF-6001, KF-6002, KF-6003 (all are available). , Shin-Etsu Chemical Co., Ltd.), compounds such as XF42-B0970 and Fluid OFOH 702-4% (all manufactured by Momentive).

  Examples of the polysiloxane compound having an alkoxy group in the molecule include those having a structure represented by the following general formula (5). By using a polysiloxane compound having a structure represented by the following general formula (5), a ladder-type structure having a bridging portion represented by the general formulas (2) and (3) described later can be formed into an airgel composite. It can be introduced into the skeleton.

In formula (5), R ₁₄ represents an alkyl group or an alkoxy group, R ₁₅ and R ₁₆ each independently represent an alkoxy group, R ₁₇ and R ₁₈ each independently represent an alkyl group or an aryl group, and m represents An integer of 1 to 50 is shown. Here, examples of the aryl group include a phenyl group and a substituted phenyl group. Moreover, examples of the substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, and a cyano group. In the formula (5), two R _{14 s} may be the same or different, and two R _{15 s} may be the same or different, and similarly two R _{14 s} are the same. ₁₆ may be the same or different. Further, in the formula (5), when m is an integer of 2 or more, two or more R ₁₇ may be the same or different, and similarly, two or more R ₁₈ are also the same. May also be different.

By using a wet gel produced from a sol containing the polysiloxane compound having the above structure, a flexible airgel composite having low thermal conductivity can be obtained more easily. From such a viewpoint, in the formula (5), R ₁₄ includes an alkyl group having 1 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms, and the like, and the alkyl group or alkoxy group is a methyl group. , A methoxy group, an ethoxy group and the like. Further, in the formula (5), R ₁₅ and R ₁₆ each independently include an alkoxy group having a carbon number of 1 to 6, and the alkoxy group includes a methoxy group, an ethoxy group, and the like. In formula (5), R ₁₇ and R ₁₈ each independently include an alkyl group having 1 to 6 carbon atoms, a phenyl group, and the like, and the alkyl group includes a methyl group and the like. Further, in the formula (5), m may be, for example, 2 to 30, but may be 5 to 20.

  The polysiloxane compound having the structure represented by the general formula (5) can be obtained, for example, by appropriately referring to the production method reported in JP 2000-26609 A, JP 2012-233110 A, or the like. You can

  In addition, since the alkoxy group is hydrolyzed, the polysiloxane compound having an alkoxy group in the molecule may be present as a hydrolysis product in the sol. Decomposition products may be mixed. Further, in the polysiloxane compound having an alkoxy group in the molecule, all the alkoxy groups in the molecule may be hydrolyzed or may be partially hydrolyzed.

  These polysiloxane compounds and the like may be used alone or in combination of two or more.

  The content of the silicon compound or the like contained in the sol can be, for example, 5 to 50 parts by mass with respect to 100 parts by mass of the total amount of the sol, but may be 10 to 30 parts by mass. When this content is 5 parts by mass or more, good reactivity is easily obtained, and when it is 50 parts by mass or less, good compatibility is easily obtained.

  When the sol further contains a polysiloxane compound or the like, the total content of the silicon compound or the like and the polysiloxane compound or the like is, for example, 5 to 50 parts by mass with respect to 100 parts by mass of the total amount of the sol. However, the amount may be 10 to 30 parts by mass. When the total content is 5 parts by mass or more, it becomes easier to obtain good reactivity, and when it is 50 parts by mass or less, it becomes easier to obtain good compatibility. At this time, the ratio of the content of the silicon compound or the like to the content of the hydrolysis product such as the polysiloxane compound can be, for example, 0.5: 1 to 4: 1, but 1: 1 to 2 : 1 may be sufficient. When the content ratio of these compounds is 0.5: 1 or more, good compatibility is more easily obtained, and when it is 4: 1 or less, the shrinkage of the gel is more easily suppressed.

  The content of the silica particles contained in the sol may be, for example, 1 to 20 parts by mass with respect to 100 parts by mass of the total amount of the sol, but may be 4 to 15 parts by mass. By setting the content to 1 part by mass or more, it becomes easy to impart appropriate strength to the airgel, and it becomes easy to obtain an airgel composite having excellent shrinkage resistance during drying. Further, by setting the content to 20 parts by mass or less, it is easy to suppress the solid heat conduction of the silica particles, and it is easy to obtain an airgel composite having excellent heat insulating properties.

<Specific embodiment of airgel composite>
Examples of the airgel component in the airgel composite of the present embodiment include the following modes. By adopting these modes, it becomes easy to control the heat insulating property and the flexibility of the airgel composite to a desired level. However, adopting each of these aspects is not necessarily the purpose of obtaining the airgel composite defined in the present embodiment. By adopting each aspect, it is possible to obtain an airgel composite having a thermal conductivity and a compression elastic modulus according to each aspect. Therefore, it is possible to provide an airgel composite having heat insulating properties and flexibility depending on the application.

  The airgel composite of the present embodiment may have a structure represented by the following general formula (1), for example.

In formula (1), R ₁ and R ₂ each independently represent an alkyl group or an aryl group, and R ₃ and R ₄ each independently represent an alkylene group. Here, examples of the aryl group include a phenyl group and a substituted phenyl group. Examples of the substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group and a cyano group.

By introducing the above structure into the skeleton of the airgel composite as an airgel component, a flexible airgel composite having low thermal conductivity is obtained. From such a viewpoint, in the formula (1), R ₁ and R ₂ each independently include an alkyl group having 1 to 6 carbon atoms, a phenyl group, and the like, and the alkyl group includes a methyl group and the like. .. In formula (1), R ₃ and R ₄ each independently include an alkylene group having 1 to 6 carbon atoms, and the alkylene group includes an ethylene group, a propylene group, and the like.

  The airgel composite of the present embodiment is an airgel composite having a ladder-type structure including a pillar and a bridge, and the bridge has a structure represented by the following general formula (2). May be By introducing such a ladder type structure into the skeleton of the airgel composite as an airgel component, heat resistance and mechanical strength can be improved. In the present embodiment, the "ladder structure" has two strut parts and bridges connecting the strut parts to each other (having a so-called "ladder" form). Is. In this embodiment, the skeleton of the airgel composite may have a ladder-type structure, but the airgel composite may partially have a ladder-type structure.

In formula (2), R ₆ and R ₇ each independently represent an alkyl group or an aryl group, and b represents an integer of 1 to 50. Here, examples of the aryl group include a phenyl group and a substituted phenyl group. Moreover, examples of the substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, and a cyano group. In the formula (2), when b is an integer of 2 or more, two or more R ₆ may be the same or different, and similarly two or more R ₇ are also the same. May also be different.

  By introducing the above structure into the skeleton of the airgel composite as an airgel component, for example, it has a structure derived from a conventional ladder-type silsesquioxane (that is, a structure represented by the following general formula (X) To have an aerogel composite having flexibility superior to that of the aerogel. As shown in the following general formula (X), in the airgel having the structure derived from the conventional ladder-type silsesquioxane, the structure of the bridging part is -O-, but the airgel composite of the present embodiment. In the body, the structure of the bridging portion is the structure represented by the general formula (2) (polysiloxane structure).

  In formula (X), R represents a hydroxy group, an alkyl group or an aryl group.

  The structure of the strut and its chain length, and the interval of the structure serving as the bridge are not particularly limited, but from the viewpoint of further improving heat resistance and mechanical strength, the ladder-type structure has the following general formula ( It may have a structure represented by 3).

In formula (3), R ₅ , R ₆ , R ₇ and R ₈ each independently represent an alkyl group or an aryl group, a and c each independently represent an integer of 1 to 3000, and b is 1 to 50. Indicates an integer. Here, examples of the aryl group include a phenyl group and a substituted phenyl group. Moreover, examples of the substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, and a cyano group. In the formula (3), when b is an integer of 2 or more, two or more R ₆ may be the same or different, and similarly two or more R ₇ are also the same. May also be different. Further, in the formula (3), when a is an integer of 2 or more, two or more R ₅ may be the same or different, and similarly, when c is an integer of 2 or more, 2 or more. R _{8 s} in each may be the same or different.

From the viewpoint of obtaining better flexibility, as R ₅ , R ₆ , R _7, and R _{8 in} the formulas (2) and (3) (provided that R ₅ and R ₈ are only in the formula (3)). Independently include an alkyl group having 1 to 6 carbon atoms, a phenyl group, and the like, and the alkyl group includes a methyl group and the like. Further, in the formula (3), a and c can each independently be 6 to 2000, but may be 10 to 1000. Further, in the formulas (2) and (3), b can be 2 to 30, but may be 5 to 20.

  The airgel composite of the present embodiment may have a structure represented by the following general formula (6), for example.

In formula (6), R ₁₉ represents an alkyl group. Here, examples of the alkyl group include an alkyl group having 1 to 6 carbon atoms, and examples of the alkyl group include a methyl group.

  The airgel composite of the present embodiment may have a structure represented by the following general formula (7), for example.

In formula (7), R ₂₀ and R ₂₁ each independently represent an alkyl group. Here, examples of the alkyl group include an alkyl group having 1 to 6 carbon atoms, and examples of the alkyl group include a methyl group.

  The airgel composite of the present embodiment may have a structure represented by the following general formula (8), for example.

In formula (8), R ₂₂ represents an alkylene group. Here, examples of the alkylene group include an alkylene group having 1 to 10 carbon atoms, and examples of the alkylene group include an ethylene group and a hexylene group.

<Physical properties of airgel composite>
[Thermal conductivity]
In the airgel composite of the present embodiment, the thermal conductivity at 25 ° C. under atmospheric pressure can be, for example, 0.03 W / m · K or less, but even if it is 0.025 W / m · K or less. It may be 0.02 W / m · K or less. When the thermal conductivity is 0.03 W / m · K or less, it is possible to obtain the heat insulating property which is higher than that of polyurethane foam which is a high performance heat insulating material. The lower limit of the thermal conductivity is not particularly limited, but may be 0.01 W / m · K, for example.

  The thermal conductivity can be measured by a stationary method. Specifically, for example, it can be measured using a steady-state thermal conductivity measuring device “HFM436 Lambda” (product name, HFM436 Lambda is a registered trademark, manufactured by NETZSCH). The outline of the thermal conductivity measurement method using the steady-state thermal conductivity measurement device is as follows.

(Preparation of measurement sample)
The airgel composite is processed into a size of 150 mm × 150 mm × 100 mm by using a blade having a blade angle of about 20 to 25 degrees, which is used as a measurement sample. The recommended sample size for HFM436 Lambda is 300 mm × 300 mm × 100 mm, but the thermal conductivity when measured with the above sample size is similar to the thermal conductivity when measured with the recommended sample size. It has been confirmed. Next, in order to ensure the parallelism of the surfaces, the measurement sample is shaped with sandpaper of # 1500 or more as needed. Then, before measuring the thermal conductivity, a constant temperature dryer "DVS402" (manufactured by Yamato Scientific Co., Ltd., product name) is used to dry the measurement sample under atmospheric pressure at 100 ° C for 30 minutes. Then, the measurement sample is transferred into a desiccator and cooled to 25 ° C. As a result, a measurement sample for measuring thermal conductivity is obtained.

(Measuring method)
The measurement conditions are an atmospheric pressure and an average temperature of 25 ° C. The measurement sample obtained as described above was sandwiched between the upper and lower heaters with a load of 0.3 MPa, the temperature difference ΔT was set to 20 ° C., and a guard heater was used to adjust the heat flow to a one-dimensional heat flow. Measure the upper surface temperature, lower surface temperature, etc. Then, the thermal resistance R _S of the measurement sample is obtained from the following equation.
R _S = N ((T _U −T _L ) / Q) −R _O
In the formula, T _U represents the upper surface temperature of the measurement sample, T _L represents the lower surface temperature of the measurement sample, R _O represents the contact thermal resistance at the upper and lower interfaces, and Q represents the heat flux meter output. Note that N is a proportional coefficient and is obtained in advance using a calibration sample.

From the obtained thermal resistance R _S , the thermal conductivity λ of the measurement sample is calculated by the following formula.
λ = d / R _S
In the formula, d represents the thickness of the measurement sample.

[Compression modulus]
In the airgel composite of the present embodiment, the compressive elastic modulus at 25 ° C. may be, for example, 3 MPa or less, but may be 2 MPa or less, 1 MPa or less, or 0.5 MPa or less. May be. When the compressive elastic modulus is 3 MPa or less, it becomes easy to form an airgel composite having excellent handleability. The lower limit of the compressive elastic modulus is not particularly limited, but may be 0.05 MPa, for example.

[Deformation recovery rate]
In the airgel composite of the present embodiment, the deformation recovery rate at 25 ° C. can be 90% or more, for example, but may be 94% or more, or 98% or more. When the deformation recovery rate is 90% or more, it becomes easier to obtain excellent strength, excellent flexibility with respect to deformation and the like. The upper limit of the deformation recovery rate is not particularly limited, but may be 100% or 99%, for example.

[Maximum compression deformation rate]
In the airgel composite of the present embodiment, the maximum compressive deformation rate at 25 ° C. can be, for example, 80% or more, but may be 83% or more, or 86% or more. When the maximum compressive deformation rate is 80% or more, it becomes easier to obtain excellent strength, excellent flexibility with respect to deformation, and the like. The upper limit of the maximum compressive deformation rate is not particularly limited, but may be 90%, for example.

  The compression elastic modulus, the deformation recovery rate, and the maximum compression deformation rate can be measured using a small bench tester “EZTest” (manufactured by Shimadzu Corporation, product name). The outline of the method for measuring the compressive elastic modulus and the like using a small bench tester is as follows.

(Preparation of measurement sample)
The airgel composite is processed into a cube (dice shape) of 7.0 mm square using a blade having a blade angle of about 20 to 25 degrees, and is used as a measurement sample. Next, in order to ensure the parallelism of the surfaces, the measurement sample is shaped with sandpaper of # 1500 or more as needed. Then, before measurement, a constant temperature dryer "DVS402" (manufactured by Yamato Scientific Co., Ltd., product name) is used to dry the measurement sample under atmospheric pressure at 100 ° C for 30 minutes. Then, the measurement sample is transferred into a desiccator and cooled to 25 ° C. As a result, a measurement sample for measuring the compression elastic modulus, the deformation recovery rate, and the maximum compression deformation rate is obtained.

(Measuring method)
Use a 500N load cell. Further, an upper platen (φ20 mm) and a lower platen (φ118 mm) made of stainless steel are used as a jig for compression measurement. The measurement sample is set between these jigs, compressed at a speed of 1 mm / min, and the displacement of the measurement sample size at 25 ° C. is measured. The measurement ends when a load of more than 500 N is applied or when the measurement sample breaks. Here, the compressive strain ε can be obtained from the following equation.
ε = Δd / d1
In the formula, Δd represents the displacement (mm) of the thickness of the measurement sample due to the load, and d1 represents the thickness (mm) of the measurement sample before applying the load.
The compressive stress σ (MPa) can be obtained from the following equation.
σ = F / A
In the formula, F represents the compressive force (N), and A represents the cross-sectional area (mm ² ) of the measurement sample before applying a load.

The compressive elastic modulus E (MPa) can be obtained from the following equation in the compressive force range of 0.1 to 0.2 N, for example.
E = ([sigma] _{2- [} sigma] ₁ ) / ([epsilon] _{2- [} epsilon] ₁ )
In the formula, σ ₁ indicates a compressive stress (MPa) measured at a compressive force of 0.1 N, σ ₂ indicates a compressive stress (MPa) measured at a compressive force of 0.2 N, and ε ₁ indicates a compressive stress. The compressive strain measured at σ ₁ is shown, and ε ₂ is the compressive strain measured at compressive stress σ ₂ .

On the other hand, the deformation recovery rate and the maximum compressive deformation rate are the thickness of the measurement sample before applying the load d1, the thickness of the measurement sample at the time when the maximum load of 500 N is applied or the measurement sample breaks, and the load is removed. It can be calculated according to the following formula, where d3 is the thickness of the measured sample after the measurement.
Deformation recovery rate = (d3-d2) / (d1-d2) × 100
Maximum compression deformation rate = (d1−d2) / d1 × 100

  The thermal conductivity, compressive elastic modulus, deformation recovery rate, and maximum compressive deformation rate can be appropriately adjusted by changing the production conditions, raw materials, and the like of the airgel composite described later.

[Density and porosity]
In the airgel composite of the present embodiment, the size of the pores 3, that is, the average pore diameter can be, for example, 5 to 1000 nm, but may be 25 to 500 nm. When the average pore diameter is 5 nm or more, it becomes easy to obtain an airgel composite having excellent flexibility, and when it is 1000 nm or less, it becomes easy to obtain an airgel composite having excellent heat insulating properties.

In airgel composite of this embodiment, density at 25 ° C., for example, can be a 0.05~0.25g / cm ^3, may be 0.1 to 0.2 g / cm ^3. When the density is 0.05 g / cm ³ or more, more excellent strength and flexibility can be obtained, and when the density is 0.25 g / cm ³ or less, more excellent heat insulating property can be obtained. it can.

  In the airgel composite of the present embodiment, the porosity at 25 ° C. can be set to 85 to 95%, for example, but it may be 87 to 93%. When the porosity is 85% or more, more excellent heat insulating property can be obtained, and when it is 95% or less, more excellent strength and flexibility can be obtained.

  The average pore diameter, the density and the porosity of the three-dimensional mesh-like pores (through-holes) in the airgel composite can be measured by the mercury porosimetry according to DIN66133. As the measuring device, for example, Autopore IV9520 (manufactured by Shimadzu Corporation, product name) can be used.

<Method for producing airgel composite>
Next, an embodiment of a method for producing an airgel composite will be described.

  The method for producing an airgel composite according to the present embodiment includes a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in a molecule, and a hydrolysis of the silicon compound. And a step of drying a wet gel formed from a sol containing at least one selected from the group consisting of decomposition products. According to such a production method, unlike the airgel obtained by the conventional technique, an airgel composite having excellent heat insulating properties and flexibility can be produced.

  Here, the specific aspect of the sol in the above step is, for example, the same as that of the sol described above. The sol further contains at least one selected from the group consisting of a polysiloxane compound having a reactive group in the molecule and a hydrolysis product of the polysiloxane compound, from the viewpoint of achieving further excellent heat insulation and flexibility. You may have. Further, the average primary particle diameter of the silica particles may be, for example, 1 to 500 nm from the viewpoint of further improving heat insulation and flexibility. From the viewpoint of achieving excellent heat insulation and flexibility, the silica particles may have a spherical shape, and the silica particles may be colloidal silica particles.

  The drying may be carried out at a temperature below the critical point of the solvent used for drying and under atmospheric pressure from the viewpoint of easily obtaining an airgel composite having excellent heat insulating properties and flexibility.

  The method for producing an airgel composite according to the present embodiment includes a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in a molecule, and a hydrolysis of the silicon compound. At least one selected from the group consisting of decomposition products, a sol generation step of generating a sol containing, a wet gel generation step of generating a wet gel from the sol, a drying step of drying the wet gel, May be provided.

  Hereinafter, the production method of the airgel composite will be described in more detail with reference to specific examples, but the production method of the airgel composite of the present embodiment is not limited thereto.

  The airgel composite of the present embodiment is, for example, a step of washing the sol-forming step, the wet gel-forming step, and the wet gel obtained in the wet-gel forming step and performing solvent substitution (if necessary) (washing and solvent). It can be manufactured by a manufacturing method mainly including a replacement step) and a drying step of drying the washed and solvent-substituted wet gel. Note that the sol is a state before the gelation reaction occurs, and in the present embodiment, the silicon compound and the like, and optionally the polysiloxane compound and the like, and silica particles are dissolved or dispersed in a solvent. Means a state. In addition, the wet gel means a gel solid in a wet state that does not have fluidity even though it contains a liquid medium.

  Hereinafter, each step will be described.

(Sol generation process)
In the sol generation step, for example, the silicon compound described above, the silica particle dispersion liquid described above, and optionally a polysiloxane compound or a solvent are mixed and hydrolyzed to generate a sol. In this step, an acid catalyst may be further added to accelerate the hydrolysis reaction. Further, as shown in Japanese Patent No. 5250900, a surfactant, a thermohydrolyzable compound or the like can be added. Furthermore, components such as carbon graphite, aluminum compounds, magnesium compounds, silver compounds and titanium compounds may be added for the purpose of suppressing heat ray radiation.

  As the solvent, for example, water or a mixed liquid of water and alcohols can be used. Examples of alcohols include methanol, ethanol, n-propanol, 2-propanol, n-butanol, 2-butanol, t-butanol and the like. Among these, methanol, ethanol, 2-propanol, etc. are mentioned as an alcohol with a low surface tension and a low boiling point in order to reduce the interfacial tension with a gel wall. You may use these individually or in mixture of 2 or more types.

  For example, when alcohols are used as the solvent, the amount of alcohols may be, for example, 4 to 8 mol, based on 1 mol of the total amount of the silicon compound and the polysiloxane compound, but is 4 to 6.5. It may be 4.5 to 6 mol. When the amount of alcohols is 4 mol or more, good compatibility is more easily obtained, and when it is 8 mol or less, shrinkage of the gel is more easily suppressed.

  As the acid catalyst, inorganic acids such as hydrofluoric acid, hydrochloric acid, nitric acid, sulfuric acid, sulfurous acid, phosphoric acid, phosphorous acid, hypophosphorous acid, hydrobromic acid, chloric acid, chlorous acid and hypochlorous acid; acidic phosphoric acid Acidic phosphates such as aluminum, magnesium acid phosphate, and zinc acid phosphate; acetic acid, formic acid, propionic acid, oxalic acid, malonic acid, succinic acid, citric acid, malic acid, adipic acid, azelaic acid and other organic carboxylic acids And so on. Among these, organic carboxylic acids are mentioned as an acid catalyst which further improves the water resistance of the obtained airgel composite. Examples of the organic carboxylic acids include acetic acid, but may be formic acid, propionic acid, oxalic acid, malonic acid and the like. You may use these individually or in mixture of 2 or more types.

  By using the acid catalyst, the hydrolysis reaction of the silicon compound and the polysiloxane compound can be promoted, and the sol can be obtained in a shorter time.

  The addition amount of the acid catalyst can be, for example, 0.001 to 0.1 parts by mass with respect to 100 parts by mass of the total amount of the silicon compound and the polysiloxane compound.

  As the surfactant, a nonionic surfactant, an ionic surfactant or the like can be used. You may use these individually or in mixture of 2 or more types.

  As the nonionic surfactant, for example, one containing a hydrophilic part such as polyoxyethylene and a hydrophobic part mainly consisting of an alkyl group, one containing a hydrophilic part such as polyoxypropylene, etc. can be used. Examples of those containing a hydrophilic part such as polyoxyethylene and a hydrophobic part mainly composed of an alkyl group include polyoxyethylene nonyl phenyl ether, polyoxyethylene octyl phenyl ether and polyoxyethylene alkyl ether. Examples of those containing a hydrophilic portion such as polyoxypropylene include polyoxypropylene alkyl ethers and block copolymers of polyoxyethylene and polyoxypropylene.

  Examples of the ionic surfactant include a cationic surfactant, an anionic surfactant, and an amphoteric surfactant. Examples of the cationic surfactant include cetyltrimethylammonium bromide, cetyltrimethylammonium chloride, and the like, and examples of the anionic surfactant include sodium dodecylsulfonate. Examples of the zwitterionic surfactants include amino acid-based surfactants, betaine-based surfactants, amine oxide-based surfactants and the like. Examples of the amino acid-based surfactant include acylglutamic acid. Examples of betaine-based surfactants include betayl lauryldimethylaminoacetate and betaine stearyldimethylaminoacetate. Examples of the amine oxide-based surfactant include lauryl dimethyl amine oxide.

  These surfactants reduce the difference in chemical affinity between the solvent in the reaction system and the growing siloxane polymer and suppress the phase separation in the wet gel formation step described later. Is believed to be.

  The addition amount of the surfactant depends on the kind of the surfactant or the kind and amount of the silicon compound and the polysiloxane compound, but is, for example, 1 to 100 parts by mass of the total amount of the silicon compound and the polysiloxane compound. It can be 100 parts by mass. The added amount may be 5 to 60 parts by mass.

  It is considered that the thermohydrolyzable compound generates a basic catalyst by thermal hydrolysis to make the reaction solution basic, and promotes the sol-gel reaction in the wet gel forming step described later. Therefore, the thermohydrolyzable compound is not particularly limited as long as it is a compound that can make the reaction solution basic after hydrolysis, and urea; formamide, N-methylformamide, N, N-dimethylformamide, acetamide, N Acid amides such as -methylacetamide and N, N-dimethylacetamide; cyclic nitrogen compounds such as hexamethylenetetramine. Of these, urea is particularly likely to obtain the above-mentioned promoting effect.

  The addition amount of the heat-hydrolyzable compound is not particularly limited as long as it is an amount capable of sufficiently promoting the sol-gel reaction in the wet gel formation step described below. For example, when urea is used as the thermally hydrolyzable compound, the addition amount thereof can be, for example, 1 to 200 parts by mass with respect to 100 parts by mass of the total amount of the silicon compound and the polysiloxane compound. The same amount may be 2 to 150 parts by mass. By setting the addition amount to 1 part by mass or more, it becomes easier to obtain good reactivity, and by setting it to 200 parts by mass or less, it becomes easier to further suppress the precipitation of crystals and the decrease in gel density.

  The hydrolysis in the sol generation step depends on the type and amount of the silicon compound, polysiloxane compound, silica particles, acid catalyst, surfactant, etc. in the mixed solution, but for example, in a temperature environment of 20 to 60 ° C. May be performed for 10 minutes to 24 hours, or may be performed for 5 minutes to 8 hours under a temperature environment of 50 to 60 ° C. Thereby, the hydrolyzable functional groups in the silicon compound and the polysiloxane compound are sufficiently hydrolyzed, and the hydrolysis product of the silicon compound and the hydrolysis product of the polysiloxane compound can be more reliably obtained.

  However, when the thermohydrolyzable compound is added to the solvent, the temperature environment of the sol generation step may be adjusted to a temperature at which hydrolysis of the thermohydrolyzable compound is suppressed and gelation of the sol is suppressed. .. The temperature at this time may be any temperature as long as it can suppress the hydrolysis of the thermohydrolyzable compound. For example, when urea is used as the thermally hydrolyzable compound, the temperature environment of the sol generation step can be set to 0 to 40 ° C, but may be 10 to 30 ° C.

(Wet gel formation process)
In the wet gel production step, for example, the sol obtained in the sol production step is gelated and then aged to produce a wet gel. In this step, a base catalyst can be used to promote gelation.

  As the base catalyst, alkali metal hydroxides such as lithium hydroxide, sodium hydroxide, potassium hydroxide and cesium hydroxide; ammonium compounds such as ammonium hydroxide, ammonium fluoride, ammonium chloride and ammonium bromide; sodium metaphosphate. , Basic sodium phosphates such as sodium pyrophosphate, sodium polyphosphate; allylamine, diallylamine, triallylamine, isopropylamine, diisopropylamine, ethylamine, diethylamine, triethylamine, 2-ethylhexylamine, 3-ethoxypropylamine, diisobutylamine, 3 -(Diethylamino) propylamine, di-2-ethylhexylamine, 3- (dibutylamino) propylamine, tetramethylethylenediamine, t-butylamine, sec- Aliphatic amines such as tylamine, propylamine, 3- (methylamino) propylamine, 3- (dimethylamino) propylamine, 3-methoxyamine, dimethylethanolamine, methyldiethanolamine, diethanolamine, triethanolamine; morpholine, N -Methylmorpholine, 2-methylmorpholine, piperazine and its derivatives, piperidine and its derivatives, imidazole and its derivatives, and other nitrogen-containing heterocyclic compounds. Among these, ammonium hydroxide (ammonia water) has high volatility and is unlikely to remain in the dried airgel composite, so that it does not impair the water resistance and is further excellent in economical efficiency. The above base catalysts may be used alone or in combination of two or more.

  By using a base catalyst, it is possible to accelerate the dehydration condensation reaction, dealcoholization condensation reaction, or the reaction of both of the silicon compound, the polysiloxane compound, and the like in the sol, and the silica particles, and to prevent gelation of the sol. It can be done in a shorter time. Further, this makes it possible to obtain a wet gel having higher strength (rigidity). In particular, ammonia has high volatility and is unlikely to remain in the airgel composite. Therefore, by using ammonia as the base catalyst, an airgel composite having more excellent water resistance can be obtained.

  The addition amount of the base catalyst can be, for example, 0.5 to 5 parts by mass with respect to 100 parts by mass of the total amount of the silicon compound and the polysiloxane compound, but may be 1 to 4 parts by mass. By setting the addition amount to 0.5 parts by mass or more, gelation can be performed in a shorter time, and by setting the addition amount to 5 parts by mass or less, deterioration of water resistance can be further suppressed.

  The gelation of the sol in the wet gel formation step may be performed in a closed container so that the solvent and the base catalyst do not volatilize. The gelling temperature may be, for example, 30 to 90 ° C, but may be 40 to 80 ° C. By setting the gelling temperature to 30 ° C. or higher, gelation can be performed in a shorter time, and a wet gel having higher strength (rigidity) can be obtained. Further, by setting the gelling temperature to 90 ° C. or lower, it becomes easy to suppress the volatilization of the solvent (particularly alcohols), so that the gelation can be performed while suppressing the volume shrinkage.

  The aging in the wet gel forming step may be performed in a closed container so that the solvent and the base catalyst do not volatilize. By aging, the binding of the components constituting the wet gel is strengthened, and as a result, a wet gel having high strength (rigidity) sufficient to suppress shrinkage during drying can be obtained. The aging temperature may be, for example, 30 to 90 ° C, but may be 40 to 80 ° C. By setting the aging temperature to 30 ° C or higher, a wet gel having higher strength (rigidity) can be obtained, and by setting the aging temperature to 90 ° C or lower, it becomes easy to suppress the volatilization of the solvent (especially alcohols). Therefore, gelation can be achieved while suppressing volume shrinkage.

  Since it is often difficult to determine when the sol has finished gelling, gelation of the sol and subsequent aging may be carried out continuously by a series of operations.

  The gelation time and the aging time are different depending on the gelation temperature and the aging temperature, but in the present embodiment, since silica particles are contained in the sol, the gelation time is particularly longer than that of the conventional airgel production method. Can be shortened. The reason for this is presumed to be that the silanol group or reactive group of the silicon compound, the polysiloxane compound, etc. in the sol forms a hydrogen bond or a chemical bond with the silanol group of the silica particles. The gelling time may be, for example, 10 to 120 minutes, but may be 20 to 90 minutes. By setting the gelling time to 10 minutes or longer, it is easy to obtain a homogeneous wet gel, and by setting it to 120 minutes or shorter, the washing and solvent replacement steps described later and the drying step can be simplified. The total time of the gelation time and the aging time can be, for example, 4 to 480 hours in the entire steps of gelation and aging, but may be 6 to 120 hours. By setting the total of the gelling time and the aging time to 4 hours or more, a wet gel having higher strength (rigidity) can be obtained, and by setting it to 480 hours or less, the effect of aging can be more easily maintained.

  To reduce the density of the obtained airgel composite or to increase the average pore size, the gelation temperature and the aging temperature are increased within the above range, and the total time of the gelation time and the aging time is increased within the above range. May be. Further, in order to increase the density of the obtained airgel composite or to reduce the average pore size, the gelation temperature and the aging temperature are lowered within the above range, and the total time of the gelation time and the aging time is within the above range. May be shortened with.

(Washing and solvent replacement steps)
The washing and solvent replacement steps include a step of washing the wet gel obtained by the wet gel generation step (washing step) and a step of replacing the washing solution in the wet gel with a solvent suitable for the drying conditions (drying step described later). This is a step including (solvent replacement step). The washing and solvent replacement steps can be performed in a form in which only the solvent replacement step is performed without performing the step of washing the wet gel, but unreacted substances in the wet gel, impurities such as byproducts are reduced, and The wet gel may be washed from the viewpoint of enabling production of a highly pure airgel composite. In addition, in this embodiment, since the silica particles are contained in the gel, the solvent replacement step is not always essential as described later.

  In the washing step, the wet gel obtained in the wet gel generating step is washed. The washing can be repeated using, for example, water or an organic solvent. At this time, the heating efficiency can be improved by heating.

  As the organic solvent, for example, methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, acetone, methyl ethyl ketone, 1,2-dimethoxyethane, acetonitrile, hexane, toluene, diethyl ether, chloroform, ethyl acetate, tetrahydrofuran, Various organic solvents such as methylene chloride, N, N-dimethylformamide, dimethylsulfoxide, acetic acid and formic acid can be used. The above organic solvents may be used alone or in combination of two or more.

  In the solvent replacement step described below, a solvent having a low surface tension can be used in order to suppress shrinkage of the gel due to drying. However, low surface tension solvents generally have very low mutual solubility with water. Therefore, when a low surface tension solvent is used in the solvent replacement step, examples of the organic solvent used in the washing step include hydrophilic organic solvents having high mutual solubility in both water and the low surface tension solvent. The hydrophilic organic solvent used in the washing step can serve as a preliminary replacement for the solvent replacement step. Among the above organic solvents, examples of the hydrophilic organic solvent include methanol, ethanol, 2-propanol, acetone and methyl ethyl ketone. In addition, methanol, ethanol, methyl ethyl ketone and the like are excellent in economical efficiency.

  The amount of water or the organic solvent used in the washing step can be an amount that can be washed by sufficiently replacing the solvent in the wet gel. The amount can be, for example, 3 to 10 times the amount of the wet gel. The washing can be repeated until the water content in the wet gel after washing becomes 10% by mass or less based on the mass of silica.

  The temperature environment in the washing step can be set to a temperature equal to or lower than the boiling point of the solvent used for washing. For example, when methanol is used, it can be heated at about 30 to 60 ° C.

  In the solvent replacement step, the solvent of the washed wet gel is replaced with a predetermined replacement solvent in order to suppress shrinkage in the drying step described later. At this time, the replacement efficiency can be improved by heating. Specific examples of the displacing solvent include a solvent having a low surface tension, which will be described later, when the solvent for drying is dried under atmospheric pressure at a temperature lower than the critical point of the solvent used for the drying. On the other hand, in the case of performing supercritical drying, examples of the solvent for substitution include ethanol, methanol, 2-propanol, dichlorodifluoromethane, carbon dioxide, and the like, or a solvent in which two or more kinds thereof are mixed.

  Examples of the low surface tension solvent include those having a surface tension at 20 ° C. of 30 mN / m or less. The surface tension may be 25 mN / m or less, or 20 mN / m or less. Examples of the low surface tension solvent include pentane (15.5), hexane (18.4), heptane (20.2), octane (21.7), 2-methylpentane (17.4), 3- Aliphatic hydrocarbons such as methylpentane (18.1), 2-methylhexane (19.3), cyclopentane (22.6), cyclohexane (25.2), 1-pentene (16.0); benzene (28.9), toluene (28.5), m-xylene (28.7), p-xylene (28.3) and other aromatic hydrocarbons; dichloromethane (27.9), chloroform (27.2). ), Carbon tetrachloride (26.9), 1-chloropropane (21.8), 2-chloropropane (18.1) and the like halogenated hydrocarbons; ethyl ether (17.1), propyl ether (20.5). ), Aesop Ethers such as pill ether (17.7), butyl ethyl ether (20.8), 1,2-dimethoxyethane (24.6); acetone (23.3), methyl ethyl ketone (24.6), methyl propyl ketone (25.1), ketones such as diethyl ketone (25.3); methyl acetate (24.8), ethyl acetate (23.8), propyl acetate (24.3), isopropyl acetate (21.2), Examples thereof include esters such as isobutyl acetate (23.7) and ethyl butyrate (24.6) (inside the parentheses, the surface tension at 20 ° C. is shown, and the unit is [mN / m]). Of these, aliphatic hydrocarbons (hexane, heptane, etc.) have low surface tension and are excellent in work environment. Further, among these, by using a hydrophilic organic solvent such as acetone, methyl ethyl ketone, or 1,2-dimethoxyethane, it can be used also as the organic solvent in the above-mentioned washing step. Among these, those having a boiling point of 100 ° C. or less at normal pressure may be used because they are easier to dry in the drying step described later. You may use the said solvent individually or in mixture of 2 or more types.

  The amount of the solvent used in the solvent replacement step can be an amount sufficient to replace the solvent in the wet gel after washing. The amount can be, for example, 3 to 10 times the amount of the wet gel.

  The temperature environment in the solvent replacement step can be a temperature equal to or lower than the boiling point of the solvent used for the replacement, and for example, when heptane is used, it can be heated at about 30 to 60 ° C.

  In addition, in this embodiment, since the silica particles are contained in the gel, the solvent replacement step is not always essential as described above. The inferred mechanism is as follows. That is, in the past, in order to suppress shrinkage in the drying step, the solvent of the wet gel was replaced with a predetermined displacing solvent (a solvent having a low surface tension), but in the present embodiment, the silica particles have a three-dimensional network shape. By functioning as a support of the skeleton, the skeleton is supported and the shrinkage of the gel in the drying step is suppressed. Therefore, it is considered that the gel can be directly subjected to the drying step without replacing the solvent used for washing. As described above, in the present embodiment, it is possible to simplify the washing and solvent replacement steps to the drying step. However, the present embodiment does not exclude performing the solvent replacement step.

(Drying process)
In the drying step, the washed and solvent-substituted wet gel (if necessary) is dried. Thereby, the airgel composite can be finally obtained.

  The drying method is not particularly limited, and known atmospheric drying, supercritical drying or freeze drying can be used. Of these, atmospheric drying or supercritical drying can be used from the viewpoint of easily producing a low-density airgel composite. From the viewpoint of being able to produce at low cost, atmospheric drying can be used. In the present embodiment, normal pressure means 0.1 MPa (atmospheric pressure).

  As described above, the drying step is performed, for example, at a temperature below the critical point of the solvent used for drying and under atmospheric pressure. The drying temperature depends on the type of solvent that has been replaced (the solvent used for washing when solvent replacement is not performed), but especially when drying at high temperatures accelerates the evaporation rate of the solvent and causes large cracks in the gel. In view of the fact that there is, for example, the temperature may be 20 to 150 ° C. The drying temperature may be 60 to 120 ° C. The drying time may vary depending on the volume of the wet gel and the drying temperature, but may be, for example, 4 to 120 hours. In addition, in the present embodiment, to accelerate the drying by applying a pressure below the critical point within a range that does not impair the productivity is also included in the atmospheric drying.

  The drying method may be, for example, supercritical drying. Supercritical drying can be performed by a known method. Examples of the supercritical drying method include a method of removing the solvent at a temperature and a pressure not lower than the critical point of the solvent contained in the wet gel. Alternatively, as a method of supercritical drying, by dipping the wet gel in liquefied carbon dioxide under conditions of, for example, 20 to 25 ° C. and 5 to 20 MPa, all or part of the solvent contained in the wet gel. After substituting the carbon dioxide with carbon dioxide having a lower critical point than the solvent, carbon dioxide may be used alone or a mixture of carbon dioxide and the solvent may be removed.

  The airgel composite obtained by such atmospheric pressure drying or supercritical drying may be further dried under atmospheric pressure at 105 to 200 ° C. for about 0.5 to 2 hours. This makes it easier to obtain an airgel composite having a low density and small pores. The additional drying may be performed at 150 to 200 ° C. under normal pressure.

<Supporting member with airgel composite>
The support member with an airgel composite according to the present embodiment includes the airgel composite described above and a support member carrying the airgel composite. With such a support member with an airgel composite, it is possible to exhibit high heat insulation and excellent flexibility.

  Examples of the supporting member include a film-shaped supporting member, a sheet-shaped supporting member, a foil-shaped supporting member, and a porous supporting member.

  The film-shaped support member is formed by molding a polymer raw material into a thin film, and examples thereof include organic films such as PET and polyimide, and glass films (including metal vapor deposition films).

  The sheet-shaped support member is formed by molding at least one kind of fibrous raw material selected from the group consisting of organic, inorganic and metal, and includes paper, non-woven fabric (including glass mat), organic fiber cloth, glass cloth and the like. Can be mentioned.

  The foil-shaped support member is formed by forming a metal raw material into a thin film, and examples thereof include aluminum foil and copper foil.

  The porous support member has a porous structure in which at least one selected from the group consisting of organic, inorganic and metal is used as a raw material, and a porous organic material (for example, polyurethane foam), a porous inorganic material (for example, , A zeolite sheet), a porous metal material (for example, a porous metal sheet, a porous aluminum sheet) and the like.

  The support member with an airgel composite can be produced, for example, as follows. First, a sol is prepared according to the sol generation process described above. This is applied onto a supporting member using a film applicator or the like, or after impregnating the supporting member, a film-like supporting member with a wet gel is obtained according to the above-described wet gel generating step. Then, the obtained film-like support member with a wet gel is washed according to the above-mentioned washing and solvent replacement steps and after solvent replacement (as necessary), and then dried according to the above-mentioned drying step, thereby providing a support member with an airgel composite. Can be obtained.

  The thickness of the airgel composite formed on the film-shaped support member or the foil-shaped support member can be, for example, 1 to 200 μm, but may be 10 to 100 μm or 30 to 80 μm. When the thickness is 1 μm or more, good heat insulating properties are easily obtained, and when the thickness is 200 μm or less, flexibility is easily obtained.

  The airgel composite of the present embodiment described above has excellent heat insulating properties and flexibility that are difficult to achieve with conventional airgel. Particularly excellent flexibility has made it possible to form a layer of an airgel composite on a film-shaped support member and a foil-shaped support member, which have been difficult to achieve in the past. Therefore, the support member with the airgel composite of the present embodiment has high heat insulation and excellent flexibility. Even in the mode in which the sheet-shaped support member and the porous support member are impregnated with the sol, it is possible to suppress the powder drop of the airgel composite during handling after drying.

  Due to such advantages, the airgel composite and the support member with the airgel composite according to the present embodiment can be applied to applications such as a heat insulating material in the fields of construction, automobiles, home appliances, semiconductors, industrial equipment, and the like. Further, the airgel composite of the present embodiment can be used not only as a heat insulating material but also as an additive for paints, cosmetics, an anti-blocking agent, a catalyst carrier, and the like.

<Insulation material>
The heat insulating material of the present embodiment includes the airgel composite described above, and has high heat insulating properties and excellent flexibility. The airgel composite obtained by the above-described method for producing an airgel composite can be used as it is (processed into a predetermined shape if necessary) to serve as a heat insulating material.

  The present disclosure will now be described in more detail with reference to the following examples, which are not intended to limit the present disclosure.

(Example 1)
[Wet gel, airgel composite]
60.0 parts by mass of methyltrimethoxysilane LS-530 (manufactured by Shin-Etsu Chemical Co., Ltd., product name: abbreviated as "MTMS" hereinafter) as a silicon compound and dimethyldimethoxysilane LS-520 (manufactured by Shin-Etsu Chemical Co., Ltd., product Name: 40.0 parts by mass of “DMDMS” hereinafter, and PL-2L as a silica particle dispersion liquid (hereinafter, sometimes referred to as “silica particle-containing raw material”) (details of PL-2L are shown in Table 1). The same applies to the silica particle-containing raw material) 100.0 parts by mass, 40.0 parts by mass of water and 80.0 parts by mass of methanol, and 0.10 parts by mass of acetic acid as an acid catalyst is added to the mixture. Sol 2 was obtained by reacting at 2 ° C. for 2 hours. 40.0 parts by mass of aqueous ammonia having a concentration of 5% as a base catalyst was added to the obtained sol 1, gelled at 60 ° C., and then aged at 80 ° C. for 24 hours to obtain wet gel 1.

  Then, the obtained wet gel 1 was immersed in 2500.0 parts by mass of methanol and washed at 60 ° C. for 12 hours. This washing operation was repeated 3 times while replacing with fresh methanol. Next, the washed wet gel was immersed in 2500.0 parts by mass of heptane, which is a low surface tension solvent, and solvent replacement was performed at 60 ° C. for 12 hours. This solvent replacement operation was performed 3 times while replacing with new heptane. The washed and solvent-substituted wet gel is dried under normal pressure at 40 ° C. for 96 hours, and then further dried at 150 ° C. for 2 hours to obtain the above-described general formulas (6) and (7). An airgel composite 1 having a structure was obtained.

[Supporting member with airgel composite]
-Film-shaped support member with airgel composite The above sol 1 was applied to a polyethylene terephthalate film of 300 mm x (horizontal) 270 mm x (thickness) of 12 µm so that the thickness after gelation was 40 µm (tester). It was applied using Sangyo Co., Ltd., PI-1210), gelled at 60 ° C. for 3 hours, and then aged at 80 ° C. for 24 hours to obtain a film-like support member 1 with a wet gel.

  Then, the obtained film-like supporting member 1 with a wet gel was immersed in 100 mL of methanol and washed at 60 ° C. for 2 hours. Next, the washed film-like support member with a wet gel was immersed in 100 mL of methyl ethyl ketone, and the solvent was replaced at 60 ° C. for 2 hours. This solvent replacement operation was performed twice while exchanging new methyl ethyl ketone. The washed and solvent-substituted film-like support member with a wet gel was dried at 120 ° C. for 6 hours under normal pressure to obtain a film-like support member 1 with an airgel composite.

-Sheet-shaped support member with airgel composite The above sol 1 was put on E glass cloth of (length) 300 mm x (width) 270 mm x (thickness) 100 µm so that the thickness of the sheet-shaped support member after gelation was 120 µm. After impregnation and gelation at 60 ° C. for 3 hours, it was aged at 80 ° C. for 24 hours to obtain a sheet-shaped supporting member 1 with a wet gel.

  Then, the obtained sheet-shaped supporting member 1 with a wet gel was immersed in 300 mL of methanol and washed at 60 ° C. for 2 hours. Next, the washed sheet-shaped supporting member with a wet gel was immersed in 300 mL of methyl ethyl ketone, and the solvent was replaced at 60 ° C. for 2 hours. This solvent replacement operation was performed twice while exchanging new methyl ethyl ketone. The sheet-like support member with a wet gel, which had been washed and subjected to solvent substitution, was dried at 120 ° C. for 8 hours under normal pressure to obtain a sheet-like support member 1 with an airgel composite.

-Foil-shaped support member with airgel composite: The above-mentioned sol 1 was applied to an aluminum foil of (length) 300 mm x (width) 270 mm x (thickness) 12 µm using a film applicator so that the thickness after gelling would be 40 µm. Then, after gelling at 60 ° C. for 3 hours, it was aged at 80 ° C. for 24 hours to obtain a foil-like support member 1 with a wet gel.

  Thereafter, the obtained foil-like support member with a wet gel 1 was immersed in 100 mL of methanol and washed at 60 ° C. for 2 hours. Next, the washed foil-like support member with a wet gel was immersed in 100 mL of methyl ethyl ketone, and the solvent was replaced at 60 ° C. for 2 hours. This solvent replacement operation was performed twice while exchanging new methyl ethyl ketone. The washed and solvent-replaced foil-shaped support member with a wet gel was dried at 120 ° C. for 6 hours under normal pressure to obtain a foil-shaped support member with an airgel composite 1.

Porous support member with airgel composite The above sol 1 was applied to a soft urethane foam of (length) 300 mm x (width) 270 mm x (thickness) 10 mm so that the thickness of the porous support member after gelation was 10 mm. After impregnation and gelation at 60 ° C. for 3 hours, aging was carried out at 80 ° C. for 24 hours to obtain a porous support member 1 with a wet gel.

  Then, the obtained porous support member 1 with a wet gel was immersed in 300 mL of methanol and washed at 60 ° C. for 2 hours. Next, the washed porous support member with a wet gel was immersed in 300 mL of methyl ethyl ketone, and the solvent was replaced at 60 ° C. for 2 hours. This solvent replacement operation was performed twice while exchanging new methyl ethyl ketone. The washed and solvent-substituted porous support member with a wet gel was dried at 120 ° C. for 10 hours under normal pressure to obtain a porous support member 1 with an airgel composite.

(Example 2)
[Wet gel, airgel composite]
100.0 parts by mass of PL-2L as a silica particle-containing raw material, 100.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, and cetyltrimethylammonium bromide as a cationic surfactant (Wako Pure Chemical Industries, Ltd. Co., Ltd .: abbreviated as "CTAB" hereinafter) (20.0 parts by mass) and urea (120.0 parts by mass) as a thermohydrolyzable compound are mixed, and MTMS (70.0 parts by mass) and DDMMS (30) are mixed as a silicon compound. 0.0 parts by mass was added, and the mixture was reacted at 25 ° C. for 2 hours to obtain Sol 2. The obtained sol 2 was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 2. Thereafter, the obtained wet gel 2 was used to obtain an airgel composite 2 having a structure represented by the general formulas (6) and (7) in the same manner as in Example 1.

[Supporting member with airgel composite]
Using the sol 2, in the same manner as in Example 1, a film-shaped support member 2 with an airgel composite, a sheet-shaped support member 2 with an airgel composite, a foil-shaped support member 2 with an airgel composite, and a porous body with an airgel composite. The quality support member 2 was obtained.

(Example 3)
[Wet gel, airgel composite]
200.0 parts by mass of PL-5 as a raw material containing silica particles, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant, and 120% by mass of urea as a thermohydrolyzable compound. 0 parts by mass were mixed, 60.0 parts by mass of MTMS and 40.0 parts by mass of DMDMS as a silicon compound were added thereto, and reacted at 25 ° C. for 2 hours to obtain Sol 3. The obtained sol 3 was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 3. Thereafter, the obtained wet gel 3 was used to obtain an airgel composite 3 having a structure represented by the general formulas (6) and (7) in the same manner as in Example 1.

[Supporting member with airgel composite]
Using the sol 3 in the same manner as in Example 1, a film-like support member 3 with an airgel composite, a sheet-like support member 3 with an airgel composite, a foil-like support member 3 with an airgel composite, and a porous body with an airgel composite. A quality support member 3 was obtained.

(Example 4)
[Wet gel, airgel composite]
PL-2L as a silica particle-containing raw material is 100.0 parts by mass, water is 100.0 parts by mass, acetic acid is 0.10 parts by mass as an acid catalyst, CTAB is 20.0 parts by mass as a cationic surfactant, and hot water is added thereto. 120.0 parts by mass of urea was mixed as a decomposable compound, 60.0 parts by mass of MTMS and 20.0 parts by mass of DMDMS as a silicon compound, and 20.0 parts by mass of polysiloxane compound A as a polysiloxane compound were mixed with urea. In addition, sol 4 was obtained by reacting at 25 ° C. for 2 hours. The obtained sol 4 was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 4. Thereafter, the obtained wet gel 4 was used to obtain an airgel composite 4 having a structure represented by the general formulas (3), (6) and (7) in the same manner as in Example 1.

  The "polysiloxane compound A" was synthesized as follows. First, in a 1-liter three-necked flask equipped with a stirrer, a thermometer, and a Dimroth condenser, 100.0 parts by mass of hydroxy-terminated dimethylpolysiloxane "XC96-723" (manufactured by Momentive, Inc., product name), methyl 181.3 parts by mass of trimethoxysilane and 0.50 parts by mass of t-butylamine were mixed and reacted at 30 ° C. for 5 hours. Then, this reaction liquid was heated at 140 ° C. for 2 hours under a reduced pressure of 1.3 kPa to remove a volatile matter, thereby obtaining a bifunctional alkoxy-modified polysiloxane compound having both ends (polysiloxane compound A).

[Supporting member with airgel composite]
Using the sol 4, in the same manner as in Example 1, a film-shaped support member 4 with an airgel composite, a sheet-shaped support member 4 with an airgel composite, a foil-shaped support member 4 with an airgel composite, and a porous body with an airgel composite. A quality support member 4 was obtained.

(Example 5)
[Wet gel, airgel composite]
100.0 parts by mass of HL-3L as a silica particle-containing raw material, 100.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant, and hot hydration. 120.0 parts by mass of urea was mixed as a decomposable compound, 60.0 parts by mass of MTMS and 20.0 parts by mass of DMDMS as a silicon compound, and 20.0 parts by mass of polysiloxane compound A as a polysiloxane compound were mixed with urea. In addition, sol 5 was obtained by reacting at 25 ° C. for 2 hours. The obtained sol 5 was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 5. Thereafter, the obtained wet gel 5 was used to obtain an airgel composite 5 having a structure represented by the general formulas (3), (6) and (7) in the same manner as in Example 1.

[Supporting member with airgel composite]
Using the sol 5, in the same manner as in Example 1, a film-shaped support member 5 with an airgel composite, a sheet-shaped support member 5 with an airgel composite, a foil-shaped support member 5 with an airgel composite, and a porous body with an airgel composite. A quality support member 5 was obtained.

(Example 6)
[Wet gel, airgel composite]
As a silica particle-containing raw material, 143.0 parts by mass of ST-OZL-35, 57.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant, and 120.0 parts by mass of urea was mixed as a thermally hydrolyzable compound, 60.0 parts by mass of MTMS and 20.0 parts by mass of DMDMS as a silicon compound, and 20.0 parts of polysiloxane compound B as a polysiloxane compound were mixed with urea. By mass, sol 6 was obtained by reacting at 25 ° C. for 2 hours. The obtained sol 6 was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 6. Thereafter, the obtained wet gel 6 was used to obtain an airgel composite 6 having a structure represented by the general formulas (2), (6) and (7) in the same manner as in Example 1.

  The "polysiloxane compound B" was synthesized as follows. First, in a 1-liter three-necked flask equipped with a stirrer, a thermometer, and a Dimroth condenser, 100.0 parts by mass of XC96-723, 202.6 parts by mass of tetramethoxysilane, and 0. 50 parts by mass were mixed and reacted at 30 ° C. for 5 hours. Then, this reaction liquid was heated at 140 ° C. for 2 hours under a reduced pressure of 1.3 kPa to remove volatile matter, thereby obtaining a trifunctional alkoxy-modified polysiloxane compound (polysiloxane compound B) at both ends.

[Supporting member with airgel composite]
Using the sol 6, in the same manner as in Example 1, a film-shaped support member 6 with an airgel composite, a sheet-shaped support member 6 with an airgel composite, a foil-shaped support member 6 with an airgel composite, and a porous structure with an airgel composite. A quality support member 6 was obtained.

(Comparative Example 1)
[Wet gel, aerogel]
200.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant and 120.0 parts by mass of urea as a thermally hydrolyzable compound are mixed, 100.0 parts by mass of MTMS as a silicon compound was added thereto and reacted at 25 ° C. for 2 hours to obtain Sol 1C. The obtained sol 1C was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 1C. Then, using the obtained wet gel 1C, an airgel 1C was obtained in the same manner as in Example 1.

[Supporting member with airgel]
Using the sol 1C, in the same manner as in Example 1, a film-like support member with airgel 1C, a sheet-like support member with airgel 1C, a foil-like support member with airgel 1C, and a porous support member with airgel 1C were obtained.

(Comparative example 2)
[Wet gel, aerogel]
200.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant and 120.0 parts by mass of urea as a thermally hydrolyzable compound are mixed, Then, 80.0 parts by mass of MTMS and 20.0 parts by mass of DMDMS as a silicon compound were added, and reacted at 25 ° C. for 2 hours to obtain Sol 2C. The obtained sol 2C was gelated at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain a wet gel 2C. Then, using the obtained wet gel 2C, an airgel 2C was obtained in the same manner as in Example 1.

[Supporting member with airgel]
Using the sol 2C, in the same manner as in Example 1, a film-like support member with airgel 2C, a sheet-like support member with airgel 2C, a foil-like support member with airgel 2C, and a porous support member with airgel 2C were obtained.

(Comparative example 3)
[Wet gel, aerogel]
200.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant and 120.0 parts by mass of urea as a thermally hydrolyzable compound are mixed, 70.0 parts by mass of MTMS and 30.0 parts by mass of DMDMS as a silicon compound were added thereto and reacted at 25 ° C. for 2 hours to obtain Sol 3C. The obtained sol 3C was gelled at 60 ° C. and then aged at 80 ° C. for 24 hours to obtain wet gel 3C. Then, using the obtained wet gel 3C, an airgel 3C was obtained in the same manner as in Example 1.

[Supporting member with airgel]
Using the sol 3C, in the same manner as in Example 1, a film-like support member with airgel 3C, a sheet-like support member with airgel 3C, a foil-like support member with airgel 3C, and a porous support member with airgel 3C were obtained.

(Comparative example 4)
As a silica particle-containing raw material, 143.0 parts by mass of ST-S, 57.0 parts by mass of water, 0.10 parts by mass of acetic acid as an acid catalyst, 20.0 parts by mass of CTAB as a cationic surfactant, and hydrolyzed water. 120.0 parts by mass of urea was mixed as a decomposable compound, 60.0 parts by mass of MTMS and 20.0 parts by mass of DMDMS as a silicon compound, and 20.0 parts by mass of polysiloxane compound B as a polysiloxane compound. In addition, when the mixture was reacted at 25 ° C for 2 hours, gelation occurred and a wet gel could not be prepared.

  Table 1 shows the modes of the silica particle-containing raw materials in each Example and Comparative Example. Table 2 collectively shows the drying method, the types and addition amounts of Si raw materials (silicon compounds and polysiloxane compounds), and the addition amounts of the silica particle-containing raw materials in each example and comparative example.

  The pH of the silica particle-containing raw material was measured using a pH meter (manufactured by Denki Kagaku Keiki Co., Ltd., model number: PHL-40). The measured pH values are standard buffer solutions (phthalate pH buffer solution pH: 4.01 (25 ° C), neutral phosphate pH buffer solution pH: 6.86 (25 ° C), borate pH buffer solution. After performing three-point calibration using a liquid pH: 9.18 (25 ° C.), an electrode was placed in the dispersion liquid, and a value after 2 minutes or more to stabilize the temperature was adopted.

[Various evaluations]
Regarding the wet gel, the airgel composite and the support member with the airgel composite obtained in each example, and the wet gel, the airgel and the support member with the airgel obtained in each comparative example (excluding Comparative Example 4), the following conditions Was measured or evaluated according to The gelling time in the wet gel formation step, the state of the airgel composite and the airgel in the atmospheric drying of the methanol-substituted gel, and the evaluation results of the thermal conductivity, the compression elastic modulus, the density and the porosity of the airgel composite and the airgel are summarized. Table 3 summarizes the evaluation results of the 180 ° bending test of the support member with the airgel composite and the support member with the airgel.

(1) Measurement of gelation time 30 mL of the sol obtained in each of the examples and comparative examples was transferred to a 100 mL PP closed container to obtain a measurement sample. Next, using a constant temperature dryer "DVS402" (manufactured by Yamato Scientific Co., Ltd., product name) set at 60 ° C, the time from the introduction of the measurement sample to the gelation was measured.

(2) State of Airgel Complex and Airgel in Normal Pressure Drying of Methanol-Substituted Gel 30.0 parts by mass of the wet gel obtained in each Example and Comparative Example is immersed in 150.0 parts by mass of methanol, and then at 60 ° C. It was washed for 12 hours. This washing operation was repeated 3 times while replacing with fresh methanol. Next, the washed wet gel was processed into a size of 100 mm × 100 mm × 100 mm by using a blade having a blade angle of about 20 to 25 degrees to obtain a sample before drying. The obtained pre-dried sample was dried at 60 ° C. for 2 hours and 100 ° C. for 3 hours using a thermostat “SPH (H) -202” (manufactured by ESPEC Co., Ltd.) with a safety door, and then further dried at 150 ° C. A sample was obtained after drying by drying at 0 ° C. for 2 hours (particularly the solvent evaporation rate etc. was not controlled). Here, the volumetric shrinkage rate SV of the sample before and after drying was determined by the following equation. Then, when the volume shrinkage rate SV was 5% or less, it was evaluated as "no shrinkage", and when it was 5% or more, it was evaluated as "shrinkage".
SV = (V ₀ −V ₁ ) / V ₀ × 100
In the formula, V ₀ represents the volume of the sample before drying, and V ₁ represents the volume of the sample after drying.

(3) Measurement of thermal conductivity Using a blade having a blade angle of about 20 to 25 degrees, the airgel composite and the airgel were processed into a size of 150 mm × 150 mm × 100 mm to obtain a measurement sample. Next, in order to secure the parallelism of the surfaces, sanding of # 1500 or more was performed as needed. The obtained measurement sample was dried at 100 ° C. for 30 minutes under atmospheric pressure using a constant temperature dryer “DVS402” (manufactured by Yamato Scientific Co., Ltd.) before measuring the thermal conductivity. Then, the measurement sample was transferred into a desiccator and cooled to 25 ° C. Thus, a measurement sample for measuring thermal conductivity was obtained.

The thermal conductivity was measured using a steady-state method thermal conductivity measuring device “HFM436 Lambda” (manufactured by NETZSCH, product name). The measurement conditions were an atmospheric pressure and an average temperature of 25 ° C. The measurement sample obtained as described above was sandwiched between the upper and lower heaters with a load of 0.3 MPa, the temperature difference ΔT was set to 20 ° C., and a guard heater was used to adjust the heat flow to a one-dimensional heat flow. The upper surface temperature and the lower surface temperature were measured. Then, the thermal resistance R _S of the measurement sample was obtained from the following equation.
R _S = N ((T _U −T _L ) / Q) −R _O
In the formula, T _U represents the upper surface temperature of the measurement sample, T _L represents the lower surface temperature of the measurement sample, R _O represents the contact thermal resistance at the upper and lower interfaces, and Q represents the heat flux meter output. It should be noted that N is a proportional coefficient and was obtained in advance using a calibration sample.

The thermal conductivity λ of the measurement sample was calculated from the obtained thermal resistance R _S by the following equation.
λ = d / R _S
In the formula, d represents the thickness of the measurement sample.

(4) Measurement of compression elastic modulus Using a blade having a blade angle of about 20 to 25 degrees, the airgel composite and the airgel were processed into a 7.0 mm square cube (dice shape) to obtain a measurement sample. Next, in order to ensure the parallelism of the surfaces, the measurement sample was shaped with sandpaper of # 1500 or more as needed. Prior to measurement, the obtained measurement sample was dried at 100 ° C. for 30 minutes under atmospheric pressure using a constant temperature dryer “DVS402” (manufactured by Yamato Scientific Co., Ltd.). Then, the measurement sample was transferred into a desiccator and cooled to 25 ° C. Thus, a measurement sample for measuring the compression elastic modulus was obtained.

As a measuring device, a small bench tester "EZTest" (manufactured by Shimadzu Corporation, product name) was used. A load cell of 500N was used. Further, an upper platen (φ20 mm) and a lower platen (φ118 mm) made of stainless steel were used as a jig for compression measurement. The measurement sample was set between the upper platen and the lower platen arranged in parallel, and compression was performed at a speed of 1 mm / min. The measurement temperature was 25 ° C., and the measurement was terminated when a load of more than 500 N was applied or when the measurement sample was destroyed. Here, the strain ε was obtained from the following equation.
ε = Δd / d1
In the formula, Δd represents the displacement (mm) of the thickness of the measurement sample due to the load, and d1 represents the thickness (mm) of the measurement sample before applying the load.
Further, the compressive stress σ (MPa) was obtained from the following equation.
σ = F / A
In the formula, F represents the compressive force (N), and A represents the cross-sectional area (mm ² ) of the measurement sample before applying a load.

The compression elastic modulus E (MPa) was obtained from the following equation in the compression force range of 0.1 to 0.2N.
E = ([sigma] _{2- [} sigma] ₁ ) / ([epsilon] _{2- [} epsilon] ₁ )
In the formula, σ ₁ indicates a compressive stress (MPa) measured at a compressive force of 0.1 N, σ ₂ indicates a compressive stress (MPa) measured at a compressive force of 0.2 N, and ε ₁ indicates a compressive stress. The compressive strain measured at σ ₁ is shown, and ε ₂ is the compressive strain measured at compressive stress σ ₂ .

(5) Measurement of Density and Porosity The density and porosity of three-dimensional mesh-like pores (through holes) in the airgel composite and airgel were measured by the mercury porosimetry method according to DIN66133. The measuring temperature was room temperature (25 ° C.), and Autopore IV9520 (manufactured by Shimadzu Corporation, product name) was used as a measuring device.

(6) Bending resistance test The airgel composite supporting member and the airgel supporting member obtained in each of the examples and comparative examples were processed into a width of 50 mm, and according to JIS K5600-1, the airgel composite layer side mandrel. The test was conducted. As the mandrel tester, the one manufactured by Toyo Seiki Seisakusho was used. The presence or absence of cracks and peeling on the side of the airgel composite and the airgel layer when bent 180 ° at a mandrel radius of 1 mm was visually evaluated. Then, those in which neither cracking nor peeling occurred were evaluated as "non-destructive", and those in which cracking or peeling occurred were evaluated as "destructive".

  From Table 3, the airgel composites of Examples had a short gelling time in the wet gel formation step and excellent reactivity, and had good shrink resistance in atmospheric drying using a methanol-substituted gel. Incidentally, in this evaluation, good shrink resistance was shown in any of the Examples, which means that it was possible to obtain a good quality airgel composite without performing the solvent replacement step. ..

  Further, it can be read that the airgel composites of Examples have small thermal conductivity and compression elastic modulus, and are excellent in both high heat insulation and high flexibility. Moreover, the support member with an airgel composite of the example had good bending resistance.

  On the other hand, in Comparative Examples 1 to 3, the gelation time in the wet gel formation step was long, and the gel shrank and cracked on the surface in the atmospheric pressure drying using the methanol-substituted gel. Moreover, either thermal conductivity or flexibility was poor. Further, the support member with airgel is brittle against bending and thus easily broken.

(7) SEM Observation The surface of the airgel composite in the airgel composite-attached foil-like support member obtained in Example 4 and Example 6 was observed by SEM. FIG. 4 shows the surface of the airgel composite in the foil-like support member with the airgel composite obtained in Example 4, (a) 10,000 times, (b) 50,000 times, (c) 200,000 times and (d). ) SEM images observed at 350,000 times. FIG. 5 shows the surface of the airgel composite in the foil-like support member with the airgel composite obtained in Example 6, at (a) 10,000 times, (b) 50,000 times, and (c) 200,000 times, respectively. It is an observed SEM image.

  As shown in FIG. 4, it was observed that the airgel composite obtained in Example 4 had a three-dimensional network skeleton (three-dimensionally fine porous structure). The particle size of the observed particles was mainly about 20 nm derived from silica particles. Although it is possible to confirm a spherical airgel component having a smaller particle size than the silica particles (airgel particles), mainly the airgel component does not take a spherical form and does not cover the silica particles or functions as a binder between silica particles. It is observed that they appear to be. As described above, since some of the airgel components function as a binder between the silica particles, it is presumed that the strength of the airgel composite can be improved.

  As shown in FIG. 5, it was observed that the airgel composite obtained in Example 6 also had a three-dimensional network skeleton. However, its cluster structure is unique. In this example, unlike the ordinary airgel, it does not have a structure in which particles are connected to each other in a beaded shape, and the connecting portion between particles seems to be densely packed with an airgel component (silicone). Is observed. Moreover, since the particle size of the particles derived from the silica particles is significantly larger than the particle size of the silica particles themselves, it is presumed that the silica particles are thickly covered with the airgel component. As described above, in this example, since the airgel component not only functions as a binder between particles but also covers the entire cluster structure, it is presumed that the strength of the airgel composite can be further improved. To be done. In Example 6, since the ST-OZL-35 used was an acidic sol, the airgel composite was produced in a state where the pH in the system was low. Therefore, it is presumed that the generation rate of the airgel component was slowed down, and it was difficult for the airgel component in the obtained airgel composite to be in the form of particles.

  1 ... Airgel particles, 2 ... Silica particles, 3 ... Pores, 10 ... Airgel composite, L ... Enclosing rectangle.

Claims (5)

At least one selected from the group consisting of a silica particle dispersion liquid in which silica particles are dispersed and having a pH of 8.5 or less, a silicon compound having a hydrolyzable functional group in the molecule, and a hydrolysis product of the silicon compound. A method of manufacturing an airgel composite, comprising a step of drying a wet gel produced from a sol containing ,
The method for producing an airgel composite, wherein the sol further contains at least one selected from the group consisting of a polysiloxane compound having a reactive group in the molecule and a hydrolysis product of the polysiloxane compound . The method for producing an airgel composite according to claim 1, wherein the average primary particle diameter of the silica particles is 1 to 500 nm. The shape of the silica particles are spherical, the manufacturing method of the airgel composite of claim 1 or 2. The silica particles are colloidal silica particles, a manufacturing method of the airgel composite according to any one of claims 1-3. The drying temperatures below the critical point of the solvent used for drying and is carried out under atmospheric pressure, the production method of the airgel composite according to any one of claims 1-4.