KR102161461B1 - aergel type thermal insulator having air permeable waterproof resin outer layer, method of making the same and thermal insulator goods - Google Patents

Abstract

The inner layer is made of an airgel blanket, the outer layer is made of a waterproof and moisture-permeable resin, and the inner layer and the outer layer are bonded with an intermediate adhesive layer, and an airgel insulation material and a method of manufacturing the same are disclosed.
According to the present invention, an insulation material using airgel is formed, but a surface layer resin having a function of waterproof and moisture permeation is placed, so that the entire insulation material has a function of waterproof and moisture permeability, and even when applied to a human body wear product, long-term wear and comfort can be improved. Since products can be implemented, the application range or usability can be improved.

Description

Airgel insulation having a moisture-permeable resin surface layer, and its manufacturing method, and insulation products using the same {aergel type thermal insulator having air permeable waterproof resin outer layer, method of making the same and thermal insulator goods}

The present invention relates to an airgel insulation material and a method of manufacturing the same, and more particularly, to an airgel insulation material capable of solving the problems of the conventional airgel insulation product for human body, a manufacturing method thereof, and an insulation product using the same.

Aerogel is an ultra-porous silica material having a porosity of 90% or more and a pore size of 50 nm or less. In particular, its insulation performance is several times superior to that of existing materials, and is a material attracting attention as a next-generation insulation material.

However, despite having such excellent material properties, the manufacturing process is complicated and the manufacturing cost is high. For example, an aerogel is a nanostructured gel containing a large amount of solvent by reacting a raw material with a sol-gel, and then removing the solvent almost without shrinkage by a method such as supercritical drying to create a nanostructure of the original gel. It is manufactured in a state that is kept as it is. Therefore, conventional airgel insulation has been used only for extremely limited applications.

In addition, the mechanical strength is very weak and there is a disadvantage that it is easy to break. Therefore, recently, an airgel blanket complex technology has been proposed that compensates for the disadvantages of the airgel itself and enables processing in various forms.

Airgel blankets are made in the form of mattresses or sheets by compounding airgel materials, and airgel blankets have the feature that they can bend, fold, or cut because of their flexibility. It is widely used for insulation purposes such as pipes, LNG transfer pipes, and deep-sea pipes, and can be applied to various industries such as clothing, sports shoes, transportation and vehicles.

However, since the aerogel powder supported in the airgel blanket is inevitably removed from the base material, there is a problem that a large amount of dust caused by the released airgel particles is generated during the manufacturing process of products such as clothes including airgel insulation materials.

In order to prevent the separation of the airgel particles, several methods have been proposed. Patent Document 1 discloses a method of laminating a protective film on an airgel insulation base material containing airgel particles. Patent Document 1 proposes two methods for laminating a protective film on an airgel insulation base material, and will be described with reference to FIGS. 1 and 2 as follows.

The first method is a method in which the protective film 20 is directly laminated to the heat insulating layer 10 including airgel particles as shown in FIG. 1. The second method is a method in which the adhesive coating layer 30 is disposed on the heat insulating layer 10 including airgel particles, and the protective film 20 is laminated on the adhesive coating layer 30 as shown in FIG. 2.

However, in the case of the airgel insulating material in which the protective film is disposed in the first method and the second method, the adhesive coating layer or the protective film is formed from the insulating material containing the airgel particles as the airgel insulating material is repeatedly wrinkled during product manufacturing, use, and washing. It can be easily dislodged. In this case, the effect of disposing the protective film is canceled, so that the airgel particles are separated from the heat insulating material, and thus the heat insulating effect may be greatly reduced.

On the other hand, due to the characteristics of the material itself, airgel is difficult to make into a pressurized molded product because it is not suitable for heating and pressure molding, which are widely used in conventional synthetic resin molding in a pure form. For the molding of ceramic materials, a method of mixing ceramic particles with a bonding material suitable for heating and pressurization is also conceivable, but when the method of mixing and molding such a bonding material in airgel molding is introduced, the finished molded product will be formed with the bonding material between the airgel particles. Due to the heat transfer through the airgel, the effect of heat insulation can be greatly reduced.

In addition, in some cases, the binder component may penetrate into the empty space of the airgel particles and damage the thermal insulation effect due to the porosity of the airgel particles.If the amount of the binder is small and there are many aerogels, heat and pressure are applied from the outside due to the thermal insulation properties of the airgel. It is difficult to transfer heat to the process, which can be a problem in the process.

In addition, it is not easy to use resin coating for airgel insulation to solve the dust problem, but even when making resin-coated products, it is difficult to make articles for human body wear. Although the resin coating can solve the problem of dust, ordinary resins do not easily release moisture in the short term, so that sweat is easy and it is difficult to wear continuously.

Korean Patent Registration No. 10-1237013 Korean Patent Registration No. 10-1146778 Korean Patent Application No. 10-2011-0069416

An object of the present invention is to provide an insulating material and a method of manufacturing the same, which can solve the problem of dust while forming an insulating material using an airgel blanket, and also discharge moisture when worn by the human body to maintain comfort.

According to an aspect of the present invention, it is an object of the present invention to provide a heat insulating material and a method of manufacturing the same, which is relatively easy to form and is convenient to process into various articles by using it while forming an insulating material using an airgel blanket.

According to an aspect of the present invention, it is an object of the present invention to provide an insulating product without a problem of moisture permeation when formed of an insulating material using an airgel blanket.

In the airgel insulation material of the present invention for achieving the above object, the inner layer is made of an airgel blanket, the outer layer is made of a waterproof and moisture-permeable resin, and the inner layer and the outer layer are intermediate adhesive layers (hereinafter, the adhesive layer includes an adhesive layer. It is characterized in that it is combined in a broad sense).

In the insulation of the present invention, the moisture-permeable resin may have a pore range of, for example, 0.01 micrometer or more and 20 micrometers or less, and each adhesive layer has an opening of 5 to 95% of the contact area between the inner and outer layers, so that the medium adhesive layer itself has a moisture-permeable and moisture-proof function. Even without it, it is possible to provide moisture-permeable and moisture-proof as a whole insulator, and increase the degree of bonding between the outer layer and the inner airgel blanket.

In the heat insulating material of the present invention, the intermediate adhesive layer may be located in a place that allows the inner layer and the outer layer to be evenly bonded in a mesh form or a grid point form, and may be a hot-melt resin, and in the case of a material requiring high temperature, a polyimide resin Can be used. At this time, the polyimide may be used in the form of a polyamic acid solution as a precursor, and then dried and heated in a subsequent process to form a polyimide.

As the moisture-permeable resin in the present invention, various moisture-permeable resins such as those used for Micro-Tex or Gore-Tex, which are known in the past, may be used, and fine particles having heat resistance to temperatures below 300 degrees Celsius for use in a high-temperature environment. Porous Teflon resin or microporous polyurethane resin used in an ordinary environment may be used.

The heat insulating material of the present invention may be made in a simple flat plate shape or in a convex embossed shape. These forms may be made through pressurized heating molding in the process.

The insulating material of the present invention does not have to have a layer structure of an inner layer, an intermediate adhesive layer, and an outer layer resin in all areas, and has a structure in which a plurality of cells are combined, so that an airgel blanket or an intermediate adhesive layer is not provided between the cells. May be.

The manufacturing method of the present invention for achieving the above object comprises an inner layer preparation step of forming an airgel blanket by using airgel impregnation, an outer layer preparation step of preparing an outer layer (surface of insulating material) with a moisture-permeable material, and an airgel blanket using an intermediate adhesive layer material. It comprises a bonding step of forming a heat insulating material in a state in which the outer layer is bonded to the surface of the jacket.

In the method of the present invention, the bonding step may be performed by first bonding the material of the intermediate adhesive layer to at least one of the inner surface and the inner side of the outer layer, and aligning and bonding with the remaining outer layer or inner layer in a bonded state.

In the present invention, in order to combine the material of the intermediate adhesive layer with the inner layer or the outer layer, a method of applying the intermediate adhesive layer to a required part by adjusting the viscosity in a fluid state such as a liquid or semi-liquid can be used. It is also possible to use a precursor state that can achieve a state and can be cured through a subsequent process as an intermediate adhesive layer material.

In the bonding step in the present invention, heat-pressing molding may be performed to bond the inner layer, the outer layer, and the intermediate adhesive layer. Since the inner layer, such as an airgel blanket, is not suitable for heat press molding by itself, the heat press molding may be performed in a state in which the intermediate adhesive layer material or the outer layer resin material are bonded.

An alternative manufacturing method of the present invention for achieving the above object includes the step of preparing an inner layer of forming an airgel blanket using airgel impregnation, bonding a material of an intermediate adhesive layer to the surface of the airgel blanket, and on the surface of the intermediate adhesive layer material and the airgel blanket. It may be achieved by providing a step of forming an outer layer of the moisture-permeable material.

In this manufacturing method, a molding step of heating and pressing the airgel blanket may be performed, and the molding step may be performed after bonding the material of the intermediate adhesive layer or after applying the outer layer of the moisture-permeable material.

The heat insulation product of the present invention is characterized in that it is formed using the airgel insulation of the present invention, and can be a firefighting suit inner skin worn on the human body, a waterproof suit, a cold protection product, a sleeping bag, etc., a rug tent, and other industrial products, an insulation product for agricultural facilities.

The heat insulation product of the present invention may have an embossed shape, and a vent for enhancing ventilation may be installed in the area between the embosses.

According to the present invention, an insulation material using airgel is formed, but a surface layer (outer layer) resin having a function of waterproof moisture permeation is placed so that the entire insulation material has a function of waterproof moisture permeation, and long-term wear and comfort can be improved even when applied to a product worn by the human body. Is done.

According to an aspect of the present invention, since the insulating material not only has a waterproof and moisture-permeable function, but also can implement various products in terms of shape, it is possible to increase the application range or usability.

The present invention can secure suitable insulation and moisture-permeable function in products used at high or low temperatures such as firefighting suits, heat-resistant fireproof suits, winter clothing, wetsuits, gloves, footwear, hoods, condensation prevention wallpaper, insulation covers, etc., and the efficiency of airgel insulation As a result, the increase in volume can be minimized, and convenience and safety can be improved by increasing the activity, especially in articles worn on the human body.

1 and 2 are cross-sectional views showing a configuration in which both sides of a conventional airgel insulation layer are directly covered with a protective film or once covered with an adhesive coating layer and then covered with a protective film,
3 is a cross-sectional view showing a cross-sectional structure of an airgel insulating material according to an embodiment of the present invention,
4 is a flow chart showing important steps according to an embodiment of the method of the present invention;
5 is a flow chart showing important steps according to another embodiment of the method of the present invention;
6 is a photograph of an insulating material in a state of bonding an inner layer and an intermediate adhesive layer, having a three-dimensional embossing curve after heat-press molding before applying a moisture-permeable resin, formed by another embodiment of the method of the present invention;
7 is a photograph showing a heat insulating material in a state in which the moisture-permeable resin sheet formed in advance in the state of FIG.
8 is a photograph of an airgel insulation formed in a flat plate shape by a laminating method according to another embodiment of the method of the present invention,
9 is a plan view showing the airgel heat insulation according to an embodiment of the present invention made in the form of a plurality of cells;
Figure 10 is a photograph showing an embodiment of the endothelium of the firefighting suit according to the present invention.

Hereinafter, the present invention will be described in more detail through specific embodiments with reference to the drawings.

3 is a cross-sectional view showing a state in which an intermediate adhesive layer and an outer layer of a moisture-permeable material are installed on the surface of an inner layer, which is an insulating layer made of an airgel blanket, according to an embodiment of the present invention.

As shown, the insulating material of this embodiment includes an inner layer 110 made of an airgel blanket, an outer layer of a moisture-permeable resin (surface layer: 130) having a waterproof and moisture permeable function, and an intermediate adhesive layer 120 between the inner and outer layers. Done.

The intermediate adhesive layer 120 does not exist on the entire contact surface between the inner layer 110 and the outer layer 130, but it is sufficient to have an area and a distribution shape capable of stably attaching the two layers. In addition, since the intermediate adhesive layer 120 itself is not necessarily a moisture-permeable resin, at least a portion of the surface of the inner layer, for example, 5% to 95%, is provided so as not to be covered with the intermediate adhesive layer in case there is no moisture permeable function.

The installation form or distribution form of each adhesive layer may be a grid point form, a mesh form, or a simple and irregular scattering form, and it is desirable to have a uniform distribution overall without being biased to any one part.

The heat insulating material inner layer 110 may be a single layer of an airgel blanket, but is usually made by overlapping the airgel blanket to a thickness necessary for insulation, and the intermediate adhesive layer 120 is mainly made of a synthetic resin layer having adhesive force or adhesive force.

As such an intermediary adhesive layer, polyimide or melamine resin used for forming Formica may be used, and it is preferable to form a material having heat resistance and durability in preparation for the case of subsequent heating and pressure molding. Do.

In order to increase adhesion, it is preferable that a part of the intermediate adhesive layer 120 penetrates into the surface of the inner layer 110 made of an airgel blanket so that the bonding strength with the inner layer 110 can be well maintained. However, if the synthetic resin layer penetrates too deeply into the inner layer, the thermal insulation performance of the airgel itself may be deteriorated, so the appropriate depth and penetration pattern should be shown.

In order to achieve this shape, an intermediate adhesive layer material may be applied to the surface including both sides and side surfaces of the inner layer of the airgel blanket. The intermediate adhesive layer itself, such as polyimide, does not necessarily need to be used as the intermediate adhesive layer material, and for example, polyamic acid, a precursor material of polyimide, is dissolved in a solvent to form a solution, which can be applied to the surface and dried. The application and drying operation can be performed at once, but it is also possible to apply and dry the application and drying operation multiple times to achieve the desired thickness.

At this time, the fabric fiber impregnated with the airgel may be made of a variety of materials including a plurality of pores such as a knitted fabric, a woven fabric, a sponge, a porous polymer, etc. so that the polyamic acid solution partially penetrates, and a polyethylene nonwoven fabric form is also possible. In addition, in the case of forming the heat insulating material by heating and pressing through a press in the future, a material having elasticity is preferable to be applied to the molding process.

On the other hand, as the moisture-permeable resin, a microporous polyurethane resin or microporous Teflon resin having a pore size in the range of 0.01 micrometer to 20 micrometers may be used, and here, it can exhibit heat resistance in a high temperature environment of 300 degrees Celsius or less. A suitable Teflon resin is used when molding in a heated and pressurized environment of about 50°C to 300°C.

4 is a flow chart showing each step according to an embodiment of the method of the present invention.

According to this embodiment, the airgel blanket is folded or cut to a required size and thickness to form an inner layer in the form of a plate or sheet (S10). Then, the medium adhesive layer material is evenly sprayed on the surface of the liquid or applied in a printing method in the form of a grid point or a mesh (S20). At this time, when the liquid is sprayed, the material of the intermediate adhesive layer does not cover the entire surface of the inner layer, and at least a portion of the material is exposed, so that moisture permeation can be maintained even if the intermediate adhesive layer has no ventilation.

In this state, the insulating material in which the inner layer and the intermediate adhesive layer material are combined is placed on a press molding mold and heated and pressurized at a temperature of 200°C to 300°C (S30). At this time, the molding result may have an embossed surface in which an even emboss is formed as a whole, and a small ventilation hole may be formed in an area between the embosses as necessary.

Next, an outer layer of the moisture-permeable resin is formed by evenly applying the moisture-permeable resin onto the molded product in which the medium adhesive layer material and the inner layer are pressed (S40). In this case, the application method may be performed by spraying a liquid resin material, or a method of dipping into a liquid resin tank may be used.

After that, depending on the type of moisture-permeable resin, a necessary drying or curing process may be further performed.

5 is a flow chart showing each step according to another embodiment of the method of the present invention.

In this embodiment as well, the airgel blanket is folded or cut to a required size and thickness to form an inner layer in the form of a plate or sheet (S110). At this time, the inner layer may be press-molded to form an embossed surface or a ventilation hole may be formed between the embosses.

Then, the medium adhesive layer material is evenly sprayed on the surface of the liquid or applied in a printing method in the form of a grid point or a mesh (S120). However, when spraying the material of the intermediate adhesive layer, the material of the intermediate adhesive layer does not completely cover the surface of the airgel blanket, and a large portion of the surface is exposed for moisture permeation.

6 is a photograph showing an in-process heat insulating material having an airgel blanket molded in this manner and an intermediate adhesive layer.

And the moisture-permeable resin outer layer is bonded in this state. Unlike the previous example process, in this case, a sheet or plate form is first formed with a moisture-permeable resin in advance (S130), and then the inner layer and the intermediate adhesive layer material are combined with each other and adhered (S130). Of course, they may be bonded by first installing an intermediary adhesive layer material on the moisture-permeable resin and bonding it to the surface of the inner layer.

For this outer layer bonding, the pressing mold used in the inner layer molding can be used again, and at this time, a heater of the mold mold may be used for bonding or curing of the material of each adhesive layer, and heating and pressing may be performed.

When laminating or heat-pressing molding, a moisture-permeable resin is prepared wider than the inner layer, and a sealing layer is formed around the inner layer, but a sealing layer is formed in the form of heat fusion or adhesive attachment, and the fine powder of the aerogel from the airgel blanket is separated from the resin. Can be prevented.

7 is a photograph showing a state in which the moisture-permeable resin is bonded to the surface in the form of a sheet or film in the state of FIG. 6 to be covered.

Of course, the molding of the insulation can be done in other ways. For example, when the inner layer and intermediate adhesive layer materials are first made into a flat plate, and when the moisture-permeable resin is bonded with the inner layer and intermediate adhesive layer materials, they are arranged in a temporary bonded state, and then sheet laminating or film laminating is used. I can.

8 is a photograph showing a flat airgel insulation obtained through such lamination.

As another method, the inner layer and intermediate adhesive layer materials are first made into a flat plate shape, and when the moisture-permeable resin is bonded to the inner layer and intermediate adhesive layer materials, they are arranged in a temporary bonding state, and then placed on a press molding mold with embossing. It is also possible to use heat-pressing molding using a heater to heat and pressurize, and it is also possible to use a method of forming a flat heat insulating material as shown in FIG. 8 through laminating and then pressing and heating-molding it in an embossed form.

On the other hand, when performing pressure molding with a molding mold, continuous pressure molding may be performed using a roller shape with an upper and lower molding mold, and this form can be seen similar to the form of roll lamination. When pressing using a vertical pressurization mold (mold), the upper and lower tolerance of the upper and lower molds is made to be less than the thickness of the airgel by, for example, 1mm or more, so that the pressure can be reliably applied.In this case, the pressure is used as an intermediate adhesive layer. The hot melt can be fused to the inner or outer layer. However, even in this case, the pressure level must be adjusted so that the press mold pressure does not deform or damage the airgel pore structure in the inner layer.

On the other hand, the heat insulating material of the present invention does not need to have a layer structure of an inner layer, an intermediate adhesive layer, and an outer layer resin in all areas, and an airgel blanket having the size of a unit cell 210 such as a circle, hexagonal shape, or octagonal shape may cover most of the matrix arrangement or area. It is placed between the upper and lower moisture-permeable resins in an arbitrary arrangement of filling, and there is no airgel blanket in the connection region 220 between the unit cell 210 and the unit cell, and the moisture-permeable resin is directly fused or attached or an intermediate adhesive layer, It is possible to form an airgel insulation material in the form of a cell that is adhered with the other adhesive layer therebetween.

9 is a plan view showing such a cell structure airgel insulation material constituting an embodiment of the present invention.

Such an airgel insulating material, for example, prepares upper and lower moisture-permeable resin sheets in which an intermediate adhesive layer material is partially coated on the inner surface, and a plurality of cells 210 are arranged on the lower moisture-permeable resin sheet, and the upper moisture-permeable resin sheet is arranged on it again. After making a kind of sandwich laminated structure by covering the resin, the laminated structure is passed between rollers made of an elastic body such as soft rubber, and laminating to adhere them in close contact can be made to achieve a plane as shown in FIG. 9.

The airgel insulation material of the present invention can be used in a very large number of fields. For example, the airgel insulation fabric is cut and sewn to form the inner skin of a firefighting suit as if making clothes from other fabrics, or the front and rear pieces are formed in three dimensions, and the periphery of them is used as the inner skin of firefighting suits by bonding, fusion, or sewing. I can. Of course, instead of forming the airgel insulation fabric of the present invention and cutting it, it is possible to make the inner skin of the firefighting suit by a bonding method other than sewing, such as taping or bonding it.

Since the inner skin of the firefighting suit is also used at a relatively high temperature, it is desirable to endure high temperatures and have a waterproof and moisture-permeable function, so it is preferable to use a heat-resistant material for the moisture-permeable resin, the intermediate adhesive layer, and the blanket fabric.

In addition, since they can undergo high-temperature processes such as pressurized heating molding during processing, it is desirable to be formed of a material that has heat resistance and can be flexibly deformed according to each process.For example, moisture-permeable resins are heat-resistant to withstand temperatures below 300 degrees Celsius. A Teflon material may be used as the resin, and a polyimide resin that is resistant to relatively high temperatures may be selected as the intermediate adhesive layer.

In addition, the moisture-permeable resin on the surface may be made of a meta aramid fiber sheet or a meta aramid fiber sheet for mechanical strength or function, and heat resistance.

Fig. 10 is a photograph showing an embodiment of a fire fighting suit endothelium made in this way.

In the above, the present invention has been described through limited embodiments, but this has been illustratively described to aid understanding of the present invention, and the present invention is not limited to these specific embodiments.

Therefore, those of ordinary skill in the field to which the present invention belongs may implement various changes or application examples based on the present invention, and it is natural that such modifications or application examples belong to the appended claims.

110: inner layer 120: intermediate adhesive layer
130: outer layer (surface layer) 210: cell (unit cell)
220: connection area

Claims (10)

Inner layer of airgel blanket,
An outer layer made of a moisture-permeable and moisture-permeable resin, at least partially,
It is provided on at least a portion of a portion of the inner layer and the outer layer facing each other and includes an intermediate adhesive layer bonding the inner layer and the outer layer,
The moisture-permeable resin has pores in the range of 0.01 micrometer or more and 20 micrometers or less,
The intermediate adhesive layer is an airgel insulation material, characterized in that installed in an area of 5% or more and 95% or less of a portion (contact area) facing each other in the inner layer and the outer layer, delete The method of claim 1,
The intermediate adhesive layer is a liquid or semi-liquid flow state by melting or melting, and partially penetrated from the surface of the inner layer to the inside, and then solidified. The method of claim 3,
The intermediate adhesive layer is polyimide and is applied to the surface of the inner layer in the form of a polyamic acid solution and cured with polyimide through dry heating in a subsequent process, or a polyimide hot melt (heat melting type adhesive),
Airgel insulation, characterized in that the moisture-permeable resin is a Teflon resin having heat resistance at a temperature of 300 degrees or less. The method according to any one of claims 1, 3, and 4,
Airgel insulation, characterized in that it is molded in a flat or three-dimensional shape through heating and pressure molding in a mold. The method according to any one of claims 1, 3, and 4,
Having the inner layer, the outer layer, and the intermediate adhesive layer in a plurality of cell regions spaced apart from each other,
Airgel insulation, characterized in that the inner layer is not installed in the connection area between the cell areas. As a method of manufacturing the airgel insulation of any one of claims 1, 3, 4,
Preparing the inner layer to form an airgel blanket using airgel impregnation,
The outer layer preparation step of preparing the outer layer with a moisture-permeable material,
A method of manufacturing an airgel insulation material comprising a bonding step of forming an insulation material in a state in which the outer layer is bonded to at least a portion of the surface of the inner layer by using an intermediate adhesive layer material. The method of claim 7,
The bonding step is performed by first bonding the material of the intermediate adhesive layer to at least one of the inner surface and the inner side of the outer layer, and aligning and bonding with the outer layer or the inner layer, which is the remaining portion in a bonded state,
As the material of the intermediate adhesive layer, the intermediate adhesive layer itself or the precursor of the intermediate adhesive layer are melted or dissolved to achieve a liquid or semi-liquid state,
The method of manufacturing an airgel insulation material, characterized in that it is applied to the inner surface or the inner surface of the outer layer in one of a grid point form, a mesh form, and an irregular scattering state. The method of claim 8,
In the bonding step, the method of manufacturing an airgel insulator, characterized in that the step of performing heat press molding while placing the material of the intermediate adhesive layer between the inner layer and the outer layer. As a heat insulation product comprising the airgel insulation of any one of claims 1, 3 and 4,
Firefighting suit inner skin worn on the human body, waterproof suit, cold weather clothing, sleeping bag, rug, tent, industrial insulation products, and firefighting suit inner skin, characterized in that one of the insulation products for agricultural facilities.

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