WO2017159438A1 - 断熱シートとその製造方法 - Google Patents
断熱シートとその製造方法 Download PDFInfo
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- WO2017159438A1 WO2017159438A1 PCT/JP2017/008881 JP2017008881W WO2017159438A1 WO 2017159438 A1 WO2017159438 A1 WO 2017159438A1 JP 2017008881 W JP2017008881 W JP 2017008881W WO 2017159438 A1 WO2017159438 A1 WO 2017159438A1
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/07—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with halogens; with halogen acids or salts thereof; with oxides or oxyacids of halogens or salts thereof
- D06M11/11—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with halogens; with halogen acids or salts thereof; with oxides or oxyacids of halogens or salts thereof with halogen acids or salts thereof
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L59/00—Thermal insulation in general
- F16L59/04—Arrangements using dry fillers, e.g. using slag wool which is added to the object to be insulated by pouring, spreading, spraying or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/18—Processes for applying liquids or other fluent materials performed by dipping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
- B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
- B05D3/065—After-treatment
- B05D3/067—Curing or cross-linking the coating
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B33/00—Silicon; Compounds thereof
- C01B33/113—Silicon oxides; Hydrates thereof
- C01B33/12—Silica; Hydrates thereof, e.g. lepidoic silicic acid
- C01B33/16—Preparation of silica xerogels
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/26—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by elimination of a solid phase from a macromolecular composition or article, e.g. leaching out
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/07—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with halogens; with halogen acids or salts thereof; with oxides or oxyacids of halogens or salts thereof
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
- D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/50—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with organometallic compounds; with organic compounds containing boron, silicon, selenium or tellurium atoms
- D06M13/503—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with organometallic compounds; with organic compounds containing boron, silicon, selenium or tellurium atoms without bond between a carbon atom and a metal or a boron, silicon, selenium or tellurium atom
- D06M13/507—Organic silicon compounds without carbon-silicon bond
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/50—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with organometallic compounds; with organic compounds containing boron, silicon, selenium or tellurium atoms
- D06M13/51—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond
- D06M13/513—Compounds with at least one carbon-metal or carbon-boron, carbon-silicon, carbon-selenium, or carbon-tellurium bond with at least one carbon-silicon bond
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2518/00—Other type of polymers
- B05D2518/10—Silicon-containing polymers
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/02—Natural fibres, other than mineral fibres
- D06M2101/04—Vegetal fibres
- D06M2101/06—Vegetal fibres cellulosic
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- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/32—Polyesters
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- D—TEXTILES; PAPER
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- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/34—Polyamides
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- D—TEXTILES; PAPER
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- D06M2400/00—Specific information on the treatment or the process itself not provided in D06M23/00-D06M23/18
- D06M2400/02—Treating compositions in the form of solgel or aerogel
Definitions
- the present invention relates to a heat insulating sheet and a manufacturing method thereof.
- heat insulating materials examples include silica airgel and silica xerogel.
- Silica aerogel and silica xerogel have pores smaller than the mean free path of air of 68 nm, have little heat conduction due to solid heat conduction or convection, and have an excellent heat insulating effect. It is a material useful in solving the above heat insulation problem.
- silica airgel and silica xerogel have low mechanical strength, and it is difficult to use them alone. Therefore, there is a method in which silica aerogel or silica xerogel is impregnated into a fiber and used as a heat insulating material.
- This heat insulating material utilizes the excellent heat insulating property of silica airgel or silica xerogel, and exhibits excellent heat insulating properties.
- silica fine particles are detached from the heat insulating material during use, there is a problem that the heat insulating performance is deteriorated.
- Patent Document 1 is known as prior art document information.
- a fiber sheet containing silica xerogel and nanofibers is prepared by the following manufacturing method.
- the nanofiber prevents the silica fine particles from detaching from the fiber sheet.
- sodium in water glass is removed, and a silica sol adjusted to a gelling pH is impregnated into a fiber sheet containing nanofibers before gelation. Then, curing for strengthening the skeleton is performed so that the silica pores can withstand the capillary force during solvent drying.
- a hydrophobic step of hydrophobizing the surface of the silica xerogel using a mixed solution of a silylating agent and an alcohol is performed, and a fibrous heat insulating material is obtained by a procedure of removing the solvent present in the product.
- an object of the present application is to provide a method and a heat insulating material that can be hydrophobized and remove a solvent up to the inside of a thick heat insulating sheet.
- the present invention provides an impregnation step of impregnating a silica aerosol into a nonwoven fabric base material containing an insoluble fiber in an acidic solution and a soluble fiber in the acidic solution, and a gelation for gelling the silica aerosol.
- a method for producing a heat insulating sheet comprising a step, a hydrophobizing step for hydrophobizing the gel, and a drying step for drying the gel, wherein soluble fibers are dissolved in the hydrophobizing step in the acidic solution is used.
- a heat insulating sheet containing fibers, silica aerogel contained in the fibers, and fibrous cavities is used.
- the mixed solution of hydrochloric acid, a silylating agent, and alcohol can be permeated and discharged through the cavity generated during the hydrochloric acid immersion treatment in the hydrophobizing step to the inside of the heat insulating sheet.
- hydrochloric acid, silylating agent, and alcohol can be released to the outside of the heat insulating sheet through the cavity. For this reason, even if it uses the nonwoven fabric base material of thickness 1.5mm or more, the heat insulation sheet which has a heat conductivity of 24 mW / m * K or less can be manufactured.
- FIG. 2A is a perspective view of a base material of a heat insulating sheet in one embodiment of the present invention.
- 2B is a partially enlarged side view of the substrate of FIG. 2A.
- FIG. 2C is a side view showing a state in which a silica sol is infiltrated into a base material in one embodiment of the present invention.
- FIG. 2D is a perspective view of a heat insulating sheet in one embodiment of the present invention.
- FIG. 3 is an enlarged side view of the heat insulating sheet in one embodiment of the present invention.
- FIG. 1 is a process diagram for obtaining the heat insulating sheet 27 of the embodiment.
- the outline for obtaining the heat insulating sheet 27 of the embodiment is as follows. 2A to 2D are diagrams for explaining the process.
- FIG. 3 is an enlarged side view of the heat insulating sheet 27 produced.
- FIG. 2A is a perspective view of the base material 21.
- FIG. 2B is an enlarged side view of the base material 21.
- FIG. 2C is a side view showing a state where the silica sol solution 25 is infiltrated into the base material 21.
- FIG. 2D shows the manufactured heat insulating sheet 27.
- FIG. 3 is an enlarged side view of the heat insulating sheet 27.
- a silica sol solution 25 prepared in advance is poured onto the base material 21, and the base material 21 is impregnated with silica sol.
- the base material 21 is covered with the PP film 26 for preventing drying shown in FIG. This is left for a while and after confirming that the gelation of the silica sol solution 25 is completed, the thickness is adjusted. After adjusting the thickness, curing is performed to strengthen the gel skeleton. After curing, hydrophobization (hydrochloric acid immersion and silylation treatment) and drying are performed. The heat insulating sheet 27 is obtained through the above steps.
- FIG. 2A shows the base material 21.
- the base material 21 contains two types of fibers.
- FIG. 2B is an enlarged cross-sectional view of the base material 21.
- the base material 21 includes a first fiber 22 and a second fiber 23.
- the first fiber 22 is an insoluble fiber in the acidic solution.
- the first fiber 22 can use polyethylene terephthalate (PET) as an organic fiber.
- PET polyethylene terephthalate
- the first fibers 22 may be made of other materials as long as they are insoluble in the acid used in the hydrophobizing step described below. It is also possible to use an inorganic fiber for the first fiber 22, and in that case, an insoluble material such as glass wool or rock wool can be used.
- the diameter of the first fiber 22 is ⁇ 0.001 to 0.02 mm.
- the second fiber 23 is a fiber that is soluble in an acidic solution.
- the fiber at least one of nylon, rayon, cupra, acetate, vinylon, and cotton can be selected. Whichever fiber is selected, it is necessary to dissolve with an acid during hydrophobization (hydrochloric acid immersion) described below. It is preferable to use a fiber having a diameter of 0.01 to 0.2 mm or less as the second fiber 23 because it easily melts.
- the penetration of the silylating agent is promoted even when the second fiber 23 is dissolved in the acid and the fiber part becomes the cavity 30 in the hydrophobizing step described below. May not be.
- the second fiber 23 having a diameter of more than 0.2 mm, the second fiber 23 remains undissolved in the acid and the insoluble portion remains in the cavity 30 in a desired process time in the hydrophobizing step described below. There is.
- a fiber having a length of the acid-soluble second fiber 23 that is twice or more the diameter. This is because, in the hydrophobizing step described below, the second fiber 23 is dissolved in the acid, and the fiber portion becomes the cavity 30, and the mixed solution of hydrochloric acid, silylating agent and alcohol can permeate and discharge through the cavity 30. It is to make it. If the length of the second fiber 23 is long, the cavity 30 can be lengthened and the liquid can be moved. In order to further promote the movement of the liquid, it is preferable to arrange the second fibers 23 so that the cavities 30 exist on at least two surfaces of the heat insulating sheet 27.
- the cavity 30 is a space equivalent to the shape of the second fiber 23.
- the result is a fibrous space.
- the diameter of the cavity 30 is preferably 0.2 mm or less.
- the length of the cavity 30 is preferably at least twice the diameter.
- the acid, silylating agent, and alcohol are likely to escape outside the heat insulating sheet through the cavity 30.
- the ratio of the second fiber 23 to the first fiber 22 is 1 to 10% by weight. Above that, there are too many cavities and the heat insulation properties are not good.
- the cavity 30 is 0.02 to 0.2 vol%. If the volume of the cavity 30 is made larger than 0.2 vol%, this becomes a heat path, resulting in a decrease in thermal conductivity.
- silica sol As the silica material of the silica sol, a high molar silicic acid aqueous solution (manufactured by Toso Sangyo Co., Ltd., SiO 2 concentration 14%) is used. A silica sol solution is prepared by adding 1.4% of concentrated hydrochloric acid as a catalyst.
- the silica raw material of a silica sol it is not limited to high molar silicic acid aqueous solution, You may use an alkoxysilane and water glass.
- the high molar silicic acid aqueous solution is a silica raw material in which the sodium component is reduced to 1% or less than water glass.
- the SiO 2 concentration a desired thermal conductivity can be obtained as long as it is 5% to 14% regardless of which raw material is used.
- hydrochloric acid in consideration of acceleration of the hydrolysis reaction of silicic acid, the skeleton strength of the resulting gel, and the subsequent hydrophobization step. Is preferably 1 to 12N, more preferably 6 to 12N.
- the amount of the silica sol to be used is not less than the theoretical space volume obtained from the bulk density of the base material 21, and the impregnation is performed so that all the voids in the base material 21 are filled with the silica sol.
- a dry prevention PP film 26 is placed on the impregnated base material 21 to prevent the silica sol from drying so that the water contained in the silica sol does not easily evaporate.
- the voids in the base material 21 become airgel through a subsequent process.
- the content of the airgel is preferably 20 to 80% by weight, more preferably 40 to 70% by weight, although it depends on the bulk density of the substrate 21. If the content is less than 40% by weight, desired heat insulation may not be obtained. If the content exceeds 70% by weight, productivity and economy may be impaired.
- the base material 21 with the adjusted thickness is put in a container and stored in a constant temperature and humidity chamber set at a temperature of 85 ° C. and 85% for 3 hours to grow silica secondary particles to reinforce the structure of the gel skeleton.
- the storage temperature is preferably less than 100 ° C.
- About humidity, 80% or more is preferable so that a water
- the storage time is preferably within 0.5 to 6 hours.
- the base material 21 impregnated with the gel is immersed in 12N hydrochloric acid for 1 hour to react the gel and hydrochloric acid.
- the acid-soluble second fiber 23 contained in the base material 21 is dissolved by hydrochloric acid, and even if the base material 21 is thick, the hydrochloric acid is brought into the base material 21 by the cavity 30 formed thereby. Penetrates.
- the second fiber 23 In order to enable the solution to enter and exit, the second fiber 23 needs to have a diameter of 1 ⁇ m or more. A diameter of 10 ⁇ m or more is preferable. Furthermore, 50 micrometers or more are preferable.
- the cavity 30 is a space in which the second fibers 23 are melted and is fibrous.
- the mixed solution of the silylating agent and the alcohol penetrates into the inside of the base material 21 using the cavity 30 formed during the hydrochloric acid treatment.
- hydrochloric acid water is discharged from the base material 21 containing the gel.
- FIG. 3 shows an enlarged side view of the heat insulating sheet 27.
- the heat insulating sheet 27 includes the first fibers 22, the silica airgel 31, and the cavities 30.
- Silica sol is silica aerogel. As compared with the conventional case, the heat insulating sheet 27 having one thick layer is produced.
- the basis weight of the base material 21 (weight per unit area 550 to 580 g / m 2 ) was made constant, and the mixing rate of the second fibers 23 to be mixed was changed to obtain the heat insulating sheet 27.
- the thickness of the heat insulating sheet 27 was made to be about 4 mm.
- the mixing rate of the second fibers 23 is not limited to this example.
- Thickness measurement was performed using a Digimatic Indicator H0530 (manufactured by Mitutoyo Corporation), the measurement pressure was 7.4 kPa, nine points were measured in the plane of each sample, and the average was taken as the thickness.
- the heat conductivity was measured using a heat flow meter HFM 436 Lamda (manufactured by NETZSCH).
- the results of the implementation are shown in Table 1.
- the thermal conductivity was 24 mW / m ⁇ K or less, which is about 10% lower than the thermal conductivity of still air, 26 mW / m ⁇ K.
- Example 1 A base material comprising a non-woven fabric of inorganic first fibers 22 and second fibers 23 made of nylon that is 1.5% of the weight of the inorganic first fibers 22 and that has a diameter of 0.1 mm and a length of at least twice the diameter. 21 was prepared. The processing procedure was performed according to the present embodiment. The thickness of the completed heat insulating sheet 27 was 4.15 mm. The thermal conductivity was 21.7 mW / m ⁇ K, and the desired heat insulating sheet 27 could be obtained.
- Example 2 A base material containing a nonwoven fabric of inorganic first fibers 22 and nylon second fibers 23 having a diameter of 6.4% by weight of inorganic first fibers 22 and having a diameter of 0.2 mm or more twice the diameter. 21 was prepared. The processing procedure was performed according to the present embodiment. The completed heat insulating sheet 27 was 4.09 mm. Further, the thermal conductivity was 21.8 mW / m ⁇ K, and the desired heat insulating sheet 27 could be obtained.
- the acid-soluble second fibers 23 dissolve within 1 hour of the immersion time, This is because hydrophobization (silylation agent treatment) treatment and discharge of hydrochloric acid water generated thereby were performed using the cavities 30 generated after dissolution.
- hydrochloric acid was used as the acid, an acid other than hydrochloric acid may be used.
- a curing step is not essential, and a better heat insulating sheet 27 can be produced.
- the heat insulating sheet 27 made by the manufacturing method of the embodiment is not a laminated body but a single layer, and becomes a heat insulating sheet having a thickness of 1.5 mm or more.
- the thickness is preferably 2 mm or more, and more preferably 3 mm or more.
- a heat insulating sheet having a thickness of 1.5 mm or more and excellent heat insulating properties can be obtained.
- the heat insulation sheet 27 of embodiment is applicable to various heat insulation uses, such as various electronic devices, a house, vehicles, such as a motor vehicle, and is industrially useful.
- Substrate 22 First fiber 23
- Second fiber 24 PP film 25
- Silica sol solution 26 PP film 27
- Thermal insulation sheet 30 Cavity 31
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Abstract
Description
まず、下敷きPPフィルム24(ポリプロピレンフィルム)をセットし、その上に図2Aで示す基材21を載せる。
まず、下敷きPPフィルム24を敷く。その上に、基材21をセットする。図2Aは、基材21である。基材21は、2種類の繊維を含有している。図2Bは、基材21の拡大断面図である。
シリカゾルのシリカ材料として、高モル珪酸水溶液(東曹産業株式会社製、SiO2濃度14%)使用する。これに触媒として濃塩酸を1.4%添加してシリカゾル溶液を調製する。
使用するシリカゾルの量は、基材21の嵩密度から求めた理論空間体積以上とし、基材21中の空隙がすべてシリカゾルで満たされるように含浸する。含浸が終了したら、シリカゾルに含まれる水分が容易に蒸発しないように、乾燥防止のPPフィルム26を含浸済み基材21の上から被せて、シリカゾルの乾燥を防止する。基材21中の空隙は、後の工程を経てエアロゲルになる。そのエアロゲルの含有率は、基材21の嵩密度にもよるが、20~80重量%が好ましく、より好ましくは40~70重量%である。含有率が40重量%未満では、所望の断熱性が得られない場合がある。含有率が70重量%を超えると、生産性や経済性を損なう場合がある。
含浸された基材21を20分放置し、ゲル化するのを待つ。ゲル化が確認できたら、プレスをして厚みを整える。厚みの整え方は、ロールプレスなどの方法を用いても良い。
厚みを整えた基材21を容器に入れ、温度85℃、85%設定の恒温恒湿槽に3時間保管し、シリカ二次粒子を成長させて、ゲル骨格の構造を強化する。保管温度は100℃未満が好ましい。湿度については、基材に含まれるゲルから水分が容易に蒸発しないよう、80%以上が好ましい。保管時間は0.5時間から6時間以内が好ましい。
養生の処理が終了したら、恒温恒湿槽から基材21を取り出し、図2CのPPフィルム24、26を剥がし、疎水化処理(塩酸浸漬)を行う。
前記の処理が終了したら、疎水化処理の第二段階として、シリル化剤とアルコールの混合溶液(オクタトリメチルトリシロキサンと2-プロパノール)に浸漬させた後、55℃の恒温槽にて2時間保管する。
前記疎水化処理の2つの処理が終了したら、150℃の恒温槽にて2時間の乾燥処理を行う。この際も基材21中に形成された空洞30の作用により、基材21の厚みが厚くなっても、基材21の内部まで確実に乾燥が完了する。
断熱シート27の評価は、厚みと熱伝導率を測定した。
無機の第1繊維22の不織布と、無機の第1繊維22の重量の1.5%で直径0.1mm長さが直径の2倍以上のナイロンである第2繊維23と、を含む基材21を用意した。処理手順は本実施の形態どおり行った。完成した断熱シート27の厚みは、4.15mmであった。また、熱伝導率は21.7mW/m・Kであり、所望の断熱シート27を得ることができた。
無機の第1繊維22の不織布と、無機の第1繊維22の6.4重量%で直径0.2mm長さが直径の2倍以上のナイロンの第2繊維23と、を含有させた基材21を用意した。処理手順は本実施の形態どおり行った。完成した断熱シート27は、4.09mmであった。また、熱伝導率は21.8mW/m・Kであり、所望の断熱シート27を得ることができた。
無機の第1繊維22のみで構成される不織布を使用し、処理手順は本実施の形態どおり行った。製品の完成厚みは、4.23mmであった。熱伝導率を測定しようとしたが、内部から塩酸およびシリル化剤の混合物と見られる液体が染み出しているのを確認したため、測定することができなかった。この条件では正常な断熱シートを得ることができなかった。
無機の第1繊維22の不織布と、無機の第1繊維22の25.6重量%で直径0.4mm長さが直径の2倍以上のナイロンの第2繊維23と、を含有させた基材21を用意した。処理手順は本実施の形態どおりに行なった。その結果、直径0.4mm以上の第2繊維23を使用すると、疎水化(塩酸浸漬)時に可溶繊維である第2繊維23の溶け残りが発生し、酸性溶液に溶かされて造られる空洞内に、第2繊維23の溶け残りが残留した。
表1記載の疎水化(シリル化剤処理)での塩酸排出量(g)を見ると、実施例1および2と比較例1とでは、塩酸排出量にそれぞれ12g、11gの差が見られる。
酸として塩酸を使用したが、塩酸以外の酸でもよい。養生の工程を必須でなく、あればよりよい断熱シート27を作製できる。
22 第1繊維
23 第2繊維
24 PPフィルム
25 シリカゾル溶液
26 PPフィルム
27 断熱シート
30 空洞
31 シリカエアロゲル
Claims (11)
- 第1繊維と、
前記第1繊維に含まれるシリカエアロゲルと、
繊維状の空洞と、を含む断熱シート。 - 前記断熱シートは、積層体でなく、1層であり、厚さ1.5mm以上である請求項1記載の断熱シート。
- 前記繊維状の空洞は、直径0.2mm以下、長さが直径の2倍以上である請求項1記載の断熱シート。
- 前記繊維状の空洞は、直径0.01mm以上である請求項1に記載の断熱シート。
- 前記繊維状の空洞は、前記断熱シートの少なくとも2面に存在する、請求項1に記載の断熱シート。
- 前記繊維状の空洞の体積割合は、0.02~2vol%である、請求項1に記載の断熱シート。
- 前記シリカエアロゲルの断熱シートに占める重量割合は、40~70重量%である、請求項1に記載の断熱シート。
- 酸性溶液に不可溶な第1繊維と前記酸性溶液に可溶な第2繊維とを含む不織布基材にシリカエアロゾル溶液を含浸させる含浸工程と、
前記シリカエアロゾル溶液をゲル化させるゲル化工程と、
前記ゲルを疎水化する疎水化工程と、
前記ゲルを乾燥させる乾燥工程と、を備え、
前記第2繊維が前記疎水化工程で溶解する断熱シートの製造方法。 - 前記第2繊維は、ナイロン、レーヨン、キュプラ、アセテート、ビニロン、綿のうち、少なくとも1つ以上である請求項8に記載の断熱シートの製造方法。
- 前記第2繊維は、直径0.2mm以下、長さが直径の2倍以上である請求項8に記載の断熱シートの製造方法。
- 前記第2繊維は、直径0.01mm以上である請求項8に記載の断熱シートの製造方法。
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JP2020193413A (ja) * | 2019-05-29 | 2020-12-03 | パナソニックIpマネジメント株式会社 | 断熱シートおよびその製造方法、ならびに電子機器および電池ユニット |
JPWO2020100460A1 (ja) * | 2018-11-15 | 2021-10-07 | パナソニックIpマネジメント株式会社 | 断熱シートおよびその製造方法 |
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US11707721B2 (en) | 2017-10-11 | 2023-07-25 | University Of Utah Research Foundation | Methods of making permeable aerogels |
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