WO2019069406A1 - エアロゲル及びその製造方法 - Google Patents
エアロゲル及びその製造方法 Download PDFInfo
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- WO2019069406A1 WO2019069406A1 PCT/JP2017/036165 JP2017036165W WO2019069406A1 WO 2019069406 A1 WO2019069406 A1 WO 2019069406A1 JP 2017036165 W JP2017036165 W JP 2017036165W WO 2019069406 A1 WO2019069406 A1 WO 2019069406A1
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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
- C01B33/14—Colloidal silica, e.g. dispersions, gels, sols
- C01B33/155—Preparation of hydroorganogels or organogels
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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
- C01B33/163—Preparation of silica xerogels by hydrolysis of organosilicon compounds, e.g. ethyl orthosilicate
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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
- C01B33/14—Colloidal silica, e.g. dispersions, gels, sols
- C01B33/145—Preparation of hydroorganosols, organosols or dispersions in an organic medium
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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
- C01B33/14—Colloidal silica, e.g. dispersions, gels, sols
- C01B33/146—After-treatment of sols
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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
- C01B33/14—Colloidal silica, e.g. dispersions, gels, sols
- C01B33/157—After-treatment of gels
- C01B33/158—Purification; Drying; Dehydrating
- C01B33/1585—Dehydration into aerogels
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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
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/32—Thermal properties
Definitions
- the present invention relates to an airgel and a method for producing the same.
- Silica airgel is known as a material having a small thermal conductivity and thermal insulation. Silica airgel is useful as a functional material having excellent functionality (heat insulation etc.), specific optical characteristics, specific electrical characteristics, etc.
- an electronic substrate utilizing the ultra low dielectric constant characteristics of silica aerogel It is used as a material, a heat insulating material utilizing high heat insulation of silica airgel, a light reflecting material using ultra low refractive index of silica airgel, etc.
- a supercritical drying method in which a gel compound (alcogel) obtained by hydrolyzing and polymerizing an alkoxysilane is dried under supercritical conditions of a dispersion medium.
- a gel compound (alcogel) obtained by hydrolyzing and polymerizing an alkoxysilane is dried under supercritical conditions of a dispersion medium.
- Supercritical drying method is included in the alcogel by introducing the alcogel and the dispersion medium (solvent used for drying) into a high pressure vessel, and making the dispersion medium a supercritical fluid by applying temperature and pressure above its critical point. Solvent is removed.
- the supercritical drying method requires a high pressure process, it is necessary to invest in equipment for special equipment capable of withstanding the supercritical condition, and also requires much labor and time.
- the method of drying alcogel using the general purpose method which does not require a high pressure process is proposed.
- a method for example, a method is known in which the strength of the resulting alcogel is improved by using a monoalkyltrialkoxysilane and a tetraalkoxysilane in combination in a specific ratio as a gel raw material, and drying is carried out under normal pressure.
- Patent Document 2 See, for example, Patent Document 2.
- the gel tends to shrink due to the stress caused by the capillary force inside the alcogel.
- the present invention has been made in view of the above circumstances, and an object of the present invention is to provide an airgel having a small volumetric shrinkage at the time of drying and being excellent in moldability (for example, film forming ability) and a method for producing the same.
- the volume shrinkage in the drying step is suppressed, so that the shape of the wet gel at the time of drying is sufficiently maintained, and the airgel can be formed with good moldability.
- the weight average molecular weight of the silane oligomer may be 200 or more and 10000 or less. Thereby, the volume contraction in the drying step is further suppressed.
- the weight average molecular weight of a silane oligomer shows the weight average molecular weight of standard polystyrene conversion measured by gel permeation chromatography (GPC).
- the silane oligomer may have an alkoxy group, and the content of the alkoxy group may be 2% by mass or more and 60% by mass or less based on the total amount of the silane oligomer. Thereby, the volume contraction in the drying step is further suppressed.
- the present disclosure is also a dry product of a wet gel which is a condensation product of a sol containing a silane oligomer, wherein the ratio of silicon atoms bonded to three oxygen atoms is 50 with respect to the total number of silicon atoms in the silane oligomer.
- a dry product of a wet gel which is a condensation product of a sol containing a silane oligomer, wherein the ratio of silicon atoms bonded to three oxygen atoms is 50 with respect to the total number of silicon atoms in the silane oligomer.
- an aerogel that is at least%.
- the weight average molecular weight of the silane oligomer may be 200 or more and 10000 or less.
- the silane oligomer may have an alkoxy group, and the content of the alkoxy group may be 2% by mass or more and 60% by mass or less based on the total amount of the silane oligomer.
- the airgel with little volume shrinkage at the time of drying and being excellent in a moldability (for example, film-forming property) and its manufacturing method are provided.
- ⁇ Aerogel manufacturing method> In the method of producing an airgel according to the present embodiment, a sol formation step of hydrolyzing a silane oligomer to form a sol containing a hydrolysis product of the silane oligomer, and gelation of the sol to obtain a wet gel And a drying step of drying the wet gel to obtain an aerogel.
- the ratio of silicon atoms bonded to three oxygen atoms to the total number of silicon atoms in the silane oligomer is 50% or more.
- volume shrinkage in the drying step is suppressed by using a specific silane oligomer, so the shape of the wet gel at the time of drying is sufficiently maintained, and an airgel can be formed with good moldability.
- molded by the film form can be formed easily, for example.
- sol means a state before a gelation reaction occurs, and in the present embodiment, a state in which a silicon compound containing a hydrolysis product of a silane oligomer is dissolved or dispersed in a liquid medium.
- wet gel refers to a gel solid in a wet state having no flowability while containing a liquid medium.
- the method for producing an aerogel according to the present embodiment may further include a washing step of washing (and, if necessary, solvent substitution) the wet gel obtained in the wet gel formation step.
- a washing step of washing (and, if necessary, solvent substitution) the wet gel obtained in the wet gel formation step.
- a washing step can be omitted to produce an airgel.
- the omission of the cleaning step achieves process simplification and cost reduction.
- the sol formation step is a step of hydrolyzing a silane oligomer to form a sol containing a hydrolysis product of the silane oligomer.
- the silane oligomer is a polymer of a silane monomer, and has a structure in which a plurality of silicon atoms are linked via an oxygen atom.
- a silane oligomer refers to a polymer having 2 to 100 silicon atoms in one molecule.
- the silane oligomer may be, for example, a polymer of one or more types of silane monomers described later, and is preferably a polymer of silane monomers including an alkyltrialkoxysilane.
- the silicon atom contained in the silane oligomer is a silicon atom bonded to one oxygen atom (M unit), a silicon atom bonded to two oxygen atoms (D unit), a silicon atom bonded to three oxygen atoms ( T units) and silicon atoms (Q units) bound to four oxygen atoms can be distinguished.
- M unit silicon atom bonded to one oxygen atom
- D unit silicon atom bonded to two oxygen atoms
- T units silicon atom bonded to three oxygen atoms
- Q units silicon atoms bound to four oxygen atoms
- R represents an atom (such as a hydrogen atom) or an atomic group (such as an alkyl group) other than an oxygen atom bonded to silicon. Information on the content of these units can be obtained by Si-NMR.
- the ratio of T units to the total number of silicon atoms is 50% or more, preferably 60% or more, more preferably 70% or more, and may be 100%.
- the silane oligomer preferably has an alkyl group or an aryl group as R in the formulas (M), (D), (T) and (Q) described above.
- alkyl group examples include alkyl groups having 1 to 6 carbon atoms. Specific examples of the alkyl group include a methyl group, an ethyl group, a propyl group and a butyl group. Among these, a methyl group and an ethyl group are preferable, and a methyl group is more preferable.
- aryl group a phenyl group, a substituted phenyl group, etc. are mentioned.
- substituent of the substituted phenyl group include an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group and the like.
- aryl group a phenyl group is preferable.
- the silane oligomer has a hydrolyzable functional group, and in the sol formation step, it is considered that the hydrolyzable functional group is hydrolyzed to form a silanol group.
- the hydrolyzable functional group includes an alkoxy group. A methoxy group, an ethoxy group, a propoxy group etc. are mentioned as a specific example of an alkoxy group, From a viewpoint of the reaction rate of a hydrolysis reaction, a methyl group and an ethoxy group are preferable.
- the content of the hydrolyzable functional group may be, for example, 2% by mass or more, preferably 10% by mass or more, and more preferably 20% by mass or more, based on the total amount of the silane oligomer. Further, the content of the hydrolyzable functional group may be, for example, 60% by mass or less, preferably 50% by mass or less, more preferably 45% by mass or less, based on the total amount of the silane oligomer. According to such a silane oligomer, the volume shrinkage in the drying step can be further suppressed, and an airgel having more excellent moldability can be obtained.
- the weight average molecular weight of the silane oligomer may be, for example, 200 or more, preferably 400 or more, and more preferably 600 or more.
- the weight average molecular weight of the silane oligomer may be, for example, 10000 or less, preferably 7000 or less, and more preferably 5000 or less. According to such a silane oligomer, the volume shrinkage in the drying step can be further suppressed, and an airgel having more excellent moldability can be obtained.
- the weight average molecular weight of a silane oligomer shows the weight average molecular weight of standard polystyrene conversion measured by gel permeation chromatography (GPC).
- silane oligomer you may use a commercial item, For example, XR31-B1410, XC96-B0446 (all are Momentive company make), KR-500, KR-515, X-40-9225, KC-89S (all are And Shin-Etsu Chemical Co., Ltd., SR-2402 and AY 42-163 (all of which are manufactured by Toray Dow Coating Co., Ltd.).
- silicon compounds other than the silane oligomer may be further subjected to hydrolysis.
- Other silicon compounds include, for example, silane monomers having hydrolyzable functional groups or condensable functional groups.
- the hydrolyzable functional group the same groups as those exemplified as the hydrolyzable functional group possessed by the silane oligomer can be exemplified.
- a silanol group is mentioned as a condensable functional group.
- the silane monomer can also be referred to as a silicon compound having no siloxane bond (Si-O-Si).
- silane monomers having a hydrolyzable functional group examples include monoalkyltrialkoxysilane, monoaryltrialkoxysilane, monoalkyldialkoxysilane, monoaryldialkoxysilane, dialkyldialkoxysilane, diaryldialkoxysilane, mono Alkyl monoalkoxysilane, monoaryl monoalkoxysilane, dialkyl monoalkoxysilane, diaryl monoalkoxysilane, trialkyl monoalkoxysilane, triaryl monoalkoxysilane, tetraalkoxysilane, etc. are mentioned.
- methyltrimethoxysilane, methyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, methyldimethoxysilane, dimethyldiethoxysilane, dimethyldimethoxysilane, ethyltrimethoxysilane, hexyltrimethoxysilane, tetraethoxysilane Silane etc. are mentioned.
- silane monomers having a condensable functional group examples include silanetetraol, methylsilanetriol, dimethylsilanediol, phenylsilanetriol, phenylmethylsilanediol, diphenylsilanediol, n-propylsilanetriol, hexylsilanetriol, octyl Silantriol, decylsilanetriol, trifluoropropylsilanetriol and the like can be mentioned.
- the silane monomer may further have a reactive group different from the hydrolyzable functional group and the condensable functional group.
- the reactive group include epoxy group, mercapto group, glycidoxy group, vinyl group, acryloyl group, methacryloyl group, amino group and the like.
- the epoxy group may be contained in an epoxy group-containing group such as a glycidoxy group.
- silane monomer having a hydrolyzable functional group and a reactive group for example, vinyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 3-methacryloxypropyltriol Methoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-acryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropylmethyldimethoxysilane, N-phenyl-3-aminopropyltrimethoxysilane, N -2- (aminoethyl) -3-aminopropylmethyldimethoxysilane and the like.
- vinyltrimethoxysilane 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 3-methacryloxypropyltriol Methoxys
- silane monomers having a condensable functional group and a reactive group examples include vinylsilanetriol, 3-glycidoxypropylsilanetriol, 3-glycidoxypropylmethylsilanediol, 3-methacryloxypropylsilanetriol, 3--3.
- the silane monomer may have two or more silicon atoms, and as such a silane monomer, bistrimethoxysilylmethane, bistrimethoxysilylethane, bistrimethoxysilylhexane and the like can be mentioned.
- a polysiloxane compound having a hydrolyzable reactive group or a condensable functional group (provided that the proportion of T units is less than 50% or the number of silicon atoms is more than 100).
- the hydrolyzable reactive group and the condensable functional group the same groups as described above can be exemplified.
- polysiloxane compound which has a hydroxyalkyl group among the said polysiloxane compounds what has a structure represented by the following general formula (A) is mentioned, for example.
- a polysiloxane compound having a structure represented by the following general formula (A) structures represented by the general formula (1) and the formula (1a) described later can be introduced into the skeleton of the airgel .
- R 1a represents a hydroxyalkyl group
- R 2a represents an alkylene group
- R 3a and R 4a each independently represent an alkyl group or an aryl group
- n represents an integer of 1 to 50.
- examples of the aryl group include a phenyl group and a substituted phenyl group.
- a substituent of a substituted phenyl group an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group etc. are mentioned.
- two R 1a 's may be the same as or different from each other, and similarly, two R 2a' s may be the same as or different from each other.
- two or more R 3a s may be the same as or different from each other.
- two or more R 4a s may be the same as or different from each other.
- examples of R 1a include a hydroxyalkyl group having 1 to 6 carbon atoms, and the like, and examples of the hydroxyalkyl group include a hydroxyethyl group and a hydroxypropyl group.
- examples of R 2a include an alkylene group having 1 to 6 carbon atoms, and examples of the alkylene group include an ethylene group and a propylene group.
- R 3a and R 4a each independently represent an alkyl group having 1 to 6 carbon atoms, a phenyl group or the like, and examples of the alkyl group include a methyl group.
- n can be 2 to 30, but may be 5 to 20.
- a commercial item can be used as a polysiloxane compound which has a structure represented by the said General formula (A), Compounds, such as X-22-160AS, KF-6001, KF-6002, KF-6003 (all are mentioned And Shin-Etsu Chemical Co., Ltd., XF42-B0970, Fluid OFOH 702-4%, etc. (all are manufactured by Momentive, Inc.) and the like.
- polysiloxane compound which has an alkoxy group among the said polysiloxane compounds what has a structure represented by the following general formula (B) is mentioned, for example.
- a ladder type structure having a cross-linked part represented by the general formula (2) or (3) described later can be contained in the skeleton of the airgel Can be introduced.
- R 1b represents an alkyl group, an alkoxy group or an aryl group
- R 2b and R 3b each independently represent an alkoxy group
- R 4b and R 5b each independently represent an alkyl group or an aryl group.
- m represent an integer of 1 to 50.
- examples of the aryl group include a phenyl group and a substituted phenyl group.
- a substituent of a substituted phenyl group an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group etc. are mentioned.
- two R 1b 's may be the same as or different from each other, and two R 2b' s may be the same as or different from one another, 3b may be the same or different.
- m is an integer of 2 or more
- two or more R 4b may be the same or different
- two or more R 5b are also the same May also be different.
- examples of R 1b include an alkyl group having 1 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms, and the like, and examples of the alkyl group or alkoxy group include a methyl group, a methoxy group and an ethoxy group.
- R 2b and R 3b each independently represent an alkoxy group having 1 to 6 carbon atoms, and the alkoxy group includes a methoxy group, an ethoxy group, and the like.
- examples of R 4b and R 5b each independently include an alkyl group having 1 to 6 carbon atoms, a phenyl group and the like, and examples of the alkyl group include a methyl group and the like.
- m can be 2 to 30, but may be 5 to 20.
- the polysiloxane compound having a structure represented by the above general formula (B) can be obtained by appropriately referring to the production method reported in JP-A-2000-26609, JP-A-2012-233110, etc. .
- silicate oligomers such as a methyl silicate oligomer and an ethyl silicate oligomer
- silicate oligomers such as a methyl silicate oligomer and an ethyl silicate oligomer
- the methyl silicate 51, the methyl silicate 53A, the ethyl silicate 40, the ethyl silicate 48 (all are Corcoat Co., Ltd. make) etc. are mentioned, for example.
- the polysiloxane compound having the alkoxy group may be present as a hydrolysis product in the sol, and the polysiloxane compound having the alkoxy group and the hydrolysis product thereof are mixed. It may be Further, in the polysiloxane compound having an alkoxy group, all of the alkoxy groups in the molecule may be hydrolyzed or may be partially hydrolyzed.
- the ratio of the above-mentioned silane oligomer may be, for example, 5% by mass or more, preferably 10% by mass or more, and more preferably 20% by mass or more in the silicon compound to be subjected to hydrolysis in the sol formation step.
- the amount of the silane monomer may be 2000 parts by mass or less, preferably 1000 parts by mass or less, per 100 parts by mass of the silane oligomer. Preferably, it is 500 parts by mass or less.
- the amount of the silane monomer may be, for example, 1 part by mass or more, preferably 10 parts by mass or more, and more preferably 50 parts by mass or more, with respect to 100 parts by mass of the silane oligomer.
- the amount of the polysiloxane compound may be 100 parts by mass or less, preferably 50 parts by mass or less, with respect to 100 parts by mass of the silane oligomer. And more preferably 25 parts by mass or less.
- the addition of the polysiloxane compound may improve the flexibility and toughness of the airgel.
- a silicon compound containing a silane oligomer can be hydrolyzed in a solvent.
- the solvent for example, water or a mixed solvent containing water and an alcohol can be used.
- the alcohol include methanol, ethanol, n-propanol, 2-propanol, n-butanol, 2-butanol, t-butanol and the like.
- methanol, ethanol, 2-propanol and the like which are alcohols having a low surface tension and a low boiling point are preferable. You may use these individually or in mixture of 2 or more types.
- the mixing ratio of water and alcohol is not particularly limited.
- the volume ratio of alcohol to water may be 1 or more, preferably 1.5 or more, and more preferably 2 or more.
- the volume ratio may be, for example, 100 or less, preferably 50 or less, and more preferably 10 or less.
- a solvent having a low surface tension can be further added to the above-mentioned mixed solvent.
- the low surface tension solvent one having a surface tension of 30 mN / m or less at 20 ° C. can be mentioned.
- the surface tension may be 25 mN / m or less, or 20 mN / m or less.
- low surface tension solvents examples include pentane (15.5), hexane (18.4), heptane (20.2), octane (21.7), 2-methylpentane (17.4), 3- Aliphatic hydrocarbons such as methyl pentane (18.1), 2-methyl hexane (19.3), cyclopentane (22.6), cyclohexane (25.2), 1-pentene (16.0); benzene Aromatic hydrocarbons such as (28.9), toluene (28.5), m-xylene (28.7), p-xylene (28.3); dichloromethane (27.9), chloroform (27.2) Halogenated hydrocarbons such as carbon tetrachloride (26.9), 1-chloropropane (21.8), 2-chloropropane (18.1), etc .; ethyl ether (17.1), propyl ether (20.5) ), Isop Ethers such as pill ether (17.7), buty
- an acid catalyst may be further added to the solvent to accelerate the hydrolysis reaction.
- inorganic acids such as hydrofluoric acid, hydrochloric acid, nitric acid, sulfuric acid, sulfurous acid, phosphoric acid, phosphorous acid, hypophosphorous acid, bromic acid, chloric acid, chlorous acid, hypochlorous acid, etc .
- acidic phosphoric acid Acidic phosphates such as aluminum, acidic magnesium phosphate, acidic zinc phosphate, etc .
- Organic carboxylic acids such as acetic acid, formic acid, propionic acid, oxalic acid, malonic acid, succinic acid, citric acid, malic acid, adipic acid, azelaic acid Etc.
- an organic carboxylic acid is mentioned as an acid catalyst which the water resistance of the obtained airgel improves more.
- the organic carboxylic acid include acetic acid, but formic acid, propionic acid, oxalic acid, malonic acid and the like may be used. From the viewpoint of omitting the washing step, it is preferable to use acetic acid, formic acid or the like as the acid catalyst.
- the addition amount of the acid catalyst is not particularly limited, it can be, for example, 0.001 to 10 parts by mass with respect to 100 parts by mass of the total amount of silicon compounds.
- a surfactant, a thermally hydrolysable compound, etc. can be added to the solvent.
- nonionic surfactants nonionic surfactants, ionic surfactants and the like can be used. You may use these individually or in mixture of 2 or more types.
- nonionic surfactant for example, a compound containing a hydrophilic part such as polyoxyethylene and a hydrophobic part mainly composed of an alkyl group, a compound containing a hydrophilic part such as polyoxypropylene and the like can be used.
- a compound containing a hydrophilic moiety such as polyoxyethylene and a hydrophobic moiety mainly composed of an alkyl group include polyoxyethylene nonylphenyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene alkyl ether and the like.
- the compound containing a hydrophilic portion such as polyoxypropylene include polyoxypropylene alkyl ether and block copolymers of polyoxyethylene and polyoxypropylene.
- Examples of the ionic surfactant include cationic surfactants, anionic surfactants and amphoteric surfactants.
- Examples of the cationic surfactant include cetyltrimethylammonium bromide, cetyltrimethylammonium chloride and the like, and examples of the anionic surfactant include sodium dodecyl sulfonate and the like.
- an amphoteric surfactant an amino acid surfactant, a betaine surfactant, an amine oxide surfactant, etc. are mentioned.
- Examples of amino acid surfactants include, for example, acyl glutamic acid.
- Examples of betaine surfactants include lauryl dimethylaminoacetic acid betaine and stearyl dimethylaminoacetic acid betaine.
- Examples of amine oxide surfactants include lauryldimethylamine oxide.
- surfactants have the function of reducing the difference in chemical affinity between the solvent in the reaction system and the growing siloxane polymer and suppressing the phase separation in the wet gel formation step described later. It is believed that.
- the alcohol when a mixed solvent containing water and an alcohol is used as the solvent, it is considered that the alcohol exhibits the same effect as the above-mentioned effect of the surfactant, and the wet gel is obtained without adding the surfactant. Can be suitably generated.
- thermohydrolyzable compound is considered to generate a base catalyst by thermal hydrolysis to make the reaction solution basic and to promote the sol-gel reaction in the wet gel formation 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 And acid amides such as methylacetamide and N, N-dimethylacetamide; and cyclic nitrogen compounds such as hexamethylenetetramine. Among these, urea is particularly easy to obtain the above promoting effect.
- components such as carbon graphite, an aluminum compound, a magnesium compound, a silver compound, and a titanium compound may be added to the solvent for the purpose of suppressing heat ray radiation and the like.
- silica particles described later may be added to the solvent.
- the hydrolysis in the sol formation step depends on the type and amount of silicon compound, acid catalyst, etc. in the mixture, but may be carried out, for example, in a temperature environment of 20 to 80 ° C. for 10 minutes to 24 hours, The heating may be performed for 5 minutes to 8 hours in a temperature environment of ⁇ 60 ° C.
- the hydrolyzable functional group in the silicon compound is sufficiently hydrolyzed, and the hydrolysis product of the silicon compound can be more reliably obtained.
- the temperature environment of the sol formation step may be adjusted to a temperature at which the hydrolysis of the thermally hydrolysable compound is suppressed to suppress the gelation of the sol. .
- the temperature at this time may be any temperature that can suppress the hydrolysis of the thermally hydrolysable compound.
- the temperature environment of the sol formation step can be 0 to 40 ° C., but may be 10 to 30 ° C.
- a silicon compound containing a silane oligomer is hydrolyzed to form a sol containing a hydrolysis product of the silicon compound.
- the said hydrolysis product can also be said that one part or all part of the hydrolysable functional group which a silicon compound has was hydrolyzed.
- the wet gel formation step is a step of gelling the sol obtained in the sol formation step to obtain a wet gel.
- This step may be a step of gelling the sol and then ripening to obtain a wet gel.
- a base catalyst can be used to promote gelation.
- carbonates such as calcium carbonate, potassium carbonate, sodium carbonate, barium carbonate, magnesium carbonate, lithium carbonate, ammonium carbonate, copper (II) carbonate, iron (II) carbonate, silver (I) carbonate, etc .
- Hydrogen carbonates such as calcium, potassium hydrogen carbonate, sodium hydrogen carbonate and ammonium hydrogen carbonate
- alkali metal hydroxides such as lithium hydroxide, sodium hydroxide, potassium hydroxide and cesium hydroxide
- ammonium hydroxide, ammonium fluoride Ammonium compounds such as ammonium chloride and ammonium bromide
- Basic phosphoric acid sodium salts such as sodium metaphosphate, sodium pyrophosphate and sodium polyphosphate
- ammonium hydroxide (ammonia water) is high in volatility and less likely to remain in airgel particles after drying, so that it is difficult to impair water resistance, and is further excellent in economic point.
- ammonium hydroxide (ammonia water) is preferable as the base catalyst.
- the above base catalysts may be used alone or in combination of two or more.
- the dehydration condensation reaction or the dealcoholization condensation reaction of the silicon compound in the sol can be promoted, and the gelation of the sol can be performed in a shorter time. Also, this makes it possible to obtain a wet gel with higher strength (rigidity).
- ammonia has high volatility and is unlikely to remain in airgel particles, so that by using ammonium hydroxide as a base catalyst, an airgel having more excellent water resistance can be obtained.
- the addition amount of the base catalyst can be 0.1 to 10 parts by mass with respect to 100 parts by mass of the total amount of silicon compounds used in the sol formation step, but may be 1 to 4 parts by mass. By setting it as 0.1 mass part or more, gelation can be performed in a short time, and the fall of water resistance can be suppressed more by setting it as 10 mass parts or less.
- the gelation of the sol in the wet gel formation step may be performed in a closed vessel so that the solvent and the base catalyst do not evaporate.
- the gelling temperature may be 30-90 ° C., but may be 40-80 ° C.
- the gelation temperature may be set to 30 ° C. or more, gelation can be performed in a shorter time, and a wet gel with higher strength (rigidity) can be obtained.
- the gelation temperature to 90 ° C. or less, volatilization of the solvent (particularly alcohol) can be easily suppressed, and thus gelation can be performed while suppressing volumetric shrinkage.
- Aging in the wet gel formation step may be performed in a closed vessel so that the solvent and the base catalyst do not evaporate. Aging strengthens the bonding of the components constituting the wet gel, and as a result, it is possible to obtain a wet gel having a high strength (rigidity) sufficient to suppress shrinkage upon drying.
- the ripening temperature may be 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, volatilization of the solvent (particularly alcohol) is easily suppressed. And can be gelled while suppressing volume contraction.
- the gelation of the sol and the subsequent aging may be performed in a series of continuous operations.
- the gelation time and the aging time can be appropriately set by the gelling temperature and the aging temperature.
- the gelling time can be 10 to 120 minutes, but can be 20 to 90 minutes. By setting the gelation time to 10 minutes or more, it becomes easy to obtain a homogeneous wet gel, and by setting the gelation time to 120 minutes or less, it is possible to simplify the washing process from the washing process described later.
- the total time of the gelation time and the aging time can be 4 to 480 hours as the whole of the gelation and the aging process, but it may be 6 to 120 hours. By setting the total of the gelation time and the ripening time to 4 hours or more, a wet gel with higher strength (rigidity) can be obtained, and by making it 480 hours or less, the effect of ripening can be more easily maintained.
- the gelling temperature and the aging temperature are increased within the above range, or the total time of the gelling time and the aging time is increased within the above range. It is also good.
- the gelling temperature and the aging temperature are lowered within the above range, or the total time of the gelling time and the aging time is short within the above range. You may
- the washing step is a step of washing the wet gel obtained in the wet gel formation step.
- solvent replacement may be further performed to replace the washing solution in the wet gel with a solvent suitable for drying conditions (drying step described later).
- the wet gel obtained by the wet gel formation step is washed.
- the washing can be repeated, for example, using water or an organic solvent. At this time, the washing efficiency can be improved by heating.
- organic solvent methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, acetone, methyl ethyl ketone, 1,2-dimethoxyethane, acetonitrile, hexane, toluene, diethyl ether, chloroform, ethyl acetate, tetrahydrofuran, methylene chloride
- organic solvents such as 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.
- examples of the organic solvent used for washing include hydrophilic organic solvents having high mutual solubility in both water and solvents of low surface tension.
- cleaning can play the role of the pre-substitution for solvent substitution.
- examples of the hydrophilic organic solvent include methanol, ethanol, 2-propanol, acetone, methyl ethyl ketone and the like. Methanol, ethanol, methyl ethyl ketone and the like are excellent in economical point.
- the amount of water or organic solvent used for washing can be sufficient to replace the solvent in the wet gel and to be washable.
- the amount can be 3 to 10 times the volume of the wet gel.
- the temperature environment in the washing can be set to a temperature equal to or lower than the boiling point of the solvent used for the washing.
- heating can be performed at about 30 to 60.degree.
- the solvent of the washed wet gel is replaced with a predetermined substitution solvent in order to suppress the shrinkage of the airgel in the drying step.
- the substitution efficiency can be improved by heating.
- Specific examples of the substitution solvent include, in the drying step, a solvent having a low surface tension described later when drying under atmospheric pressure at a temperature less than the critical point of the solvent used for drying.
- examples of the substitution solvent include ethanol, methanol, 2-propanol, dichlorodifluoromethane, carbon dioxide and the like, or solvents in which two or more of these are mixed.
- solvents having a surface tension of 30 mN / m or less at 20 ° C. As a low surface tension solvent, solvents having a surface tension of 30 mN / m or less at 20 ° C. can be mentioned.
- the surface tension may be 25 mN / m or less, or 20 mN / m or less.
- low surface tension solvents examples include pentane (15.5), hexane (18.4), heptane (20.2), octane (21.7), 2-methylpentane (17.4), 3- Aliphatic hydrocarbons such as methyl pentane (18.1), 2-methyl hexane (19.3), cyclopentane (22.6), cyclohexane (25.2), 1-pentene (16.0); benzene Aromatic hydrocarbons such as (28.9), toluene (28.5), m-xylene (28.7), p-xylene (28.3); dichloromethane (27.9), chloroform (27.2) Halogenated hydrocarbons such as carbon tetrachloride (26.9), 1-chloropropane (21.8), 2-chloropropane (18.1), etc .; ethyl ether (17.1), propyl ether (20.5) ), Isop Ethers such as pill ether (17.7), buty
- aliphatic hydrocarbons (hexane, heptane, etc.) have low surface tension and are excellent in working environment.
- a hydrophilic organic solvent such as acetone, methyl ethyl ketone or 1,2-dimethoxyethane, it can also be used as an organic solvent at the time of washing.
- a solvent having a boiling point of 100 ° C. or less at normal pressure may be used at the point of easy drying in the drying step described later.
- the above solvents may be used alone or in combination of two or more.
- the amount of solvent used for solvent substitution can be an amount that can sufficiently replace the solvent in the wet gel after washing.
- the amount can be 3 to 10 times the volume of the wet gel.
- the temperature environment in the solvent substitution can be a temperature equal to or lower than the boiling point of the solvent used for the substitution. For example, in the case of using heptane, heating at about 30 to 60 ° C. can be performed.
- an organic catalyst selected from the group consisting of acetic acid, formic acid and propionic acid as an acid catalyst, water and an alcohol as a solvent (for example, methanol, ethanol, 2-propanol, n-propanol, t-butanol
- the washing step can be omitted by respectively selecting the mixed solvent containing (E) and the like and ammonium hydroxide as the base catalyst.
- the airgel is produced, for example, by removing the solvent in the wet gel obtained in the wet gel formation step in the drying step.
- the aerogel can be obtained by drying the wet gel (which has been subjected to the washing step if necessary). That is, an airgel can be obtained by drying the wet gel produced from the above sol.
- the drying method is not particularly limited, and known atmospheric pressure drying, supercritical drying or lyophilization can be used. Among these, lyophilization or supercritical drying can be used from the viewpoint of easily producing a low density aerogel. In addition, normal pressure drying can be used from the viewpoint of low cost production. In the present embodiment, normal pressure means 0.1 MPa (atmospheric pressure).
- Aerogels can be obtained by drying the wet gel under atmospheric pressure at a temperature below the critical point of the solvent in the wet gel.
- the drying temperature varies depending on the type of solvent in the wet gel, in particular, the temperature should be 20 to 180 ° C. in view of the fact that drying at high temperature accelerates the evaporation rate of the solvent and may cause large cracks in the gel.
- the drying temperature may be 60 to 120 ° C.
- the drying time may vary depending on the wet gel volume and the drying temperature, but may be 4 to 120 hours.
- accelerating under a pressure by applying a pressure less than the critical point within a range not inhibiting productivity is also included in normal-pressure drying.
- Aerogels can also be obtained by supercritical drying of wet gels.
- Supercritical drying can be performed by a known method.
- a method of performing supercritical drying for example, a method of removing the solvent at a temperature and pressure higher than the critical point of the solvent contained in the wet gel can be mentioned.
- the whole or a part of the solvent contained in the wet gel is immersed in liquefied carbon dioxide, for example, under the conditions of about 20 to 25 ° C., about 5 to 20 MPa.
- a method of removing carbon dioxide alone or a mixture of carbon dioxide and a solvent after replacing the solvent with carbon dioxide having a lower critical point than the solvent for example, under the conditions of about 20 to 25 ° C., about 5 to 20 MPa.
- the airgel obtained by such normal pressure drying or supercritical drying may be additionally dried at 105 to 200 ° C. for about 0.5 to 2 hours under normal pressure. This further facilitates obtaining an airgel with low density and small pores.
- the additional drying may be performed at 150 to 200 ° C. under normal pressure.
- the drying step may be performed after the wet gel is formed into a desired shape.
- granular airgel can be obtained by grinding the wet gel with a mixer or the like and then carrying out the drying step.
- the manufacturing method according to the present embodiment may further include the step of forming the airgel obtained in the drying step.
- granular airgel can be obtained by crushing the airgel obtained in the drying step.
- the airgel according to the present embodiment is a dry product of a wet gel which is a condensation product of a sol containing a silane oligomer.
- the airgel which concerns on this embodiment may be obtained by the above-mentioned manufacturing method, for example.
- the resulting low density dried gel is referred to as "aerogel” regardless of these drying techniques of the wet gel. That is, in the present embodiment, the “aerogel” is a gel in the broad sense “gel composed of a microporous solid in which the dispersed phase is a gas (a gel composed of a microporous solid in which the dispersed phase is a gas)” Means ".
- the inside of the airgel has a mesh-like microstructure, and has a cluster structure in which a particle-like airgel component of about 2 to 20 nm is bonded. Between the frameworks formed by the clusters, there are pores less than 100 nm. Thus, the aerogel has a three-dimensionally formed fine porous structure.
- the airgel which concerns on this embodiment is a silica airgel which has a silica as a main component, for example.
- the silica aerogels include so-called organic-inorganic hybridised silica aerogels into which organic groups (such as methyl groups) or organic chains have been introduced.
- Examples of the airgel according to the present embodiment include the following. By adopting these modes, it becomes easy to obtain an airgel excellent in heat insulation, flame retardancy, heat resistance and flexibility. By adopting each aspect, it is possible to obtain an airgel having thermal insulation, flame retardancy, heat resistance and flexibility according to each aspect.
- the airgel which concerns on this embodiment can have a structure represented by following General formula (1).
- the airgel which concerns on this embodiment can have a structure represented by following General formula (1a) as a structure containing the structure represented by Formula (1).
- R 1 and R 2 each independently represent an alkyl group or an aryl group
- R 3 and R 4 each independently represent an alkylene group.
- examples of the aryl group include a phenyl group and a substituted phenyl group.
- a substituent of a substituted phenyl group an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group etc. are mentioned.
- p represents an integer of 1 to 50.
- two or more R 1 s may be the same as or different from each other, and similarly, two or more R 2 s may be the same as or different from each other.
- two R 3 s may be the same or different, and similarly, two R 4 s may be the same or different.
- R 1 and R 2 each independently represent an alkyl group having 1 to 6 carbon atoms, a phenyl group or the like, and the alkyl group is methyl And the like.
- R 3 and R 4 each independently represent an alkylene group having 1 to 6 carbon atoms, and the alkylene group includes an ethylene group, a propylene group, etc.
- p may be 2 to 30, and may be 5 to 20.
- the airgel according to the present embodiment can have a ladder-type structure including a support portion and a bridging portion, and the bridging portion can have a structure represented by the following general formula (2).
- Heat resistance and mechanical strength can be improved by introducing such a ladder-type structure as an airgel component into the skeleton of the airgel.
- the term “ladder type structure” refers to one having two struts (struts) and bridges connecting the struts (so-called “ladder”). It is.
- the skeleton of the airgel may have a ladder structure, but the airgel may partially have a ladder structure.
- R 5 and R 6 each independently represent an alkyl group or an aryl group, and b represents an integer of 1 to 50.
- examples of the aryl group include a phenyl group and a substituted phenyl group.
- a substituent of a substituted phenyl group an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group etc. are mentioned.
- b is an integer of 2 or more
- two or more R 5 s may be the same as or different from each other, and similarly, two or more R 6 s may be the same as each other May also be different.
- silsesquioxane is a polysiloxane having a compositional formula: (RSiO 1.5 ) n and can have various skeleton structures such as a cage type, a ladder type, and a random type.
- the structure of the cross-linked portion is -O-, but the airgel according to the present embodiment
- the structure of the crosslinked portion is a structure (polysiloxane structure) represented by the above general formula (2).
- the airgel of this embodiment may have a structure derived from silsesquioxane in addition to the structure represented by the general formula (2).
- R represents a hydroxy group, an alkyl group or an aryl group.
- the ladder type structure It may have a ladder type structure represented by 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
- b is 1 to 50.
- examples of the aryl group include a phenyl group and a substituted phenyl group.
- a substituent of a substituted phenyl group an alkyl group, a vinyl group, a mercapto group, an amino group, a nitro group, a cyano group etc. are mentioned.
- R 5 , R 6 , R 7 and R 8 (wherein R 7 and R 8 are only in the formula (3))
- R 5 , R 6 , R 7 and R 8 each independently represents an alkyl group having 1 to 6 carbon atoms, a phenyl group or the like, and examples of the alkyl group include a methyl group.
- a and c can be independently 6 to 2000, but may be 10 to 1000.
- b can be 2 to 30, but may be 5 to 20.
- the airgel according to the present embodiment may further contain silica particles in addition to the airgel component from the viewpoint of further toughening and from the viewpoint of achieving further excellent heat insulation and flexibility.
- An airgel containing an airgel component and silica particles can also be referred to as an airgel composite.
- the airgel complex is considered to have a three-dimensionally fine porous structure, although the airgel component and the silica particles are complexed, but having a cluster structure characteristic of the airgel. .
- An aerogel containing an aerogel component and silica particles can be said to be a dried product of a wet gel which is a condensation product of a sol containing a hydrolysis product of a silicon compound containing the above-mentioned silane oligomer and a silica particle. Therefore, the description of the first and second embodiments can be applied to the airgel according to this embodiment as appropriate.
- the silica particles can be used without particular limitation, and examples thereof include amorphous silica particles and the like.
- the amorphous silica particles include fused silica particles, fumed silica particles, colloidal silica particles and the like. Among these, colloidal silica particles have high monodispersity, and easily suppress aggregation in the sol.
- the silica particles may be silica particles having a hollow structure, a porous structure or the like.
- the shape of the silica particles is not particularly limited, and examples thereof include spheres, bowls, and associated types. Among these, use of spherical particles as the silica particles makes it easy to suppress aggregation in the sol.
- the average primary particle diameter of the silica particles may be 1 nm or more, or 5 nm or more, from the viewpoint that it is easy to impart appropriate strength and flexibility to the airgel and airgel having excellent shrinkage resistance during drying can be easily obtained. It may be 20 nm or more.
- the average primary particle diameter of the silica particles may be 500 nm or less, may be 300 nm or less, or 100 nm from the viewpoint that solid heat conduction of the silica particles is easily suppressed and an airgel having excellent thermal insulation properties is easily obtained. It may be the following. From these viewpoints, the average primary particle diameter of the silica particles may be 1 to 500 nm, 5 to 300 nm, or 20 to 100 nm.
- the average particle size of the airgel component and the average primary particle size of the silica particles can be obtained by directly observing the airgel using a scanning electron microscope (hereinafter abbreviated as “SEM”).
- SEM scanning electron microscope
- the term "diameter” as used herein means the diameter when the cross section of the particle exposed to the cross section of the airgel is regarded as a circle.
- the diameter when the cross section is regarded as a circle is the diameter of the true circle when the area of the cross section is replaced with a true circle of the same area.
- yen is calculated
- the average particle diameter of a silica particle can be measured also from a raw material.
- the biaxial average primary particle diameter is calculated as follows from the result of observing 20 arbitrary particles by SEM. That is, for example, when colloidal silica particles having a solid concentration of about 5 to 40% by mass and dispersed in water are taken as an example, it was obtained by cutting a wafer with a patterned wiring into 2 cm square into a dispersion of colloidal silica particles. After soaking the chip for about 30 seconds, the chip is rinsed with pure water for about 30 seconds and blown dry with nitrogen.
- the chip is placed on a sample stage for SEM observation, an acceleration voltage of 10 kV is applied, silica particles are observed at a magnification of 100,000 times, and an image is photographed. Twenty silica particles are arbitrarily selected from the obtained image, and the average of the particle sizes of those particles is taken as the average particle size.
- the number of silanol groups per 1 g of the silica particles may be 10 ⁇ 10 18 particles / g or more, or 50 ⁇ 10 18 particles / g or more from the viewpoint of easily obtaining an airgel having excellent shrinkage resistance. And 100 ⁇ 10 18 pieces / g or more.
- the number of silanol groups per 1 g of the silica particles may be 1,000 ⁇ 10 18 particles / g or less, or 800 ⁇ 10 18 particles / g or less, from the viewpoint of obtaining a homogeneous airgel easily, 700 ⁇ It may be 10 18 pieces / g or less.
- the number of silanol groups per 1 g of the silica particles may be 10 ⁇ 10 18 to 1000 ⁇ 10 18 pieces / g, and may be 50 ⁇ 10 18 to 800 ⁇ 10 18 pieces / g. Or 100 ⁇ 10 18 to 700 ⁇ 10 18 pieces / g.
- the content of the silicon compound contained in the sol may be 5 parts by mass or more and 10 parts by mass or more with respect to 100 parts by mass of the total amount of sols, from the viewpoint of easily obtaining good reactivity. It is also good.
- the content of the silicon compound contained in the sol may be 50 parts by mass or less and 30 parts by mass or less with respect to 100 parts by mass of the total amount of sols, from the viewpoint of facilitating obtaining good compatibility. It is also good. From these viewpoints, the content of the silicon compound contained in the sol may be 5 to 50 parts by mass, or 10 to 30 parts by mass with respect to 100 parts by mass of the total amount of the sol.
- the content of the silica particles makes it easy to impart appropriate strength to the airgel, and from the viewpoint of easily obtaining an airgel having excellent shrinkage resistance during drying, the total amount of sol is 100 parts by mass On the other hand, it may be 1 part by mass or more, or 4 parts by mass or more.
- the content of the silica particles may be 20 parts by mass or less with respect to 100 parts by mass of the total amount of sol from the viewpoint that solid heat conduction of the silica particles is easily suppressed and an airgel having excellent thermal insulation properties is easily obtained. It may be 15 parts by mass or less. From these viewpoints, the content of the silica particles may be 1 to 20 parts by mass, or 4 to 15 parts by mass with respect to 100 parts by mass of the total amount of the sol.
- Example 1 100 parts by mass of “XR31-B1410” (product name, manufactured by Momentive Performance Materials Japan Ltd.) as a silane oligomer, and tetraethoxysilane “KBE-04” (product name, manufactured by Shin-Etsu Chemical Co., Ltd.) as a silane monomer , 50 parts by mass of "TEOS”, 300 parts by mass of 2-propanol and 100 parts by mass of water are mixed with 0.1 parts by mass of acetic acid as an acid catalyst, and the mixture is stirred at 25 ° C for 4 hours The reaction was carried out to obtain a sol. To the obtained sol, 80 parts by mass of 5% aqueous ammonia was added as a base catalyst, and gelled at 60 ° C.
- the obtained wet gel was dried at 25 ° C. for 72 hours under normal pressure, and then dried at 150 ° C. for 2 hours to obtain an airgel.
- Example 2 An airgel was produced in the same manner as in Example 1 except that “SR-2402” (product name of Toray Dow Corning Co., Ltd., product name) was used as the silane oligomer.
- SR-2402 product name of Toray Dow Corning Co., Ltd., product name
- Example 3 An airgel was produced in the same manner as in Example 1 except that “AY42-163” (product name of Toray Dow Corning Co., Ltd., product name) was used as the silane oligomer.
- Example 4 100 parts by mass of "KC-89S" (product name, manufactured by Shin-Etsu Chemical Co., Ltd.) as a silane oligomer, 200 parts by mass of 2-propanol, and 50 parts by mass of water are mixed with 0 acetic acid as an acid catalyst .15 parts by mass was added and reacted at 25 ° C for 4 hours to obtain a sol. 60 parts by mass of 5% aqueous ammonia as a base catalyst was added to the obtained sol, gelled at 60 ° C. for 1 hour, and then aged at 60 ° C. for 48 hours to obtain a wet gel. Thereafter, in the same manner as in Example 1, an airgel was produced.
- KC-89S product name, manufactured by Shin-Etsu Chemical Co., Ltd.
- Example 5 100 parts by mass of "KR-500” (product name, manufactured by Shin-Etsu Chemical Co., Ltd.) as a silane oligomer, tetraethoxysilane “KBE-04" (product name, hereinafter "TEOS", manufactured by Shin-Etsu Chemical Co., Ltd.) as a silane monomer 100 parts by mass, 250 parts by mass of 2-propanol, and 80 parts by mass of water are mixed with 0.15 parts by mass of acetic acid as an acid catalyst, and reacted at 25 ° C. for 4 hours to obtain a sol Obtained. 90 parts by mass of 5% aqueous ammonia as a base catalyst was added to the obtained sol, gelled at 60 ° C. for 1 hour, and then aged at 60 ° C. for 48 hours to obtain a wet gel. Thereafter, in the same manner as in Example 1, an airgel was produced.
- KR-500 product name, manufactured by Shin-Etsu Chemical Co., Ltd.
- Example 6 100 parts by mass of "KR-515" (product name, manufactured by Shin-Etsu Chemical Co., Ltd.) as a silane oligomer, tetraethoxysilane "KBE-04" (product name, manufactured by Shin-Etsu Chemical Co., Ltd., hereinafter "TEOS”) as a silane monomer 20 parts by mass, dimethyldiethoxysilane "KBE-22" (product name from Shin-Etsu Chemical Co., Ltd., product name, hereinafter abbreviated as "DMDES”) 20 parts by mass, 300 parts by mass of 2-propanol, 80 parts by mass of water was mixed, 0.12 parts by mass of acetic acid as an acid catalyst was added thereto, and reacted at 25 ° C.
- DMDES dimethyldiethoxysilane
- Example 7 100 parts by mass of "XR31-B1410” (product name of Momentive Performance Materials Japan GK Co., Ltd.) as a silane oligomer, and dimethyldiethoxysilane “KBE-22" (product name of Shin-Etsu Chemical Co., Ltd .; 70 parts by mass of “DMDES”, 300 parts by mass of 2-propanol, and 80 parts by mass of water are mixed with 0.1 parts by mass of acetic acid as an acid catalyst, and reacted at 25 ° C. for 4 hours To obtain a sol. To the obtained sol, 80 parts by mass of 5% aqueous ammonia was added as a base catalyst, and gelled at 60 ° C. for 1 hour, and then aged at 60 ° C. for 48 hours to obtain a wet gel. Thereafter, in the same manner as in Example 1, an airgel was produced.
- XR31-B1410 product name of Momentive Performance Materials Japan GK Co., Ltd.
- KBE-22 product name of Shin-Ets
- Example 8 100 parts by mass of "XR31-B1410” (product name of Momentive Performance Materials Japan GK Co., Ltd.) as a silane oligomer, methyltrimethoxysilane "KBM-13” (product name of Shin-Etsu Chemical Co., Ltd., product name, 200 parts by mass of “MTMS”, 50 parts by mass of tetraethoxysilane “KBE-04” (product name, hereinafter abbreviated as “TEOS”, manufactured by Shin-Etsu Chemical Co., Ltd.), and 800 parts by mass of 2-propanol And, 200 parts by mass of water was mixed, 0.5 parts by mass of acetic acid as an acid catalyst was added thereto, and the mixture was reacted at 25 ° C.
- Example 1 The same procedure as in Example 1 was repeated except that methyltrimethoxysilane "KBM-13" (Shin-Etsu Chemical Co., Ltd. product name: hereinafter abbreviated as "MTMS”), which is a silane monomer, was used in place of the silane oligomer. Airgel was prepared.
- KBM-13 Shin-Etsu Chemical Co., Ltd. product name: hereinafter abbreviated as "MTMS”
- Airgel was prepared.
- Example 2 The same as Example 1 was carried out except that instead of the silane oligomer, it was changed to "methyl silicate 51" (a silane oligomer having no T unit and composed only of Q units, manufactured by Corcoat Co., Ltd., product name) Airgel was prepared.
- methyl silicate 51 a silane oligomer having no T unit and composed only of Q units, manufactured by Corcoat Co., Ltd., product name
- volume shrinkage ratio [(volume of dry gel) / (volume of wet gel)] ⁇ 100
- Density The density of the airgel was measured using an electronic hydrometer (product name SD-200L, manufactured by Alpha Mirage Co., Ltd.) according to the water displacement method.
- the aerogel was processed into a size of 150 ⁇ 150 ⁇ 100 mm 3 using a blade having an edge angle of about 20 to 25 °, and used as a measurement sample. Next, in order to ensure the parallelism of the surface, it was trimmed with # 1500 or more of sandpaper if necessary.
- the obtained measurement sample was dried at 100 ° C. for 30 minutes under atmospheric pressure using a constant temperature drier “DVS 402” (product name of Yamato Scientific Co., Ltd.) before measurement of thermal conductivity. The measurement sample was then transferred into a desiccator and cooled to 25 ° C.
- the measurement of thermal conductivity was performed using a steady-state thermal conductivity measurement apparatus "HFM 436 Lambda" (product name, manufactured by NETZSCH).
- the measurement conditions were atmospheric pressure and an average temperature of 25 ° C.
- the measurement sample obtained as described above is sandwiched between the upper and lower heaters with a load of 0.3 MPa, the temperature difference ⁇ T is set to 20 ° C., and the guard heater is adjusted to become a one-dimensional heat flow.
- the upper surface temperature, the lower surface temperature, etc. were measured.
- the thermal resistance RS of the measurement sample was determined by the following equation.
- R S N ((T U -T L ) / Q) -R O
- T U indicates the temperature on the upper surface of the measurement sample
- T L indicates the temperature on the lower surface of the measurement sample
- R O indicates the contact thermal resistance at the upper and lower interfaces
- Q indicates the heat flux meter output.
- N is a proportional coefficient, which was previously obtained using a calibration sample.
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Abstract
Description
本実施形態に係るエアロゲルの製造方法は、シランオリゴマーを加水分解して、当該シランオリゴマーの加水分解生成物を含有するゾルを生成するゾル生成工程と、ゾルをゲル化して、湿潤ゲルを得る湿潤ゲル生成工程と、湿潤ゲルを乾燥してエアロゲルを得る乾燥工程と、を備える。この製造方法において、シランオリゴマー中のケイ素原子の総数に対する、3個の酸素原子と結合したケイ素原子の割合は、50%以上である。
ゾル生成工程は、シランオリゴマーを加水分解して、シランオリゴマーの加水分解生成物を含むゾルを生成する工程である。
湿潤ゲル生成工程は、ゾル生成工程で得られたゾルをゲル化して、湿潤ゲルを得る工程である。本工程は、ゾルをゲル化し、その後熟成して湿潤ゲルを得る工程であってもよい。本工程では、ゲル化を促進させるため塩基触媒を用いることができる。
洗浄工程は、湿潤ゲル生成工程で得られた湿潤ゲルを洗浄する工程である。洗浄工程では、湿潤ゲル中の洗浄液を乾燥条件(後述の乾燥工程)に適した溶媒に置換する溶媒置換を更に行ってもよい。
乾燥工程では、(必要に応じて洗浄工程を経た)湿潤ゲルを乾燥させることにより、エアロゲルを得ることができる。すなわち、上記ゾルから生成された湿潤ゲルを乾燥してなるエアロゲルを得ることができる。
本実施形態に係るエアロゲルは、シランオリゴマーを含有するゾルの縮合物である湿潤ゲルの乾燥物である。本実施形態に係るエアロゲルは、例えば、上述の製造方法によって得られたものであってよい。
本実施形態に係るエアロゲルは、下記一般式(1)で表される構造を有することができる。本実施形態に係るエアロゲルは、式(1)で表される構造を含む構造として、下記一般式(1a)で表される構造を有することができる。
本実施形態に係るエアロゲルは、支柱部及び橋かけ部を備えるラダー型構造を有し、かつ橋かけ部が下記一般式(2)で表される構造を有することができる。このようなラダー型構造をエアロゲル成分としてエアロゲルの骨格中に導入することにより、耐熱性と機械的強度を向上させることができる。なお、本実施形態において「ラダー型構造」とは、2本の支柱部(struts)と支柱部同士を連結する橋かけ部(bridges)とを有するもの(いわゆる「梯子」の形態を有するもの)である。本態様において、エアロゲルの骨格がラダー型構造からなっていてもよいが、エアロゲルが部分的にラダー型構造を有していてもよい。
本実施形態に係るエアロゲルは、さらに強靱化する観点並びにさらに優れた断熱性及び柔軟性を達成する観点から、エアロゲル成分に加え、さらにシリカ粒子を含有していてもよい。エアロゲル成分及びシリカ粒子を含有するエアロゲルを、エアロゲル複合体ということもできる。エアロゲル複合体は、エアロゲル成分とシリカ粒子とが複合化されていながらも、エアロゲルの特徴であるクラスター構造を有しており、三次元的に微細な多孔性の構造を有していると考えられる。
シランオリゴマーとして「XR31-B1410」(モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製、製品名)を100質量部、シランモノマーとしてテトラエトキシシラン「KBE-04」(信越化学工業株式会社製、製品名、以下「TEOS」と略記)を50質量部、2-プロパノールを300質量部、及び、水を100質量部混合し、これに酸触媒として酢酸を0.1質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を80質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後、得られた湿潤ゲルを、常圧下にて、25℃で72時間乾燥し、その後150℃で2時間乾燥することで、エアロゲルを得た。
シランオリゴマーとして「SR-2402」(東レ・ダウコーニング株式会社製、製品名)を用いたこと以外は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「AY42-163」(東レ・ダウコーニング株式会社製、製品名)を用いたこと以外は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「KC-89S」(信越化学工業株式会社製、製品名)を100質量部、2-プロパノールを200質量部、及び、水を50質量部混合し、これに酸触媒として酢酸を0.15質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を60質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「KR-500」(信越化学工業株式会社製、製品名)を100質量部、シランモノマーとしてテトラエトキシシラン「KBE-04」(信越化学工業株式会社製、製品名、以下「TEOS」と略記)を100質量部、2-プロパノールを250質量部、及び、水を80質量部混合し、これに酸触媒として酢酸を0.15質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を90質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「KR-515」(信越化学工業株式会社製、製品名)を100質量部、シランモノマーとしてテトラエトキシシラン「KBE-04」(信越化学工業株式会社製、製品名、以下「TEOS」と略記)を20質量部、ジメチルジエトキシシラン「KBE-22」(信越化学工業株式会社製、製品名、以下「DMDES」と略記)を20質量部、2-プロパノールを300質量部、及び、水を80質量部混合し、これに酸触媒として酢酸を0.12質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を90質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「XR31-B1410」(モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製、製品名)を100質量部、ジメチルジエトキシシラン「KBE-22」(信越化学工業株式会社製、製品名、以下「DMDES」と略記)を70質量部、2-プロパノールを300質量部、及び、水を80質量部混合し、これに酸触媒として酢酸を0.1質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を80質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーとして「XR31-B1410」(モメンティブ・パフォーマンス・マテリアルズ・ジャパン合同会社製、製品名)を100質量部、メチルトリメトキシシラン「KBM-13」(信越化学工業株式会社製、製品名、以下「MTMS」と略記)を200質量部、テトラエトキシシラン「KBE-04」(信越化学工業株式会社製、製品名、以下「TEOS」と略記)を50質量部、2-プロパノールを800質量部、及び、水を200質量部混合し、これに酸触媒として酢酸を0.5質量部加え、25℃で4時間反応させてゾルを得た。得られたゾルに塩基触媒として5%濃度のアンモニア水を200質量部加え、60℃で1時間ゲル化した後、60℃で48時間熟成して湿潤ゲルを得た。その後は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーに代えて、シランモノマーであるメチルトリメトキシシラン「KBM-13」(信越化学工業株式会社製、製品名:以下「MTMS」と略記)を用いたこと以外は、実施例1と同様にしてエアロゲルを作製した。
シランオリゴマーに代えて、「メチルシリケート51」(T単位を有さず、Q単位のみで構成されたシランオリゴマー、コルコート株式会社製、製品名)に変更したこと以外は、実施例1と同様にしてエアロゲルを作製した。
各実施例及び比較例で得られたエアロゲルについて、以下の条件に従って外観観察、体積収縮率測定、密度測定及び熱伝導率測定を行い、評価した。評価結果を表1に示す。
得られたエアロゲルにおいて、湿潤ゲルと同様の形状を保っているものを「A」とし、クラック等で形状が保たれていないものを「C」とした。
得られたエアロゲルにおいて、下記の式により体積収縮率を算出した。体積収縮率が20%未満のものを「A」、20%以上のものを「C」とした。
体積収縮率[%]=[(乾燥ゲルの体積)/(湿潤ゲルの体積)]×100
水中置換法に従い、電子比重計(アルファミラージュ株式会社製、製品名SD-200L)を用いてエアロゲルの密度を測定した。
刃角約20~25度の刃を用いて、エアロゲルを150×150×100mm3のサイズに加工し、測定サンプルとした。次に、面の平行を確保するために、必要に応じて#1500以上の紙やすりで整形した。得られた測定サンプルを、熱伝導率測定前に、定温乾燥機「DVS402」(ヤマト科学株式会社製、製品名)を用いて、大気圧下、100℃で30分間乾燥した。次いで測定サンプルをデシケータ中に移し、25℃まで冷却した。
RS=N((TU-TL)/Q)-RO
式中、TUは測定サンプル上面温度を示し、TLは測定サンプル下面温度を示し、ROは上下界面の接触熱抵抗を示し、Qは熱流束計出力を示す。なお、Nは比例係数であり、較正試料を用いて予め求めておいた。
λ=d/RS
式中、dは測定サンプルの厚さを示す。
Claims (6)
- シランオリゴマーを加水分解して、前記シランオリゴマーの加水分解生成物を含有するゾルを生成するゾル生成工程と、
前記ゾルをゲル化して、湿潤ゲルを得る湿潤ゲル生成工程と、
前記湿潤ゲルを乾燥してエアロゲルを得る乾燥工程と、
を備え、
前記シランオリゴマー中のケイ素原子の総数に対する、3個の酸素原子と結合したケイ素原子の割合が50%以上である、エアロゲルの製造方法。 - 前記シランオリゴマーの重量平均分子量が200以上10000以下である、請求項1に記載の製造方法。
- 前記シランオリゴマーがアルコキシ基を有し、
前記アルコキシ基の含有量が、前記シランオリゴマーの全量基準で、2質量%以上60質量%以下である、請求項1又は2に記載の製造方法。 - シランオリゴマーの加水分解生成物を含有するゾルの縮合物である湿潤ゲルの乾燥物であって、
前記シランオリゴマー中のケイ素原子の総数に対する、3個の酸素原子と結合したケイ素原子の割合が50%以上である、エアロゲル。 - 前記シランオリゴマーの重量平均分子量が200以上10000以下である、請求項4に記載のエアロゲル。
- 前記シランオリゴマーがアルコキシ基を有し、
前記アルコキシ基の含有量が、前記シランオリゴマーの全量基準で2質量%以上60質量%以下である、請求項4又は5に記載のエアロゲル。
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