WO2022186762A1 - Aérogels à base de fibres continues obtenus par des techniques de non-tissé - Google Patents

Aérogels à base de fibres continues obtenus par des techniques de non-tissé Download PDF

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Publication number
WO2022186762A1
WO2022186762A1 PCT/SG2021/050106 SG2021050106W WO2022186762A1 WO 2022186762 A1 WO2022186762 A1 WO 2022186762A1 SG 2021050106 W SG2021050106 W SG 2021050106W WO 2022186762 A1 WO2022186762 A1 WO 2022186762A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
coating
fibre web
vinyl acetate
aerogel
Prior art date
Application number
PCT/SG2021/050106
Other languages
English (en)
Inventor
Ming Qian SIOW
Keng Liang CHENG
Original Assignee
Dp Aerogels International Pte. Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dp Aerogels International Pte. Ltd. filed Critical Dp Aerogels International Pte. Ltd.
Priority to PCT/SG2021/050106 priority Critical patent/WO2022186762A1/fr
Publication of WO2022186762A1 publication Critical patent/WO2022186762A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres

Definitions

  • the present disclosure relates to a method of manufacturing nonwoven aerogel blankets and in particular to the use of nonwoven aerogel blanket as insulative materials.
  • Aerogels are some of the lightest solid materials known and are characterised by their low thermal conductivity, high porosity, low density. Since their discovery in the 1930s, the potential applications of these nanostructured solids are numerous and include heat insulations, sound absorptions, sorbents for gases such as carbon dioxide, volatile organic compounds and hazardous gases, drug delivery and as construction materials.
  • the traditional aerogel fabrication process is typically manufactured in 3 distinct steps namely gelation, ageing and drying.
  • precursor materials are allowed to disperse in a suitable solvent and are encouraged to gel thus transitioning to a colloidal network. This prevents shrinkage and the pores from collapsing, particularly during the drying stage.
  • the gel is dried to remove the remaining liquid in a manner that minimises the surface tension of the pores of the solid network. This is typically achieved by supercritical drying or freeze-drying.
  • supercritical drying the liquid within the aerogel is gasified and removed from the aerogel without crossing the liquid-gas boundary, thus eliminating the increase in surface tension that would otherwise result during evaporation which can lead to pore collapse.
  • a primary embodiment of the present invention is a method of manufacturing nonwoven aerogel blanket comprising the steps of forming a fibre web comprising polymeric fibres and low melting-point polymer fibres using nonwoven web formation techniques, calendering the polymeric fibres, curing the polymeric fibres and applying a mixture comprising aerogel particles and an adhesive to the fibre web.
  • the polymeric fibres are selected from a group consisting of acetate fibres, acrylic fibres, aramid fibres, azlon fibres, carbon fibres, melamine fibres, modacrylic fibres, olefin fibres, nylon fibres, poiybenzimidazoie fibres, polyacrylate fibres, polyester fibres, polyvinyl alcohol fibres, polyvinylidene fibres, polyurethane fibres, fibreglass, silica fibreglass, cellulose- based fibres or a combination thereof.
  • the adhesive is selected from a group consisting of vinyl acetate, ethylene-vinyl acetate, acrylic ester, vinyl acetate-acrylic ester, styrene-acrylic ester, ethylene-vinyl acetate- vinyl ester, ethylene-vinyl acetate-acrylic ester, alkali silicates or a combination thereof
  • the mixture further comprises an additive.
  • the additive is thermal stable up to a temperature of about 650°C.
  • the additive is selected from a group consisting of graphene oxide, carbon nitride, magnesium oxide, titanium dioxide, silicon carbide, sodium silicate, potassium silicate, magnesium oxide and titanium dioxide or a combination thereof.
  • the additive is sodium silicate, potassium silicate, magnesium oxide, titanium dioxide, silicon carbide or a combination thereof.
  • the mixture is applied to the fibre web by dip-coating or spraying at a pressure of 1-100 kg/cm 2 .
  • the fibre web is formed is formed using needle-punching.
  • the needle punching comprises a pre-needling step with a stroke frequency of 5-50 Hz, a stroke of 10-100 mm, and a needle density of 1000-10000 s/m and a needle punching step with double-sided needling with a stroke frequency of 5 - 50 Hz, a stroke of 10-100 mm, and a needle density of 1000-10000 s/m.
  • the method comprises a further step of applying a coating to the nonwoven aerogel blanket.
  • the coating is selected from a group consisting of hydrophobic coating fire retardant coating, flame retardant coating, weather, and UV resistant coating, heat resistant coating, chemical resistant coating, oxidation and corrosion-resistant coating or combination thereof.
  • a primary embodiment of the invention is a method of manufacturing nonwoven insulation blanket using techniques traditionally associated with the manufacture of nonwovens
  • the method is preferably performed by non-woven machinery assembled in a conveyor system to allow the continuous production of aerogels.
  • Polymeric fibres are fed into a fibre opening machine used in the manufacture of nonwovens that employs a fibre web formation technique. Suitable web formation techniques include dry- laid carding, air-laid and spun-laid.
  • a suitable polymeric fibre generally include natural fibres or synthetic fibres such as but not limited to acetate fibres, acrylic fibres, aramid fibres, azlon fibres, carbon fibres, melamine fibres, modacrylic fibres, olefin fibres, nylon fibres, Polybenzimidazo!e fibres, polyarylate fibres, polyester fibres, polyvinyl alcohol fibres, polyvinylidene fibres, polyurethane fibres, fibreglass, silica fibreglass, cellulose based fibres or a combination thereof.
  • polyethene terephthalate fibres polyethene fibres, polypropylene fibres, fibreglass, silica fibreglass, and cellulose fibres is used as the polymeric fibres.
  • cellulose-based fibres can be derived from cotton, flax, hemp, jute, ramie, sisal and coir or any other fibre where cellulose is a major constituent.
  • low melting point polymers are polymers that have a melting point of not more than 200°C and is lower than that of the melting point of the polymeric fibres.
  • the low melting point polymer in the form of fibres is incorporated into the polymeric fibres, that is, low melting point polymeric fibres are mixed in along with the polymeric fibres and a bundle comprising low melting point polymeric fibres and polymeric fibres are present during fibre opening. These low melting point polymers will provide the bonding between the polymeric fibres after the calendering process.
  • the adhesive can be applied to the fibre web at any time after the formation of the fibre web and before the calendaring step.
  • suitable polymers include polyethene terephthalate, polyethene, and polypropylene. More than one low melting point polymer may be used simultaneously. The web formation process gives rise to a highly porous structure.
  • the fibre web may in some embodiments be optionally thickened by being subjected to cross-lapping in order to be paved to a desired thickness.
  • the fibres are bonded to create mechanical resistance between the fibres that make up the fibre web using known bonding methods employed in the manufacture of non-woven.
  • the fibre web is formed by needle punching by a non-woven needle punching machine.
  • needle punching involves a pre-needling step to initially tangle and create a pre-formed tension in the fibres, with a stroke frequency of 5-50 Hz, a stroke of 10-100 mm, and a needle density of 1000-10000 s/m, depending on the fibre sources or the production rate.
  • a needle punching step to form a coherent matrix and preferably involves double-sided needling with both stages having a stroke frequency of 5-50 Hz, a stroke of 10-100 mm, and a needle density of 1000-10000 s/m, depending on the fibre sources and/or the production rate.
  • other known bonding methods used in the manufacture of non-woven that may be used are stitch bonding, chemical bonding, and thermal bonding.
  • the fibre web can then be subjected to a calendering process where the calendar rolls are heated to a temperature of 100°C-300°C to smoothen the surface of the aerogel before curing the fibre web at a temperature of less than 100°C-300°C to cure the crosslinks and if present, a surface coating It is understood by a person skilled in the art that the temperature used is dependent on the nature of the crosslinking/surface coating agent used.
  • a mixture comprising aerogel particles and adhesives is then applied to the nonwoven insulation blanket.
  • the particle size of the aerogel particles is typically in the range of 5pm - 5mm.
  • Suitable adhesives include but are not limited to vinyl acetate, ethylene-vinyl acetate, acrylic ester, vinyl acetate-acrylic ester, styrene-acrylic ester, ethylene-vinyl acetate-vinyl ester, ethylene-vinyl acetate-acrylic ester, alkali silicates or a combination thereof. It would be understood by a person skilled in the art that most organic or inorganic adhesives may be suitable.
  • the mixture comprises approximately 10% aerogel particles, 10% ethylene vinyl acetate, 80% water, by weight percentage.
  • the mixture may be applied to the non-woven insulation blanket by spraying or dip coating.
  • Adhesive used is typically available commercially as an emulsion or powder at room temperature.
  • the mixture of adhesive and additives should be applied to the nonwoven insulation blanket by spraying the mixture at a pressure of 1-100 kg/cm 2 or dip-coated, depending on the viscosity of the mixture of adhesives and additives. This will ensure that the adhesive is sprayed or dip-coated to the extent that sufficiently fine mist is generated which will in turn ensure sufficient penetration of the fibre, thus ensuring that the fibres are uniformly coated.
  • the mixture further comprises at least one additive or a combination thereof.
  • Suitable additives include but are not limited to graphene oxide, carbon nitride, magnesium oxide, titanium dioxide, silicon carbide, sodium silicate, potassium silicate, magnesium oxide and titanium dioxide.
  • the mixture composition as provided in Table 1 contains up to four additives, namely sodium silicate, potassium silicate, magnesium oxide, titanium dioxide and silicon carbide in quantities of up to 10 wt. %, depending on the target density and thermal conductivity of the nonwoven aerogel blankets.
  • the mixture of adhesive and additives is applied by spraying or dip-coating onto one side, both sides, or through the nonwoven insulation blanket. This serves to strengthen the structure by forming bonds between the polymeric fibres. It would be understood that compounds with a high thermal stability, that is thermal stable at temperatures of up to approximately 650°C would be suitable for use as additives.
  • Table 1 depicts a mixture composition with up to four additives as described in example 1
  • a typical working example for the mixture is prepared as follows: aerogel particles (20%), ethylene-vinyl acetate (10%), and water (70%) by weight are dispersed homogeneously at
  • the nonwoven aerogel blanket has a pore size of 6 nm, a density of 90 kg/m 3 , a porosity of 90%, a surface area of 400 m 2 /g, a thermal conductivity of 0 023 W/mK, a noise reduction coefficient of 050, and an oil absorption capacity of 35 g oil /g samples
  • the mixture can be added with some additives such as sodium silicate, potassium silicate, magnesium oxide, titanium dioxide, and silicon carbide to increase the original product's thermal stability.
  • the other characteristics of the nonwoven aerogel are also varied when adjusting the amount of aerogel particles, adhesives, and additives and will exhibit characteristics as depicted in Table 2.
  • the method may include an optional step of applying a coating to the nonwoven aerogel blanket.
  • coatings include the application of hydrophobic coating fire retardant coating, flame retardant coating, weather and UV resistant coating, heat resistant coating, chemical resistant coating, oxidation and corrosion-resistant coating or combination thereof. More than one coating can be applied. It is envisaged that other coatings may be applied depending on application requirements of the aerogel
  • the coating includes both the application of a thin polymer coat to the surface of the aerogel or the entire internal structure including the surface of pores and junction therebetween and includes surface modification by a coating
  • the application of MTMS leads to the modification of hydroxyl groups to methyl groups thus conferring hydrophobicity to the aerogel.
  • the coating is applied preferably before calendaring/curing.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

La présente invention concerne un procédé de fabrication en continu d'aérogel à l'aide de techniques en général associées à la production de non-tissés. Des fibres polymères sont agencées en une bande de fibres. Des particules d'aérogel et un adhésif sont appliqués sur la bande de fibres pour renforcer la structure. Un renforcement supplémentaire a lieu lorsque les fibres polymères sont liées. Un revêtement peut être appliqué pour modifier les propriétés physiques de l'aérogel en fonction des besoins d'utilisation. L'aérogel subit alors une finition par un calandrage qui permet le lissage de sa surface et un durcissement qui permet de durcir les réticulations et/ou le revêtement de surface. .
PCT/SG2021/050106 2021-03-03 2021-03-03 Aérogels à base de fibres continues obtenus par des techniques de non-tissé WO2022186762A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/SG2021/050106 WO2022186762A1 (fr) 2021-03-03 2021-03-03 Aérogels à base de fibres continues obtenus par des techniques de non-tissé

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/SG2021/050106 WO2022186762A1 (fr) 2021-03-03 2021-03-03 Aérogels à base de fibres continues obtenus par des techniques de non-tissé

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105799294A (zh) * 2016-03-11 2016-07-27 浙江理工大学 一种汽车内饰用淋膜复合材料的制造方法
CN110983812A (zh) * 2020-01-13 2020-04-10 中原工学院 一种具有隔热特性的非织造复合材料及其制备方法
US20200224005A1 (en) * 2015-04-07 2020-07-16 Lg Chem, Ltd. Aerogel-containing composition and insulation blanket prepared using the same

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200224005A1 (en) * 2015-04-07 2020-07-16 Lg Chem, Ltd. Aerogel-containing composition and insulation blanket prepared using the same
CN105799294A (zh) * 2016-03-11 2016-07-27 浙江理工大学 一种汽车内饰用淋膜复合材料的制造方法
CN110983812A (zh) * 2020-01-13 2020-04-10 中原工学院 一种具有隔热特性的非织造复合材料及其制备方法

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