Apparatus and method for manufacturing composite sheet comprising aerogel sheet

Patent metadata

Field	Value
Publication number	US-10493741-B2
Application number	US-201715755487-A
Country	US
Kind code	B2
Filing date	Feb 7, 2017
Priority date	Feb 17, 2016
Publication date	Dec 3, 2019
Grant date	Dec 3, 2019

Abstract

The present invention relates to a method for manufacturing a composite sheet comprising an aerogel sheet, which comprises: a step (S 10 ) of preparing a fiber sheet ( 10 ); a step (S 20 ) of laminating the aerogel sheet ( 30 ) on each of both surfaces of the fiber sheet ( 10 ); and a step (S 30 ) of applying heat and a pressure to the aerogel sheet ( 30 ) and the fiber sheet ( 10 ), which are laminated, to bond the sheets to each other and to manufacture the composite sheet ( 40 ) in which the aerogel sheet ( 30 ), the fiber sheet ( 10 ), the aerogel sheet ( 30 ) are laminated.

First claim

The invention claimed is:

1. A method for manufacturing a composite sheet comprising an aerogel sheet, the method comprising:
a step (S 10 ) of preparing a fiber sheet ( 10 );
a step (S 20 ) of laminating the aerogel sheet ( 30 ) on each of both surfaces of the fiber sheet ( 10 ), wherein the step (S 20 ) comprises:
a step (a) of manufacturing a silica sol ( 2 );
a step (b) of manufacturing a gelling catalyst;
a step (c) of injecting the silica sol ( 2 ), which is manufactured in the step (a), to a surface of the fiber sheet ( 1 ) to impregnate with the silica sol ( 2 );
a step (d) of injecting the gelling catalyst ( 3 ), which is manufactured in step (b), to the surface of the fiber sheet ( 1 ), into which the silica sol ( 2 ) is impregnated, to manufacture a gel sheet ( 20 ) in which the silica sol is impregnated;
a step (e) of aging the gel sheet ( 20 ) in which the silica sol is gelated;
a step (f) of applying a coating solution to the aged gel sheet ( 20 ) to modify a surface of the gel sheet ( 20 ); and
a step (g) of drying the gel sheet ( 20 ) of which the surface is modified to manufacture the aerogel sheet ( 30 ); and

a step (S 30 ) of applying heat and a pressure to the aerogel sheet ( 30 ) and the fiber sheet ( 10 ), which are laminated, to bond the sheets to each other and to manufacture the composite sheet ( 40 ) in which the aerogel sheet ( 30 ), the fiber sheet ( 10 ), the aerogel sheet ( 30 ) are laminated.

2. The method of claim 1 , further comprising a step (S 26 ) of performing needling on the aerogel sheet ( 30 ) and the fiber sheet ( 10 ), which are laminated, to temporarily fix the aerogel sheet ( 30 ) and the fiber sheet ( 10 ) between the step (S 20 ) and the step (S 30 ).

3. The method of claim 1 , further comprising a step (S 40 ) of cutting the composite sheet ( 40 ) to a predetermined size to manufacture a composite pad ( 50 ) after the step (S 30 ).

4. The method of claim 1 , wherein, in the step (a), tetraethyl orthosilicate (TEOS) and ethanol are mixed to manufacture the silica sol ( 2 ).

5. The method of claim 4 , wherein the tetraethyl orthosilicate (TEOS) comprises hydrolyzed TEOS.

6. The method of claim 1 , wherein, in the step (b), ethanol and ammonia water (NH 4 OH) are mixed to manufacture the gelling catalyst ( 3 ).

7. The method of claim 1 , wherein the step (c) and the step (d) are performed within a conveyor belt that transfers the fiber sheet ( 1 ) from one side to the other side thereof.

8. The method of claim 1 , wherein, in the step (d), the gelling catalyst ( 3 ) is injected to the surface of the fiber sheet ( 1 ) at a rate of 0.035 L/min to 0.012 L/min to leave the gelling catalyst ( 3 ) for 8 minutes to 12 minutes and thereby to gelate the silica sol.

9. The method of claim 1 , wherein, in the step (e), the gel sheet ( 20 ), in which the silica sol is gelated, is aged at a temperature of 70° C. and aged for 50 minutes.

10. The method of claim 1 , wherein, in the step (f), the coating solution is manufactured by mixing ethanol with ammonia water (NH 4 OH).

11. The method of claim 10 , wherein, in the step (f), the coating solution is injected with 1.6 times of the silica sol ( 2 ) impregnated into the surface of the fiber sheet ( 1 ), and the aging is performed at a high temperature of 70° C. for one hour to modify the surface of the fiber sheet ( 10 ) by using hexamethyldisilazane (HMDS).

12. The method of claim 1 , wherein the step (g) comprises a first drying step of injecting carbon dioxide at a rate of 70 L/min for ten minutes under environments of a temperature of 28° C. and a pressure of 70 bar to dry the gel sheet ( 20 ) of which the surface is modified, a second drying step of raising to a temperature of 50° C. for 1 hour and 20 minutes to dry the gel sheet ( 20 ), a third drying step of injecting carbon dioxide at a rate of 0.7 L/min for 20 minutes under a temperature of 50° C. and a pressure of 150 bar to dry the gel sheet ( 20 ), and a fourth drying step of injecting carbon dioxide at a rate of 0.7 L/min for 20 minutes after breaking for 20 minutes to dry the gel sheet ( 20 ).

13. The method of claim 12 , wherein, in the third drying step of the step (g), the ethanol generated from the gel sheet ( 20 ) of which the surface is modified is collected while injecting the carbon dioxide.

14. The method of claim 12 , wherein the step (g) further comprises a step of discharging the carbon dioxide for 2 hours after the fourth drying step.

15. A method for manufacturing a composite sheet comprising an aerogel sheet, the method comprising:
preparing a fiber sheet ( 10 );
preparing an aerogel sheet ( 30 ) by a method comprising:
injecting a silica sol ( 2 ) to a surface of a fiber sheet ( 1 ) to impregnate with the silica sol ( 2 );
injecting a gelling catalyst ( 3 ) to the surface of the fiber sheet ( 1 ), into which the silica sol ( 2 ) is impregnated, to manufacture a gel sheet ( 20 );
aging the gel sheet ( 20 );
applying a coating solution to a surface of the aged gel sheet ( 20 ) to modify the surface of the gel sheet ( 20 ); and
drying the gel sheet ( 20 ) of which the surface is modified to yield the aerogel sheet ( 30 );

laminating the aerogel sheet ( 30 ) on each of both surfaces of the fiber sheet ( 10 ); and
applying heat and a pressure to the aerogel sheet ( 30 ) and the fiber sheet ( 10 ), which are laminated, to bond the sheets to each other and to manufacture the composite sheet ( 40 ) in which the aerogel sheet ( 30 ), the fiber sheet ( 10 ), and the aerogel sheet ( 30 ) are laminated,
wherein:
the aerogel sheet ( 30 ) comprises a compound comprising an aerogel matrix and a reinforcing structure, and
in the compound the aerogel matrix is continuous through the reinforcing structure, and the reinforcing structure is a lofty fibrous batting, wherein the fibers are oriented along all three axes, the lofty fibrous batting has the form of a sheet, the compound is a lightweight insulation product having resilience and durability, the lofty fibrous batting is compressible by at least 50% of its natural thickness and returns to at least 70% of its original thickness after being compressed for 5 seconds, the lofty fibrous batting has a density of 0.001 g/cm 3 to 0.26 g/cm 3 , and the fibers discriminable in a cross-sectional area of the compound has a cross-sectional area less than 10% of the total cross-sectional area.

Assignees

• Lg Chemical Ltd

Inventors

• Kim Ye Hon
• Lee Je Kyun
• Oh Kyoung Shil

Classifications

• B32B37/203

  One or more of the layers being plastic · CPC title

• B32B2266/126

  Aerogel, i.e. a supercritically dried gel · CPC title

• B32B2038/0052

  Other operations not otherwise provided for · CPC title

• B32B2309/027

  Ambient temperature · CPC title

• B32B5/02

  characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} · CPC title