Method and apparatus for manufacturing aerogel sheet

Patent metadata

Field	Value
Publication number	US-10737231-B2
Application number	US-201715738495-A
Country	US
Kind code	B2
Filing date	Jan 17, 2017
Priority date	Jan 19, 2016
Publication date	Aug 11, 2020
Grant date	Aug 11, 2020

Abstract

A method for manufacturing an aerogel sheet according to the present invention includes: a step (a) of preparing a blanket having a plate shape; a step (b) of mixing silica sol with gelling catalyst to prepare a silica sol precursor; and a step (c) of injecting the silica sol precursor prepared in the step (b) to a surface of the blanket prepared in the step (a) through an injection device to gelate the silica sol precursor, wherein, in the step (c), the injection device injects the silica sol precursor while moving from one side to the other side of the surface of the blanket.

First claim

The invention claimed is:

1. A method for manufacturing an aerogel sheet, the method comprising:
a step (a) of preparing a blanket having a plate shape;
a step (b) of mixing a silica sol with a gelling catalyst to prepare a silica sol precursor;
a step (c) of injecting the silica sol precursor prepared in the step (b) to a surface of the blanket prepared in the step (a) through an injection device to gelate the silica sol precursor,
wherein, in the step (c), the injection device injects the silica sol precursor while moving from a first side to an opposite second side in a width direction or a length direction of the surface of the blanket to uniformly inject the silica sol precursor to the surface of the blanket, and the injection device comprises a scraper for uniformly adjusting a thickness of the silica sol precursor injected to the surface of the blanket;
a step (d) of aging the blanket in which the silica sol precursor is gelated;
a step (e) of injecting a coating solution to the aged blanket to modify a surface of the blanket; and
a step (f) of drying the blanket of which the surface is modified to yield the aerogel sheet.

2. The method of claim 1 , wherein:
the step (a) comprises:
loading the blanket having the plate shape in a storage vessel;
transferring the plate-shaped blanket from the storage vessel to a fixing vessel using a transfer part; and
inserting the blanket transferred by the transfer part into the fixing vessel.

3. The method of claim 1 , wherein, in the step (b), the silica sol is prepared by mixing tetraethyl orthosilicate (TEOS) and ethanol.

4. The method of claim 3 , wherein the tetraethyl orthosilicate (TEOS) comprises hydrolyzed TEOS.

5. The method of claim 1 , wherein, in the step (b), the gelling catalyst is prepared by mixing ethanol and ammonia water (NH 4 OH).

6. The method of claim 1 , wherein, in the step (b), the silica sol and the gelling catalyst are mixed by passing through a mixing device, the mixing device comprising a silica sol accommodation part in which the silica sol is accommodated, a catalyst accommodation part in which the gelling catalyst is accommodated, and a mixing part in which the silica sol of the silica sol accommodation part and the gelling catalyst of the catalyst accommodation part are introduced and mixed to prepare the silica sol precursor, and
the silica sol precursor accommodated in the mixing part is supplied to the injection device.

7. The method of claim 1 , wherein, in the step (c), the injection device comprises:
an injection part injecting the silica sol precursor to the surface of the blanket; and
a moving part moving the injection part in the width direction from the first side to the opposite second side of the surface of the blanket; or
a moving part moving the injection part in the length direction from the first side to the opposite second side of the surface of the blanket.

8. The method of claim 1 , wherein, in the step (d), the blanket in which the silica sol precursor is gelated is aged at a temperature of 70° C. for 50 minutes.

9. The method of claim 1 , wherein, in the step (d), the blanket in which the silica sol precursor is gelated is maintained at room temperature for 10 minutes to perform the aging.

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

11. The method of claim 1 , wherein, in the step (e), the amount of the coating solution injected is 1.6 times the amount of the silica sol injected into the surface of the blanket in the step (c), and the aging is performed at a temperature of 70° C. for one hour in a reaction vessel to modify the surface of the blanket by using hexamethyldisilazane (HMDS).

12. The method of claim 1 , wherein the step (f) 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 blanket 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 blanket, 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 blanket again, 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 blanket.

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

14. The method of claim 12 , wherein the step (f) further comprises a step of discharging the carbon dioxide out of the reaction vessel through a discharge hole in the reaction vessel over a period of 2 hours after the fourth drying step.

15. The method of claim 1 , wherein the steps (d), (e), and (f) are performed in a reaction vessel accommodating the blanket.

16. The method of claim 2 , wherein the silica sol precursor is injected through the injection device to a surface of the blanket inserted into the fixing vessel.

Assignees

• Lg Chemical Ltd

Inventors

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

Classifications

• C01B33/141

  Preparation of hydrosols or aqueous dispersions · CPC title

• C01B33/152

  Preparation of hydrogels · CPC title

• B65H3/08

  using pneumatic force {(B65H3/40, B65H3/42 take precedence)} · CPC title

• C01B33/158

  Purification; Drying; Dehydrating · CPC title

• C01B33/1585

  Dehydration into aerogels · CPC title