Method for producing aerogel blanket

Patent metadata

Field	Value
Publication number	US-12090460-B2
Application number	US-202017614164-A
Country	US
Kind code	B2
Filing date	Sep 3, 2020
Priority date	Sep 3, 2019
Publication date	Sep 17, 2024
Grant date	Sep 17, 2024

Abstract

The production method of the present invention can reuse a non-impregnated catalyzed sol, which has been typically discarded, by recovering the catalyzed sol, which is not impregnated in impregnating of a catalyzed sol into a blanket base, to stop gelating the catalyzed sol, and then using this in subsequently preparing a catalyzed sol.

First claim

The invention claimed is:

1. A method for producing an aerogel blanket, the method comprising:
1) impregnating a catalyzed sol into a blanket base; and
2) gelating the catalyzed sol to prepare a wet-gel blanket composite, wherein the method comprises:
A) after the impregnating, recovering a non-impregnated catalyzed sol, and then stopping gelation of the recovered sol by adding a solvent to dilute the non-impregnated catalyzed sol; and
B) reusing the gelation-stopped recovered sol in preparing of a catalyzed sol,
wherein the catalyzed sol prepared through step B) above contains 5 to 50 wt % of the gelation-stopped recovered sol.

2. The method of claim 1 , wherein in step A) above, the adding of the solvent is carried out when the viscosity of the recovered sol is 2 cp to 10 cp.

3. The method of claim 1 , wherein the recovered sol through the dilution in step A) above has a viscosity of 1 cp to 5 cp.

4. The method of claim 1 , wherein the catalyzed sol prepared through step B) above comprises the gelation-stopped recovered sol in an amount of 7 to 40 wt %.

5. The method of claim 1 , wherein the catalyzed sol is added so as to be a volume of 100 to 170% with respect to the volume of the blanket base.

6. The method of claim 1 , wherein performing step 2) above begins before completing step 1) above.

7. The method of claim 1 , further comprising:
3) Aging the gelated wet-gel blanket composite; and
4) surface-modifying the gelated wet-gel blanket composite.

8. The method of claim 1 , further comprising 5) drying the wet-gel blanket composite,
wherein the drying is performed by a process of supercritical drying or atmospheric pressure drying at a pressure of 1±0.3 atm and a temperature of 70° C. to 200° C.

9. The method of claim 1 , wherein the impregnation in step 1) above is performed while the blanket base rotates.

10. The method of claim 9 , wherein the rotation of the blanket base has a rotation speed of 1 rpm to 300 rpm.

11. The method of claim 1 , wherein step 1) above is carried out by a process of adding the blanket base, which is wound around a bobbin, to a reaction container, then rotating the bobbin to allow the blanket base to rotate, and impregnating the catalyzed sol to the blanket base.

12. The method of claim 11 , wherein step 1) above is carried out by any one method from among a method of adding the catalyzed sol to the reaction container after adding the blanket base thereto, a method of adding the blanket base to the reaction container after adding the catalyzed sol thereto, and a method of adding the blanket base to the reaction container while adding the catalyzed sol thereto.

13. The method of claim 1 , wherein in step 2) above, the gelation is performed while rotating the blanket base impregnated with the catalyzed sol.

14. The method of claim 1 , further comprising impregnating the catalyzed sol prepared in step B) above into a separate blanket base and
gelating the blanket base impregnated with the catalyzed sol while rotating the same.

15. The method of claim 7 , wherein the aging and the surface-modifying are carried out while rotating the wet-gel blanket composite prepared in step 2) above.

Assignees

• Lg Chemical Ltd

Inventors

• Kang Tae Gyeong
• Baek Se Won

Classifications

• C01P2006/32

  Thermal properties · CPC title

• B01J3/008

  Processes carried out under supercritical conditions · CPC title

• C01B33/159

  Coating or hydrophobisation · CPC title

• C01B33/1585 Primary

  Dehydration into aerogels · CPC title

• C01B33/155

  Preparation of hydroorganogels or organogels · CPC title