Method for manufacturing aerogel blanket

Patent metadata

Field	Value
Publication number	US-12097478-B2
Application number	US-202017425906-A
Country	US
Kind code	B2
Filing date	Sep 1, 2020
Priority date	Sep 3, 2019
Publication date	Sep 24, 2024
Grant date	Sep 24, 2024

Abstract

The present invention relates to a method for manufacturing an aerogel blanket, the method including 1) introducing a catalyzed sol and a substrate for a blanket into a reaction vessel to impregnate the catalyzed sol into the substrate for a blanket, and 2) rotating the substrate for a blanket into which the catalyzed sol is impregnated to perform gelation, wherein the catalyzed sol includes a silica precursor composition, and the silica precursor composition includes a silicate containing a hydrophobic group and a tetraalkyl silicate, wherein a molar ratio of the silicate containing a hydrophobic group and the tetraalkyl silicate is 60:40 to 98:2.

First claim

The invention claimed is:

1. A method for manufacturing an aerogel blanket, the method comprising:
introducing a catalyzed sol and a substrate into a reaction vessel, and rotating the substrate to impregnate the catalyzed sol into the substrate; and
rotating the substrate for gelation in the reaction vessel,
wherein the catalyzed sol includes a silica precursor composition,
the silica precursor composition includes a silicate containing a hydrophobic group and a tetraalkyl silicate, wherein a molar ratio of the silicate containing a hydrophobic group and the tetraalkyl silicate is 60:40 to 98:2, and
while rotating the substrate, centrifugal force and centripetal force are applied.

2. The method of claim 1 , wherein the molar ratio of the silicate containing a hydrophobic group and the tetraalkyl silicate is 85:15 to 98:2.

3. The method of claim 1 , wherein the silicate containing a hydrophobic group is one or more selected from the group consisting of methyltriethoxysilane (MTES), trimethylethoxysilane (TMES), trimethylsilanol (TMS), methyltrimethoxysilane (MTMS), dimethyldiethoxysilane (DMDEOS), ethyltriethoxysilane (ETES), and phenyltriethoxysilane (PTES).

4. The method of claim 1 , wherein the substrate is introduced into the reaction vessel in the state of being wound on a bobbin, and the bobbin is rotated to rotate the substrate into which the catalyzed sol is impregnated.

5. The method of claim 4 , wherein the bobbin includes a winding rod having a cylindrical shape with a hollow penetrating in the longitudinal direction, and the substrate, and the substrate is wound in a roll form on an outer circumferential surface of the winding rod.

6. The method of claim 5 , wherein the winding rod include a plurality of connection holes.

7. The method of claim 6 , wherein the plurality of connection holes are placed at regular intervals on the outer circumferential surface of the winding rod.

8. The method of claim 6 , wherein the plurality of connection holes have a diameter of 3 to 5 mm.

9. The method of claim 1 , wherein the introducing of a catalyzed sol and a substrate is performed by:
introducing the substrate into the reaction vessel and then introducing a catalyzed sol;
introducing the catalyzed sol into the reaction vessel and then introducing the substrate; or
introducing the substrate while introducing the catalyzed sol into the reaction vessel.

10. The method of claim 1 , wherein the rotating the substrate is performed before completion of the introducing a catalyzed sol and a substrate into a reaction vessel, and when the rotating the substrate is performed before the completion of the introducing a catalyzed sol and a substrate into a reaction vessel, all of the catalyzed sol is introduced into the reaction vessel before the gelation is completed.

11. The method of claim 1 , wherein the substrate into which the catalyzed sol is impregnated is rotated at a rate of 1 rpm to 300 rpm.

12. The method of claim 1 , wherein the catalyzed sol is a catalyzed silica sol.

13. The method of claim 1 , wherein the catalyzed sol comprises a silica sol and a base catalyst, and the silica sol contains a silica precursor composition, water, and an organic solvent.

14. The method of claim 13 , wherein the silica sol further comprises an acid catalyst.

15. The method of claim 13 , wherein the base catalyst includes sodium hydroxide (NaOH), potassium hydroxide (KOH), ammonium hydroxide (NH 4 OH), triethylamine, pyridine, or a mixture thereof.

16. The method of claim 13 , wherein the acid catalyst comprises hydrochloric acid, nitric acid, or sulfuric acid.

17. The method of claim 1 , further comprising drying after the rotating the substrate, wherein the drying is performed by supercritical drying or by an atmospheric drying process performed at a pressure of 1±0.3 atm and a temperature of 70° C. to 200° C.

18. The method of claim 1 , further comprising aging the aerogel blanket after the drying, by leaving the wet gel blanket composite to stand for 1 to 10 hours at a temperature of 30 to 70° C.

19. The method of claim 1 , wherein the molar ratio of the silicate containing a hydrophobic group and the tetraalkyl silicate is 60:40 to 95:5.

20. The method of claim 1 , wherein the molar ratio of the silicate containing a hydrophobic group and the tetraalkyl silicate is 60:40 to 90:10.

Assignees

• Lg Chemical Ltd

Inventors

• Oh Myung Eun
• Kim Mi Ri
• Kang Tae Kyeong
• 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