Porous polymer resin layer and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-2016280877-A1
Application number	US-201514929539-A
Country	US
Kind code	A1
Filing date	Nov 2, 2015
Priority date	Mar 23, 2015
Publication date	Sep 29, 2016
Grant date	—

Abstract

The present invention provides a porous polymer resin layer that comprises a binder resin with pores having a mean maximum diameter of about 0.5 mm to 1.6 mm; and aerogels dispersed in the binder resin. In particular, the porous polymer resin layer has a density of about 0.5 g/ml to 1.6 g/ml.

First claim

What is claimed is:

1 . A porous polymer resin layer, comprising:
a binder resin comprising pores and an aerogel dispersed in the binder resin, wherein the pores have a mean maximum diameter of about 0.5 mm to about 1.6 mm, wherein the porous polymer resin layer has a density of about 0.5 g/ml to 1.6 g/ml.

2 . The porous polymer resin layer according to claim 1 , wherein the porous polymer resin layer is used for coating of the inner side of an internal combustion engine or parts of an internal combustion engine.

3 . The porous polymer resin layer according to claim 1 , wherein the porous polymer resin layer has a thickness of about 20 μm to 2000 μm.

4 . The porous polymer resin layer according to claim 1 , wherein the porous polymer resin layer has a thermal conductivity of about 0.02 W/mK to 0.8 W/mK, as measured according to ASTM E1461.

5 . The porous polymer resin layer according to claim 1 , wherein the porous polymer resin layer has a volume heat capacity of about 600 KJ/m 3 K to 2500 KJ/m 3 K, as measured according to ASTM E1269.

6 . The porous polymer resin layer according to claim 1 , wherein the porous polymer resin layer comprises an amount of about 0.1 wt % to 10 wt % of the aerogel and the binder resin constituting the balance of the weight of the porous polymer resin layer.

7 . The porous polymer resin layer according to claim 1 , wherein the binder resin comprises a non-water soluble silicon resin.

8 . The porous polymer resin layer according to claim 1 , wherein the binder resin has a weight average molecular weight of about 20,000 g/mol to 300,000 g/mol.

9 . The porous polymer resin layer according to claim 1 , wherein the aerogel has a specific surface area of about 400 cm 3 /g to 600 cm 3 /g.

10 . The porous polymer resin layer according to claim 1 , wherein an amount of about 2 wt % or less of the binder resin is present inside the aerogel.

11 . The porous polymer resin layer according to claim 1 , wherein pores have a mean maximum diameter of of about 0.5 mm to 0.9 mm.

12 . The porous polymer resin layer according to claim 1 , wherein the pores have a mean maximum diameter of of about 1.0 mm to 1.6 mm.

13 . A method for manufacturing a porous polymer resin layer, comprising:
conducting a thermal decomposition by increasing a temperature of a polymer resin composition from about 50° C. to about 150° C., at a rate of about 3° C./min to 20° C./min, wherein the polymer resin composition comprises a binder resin dispersed in a first solvent, and an aerogel dispersed in a second solvent.

14 . The method according to claim 13 , wherein the solid content of the binder resin in the first solvent is from about 5 wt % to about 75 wt %.

15 . The method according to claim 13 , wherein the solid content of the aerogel in the second solvent is from about 5 wt % to about 75 wt %.

16 . The method according to claim 13 , wherein a boiling point of the first solvent is greater than the second solvent by about 10° C. or greater.

17 . The method according to claim 13 , wherein the first solvent has a boiling point of about 110° C. or greater.

18 . The method according to claim 13 further comprising,
heat treating the polymer resin composition at a temperature of about 50° C. to 90° C., before conducting the thermal decomposition.

19 . The method according to claim 13 further comprising,
heat treating the polymer resin composition at a temperature of about 180° C. to 300° C., after conducting the thermal decomposition.

20 . The method according to claim 13 , wherein the thermal decomposition is conducted by increasing the temperature at a rate of about 3° C./min to 7° C./min.

21 . The method according to claim 13 , wherein the thermal decomposition is conducted by increasing the temperature at a rate of about 13° C./min to 17° C./min.

22 . A method of manufacturing an internal combustion engine of a vehicle comprising,
coating a porous polymer resin layer of claim 1 on an inner side of the internal combustion engine.

23 . A method of manufacturing an internal combustion engine of a vehicle comprising,
coating a porous polymer resin layer of claim 1 on an outer side of the internal combustion engine or a part thereof.

24 . A vehicle part that comprising a porous polymer resin layer of claim 1 .

Assignees

• Hyundai Motor Co Ltd

Inventors

• Kim Bokyung
• Lyo In Woong
• Hong Woong Pyo
• Baek Hong Kil
• Choi Kwang Hoon
• Lee Seung Woo
• Seo Jiyoun

Classifications

• C08J2205/026

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

• C08J2207/04

  Aerosol, e.g. polyurethane foam spray · CPC title

• C08L2201/02

  Flame or fire retardant/resistant · CPC title

• F02F1/004 Primary

  Cylinder liners (F02F1/08, F02F1/16 take precedence) · CPC title

• F02F1/00

  Cylinders; Cylinder heads · CPC title