Vacuum insulation panel comprising an organic aerogel

Patent metadata

Field	Value
Publication number	US-2017165946-A1
Application number	US-201415118346-A
Country	US
Kind code	A1
Filing date	Feb 12, 2014
Priority date	Feb 12, 2014
Publication date	Jun 15, 2017
Grant date	—

Abstract

The present invention relates to a vacuum insulation board ( 1 ) comprising:
a hermetically closed covering ( 3 ) in which the pressure is lower than atmospheric pressure, a core material ( 5 ) made of organic aerogel placed inside said covering ( 3 ),

said organic aerogel being based on a resin resulting at least in part from polyhydroxybenzene(s) R and formaldehyde(s) F,

said organic aerogel being a polymeric monolithic organic gel comprising at least one water-soluble cationic polyelectrolyte,

or said organic aerogel being a pyrolysate of said gel in the form of a porous carbon monolith comprising the product of the pyrolysis of said at least one water-soluble cationic polyelectrolyte P,

said organic aerogel exhibiting a specific thermal conductivity of between 10 and 40 mW·m −1 ·K −1 at atmospheric pressure.

First claim

1 . A vacuum insulation board comprising:
a hermetically closed covering in which the pressure is lower than atmospheric pressure, a core material made of organic aerogel placed inside said covering, wherein said organic aerogel comprises a resin produced at least in part from polyhydroxybenzene(s) R and formaldehyde(s) F, wherein said organic aerogel is a polymeric monolithic organic gel comprising at least one water-soluble cationic polyelectrolyte, or said organic aerogel is a pyrolysate of said gel in the form of a porous carbon monolith comprising the product of pyrolysis of said at least one water-soluble cationic polyelectrolyte P, and wherein said organic aerogel exhibits a specific thermal conductivity of between 10 and 40 mW·m −1 ·K −1 at atmospheric pressure.

2 . The vacuum insulation board as claimed in claim 1 , wherein said at least one water-soluble cationic polyelectrolyte P is an organic polymer selected from the group consisting of quaternary ammonium salts, poly(vinylpyridinium chloride), polyethyleneimine, polyvinylpyridine, poly(allylamine hydrochloride), poly(trimethylammonioethyl methacrylate chloride), poly(acrylamide-co-dimethylammonium chloride) and their mixtures.

3 . The vacuum insulation board as claimed in claim 2 , wherein said at least one water-soluble cationic polyelectrolyte P is a salt comprising units resulting from a quaternary ammonium that is poly(diallyldimethylammonium chloride), poly(diallyldimethylammonium bromide) or another poly(diallyldimethylammonium halide).

4 . The vacuum insulation board as claimed in claim 1 wherein the organic aerogel comprises the product of a polymerization reaction in an aqueous solvent W of the polyhydroxybenzene(s) R and formaldehyde(s) F, in the presence of the at least one water-soluble cationic polyelectrolyte P dissolved in said aqueous solvent and of a catalyst.

5 . The vacuum insulation board as claimed in claim 4 , wherein said product of the polymerization reaction comprises said at least one water-soluble cationic polyelectrolyte P according to a mass fraction of between 0.2% and 2%.

6 . The vacuum insulation board as claimed in claim 4 , wherein said product of the polymerization reaction comprises said at least one water-soluble cationic polyelectrolyte P according to a P/(R+F) ratio by weight, with respect to said polyhydroxybenzene(s) R and formaldehyde(s) F, which is between 2% and 10%.

7 . The vacuum insulation board as claimed in claim 4 , wherein said product of the polymerization reaction comprises said at least one water-soluble cationic polyelectrolyte P according to a P/(R+F+W) ratio by weight, with respect to said polyhydroxybenzene(s) R, formaldehyde(s) F and aqueous solvent W, which is between 0.3% and 2%.

8 . The vacuum insulation board as claimed in claim 1 , wherein the organic aerogel exhibits:
a specific surface of between 400 m 2 /g and 1200 m 2 /g, and/or a pore volume of between 0.1 cm 3 /g and 3 cm 3 /g, and/or a mean pore diameter of between 3 nm and 30 nm, and/or a density of between 0.01 and 0.4.

9 . The vacuum insulation board as claimed in claim 1 , wherein the pressure within the covering is between 0.1 and 500 mbar.

10 . The vacuum insulation board as claimed in claim 1 , wherein the covering is produced from a film with a thickness of between 20 and 500 μm.

11 . The vacuum insulation board as claimed in claim 1 , wherein the covering comprises at least one layer made of aluminum.

12 . The vacuum insulation board as claimed in claim 1 , wherein the covering comprises at least one layer made of polymer.

13 . The vacuum insulation board as claimed in claim 1 , wherein the at least one layer made of polymer is produced from at least one of one of the following polymers: high- or low-density polyethylene, silicone, polyurethane, ethylene/vinyl alcohol, polyethylene terephthalate or polyamide.

14 . The vacuum insulation board as claimed in claim 1 , wherein the covering is produced from a multilayer film comprising at least one layer made of polymer material on its internal face.

15 . The vacuum insulation board as claimed in claim 13 , wherein the multilayer film forming the covering comprises the following layers:
polyethylene/polyacrylic/aluminum/polyethylene terephthalate, or polyethylene/aluminum/polyethylene terephthalate, or also polyethylene/aluminum/polyethylene/aluminum/polyethylene.

16 . A process for the manufacture of a vacuum insulation board that comprises:
preparation of an organic aerogel as core material according to the following stages:
a) polymerizing in an aqueous solvent W polyhydroxybenzene(s) R and formaldehyde(s) F, in the presence of at least one water-soluble cationic polyelectrolyte P dissolved in said aqueous solvent W and of a catalyst,
b) gelling of the solution obtained in a),
c) drying of the gel obtained in b) in order to obtain said polymeric monolithic organic gel,
placing said organic aerogel in a covering, lowering the pressure within the covering and hermetically closing said covering.

17 . The manufacturing process as claimed in claim 16 , wherein preparation of the organic aerogel further comprises pyrolysis of the dried gel obtained in c), in order to obtain a porous carbon.

18 . The manufacturing process as claimed in claim 16 , wherein stage a) is carried out by using said at least one water-soluble cationic polyelectrolyte P:
according to a mass fraction in the composition of between 0.2% and 2%, and/or according to a P/(R+F) ratio by weight, with respect to said polyhydroxybenzene(s) R and formaldehyde(s) F, of between 2% and 10%, and/or according to a P/(R+F+W) ratio by weight, with respect to said polyhydroxybenzene(s) R, formaldehyde(s) F and aqueous solvent W, of between 0.3% and 2%.

19 . The manufacturing process as claimed in claim 16 , wherein:
stage a) is carried out at ambient temperature, by dissolving said polyhydroxybenzene(s) R and said at least one water-soluble cationic polyelectrolyte P in said aqueous solvent W, preferably composed of water, and by then adding, to the solution obtained, said formaldehyde(s) F and said acidic or basic catalyst, and stage b) is carried out by curing said solution in an oven.

20 . The manufacturing process as claimed in claim 16 , wherein stage c) is carried out by drying with air in order to obtain said polymeric monolithic organic gel exhibiting:
a specific surface of between 400 m 2 /g and 1200 m 2 /g, and/or a pore volume of between 0.1 cm 3 /g and 3 cm 3 /g, and/or a mean pore diameter of between 3 nm and 30 nm, and/or a density of between 0.01 and 0.4.

21 . The manufacturing process as claimed in claim 16 , wherein the closing of the covering is carried out by heat sealing.

Assignees

• Hutchinson

Inventors

• Poupa Parsigneau Nadine
• Swoboba Benjamin
• Huillet Cedric
• Dominiak Christophe

Classifications

• B32B15/082

  comprising vinyl resins; comprising acrylic resins · CPC title

• B32B15/085

  comprising polyolefins · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B37/182

  one or more of the layers being plastic · CPC title

• B32B27/36

  comprising polyesters · CPC title