High-performance thermal insulation materials

Patent metadata

Field	Value
Publication number	US-9249272-B2
Application number	US-201514645807-A
Country	US
Kind code	B2
Filing date	Mar 12, 2015
Priority date	Feb 3, 2010
Publication date	Feb 2, 2016
Grant date	Feb 2, 2016

Abstract

Thermal insulation material capable of being obtained from the mixture of at least the following elements:
an aqueous foam; silica aerogel particles; and at least one binder selected from an organic binder and a mineral binder.

First claim

The invention claimed is:

1. A thermal insulation material obtained from a mixture comprising:
an aqueous foam;
silica aerogel particles; and
a binder comprising an organic binder and/or a mineral binder,
wherein the aqueous foam comprises:
(i) a cationic surfactant salt of formula (I):

wherein:
R is an aliphatic chain having from 8 to 24 carbon atoms;
R 1 is an alkyl group comprising from 1 to 16 carbon atoms, a hydroxyalkyl comprising from 1 to 16 carbon atoms, a benzyl group, or a group which, taken together with the nitrogen of formula (I), forms a heterocycle optionally substituted by a fluorine atom;
R 2 and R 3 are each independently an alkyl group comprising from 1 to 6 carbon atoms, a hydroxyalkyl comprising from 1 to 6 carbon atoms, a hydrogen atom, a benzyl group, a group which, taken together with the nitrogen of formula (I), forms a heterocycle optionally substituted by a fluorine atom; and
X − is a counteranion; and

(ii) an anionic surfactant salt of formula (II):
R—X − ,Y −   (II)

wherein:
R is an aliphatic chain having from 10 to 24 carbon atoms;
X − is a group bearing a negative charge selected from the group consisting of a carboxylate a sulfate, and a phosphate group: and
Y + is a countercation selected from the group consisting of an ammonium, a sodium, and a potassium groups; and group, and

wherein a weight ratio of the cationic surfactant salt to the anionic surfactant salt is from 0.05:1 to 15:1.

2. The thermal insulation material of claim 1 , wherein the mixture comprises, relative to a total weight of the mixture:
from 25 to 75% of the aqueous foam,
from 5 to 35% of the silica aerogel particles, and
from 5 to 35% of the binder.

3. The thermal insulation material of claim 2 , wherein the mixture comprises, relative to a total weight of the mixture:
from 35 to 65% of aqueous foam,
from 17 to 25% of silica aerogel particles, and
from 17 to 25% of the binder.

4. The thermal insulation material of claim 1 , wherein the cationic surfactant salt is at least one salt selected from the group consisting of dodecyltrimethylammonium bromide, dodecyltrimethylammonium chloride, tetradecyltrimethylammonium bromide, tetradecyltrimethylammonium chloride, hexadecyltrimethylammonium bromide, hexadecyltrimethylammonium chloride, octadecyltrimethylammonium bromide, octadecyltrimethylammonium chloride, cetyltrimethylammonium bromide, cetyltrimethylammonium chloride, cetylbenzyldimethylammonium chloride, cetyltriethylammonium bromide, and (tallow)trimethylammonium chloride.

5. The thermal insulation material of claim wherein the cationic surfactant salt is (tallow)trimethylammonium chloride.

6. The thermal insulation material of claim 1 , wherein the anionic surfactant salt is at least one salt selected from the group consisting of ammonium stearate, potassium stearate, and sodium stearate.

7. The thermal insulation material of claim 1 , wherein the aqueous foam comprises a mixture comprising water, glycerol, a surfactant, and a zwitterion.

8. The thermal insulation material of claim 7 , wherein the aqueous foam comprises from 35 to 45% of glycerol.

9. The thermal insulation material of claim 7 , wherein the aqueous foam comprises less than 0.5% of dodecyl polyoxyethylene-3-sulfate, less than 0.5% of cocamidopropyl betaine, and less than 0.05% of myristic acid.

10. The thermal insulation material of claim 1 , wherein the binder is a latex.

11. The thermal insulation material of claim 10 , wherein the latex has a glass transition temperature T g below 50° C.

12. The thermal insulation material of claim 1 , having a thermal conductivity of less than or equal to 23 mW/m·K.

13. The thermal insulation material of claim 1 , having a thermal conductivity of less than or equal to 19 mW/m·K.

14. The thermal insulation material of claim 1 , having a density of less than or equal to 150 kg/m 3 .

15. The thermal insulation material of claim 1 , having a density of less than or equal to 100 kg/m 3 .

16. A process for manufacturing the thermal insulation material of claim 1 , the process comprising:
mixing the aqueous foam with a binder, thereby forming an intermediate mixture;
adding a silica aerogel powder to the intermediate mixture while agitating or mixing, thereby obtaining the mixture; and
drying the mixture, thereby obtaining the thermal insulation material.

17. The process of claim 16 , further comprising shaping the material during the drying.

Assignees

• Saint Gobain Isover

Inventors

• Pasquero Daniela
• Da Silva Claude

Classifications

• C08J2321/02

  Latex · CPC title

• C08J9/0066 Primary

  Use of inorganic compounding ingredients · CPC title

• C08J2433/08

  Homopolymers or copolymers of acrylic acid esters · CPC title

• E04B2001/742

  Use of special materials; Materials having special structures or shape · CPC title

• C08J9/30

  by mixing gases into liquid compositions or plastisols, e.g. frothing with air · CPC title