Heat-insulation material and production method thereof

Abstract

A heat-insulation material, includes: a first substrate layer that includes an aerogel and first fibers; and a second substrate layer that is layered on the first substrate layer and that includes an aerogel and second fibers, wherein a volume density of the aerogel in the first substrate layer is larger than a volume density of the aerogel in the second substrate layer, and an amount of the aerogel that is present around a first surface of the second substrate layer inside the second substrate layer, not adjacent to the first substrate layer, is smaller than an amount of the aerogel that is present around a second surface (inside the second substrate layer adjacent to the first substrate layer.

Claims

1. A heat-insulation material, comprising: a first substrate layer that includes an aerogel and first fibers; and at least one second substrate layer that is layered on the first substrate layer and that includes an aerogel and second fibers, wherein a volume density of the aerogel in the first substrate layer is larger than a volume density of the aerogel in the at least one second substrate layer, an amount of the aerogel that is present on a first surface of the at least one second substrate layer not being adjacent to the first substrate layer is smaller than an amount of the aerogel that is present on a second surface of the at least one second substrate layer being adjacent to the first substrate layer, and the first fibers and the second fibers are made of the same material, and the second fibers are surface-treated to be water repellent, wherein the first fibers are not surface-treated to be water repellant.

2. The heat-insulation material according to claim 1, wherein the aerogel in the at least one second substrate layer is distributed in such a manner that a content of the aerogel becomes smaller towards a direction from the second surface to the first surface.

3. The heat-insulation material according to claim 1, wherein the at least one second substrate layer includes two second substrate layers, and the first substrate layer is placed between the two second substrate layers.

4. The heat-insulation material according to claim 1, wherein the first fibers have a bulk density lower than a bulk density of the second fibers.

5. The heat-insulation material according to claim 1, wherein the first fibers have a bulk density of 0.01 g/cm.sup.3 or more and 0.04 g/cm.sup.3 or less.

6. The heat-insulation material according to claim 1, wherein the second fibers have a bulk density of 0.1 g/cm.sup.3 or more and 0.12 g/cm.sup.3 or less.

7. The heat-insulation material according to claim 1, wherein an existing area of the aerogel defined by a proportion of an area onto which the aerogel adheres on the second surface of the at least one second substrate layer facing the first substrate layer side is 5% or less.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a diagram that shows a structure of a bilayer heat-insulation sheet according to a first embodiment of the disclosure.

(2) FIG. 2 is a diagram that shows a first impregnation method for production of the bilayer heat-insulation sheet according to the first embodiment of the disclosure.

(3) FIG. 3 is a diagram that shows a second impregnation method for production of the bilayer heat-insulation sheet according to the first embodiment of the disclosure.

(4) FIG. 4 is a diagram that shows an example of production of the bilayer heat-insulation sheet according to the first embodiment of the disclosure.

(5) FIG. 5 is a diagram that shows a structure of a trilayer heat-insulation sheet according to a second embodiment of the disclosure.

(6) FIG. 6 is a diagram that shows a first impregnation method for production of the trilayer heat-insulation sheet according to the second embodiment of the disclosure.

(7) FIG. 7 is a diagram that shows an example of production of the trilayer heat-insulation sheet according to the second embodiment of the disclosure.

(8) FIG. 8 is a cross-section diagram that shows a structure of the heat-insulation material disclosed in JP-A-2009-299893.

DESCRIPTION OF EMBODIMENTS

(9) Hereinafter, embodiments of the disclosure will be described with reference to the drawings.

First Embodiment

(10) FIG. 1 a diagram that shows a structure of the heat-insulation material according to the first embodiment of the disclosure.

(11) In FIG. 1, a heat-insulation sheet 200 is a laminate of a first substrate layer 201 and a second substrate layer 202.

(12) In FIG. 1, the first substrate layer 201 includes an aerogel, and first fibers that are completely filled with the aerogel. The state in which the first fibers are completely filled with the aerogel refers to a state in which the air that had been contained between the first fibers is replaced with the aerogel. In cases where the resulting product is used as a heat-insulation material, a volume density of the aerogel is preferably 90% or more of the entire volume of the first substrate layer 201. However, even if the volume density is less than 90% of the entire volume, the resulting product can be used as a heat-insulation material, although the heat-insulation performance may be relatively lower. The heat-insulation performance of the first substrate layer 201 will be determined by the volume density of the aerogel.

(13) The second substrate layer 202 includes an aerogel, and second fibers that are not completely filled with the aerogel. The state in which the second fibers are not completely filled with the aerogel refers to a state in which the aerogel had not been able to penetrate into the second fibers, and the air has remained between the second fibers. A volume density of the aerogel is preferably 30 vol % or less of the second substrate layer 202. If the volume density of the aerogel is larger than 30 vol %, a proportion of the aerogel that adheres onto the lower face (surface) of the second substrate layer 202 will be higher, and thus, the adhesion performance may be impaired.

(14) Within the lower side of the second substrate layer 202, i.e. the surface of the second substrate layer 202 that does not face the first substrate layer 201, a proportion of an area onto which the aerogel adheres is preferably 5% or less in terms of sufficient adhesiveness. Even in cases where the proportion is larger than 5%, adhesiveness will be present. However, the proportion is preferably 5% or less. With regard to a distribution of the aerogel in the second substrate layer 202, a distribution in which the aerogel is the most intensively present around the boundary face between the first and second substrate layers 201 and 202, and the volume density of the aerogel becomes smaller towards the opposite face is adopted. The volume density of the aerogel in the entire of the second substrate layer 202 is preferably 30 vol % or less, and a proportion of the area within the lower face where the aerogel is present is preferably 5% or less.

(15) It becomes possible to attach a material used for adhesion (e.g. adhesives, adherent materials, tapes) to a lower face of the second substrate layer 202 onto which only a small amount of the aerogel is adhered. Accordingly, it further becomes possible to easily apply the heat-insulation sheet 200, containing an aerogel with excellent heat-insulation properties, onto a desired location.

(16) Types of the first fibers in the first substrate layer 201 and the second fibers in the second substrate layer 202 may be the same or different. However, their shapes, bulk densities, etc. are different from each other as described below.

(17) An example of a property list that describes differences in properties between the first substrate layer 201 and the second substrate layer 202 is shown in Table 1. The unit weights refer to unit weights of the first fibers in the first substrate layer 201 and the second fibers in the second substrate layer 202.

(18) TABLE-US-00001 TABLE 1 Unit weights Water repellency Substrates (Bulk densities) treatment First substrate 0.04 g/cm.sup.3 or less No layer 201 Second substrate 0.1 g/cm.sup.3 or more Yes layer 202

(19) When a larger amount of the aerogel is included in the first fibers in the first substrate layer 201, the heat-insulation performance will be higher. That is, when fibers having the same thickness are compared, fibers having a smaller unit weight can include a larger amount of the aerogel, and therefore, such fibers will deliver higher heat-insulation performance.

(20) However, if the thickness of fibers changes, their unit weight also changes. Therefore, it is considered that a unit weight per unit thickness is calculated. When a bulk density that is calculated as unit weight [g/m.sup.2]/thickness [mm] is obtained, fibers having a bulk density of 0.04 g/cm.sup.3 or less are preferable for the first fibers in the first substrate layer 201. This is because, when the bulk density is 0.04 g/cm.sup.3 or less, the heat conductivity that serves as an index for heat-insulation performance will be lower than 26 mW/mK, which corresponds to the heat conductivity of the air, and sufficient heat-insulation performance can be secured.

(21) A lower limit for the bulk density is preferably 0.01 g/cm.sup.3 or higher in order to secure sufficient strength.

(22) On the other hand, the second substrate layer 202 has properties different from those of the first substrate layer 201. A unit weight of the second fibers in the second substrate layer 202 is larger than that of the first fibers, and fibers having a larger bulk density are preferable therefor. This is because, if the unit weight is larger, an amount of the air included in the fibers will be smaller, and the aerogel hardly penetrates into the second substrate layer 202. In consideration of heat-insulation performance of the entire heat-insulation sheet 200, the thickness of the second substrate layer 202 that contains a smaller amount of the aerogel is preferably as small as possible since the heat-insulation performance of the entire heat-insulation sheet 200 will be higher. The thickness is preferably 0.1 mm or smaller since the heat-insulation performance will be higher than the air.

(23) However, there will be ho problem even when the thickness is larger than 0.1 mm. The bulk density, which corresponds to a unit weight per unit thickness, is preferably 0.1 g/cm.sup.3 or more. When the bulk density is 0.1 g/cm.sup.3 or more, the amount of the aerogel that penetrates into the first substrate layer 201 will be less than 30 vol %, and therefore, it becomes possible to limit the amount of the aerogel adhering on the lower face of the second substrate layer 202 to 5 vol % or less.

(24) An upper limit for the bulk density is preferably 0.12 g/cm.sup.3 or less to realise appropriate penetration of the aerogel and appropriate heat conductivity.

(25) Furthermore, water repellency, which is a property different from the above-mentioned unit weight, may be imparted to the second fibers in the second substrate layer 202. Water repellency may be imparted to the second fibers through UV washing, plasma washing, or the like. When the water repellency treatment is carried out, the aerogel can be prevented from penetrating into the second substrate layer 202. Accordingly, even if the unit weight of the second fibers is set to be smaller, the aerogel cannot penetrate into the second fibers due to the water repellency treatment, and therefore, it becomes possible to use second fibers having a bulk density of less than 0.1 g/cm.sup.3. In that case, water repellency is not imparted to the first substrate layer 201. If water repellency is imparted thereto, the aerogel cannot penetrate into the first substrate layer 201, and the resulting product cannot be used for the purpose of a heat-insulation material.

(26) The first fibers in the first substrate layer 201 at least have water repellency lower than the second fibers in the second substrate layer 202.

(27) Water repellency may be imparted to the second fibers before the first fibers in the first substrate layer 201 and the second fibers in the second substrate layer 202 are adhered to each other. The water repellency-imparting treatment is carried out with respect to the entire of the second fibers in the second substrate layer 202. In particular, the surfaces of the second fibers are preferably homogenously imparted with water repellency. Then, the first fibers for the first substrate layer 201 and the second fibers for the second substrate layer 202 can be adhered to each other based on a needle punch method or the like which corresponds to a method for adhering non-woven fabrics to each other to produce a composite material.

(28) <First Production Method>

(29) The aerogel may be prepared in the following way. A gel material, i.e. water glass or a metal alkoxide such as tetramethoxysilane, a solvent such as water or an alcohol, and a catalyst as needed are mixed. In this way, a wet gel is prepared from the gel material in the solvent. Then, the solvent inside the gel is evaporated, to produce an aerogel. Therefore, the material itself is in a liquid state.

(30) FIG. 2 is a cross-section diagram that shows the first method for coating a material 302 for an aerogel onto fibers to impregnate the fibers with the material 302. A coating head 301 is filled with the material 302. The material 302 that has been discharged from a coating nozzle 303 is impregnated into first fibers in the first substrate layer 201. However, since the unit weight of the second fibers in the second substrate layer 202 is larger than the unit weight of the first fibers in the first substrate layer 201, the material 302 is less likely to impregnate into the second substrate layer 202. The material 302 will be distributed around the upper face of the second substrate layer 202 that faces the first substrate layer 201. Accordingly, the material 302 does not reach the lower face of the second substrate layer 202. Eventually, this leads to the volume density of the aerogel mentioned above.

(31) <Second Production Method>

(32) FIG. 3 is a cross-section diagram that shows the second impregnation method for impregnating the fibers with a material 302 for an aerogel by way of soaking. A soaking bath 401 is filled with the material 302. Only the first fibers in the first substrate layer 201 are preferably soaked therein. Preferably, the second substrate layer 202 is not soaked in the material 302 in order to prevent even a small amount of the aerogel from adhering on the surface of the second substrate layer 202. After completion of soaking, the composite material is taken out of the soaking bath 401, and the impregnated material 302 is gelatinized. A part of the material 302 moves from the first substrate layer 201 to the second substrate layer 202. Eventually, this leads to the volume density of the aerogel mentioned above.

(33) <Third Production Method>

(34) FIG. 4 shows the third method in which a material 302 for the aerogel is impregnated into the first substrate layer 201, and then, the first substrate layer 201 is adhered onto the second substrate layer 202 to produce a heat-insulation sheet. A coating head 301 is filled with the material 302. The material 302 that has been discharged from a coating nozzle 303 is impregnated into first fibers in the first substrate layer 201.

(35) Then, the first fibers in the first substrate layer 201 and second fibers in the second substrate layer 202 are layered. Then, the first substrate layer 201 and the second substrate layer 202 are combined by a roller 501. After they are combined, the material 302 is gelatinised in that state, and it comes into a state in which the first substrate layer 201 and the second substrate layer 202 are joined. Actually, the material 302 is gelatinized in a state that the material 302 that comes out of the first substrate layer 201 adheres onto the outermost layer of the second substrate layer 202, and therefore, it becomes possible to join the first and second substrate layers 201 and 202 due to binding force of the gel. The material 302 in the first substrate layer 201 penetrates into the second substrate layer 202.

(36) Consequently, the aerogel is distributed in the second substrate layer 202 of the heat-insulation sheet 200 in such a manner that a content of the aerogel becomes smaller towards the direction from the surface of the second substrate layer 202, the surface being adjacent to the first substrate layer 201, to the surface of the second substrate layer 202, the surface not being adjacent to the first substrate layer 201. As a result of this, an area of the surface of the second substrate layer 202 on which the aerogel is present will be 5% or less.

Second Embodiment

(37) <Structure>

(38) A trilayer heat-insulation sheet 601 shown in FIG. 5 has a trilayer structure in which a first substrate layer 201 is placed between two pieces of second substrate layers 202. In this case, since both sides of the trilayer heat-insulation sheet 601 are formed by the second substrate layers 202, materials for adhesion, (e.g. adherent materials, adhesives, and tapes) can be applied onto both sides of the trilayer heat-insulation sheet 601, and therefore, a range of application of the heat-insulation sheet 601 will further be broadened.

(39) <Fourth Production Method>

(40) FIG. 6 is a diagram that snows a method for impregnation of a material 302 for the aerogel to produce the above trilayer heat-insulation sheet 601. For coating of the material, it is required that the material 302 is impregnated directly into the first substrate layer 201 that is a middle layer among the three layers. Therefore, preferably, in a state where the heat-insulation sheet 601 is caused to stand vertically, the material 302 is coated onto one side of the heat-insulation sheet 601, and the material 302 is impregnated into the heat-insulation sheet 601 by gravity.

(41) <Fifth Production Method>

(42) FIG. 7 is a diagram that shows a method in which a material 302 for an aerogel is impregnated into the first substrate layer 201, and then, the first substrate layer 201 is adhered onto the second substrate layer 202 to produce a heat-insulation sheet. A coating head 301 is filled with the material 302. The material 302 that has been discharged from a coating nozzle 303 is impregnated into the first substrate layer 201. Then, the first substrate layer 201 is placed between the second substrate layers 202 to thereby layer the three layers, and these layers are joined by a joining roller 501 to produce a heat-insulation sheet.

(43) Heat-insulation sheets according to the disclosure are aerogel-based heat-insulation materials that can be adhered to desired objects or locations with adhesives or adherent materials and that deliver excellent heat-insulation performance, and can be used for various purposes that require heat-insulation materials.