Manufacturing method of fire-resistant pad

Abstract

A manufacturing method of a fire-resistant pad according to the present disclosure comprises a step of mixing silicone and aerogel to form a silicone-aerogel composite, wherein the content of the aerogel is 0.5 wt.% or more and 40 wt.% or less based on the total mixing amount of the silicone-aerogel composite.

Description

Method for manufacturing a refractory pad

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2024-0059995, filed May 7, 2024, Korean Patent Application No. 10-2024-0074276, filed June 7, 2024, and Korean Patent Application No. 10-2025-0044610, filed April 7, 2025, the entire contents of which are incorporated herein by reference.

[0003] The present invention relates to a method for manufacturing a refractory pad, and more particularly, to a method for manufacturing a refractory pad, which includes a method for manufacturing a solid silicone-aerogel composite.

[0004] As technological developments and demand for mobile devices increase, the demand for secondary batteries as an energy source is rapidly increasing. In particular, secondary batteries are attracting significant attention as an energy source not only for mobile devices such as cell phones, digital cameras, laptops, and wearable devices, but also for powertrains such as electric bicycles, electric cars, and hybrid electric vehicles.

[0005] Secondary battery cells are manufactured by embedding electrode assemblies together with electrolytes in a secondary battery case, and the electrode assemblies are manufactured by stacking and / or winding a cathode, a separator, and anode. The manufactured battery cells are stacked in multiple pieces to form a battery module or battery pack.

[0006] As the cells are driven, heat may be generated in the battery cells, and if the heat is transferred to and accumulated in adjacent battery cells, battery thermal propagation may occur.

[0007] To address these issues, extensive research is being conducted on preventing fires within battery packs by placing refractory pads between battery cells. In particular, research is ongoing on methods for manufacturing refractory pads that offer superior fire resistance and high manufacturing efficiency.

[0008] The present invention is intended to solve the above-mentioned problem, and provides a method for manufacturing a refractory pad by manufacturing a solid silicone-aerogel composite.

[0009] In addition, a method for manufacturing a fireproof pad including an insulating layer including the above-described silicone-aerogel composite and a fireproof layer including a fireproof material can be provided.

[0010] The method for manufacturing a fire-resistant pad of the present invention includes a step of forming a silicone-aerogel composite by mixing silicone and aerogel, and the content of the aerogel is 0.5 wt% or more and 40 wt% or less based on the total mixing amount of the silicone-aerogel composite.

[0011] In a specific embodiment, based on the total amount of the silicone-aerogel composite, the content of the silicone may be 60 wt% or more and 99.5 wt% or less.

[0012] In one embodiment, the silicone may be provided in a liquid state without solvent, and the silicone-aerogel composite may be formed in a solid state.

[0013] In one embodiment, the content of the aerogel may be 15 wt% or more and 30 wt% or less.

[0014] In one embodiment, the method may further include: preparing a refractory material including at least one of a non-combustible material and a flame retardant material; laminating the refractory material on at least one surface of the silicone-aerogel composite to form a laminate; and curing and sheeting the laminate to form a refractory pad.

[0015] In one embodiment, the step of forming the refractory pad may be performed in one step by thermocompression bonding the laminate.

[0016] In one embodiment, the step of forming the refractory pad may include a first step of thermocompression-forming the laminate into a sheet shape; and a second step of thermosetting the thermocompression-bonded laminate.

[0017] In one embodiment, the refractory material may include at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and aramid fibers.

[0018] In one embodiment, in the laminate, the silicone-aerogel composite may be arranged in a single plane shape.

[0019] In one embodiment, in the laminate, the silicone-aerogel composite may be arranged in a stripe shape.

[0020] In one embodiment, the aerogel may comprise silica gel.

[0021] In one embodiment, the silicone may comprise a poly(dimethyl siloxane) (PDMS) resin, and optionally further comprise at least one of a crosslinking agent and a catalyst.

[0022] In one embodiment, based on the total blending amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin may be 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent may be 0 wt% or more and 10 wt% or less, and the content of the catalyst may be 0 wt% or more and 3 wt% or less.

[0023] In one embodiment, the step of forming the laminate may include the step of laminating an adhesive material on one surface of the refractory material and the step of laminating the silicone-aerogel composite on the adhesive material.

[0024] In one embodiment, the adhesive material may include a poly(dimethyl siloxane) (PDMS) resin, a crosslinking agent, and a catalyst, and optionally further include a coupling agent.

[0025] In one embodiment, the content of the aerogel may be 30 wt% or more and 40 wt% or less.

[0026] In one embodiment, the method comprises the steps of: providing a first layer comprising a refractory material; providing a first composite layer comprising the silicone-aerogel composite on the first layer; providing a third layer comprising the refractory material on the first composite layer; curing the first composite layer to provide a second layer; providing a second composite layer comprising the silicone-aerogel composite on the third layer; providing a fifth layer comprising the refractory material on the second composite layer; and curing the second composite layer to provide a fourth layer, wherein the refractory material may include at least one of mica fibers, glass fibers, basalt fibers, ceramic paper, and vermiculite-coated glass fiber cloth.

[0027] In one embodiment, the first layer, the third layer, and the fifth layer may comprise the same refractory material.

[0028] In one embodiment, the third layer may comprise a refractory material different from the first layer and the fifth layer.

[0029] In one embodiment, the step of providing the second layer may include simultaneously thermally compressing the first layer, the first composite layer, and the third layer to cure the first composite layer into the second layer.

[0030] In one embodiment, the step of providing the fourth layer may include simultaneously thermally compressing the third layer, the second composite layer, and the fifth layer to cure the second composite layer into the fourth layer.

[0031] The present invention can provide a method for manufacturing a refractory pad by forming a solid silicone-aerogel composite, which is more price competitive and has higher process efficiency than a conventional wet-manufactured silicone-aerogel composite.

[0032] The present invention can provide a method for manufacturing a fire-resistant pad having excellent insulation, heat resistance, and fire resistance.

[0033] Figure 1 illustrates one step of a method for manufacturing a refractory pad according to one embodiment.

[0034] Figure 2 illustrates one step of a method for manufacturing a refractory pad according to one embodiment.

[0035] FIG. 3 illustrates a refractory pad manufactured according to the method for manufacturing the refractory pad of FIG. 1.

[0036] Figure 4 illustrates a refractory pad manufactured according to the method for manufacturing the refractory pad of Figure 2.

[0037] Figure 5 illustrates one step of a method for manufacturing a refractory pad according to one embodiment.

[0038] A refractory pad manufactured according to the manufacturing method of the refractory pad of Fig. 6 is illustrated.

[0039] FIGS. 7 to 15 each schematically illustrate one step of a method for manufacturing a refractory pad according to one embodiment.

[0040] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0041] In order to clearly explain the present invention, parts that are not related to the description are omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0042] Furthermore, the sizes and thicknesses of each component shown in the drawings are arbitrarily indicated for convenience of explanation, and thus the present invention is not necessarily limited to the illustrated components. In the drawings, the thicknesses are enlarged to clearly represent various layers and regions. Furthermore, in the drawings, the thicknesses of some layers and regions are exaggerated for convenience of explanation.

[0043] Furthermore, when we say that a layer, membrane, region, plate, or other part is "on" or "over" another part, this includes not only cases where it is "directly on" the other part, but also cases where there are other parts in between. When we say that a part is "directly on" another part, we mean that there are no other parts in between. Furthermore, when we say that a part is "on" or "over" a reference part, we mean that it is located above or below the reference part, and we do not necessarily mean that it is located "above" or "over" the reference part in the opposite direction of gravity.

[0044] Additionally, throughout the specification, whenever a part is said to “include” a component, this does not mean that it excludes other components, but rather that it may include other components, unless otherwise specifically stated.

[0045]

[0046] Hereinafter, a method for manufacturing a refractory pad of the present invention will be described.

[0047] The method for manufacturing the refractory pad of the present invention is as follows:

[0048] Comprising a step of mixing silicone and aerogel to form a silicone-aerogel composite,

[0049] Based on the total mixing amount of the above silicone-aerogel composite, the content of the aerogel is 0.5 wt% or more and 40 wt% or less.

[0050] In one example of such a manufacturing method, the content of the silicone may be 60 wt% or more and 99.5 wt% or less based on the total blending amount of the silicone-aerogel composite.

[0051]

[0052] In one embodiment, the silicone is provided in a liquid state without solvent, and the silicone-aerogel composite is formed in a solid state.

[0053] That is, the method for manufacturing a fire-resistant pad according to the present invention includes a step of forming a solid silicone-aerogel composite by mixing silicone and aerogel using a solvent-free technique. Accordingly, the method for manufacturing a fire-resistant pad according to the present invention omits the step for removing the solvent, thereby reducing the cost and time of the process and simplifying the process, thereby facilitating the mass production of fire-resistant pads.

[0054]

[0055] The step of forming a silicone-aerogel composite by mixing silicone and aerogel is a step of mixing solvent-free liquid silicone and aerogel. The solvent-free liquid silicone may be a silicone solution containing a silicone main agent and further containing at least one of a crosslinking agent and a catalyst. During the mixing process, the solvent-free liquid silicone is surrounded by a high-surface-area aerogel, thereby forming a solid silicone-aerogel composite. For example, the silicone-aerogel composite may be in the form of a dispersed powder.

[0056] Silicone-aerogel composites can exhibit excellent insulation performance by having low thermal conductivity. Specifically, the thermal conductivity of the silicone-aerogel composite may be 10 mW / m·K or more and 200 mW / m·K or less, preferably 10 mW / m·K or more and 150 mW / m·K or less.

[0057] The conventional wet manufacturing process of aerogel composites involves dispersing aerogel in a solvent, impregnating the fiber structure, growing the aerogel precursor, and drying the solvent. In this case, it takes about 1 to 3 days to grow the aerogel precursor on the surface of a fiber structure such as glass fiber, and since a process is required to selectively remove the solvent within the aerogel precursor using a supercritical fluid method, room temperature pressurization method, etc., the time required for the process and the cost are high. In contrast, the present invention forms an aerogel composite by mixing liquid silicone and aerogel, which are solvent-free, so the process time is less than 10 minutes, and the conventional solvent removal process is omitted, simplifying the process compared to the wet manufacturing process, and having the advantage of relatively short process time and cost.

[0058]

[0059] In one embodiment, based on the total mixing amount of the silicone-aerogel composite, the content of the aerogel is 0.5 wt% or more and 40 wt% or less. In addition, the content of the silicone may be 60 wt% or more and 99.5 wt% or less. The content of the aerogel may be preferably 0.5 wt% or more and 30 wt% or less, more preferably 10 wt% or more and 30 wt% or less, and even more preferably 15 wt% or more and 30 wt% or less. When the content of the aerogel is less than 0.5 wt%, it becomes difficult to form a silicone-aerogel composite when mixing silicone and aerogel, and the insulating properties of the silicone-aerogel composite may also deteriorate. When the content of the aerogel exceeds 40 wt%, it may become difficult to form a pad of the silicone-aerogel composite.

[0060] In one embodiment, the aerogel may comprise silica gel.

[0061] In one embodiment, the liquid silicone in a solvent-free form may include a polydimethylsiloxane (PDMS) resin, and optionally further include at least one of a crosslinking agent and a catalyst. Specifically, the polydimethylsiloxane resin has a siloxane backbone and a vinyl group at the terminal (PDMS-vinyl terminated, ViMe2SiO(Me2SiO) X It may be SiMe2Vi). In addition, the molecular weight of the polydimethylsiloxane resin used in the silicone of the present invention may be 1,000 g / mol or more and 100,000 g / mol or less. The crosslinking agent may be a silicone-based crosslinking agent containing at least one Si-H structure, and for example, polymethylhydrogen siloxane may be used. As the catalyst, a platinum catalyst may be used, or a peroxide-based initiator may be used depending on the curing mechanism.

[0062] In one embodiment, the composition of the silicone may include a polydimethylsiloxane resin and a crosslinker, a polydimethylsiloxane resin and a catalyst, or a polydimethylsiloxane resin, a crosslinker, and a catalyst.

[0063] In one embodiment, based on the total blending amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin may be 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent may be 0 wt% or more and 10 wt% or less, and the content of the catalyst may be 0 wt% or more and 3 wt% or less.

[0064] However, the composition of the silicone is not limited thereto, and the silicone can further include a known flame retardant additive to enhance the flame retardant effect. For example, the flame retardant additive may include at least one selected from the group consisting of nitrogen-based substances such as guanidine compounds and melamine compounds, phosphate-based substances such as triphenyl phosphate, trixylenyl phosphate, tricresyl phosphate, and triisophenyl phosphate, metal hydroxide-based substances such as Al(OH)3 and Mg(OH)2, ammonium-based substances such as ammonium polyphosphate, ammonium phosphate, and ammonium carbonate, and antimony-based substances.

[0065] Meanwhile, in the step of mixing silicone and aerogel to form a solid silicone-aerogel composite, only the mixing process is performed, so the silicone-aerogel composite can exist in a dispersed powder form. Subsequently, the dispersed powder silicone-aerogel composite can be cured and pressurized to form a sheet. In this regard, the following describes a method for manufacturing a refractory pad.

[0066]

[0067] A method for manufacturing a refractory pad according to one embodiment of the present invention,

[0068] A step of preparing a fire-resistant material including at least one of a non-combustible material and a flame-retardant material;

[0069] A step of forming a laminate by laminating the refractory material on at least one surface of the silicone-aerogel composite; and

[0070] The step of forming a refractory pad by curing and sheeting the above laminate may further be included.

[0071]

[0072] Figures 1 and 2 illustrate one step of a method for manufacturing a refractory pad of one embodiment.

[0073] Referring to FIG. 1, the step of preparing a refractory material including at least one of a non-combustible material and a flame retardant material may be a step of providing a refractory material (FM) including at least one of a non-combustible material and a flame retardant material, such as mica fiber, glass fiber, basalt fiber, ceramic paper, and aramid fiber. For example, the refractory material (FM) may use Alkaline Earth Silicate (AES) wool, such as Morgan's Super wool product, to enhance the refractory effect. The refractory material (FM) may be provided in a sheet form, and the step of providing the refractory material (FM) may be performed, for example, by providing the refractory material (FM) in a sheet form to a mold.

[0074]

[0075] Next, a step of forming a laminate by laminating the refractory material on at least one side of the silicone-aerogel composite is performed. This step is a step of laminating the refractory material (FM) on one side or both sides of the silicone-aerogel composite (CM). For example, the step of forming the laminate may be a step of sequentially laminating the refractory material (FM), the silicone-aerogel composite (CM), and the refractory material (FM). For example, the silicone-aerogel composite (CM) may be injected onto the refractory material (FM) provided in a mold, and the refractory material (FM) may be laminated thereon to form the laminate (LM). Since the silicone-aerogel composite (CM) is in the form of a dispersed powder, it can be arranged in a desired shape. In Fig. 1, as an example, the silicone-aerogel composite (CM) is arranged in the form of a single side. That is, the silicone-aerogel composite (CM) is provided in the form of a layer. However, without being limited thereto, in the laminate (LM-1) of one embodiment, as shown in FIG. 2, the silicone-aerogel composite (CM) may be arranged in a stripe shape spaced apart from each other.

[0076] In addition, in FIGS. 1 and 2, a refractory material (FM) is laminated on both sides of the silicone-aerogel composite (CM). That is, the refractory material (FM) may be arranged on the outermost surface to provide the outer surface of the refractory pad (1). However, the present invention is not limited thereto, and the refractory material (FM) may be laminated on only one side of the silicone-aerogel composite (CM).

[0077]

[0078] The step of forming a refractory pad is a step of curing and sheeting the aforementioned laminate (LM).

[0079] In one embodiment, the step of curing and sheeting the laminate to form a refractory pad can be performed in one step. For example, as illustrated in FIG. 1, the laminate (LM) can be pressed and heated using a plate hot press (Plate Hot Press, PR1) or a hot roll press (roll-to-roll & heating) to simultaneously thin and cure the silicone-aerogel composite (CM) and the refractory material (FM) and bond them. That is, the laminate (LM) can be thermo-compression bonded using the above method to form a refractory pad in one step. Meanwhile, curing starts at a temperature of 50°C or higher, but the temperature at which curing starts can be controlled depending on the content of the catalyst and crosslinking agent included in the silicone.

[0080] However, the embodiments of the method for manufacturing the refractory pad of the present invention are not limited thereto. Although not illustrated, in another embodiment of the present invention, the step of curing and sheeting the laminate to form the refractory pad may be performed in two steps. For example, the step of curing and sheeting the laminate (LM) to form the refractory pad may include a first step of thermocompression-bonding the laminate (LM) into a sheet shape, and a second step of thermosetting the thermocompression-bonded laminate.

[0081] The first step may be to press the laminate into a sheet shape for a short time of less than 30 seconds. For example, the first step may be to press the laminate into a sheet shape using a press machine at 100°C and 1.5 kgf / cm. 2 It can be pressed for 5 seconds. The first step can be performed at a high temperature rather than room temperature so that the laminate can have sufficient cohesion and can be easily sheeted. The second step can be to harden the laminate only by heating without pressurization. For example, the laminate can be heated at 100°C for 10 minutes or more to harden the silicone-aerogel composite.

[0082] As above, the step of forming a refractory pad by curing and sheeting the laminate can be formed in one step or two steps.

[0083]

[0084] FIG. 3 illustrates an example of a refractory pad manufactured according to the method for manufacturing the refractory pad of FIG. 1.

[0085] When the step of forming a refractory pad by hardening and sheeting the above laminate is completed, a refractory pad (1) is formed as shown in FIG. 3.

[0086] Referring to FIG. 3, a refractory pad (1) of one embodiment may include an insulating layer (LL1) in which a silicone-aerogel composite (CM, see FIG. 1) is cured, and a refractory layer (LL2) in which a refractory material (FM, see FIG. 1) is cured. The insulating layer (LL1) is a cured silicone (SL) in which an aerogel (AG) is dispersed in the form of particles. The refractory layer (LL2) is a sheet-shaped refractory material (FM) as described above.

[0087] The thickness of one insulation layer (LL1) may be 0.1 mm or more and 5 mm or less. For example, the thickness of the insulation layer (LL1) may be 0.1 mm or more and 3 mm or less, or 0.1 mm or more and 2 mm or less, and specifically, may be 1 mm or 2 mm, but the embodiment is not limited thereto. The thickness of one fire-resistant layer (LL2) may be 0.1 mm or more and 5 mm or less. For example, the thickness of the fire-resistant layer (LL2) may be 0.1 mm or more and 3 mm or less, or 0.5 mm or more and 2 mm or less.

[0088] If the thickness of the insulation layer (LL1) is less than 0.1 mm, the insulation performance of the refractory pad (1) may deteriorate. If the thickness of the refractory layer (LL2) is less than 0.1 mm, the fire resistance performance of the refractory pad (1) may deteriorate. If the thickness of either the insulation layer (LL1) or the refractory layer (LL2) exceeds 5 mm, the volume of the refractory pad (1) may increase excessively, making it difficult to secure energy density per volume of the battery when applied to the battery.

[0089] The thickness of the insulation layer (LL1) and the thickness of the fire-resistant layer (LL2) may be the same or different.

[0090] The overall thickness of the refractory pad (1) may be 0.2 mm or more and 5 mm or less. When the refractory pad (1) includes only an insulating layer (LL1), it may include two or more insulating layers (LL1). For example, the overall thickness of the refractory pad (1) may be 1 mm or more and 5 mm or less, but the embodiment is not limited thereto.

[0091] FIG. 4 illustrates an example of a refractory pad manufactured according to the method for manufacturing the refractory pad of FIG. 2.

[0092] Referring to FIG. 4, since the silicone-aerogel composite (CM, see FIG. 2) is arranged in a stripe shape, the composite layers (LL1-1) in the refractory pad (1-1) of one embodiment can be formed in a stripe shape with a predetermined gap (GP). In the refractory pad (1-1) of one embodiment, since there is a gap (GP) filled with air between the composite layers (LL1-1), the insulation performance can be further improved.

[0093] Meanwhile, although the laminate (LM, LM-1) is described above as being formed by laminating a silicone-aerogel composite and a refractory material, the embodiment of the method for manufacturing the refractory pad of the present invention is not limited thereto.

[0094]

[0095] In a method for manufacturing a refractory pad according to another embodiment of the present invention, a laminate may be formed to include a silicone-aerogel composite, a refractory material, and an adhesive material.

[0096] Figure 5 illustrates one step of a method for manufacturing a refractory pad according to one embodiment.

[0097] Referring to FIG. 5, in a method for manufacturing a refractory pad of one embodiment, the step of forming a laminate may include a step of laminating an adhesive material on one surface of the refractory material and a step of laminating the silicone-aerogel composite on the adhesive material.

[0098] An adhesive material (AM) is provided for the purpose of enhancing the adhesion between a silicone-aerogel composite (CM) and a refractory material (FM). Specifically, when the silicone-aerogel composite (CM) contains 30 wt% or more of aerogel, the adhesive material (AM) may be provided to enhance the adhesion of the silicone-aerogel composite (CM). However, the content of the aerogel is not limited, and the adhesive material (AM) may be provided between the silicone-aerogel composite (CM) and the refractory material (FM) as needed. The specific composition of the adhesive material (AM) will be described later.

[0099]

[0100] As illustrated in FIG. 5, a laminate (LM-2) according to one embodiment may have a structure in which a refractory material (FM), an adhesive material (AM), a silicone-aerogel composite (CM), an adhesive material (AM), and a refractory material (FM) are sequentially laminated.

[0101] The adhesive material (AM) may be provided in the form of a spray, roll-to-roll coating, or bar coating on the refractory material (FM). The thickness of the adhesive material (AM) applied may be 10 μm or more and 0.5 mm or less, but the embodiment is not limited thereto.

[0102] Additionally, the application area of ​​the adhesive material (AM) may not exceed the area of ​​the refractory material (FM). Accordingly, the adhesive material (AM) can be prevented from being exposed outside the refractory material (FM). Furthermore, the adhesive material (AM) can be applied so as to cover the entire surface of the silicone-aerogel composite (CM), thereby enhancing the adhesive properties of the entire surface of the silicone-aerogel composite (CM).

[0103] Meanwhile, in the step of forming the laminate (LM-2), the silicone-aerogel composite (CM) may be provided in an uncured state, or may be provided in a pre-cured form in the form of a sheet.

[0104] Thereafter, a step of curing and sheeting the laminate to form a refractory pad is performed. The laminate (LM-2) can be thermoset or thermocompressed. For example, if the silicone-aerogel composite (CM) and the adhesive material (AM) in the laminate (LM-2) are not cured, the laminate (LM-2) can be thermoset to form a refractory pad. Alternatively, if the silicone-aerogel composite (CM) in the laminate (LM-2) is already cured and the adhesive material (AM) is not cured, only the adhesive material (AM) of the laminate (LM-2) can be thermoset to form a refractory pad.

[0105] In one embodiment, the adhesive material (AM) may be a known adhesive material, such as a silicone-based adhesive material, an acrylic-based adhesive material, or an epoxy-based adhesive material. For example, the adhesive material (AM) may be a silicone-based adhesive material, and may include a polydimethylsiloxane resin, a crosslinking agent, and a catalyst, and optionally further include a coupling agent. The polydimethylsiloxane resin may have a siloxane backbone and may include one or more vinyl groups. In addition, the viscosity of the polydimethylsiloxane resin used in the silicone-based adhesive material of the present invention may be 5 cP or more and 5,000 cP or less. The crosslinking agent may be a silicone-based crosslinking agent containing at least one Si-H structure, for example, polymethylhydrogen siloxane may be used. The catalyst may be a platinum catalyst. A coupling agent of the silane series represented by X-Si-OR3 (X=vinyl group, epoxy group, amino group, methacryloxy group, or mercapto group, R=methoxy group, ethoxy group, dialkoxy group, or trialkoxy group) can be used.

[0106] Because silicone-based adhesives (AMs) inherently possess pressure-sensitive adhesive (PSA) properties, they can achieve sufficient adhesion even without a coupling agent. However, depending on the type of refractory material (FM), the AMs can be formulated to include a coupling agent to further enhance adhesion.

[0107] For example, the adhesive material (AM) of one embodiment may include a polydimethylsiloxane resin, a crosslinking agent, a catalyst, and a coupling agent. For example, based on the total weight of the adhesive material (AM), the content of the polydimethylsiloxane resin may be greater than 77 wt% and less than 100 wt%, the content of the crosslinking agent may be greater than 0 wt% and less than 10 wt%, the content of the catalyst may be greater than 0 wt% and less than 3 wt%, and the content of the coupling agent may be greater than 0 wt% and less than 10 wt%. For example, based on the total weight of the adhesive material (AM), the content of the polydimethylsiloxane resin may be 95 wt%, the content of the crosslinking agent may be 1 wt%, the content of the catalyst may be 0.5 wt%, and the content of the coupling agent may be 3.5 wt%, but the embodiment is not limited thereto.

[0108] Meanwhile, when the adhesive material (AM) is sprayed in a spray form, the adhesive material (AM) is stored separately as a first compounding agent and a second compounding agent to prevent thermal curing due to long-term storage, and the first and second compounding agents can be mixed and used immediately before spraying. For example, the first compounding agent may include a polydimethylsiloxane resin and a crosslinking agent, and the second compounding agent may include a polydimethylsiloxane resin, a catalyst, and a coupling agent. When the first and second compounding agents are mixed, the content ratio of each component is the same as described above.

[0109] A refractory pad manufactured according to the manufacturing method of the refractory pad of Fig. 6 is illustrated.

[0110] Referring to Fig. 6, the refractory pad (1-2) may further include the aforementioned insulating layer (LL1), a refractory layer (LL2) disposed on at least one surface of the insulating layer (LL1), and an adhesive layer (LL3) disposed between the insulating layer (LL1) and the refractory layer (LL2). The adhesive layer (LL3) is a layer formed by curing the aforementioned adhesive material (AM).

[0111]

[0112] Meanwhile, the embodiments of the method for manufacturing the refractory pad of the present invention are not limited thereto.

[0113] A method for manufacturing a refractory pad according to one embodiment of the present invention,

[0114] A step of providing a first layer comprising a refractory material;

[0115] A step of providing a first composite layer comprising the silicone-aerogel composite on the first layer;

[0116] A step of providing a third layer comprising a refractory material on the first composite layer;

[0117] A step of curing the first composite layer to provide a second layer;

[0118] A step of providing a second composite layer comprising the silicone-aerogel composite on the third layer;

[0119] providing a fifth layer comprising a refractory material on the second composite layer; and

[0120] comprising a step of curing the second composite layer to provide a fourth layer;

[0121] The above refractory material may include at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and vermiculite-coated glass fiber cloth.

[0122]

[0123] FIGS. 7 to 15 each schematically illustrate one step of a method for manufacturing a refractory pad according to one embodiment.

[0124] Referring to FIG. 7, the method for manufacturing a fireproof pad of the present invention includes a step of providing a first layer comprising a fireproof material. The fireproof material may be a non-combustible material. For the fireproof properties of the fireproof pad, the first layer (10) is provided on the outer surface. The fireproof material may include at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and vermiculite. For example, ceramic paper may be used as the material of the first layer (10), and specifically, AES wool, such as Morgan's Super wool product, may be used to enhance the fireproof effect. The first layer (10) corresponds to the aforementioned fireproof layer (LL2).

[0125]

[0126] Next, a step of providing a first composite layer comprising the silicone-aerogel composite on the first layer is performed.

[0127] Referring to Fig. 8, the step of providing the first composite layer is a step of arranging a silicone-aerogel composite (CM) in a layer form on the first layer (10). Fig. 8 illustrates a method of uniformly spraying and coating a silicone-aerogel composite (CM) in powder form on the first layer (10). However, the present invention is not limited thereto, and a roll bar (RL) may be used to evenly coat the silicone-aerogel composite (CM) on the first layer (10), as shown in Fig. 9. As illustrated in Figs. 8 and 9, the first composite layer (CML1) refers to a layer in which a silicone-aerogel composite (CM) in a pre-cured state is arranged.

[0128]

[0129] Next, a step is performed of providing a third layer comprising a refractory material on the first composite layer.

[0130] Referring to Fig. 10, a third layer (30) is provided on the first composite layer (CML1). The third layer (30) includes a refractory material. The third layer (30) corresponds to the refractory layer (LL2) described above.

[0131] In one embodiment, the third layer (30) may comprise a different refractory material than the first layer (10). For example, the first layer (10) may be ceramic paper, and the third layer (30) may be vermiculite. Alternatively, in one embodiment, the third layer (30) may comprise the same refractory material as the first layer (10). For example, the first layer (10) and the third layer (30) may be ceramic paper. Alternatively, the first layer (10) and the third layer (30) may be vermiculite. The descriptions of the ceramic paper and vermiculite may be equally applicable to the above.

[0132] Referring to FIGS. 10 and 11 together, the step of curing the first composite layer (CML1) to provide the second layer is a step of simultaneously thermally compressing the first layer (10), the first composite layer (CML1), and the third layer (30). Through this, the first layer (10), the first composite layer (CML1), and the third layer (30) are thinned, and the first composite layer (CML1) is cured to become the second layer (20). The thermal compression method can use a known technology, and as illustrated in FIG. 10, a hot press (Plate Hot press, PR1) method can be used, or as illustrated in FIG. 11, a roll-to-roll (PR2) method can be used.

[0133] The second layer (20) includes silicone (SL) and serves as an adhesive layer that binds the first layer (10) and the third layer (30), and has insulating properties by including aerogel (AG). The second layer (20) corresponds to the aforementioned insulating layer (LL1).

[0134]

[0135] Next, a step is performed to provide a second composite layer on the third layer.

[0136] Referring to Fig. 12, the step of providing a second composite layer on the third layer is a step of providing a second composite layer (CML2) by coating a silicone-aerogel composite (CM) on the third layer (30). The second composite layer (CML2) refers to a layer in which a silicone-aerogel composite (CM) in a pre-cured state is arranged.

[0137] Fig. 12 illustrates a method of coating a silicone-aerogel composite (CM) in powder form by uniformly spraying it on the third layer (30). However, the present invention is not limited thereto, and a silicone-aerogel composite (CM) may be evenly coated on the third layer (30) using a roll bar (RL), as shown in Fig. 13.

[0138] Thereafter, a step of providing a fifth layer containing a refractory material on the second composite layer (CML2) is performed.

[0139] Referring to FIGS. 14 and 15 together, the step of providing a fifth layer is a step of providing a fifth layer (50) on the second composite layer (CML2). The fifth layer (50), which is the outer layer, includes a refractory material. The fifth layer (50) corresponds to the aforementioned refractory layer (LL2).

[0140] In one embodiment, the fifth layer (50) may comprise the same refractory material as the first layer (10). For example, the fifth layer (50) may be a sintered stone or a ceramic paper.

[0141] After the fifth layer (50) is provided, a step of curing the second composite layer (CML2) to provide a fourth layer (40) is performed. The step of providing the fourth layer (40) is performed by simultaneously thermally compressing the third layer (30), the second composite layer (CML2), and the fifth layer (50). Through this, the third layer (30), the second composite layer (CML2), and the fifth layer (50) are thinned, and the second composite layer (CML2) is cured to become the fourth layer (40). The thermal compression method can use a known technology, and as shown in FIG. 14, a hot press (Plate Hot press, PR1) method can be used, or as shown in FIG. 15, a roll-to-roll (PR2) method can be used. The fourth layer (40) includes silicone (SL) and serves as an adhesive layer that binds the third layer (30) and the fifth layer (50), and has insulating properties by including aerogel (AG). The fourth layer (40) corresponds to the aforementioned insulating layer (LL1).

[0142] When the fourth layer (40) is hardened, the refractory pad is manufactured.

[0143] Meanwhile, in FIGS. 7 to 15, the second layer (20) and the fourth layer (40) are described as being cured in separate stages, but this is not limited thereto, and the second layer (20) and the fourth layer (40) may be cured simultaneously. Specifically, the refractory pad may be manufactured by laminating the first layer (10), the first composite layer (CML1), the third layer (30), the second composite layer (CML2), and the fifth layer (50) described above at once, and then simultaneously thermally pressing them.

[0144]

[0145] A method for manufacturing a refractory pad according to one embodiment can provide a method for manufacturing a refractory pad that reduces the cost and time of the process and facilitates mass production by manufacturing a solid silicone-aerogel composite as described above.

[0146] In addition, the method for manufacturing a fireproof pad of one embodiment can provide a method for manufacturing a fireproof pad with improved fire resistance and processability by manufacturing a fireproof pad by laminating a composite layer including a silicone-aerogel composite and a fireproof layer including a refractory material.

[0147] In addition, the method for manufacturing a fireproof pad of one embodiment can exhibit excellent fire resistance and thermal insulation by alternately laminating a first layer, a third layer, and a fifth layer including a fireproof material and a second layer and a fourth layer including a silicone-aerogel composite. The step of providing the second layer and the fourth layer can increase the efficiency of the process compared to a wet manufacturing process by including a step of manufacturing a solid silicone-aerogel composite. In addition, since the second layer and the fourth layer include a thermosetting silicone-aerogel composite, curing occurs simultaneously during the process of thermocompression-bonding and laminating the first to fifth layers, thereby simplifying the manufacturing process.

[0148]

[0149] Hereinafter, embodiments of the invention will be described in detail so that those skilled in the art can easily implement the invention. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0150]

[0151] 1. Preparation of the insulation layer of Examples 1 to 3 and Comparative Examples 1 to 4

[0152]

[0153] Preparation of the insulation layer of Example 1

[0154] A solid silicone-aerogel composite was formed by mixing solvent-free silicone and aerogel in a weight ratio of 87.18:12.82. The silicone was PDMS resin, Dowsil from DOW. TM 7626 was used, and Dow Syl-off was used as a crosslinking agent. TM7028 was used, and Dow's Syl-off was used as a Pt catalyst. TM 4000 was used. Cabot EV5200 was used as the aerogel.

[0155] The manufactured silicone-aerogel composite was subjected to a test at 150°C with a strength of 1.5 kgf / cm 2 The insulating layer of Example 1 having a thickness of 0.7 to 2 mm was manufactured by hot-pressing for 30 seconds to form a pad and further heat-curing in an oven at 150°C for 10 minutes.

[0156]

[0157] Preparation of the insulation layer of Example 2

[0158] The insulation layer of Example 2 was manufactured in the same manner as the insulation layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 83.61:16.39.

[0159]

[0160] Preparation of the insulation layer of Example 3

[0161] The insulation layer of Example 3 was manufactured in the same manner as the insulation layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 80.31:19.69.

[0162]

[0163] Manufacturing of insulation layer of comparative example 1

[0164] Only silicone was used without aerogel. That is, the insulation layer of Comparative Example 1 was manufactured in the same manner as the insulation layer of Example 1, except that silicone was used instead of the silicone-aerogel composite in Example 1.

[0165]

[0166] Manufacturing of insulation layer of comparative example 2

[0167] An insulating layer of Comparative Example 2 was prepared in the same manner as the insulating layer of Example 1, except that silicone and aerogel were mixed in a weight ratio of 50:50. However, padding of the silicone-aerogel composite was not achieved.

[0168]

[0169] Manufacturing of insulation layer of comparative example 3

[0170] An insulating layer of Comparative Example 3 was prepared in the same manner as the insulating layer of Example 1, except that the silicone and aerogel were mixed in a weight ratio of 30:70. However, padding of the silicone-aerogel composite was not achieved.

[0171]

[0172] Manufacturing of insulation layer of comparative example 4

[0173] Pure aerogel containing 100% aerogel without silicone was prepared. It was provided in powder form and was not padded.

[0174]

[0175] 2. Evaluation of thermal conductivity of insulation layers of Examples 1 to 3 and Comparative Examples 1 to 4

[0176] For the insulation layers of Examples 1 to 3 and Comparative Examples 1 to 4 manufactured above, thermal conductivity was evaluated using the TPS method (ISO 2207-2). For Comparative Examples 2 to 4, which were not padded, thermal conductivity was measured in powder form.

[0177] Thermal conductivity (mW / m K) Padded or not Example 1131.9O Example 2107.2O Example 381.9O Comparative Example 1231O Comparative Example 245X Comparative Example 340.3X Comparative Example 429.3X

[0178] Referring to Table 1 above, it can be confirmed that the insulation layers of Examples 1 to 3 have sufficiently low thermal conductivity of about 150 mW / m·K or less, specifically, 131.9 mW / m·K or less, and thus have excellent insulation properties. In particular, it was confirmed that the insulation layers of Examples 2 and 3 have even lower thermal conductivity of about 110 mW / m·K or less, specifically, 107.2 mW / m·K or less, and optimized insulation properties as the aerogel content becomes 15 wt% or more. In addition, it can be confirmed that the insulation layers of Examples 1 to 3 have sufficient insulation performance and are easily padded by including 0.5 wt% or more and 40 wt% or less of aerogel, or 10 wt% or more and 30 wt% or less of silicone, and 60 wt% or more and 99.5 wt% or less of silicone, or 70 wt% or more and 90 wt% or less. In particular, it can be confirmed that the insulation layers of Examples 2 and 3 have excellent insulation performance and are padded without deterioration of mechanical properties by including 15 wt% or more and 30 wt% or less of aerogel and 70 wt% or more and 85 wt% or less of silicone.

[0179] The insulation layer of Comparative Example 1 did not contain aerogel, so its thermal conductivity was very high and it is expected that it will be difficult to expect insulation performance.

[0180] The insulation layers of Comparative Examples 2 and 3 had low thermal conductivity when the aerogel content exceeded 40 wt%, but did not become padded.

[0181] The insulation layer of Comparative Example 4 is 100% aerogel, has very low thermal conductivity, but exists in powder form and is not padded, so it cannot be applied as a fire-resistant pad.

[0182]

[0183] Accordingly, the method for manufacturing a fire-resistant pad of the present invention includes a step of forming a silicone-aerogel composite by mixing silicone and aerogel, and based on the total mixing amount of the silicone-aerogel composite, the content of the aerogel is 0.5 wt% or more and 40 wt% or less, and the content of the silicone is 60 wt% or more and 99.5 wt% or less, thereby providing a method for manufacturing a fire-resistant pad that has low thermal conductivity, thus exhibiting excellent insulation properties, and is easy to form into a pad, thereby providing excellent processability.

[0184]

[0185] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims also fall within the scope of the present invention.

[0186] [Explanation of symbols]

[0187] FM: Fire-resistant material

[0188] CM: Silicone-aerogel composite

[0189] LM, LM-1, LM-2: laminates

[0190] 1, 1-1, 1-2: Fireproof pad

[0191] LL1: Insulation layer

[0192] LL2: Refractory layer

[0193] LL3: Adhesive layer

[0194] CML1: First composite layer

[0195] CML2: Second composite layer

[0196] 10: 1st floor

[0197] 20: Second floor

[0198] 30: Third floor

[0199] 40: 4th floor

[0200] 50: Fifth floor

[0201] AG: Aerogel

[0202] SL: Silicone

Claims

1. A step of forming a silicone-aerogel composite by mixing silicone and aerogel, A method for manufacturing a fireproof pad, wherein the content of the aerogel is 0.5 wt% or more and 40 wt% or less based on the total mixing amount of the above silicone-aerogel composite.

2. In paragraph 1, The above silicone is provided in a liquid form without solvent, A method for manufacturing a refractory pad, wherein the above silicone-aerogel composite is formed in a solid phase.

3. In paragraph 1, A method for manufacturing a fireproof pad, wherein the content of the silicone is 60 wt% or more and 99.5 wt% or less based on the total mixing amount of the silicone-aerogel composite.

4. In paragraph 1, A method for manufacturing a fireproof pad, wherein the content of the above aerogel is 15% by weight or more and 30% by weight or less.

5. In paragraph 1, A step of preparing a fire-resistant material including at least one of a non-combustible material and a flame-retardant material; A step of forming a laminate by laminating the refractory material on at least one surface of the silicone-aerogel composite; and A method for manufacturing a refractory pad, further comprising: a step of forming a refractory pad by curing and sheeting the laminated body; 6. In paragraph 5, A method for manufacturing a refractory pad, wherein the step of forming the refractory pad is performed in one step by thermally compressing the laminate.

7. In paragraph 5, The step of forming the above refractory pad is: A first step of forming the laminate into a sheet shape by thermocompression; and A method for manufacturing a refractory pad, comprising: a second step of heat-curing the heat-pressed laminate.

8. In paragraph 5, A method for manufacturing a fireproof pad, wherein the refractory material comprises at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and aramid fiber.

9. In paragraph 5, A method for manufacturing a refractory pad, wherein in the above laminate, the silicone-aerogel composite is arranged in a single plane shape.

10. In paragraph 5, A method for manufacturing a refractory pad, wherein in the above laminate, the silicone-aerogel composite is arranged in a stripe shape.

11. In paragraph 1, A method for manufacturing a refractory pad, wherein the above aerogel comprises silica gel.

12. In paragraph 1, A method for manufacturing a refractory pad, wherein the silicone comprises a polydimethylsiloxane (PDMS) resin and optionally further comprises at least one of a crosslinking agent and a catalyst.

13. In paragraph 12, A method for manufacturing a fireproof pad, wherein, based on the total mixing amount of the silicone-aerogel composite, the content of the polydimethylsiloxane resin is 47 wt% or more and 99.5 wt% or less, the content of the crosslinking agent is 0 wt% or more and 10 wt% or less, and the content of the catalyst is 0 wt% or more and 3 wt% or less.

14. In paragraph 5, A method for manufacturing a refractory pad, wherein the step of forming the laminate comprises the step of laminating an adhesive material on one surface of the refractory material and the step of laminating the silicone-aerogel composite on the adhesive material.

15. In paragraph 14, A method for manufacturing a refractory pad, wherein the adhesive material comprises polydimethylsiloxane (PDMS) resin, a crosslinking agent, and a catalyst, and optionally further comprises a coupling agent.

16. In paragraph 1, A step of providing a first layer comprising a refractory material; A step of providing a first composite layer comprising the silicone-aerogel composite on the first layer; A step of providing a third layer comprising a refractory material on the first composite layer; A step of curing the first composite layer to provide a second layer; A step of providing a second composite layer comprising the silicone-aerogel composite on the third layer; providing a fifth layer comprising a refractory material on the second composite layer; and comprising a step of curing the second composite layer to provide a fourth layer; A method for manufacturing a fireproof pad, wherein the refractory material comprises at least one of mica fiber, glass fiber, basalt fiber, ceramic paper, and vermiculite-coated glass fiber cloth.

17. In paragraph 16, A method for manufacturing a refractory pad, wherein the first layer, the third layer, and the fifth layer comprise the same refractory material.

18. In paragraph 16, A method for manufacturing a refractory pad, wherein the third layer comprises a refractory material different from the first layer and the fifth layer.

19. In paragraph 16, The step of providing the second layer is: A method for manufacturing a refractory pad, wherein the first layer, the first composite layer, and the third layer are simultaneously thermally compressed to harden the first composite layer into the second layer.

20. In paragraph 16, The step of providing the above fourth layer is: A method for manufacturing a refractory pad, wherein the third layer, the second composite layer, and the fifth layer are simultaneously thermally compressed to harden the second composite layer into the fourth layer.