Device and method for manufacturing aerogel felt

Abstract

The present invention relates to an apparatus for manufacturing aerogel felt and a method for manufacturing aerogel felt. The apparatus for manufacturing aerogel felt of the present invention is an apparatus for manufacturing aerogel felt, comprising a supply portion for supplying fibers containing sol and a conveyor belt for moving the fibers supplied from the supply portion, wherein the conveyor belt is arranged in multiple stages so as to move the fibers while flipping the fibers, and the start time of flipping the fibers by the conveyor belt is before the fluidity of the sol is completely lost.

Description

Technical Field

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to Korean Patent Application No. 10-2021-0070447, filed on May 31, 2021, which is hereby incorporated by reference in its entirety. Technical Field

[0004] The present invention relates to an apparatus and a method for producing an aerogel felt. Background Art

[0005] Aerogel is a highly porous material composed of nanoparticles, having high porosity and specific surface area and low thermal conductivity. Therefore, aerogels used for high-efficiency thermal insulation materials, sound insulation materials, etc. have attracted attention. Such aerogels have very low mechanical strength due to their porous structure, so aerogel composites have been developed, in which aerogels are combined with fiber felts by impregnating aerogels in fiber felts made of inorganic fibers or organic fibers, which are typical thermal insulation fibers. For example, a silica aerogel-containing felt using silica aerogel is manufactured through a silica sol preparation process, a gelation process, a aging process, a surface modification process, and a drying process.

[0006] Here, when the fiber is impregnated with the sol liquid containing silica and moved, the low-viscosity sol settles to the lower part of the fiber impregnated with the sol before gelling.

[0007] Therefore, a difference in the amount of sol impregnation occurs between the top and bottom surfaces of the fiber, which leads to a problem of forming an uneven cross section. Here, the top surface of the fiber is exposed, resulting in a decrease in surface water repellency.

[0008] In particular, a heavy additive settles to the bottom of the sol during the gelation process to form a layer, which causes a problem of increased dust generation.

[0009] [Prior art document] (Patent document) Korean Patent Gazette No. 10-2011-0125773 Summary of the invention

[0010] Technical issues

[0011] One aspect of the present invention is to provide an apparatus and method for manufacturing an aerogel felt, wherein a sol is uniformly impregnated in fibers.

[0012] Technical Solution

[0013] The device for manufacturing aerogel felt according to an embodiment of the present invention is a device for manufacturing aerogel felt, which includes a supply unit for supplying fibers containing sol and a conveyor belt for moving the fibers supplied from the supply unit. The conveyor belt can be arranged in multiple stages so as to move the fibers while turning over the fibers, and the start time of turning over the fibers by the conveyor belt can be before the fluidity of the sol is completely lost.

[0014] The method for manufacturing aerogel felt according to an embodiment of the present invention is a method for manufacturing aerogel felt, which includes a supply process of supplying fibers containing sol, and a moving process of moving the fibers supplied through the supply process by a conveyor belt. In the moving process, the conveyor belt can be set in multiple stages so as to move the fibers while flipping the fibers, and the start time of flipping the fibers in the moving process can be before the fluidity of the sol is completely lost.

[0015] Beneficial effects

[0016] According to the present invention, the conveyor belt that moves the fibers may be disposed in multiple stages, thereby moving the fibers while turning them over so that the sol may be uniformly impregnated in the fibers.

[0017] Additionally, the conveyor belts that move the fibers may be arranged in multiple stages in the vertical direction to reduce the horizontal space occupied by the conveyor belts. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 : is a front view showing an example of an apparatus for manufacturing an aerogel felt according to an embodiment of the present invention.

[0019] Figure 2 1 is an enlarged front view showing a portion where a guide is installed in the apparatus for manufacturing an aerogel felt according to an embodiment of the present invention.

[0020] Figure 3 is a front view showing an example of an apparatus for manufacturing an aerogel felt according to another embodiment of the present invention. DETAILED DESCRIPTION

[0021] The objects, advantages and features of the present invention will be illustrated by the following embodiments described with reference to the accompanying drawings. Note that even if shown in different drawings, the same elements are represented by the same reference numerals as much as possible. The present invention can be implemented in different forms and should not be construed as being limited to the embodiments set forth herein. In addition, detailed descriptions related to known technologies will be excluded so as not to unnecessarily obscure the subject matter of the present invention.

[0022] Apparatus for manufacturing aerogel felt according to an embodiment

[0023] Figure 1 : is a front view showing an example of an apparatus for manufacturing an aerogel felt according to an embodiment of the present invention.

[0024] See also Figure 1 The device 100 for manufacturing aerogel felt according to an embodiment of the present invention is the device 100 for manufacturing aerogel felt, which includes a supply part S for supplying fibers 10 containing sol, and a conveyor belt 130 for moving the fibers 10 supplied from the supply part S. The conveyor belt 130 is arranged in multiple stages, thereby moving the fibers 10 while turning over the fibers 10. In addition, the device 100 for manufacturing aerogel felt according to an embodiment of the present invention may further include guide parts 141, 142, 143 and 144, a heater 150 and a heat-insulating cover part 160.

[0025] More specifically, the supply part S may supply the fiber containing the sol. Here, the fiber 10 impregnated with the sol may be movably supplied to the conveyor belt 130 by the supply part S.

[0026] The supply part S may include a pair of moving rollers 110 engaged to move the fiber 10 , and an impregnation part 120 impregnating the fiber 10 with the sol.

[0027] The pair of moving rollers 110 may include a first roller 111 and a second roller 112. Here, the pair of moving rollers 110 may rotate in opposite directions to face each other, and may move the fiber 10 while passing between the rollers facing each other. That is, during the supply process, the fiber 10 may move while passing between the first roller 111 and the second roller 112.

[0028] The impregnation part 120 may spray the sol onto the fiber 10 to impregnate the fiber 10 with the sol. Here, the impregnation part 120 may be disposed above the pair of moving rollers 110 to spray the sol onto the upper portion of the fiber 10 introduced between the pair of moving rollers 110 so that the sol flows downward to the space between the pair of moving rollers 110.

[0029] However, in the apparatus 100 for manufacturing aerogel felt according to the embodiment of the present invention, the impregnation unit is not necessarily limited to the impregnation section 120 that sprays the sol to impregnate the fiber 10 with the sol, and various impregnation units may be used. For example, the fiber 10 may be impregnated with the sol while passing through an impregnation container containing the sol.

[0030] The sol may be formed as a precursor solution containing, for example, silica sol and additives.

[0031] Silica sol can be prepared by mixing, for example, tetraethyl orthosilicate (TEOS, ethyl silicate), ethanol, H2O, and hydrogen chloride (HCL).

[0032] Additives may include, for example, flame retardants, sunscreens, and the like.

[0033] The sol may also contain an alkaline catalyst for inducing gelation of the sol impregnated in the fibers.

[0034] Here, the alkali catalyst can make the gel time a predetermined time.

[0035] Here, the alkali catalyst may be, for example, sodium hydroxide (NaOH), but the type of the alkali catalyst used in the apparatus 100 for manufacturing an aerogel felt according to the embodiment of the present invention is not necessarily limited to NaOH.

[0036] In addition, a base catalyst may be used, for example, to allow the sol to have a pH of about 6 to about 8.

[0037] Figure 2 1 is an enlarged front view showing a portion where a guide is installed in the apparatus for manufacturing an aerogel felt according to an embodiment of the present invention.

[0038] See also Figure 1 and Figure 2 , the conveyor belt 130 may be provided in multiple stages so as to move the fiber 10 supplied from the supply part S while turning the fiber 10 .

[0039] Here, the start time of turning over the fiber 10 by the conveyor belt 130 may be before the fluidity of the sol is completely lost.

[0040] In addition, the start time of the conveyor belt 130 turning over the fiber 10 may be, for example, about 1 minute before the fluidity of the sol is completely lost. Here, the time when the fluidity of the sol is completely lost may be the time when the gelation of the liquid sol is completed. Here, the start time of the conveyor belt 130 turning over the fiber 10 may be, for example, before about 9 minutes have passed after the fiber 10 is impregnated with the sol.

[0041] In the conveyor belt 130 configured in multiple stages, the conveyor belt 130 on each stage may include a plurality of rollers 131a, 131b, and 132b, and belts mounted on the plurality of rollers 131a, 131b, and 132b.

[0042] Furthermore, the conveyor belts 130 provided in multiple stages may be horizontally provided at each stage.

[0043] The conveyor belts 130 may be arranged in 2 to 5 stages in the vertical direction. Here, the conveyor belts 130 may be arranged in 2 or more stages in the vertical direction to turn over the fiber 10, and may be arranged in 5 stages at most to prevent the device from becoming unnecessarily complicated and to prevent the space efficiency from being reduced due to occupying an excessive amount of space.

[0044] In one example, when set to level 2, the conveyor belt 130 may include a first conveyor belt 131 and a second conveyor belt 132 .

[0045] In another example, when set to level 5, the conveyor belt 130 may include a first conveyor belt 131 , a second conveyor belt 132 , a third conveyor belt 133 , a fourth conveyor belt 134 , and a fifth conveyor belt 135 .

[0046] The guides 141, 142, 143, and 144 may each be provided with a certain gap from the lower corner of the conveyor belt 130 to guide the movement of the fiber 10. Here, the guides 141, 142, 143, and 144 may each allow the fiber 10 to reabsorb the sol that falls when the fiber 10 is separated from the fiber 10 turned over on the end of the conveyor belt 130. That is, for example, the guides 141, 142, 143, and 144 may each allow the sol that is separated and falls when the fiber 10 is turned over while passing through the end of the first conveyor belt 131 on the top level of the multi-stage conveyor belt 130 to flow on the upper part of the second conveyor belt 132 provided at the lower level, so that the sol may be reabsorbed by a part of the fiber 10 that passes through the second conveyor belt 132.

[0047] In addition, the guides 141 , 142 , 143 , and 144 may each have a shape corresponding to the conveyor belt 130 and contact the bottom surface of the fiber 10 .

[0048] The guides 141, 142, 143, and 144 may each include a contact portion 141a contacting the fiber 10 and a support portion 141b supporting the contact portion 141a. The contact portion 141a may have a circular shape. Here, the lower portion of the contact portion 141a may be disposed toward the upper portion of the conveyor belt 130 disposed at the lower stage.

[0049] The heater 150 may be disposed above the conveyor belt 130 to apply heat to the fiber 10. Thus, gelation of the sol impregnated in the fiber 10 may be promoted.

[0050] The heat-retaining cover part 160 may accommodate the conveyor belt 130 and heat the fiber 10 moving through the conveyor belt 130. Therefore, the heat applied to the fiber 10 by the heater 150 may be prevented from being lost to uniformly apply the heat to the fiber 10.

[0051] The sol impregnated in the fiber 10 may be gelled over time while passing through the conveyor belt 130. Afterwards, the fiber 10 after the gelation of the sol is completed may be passed through the conveyor belt 130 and wound on a winding roller.

[0052] In the apparatus 100 for manufacturing aerogel felt according to an embodiment of the present invention configured as above, the conveyor belt 130 for moving the fiber 10 can be set to multiple stages, so that the fiber 10 is moved while flipping the fiber 10, thereby having the effect of evenly impregnating both sides of the fiber 10 with the sol to improve the uniformity of the product. In addition, dust generation can be reduced by about 80%, and the surface moisture impregnation rate can be reduced to less than about 50%, thereby improving the surface water repellency to maintain water repellency.

[0053] Furthermore, the conveyor belt 130 that moves the fiber 10 may be disposed at multiple stages in the vertical direction, and thus, there is an effect that the horizontal space occupied by the conveyor belt 130 may be reduced to improve space efficiency.

[0054] Apparatus for manufacturing aerogel felt according to another embodiment

[0055] Figure 3 is a front view showing an example of an apparatus for manufacturing an aerogel felt according to another embodiment of the present invention.

[0056] See also Figure 3 , the apparatus 200 for manufacturing aerogel felt according to another embodiment of the present invention is the apparatus 200 for manufacturing aerogel felt, which includes a supply part S for supplying fibers 10 impregnated with sol, and a conveyor belt 230 for moving the fibers 10 supplied from the supply part S. The conveyor belt 230 is arranged in multiple stages, thereby moving the fibers 10 while turning over the fibers 10. In addition, the apparatus 200 for manufacturing aerogel felt according to another embodiment of the present invention may further include guide parts 141, 142, 143 and 144, a heater 150 and a heat-insulating cover part 160.

[0057] Compared with the above-mentioned apparatus for manufacturing aerogel felt according to one embodiment of the present invention, the apparatus 200 for manufacturing aerogel felt according to another embodiment of the present invention is different in that the two side portions of the conveyor belt 230 are arranged in a curved shape. Therefore, another embodiment of the apparatus 200 for manufacturing aerogel felt is described by omitting or briefly describing the contents shared with the above-mentioned embodiment and focusing on the differences.

[0058] More specifically, the conveyor belt 230 may be provided in multiple stages so as to move the fiber 10 supplied from the supply part S while turning the fiber 10 .

[0059] Here, the conveyor belt 230 may start turning over the fiber 10 before the fluidity of the sol is completely lost.

[0060] In addition, the start time of the conveyor belt 230 turning over the fiber 10 may be, for example, about 1 minute before the fluidity of the sol is completely lost. Here, the time when the fluidity of the sol is completely lost may be the time when the gelation of the liquid sol is completed. Here, the start time of the conveyor belt 230 turning over the fiber 10 may be, for example, before about 9 minutes have passed after the fiber 10 is impregnated with the sol.

[0061] The conveyor belts 230 may be arranged in 2 to 5 stages in the vertical direction.

[0062] Here, in the conveyor belt 230 configured in multiple stages, the conveyor belt 230 on each stage may include a plurality of rollers, and belts mounted on the plurality of rollers.

[0063] Among the conveyor belts 230 arranged in multiple stages, the conveyor belts 230 at at least one stage may be arranged in a shape in which one side portion or the other side portion is bent upward. Among the conveyor belts 230 arranged in multiple stages may be arranged in a shape in which one side portion and the other side portion are alternately bent upward relative to the central portion. Here, for example, one side portion of the conveyor belt 230 may be the end portion of the conveyor belt 230 in one direction O, and the other side portion may be the end portion of the conveyor belt 230 in another direction I. That is, see Figure 3 , one side or the other side of the conveyor belt 230 may be, for example, the right end and the left end. In addition, one side and the other side bent upward in the multi-stage conveyor belt 230 may be formed to extend further than the end of the conveyor belt 230 provided at the upper stage. That is, the bent portion of the conveyor belt 230 may be extended.

[0064] Therefore, the sol separated from the fiber 10 flipped on the end of the conveyor belt 230 set on the upper side of the multi-stage conveyor belt 230 can fall to the top surface of the conveyor belt 230 set on the lower side, and thus be reabsorbed by a portion of the fiber 10 passing through the conveyor belt 230 set on the lower side.

[0065] In one example, when set to 2 levels, the conveyor belt 230 may include a first conveyor belt 231 and a second conveyor belt 232. Here, in the conveyor belt 230 set to 2 levels, the first conveyor belt 231 set to the uppermost level is horizontally arranged, and the second conveyor belt 232 set below the first conveyor belt 231 may be arranged in a shape with a side portion bent upward. In another example, when set to 5 levels, the conveyor belt 230 may include a first conveyor belt 231, a second conveyor belt 232, a third conveyor belt 233, a fourth conveyor belt 234, and a fifth conveyor belt 235. Here, in the conveyor belt 230 set to 5 levels, the first conveyor belt 231 set at the uppermost level is horizontally set, the second conveyor belt 232 set below the first conveyor belt 231 can be set to a shape with one side bent upward, the third conveyor belt 233 set below the second conveyor belt 232 can be set to a shape with the other side bent upward, the fourth conveyor belt 234 set below the third conveyor belt 233 can be set to a shape with one side bent upward, and the fifth conveyor belt 235 set below the fourth conveyor belt 234 can be set to a shape with the other side bent upward.

[0066] The guides 141, 142, 143, and 144 may each be disposed at a certain gap from the lower corner of the conveyor belt 230 to guide the movement of the fiber 10. Here, the guides 141, 142, 143, and 144 may each allow the fiber 10 to reabsorb the sol falling when the fiber 10 flipped over the end of the conveyor belt 230 is separated.

[0067] The sol impregnated in the fiber 10 may be gelled over time while passing through the conveyor belt 230 . Afterwards, the fiber 10 after the gelation of the sol is completed may be wound on the winding roller 270 through the conveyor belt 230 .

[0068] Method for manufacturing aerogel felt according to an embodiment

[0069] Hereinafter, a method for manufacturing an aerogel felt according to an embodiment of the present invention will be described.

[0070] See also Figure 1 , the method for manufacturing aerogel felt according to an embodiment of the present invention is the following method for manufacturing aerogel felt, which includes a supply process of supplying fibers 10 containing sol, and a moving process of moving the fibers 10 supplied through the supply process by a conveyor belt 130. In the moving process, the conveyor belt 130 may be arranged in multiple stages so as to move the fibers 10 while flipping the fibers 10. In addition, in the method for manufacturing aerogel felt according to an embodiment of the present invention, the moving process may include a guiding process and a heating process.

[0071] The method for manufacturing aerogel felt according to an embodiment of the present invention is a method for manufacturing aerogel felt by using the apparatus for manufacturing aerogel felt according to the embodiment of the present invention described above. Therefore, the embodiment of this method for manufacturing aerogel felt is described by omitting or briefly describing the contents shared with the embodiment of the apparatus for manufacturing aerogel felt described above and focusing on the differences.

[0072] More specifically, in the supply process, the fiber 10 containing the sol may be supplied. Here, in the supply process, the fiber 10 impregnated with the sol may be movably supplied to the conveyor belt 130 through the supply part S.

[0073] The supply part S may include a pair of moving rollers 110 engaged to move the fiber 10 , and an impregnation part 120 impregnating the fiber 10 with the sol.

[0074] The pair of moving rollers 110 may include a first roller 111 and a second roller 112. Here, the pair of moving rollers 110 may rotate in opposite directions to face each other, and may move the fiber 10 while passing between the rollers facing each other. That is, during the supply process, the fiber 10 may move while passing between the first roller 111 and the second roller 112.

[0075] During the supply process, the fiber 10 may be impregnated with the sol, for example, by spraying the sol onto the fiber 10 through the impregnation section 120. Here, during the supply process, the impregnation section 120 may be disposed above the pair of moving rollers 110 to spray the sol onto the upper portion of the fiber 10 introduced between the pair of moving rollers 110, so that the sol flows downward to the space between the pair of moving rollers 110. However, in the method for manufacturing an aerogel felt according to an embodiment of the present invention, the impregnation method is not necessarily limited to spraying the sol through the impregnation section 120 to impregnate the fiber 10 with the sol, and various impregnation methods may be used. For example, the fiber 10 may be impregnated with the sol while passing through an impregnation container containing the sol.

[0076] The sol may be formed as a precursor solution containing, for example, silica sol and additives.

[0077] Silica sol can be prepared by mixing, for example, tetraethyl orthosilicate (TEOS, ethyl silicate), ethanol, H2O, and hydrogen chloride (HCL).

[0078] Additives may include, for example, flame retardants, sunscreens, and the like.

[0079] The sol may also contain an alkaline catalyst for inducing gelation of the sol impregnated in the fibers.

[0080] Here, the alkali catalyst can make the gel time a predetermined time.

[0081] Here, the alkali catalyst may be, for example, sodium hydroxide (NaOH), but the type of the alkali catalyst used in the apparatus 100 for manufacturing an aerogel felt according to the embodiment of the present invention is not necessarily limited to NaOH.

[0082] In addition, a base catalyst may be used, for example, to allow the sol to have a pH of about 7 to about 9.

[0083] During the moving process, the fiber 10 supplied through the supply process may be moved by the conveyor belt 130 .

[0084] Furthermore, during the movement, the conveyor belt 130 may be disposed in multiple stages so as to move the fiber 10 while turning the fiber 10 .

[0085] Here, the start time of turning over the fiber 10 during the moving process may be before the fluidity of the sol is completely lost.

[0086] In addition, the starting time of the conveyor belt 130 flipping the fiber 10 during the movement process can be, for example, about 30 seconds to about 1 and a half minutes before the fluidity of the sol is completely lost. Among them, the starting time of flipping the fiber 10 during the movement process can be, for example, specifically about 1 minute before the fluidity of the sol is completely lost. Here, the time when the fluidity of the sol is completely lost can be the time when the gelation of the liquid sol is completed. Therefore, the starting time of flipping the fiber 10 during the movement process can be about 1 minute before the fluidity of the sol is completely lost, so that both sides of the fiber 10 are evenly impregnated with the sol.

[0087] Here, the start time of the conveyor belt 130 turning over the fiber 10 during the movement may be, for example, before about 9 minutes have passed after the fiber 10 has been impregnated with the sol. Here, the start time of the conveyor belt 130 turning over the fiber 10 during the movement may be, for example, before about 7 minutes have passed after the fiber 10 has been impregnated with the sol. Here, the start time of the conveyor belt 130 turning over the fiber 10 during the movement may be, for example, before about 4 minutes have passed after the fiber 10 has been impregnated with the sol.

[0088] The final time that the conveyor belt 130 flips the fiber 10 during the movement may be, for example, within about 20 minutes to about 30 minutes.

[0089] In the conveyor belt 130 configured in multiple stages, the conveyor belt 130 on each stage may include a plurality of rollers 131a, 131b, and 132b, and belts mounted on the plurality of rollers 131a, 131b, and 132b.

[0090] Furthermore, the conveyor belts 130 provided in multiple stages may be horizontally provided at each stage.

[0091] The conveyor belts 130 may be arranged in 2 to 5 stages in the vertical direction.

[0092] During the movement, the fiber 10 may be turned over 1 to 4 times.

[0093] The moving process may include a guiding process and a heating process.

[0094] During the guiding process, the guide parts 141 , 142 , 143 , and 144 may each be disposed to be spaced apart from a lower corner of the conveyor belt 130 by a certain gap to guide the movement of the fiber 10 .

[0095] Here, during the guiding process, the guides 141 , 142 , 143 , and 144 each may allow the fiber 10 to reabsorb the sol dropped when the fiber 10 turned over on the end of the conveyor belt 130 is separated.

[0096] In the heating process, the heater 150 may be disposed above the conveyor belt 130 to apply heat to the fiber 10. Therefore, gelation of the sol impregnated in the fiber 10 may be promoted.

[0097] During the movement, a heat-insulating cover 160 may be provided to accommodate the conveyor belt 130 and to heat the fiber 10 moving through the conveyor belt 130. Therefore, during the heating process, the heat applied to the fiber 10 by the heater 150 may be prevented from being lost to apply heat to the fiber 10 uniformly.

[0098] During the moving process, the sol impregnated in the fiber 10 may gel over time while passing through the conveyor belt 130. That is, the moving process may include a gelling process.

[0099] The method for manufacturing an aerogel felt according to the embodiment of the present invention may further include a winding process in which the fiber 10 after gelation of the sol is wound on a winding roller via a conveyor belt 130 after the moving process.

[0100] A method for manufacturing an aerogel felt according to another embodiment

[0101] See also Figure 3 , a method for manufacturing aerogel felt according to another embodiment of the present invention is a method for manufacturing aerogel felt, which includes a supply process of supplying fibers 10 containing sol, and a moving process of moving the fibers 10 supplied through the supply process by a conveyor belt 230. In the moving process, the conveyor belt 230 may be arranged in multiple stages so as to move the fibers while turning over the fibers 10. In addition, in the method for manufacturing aerogel felt according to another embodiment of the present invention, the moving process may include a guiding process and a heating process.

[0102] Compared with the method for manufacturing aerogel felt according to one embodiment of the present invention described above, the method for manufacturing aerogel felt according to another embodiment of the present invention is different in that, during the movement, the two side portions of the conveyor belt 230 are arranged in a curved shape. Therefore, another embodiment of this method for manufacturing aerogel felt is described by omitting or briefly describing the contents shared with the above embodiment and focusing on the differences.

[0103] More specifically, during the moving process, the fiber 10 supplied through the supply process may be moved by the conveyor belt 230 .

[0104] Furthermore, during the movement, the conveyor belt 230 may be provided in multiple stages so as to move the fiber 10 supplied from the supply part S while turning the fiber 10 .

[0105] Here, the start time of the conveyor belt 230 turning over the fiber 10 during the movement may be before the fluidity of the sol is completely lost.

[0106] In addition, the starting time of the conveyor belt 230 flipping the fiber 10 during the movement process can be, for example, about 30 seconds to about 1 and a half minutes before the fluidity of the sol is completely lost. Here, the starting time of the conveyor belt 230 flipping the fiber 10 during the movement process can be, for example, specifically about 1 minute before the fluidity of the sol is completely lost.

[0107] Here, the time when the fluidity of the sol is completely lost may be the time when the gelation of the liquid sol is completed. Here, the start time of the conveyor belt 230 turning over the fiber 10 may be, for example, before about 9 minutes have passed after the fiber 10 is impregnated with the sol.

[0108] The conveyor belts 230 may be arranged in 2 to 5 stages in the vertical direction.

[0109] Here, in the conveyor belt 230 configured in multiple stages, the conveyor belt 230 on each stage may include a plurality of rollers, and belts mounted on the plurality of rollers.

[0110] Among them, in the conveyor belt 230 arranged in multiple stages, the conveyor belt 230 at at least one stage can be arranged in a shape in which one side portion or the other side portion is bent upward. Among them, the conveyor belt 230 arranged in multiple stages can be arranged in a shape in which one side portion and the other side portion are alternately bent upward relative to the central portion. In addition, the one side portion and the other side portion bent upward in the multi-stage conveyor belt 230 can be formed to extend further than the end of the conveyor belt 230 arranged in the upper stage. That is, the curved portion of the conveyor belt 230 can be extended. Therefore, during the movement, the sol separated from the fiber 10 turned over on the end of the conveyor belt 230 arranged on the upper side of the multi-stage conveyor belt 230 can fall to the top surface of the conveyor belt 230 arranged on the lower side, thereby being reabsorbed by a part of the fiber 10 passing through the conveyor belt 230 arranged on the lower side.

[0111] <Example 1>

[0112] A sol solution is prepared, which is a precursor solution containing silica sol and additives. Here, the silica sol is prepared by mixing tetraethyl orthosilicate (TEOS), ethanol, H2O and HCL. Additives such as flame retardants and sunscreens are added to the precursor solution.

[0113] The catalyst was added to the precursor solution so that the gel time was about 10 minutes.

[0114] Assuming that the total required residence time of the fibers on the conveyor was about 20 minutes, the fibers were turned over twice on the 3-stage conveyor, about 7 minutes and about 14 minutes after impregnation of the fibers with the sol.

[0115] Thereafter, the aerogel felt is manufactured through a aging process, a hydrophobic surface modification process and a supercritical drying process.

[0116] <Example 2>

[0117] The same procedure as in Example 1 was performed except that the fiber was turned over three times on the 4-stage conveyor belt at about 5 minutes, about 10 minutes, and about 15 minutes after the fiber was impregnated with the sol solution.

[0118] <Example 3>

[0119] The same process as in Example 1 was performed except that the fiber was turned over four times on the 5-stage conveyor belt at about 4 minutes, about 8 minutes, about 12 minutes, and about 16 minutes after the fiber was impregnated with the sol solution.

[0120] <Comparative Example 1>

[0121] The same procedure as in Example 1 was performed except that the fibers were not turned over on the conveyor belt after being impregnated with the sol solution.

[0122] <Comparative Example 2>

[0123] The same procedure as in Example 1 was performed except that the fibers were turned over once on the 2-stage conveyor belt about 10 minutes after the fibers were impregnated with the sol solution.

[0124] <Experimental Example 1>

[0125] The thermal conductivity, moisture impregnation rate, and dust of each of the aerogel felts produced by the examples and comparative examples were measured.

[0126] Thermal conductivity was measured at room temperature (about 25° C.) using a HFM 436 (Netzsch company) device.

[0127] The moisture penetration rate was measured according to ASTM C1511.

[0128] Dust is measured as the change in weight of a sample having dimensions of about 100 mm by about 100 mm after being vibrated at about 24 Hz with a vertical amplitude of about 3 mm for about 12 hours.

[0129] The thermal conductivity, moisture penetration rate, and dust measured by the test of Experimental Example 1 are shown in Table 1 below.

[0130]

Table 1

[0131]

[0132] Referring to Table 1, it can be seen that while Examples 1 to 3 each have a moisture impregnation rate of only about 5 wt % to about 7 wt %, Comparative Examples 1 and 2 each have a high moisture impregnation rate of about 11 wt % to about 12 wt %. That is, it can be seen that the aerogel felts of Examples 1 to 3 are significantly superior in water repellency compared to Comparative Examples 1 and 2. In addition, it can be seen that while the dust of each of Examples 1 to 3 is only about 0.17 wt % to about 0.22 wt %, the dust of each of Comparative Examples 1 and 2 is about 1.1 wt % to about 1.3 wt %, which is significantly higher. That is, it can be seen that Examples 1 to 3 show significantly lower dust generation compared to Comparative Examples 1 and 2. As a result, it can be seen that in Comparative Example 1 where the fiber was not flipped and Comparative Example 2 where the start time of the flipped fiber was after the gel time (the time when the fluidity of the sol was completely lost), there was almost no effect of improving the physical properties.

[0133] Although the present invention has been described with reference to limited embodiments and drawings, the present invention is not limited thereto but may be implemented in various ways by a person skilled in the art to which the present invention pertains within the technical concept of the present invention and equivalents of the appended claims.

[0134] Furthermore, the detailed protective scope of the present invention will be set forth by the accompanying claims.

[0135] [Explanation of symbols]

[0136] 10. Fiber

[0137] 100, 200: Device for making aerogel felt

[0138] 110: A pair of moving rollers

[0139] 111: First Roll

[0140] 112: Second roller

[0141] 120: Impregnation

[0142] 130: Conveyor belt

[0143] 131a, 131b, 132b: Roller

[0144] 141, 142, 143, 144: Guidance

[0145] 141a: Contact part

[0146] 141b: Support part

[0147] 150: Heater

[0148] 160: Insulation cover

[0149] S: Supply Department

Claims

1. A device for producing a silica aerogel felt, the device comprising: a supply unit configured to supply fibers containing silica sol; and a conveyor belt configured to move the fiber supplied from the supply portion, in, The conveyor belt is arranged in multiple stages so as to move the fiber while turning the fiber over, The conveyor belt starts flipping the fiber before the fluidity of the silica sol is completely lost, and the time when the fluidity of the silica sol is completely lost is the time when the gelation of the liquid silica sol is completed, and The conveyor belts are arranged in 2 to 5 stages in the vertical direction.

2. The device according to claim 1, wherein: The conveyor belt starts turning over the fiber 1 minute before the silica sol completely loses fluidity.

3. The device according to claim 1, wherein: The conveyor belts arranged in multiple stages are arranged in a vertical direction, wherein the conveyor belts on each stage are arranged horizontally.

4. The device according to claim 1, wherein: In the conveyor belt provided in multiple stages, the conveyor belt at least in one stage is provided in a shape in which one side portion or the other side portion is bent upward.

5. The device according to claim 4, wherein: The conveyor belts provided in multiple stages are provided in a shape in which the one side portion and the other side portion are alternately bent upward with respect to a central portion.

6. The device according to claim 1, further comprising a guide portion, the guide portion being disposed at a certain gap from a lower corner of the conveyor belt to guide movement of the fiber.

7. The device according to claim 6, wherein: The guide portion has a shape corresponding to the conveyor belt and contacts a bottom surface of the fiber.

8. The device of claim 6, wherein: The guide portion includes a contact portion that contacts the fiber and a support portion configured to support the contact portion. Wherein, the contact portion has a circular shape.

9. The apparatus of claim 1, further comprising a heater disposed above the conveyor belt to apply heat to the fibers.

10. The apparatus of claim 9, further comprising a heat-insulating hood configured to contain the conveyor belt and to heat the fibers moving through the conveyor belt.

11. A method for producing a silica aerogel felt, the method comprising: A process for supplying fibers containing silica sol; and a moving process of the fiber supplied through the supply process by a conveyor belt, wherein, during the movement, the conveyor belt is arranged in multiple stages so as to move the fiber while turning it over, The start time of flipping the fiber during the moving process is before the fluidity of the silica sol is completely lost, and the time when the fluidity of the silica sol is completely lost is the time when the gelation of the liquid silica sol is completed, and During the movement, the fiber is turned over 1 to 4 times.

12. The method of claim 11, wherein: The starting time for flipping the fiber during the moving process was 1 minute before the fluidity of the silica sol was completely lost.

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