Method for manufacturing aerogel composite fiber needle-punched product, aerogel composite fiber needle-punched product, and use thereof

Abstract

A method for producing an aerogel composite fiber needle-punched product, an aerogel composite fiber needle-punched product, and uses thereof are disclosed. The method includes step (1) of applying a weighting treatment to a hydrophobic aerogel material to obtain aerogel material I; step (2) of laying a fiber material on a net and then adding the aerogel material I onto the net to obtain aerogel composite fiber material I, and then laminating the aerogel composite fiber material I at least twice to obtain aerogel composite fiber material II; and step (3) of sequentially subjecting the aerogel composite fiber material II to pre-needle-punching, needle-punching, and heat-setting to obtain the aerogel composite fiber needle-punched product. This method for producing aerogel composite fiber needle-punched products significantly reduces solvent consumption while significantly improving aerogel composite production efficiency and enabling continuous, automated, and fully enclosed production of aerogel composites.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of Chinese Patent Application No. 202211642828.8, filed on December 20, 2022, the contents of which are incorporated herein by reference.

[0002] The present invention relates to the field of aerogel composite materials, in particular to a method for producing an aerogel composite fiber needle-punched product, an aerogel composite fiber needle-punched product, and its use. [Background technology]

[0003] Since its discovery nearly 100 years ago, aerogel has undergone gradual development, but there has been no fundamental progress in the basic process. Pure aerogel particles and powders have extremely low thermal conductivity and excellent insulating properties, but the particles and powders have not been applied on a large scale due to their poor formability.

[0004] At the beginning of the 21st century, the industry began to reinforce aerogel with fiber and combine the two to form aerogel composite products, which showed significant improvements in mechanical properties and were gradually used in the fields of insulation of industrial pipelines, equipment, and various tower equipment, insulation of interior and exterior walls of buildings, fire protection and insulation of new energy vehicles, and insulation and fire protection of power batteries.

[0005] Currently, there are two known methods for fiber-reinforced aerogel. One is in-situ composite processing, which involves immersing and curing entire irregularly structured fiber floc fragments in a sol at the front end of the aerogel production process, i.e., the sol-gel stage. A specific drying method is then used to extract the liquid from the wet gel structure, forming a nanoporous aerogel composite. The other is post-composite processing, which involves forming a suspension of the resulting aerogel particles or powder, adding it to the fiber floc fragments, and then drying the fiber floc fragments to form an aerogel composite.

[0006] Among these, the in-situ composite method has the following drawbacks: 1) The process has a complex flow, can only be produced intermittently, and cannot be made continuous, automated, or mass-produced, resulting in low production efficiency; 2) A large amount of solvent is used in the production process, and various processes cannot be seamlessly connected, resulting in the solvent being released randomly, causing some environmental pollution; 3) The production system cannot be completely sealed, resulting in a relatively low solvent recovery rate, resulting in serious waste and increasing production costs.

[0007] The method of injecting a suspension and then compounding it has the following drawbacks: 1) Because the suspension contains a large amount of solid matter, when injected into the fiber floc pieces, it cannot be uniformly dispersed into the pores of the floc pieces. As a result, it is difficult to distribute the aerogel uniformly throughout the fiber floc pieces, and the performance of the final product is likely to be uneven. 2) Because the suspension contains a large amount of solvent, it is difficult to recover the solvent, which increases the recovery cost.

[0008] CN113352709A discloses a method for producing aerogel felt without shedding, characterized by the following steps: 1) Using a fiber opener, fibers are loosened, then the loosened fibers are carded using a carding machine, and an adhesive is sprayed on the bottom surface of the fibers laid in the bottom layer of the aerogel felt. 2) A certain amount of silane coupling agent is evenly sprayed on the fibers. 3) Using a powder spreader, silica aerogel powder is further evenly sprinkled on the fibers, and the fibers are sent to a continuous oven for reaction. 4) After the reaction is complete, the fibers are laid using a laying device, and an adhesive is sprayed on the top surface of the fibers laid in the top layer of the aerogel felt. 5) The mesh is needle-punched and reinforced using a needle-punch device, shaped, trimmed using an edge trimmer, and finally wound on a winding machine. This method is simple and capable of continuous production, but the resulting product has low thermal conductivity, high insulation, a strong structure, and no shedding. However, this method has the following disadvantages: Because aerogel powder has a very low density and is very light, unless it is treated to increase its weight, it inevitably floats in the air when added, making it difficult to add uniformly to the material. Furthermore, because the silane coupling agent is added directly to the fibers, it is not possible to increase the affinity between the aerogel powder and the fibers, making the aerogel powder more likely to fall off.

[0009] CN110846891A discloses a method for producing aerogel composite fibers, characterized by the following steps: (1) Weigh out 1-500 parts by weight of aerogel composite powder, 100-450 parts by weight of a fiber substrate, 0-100 parts by weight of additives, and 0-1000 parts by weight of solvent as raw materials; (2) Add the weighed aerogel composite powder and additives to a solvent and continuously stir at 30-300°C until a uniform mixed gel material is formed; (3) Spin and unwind the fiber substrate, composite the mixed gel material with it, dry, and wind the fiber substrate to complete the production. Despite this method's wide range of raw material options, low cost, few steps, and simplicity, the products produced by this method possess excellent thermal insulation properties, high toughness, and excellent wear resistance. However, this method has the following drawbacks: The aerogel material adheres only to the surface of the composite substrate, and the amount of adhesion is very limited, making it difficult to obtain composite materials with good thermal insulation properties. Furthermore, because there is no fiber network structure, the aerogel material attached to the surface is prone to peeling off after drying, causing environmental pollution and reducing insulation performance.

[0010] Therefore, there is a need to provide a method for producing aerogel composites that can overcome the above drawbacks. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] CN113352709A [Patent Document 2] CN110846891A Summary of the Invention [Problem to be solved by the invention]

[0012] The objective of the present invention is to overcome the drawbacks of the conventional manufacturing methods of aerogel composites, such as low production efficiency, high cost, and inconsistent performance of the final product. [Means for solving the problem]

[0013] In order to achieve the above object, the first aspect of the present invention comprises: Step (1) of applying a weighting treatment to a hydrophobic aerogel material to obtain an aerogel material I; Step (2) of laying the fiber material on a net, and then adding the aerogel material I onto the thin net under controlling the addition conditions so that the content of the aerogel material I in the thin net per square meter is 5 to 500 g, thereby obtaining an aerogel composite fiber material I, and then laminating the aerogel composite fiber material I at least twice to obtain an aerogel composite fiber material II; and step (3) of sequentially subjecting the aerogel composite fiber material II to pre-needle punching, needle punching, and heat setting to obtain the aerogel composite fiber needle-punched product. The fiber material is a fiber material having a mass per unit area of ​​40 to 200 g / m, which is obtained by sequentially cutting, opening, and carding fiber filaments. 2 The present invention provides a method for manufacturing a needle-punched aerogel composite fiber product, which is a thin net to be laid.

[0014] A second aspect of the present invention provides an aerogel composite fiber needle-punched product produced by the method according to the first aspect.

[0015] A third aspect of the present invention provides use of the aerogel composite fiber needle-punched product according to the second aspect in a heat insulating material, a cold insulating material, a fire retardant material, or a sound absorbing material. [Effects of the Invention]

[0016] The present invention has at least the following advantages over the prior art.

[0017] The method of the present invention can significantly reduce the amount of solvent used while significantly improving the production efficiency of aerogel composite materials, enabling continuous, automated, and fully enclosed production of aerogel composite materials, and is expected to be applicable to large-scale industrialization.

[0018] Specifically, existing in-situ composite methods require the use of large amounts of solvent, significantly increasing the weight of the fiber material and causing deformation. Furthermore, the increased weight of the fiber material increases the time required for subsequent processes, significantly reducing production efficiency. In contrast, the present invention combines aerogel surface wetting and loading with the fiber needle-punched product production process, significantly reducing the amount of solvent used and the time required from raw materials to finished products. DETAILED DESCRIPTION OF THE INVENTION

[0019] The endpoints of the ranges and any values ​​disclosed herein should be understood not to be limited to the precise range or value, but to include values ​​close to those ranges or values. With respect to numerical ranges, the endpoints of each range, the endpoints of each range and individual point values, and the individual point values ​​can be combined to obtain one or more new numerical ranges, which are considered to be specifically disclosed herein.

[0020] In the present invention, the aerogel composite fiber material I and the aerogel composite fiber material II are different only in thickness, and the compositions of both components are the same.

[0021] As noted above, a first aspect of the present invention provides a method for producing an aerogel composite fiber needlepunched product, the method comprising: Step (1) of applying a weighting treatment to a hydrophobic aerogel material to obtain an aerogel material I; Step (2) of laying the aerogel material I on a fiber material net, and then controlling the addition conditions so that the content of the aerogel material I in the thin net per square meter is 5 to 500 g, thereby obtaining an aerogel composite fiber material I, and then stacking the aerogel composite fiber material I at least twice to obtain an aerogel composite fiber material II; and step (3) of sequentially subjecting the aerogel composite fiber material II to pre-needle punching, needle punching, and heat setting to obtain the aerogel composite fiber needle-punched product. The fiber material is a fiber material having a mass per unit area of ​​40 to 200 g / m, which is obtained by sequentially cutting, opening, and carding fiber filaments. 2 The target for laying is a thin net.

[0022] Preferably, in step (1), the mass per unit area of ​​the thin net to be laid is 80 to 120 g / m 2 The inventors have found that the aerogel composite fiber needle-punched product produced under these preferred conditions has suitable volume weight and mechanical properties.

[0023] The inventors have also found that when the addition conditions are controlled so that the content of the aerogel material I in the thin net per square meter is 5 to 100 g, the produced aerogel composite fiber needle-punched product has lower thermal conductivity and vibration loss rate.

[0024] According to a preferred embodiment, the weighting operation includes contacting the hydrophobic aerogel material with a liquid substance, followed by a dewatering process.

[0025] In the present invention, the dewatering treatment method is not particularly limited, and a person skilled in the art may select it according to existing technical means. The volume weight of the aerogel material I obtained by the dewatering treatment is 100 to 200 g / cm. 3 In the present invention, the preferred specific embodiments provided below cannot be understood by those skilled in the art as limiting the present invention.

[0026] Preferably, the liquid substance contains a solvent and an additive, and the additive is at least one selected from a silane coupling agent and a binder.

[0027] Preferably, the content of the silane coupling agent in the liquid substance is 0.5 to 10 wt %, and the content of the binder is 0.5 to 5 wt %.

[0028] Preferably, the solvent is at least one selected from water and organic solvents, and more preferably, the organic solvent is at least one selected from C1 to C10 linear monohydric alcohols.

[0029] Particularly preferably, the C1 to C10 linear monohydric alcohol is at least one selected from methanol, ethanol, n-propanol, and n-butanol.

[0030] Preferably, the silane coupling agent is at least one selected from γ-(methacryloyloxy)propyltrimethoxysilane (KH570), γ-(2,3-glycidoxy)propyltrimethoxysilane (KH560), and γ-aminopropyltriethoxysilane (KH550).

[0031] Preferably, the binder is at least one selected from the group consisting of phenol resin, acrylic resin, EVA resin, polyurethane resin, epoxy resin, water glass, and silica sol.

[0032] According to a particularly preferred embodiment, the solvent is water, and the additive is a combination of a silane coupling agent and a binder. The inventors have found that in this preferred form, the aerogel material is better bonded to the fiber material and less likely to fall off, thereby further reducing the vibration loss rate of the manufactured product. This preferred embodiment also has the advantages of low cost and environmental protection.

[0033] Preferably, the liquid substance is used in an amount such that the content of the aerogel material in the liquid phase material of the contact system is 1 to 50 wt % at the start of contacting the hydrophobic aerogel material with the liquid substance.

[0034] More preferably, the liquid substance is used in an amount such that the content of the hydrophobic aerogel material in the liquid phase material of the contact system is 5 to 20 wt % at the start of contact.

[0035] Preferably, the contact conditions are at least that contact is carried out with stirring, the stirring speed is 100 to 2000 rpm, the temperature is 5 to 40°C, preferably 20 to 40°C, and the time is 0.1 to 20 hours.

[0036] More preferably, the contact conditions are at least that the contact is carried out with stirring, the stirring speed is 200 to 1000 rpm, the temperature is 20 to 40° C., and the time is 0.5 to 2 hours.

[0037] In the present invention, the methods of cutting, opening, carding and heat setting of the fiber filaments are not particularly limited, and a person skilled in the art can select the method by combining technical means known in the art. However, the following description of the present invention provides preferred specific embodiments as examples, and a person skilled in the art should not understand this as a limitation of the present invention.

[0038] Preferably, the hydrophobic aerogel material is at least one selected from a silica aerogel material, a metal oxide aerogel material, and an organic aerogel material.

[0039] More preferably, the metal oxide in the metal oxide aerogel material is at least one selected from aluminum oxide, copper oxide, zirconium oxide, iron oxide, and zinc oxide, and the organic aerogel material is at least one selected from polyurethane aerogel material, polyimide aerogel material, polyurea aerogel material, polypropylene aerogel material, polyethylene aerogel material, polycarbonate aerogel material, and cellulose aerogel.

[0040] Particularly preferably, the metal oxide aerogel material is at least one selected from an aluminum oxide aerogel material and a zirconium oxide aerogel material, and the organic aerogel material is at least one selected from a polyurethane aerogel material, a polyimide aerogel material, and a polypropylene aerogel material.

[0041] Preferably, the fiber material is at least one selected from glass fiber, ceramic fiber, aluminum silicate fiber, basalt fiber, carbon fiber, polyacrylonitrile fiber, polyimide fiber, aramid fiber, polyester fiber, cotton fiber, nylon fiber, and pre-oxidized fiber.

[0042] More preferably, the fiber material is at least one selected from glass fiber, ceramic fiber, basalt fiber, polyimide fiber, aramid fiber, and polyester fiber.

[0043] Preferably, the average particle size of the hydrophobic aerogel material is 0.1 to 5000 μm, and more preferably, the average particle size of the hydrophobic aerogel material is 20 to 1000 μm.

[0044] As a result of extensive creative research, the inventors have found that when the hydrophobic aerogel material is an aluminum oxide aerogel material with an average particle size of 20 to 500 μm and the fiber material is a ceramic fiber, the manufactured aerogel composite fiber needle-punched product has better high temperature resistance.

[0045] The inventors have also found that when the hydrophobic aerogel material is a silica aerogel material with an average particle size of 20 to 500 μm and the fiber material is a polyimide fiber, the produced aerogel composite fiber needle-punched product has better ultra-low temperature resistance.

[0046] According to a preferred embodiment, the pre-needle punching step comprises: The method includes a step of performing single-sided needle punching on the aerogel composite material from top to bottom using a pre-needle punching device, and the single-sided needle punching is performed under the conditions that the needles have a barb shape and the needle punch density is 3 to 30 punches / cm. 2 At the very least, the following is satisfied.

[0047] In another preferred embodiment, the needle punching step comprises: The method includes a step of needle-punching both the upper and lower surfaces of the pre-needle-punched aerogel composite material using a needle-punching device, and the conditions for the double-sided needle-punching include that the needles have a barb shape and that the needle-punching density is 10 to 20 punches / cm. 2 At the very least, the following is satisfied.

[0048] It should be noted that the present invention is not particularly limited to the pre-needle punch device and the needle punch device, and a person skilled in the art can make a selection by combining them with technical means known in the art. However, the following description of the present invention provides preferred specific embodiments as examples, and a person skilled in the art should not understand this as a limitation of the present invention.

[0049] As mentioned above, a second aspect of the present invention provides an aerogel composite fiber needlepunched product produced by the method according to the first aspect.

[0050] As described above, the third aspect of the present invention provides use of the aerogel composite fiber needle-punched product according to the second aspect in a heat insulating material, a cold insulating material, a fire retardant material, or a sound absorbing material.

[0051] In the present invention, the aerogel composite fiber needle-punched product is useful as a heat insulating material, a cold insulating material, a fire retardant, and a sound absorbing material in the fields of construction, automobiles, batteries, industrial piping and devices, etc.

[0052] The present invention will be described in detail below using examples. [Example]

[0053] In the following examples, all materials used were commercially available unless otherwise stated.

[0054] In the present invention, unless otherwise specified, the room temperature or ordinary temperature means 25±2°C.

[0055] Hydrophobic aerogel material I: Silica aerogel material, average particle size 150 μm. Hydrophobic aerogel material II: aluminum oxide aerogel material, average particle size 200 μm. Fiber material I: Glass fiber. Fiber material II: Polyimide fiber. Fiber Materials III: Ceramic Fibers. Silane coupling agent: Brand KH560. Binder: Phenolic resin.

[0056] Example 1 (1) At room temperature, 100 g of silane coupling agent was added to 10 kg of deionized water and stirred uniformly. Then, 1 kg of hydrophobic aerogel material I was added, stirred at 800 rpm for 1 hour, and filtered to obtain a volumetric weight of 160 g / cm. 3 Aerogel material I was obtained. Here, the content of the hydrophobic aerogel material is 9.0 wt %, and the content of the silane coupling agent is 0.9 wt %. (2) Fiber material I was cut into short filaments (average diameter 9 μm) of 3±0.5 cm in length, then opened using a fiber opener. The short fiber filaments obtained by opening were then carded using a carding machine to obtain the fiber material to be laid. The fiber material was laid using a laying machine at 60±10 g / m 2 The aerogel composite fiber material I was obtained by adding the aerogel material I to the thin net and laminating 20 layers of the thin net. The content of aerogel material I in the thin net per square meter is 20±2 g. (3) The aerogel composite fiber material I was subjected to single-sided needle punching from top to bottom using a pre-needle punch device to obtain aerogel composite fiber material I1, and then the aerogel composite fiber material I1 was needle punched on both the top and bottom surfaces using a needle punch device to obtain aerogel composite fiber material I2, and finally the aerogel composite fiber material I2 was set by thermal pressing on both the top and bottom surfaces using a heat setting device, and then placed in a vacuum oven at 180°C and dried for 60 minutes to obtain the aerogel composite fiber needle punched product Z1. Conditions for single-sided needle punching: needles are barbed, and needle punch density is 5 punches / cm 2 is. Conditions for double-sided needle punching: needles are barbed, and needle punch density is 10 punches / cm 2 is. Conditions for thermocompression bonding the top and bottom surfaces: temperature 200°C, time 3 minutes.

[0057] Example 2 (1) At room temperature, 100 g of silane coupling agent and 200 g of phenolic resin were added to 10 kg of deionized water and stirred uniformly. Then, 1 kg of hydrophobic aerogel material I was added and stirred at 800 rpm for 1 hour. The mixture was filtered to obtain a volumetric weight of 185 g / cm. 3 Aerogel material I was obtained. Here, the content of the hydrophobic aerogel material is 8.8 wt%, the content of the silane coupling agent is 0.9 wt%, and the content of the binder is 1.8 wt%. (2) Fiber material I was cut into short filaments (average diameter 9 μm) of 3±0.5 cm in length, then opened using a fiber opener. The short fiber filaments obtained by opening were then carded using a carding machine to obtain the fiber material to be laid. The fiber material was laid using a laying machine at 60±10 g / m 2 The aerogel composite fiber material I was obtained by adding the aerogel material I to the thin net and laminating 20 layers of the thin net. The content of aerogel material I in the thin net per square meter is 20±2 g. (3) The aerogel composite fiber material I was subjected to single-sided needle punching from top to bottom using a pre-needle punch device to obtain aerogel composite fiber material I1, and then the aerogel composite fiber material I1 was needle punched on both the top and bottom surfaces using a needle punch device to obtain aerogel composite fiber material I2, and finally the aerogel composite fiber material I2 was set by thermal pressing on both the top and bottom surfaces using a heat setting device, and then placed in a vacuum oven at 180°C and dried for 60 minutes to obtain the aerogel composite fiber needle punched product Z2. Conditions for single-sided needle punching: needles are barbed, and needle punch density is 5 punches / cm 2 is. Conditions for double-sided needle punching: needles are barbed, and needle punch density is 10 punches / cm 2 is. Conditions for thermocompression bonding the top and bottom surfaces: temperature 200°C, time 3 minutes.

[0058] Example 3 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. Aerogel composite fiber needle-punched product Z3 was produced under all the same conditions as in Example 1, except that the content of aerogel material I in the thin net per square meter was increased to 40±4 g.

[0059] Example 4 In this example, the same procedure as in Example 2 was used, with the following exceptions. Aerogel composite fiber needle-punched product Z4 was produced under all the same conditions as in Example 2, except that the content of aerogel material I in the thin net per square meter was increased to 40±4 g.

[0060] Example 5 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. Except for replacing fiber material I with fiber material II of the same weight, all other conditions were the same as in Example 1 to produce aerogel composite fiber needle-punched product Z5.

[0061] Example 6 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. Aerogel composite fiber needle-punched product Z6 was produced under the same conditions as in Example 1, except that aerogel material I was replaced with the same weight of aerogel material II and fiber material I was replaced with the same weight of fiber material III.

[0062] Example 7 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. Aerogel composite fiber needle-punched product Z7 was produced under the same conditions as in Example 1, except that aerogel material I was replaced with the same weight of aerogel material II.

[0063] Example 8 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. The mass per unit area of ​​the thin net to be laid is 120g / m 2 Except for the above, all other conditions were the same as in Example 1, and an aerogel composite fiber needle-punched product Z8 was produced.

[0064] Example 9 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. Aerogel composite fiber needle-punched product Z9 was produced under all the same conditions as in Example 1, except that the content of aerogel material I in the thin net per square meter was 100±10 g.

[0065] Example 10 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. By controlling the filtration conditions, the volume weight is 210g / cm 3Except for obtaining aerogel material I, all other conditions were the same as in Example 1, and an aerogel composite fiber needle-punched product Z10 was produced.

[0066] Example 11 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. In step (1), 100 g of a silane coupling agent was added to a mixture of solvents (5 kg of deionized water and 5 kg of ethanol) at room temperature and stirred uniformly. Then, 1 kg of hydrophobic aerogel material I was added, and the mixture was stirred at 800 rpm for 1 hour and filtered to obtain aerogel material I. Except for this, all other conditions were the same as in Example 1 to produce aerogel composite fiber needle-punched product Z11.

[0067] Comparative Example 1 In this comparative example, the same procedure as in Example 1 was adopted, with the following exceptions. A thin net was laminated 20 times before needle punching, and aerogel material I was added. Except for this, all other conditions were the same as in Example 1 to produce aerogel composite fiber needle-punched product DZ1.

[0068] Comparative Example 2 In this example, the same procedure as in Example 1 was adopted, with the following exceptions. The mass per unit area of ​​the thin net to be laid is 30g / m 2 Except for the above, all other conditions were the same as in Example 1, and an aerogel composite fiber needle-punched product DZ2 was produced.

[0069] Comparative Example 3 In this comparative example, the same procedure as in Example 1 was adopted, with the following exceptions. The content of aerogel material I in the thin net per square meter is 3 g / m 2 Except for the above, all other conditions were the same as in Example 1, and an aerogel composite fiber needle-punched product DZ3 was produced.

[0070] Comparative Example 4 In this comparative example, the same procedure as in Example 1 was adopted, with the following exceptions. The silane coupling agent and the hydrophobic aerogel material were added sequentially onto the thin net, i.e., the silane coupling agent and the hydrophobic aerogel material were not brought into contact with each other in the presence of a solvent and then subjected to a dewatering treatment. The remaining conditions were all the same as in Example 1, and an aerogel composite fiber needle-punched product DZ4 was produced.

[0071] Test Example The needle-punched aerogel composite fiber products produced in the examples and comparative examples were specifically subjected to performance tests as follows. Points were randomly selected from the aerogel composite fiber needle-punched product and cut into three samples of 30 x 30 cm. For each sample, the tensile strength, thermal conductivity at 25°C, thermal conductivity at 300°C, combustion level detection, and vibration loss rate detection were performed. The detection results are shown in Table 1. (1) Tensile strength: Measured according to the method of GB / T 17911-2006. (2) Thermal conductivity at 25°C: Measured according to the method of GB / T10295-2008. (3) Thermal conductivity at 300°C: Measured according to the method of GB / T10294-2008. (4) Thermal conductivity at -200°C: Measured according to the method of GB / T34336-2017. (5) Flammability level: Measured according to the method of GB8624-2012. (6) Vibration loss rate: Measured and evaluated according to the method of GB / T34336-2017.

[0072] [Table 1]

[0073] The results in Table 1 show that the main performance parameters of the aerogel composite fiber needle-punched product produced by this invention can meet the requirements of GB / T34336-2017 (excluding products obtained using ceramic fibers, which have low tensile strength and high vibration loss due to the mechanical properties of the ceramic fibers themselves).

[0074] Comparing the data from Examples 1 and 2, it was found that when the liquid material contained a certain amount of binder, the tensile strength and vibration loss rate of the aerogel composite fiber needle-punched product produced were significantly improved. Comparing the data from Examples 1 and 3, and Comparative Examples 2 and 4, it was found that when the content of aerogel material I was increased during installation, the thermal conductivity of the aerogel composite fiber needle-punched product produced was significantly improved.

[0075] Although the preferred embodiments of the present invention have been described in detail above, the present invention is not limited thereto. Within the scope of the technical concept of the present invention, multiple simple modifications can be made to the technical solutions of the present invention, including combining each technical feature in any other suitable manner, and these simple modifications and combinations should also be considered as the disclosure content of the present invention, and all fall within the protection scope of the present invention.

Claims

1. A method for producing an aerogel composite fiber needle-punched product, comprising: Step (1) of applying a weighting treatment to a hydrophobic aerogel material to obtain an aerogel material I; Step (2) of laying the fiber material on a net, and then adding the aerogel material I onto the thin net under controlling the addition conditions so that the content of the aerogel material I in the thin net per square meter is 5 to 500 g, thereby obtaining an aerogel composite fiber material I, and then stacking the aerogel composite fiber material I at least twice to obtain an aerogel composite fiber material II; and step (3) of sequentially subjecting the aerogel composite fiber material II to pre-needle punching, needle punching, and heat setting to obtain the aerogel composite fiber needle-punched product; The fiber material is a fiber material having a mass per unit area of ​​40 to 200 g / m, which is obtained by sequentially cutting, opening, and carding fiber filaments. ２ A method for producing an aerogel composite fiber needle-punched product, characterized in that the object to be laid is a thin net.

2. 2. The method of claim 1, wherein in step (1), the weighting operation comprises contacting the hydrophobic aerogel material with a liquid substance and then performing a dewatering process.

3. In step (1), the liquid substance contains a solvent and an additive, and the additive is at least one selected from a silane coupling agent and a binder, and / or In step (1), the content of the silane coupling agent in the liquid substance is 0.5 to 10 wt %, and / or In step (1), the content of the binder in the liquid substance is 0.5 to 5 wt %; And / or the method according to claim 2, wherein in step (1), the solvent in the liquid substance is water, and the additive is a combination of a silane coupling agent and a binder.

4. 4. The method according to claim 2 or 3, wherein in step (1), the liquid substance is used in an amount such that the content of the aerogel material in the liquid phase material of the contact system is 1 to 50 wt % at the start time of contacting the hydrophobic aerogel material with the liquid substance.

5. The method according to any one of claims 2 to 4, wherein in step (1), the contacting conditions are at least that the contacting is performed with stirring, and that the stirring speed is 100 to 2000 rpm, the temperature is 5 to 40°C, preferably 20 to 40°C, and the contacting time is 0.1 to 20 hours.

6. In step (1), the silane coupling agent in the liquid substance is at least one selected from γ-(methacryloyloxy)propyltrimethoxysilane, γ-(2,3-glycidoxy)propyltrimethoxysilane, and γ-aminopropyltriethoxysilane, and / or The method according to any one of claims 2 to 5, wherein in step (1), the binder in the liquid substance is at least one selected from a phenolic resin, an acrylic resin, an EVA resin, a polyurethane resin, an epoxy resin, water glass, and a silica sol.

7. In step (1), the hydrophobic aerogel material is at least one selected from a silica aerogel material, a metal oxide aerogel material, and an organic aerogel material; and / or 7. The method according to claim 1, wherein in step (1), the metal oxide in the metal oxide aerogel material is at least one selected from aluminum oxide, copper oxide, zirconium oxide, iron oxide, and zinc oxide, and the organic aerogel material is at least one selected from polyurethane aerogel material, polyimide aerogel material, polyurea aerogel material, polypropylene aerogel material, polyethylene aerogel material, polycarbonate aerogel material, and cellulose aerogel material.

8. 8. The method according to claim 1, wherein in step (1), the average particle size of the hydrophobic aerogel material is 0.1 to 5000 μm, preferably 20 to 1000 μm.

9. An aerogel composite fiber needle-punched product produced by the method according to any one of claims 1 to 8.

10. Use of the needle-punched aerogel composite fiber product according to claim 9 in heat insulation, cold insulation, fire prevention, and sound-deadening materials.

Images