Aerogel-containing laminated sheets and thermal products using the same

Abstract

The present invention provides a sheet material (aerogel-containing laminated sheet) that possesses heat retention (insulation) and breathability, as well as various other properties such as waterproofing and flame retardancy, and thermal products using the same. [Solution] The aerogel-containing laminated sheet 10 is composed of a sheet-like base layer 1 and an aerogel-containing fiber layer 2 that is arranged on one side of the base layer and integrated with it. The aerogel-containing fiber layer includes a composite fiber layer 21 made by compounding two or more polymers with different properties and an aerogel layer 22. The composite fiber layer may be made by compounding polyester fibers. The aerogel-containing fiber layer may be made by repeatedly laminating the composite fiber layer and the aerogel layer alternately. The base layer 1 may be waterproof or flame-retardant. The aerogel-containing fiber layer is covered and integrated with a durable reinforcing layer 3. The thermal product is made using the aerogel-containing laminated sheet.

Description

Technical Field

[0001] The present invention relates to a sheet body having heat retention (heat insulation) properties and air permeability, and further capable of exhibiting various performances such as waterproofness and flame retardancy, and more particularly, to an aerogel-containing laminated sheet functioning as a thermal liner for suppressing the temperature difference from the outside air temperature to retain heat or cold, and thermal products such as blankets and covers using the same.

Background Art

[0002] Conventionally, as a sheet body using an aerogel, a first batting layer composed of a batting formed by forming chemical fiber cotton into a sheet shape, a first thermoplastic resin film layer, an aerogel-containing intermediate layer, a second thermoplastic resin film layer, and a second batting layer composed of a batting formed by forming chemical fiber cotton into a sheet shape are arranged and integrated in this order, and an aerogel-containing laminated sheet is proposed, in which the aerogel-containing intermediate layer includes a polyester composite fiber layer containing polyester composite fibers and an aerogel layer (see Patent Document 1).

[0003] It is known that a mixture of an aerogel and a resin foam not only has heat retention properties but also ensures air permeability. Therefore, according to this aerogel-containing laminated sheet, since the aerogel-containing intermediate layer is covered with a batting layer of chemical fiber cotton, it is strong against moisture and water vapor and is suitable as a filling material for clothing and bedding. Further, since this aerogel-containing laminated sheet is integrated into an extremely thin sheet shape, it is easy to process.

[0004] By the way, when the aerogel-containing laminated sheet described in Patent Document 1 is proposed, there is a demand for a sheet body that further has various performances such as waterproofness and flame retardancy in addition to the heat retention and air permeability due to the heat insulation effect of the aerogel.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Patent No. 6641061 [Overview of the project] [Problems that the invention aims to solve]

[0006] This invention was developed in view of the above-mentioned circumstances in the conventional era, and aims to provide a sheet material that possesses heat retention (insulation) and breathability, as well as various other properties such as waterproofing and flame retardancy, and thermal products using the same. [Means for solving the problem]

[0007] To achieve the above objective, the aerogel-containing laminated sheet of the present invention is composed of a sheet-like base layer and an aerogel-containing fiber layer arranged on one side of the base layer and integrated with it, wherein the aerogel-containing fiber layer includes a composite fiber layer formed by combining two or more polymers with different properties and an aerogel layer.

[0008] In the above-described aerogel-containing laminated sheet, the composite fiber layer is preferably made of polyester fibers. Furthermore, in the above-mentioned aerogel-containing laminated sheet, the aerogel-containing fiber layer is preferably formed by repeatedly laminating the composite fiber layer and the aerogel layer alternately. Furthermore, in the above-mentioned aerogel-containing laminated sheet, the base material layer may be waterproof. Furthermore, in the above-mentioned aerogel-containing laminated sheet, the base material layer is preferably flame-retardant, and in the above-mentioned aerogel-containing laminated sheet, the aerogel-containing fiber layer is preferably covered and integrated with a durable reinforcing layer. Furthermore, any of the aerogel-containing laminated sheets described above can be used to create thermal products such as covers and blankets. [Effects of the Invention]

[0009] According to this invention, a sheet body capable of exhibiting various properties such as waterproofing and flame retardancy is used as the base layer, and an aerogel-containing fiber layer that provides heat retention (insulation) and breathability is placed on one side of it and integrated. As a result, it is possible to create a sheet body that is unprecedented in that it possesses the heat retention and breathability due to the insulating effect of aerogel, as well as the properties of the base layer. Therefore, it is possible to provide a sheet material that possesses heat retention (insulation) and breathability, as well as various other properties such as waterproofing and flame retardancy, and thermal products using the same. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram illustrating an example of the structure of an aerogel-containing laminated sheet according to the present invention. [Figure 2] This is a schematic diagram illustrating another example of the structure of the aerogel-containing laminated sheet according to the present invention. [Modes for carrying out the invention]

[0011] The following describes an example of an embodiment for implementing the aerogel-containing laminated sheet according to the present invention, based on the drawings. The embodiments described below are preferred examples of the present invention and are subject to various technical limitations. However, the scope of the present invention is not limited to these forms unless otherwise specified in the following description.

[0012] As shown in Figure 1, the aerogel-containing laminated sheet 10 in this embodiment is composed of a base layer 1, an aerogel-containing fiber layer 2, and a reinforcing layer 3. Figure 1 is a schematic diagram illustrating an example of the structure of the aerogel-containing laminated sheet 10 according to this embodiment.

[0013] The base material layer 1 is a sheet material (hereinafter referred to as the "base material layer sheet") that is breathable or moisture permeable, and further possesses desired properties such as waterproofing and flame retardancy. In other words, it is appropriately selected from existing sheet materials that possess the desired properties.

[0014] As for the performance of this base material layer sheet 1, waterproof performance can be provided, for example, by selecting a microporous sheet obtained by melt-kneading an inorganic filler into an olefin resin such as polyethylene or polypropylene to form a sheet, and then stretching it in a uniaxial or biaxial direction.

[0015] Furthermore, as for the performance of the base layer sheet 1, flame retardant performance can be provided, for example, by selecting a sheet made of carbon fibers obtained by high-temperature firing (stabilization and carbonization) of PAN fibers, which are spun using polyacrylonitrile (PAN) polymerized from acrylonitrile.

[0016] This carbon fiber is known to be flame-retardant, and possesses excellent properties such as high strength, high elasticity, light weight, heat resistance, and chemical resistance. Therefore, it is widely used as a structural material in aircraft, automobiles, sporting goods such as tennis rackets and golf shafts, and industrial machinery parts.

[0017] This base material sheet 1 has an aerogel-containing fiber layer 2 on one side. The aerogel-containing fiber layer 2 is composed of a composite fiber layer 21 and an aerogel layer 22, which are the minimum constituent elements of the aerogel-containing fiber layer 2. In other words, the aerogel-containing fiber layer 2 only needs to have at least one composite fiber layer 21 and one aerogel layer 22, and depending on the purpose, the composite fiber layer 21 and the aerogel layer 22 may be laminated in alternating layers.

[0018] As the aerogel-containing fiber layer 2 in which the composite fiber layer 21 and the aerogel layer 22 are laminated, for example, as shown in FIG. 2, it can be assumed that the composite fiber layer 21, the aerogel layer 22, the composite fiber layer 21, and the aerogel layer 22 are laminated in a total of 4 layers. FIG. 2 is a schematic diagram for explaining an example of the structure of another aerogel-containing laminated sheet 20 according to the present embodiment.

[0019] Therefore, if a set of two layers composed of the composite fiber layer 21 and the aerogel layer 22 is considered as a unit of the aerogel-containing fiber layer, as shown in FIG. 1, in addition to the total of 2 layers composed of one aerogel-containing fiber layer, and as shown in FIG. 2, the total of 4 layers in which two aerogel-containing fiber layers are laminated, the aerogel-containing fiber layer 2 may also be composed of a total of 6 layers in which three aerogel-containing fiber layers are laminated, a total of 8 layers in which four aerogel-containing fiber layers are laminated, or a total of 12 layers in which six aerogel-containing fiber layers are laminated.

[0020] Further, the composite fiber layer 21 is a composite fiber obtained by compounding two or more types of polymers having different properties with a die. For example, it can be a polyester-based composite fiber obtained by compounding two types of polymer components of PET (polyethylene terephthalate) and PTT (polytrimethylene terephthalate).

[0021] Such a composite fiber does not generate excessive elasticity as in the case of a single fiber of 100% polyester. In addition, since the shrinkage rates of the plurality of polymers are different from each other, crimping occurs in the raw yarn and elasticity occurs, so it may exhibit the effect of having high elasticity.

[0022] Further, as the composite fiber layer 21, it is also possible to use acetate-based or acrylic-based composite fibers, but it is more suitable to use polyester-based composite fibers because they combine the characteristics of PET such as light weight, quick drying property, heat resistance, and durability, and the characteristics of PTT such as high elasticity, shape stability, and soft touch.

[0023] Furthermore, since polyester composite fibers are thermoplastic, they exhibit an adhesive effect when heated and pressed. Therefore, this contributes to firmly bonding the composite fiber layer 21 to the base layer sheet 1, and also allows the aerogel constituting the aerogel layer 22 to be firmly fixed to the base layer sheet 1.

[0024] The aerogel layer 22 is a layer containing aerogel, a substance that has attracted attention for its extremely high thermal insulation properties due to its structure with numerous micropores and more than 90% of its volume being air. This aerogel can be attached to the intermediate part of the composite fiber layer 21, for example, by spraying it onto a 3D printer, thereby forming the aerogel layer 22.

[0025] Examples of aerogels that make up this aerogel layer 22 include silica aerogel, carbon aerogel, and alumina aerogel, with silica aerogel being particularly suitable. Furthermore, the aerogel material used to form the aerogel layer 22 is preferably in the form of fine granules (powder).

[0026] This aerogel is an extremely low-density solid, produced by drying a porous gel prepared in a liquid using supercritical drying while maintaining its voids. Furthermore, aerogel is an extremely lightweight solid and has a lower thermal conductivity than air, resulting in high thermal insulation properties. Therefore, aerogels are currently being increasingly used as insulation materials in factory piping, automobiles, aerospace equipment, housing, and clothing. Furthermore, due to their large surface area, they are also used as CO2 adsorbents, catalysts, and materials for batteries.

[0027] The content of polyester-based composite fibers in the aerogel-containing fiber layer 2 is preferably 1 to 90% by weight relative to the total weight of the aerogel-containing fiber layer 2. With this content, an aerogel-containing laminated sheet 10 can be made that is lightweight and possesses quick-drying, heat-resistant, and durable properties. Furthermore, the aerogel content in the aerogel-containing fiber layer 2 is preferably 1 to 70% by weight relative to the total weight of the aerogel-containing fiber layer 2.

[0028] The composite fiber layer 21 constituting the aerogel-containing fiber layer 2 may contain, for example, down fibers, artificial down, or synthetic fibers known as artificial down cotton. By mixing such down fibers into the composite fiber layer 21, an aerogel-containing laminated sheet 10 can be made that has even higher heat retention, better breathability, and a softer texture.

[0029] Furthermore, the composite fiber layer 21 may also contain cupro fibers. By mixing such cupro fibers into the composite fiber layer 21, an aerogel-containing laminated sheet 10 can be made that has even higher heat retention, water absorption, and moisture absorption properties.

[0030] The reinforcing layer 3 is a durable sheet (hereinafter referred to as the "reinforcing layer sheet") positioned on the aerogel layer 22 side so as to cover the aerogel-containing fiber layer 2, and can be made of nonwoven fabric, woven fabric, knitted fabric, microporous film, etc. If the reinforcing layer sheet 3 is made of, for example, an olefin fiber nonwoven fabric, it can be bonded to the aerogel fiber layer 2 by heating alone without using an adhesive. In this case, if the olefin fiber nonwoven fabric is a long-fiber nonwoven fabric, it is expected that the reinforcing layer sheet 3 will have improved physical strength and durability.

[0031] Furthermore, the aerogel-containing fiber layer 2 and the reinforcing layer sheet 3 may be bonded together by heating with a thermoplastic film interposed between them, or by using an adhesive. In the case of bonding with an adhesive, it is preferable that there are multiple bonding points to ensure breathability.

[0032] Furthermore, the aerogel-containing laminated sheet 10 according to this embodiment can be treated as a single piece of fabric by attaching the aerogel-containing fiber layer 2, which consists of a composite fiber layer 21 and an aerogel layer 22, to the base layer sheet 1, and attaching the reinforcing layer sheet 3 to the aerogel-containing fiber layer 2. Therefore, it can be used as a material for thermal products.

[0033] Next, an example of a method for manufacturing the aerogel-containing laminated sheet 10 according to this embodiment will be described. First, a polyester composite fiber layer 21 containing polyester-based composite fibers is formed on the base layer sheet 1. Next, aerogel powder is sprayed onto the polyester composite fiber layer 21 to form an aerogel layer 22. The aerogel can be placed and fixed onto the polyester composite fiber layer 21 by spraying aerogel powder, for example, using a 3D additive manufacturing printer. This makes it possible to form an aerogel-containing fiber layer 2, which includes a polyester composite fiber layer 21 and an aerogel layer 22, on the base layer sheet 1.

[0034] Then, a reinforcing layer sheet 3 is placed on top of the aerogel-containing fiber layer 2 so as to cover the aerogel layer 22 side, and the aerogel-containing fiber layer 2 and the reinforcing layer sheet 3 are bonded together. For example, the bonding of the reinforcing layer sheet 3 can be done by heating these laminates to integrate the base layer sheet 1, the aerogel-containing fiber layer 2, and the reinforcing layer sheet 3.

[0035] The aerogel-containing laminated sheet 10 of this embodiment, configured as described above, has excellent heat insulation and heat resistance against rising and falling ambient temperatures surrounding an article, suppressing temperature differences with the outside air and providing high heat retention or cooling effect. In addition to being breathable, it can also be made waterproof or flame-retardant. Therefore, it can be used as a material to expand the applications of thermal products that protect against rapid temperature changes and enhance heat retention.

[0036] The aerogel-containing laminated sheet 10 of this embodiment can be used, for example, in thermal products that have heat insulation, heat resistance, and breathability to provide waterproofing to container covers or pallet covers that maintain a constant temperature (suppress temperature rise) for cargo placed in container yards or palletized goods, while also protecting them from external factors such as rain, dust, yellow sand, and bird droppings. Furthermore, it can be used in thermal products that provide waterproofing, heat insulation, heat resistance, and breathability, such as air conditioner outdoor unit covers used to facilitate heat dissipation from the air conditioner's outdoor unit and improve energy efficiency, and mechanical equipment covers used to operate heat-generating machinery and equipment at a relatively constant temperature.

[0037] Furthermore, it can be used in thermal products that are waterproof, have heat-insulating properties, and are breathable, such as transport bags for carrying medical drugs and vaccines at a constant temperature, or insulated bags for transporting them at low temperatures. Furthermore, it can be used in thermal products that provide waterproofing, insulation, heat resistance, and breathability, such as tents for summer use to combat heat, and hats, blankets, and sleeping bags for winter use.

[0038] Furthermore, it can be used in thermal products that have flame-retardant properties, heat-insulating properties, heat resistance, and breathability, such as industrial heat-resistant gloves, camping (BBQ) heat-resistant gloves, heat-resistant arm covers, and heat-resistant aprons. [Industrial applicability]

[0039] The aerogel-containing laminated sheet according to this invention is a material that excels in heat insulation and heat resistance, as well as breathability, and also possesses desirable properties such as waterproofing and flame retardancy. It is expected to be used in the manufacture of thermal products such as pallet covers, machinery and equipment covers, air conditioner outdoor unit covers, cargo transport container covers, jet covers, cosmo covers, transport bags, insulated bags, hats (hunting type), tents, sleeping bags, jet cool blankets, cosmo blankets, stratosphere blankets, aerogel thermal blankets, industrial heat-resistant gloves, camping heat-resistant gloves, heat-resistant arm covers, and heat-resistant aprons. [Explanation of Symbols]

[0040] 1 Base material layer 2. Aerogel-containing fiber layer 3. Reinforcement layer 10 Aerogel-containing laminated sheet 21 Composite fiber layer 22 Aerogel layer

Claims

1. A sheet-like base material layer, An aerogel-containing fiber layer is arranged on one side of the aforementioned base layer and integrated with it, Composed of, The aerogel-containing fiber layer comprises a composite fiber layer formed by compounding two or more polymers with different properties, and an aerogel layer. A laminated sheet containing aerogel, characterized by the following features.

2. The aerogel-containing laminated sheet according to claim 1, characterized in that the composite fiber layer is a composite of polyester fibers.

3. The aerogel-containing laminated sheet according to claim 1, characterized in that the aerogel-containing fiber layer is formed by repeatedly laminating the composite fiber layer and the aerogel layer alternately.

4. The aerogel-containing laminated sheet according to claim 1, characterized in that the base material layer is waterproof.

5. The aerogel-containing laminated sheet according to claim 1, characterized in that the base material layer has flame retardant properties.

6. The aerogel-containing laminated sheet according to claim 1, characterized in that the aerogel-containing fiber layer is covered and integrated with a durable reinforcing layer.

7. A thermal product such as a cover or blanket, characterized by using an aerogel-containing laminated sheet according to any one of claims 1 to 6.

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