Aerogel composite material, heat-resistant pad comprising same, and method for manufacturing heat-resistant pad

Abstract

A method for manufacturing a heat-resistant pad according to the present invention comprises the steps of: mixing a fluorine-based resin and aerogel particles at a weight ratio of 1:1 to 1:1.5 in a solid phase to form an aerogel composite material; and sheeting the aerogel composite material to form an insulation layer.

Description

Aerogel composite, heat-resistant pad comprising same, and method for manufacturing heat-resistant pad

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

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2024-0086361, filed July 1, 2024, and Korean Patent Application No. 10-2025-0085474, filed June 26, 2025, the entire contents of which are incorporated herein by reference.

[0003] The present invention relates to an aerogel composite, a heat-resistant pad comprising the same, and a method for manufacturing a heat-resistant pad, and more particularly, to a method for manufacturing a heat-resistant pad comprising a method for manufacturing a heat-resistant pad comprising an aerogel by a dry method.

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

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

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

[0007] To address these issues, extensive research is being conducted on preventing fires within battery packs by placing heat-resistant pads between battery cells. In particular, research is ongoing into heat-resistant pads with superior heat resistance and high manufacturing efficiency.

[0008] The present invention is intended to solve the above-mentioned problem, and provides a method for manufacturing an insulating layer including an aerogel composite by dry method and a method for manufacturing a heat-resistant pad including the same.

[0009] In addition, the present invention seeks to provide a heat-resistant pad including an aerogel composite and an insulating layer including the same.

[0010] The method for manufacturing a heat-resistant pad of the present invention comprises the steps of forming an aerogel composite by mixing fluorine-based resin and aerogel particles in a solid phase at a weight ratio of 1:1 or more and 1:1.5 or less; and forming the aerogel composite into a sheet to form an insulating layer.

[0011] In one embodiment, the step of forming the aerogel composite may be performed in one step.

[0012] In one embodiment, the step of forming the aerogel composite may include a first step of forming a precursor by mixing ceramic particles and the fluorine-based resin in a solid phase; and a second step of forming the aerogel composite by mixing the precursor and the aerogel particles in a solid phase.

[0013] In one embodiment, in the first step, the mixing weight ratio of the ceramic particles and the fluorine-based resin may be 2:1 or more and 9:1 or less.

[0014] In one embodiment, the first step may be a step of mixing the ceramic particles and the fluorine-based resin while applying shear stress.

[0015] In one embodiment, the second step may be a step of mixing the precursor and the aerogel particles by kneading.

[0016] In one embodiment, the ceramic particles may include at least one selected from the group consisting of silicon oxide, zirconium oxide, yttrium oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphorus oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass.

[0017] In one embodiment, the fluorine-based resin may include at least one selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin.

[0018] In one embodiment, the aerogel particles may comprise silica aerogel particles.

[0019] In one embodiment, sheeting the aerogel composite may be by pressing the aerogel composite.

[0020] In one embodiment, the thermal conductivity of the insulating layer may be greater than or equal to 0.02 W / m·K and less than or equal to 0.1 W / m·K.

[0021] In one embodiment, the method further comprises forming a support layer on at least one surface of the insulating layer, wherein the support layer may include at least one selected from the group consisting of a silicone-based resin, an aramid fiber, a spun yarn, a mica pad, and a mica paper.

[0022] In one embodiment, the silicone resin may be silicone rubber.

[0023] The aerogel composite of the present invention comprises a fluorine-based resin and aerogel particles in a weight ratio of 1:1 or more and 1:1.5 or less.

[0024] In one embodiment, the aerogel particles may comprise silica aerogel particles.

[0025] In one embodiment, the fluorine-based resin may include at least one selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin.

[0026] In one embodiment, the aerogel composite may further comprise ceramic particles.

[0027] In one embodiment, the mixing weight ratio of the ceramic particles and the fluorine-based resin may be 2:1 or more and 9:1 or less.

[0028] In one embodiment, the ceramic particles may include at least one selected from the group consisting of silicon oxide, zirconium oxide, yttrium oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphorus oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass.

[0029] The refractory pad of the present invention includes an insulating layer comprising the aerogel composite.

[0030] The present invention can provide a method for manufacturing a heat-resistant pad with high price competitiveness and high process efficiency by manufacturing an insulating layer including an aerogel composite in a dry manner.

[0031] In addition, the present invention can provide an aerogel composite manufactured by the above method and a heat-resistant pad including the same.

[0032] Figure 1 is a photograph of an aerogel composite manufactured in Example 1.

[0033] Figure 2 is an SEM image of the aerogel composite manufactured in Example 1.

[0034] Figure 3 is an SEM image of the aerogel composite manufactured in Example 1.

[0035] Figure 4 is a photograph of an aerogel composite manufactured in Example 2.

[0036] Figure 5 is an SEM image of the aerogel composite manufactured in Example 2.

[0037] Figure 6 is an SEM image of the aerogel composite manufactured in Example 2.

[0038] Figure 7 is an SEM image of the aerogel composite manufactured in Example 3.

[0039] Figure 8 is an SEM image of the aerogel composite manufactured in Example 3.

[0040] Figure 9 is an image of the insulation layer manufactured in Example 3.

[0041] Figure 10 is an image of a heat-resistant pad manufactured in Example 3.

[0042] Figure 11 is a SEM image of a mixture of fluorine-based resin and aerogel particles manufactured in Comparative Example 1.

[0043] Figure 12 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 2.

[0044] Figure 13 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 3.

[0045] Figure 14 is an SEM image of the mixture of Figure 13.

[0046] Figure 15 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 4.

[0047] Figure 16 is an SEM image of the mixture of Figure 15.

[0048] Figure 17 is an image of a mixture of fluorine-based resin and aerogel particles manufactured in Comparative Example 5.

[0049]

[0050] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0051] In order to clearly explain the present invention, parts that are not related to the description are omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0052] Furthermore, the sizes and thicknesses of each component shown in the drawings are arbitrarily indicated for convenience of explanation, and thus the present invention is not necessarily limited to the illustrated components. In the drawings, the thicknesses are enlarged to clearly represent various layers and regions. Furthermore, in the drawings, the thicknesses of some layers and regions are exaggerated for convenience of explanation.

[0053] Furthermore, when we say that a layer, membrane, region, plate, or other part is "on" or "over" another part, this includes not only cases where it is "directly on" the other part, but also cases where there are other parts in between. When we say that a part is "directly on" another part, we mean that there are no other parts in between. Furthermore, when we say that a part is "on" or "over" a reference part, we mean that it is located above or below the reference part, and we do not necessarily mean that it is located "above" or "over" the reference part in the opposite direction of gravity.

[0054] Additionally, throughout the specification, whenever a part is said to “include” a component, this does not mean that it excludes other components, but rather that it may include other components, unless otherwise specifically stated.

[0055]

[0056] Hereinafter, the aerogel composite of the present invention, a heat-resistant pad including the same, and a method for manufacturing the heat-resistant pad will be described.

[0057]

[0058] The method for manufacturing the heat-resistant pad of the present invention is as follows:

[0059] A step of forming an aerogel composite by mixing fluorine resin and aerogel particles in a solid phase at a weight ratio of 1:1 or more and 1:1.5 or less; and

[0060] A step of forming an insulating layer by forming the above aerogel composite into a sheet is included.

[0061] The method for manufacturing a heat-resistant pad of the present invention relates to a method for manufacturing a heat-resistant pad including an insulating layer. The heat-resistant pad manufactured by the method for manufacturing a heat-resistant pad of the present invention may include only the insulating layer, or may further include a support layer disposed on at least one surface of the insulating layer. Examples of such methods for manufacturing a heat-resistant pad are described in detail below.

[0062] A method for manufacturing a heat-resistant pad of one embodiment includes a step of forming an aerogel composite by mixing fluorine-based resin and aerogel particles in a solid phase at a weight ratio of 1:1 or more and 1:1.5 or less, and a step of forming the aerogel composite into a sheet to form an insulating layer.

[0063] In one embodiment, the step of forming an aerogel composite may be performed in a single step. That is, the step of forming an aerogel composite may be a step of mixing a fluorinated resin and aerogel particles, each in powder form, into a solid phase.

[0064] The above mixing can be carried out using equipment capable of applying shear stress, for example, using a household blender.

[0065] In one embodiment, the fluorinated resin may include at least one selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin. For example, polytetrafluoroethylene (PTFE) resin may be used as the fluorinated resin, but the embodiment is not limited thereto.

[0066] In one embodiment, the aerogel particles may be inorganic aerogel particles, specifically silica aerogel particles. Aerogel particles have excellent insulating properties and are used as a primary component for manufacturing an insulating layer.

[0067] Fluorine-based resin and aerogel particles are provided in powder form and mixed in a solid state. That is, the fluorine-based resin and aerogel particles are mixed in a dry manner without a separate solvent.

[0068] In general, the wet manufacturing process of aerogel composites takes about 1 to 3 days to grow an aerogel precursor on the surface of a support such as glass fiber, and then a process to selectively remove the solvent in the aerogel precursor using a supercritical fluid method, room temperature pressurization method, etc. is required, so the process cost is high. In contrast, the present invention forms an aerogel composite by mixing a fluorinated resin and aerogel particles in a dry process, so the process time is less than 10 minutes, and it is a simple process compared to the wet manufacturing process, so it has the advantage of relatively short process time and cost.

[0069] The fluorinated resin and aerogel particles can be mixed in a weight ratio of fluorinated resin:aerogel particles of 1:1 or more and 1:1.5 or less. If the amount of aerogel particles decreases and the weight ratio of the fluorinated resin and aerogel particles (weight of fluorinated resin:weight of aerogel particles) becomes less than 1:1, it may be difficult to pad the aerogel composite, or even if the manufacture of the aerogel composite and the insulation layer is possible, the manufactured insulation layer may have difficulty exhibiting sufficient insulation effect. If the amount of aerogel particles increases and the weight ratio of the fluorinated resin and aerogel particles (weight of fluorinated resin:weight of aerogel particles) exceeds 1:1.5, the amount of the fluorinated resin, which acts as a web connecting the aerogel particles, relatively decreases, making it difficult to pad the aerogel composite. In other words, it becomes difficult to manufacture the insulation layer.

[0070] In the present invention, a method for dry manufacturing an aerogel composite is provided by forming an aerogel composite by solid-state mixing a fluorine-based resin and aerogel particles in a weight ratio of 1:1 or more and 1:1.5 or less, and an aerogel composite having high price competitiveness, excellent insulation properties, and easy padding can be provided.

[0071] The aerogel composite formed as described above can be formed into a sheet and manufactured into an insulating layer. Sheeting the aerogel composite involves pressing the aerogel composite into a sheet shape. Pressing can be performed using known methods, such as calendaring.

[0072] In one embodiment, when the step of forming the aerogel composite is performed in one step, the step may include a step of forming the aerogel composite by mixing the fluorine-based resin and the aerogel particles in a solid state at a weight ratio of 1:1 or more and 1:1.5 or less, without any other components, and a step of forming the aerogel composite into a sheet to form an insulating layer.

[0073] In another embodiment, the step of forming the aerogel composite may be performed in two or more steps, for example in a two-step manner.

[0074] In one embodiment, the step of forming an aerogel composite may include a first step of mixing ceramic particles and the fluorine-based resin in a solid phase to form a precursor, and a second step of mixing the precursor and aerogel particles in a solid phase to form an aerogel composite.

[0075] The first step is to form a precursor by mixing ceramic particles and fluorine-based resin, each in powder form, into a solid.

[0076] The first step is the process of fiberizing the fluorinated resin. By mixing ceramic particles into the fluorinated resin, fiberization of the fluorinated resin can be more easily induced. This step can be performed using equipment capable of applying shear stress, such as a household blender. The mixing of the ceramic particles and the fluorinated resin is performed dry, without the use of any separate solvent. Therefore, the process time is short and the cost is relatively low.

[0077] In this embodiment, the ceramic particles and the fluorine-based resin may be mixed in a weight ratio of ceramic particles to fluorine-based resin of 2:1 or more and 9:1 or less. When the above ratio is satisfied, the fiberization of the fluorine-based resin may proceed easily.

[0078] In one embodiment, the ceramic particles may include at least one selected from the group consisting of silicon oxide, zirconium oxide, yttrium oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphate oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass. For example, milled glass fiber, chopped glass, silicon oxide, zirconium oxide, or aluminum oxide may be used as the ceramic particles, and more specifically, milled glass fiber and chopped glass may be used in combination, but the embodiment is not limited thereto.

[0079] The description of fluorinated resins applies equally to the above.

[0080] The second step is to form an aerogel composite by mixing aerogel particles into the precursor formed in the first step in a solid state. The description of the aerogel particles applies equally to the above.

[0081] Mixing of the precursor and aerogel particles is performed dry, without the use of a separate solvent. Therefore, the process time is short and costs are relatively low.

[0082] When mixing a precursor and aerogel particles, the mixing can be based on the weight ratio of the fluorinated resin contained in the precursor and the aerogel particles. That is, the precursor and aerogel particles are mixed so that the weight ratio of the fluorinated resin contained in the precursor to the aerogel particles is 1:1 or more and 1:1.5 or less. When the above ratio is satisfied, the fiberization of the fluorinated resin can easily proceed.

[0083] The second step may involve kneading the precursor and aerogel particles manufactured in the first step. For example, the process of kneading the precursor and aerogel particles may be performed using a planetary disperser mixer (PD mixer) or a twin screw extruder.

[0084] In this embodiment, if steps 1 and 2 are performed in a single step, i.e., ceramic particles, fluorine-based resin, and aerogel particles are simultaneously mixed in a solid phase, the problem of aerogel particles breaking may occur. Due to this particle breaking, the specific surface area of ​​the aerogel particles increases, while the proportion of fluorine-based resin capable of covering the surface of the aerogel particles relatively decreases, and padding of the aerogel composite may not proceed.

[0085] Therefore, when ceramic particles are added, an aerogel composite can be formed by dividing the process into the first and second stages as described above, and then an insulating layer can be formed by sheeting the aerogel composite. Sheeting of the aerogel composite can be performed using a press method as described above.

[0086] The method for manufacturing the heat-resistant pad of the present invention can be performed by mixing a fluorine-based resin, aerogel particles, and optionally ceramic particles in a solid phase to form an aerogel composite, and forming the aerogel composite into a sheet to manufacture an insulating layer.

[0087] The thermal conductivity of the manufactured insulation layer may be 0.02 W / m·K or more and 0.1 W / m·K or less. The insulation layer of the present invention has excellent heat resistance by including aerogel particles, and is manufactured in a dry manner, thereby reducing the time and cost of the process compared to a wet method.

[0088] Meanwhile, a method for manufacturing a heat-resistant pad according to one embodiment may provide a method for manufacturing an insulating layer. That is, a heat-resistant pad manufactured according to a method for manufacturing a heat-resistant pad according to one embodiment may provide the aforementioned insulating layer.

[0089]

[0090] A method for manufacturing a heat-resistant pad according to another embodiment of the present invention may include a step of forming an insulating layer and a step of forming a support layer. That is, a heat-resistant pad manufactured according to the method for manufacturing a heat-resistant pad according to one embodiment may include an insulating layer and a support layer disposed on at least one surface of the insulating layer.

[0091] The steps for forming the insulation layer are identical to the aforementioned method for manufacturing the insulation layer. That is, the steps for forming the insulation layer are performed in one or two steps, as described above, including forming an aerogel composite and forming the aerogel composite into sheets to form the insulation layer. A detailed description thereof will be omitted.

[0092] The step of forming a support layer is a step of forming a support layer on at least one side of the insulating layer. For example, the support layer may be formed on both sides of the insulating layer, but the embodiment is not limited thereto.

[0093] The support layer may include a heat-resistant material. Specifically, the support layer may include at least one selected from the group consisting of a silicone-based resin, a fabric, and a ceramic material. The silicone-based resin may be, for example, silicone rubber. The fabric may be, for example, aramid fiber or spun yarn. The ceramic material may be, for example, a mica pad or mica paper. That is, the support layer may include at least one selected from the group consisting of a silicone-based resin, aramid fiber, spun yarn, a mica pad, and mica paper.

[0094] In one embodiment, the support layer may be silicone rubber. In this case, the step may include applying and curing a silicone rubber solution to at least one surface of the insulating layer to form the support layer. However, the embodiments of the support layer are not limited thereto.

[0095] In one embodiment, the support layer may further include one or more selected from the group consisting of fabric or ceramic materials, with silicone rubber as the adhesive layer. In this case, the step may include applying a silicone rubber solution to at least one surface of the insulation layer, adhering a fabric or ceramic material onto the silicone rubber solution, and then curing the silicone rubber solution to form the support layer.

[0096] A method for manufacturing a heat-resistant pad according to one embodiment can provide a method for providing a heat-resistant pad comprising an insulating layer and a support layer. Accordingly, the heat-resistant pad provided can have improved strength and flexibility. Such a heat-resistant pad can be positioned, for example, between battery cells to prevent heat generated in one battery cell from being transferred and accumulated in an adjacent battery cell, resulting in thermal propagation.

[0097]

[0098] The aerogel composite of the present invention,

[0099] It contains fluorine resin and aerogel particles in a weight ratio of 1:1 or more and 1:1.5 or less.

[0100] In one embodiment, the aerogel composite may be manufactured according to the step of forming an aerogel composite in the method for manufacturing a heat-resistant pad described above. That is, the aerogel composite of one embodiment may be formed by mixing a fluorinated resin and aerogel particles in a solid phase at a weight ratio of 1:1 or more and 1:1.5 or less. Therefore, the detailed description of the fluorinated resin and aerogel particles in the aerogel composite of the present invention is equally applicable to the above-described content.

[0101] In one embodiment, the aerogel particles may comprise silica aerogel particles.

[0102] Additionally, in one embodiment, the fluorinated resin may include at least one selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin.

[0103] In one embodiment, the aerogel composite may further include ceramic particles to more easily induce fiberization of the fluororesin. That is, the aerogel composite of one embodiment may be formed by a first step of mixing ceramic particles and the fluororesin in a solid phase to form a precursor, and a second step of mixing the precursor and the aerogel particles in a solid phase to form the aerogel composite. Therefore, the detailed description of the ceramic particles in the aerogel composite of the present invention applies equally to the above-described content.

[0104] In one embodiment, the mixing weight ratio of the ceramic particles and the fluorine-based resin may be 2:1 or more and 9:1 or less. In addition, in one embodiment, the ceramic particles may include at least one selected from the group consisting of silicon oxide, zirconium-based oxide, yttrium-based oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphorus-based oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass.

[0105] The aerogel composite of the present invention comprises a fluorine-based resin and aerogel particles in a weight ratio of 1:1 or more and 1:1.5 or less, so that it has excellent insulation properties and can be easily formed into sheets, thereby providing excellent processability.

[0106]

[0107] The heat-resistant pad of the present invention,

[0108] It includes an insulating layer including the above aerogel composite.

[0109] In one embodiment, the heat-resistant pad includes an insulating layer comprising the aforementioned aerogel composite. Specifically, the insulating layer may be formed by sheeting the aforementioned aerogel composite. The method of sheeting may be the same as that described in the step of forming the insulating layer by sheeting the aerogel composite in the method for manufacturing the heat-resistant pad described above.

[0110] In one embodiment, the heat-resistant pad of the present invention may include an insulating layer and a support layer disposed on at least one surface of the insulating layer. The detailed description of the support layer is the same as that described above.

[0111] The heat-resistant pad of the present invention can exhibit excellent heat resistance by including an insulating layer comprising an aerogel composite. In addition, the heat-resistant pad of the present invention can improve flexibility by including a support layer in addition to the insulating layer.

[0112]

[0113] Below, embodiments of the present invention are described in detail so that those skilled in the art can easily implement them. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0114]

[0115] <Example 1>

[0116] An aerogel composite was formed by solid-phase mixing fluorinated resin and aerogel particles at a weight ratio of 1:1. PTFE was used as the fluorinated resin, and silica aerogel particles were used as the aerogel particles. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0117] Fig. 1 is a photograph of an aerogel composite manufactured in Example 1. Figs. 2 and 3 are SEM images of the aerogel composite manufactured in Example 1. Referring to Figs. 1 to 3, it can be confirmed that the fluorinated resin is adsorbed onto the surface of the aerogel particles, and the aerogel particles are uniformly bonded to each other by the fluorinated resin.

[0118]

[0119] <Example 2>

[0120] An aerogel composite was formed by solid-phase mixing fluorinated resin and aerogel particles at a weight ratio of 1:1.5. PTFE was used as the fluorinated resin, and silica aerogel particles were used as the aerogel particles. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0121] Fig. 4 is a photograph of an aerogel composite manufactured in Example 2. Figs. 5 and 6 are SEM images of an aerogel composite manufactured in Example 2.

[0122] Referring to FIGS. 4 to 6, it can be confirmed that the aerogel particles are connected and bonded to each other by adsorbing the fluorine resin onto the surface of the aerogel particles.

[0123]

[0124] <Example 3>

[0125] A precursor was formed by solid-phase mixing ceramic particles and fluorinated resin at a weight ratio of 2:1. Aluminum oxide (Al2O3) was used as the ceramic particles, and PTFE was used as the fluorinated resin. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0126] The precursor thus formed was solid-phase mixed with aerogel particles to form an aerogel composite. At this time, the aerogel particles were mixed with the fluorinated resin contained in the precursor at a weight ratio of 1:1. Silica aerogel particles were used as the aerogel particles. Mixing was performed using a hivis Mix (planetary mixer) from Primix at 45 rpm for 45 minutes.

[0127] Figures 7 and 8 are SEM images of the aerogel composite manufactured in Example 3. Referring to Figures 7 and 8, it can be confirmed that the precursor, which is a mixture of ceramic particles and fluorine-based resin, exists in a mesh form and covers the aerogel.

[0128] Thereafter, the formed aerogel composite was pressed into sheets using an air automatic hot press (Air heating plating test, QM940AS model) from Cumersys, thereby forming an insulating layer. Figure 9 is an image of the insulating layer manufactured in Example 3. Referring to Figure 9, it can be confirmed that the insulating layer has a sheet shape.

[0129] After that, a silicone rubber solution was spray-coated on both sides of the formed insulation layer and heat-cured to form a support layer. The silicone rubber solution was a mixture of PDMS (polydimethylsiloxane), a cross-linking agent, and a platinum (Pt) catalyst in a weight ratio of PDMS:cross-linking agent:platinum catalyst = 100:1:1. Heat-curing was performed in an oven at 80°C for 10 minutes. Through this, a heat-resistant pad including an insulation layer and a support layer was manufactured. Fig. 10 is an image of the heat-resistant pad manufactured in Example 3. Referring to Fig. 10, it can be confirmed that the heat-resistant pad is bent in one direction including the support layer. In other words, it can be confirmed that the flexibility of the heat-resistant pad is further enhanced by including the support layer.

[0130]

[0131] <Comparative Example 1>

[0132] An aerogel composite was formed by solid-state mixing fluorinated resin and aerogel particles at a weight ratio of 1:5. PTFE was used as the fluorinated resin, and silica aerogel particles were used as the aerogel particles. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0133] Figure 11 is a SEM image of a mixture of fluorinated resin and aerogel particles manufactured in Comparative Example 1. As illustrated in Figure 11, in Comparative Example 1, the fluorinated resin and aerogel were not mixed, and thus no aerogel composite was formed. The reason for this is presumably that, compared to Examples 1 and 2, the amount of fluorinated resin per unit volume was smaller, making it difficult to form a web through fiberization.

[0134] Since the aerogel composite was not formed, the manufacture of the insulation layer was impossible and the manufacture of the heat-resistant pad was impossible.

[0135]

[0136] Comparative Example 2

[0137] Ceramic particles, fluorinated resin, and aerogel particles were solid-phase mixed in a weight ratio of 2:1:4, and mixed simultaneously in one step. Aluminum oxide (Al2O3) was used as the ceramic particles, PTFE was used as the fluorinated resin, and silica aerogel particles were used as the aerogel particles.

[0138] Mixing was performed using a household blender at 3500 rpm for 15 minutes.

[0139] Figure 12 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 2.

[0140] Referring to Fig. 12, the mixture did not undergo padding and SEM analysis was not possible due to dust.

[0141]

[0142] <Comparative Example 3>

[0143] A precursor was formed by solid-phase mixing ceramic particles and fluorinated resin at a weight ratio of 1:1. Aluminum oxide (Al2O3) was used as the ceramic particles, and PTFE was used as the fluorinated resin. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0144] The precursor thus formed was mixed with aerogel particles in a solid state to form an aerogel composite. At this time, the aerogel particles were mixed in an amount four times the weight of the fluorinated resin contained in the precursor. Silica aerogel particles were used as the aerogel particles. Mixing was performed using a hivis Mix (planetary mixer) from Primix at 45 rpm for 45 minutes.

[0145] Fig. 13 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 3. Fig. 14 is an SEM image of the mixture of Fig. 13.

[0146] Referring to Fig. 13, it can be confirmed that an aerogel composite is not formed and the mixture exists in a powder form. Referring to Fig. 14, it can be confirmed that because the ratio of aerogel particles to precursor is relatively high, only some of the aerogel particles form a complex with the precursor, and that there are more aerogel particles that do not form a complex with the precursor.

[0147]

[0148] <Comparative Example 4>

[0149] A precursor was formed by solid-phase mixing ceramic particles and fluorinated resin at a weight ratio of 10:1. Aluminum oxide (Al2O3) was used as the ceramic particles, and PTFE was used as the fluorinated resin. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0150] The precursor thus formed was mixed with aerogel particles in a solid state to form an aerogel composite. At this time, the aerogel particles were mixed in an amount four times the weight of the fluorinated resin contained in the precursor. Silica aerogel particles were used as the aerogel particles. Mixing was performed using a hivis Mix (planetary mixer) from Primix at 45 rpm for 45 minutes.

[0151] Fig. 15 is an image of a mixture of ceramic particles, fluorine-based resin, and aerogel particles manufactured in Comparative Example 4. Fig. 16 is an SEM image of the mixture of Fig. 15.

[0152] Referring to Figure 15, it can be confirmed that an aerogel composite is not formed and the mixture exists in a powder form. Furthermore, referring to Figure 16, it can be confirmed that the ceramic particles are densely distributed within the aerogel composite due to the extremely high proportion of ceramic particles, with some particles clumping together. The aerogel particles are partially present between the ceramic particles, and it can be confirmed that sufficient bonding is not formed between the precursor and the aerogel particles.

[0153]

[0154] Comparative Example 5

[0155] An aerogel composite was formed by solid-state mixing fluorinated resin and aerogel particles at a weight ratio of 2:1. PTFE was used as the fluorinated resin, and silica aerogel particles were used as the aerogel particles. Mixing was performed using a household blender at 3,500 rpm for 15 minutes.

[0156] Figure 17 is an image of a mixture of fluorine-based resin and aerogel particles manufactured in Comparative Example 5.

[0157] Referring to Figure 17, aggregates of fluorinated resin were found in the area indicated by a circle, and the formation of numerous such aggregates confirms that the fluorinated resin and aerogel were not mixed. Since the aerogel composite was not formed, the manufacture of the insulation layer and the heat-resistant pad were impossible.

[0158] Referring to the above Examples 1, 2, Comparative Examples 1, 2, and 5, it was confirmed that when the weight ratio of the fluorine-based resin and the aerogel particles was adjusted to 1:1 or more and 1:1.5 or less during solid mixing, a uniform web was formed between the fluorine-based resin and the aerogel particles, and padding was possible.

[0159] In addition, referring to Example 3, Comparative Example 3, and Comparative Example 4, it was confirmed that even when ceramic particles, fluorine-based resin, and aerogel particles were mixed in two steps, if the weight ratio of the ceramic particles, fluorine-based resin, and aerogel particles was outside the range of the present invention, it was difficult to form an aerogel composite and difficult to pad.

[0160] Referring to Examples 1 to 3, a method for manufacturing a heat-resistant pad of the present invention provides a method of forming an aerogel composite by mixing a fluorine-based resin, aerogel particles, and optionally ceramic particles in a solid state, wherein the fluorine-based resin: aerogel particles are mixed in a weight ratio of 1:1 or more and 1:1.5 or less, and forming the formed aerogel composite into a sheet to form an insulating layer.

[0161] The method for manufacturing the heat-resistant pad of the present invention is dry, resulting in excellent processability, and the heat-resistant pad thus manufactured can have excellent insulation properties. Furthermore, the heat-resistant pad of one embodiment of the present invention further includes a step of forming a support layer on the insulating layer, thereby providing a heat-resistant pad with further enhanced strength and flexibility.

[0162]

[0163] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims also fall within the scope of the present invention.

Claims

A step of forming an aerogel composite by mixing fluorine resin and aerogel particles in a solid phase at a weight ratio of 1:1 or more and 1:1.5 or less; and A method for manufacturing a heat-resistant pad, comprising: forming an insulating layer by sheeting the above aerogel composite. In paragraph 1, A method for manufacturing a heat-resistant pad, wherein the step of forming the above aerogel composite is performed in one step. In paragraph 1, The step of forming the above aerogel composite is: A first step of forming a precursor by mixing ceramic particles and the fluorine-based resin in a solid phase; and A method for manufacturing a heat-resistant pad, comprising a second step of mixing the precursor and the aerogel particles in a solid phase to form the aerogel composite. In paragraph 3, A method for manufacturing a heat-resistant pad, wherein in the first step, the mixing weight ratio of the ceramic particles and the fluorine-based resin is 2:1 or more and 9:1 or less. In paragraph 3, The above first step is a method for manufacturing a heat-resistant pad, which is a step of mixing the ceramic particles and the fluorine-based resin while applying shear stress. In paragraph 3, A method for manufacturing a heat-resistant pad, wherein the second step is a step of mixing the precursor and the aerogel particles by kneading. In paragraph 3, A method for manufacturing a heat-resistant pad, wherein the ceramic particles include at least one selected from the group consisting of silicon oxide, zirconium-based oxide, yttrium-based oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphoric acid-based oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass. In paragraph 1, A method for manufacturing a heat-resistant pad, wherein the fluorine-based resin comprises at least one selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin. In paragraph 1, The above aerogel particles are a method for manufacturing a heat-resistant pad including silica aerogel particles. In paragraph 1, A method for manufacturing a heat-resistant pad, wherein the step of forming the above aerogel composite into a sheet is to press the above aerogel composite. In paragraph 1, A method for manufacturing a heat-resistant pad, wherein the thermal conductivity of the above-mentioned insulating layer is 0.02 W / m·K or more and 0.1 W / m·K or less. In paragraph 1, Further comprising a step of forming a support layer on at least one surface of the insulating layer, A method for manufacturing a heat-resistant pad, wherein the support layer comprises at least one selected from the group consisting of silicone-based resin, aramid fiber, spun yarn, mica pad, and mica paper. In Article 12, A method for manufacturing a heat-resistant pad in which the above silicone resin is silicone rubber. An aerogel composite comprising fluorinated resin and aerogel particles in a weight ratio of 1:1 or more and 1:1.5 or less. In Article 14, The above aerogel particles are an aerogel composite comprising silica aerogel particles. In Article 14, An aerogel composite comprising at least one fluorine-based resin selected from the group consisting of polytetrafluoroethylene (PTFE) resin, polyfluoroalkoxy (PFA) resin, and polyvinylidene fluoride (PVDF) resin. In Article 14, The above aerogel composite is an aerogel composite further comprising ceramic particles. In Article 17, An aerogel composite in which the mixing weight ratio of the ceramic particles and the fluorine-based resin is 2:1 or more and 9:1 or less. In Article 17, An aerogel composite comprising at least one selected from the group consisting of silicon oxide, zirconium oxide, yttrium oxide, aluminum oxide (Al2O3), boehmite, aluminum trihydrate, calcium oxide, phosphoric acid oxide, phosphorus pentoxide (P2O5), glass fiber, glass bubble, and chopped glass. A heat-resistant pad comprising an insulating layer including an aerogel composite according to Article 14.

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