CN109403022A - 具有亲水性或疏水性的气凝胶/非织物复合材料的制备方法及其产品 - Google Patents

具有亲水性或疏水性的气凝胶/非织物复合材料的制备方法及其产品 Download PDF

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CN109403022A
CN109403022A CN201711182197.5A CN201711182197A CN109403022A CN 109403022 A CN109403022 A CN 109403022A CN 201711182197 A CN201711182197 A CN 201711182197A CN 109403022 A CN109403022 A CN 109403022A
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coupling agent
aeroge
solution
silane coupling
woven
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CN109403022B (zh
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陈建宏
陈秀秀
张智舜
李劲直
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KUN SHAN UNIVERSITY
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Abstract

本发明公开了一种具有亲水性或疏水性的气凝胶/非织物复合材料的制备方法及其产品,该制备方法包括下列步骤:将一烷氧化硅类化合物与一硅胶类化合物进行混合,再添加一硅烷偶合剂类化合物继续搅拌,随后滴入酸触媒进行水解反应,随后再加入高含水碱触媒(或低含水碱触媒)有机水溶液进行缩合反应,以形成硅胶‑硅气凝胶‑硅烷偶合剂气凝胶溶胶溶液;将前述溶胶溶液浸泡非织物,并经凝胶化熟成以及干燥程序,得到一具柔软性的疏水性(或亲水性)气凝胶/非织物复合防火隔热材料,本发明可同时大量生产具有不同亲疏水表面性质且具有柔软性的气凝胶/非织物复合材料,其可作为产业高温设备的隔热材料或建筑结构的室内隔热与防火板材等用途。

Description

具有亲水性或疏水性的气凝胶/非织物复合材料的制备方法 及其产品
技术领域
本发明涉及一种可具有不同表面亲疏水性质并具有柔软性的气凝胶/非织物复合防火隔热材料的制备方法及其产品,特别涉及一种结合烷氧化硅类化合物、硅胶类化合物和硅烷偶合剂类化合物的硅胶-硅气凝胶-硅烷偶合剂三混合的气凝胶溶胶溶液体系;将此三混合气凝胶溶胶溶液浸泡一非织物,使前述气凝胶溶胶溶液均匀穿插在该非织物中,再经一干燥程序,以得到一可具有不同亲疏水表面性质并具有柔软性的气凝胶/非织物复合材料,该材料可应用于高温设备的隔热材料或建筑结构的室内隔热以及防火板材料。
背景技术
按,气凝胶拥有许多的特殊性质,如低密度、高孔隙率、高比表面积以及低热传导系数。目前气凝胶的制备方法一般是溶胶凝胶合成法,由烷氧化硅类(Alkoxysilane)或正硅酸甲酯等前驱物与含水有机溶剂进行混合后,添加酸触媒,进行水解反应(Hydrolysis)。水解一定时间后,再添加碱触媒,进行缩合反应(Condensation),反应后形成溶胶。溶胶内的分子继续进行缩合反应键结,逐渐形成半固态的高分子凝胶,再经过一段时间的熟化,胶体会形成结构稳定的3D立体网狀结构。
此外,气凝胶可利用化学剂进行改质,其原理为将气凝胶表面的氢氧(-OH)官能基与改质剂上的氯(-Cl)反应产生盐酸,然后取代氢(-H),改质为疏水的-OSi(CH3)3官能基。此种疏水的官能基,在气凝胶常压干燥的过程中,可以减少表面张力的大小,在极小量的体积收缩下,仍能保有湿凝胶的3D立体网狀结构。
传统气凝胶材料,因含有大量的水分子,故其干燥制程需利用二氧化碳超临界干燥机进行干燥,其制备条件是在温度34摄氏度的高压条件将液态二氧化碳转变成超临界条件,并利用超临界二氧化碳将气凝胶中水分子溶出干燥。但此制备方法无法实现工业化,其所制备的气凝胶也会明显存在龟裂而易破碎,进而影响气凝胶的整体工业应用,故制备上仍有相当改善的空间。
目前国内外一些有关气凝胶材料专利的先前技术资料,略举如下:
1.美国专利第8,029,871号「生产二氧化硅气凝胶涂层的方法」,公开了其二氧化硅气凝胶涂料是由烷氧基硅烷和有机改性剂进行水解以及聚合反应后所得到的湿的有机改性二氧化硅凝胶,利用超声波处理所制备的形成有机改性二氧化硅凝胶形成有机改性的二氧化硅分散物,添加紫外线固化型树脂和光聚合引发剂于此有机改性的二氧化硅分散物形成二氧化硅气凝胶涂料液体,应用此涂料液体于基材上,然后照射紫外线于此涂层。
2.美国专利第8,021,583号「含有气凝胶毯子」,公开了一种毯子的制备方法,其为形成型疏水性气凝胶浆液,纤维和至少一个润湿剂,干燥此浆液形成一极大的干燥产品,并将该干燥产品制成毛毯,以应用在各层面。
3.另有本发明的相关前案如中国台湾发明专利第103135659号「气凝胶/非织物复合防火/隔热材及其制备方法」,主要公开了将一烷氧化硅类或一正硅酸甲酯在一低含水有机溶液中进行混合,并添加一酸触媒,以进行一水解反应。再添加一碱触媒无水有机溶液以进行缩合反应,形成凝胶化的一气凝胶。将前述气凝胶加入一非织物中,使前述气凝胶充分穿插在该非织物中,并经一干燥程序,以形成一气凝胶/非织物复合隔热材料。藉此,能大量生产出本发明的气凝胶/非织物复合材料,作为隔热材料或防火材料的用途。
发明内容
本发明人有鉴于先前气凝胶应用于隔热或多孔吸附的众多专利,但现有技术中尚无利用硅胶以及硅气凝胶二混合气凝胶溶胶溶液含浸于复合非织物中形成接口粘结完整且相互穿插网状结构的气凝胶/复合非织物材料,特别是可同时大量生产具有不同表面亲疏水性且具有柔软性的气凝胶/复合非织物材料,作为产业高温设备的隔热材料或建筑结构的室内隔热以及防火板材料用途的专利。因此本专利提出一种结合复合非织物以及复合气凝胶溶胶溶液以制备出气凝胶/非织物复合隔热、防火材料及其制备方法。通过结合硅胶-硅气凝胶以及复合非织物的复合材料兼具柔软性、高防火、高隔热等特性。
本发明提供一种具有亲水性或疏水性的混合气凝胶溶胶溶液以及复合非织物以制备兼具柔软以及防火性质的气凝胶/复合非织物材料的制备方法,包括下列步骤:
(S1)混合步骤:将一烷氧化硅类化合物,与一硅胶类化合物进行混合,混合后加入一第一有机溶液在高速搅拌下混合均匀;
随后再添加一微量的硅烷偶合剂类化合物于溶液中继续搅拌反应,使该硅烷偶合剂结合于气凝胶结构上,添加该硅烷偶合剂于硅胶-气凝胶结构中的目的是降低气凝胶的亲水性以增加硅胶-硅气凝胶-硅烷偶合剂结构中的R-官能基与后续步骤中所用的非织物纤维(PP、PET、玻纤或岩棉等)之间的化学结合,并增加硅胶-气凝胶分子在含水有机溶液中的聚集能力以及增加气凝胶的稳定性;
其中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.0001~0.65:0.0001~1.0。
优选的,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.001~0.65:0.001~1.0。
(S2)水解步骤:将酸触媒或其水溶液滴入于上述(S1)混合步骤所得到的混合溶液中进行水解反应;水解反应后,得到一透明的硅胶-硅气凝胶-硅烷偶合剂三混合气凝胶溶胶溶液的水解溶液;
其中,酸触媒选自硫酸H2SO4、磷酸H3PO4、硝酸HNO3、盐酸HCl其中之一或其混合,所添加酸的含量越高,水解速率越快。
优选的,该水解溶液中硅胶-硅气凝胶-硅烷偶合剂与含水有机溶液的体积比为5~100:95~200。
优选的,该水解溶液中水的摩尔百分含量为0~80mol%,当溶液中水的摩尔百分含量小于10mol%时可制备表面亲水性质的气凝胶/复合非织物防火隔热材料,当溶液中水的摩尔百分含量大于10mol%时可制备表面疏水性质的气凝胶/复合非织物防火隔热材料,且当溶液中水的摩尔百分含量越高,所制备的气凝胶/复合非织物防火隔热材料的防火性能就越优异;更优选的,该缩合溶液中水的摩尔百分含量为2.0~80mol%。
(S3)缩合步骤:将碱触媒与高含水的第二有机溶液所配置成的一碱触媒高含水有机溶液逐渐加入至上述(S2)水解步骤所得到的水解溶液中,进行缩合反应,以形成高含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶缩合混合溶液。
(S30)另一缩合步骤:将碱触媒与低含水的第二有机溶液所配置成的一碱触媒低含水有机溶液逐渐加入至上述(S2)水解步骤所得到的水解溶液中,进行缩合反应,以形成低含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶缩合混合溶液。
在上述(S3)缩合步骤或(S30)另一缩合步骤中,该碱触媒选自NaOH、NaHCO3、Na2CO3、NH4OH其中之一或其组合。
优选的,该碱触媒有机溶液中碱触媒与该酸触媒或其水溶液中的酸触媒的摩尔比为1.02~3:1,当碱触酶的摩尔比越大,该气凝胶溶胶溶液的凝胶化速率就越快,最高可使硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液的缩合反应时间由1100分钟缩短至3~5分钟。
(S4)成型步骤:取前述(S3)缩合步骤所得到的溶胶态的高含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液浸泡一非织物,如回收复合非织物毯或一般复合非织物毯,使前述高含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液充分浸透该非织物,完全结合反应,使硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液凝胶化,得到一表面疏水性的气凝胶/复合非织物材料。
(S40)另一成型步骤:取前述(S30)另一缩合步骤所得到的溶胶态的低含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液低含水混合溶液浸泡一非织物,如回收复合非织物毯或一般复合非织物毯,使前述低含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液充分浸透该非织物,完全结合反应,使硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液凝胶化,得到一表面亲水性的气凝胶/非织物复合材料。
优选的,该缩合溶液中水的摩尔百分含量为0~80mol%,当溶液中水的摩尔百分含量小于10mol%时可制备表面亲水性质的气凝胶/复合非织物防火隔热材料,当溶液中水的摩尔百分含量大于10mol%时可制备表面疏水性质的气凝胶/复合非织物防火隔热材料,且当溶液中水的摩尔百分含量越高,所制备的气凝胶/复合非织物防火隔热材料的防火性能就越优异;更优选的,该缩合溶液中水的摩尔百分含量为2.0~80mol%。
优选的,在上述(S4)成型步骤或(S40)另一成型步骤中,该硅胶-硅气凝胶-硅烷偶合剂气凝胶穿插在该非织物中。
(S5、S50)干燥步骤:将上述(S4)成型步骤或(S40)另一成型步骤得到的气凝胶/非织物复合材料经一干燥步骤,得到具疏水性或亲水性的气凝胶/非织物复合防火隔热材料。
优选的,该干燥步骤为一常温常压的自然干燥步骤,以形成具柔软及多孔性的疏水性气凝胶/非织物复合材料(S5)或形成具柔软及多孔性的亲水性气凝胶/非织物复合材料(S50),随后再将温度升至80摄氏度,使气凝胶/非织物复合材料进行快速脱除水与有机溶剂結合的共沸溶液,并随后再将温度升至105~120摄氏度,使气凝胶/非织物复合材料进行快速脱除剩余水,藉此,得到具柔软及多孔性的气凝胶/非织物复合材料。
优选的,本发明使用的该硅胶(Poly(dimethenesilicone,PDMS、MDMS)类化合物为具有双末端双官能基或双末端加侧链的具有一至三个官能基的硅胶结构,该硅胶类化合物的官能基独立选自酸基(-COOH)、胺基(-NH2)、羟基(-OH)、缩酸基、环氧基、醚基等。
优选的,该硅烷偶合剂具有一含烯烃类或含长链烯烃类的硅烷结构,因其反应基团可分为选自氯化硅烷偶合剂、烯基硅烷偶合剂、环氧基硅烷偶合剂、酸基硅烷偶合剂、胺基硅烷偶合剂、羟基硅烷偶合剂或缩酸基硅烷偶合剂等。
优选的,在(S1)混合步骤中,该第一有机溶液选自水、C1-C5醇类、C1-C5酸类、C1-C5酯类或C1-C5醚类其中之一或其组合。
优选的,在(S2)水解步骤中,该酸触媒为H2SO4+H3PO4、HNO3+HCl混合酸或单一酸。
优选的,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1:0.025~0.65:0.001~0.1。
优选的,该硅胶-硅气凝胶-硅烷偶合剂气凝胶固体含量在整体气凝胶溶胶溶液中的体积百分含量为5.0~95.0V%,其中水及有机溶液的含量越高,干燥后气凝胶体机内部孔洞的数量越多,当水及有机溶液的总含量在50.0%以上时,气凝胶体机内部孔洞将会逐渐连结而形成连续式孔洞。
优选的,在(S2)水解步骤所得到的水解溶液中该酸触媒的摩尔百分含量为0.001~0.1mol%,其中,酸触媒的摩尔百分含量越高,可增加烷氧化硅类化合物、硅胶类化合物以及硅烷偶合剂类化合物之间的化学键结合能力而易形成共聚合反应。
优选的,在(S3)缩合步骤中,该第二有机溶液选自水、C1-C5醇类、C1-C5氨类、C1-C5酯类或C1-C5醚类其中之一或其组合。
优选的,在(S4)成型步骤或(S40)另一成型步骤中所述将前述硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液充分浸透该非织物并形成相互穿插结构时,是通过喷涂、淋喷、浸泡加工或溶液连续压吸加工等方式实现的。
优选的,(S5、S50)干燥步骤的干燥条件为常压下30~80摄氏度,温度越高干燥时间约短,最高可由360分钟降低至150分钟。
优选的,该气凝胶/非织物复合材料中所含该硅胶-硅气凝胶-硅烷偶合剂气凝胶的体积百分含量为5~80V%,更优选为25~70V%。
优选的,该非织物为复合非织物毯,其是由聚丙烯(PP)、聚对苯二甲酸乙二醇酯(PET)或聚酰胺(Nylon)、玻纤、岩棉、碳纤棉其中之一或其组合所制成的。
本发明还提供一种气凝胶/非织物复合材料,是使用前述任一制备方法所制备得到的气凝胶/非织物复合材料,其中,该气凝胶/非织物复合材料包含有一非织物及一硅胶-硅气凝胶-硅烷偶合剂气凝胶,该气凝胶与该非织物结合形成相互穿插的立体网状结构。
本发明的有益效果在于:
1.本发明通过结合具柔软且多孔性的硅胶-硅气凝胶-硅烷偶合剂气凝胶材料的高防火、隔热特性以及气凝胶/非织物复合材料表面亲疏水性质的可调节性,并结合非织物的柔软及力学性质以形成不同亲疏水表面性质的气凝胶/非织物复合材料,并能在常温常压条件下进行大量制造,以应用防火、隔热建材、高温工厂设施等各式防火、隔热材料以及汽车或一般民用隔音、隔热材料等。
2.本发明通过调整该硅胶-硅气凝胶-硅烷偶合剂气凝胶中的各成分含量以调整该硅胶-硅气凝胶-硅烷偶合剂气凝胶的亲疏水性质以及气凝胶及非织物间的结合能力,以改善目前现有技术中气凝胶与非织物之间结合能力弱所导致掉粉屑等问题。
3.本发明通过调整该酸触媒的浓度以控制硅胶-硅气凝胶-硅烷偶合剂的水解反应时间。当该酸触媒浓度的摩尔百分含量为0.001mol%时水解时间需达4小时,当该酸触媒浓度的摩尔百分含量为0.1mol%时水解时间缩短至20分钟。
4.本发明通过调整该碱触媒有机溶液中碱触媒含量以调整该缩合反应形成凝胶的时间。当该碱触媒对酸触媒的摩尔含量比为1.02:1时凝胶化时间约16小时,当碱触媒对酸触媒的摩尔含量比为3.0:1时凝胶化时间缩短至约3-5分钟,藉此可以控制硅胶-硅气凝胶-硅烷偶合剂凝胶溶液的微相分离行为及气凝胶微结构,并可控制气凝胶/非织物复合材料的制备加工时间。
5.本发明的制备方法是于水解反应后形成硅胶-硅气凝胶-硅烷偶合剂混合气凝胶溶胶溶液,利用硅胶-硅气凝胶-硅烷偶合剂化学结合过程中硅胶、硅烷偶合剂分子中化学结构官能基的亲、疏水基团比例,以克服由于水分子内缩力所导致的破裂以及收缩现象。因此得以使硅胶-硅气凝胶-硅烷偶合剂气凝胶可于一般常温常压条件下进行干燥,且在该干燥步骤中硅胶-硅气凝胶-硅烷偶合剂分子气凝胶的收缩率将会明显下降。藉此可以改善现有技术中气凝胶体系中在含水分子汽化过程中,因水的表面张力导致气凝胶收缩或龟裂瓦解的现象,以改善纯气凝胶的易脆性质,增加该非织物在隔热或阻热上的机能。
6.在本发明的缩合步骤中,利用一碱触媒与一高含水或低含水或不含水的有机溶液所配置成的一高含水或低含水或不含水碱触媒有机溶液,进行一缩合反应,可分别制备不同含水率的硅胶-硅气凝胶-硅烷偶合剂气凝胶混合溶液。
7.在本发明的成型步骤中,将不同含水率的硅胶-硅气凝胶-硅烷偶合剂气凝胶混合溶液体系浸泡一复合非织物毯,使前述硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液充分与非织物结合,可制备表面不同亲疏水特性的多孔性气凝胶/非织物复合材料。
8.本发明中的非织物是利用聚乙烯(PE)、聚丙烯(PP)、聚乙丙烯(PPE)、聚酯(Polyester)、聚酰胺(Polyamine)、玻璃纤维(glass fiber)以及岩棉的其中之一或其组合所制备而成。使得在硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液凝胶化后,硅胶-硅气凝胶-硅烷偶合剂气凝胶与该非织物结合形成相互穿插的三次元网状结构,达到结合力强,不易脱落的效果。
9.本发明中的未改质的亲水性与疏水性气凝胶/非织物复合材料可在常压常温中进行干燥。随后再将温度升温至105~120摄氏度温度条件下使硅胶-硅气凝胶-硅烷偶合剂气凝胶分子间进行快速脱水。
附图说明
图1为本发明气凝胶/非织物复合材料的制备方法的流程图;
图2为本发明中不同配方所制备的不同柔软性气凝胶/非织物复合材料的照片;
图3为本发明中利用硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液体系中含水量调控所制备复合材料的表面亲疏水性质的照片;
图4为本发明中气凝胶/非织物复合材料表面及断面的扫描电子显微镜(SEM)照片。
[符号说明]
S1 混合步骤
S2 水解步骤
S3 缩合步骤
S30 另一缩合步骤
S4 成型步骤
S40 另一成型步骤
S5 干燥步骤
S50 另一干燥步骤
具体实施方法
下面结合具体实施例及附图来进一步描述本发明,本发明的优点和特点将会随着描述而更为清楚。但这些实施例仅是范例性的,并不对本发明的范围构成任何限制。本领域技术人员应该理解的是,在不偏离本发明的精神和范围下可以对本发明技术方案的细节和形式进行修改或替换,但这些修改和替换均落入本发明的保护范围内。
首先,请参阅图1所示,图1为本发明的气凝胶/非织物复合材料的制备方法流程图。本发明提供一种可分别制备亲水性及疏水性的气凝胶/非织物复合材料的制备方法,包括有下列步骤:
(1)混合步骤(S1):将一烷氧化硅类化合物,在本实施例中以四乙基硅氧烷(Tetraethoxysilane,TEOS)为范例说明,与一硅胶类化合物混合,在本实施例中以聚二甲基硅胶(Poly(dimethenesilicone,PDMS)为范例说明。
随后再添加一微量的硅烷偶合剂类化合物于溶液中继续搅拌反应,在本实施例中以R-烯烃基硅偶合剂为范例说明,使该硅烷偶合剂结合于气凝胶结构上,添加该硅烷偶合剂于硅胶-气凝胶结构中的目的是降低气凝胶的亲水性以增加硅胶-硅气凝胶-硅烷偶合剂结构中的R-官能基与非织物纤维(PP、PET、玻纤或岩棉等)之间的化学结合,并增加硅胶-气凝胶分子在含水有机溶剂中的聚集能力以及增加气凝胶的稳定性及柔软性。
在本发明的另一实施例中,是将硅酸甲酯(TMOS)、硅酸乙酯(TEOS)、R-烯烃基硅酸甲酯(R-TMOS)、R-基硅酸乙酯(R-TEOS)、R-烯烃基硅胶其一或混合物进行混合,其中R-表示為具有反應性官能基基团的烷类或烯烃类分子键結,混合后加入一第一有机溶液在高速搅拌下混合均匀,在本实施例中烷氧化硅类化合物与硅胶类化合物的摩尔比为1:0.005~1:0.02。
请参阅图2所示,图2为本发明中不同配方所制备不同柔软性气凝胶/非织物复合防火隔热材料的照片。其中,由上至下的材料分别对应的配方为:烷氧化硅类化合物:硅胶类化合物的摩尔比为1:0.005、1:0.01、1:0.02或1:0.04。
其中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比(mol:mol:mol)为100:0.5:0.1。该水解溶液中硅胶-硅气凝胶-硅烷偶合剂混合物与含水有机溶液的体积比为5:95。该水解溶液中含水有机溶液中水的摩尔含量(mol%)为50mol%。
(2)水解步骤(S2):将酸触媒或其水溶液滴入于上述混合步骤所得到的混合溶液中进行水解反应,在本实施例中以0.001mol%的H2SO4溶液为范例说明;水解反应后,得到一透明的硅胶-硅气凝胶-硅烷偶合剂三混合气凝胶溶胶溶液的水解溶液。
(3)缩合步骤(S3):将碱触媒以及高含水的第二有机溶液所配置成的一碱触媒高含水有机溶液,在本实施例中以0.0015mol%的NaOH水溶液为范例说明,逐渐加入至上述(S2)水解步骤所得到的水解溶液中,进行缩合反应,以形成高含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液的缩合混合溶液,其中,该碱触媒含水有机溶液中碱触媒(NaOH溶液)与该酸触媒或其水溶液中的酸触媒(H2SO4)的酸碱摩尔比为1.5:1,通过添加碱触媒,可催化硅胶-硅气凝胶-硅烷偶合剂进行缩合反应,并促使硅胶-硅气凝胶-硅烷偶合剂分子形成局部三次元结构。
另一缩合步骤(S30):将碱触媒以及低含水的第二有机溶液所配置成的一碱触媒低含水有机溶液,在本实施例中以0.0015mol%的NaOH有机溶液为范例说明,逐渐加入至上述(S2)水解步骤所得到的水解溶液中,进行缩合反应,以形成低含水的硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液的缩合混合溶液,其中,该缩合溶液中水的摩尔含量约为5.0mol%。其中,该碱触媒有机溶液中碱触媒(NaOH、NaHCO3、Na2CO3、NH4OH混合碱溶液或单一碱溶液)与该酸触媒或其水溶液中的酸触媒的摩尔比为1.02~3:1,其中碱的摩尔比越大,则气凝胶溶胶溶液的凝胶化速率越快。
(4)成型步骤(S4):取前述(S3)缩合步骤所得到的溶胶化的硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液高含水混合溶液浸泡一非织物,在本实施例中以复合非织物毯(70%E-glass玻纤棉混合30%PP纤维)为范例说明,使前述硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液充分浸透该非织物,完全结合反应,使溶胶溶液凝胶化及熟化,在此过程中硅胶-硅气凝胶-硅烷偶合剂气凝胶穿插在该非织物中,得到一表面疏水性的气凝胶/非织物复合材料。
另一成型步骤(S40):取前述(S3)缩合步骤所得到的溶胶化的硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液低含水混合溶液浸泡一非织物,如回收复合非织物毯或一般复合非织物毯,使前述硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液充分浸透该非织物,完全结合反应,使硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液凝胶化,得到一表面亲水性的气凝胶/非织物复合材料,该硅胶-硅气凝胶-硅烷偶合剂气凝胶穿插在该非织物中。
(5)干燥步骤(S5、S50):将上述(S4)成型步骤或(S40)另一成型步骤得到的湿式气凝胶/非织物复合材料进行干燥,或利用30摄氏度至80摄氏度间进行有机溶液快速汽化干燥程序,使前述气凝胶中所含水及有机溶液气化蒸发,随后再将温度升温至105~120摄氏度,使气凝胶/非织物复合材料进行快速脱水干燥,令干燥后的前述气凝胶与该非织物呈现相互穿插的立体网状结构,以形成一多孔性的气凝胶/非织物复合材料,藉此,得到一具柔软及多孔性的一疏水性气凝胶/非织物复合材料(S5);或得到一具柔软及多孔性的一亲水性气凝胶/非织物复合材料(S50)。
在本发明一实施例中,该硅烷偶合剂具有一含烯烃类或含长链烯烃类的硅烷结构,因其反应基团可分为选自氯化硅烷偶合剂、烯基硅烷偶合剂、环氧基硅烷偶合剂、酸基硅烷偶合剂、胺基硅烷偶合剂、羟基硅烷偶合剂或缩酸基硅烷偶合剂等。
在本发明一实施例中,该酸触媒选自硫酸H2SO及盐酸HCl混合。
在本发明一实施例中,该第一有机溶液选自:水、C1-C5醇类、C1-C5酸类、C1-C5酯类或C1-C5醚类其中之一或其组合。
在本发明一实施例中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.05:0.01。
在本发明一实施例中,该硅胶-硅气凝胶-硅烷偶合剂气凝胶的固体含量在整体气凝胶溶胶溶液中的体积百分含量约为8.0%。
如图3(a)及(b)所示,其为气凝胶溶胶溶液中含水有机溶液的含量对气凝胶/复合非织物表面亲疏水性质影响照片。在制备气凝胶溶胶溶液中水的摩尔含量高于10.0mol%以上时,含水有机溶剂之间的亲水基团作用力将会将硅胶-硅气凝胶-硅烷偶合剂气凝胶体系中的疏水基团(如硅胶分子链及硅烷偶合剂疏水基团)排除在整体气凝胶结构***,从而形成一具有表面疏水性质的硅胶-硅气凝胶-硅烷偶合剂气凝胶/非织物复合材料(图3(a))。
在制备气凝胶溶胶溶液中水的含量小于10.0mol%时,可得到表面亲水性质的气凝胶/非织物复合材料(图3(b)),且气凝胶体系中所形成的纳米孔洞将会逐渐连结而形成连续式的介孔或微孔孔洞。
在本发明一较佳实施例中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.05:0.01。
在本发明一较佳实施例中,该水解溶液中硅胶-硅气凝胶-硅烷偶合剂混合物与第一有机溶液的体积比为20:80。
在本发明一较佳实施例中,该水解溶液中水的摩尔含量为50mol%。
在本发明中,该气凝胶的制备方法是以现有技术中溶胶凝胶合成法为基础做改良后所得到的,本发明利用在酸性条件下使硅胶分子、硅气凝胶分子以及硅烷偶合剂相互之间进行化学键的结合,以改善前述现有技术的缺点。图4(a)及(b)分别为本发明的硅胶-硅气凝胶-硅烷偶合剂气凝胶/非织物复合材料表面及断面的扫描电子显微镜(SEM)照片,(c)及(d)为本发明的硅胶-硅气凝胶-硅烷偶合剂气凝胶/非织物复合材料断面放大照片,由照片中可证明本发明的硅胶-硅气凝胶-硅烷偶合剂气凝胶充填于非织物纤维间空隙,并形成多孔性的网状结构,且硅胶-硅气凝胶-硅烷偶合剂气凝胶与非织物纤维之间有极优异的表面结合能力,且非织物与气凝胶相互之间形成相互穿插的3-D立体网状结构,显示利用本发明所制备的硅胶-硅气凝胶-硅烷偶合剂气凝胶可与非织物纤维间形成优异的结合,以增加本产品的使用寿命并提升其他物理性质。
在本发明一较佳实施例中,该碱触媒选自氢氧化铵NaOH及碳酸氢钠NaHCOOH混合。
在本发明一较佳实施例中,该第二有机溶液选自去离子水及C1-C5醇类、C2-C7多醇类其中之一或其组合。
在本发明一更佳实施例中,该第二有机溶液为水和乙醇的混合物,选择醇类、氨类、多醇类、酮类的目的为视非织物基材的亲疏水性质而进行的混合比例变化,主要是醇类、氨类、多醇类、酮类等可相互互溶的溶剂。
在本发明一较佳实施例中,该水解步骤的反应时间为10分钟至60分钟,该反应时间随着该酸触媒的摩尔百分含量的增加而缩短;当该碱触媒对酸触媒的摩尔百分比为1:1时凝胶化反应时间约1100分钟,当该碱触媒对酸触媒的摩尔百分比为3:1时凝胶化反应时间缩短至约3分钟,藉以控制该非织物浸泡加工的时间。该缩合反应时间随着该碱触媒的摩尔百分含量的增加而缩短。
在本发明一较佳实施例中,该气凝胶/非织物复合材料中所含该气凝胶的体积百分含量为20~75V%。当该气凝胶的体积百分含量在35V%以下时,即能作为一般隔热材料使用,藉此节省该气凝胶的用量以控制制造成本,当该气凝胶的体积百分含量在35V%以上时,除具有优良的隔热效果外,更能达到防火的效果,可以作为建筑用防火隔热材料使用。
在本发明一较佳实施例中,该干燥步骤的条件为在室温下进行自然干燥,或在30~80度摄氏,360~120分钟条件下进行快速干燥,藉此克服现有技术中气化含水有机溶剂需较高温度进行,而易导致气凝胶产生龟裂瓦解的现象的缺点,从而提高产品合格率。
在本发明一较佳实施例中,该非织物为一复合非织物毯,其是由聚乙烯(PE)、聚丙烯(PP)、聚乙丙烯(PPE)、聚对苯二甲酸乙二醇酯(PET)或聚酰胺(Nylon)、玻纤、岩棉、碳纤棉其中之一或其组合所制成,不同非织物需要配合不同的气凝胶体系中硅胶-硅气凝胶-硅烷偶合剂的混合比例,使该复合非织物能与该复合气凝胶间产生较强结合效果而不易脱落。如选用聚乙烯(PE)、聚丙烯(PP)、聚乙丙烯(PPE)、聚对苯二甲酸乙二醇酯(PET)或聚酰胺(Nylon)等非织物时,氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的最佳化摩尔比为1.0:0.02:0.01。如选用玻纤、岩棉、碳纤棉等非织物时,氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的最佳化摩尔比为1.0:0.002:0.05。

Claims (10)

1.一种具有亲水性或疏水性的气凝胶/非织物复合材料的制备方法,其特征在于,包括下列步骤:
(1)混合步骤:将一烷氧化硅类化合物,与一硅胶类化合物在一第一有机溶液中进行混合,再添加一硅烷偶合剂类化合物继续搅拌,得到一混合溶液;其中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.0001~0.65:0.0001~1.0;
(2)水解步骤:添加一酸触媒或其水溶液于上述(1)混合步骤所得到的混合溶液中进行水解反应,得到一硅胶-硅气凝胶-硅烷偶合剂混合的水解溶液;其中,该酸触媒选自H2SO4、H3PO4、HNO3、HCl其中之一或其组合;
(3)缩合步骤:将一碱触媒以及高含水或低含水的第二有机溶液所配置成的一碱触媒高含水或低含水的有机溶液加入至(2)水解步骤所得到的水解溶液中,进行缩合反应,以形成溶胶态的一硅胶-硅气凝胶-硅烷偶合剂气凝胶溶胶溶液的缩合溶液;其中,该碱触媒选自NaOH、NaHCO3、Na2CO3、NH4OH其中之一或其组合;
(4)成型步骤:取前述(3)缩合步骤所得到的溶胶态的硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液浸泡一非织物,如回收复合非织物毯或一般非织物毯,使前述硅胶-硅气凝胶-硅烷偶合剂气凝胶的溶胶溶液充分浸透该非织物,随后使其凝胶化,再经一干燥程序,得到一具有亲水性或疏水性的气凝胶/非织物复合材料。
2.如权利要求1所述的制备方法,其特征在于,在该混合步骤中,烷氧化硅类化合物与硅胶类化合物的摩尔比为1.0:0.001~0.65,且该硅胶类化合物具有一双末端双官能基或双末端加侧链的具有一至三个官能基的硅胶结构,该硅胶类化合物的官能基独立选自酸基、胺基、羟基、缩酸基、环氧基、醚基。
3.如权利要求1所述的制备方法,其特征在于,在该水解步骤中,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1.0:0.001~0.65:0.001~1.0,更优选的,该烷氧化硅类化合物:硅胶类化合物:硅烷偶合剂类化合物的摩尔比为1:0.025~0.65:0.001~0.1;该水解溶液中硅胶-硅气凝胶-硅烷偶合剂与含水有机溶液的体积比为5~100:95~200,该硅烷偶合剂具有一含烯烃类或含长链烯烃类的硅烷结构,且该硅烷偶合剂选自氯化硅烷偶合剂、烯基硅烷偶合剂、环氧基硅烷偶合剂、酸基硅烷偶合剂、胺基硅烷偶合剂、羟基硅烷偶合剂或缩酸基硅烷偶合剂等。
4.如权利要求1所述的制备方法,其特征在于,该碱触媒高含水或低含水的有机溶液中碱触媒与该酸触媒或其水溶液中酸触媒的摩尔比为1.02~3:1。
5.如权利要求1所述的制备方法,其特征在于,在该成型步骤中,该硅胶-硅气凝胶-硅烷偶合剂气凝胶穿插在该非织物中,且该成型步骤是通过喷涂、淋喷、浸泡加工或溶液连续压吸加工等方式实现的。
6.如权利要求1所述的制备方法,其特征在于,该水解溶液以及该缩合溶液中水的摩尔百分含量为0~80mol%。
7.如权利要求1所述的制备方法,其特征在于,该水解溶液以及该缩合溶液中水的摩尔百分含量为2.0~80mol%。
8.如权利要求1所述的制备方法,其特征在于,该气凝胶/非织物复合材料中所含该硅胶-硅气凝胶-硅烷偶合剂气凝胶的体积百分含量为5~80%。
9.如权利要求1所述的制备方法,其特征在于,在该成型步骤中,该干燥程序为常温常压下进行的干燥,随后在80摄氏度进行有机溶液快速汽化干燥程序,再随后在105~120摄氏度进行快速脱水程序;该非织物选自聚乙烯、聚丙烯、聚乙丙烯、聚酯、聚酰胺、玻璃纤维、岩棉其中之一或其组合制成。
10.根据权利要求1所述制备方法所制备的气凝胶/非织物复合材料,其特征在于,该气凝胶/非织物复合材料包含有一非织物及一硅胶-硅气凝胶-硅烷偶合剂气凝胶,该气凝胶与该非织物结合形成相互穿插的立体网状结构。
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