SILICA-BASED THERMAL INSULATION MOULDED BODY
The present invention relates to a process for producing silica-based thermal insulation moulded body comprising at least 50% by weight of synthetic amorphous silica and not more than 50% by weight of natural silica with a specified particle size, thermal insulation moulded body obtainable by this process and the use thereof for thermal and/or acoustic insulation.
1 - 14 . (canceled)
15 . A process for producing a hydrophobized silica-based thermal insulation moulded body comprising at least 50% by weight of synthetic amorphous silica and not more than 50% by weight of natural silica, comprising the following steps:
a) preparing a mixture comprising synthetic amorphous silica having a number average particle size d 50 (SAS) of not more than 100 µm and natural silica having a number average particle size d 50 (NAS) of more than 300 µm;
b) compressing or compacting the mixture comprising the synthetic amorphous silica and the natural silica to obtain a moulded body with a density of at least 80 g/L;
c) performing a hydrophobic treatment with a hydrophobization agent of the mixture obtained in step a) of the process or of the moulded body obtained in step b) of the process.
16 . The process of claim 15 , wherein the synthetic amorphous silica is selected from the group consisting of: fumed silica; precipitated silica; silica aerogel; silica xerogel; and mixtures thereof.
17 . The process of claim 15 , wherein the natural silica is selected from the group consisting of: perlite; expanded perlite; vermiculite; expanded vermiculite; pumice; diatomaceous earth; expanded clay; shale; and expanded shale.
18 . The process of claim 15 , wherein the natural silica has a pore volume for pores smaller than 4 µm, determined by mercury intrusion method DIN ISO 15901-1, of more than 1.0 cm 3 /g.
19 . The process of claim 15 , wherein the silica-based thermal insulation moulded body comprises an IR-opacifier selected from the group consisting of: silicon carbide; titanium dioxide; zirconium dioxide; ilmenites; iron titanates; iron oxides; zirconium silicates; manganese oxides; graphites; carbon blacks; and mixtures thereof.
20 . The process of claim 15 , wherein the natural silica has a span of particle size distribution (d 90 -d 10 )/d 50 of at least 1.2.
21 . The process of claim 15 , wherein the hydrophobization agent is selected from the group consisting of: organosilanes; silazanes; acyclic polysiloxanes; cyclic polysiloxanes; and mixtures thereof.
22 . The process of claim 15 , further comprising thermal treatment at a temperature of 300° C.-1400° C. before step c) of the process.
23 . The process of claim 15 , wherein the thermal insulation moulded body contains 50% - 91.5% by weight of synthetic amorphous silica, 5% - 50% by weight of natural silica, 3% - 30% by weight of an IR-opacifier, and 0.5% - 20% by weight of carbon.
24 . The process of claim 15 , wherein the pore volume for pores smaller than 4 µm of the moulded body, determined by mercury intrusion method according to DIN ISO 15901-1, is more than 1.5 cm 3 /g.
25 . The process of claim 15 , wherein the thermal insulation moulded body is in the form of granules with a numerical average particle size d 50 of from 10 µm to 5000 µm.
26 . The process of claim 15 , wherein the thermal insulation moulded body is a thermal insulation sheet with a thickness from 5 mm to 150 mm.
27 . The process of claim 16 , wherein the natural silica is selected from the group consisting of: perlite; expanded perlite; vermiculite; expanded vermiculite; pumice; diatomaceous earth; expanded clay; shale; and expanded shale.
28 . The process of claim 27 , wherein the natural silica has a pore volume for pores smaller than 4 µm, determined by mercury intrusion method DIN ISO 15901-1, of more than 1.0 cm 3 /g.
29 . The process of claim 28 , wherein the natural silica has a span of particle size distribution (d 90 -d 10 )/d 50 of at least 1.2.
30 . The process of claim 29 , wherein the hydrophobization agent is selected from the group consisting of: organosilanes; silazanes; acyclic polysiloxanes; cyclic polysiloxanes; and mixtures thereof.
31 . The process of claim 27 , wherein the silica-based thermal insulation moulded body comprises an IR-opacifier selected from the group consisting of: silicon carbide; titanium dioxide; zirconium dioxide; ilmenites; iron titanates; iron oxides; zirconium silicates; manganese oxides; graphites; carbon blacks; and mixtures thereof.
32 . The process of claim 31 , wherein the thermal insulation moulded body contains 50% - 91.5% by weight of synthetic amorphous silica, 5% - 50% by weight of natural silica, 3% - 30% by weight of an IR-opacifier, and 0.5% - 20% by weight of carbon.
33 . The process of claim 32 , wherein the thermal insulation moulded body is a thermal insulation sheet with a thickness from 5 mm to 150 mm.
34 . A thermal insulation moulded body made by process of claim 15 .