JP4435370B2 - Grooved insulation panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat insulating panel that can be used for heat insulation of walls and roofs, and more particularly to a heat insulating panel that can suppress the occurrence of condensation by promoting the diffusion of moisture on the surface of a heat insulating material, and a method for manufacturing the same.
[0002]
[Prior art]
In order to reduce indoor temperature fluctuations and make the living environment more comfortable, and to meet social demands to save energy resources through energy saving, more heat insulation materials are used in buildings than ever before. It is becoming. On the other hand, the airtightness of the house has been improved and the inflow and outflow of air inside and outside the building has decreased, so moisture released indoors accumulates in the room and the temperature inside the wall is below the dew point. Condensation is becoming prominent. By using the heat insulating material, the dew point is concentrated on the surface portion of the heat insulating material, particularly outside the heat insulating material in winter. When condensed water enters the heat insulating material, the heat insulating performance is significantly reduced.
[0003]
In recent years, the outer heat insulation method has been widely adopted as a heat insulation method for houses, but as a further improvement, means for preventing condensation on the surface of the heat insulating material, or for diffusing or drying the generated condensation As a method, a method of providing a breathable groove or space on the surface portion of the foamed resin heat insulating material has been proposed.
[0004]
As one method, as seen in Japanese Utility Model Laid-Open No. 5-54708, a heat insulating panel in which a face material and a foam heat insulating material are laminated and integrated, and a breathable space is provided between the heat insulating material and at least one face material. The board | plate material which has the unevenness | corrugation for forming is interposed. Using this plate material as a foaming mold, a foamable resin is foamed between this plate material and the other face material to create a heat insulating panel with a ventilation path. As another method, as seen in JP-A-4-189542, a plate-like heat insulating material made of a foamed resin is provided with slits at intervals of about 30 mm, and a rotating roll or There is a heat insulating panel with a ventilation groove that is pressed with a convex shape to form a ventilation groove.
[0005]
In the former method, since the structure is complicated, a plate material having not only versatility for use but also a shape retaining property sufficient to withstand the foaming pressure when foaming a plate material having unevenness, that is, foamed resin, is used. Because it has to be used, because it has irregularities, such as kraft paper, which is usually used as a face material, aluminum material such as aluminum foil, aluminum sheet or laminate material laminated with these and synthetic resin such as polyethylene However, a face material that cannot retain the unevenness due to the foaming pressure of the foamed resin, that is, a face material that does not have self-retaining property, could not be used.
In the latter method, the above-mentioned general-purpose face material can be used. However, the slit width, that is, the maximum groove width is only about 100 mm, and a wide groove width such as a 200 mm width groove cannot be formed. . Moreover, since the groove | channel side wall part in a grooved shaped part becomes a foaming resin (urethane foam) exposed surface, the problem of the water absorption from the said part also arises in the heat insulation panel obtained by it.
[0006]
[Problems to be solved by the invention]
The purpose of the present invention is extremely easy to process such as cutting, and can be applied to a part that requires heat insulation, and can prevent moisture from staying on the surface of the heat insulating material after construction. It is providing the heat insulation panel which can prevent generation | occurrence | production effectively, and its manufacturing method.
[0007]
[Means for Solving the Problems]
The present invention provides a grooved heat insulating panel in which a groove extending in the length direction is provided on the surface of a foamed resin heat insulating material having a face material, and the groove has a thickness of the face material on both side portions corresponding to a groove bottom boundary portion. It is formed by making a notch more than this length and compressing and compressing the bottom surface of the groove so that the face material of the groove bottom is positioned lower than the face material on both sides and forming a step between the both face materials. Further, the present invention relates to a grooved heat insulating panel in which a foamed resin exposed portion generated by the step is coated with a hot melt resin.
[0008]
The feature of the grooved heat insulation panel of the present invention is that at least the exposed portion of the foamed resin is coated with resin among the side wall portions of the groove, thereby preventing intrusion of water from the groove processed portion. In addition, it is possible to maintain the shape of the groove formed by pressure compression, that is, the recess. When water enters the foam resin, which is a heat-insulating material, the heat insulation performance deteriorates.Therefore, a water-resistant panel is usually bonded to the surface of the insulation panel to prevent water from entering the foam resin. When partial compression is applied to the surface, the face material of that part is torn and water intrusion is allowed. In addition, after the foamed resin is compressed, the compression is restored with time, and the depth of the groove is reduced or the shape is changed. In the present invention, since the groove side wall portion after compression is shaped by resin coating, it is possible to minimize the shape recovery of the compressed foamed resin.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
The resin used for covering the groove sidewall of the grooved heat insulation panel of the present invention may be of any type as long as it has a water intrusion blocking property, and these resins may be solutions, emulsions, suspensions or melts. It can be applied to the groove sidewall by using it in any state. From the viewpoint of workability and productivity, it is advantageous to use a resin in a molten state because it can be applied with a sufficient thickness, and therefore a hot melt resin is optimal. The hot melt resin used in the present invention is not particularly limited, and examples thereof include general-purpose hot melt resins such as urethane, ethylene, natural rubber, and synthetic rubber. Particularly preferred are paper used as a face material, polyethylene resin or aluminum, urethane resin usually used as foamed resin, and synthetic rubber-based hot melt resin excellent in adhesion to both.
The first purpose of the resin coating for covering the groove sidewall is to prevent water from entering the heat insulating panel, and the thickness of the coating may be selected so as to prevent water from entering.
The second object of the resin coating is to shape a groove that can minimize the shape recovery of the compressed foamed resin by the rigidity of the resin for covering the groove sidewall.
[0010]
The groove shape of the grooved heat insulating panel of the present invention may have an inclination such that the side surface and the bottom surface of the groove form an obtuse angle α as shown in FIG. Also good. When it has an inclination, the magnitude of the inclination is 100 to 170 °, preferably 110 to 150 °, expressed by the obtuse angle α.
As a preferable groove shape, as shown in FIG. 2, the side wall portion includes a foamed resin exposed portion 4 and an inclined portion 5 having a face material provided with a gradient between the exposed portion and the panel surface. Shape. If it is this shape, it becomes possible to leave a face material in the said inclination part 5, and since the exposed surface of foaming resin decreases, the application quantity of the hot-melt resin which should coat | cover the part can be reduced. If the hot melt resin is applied to the inclined portion when applied, it flows down toward the bottom of the groove, so that it can be applied to the foamed resin portion more easily and reliably than the vertical shape. The gradient of the inclined portion (β in FIG. 2) is 10 to 80 °, preferably 20 to 60 °.
[0011]
Formation of the groove and the gradient portion by compression can be performed using a roll or a press.
Prior to forming the groove by pressure compression, it is preferable to cut at least the thickness of the face material at the corresponding portion of both side surface portions of the groove or the boundary portion between the inclined portion of the groove side wall and the groove bottom portion. . By doing so, the groove is formed in a clear shape, and the face material is not irregularly broken at an unintended portion.
[0012]
The coating of the side wall of the groove with the above-mentioned resin, particularly the hot melt resin, means that at least the exposed portion of the foam insulation is covered, in order to block water from entering the foam insulation. In terms of shape, it is necessary to cover the face material at the bottom of the groove and the slope face material at the groove side wall or the face material at the panel surface.
[0013]
Next, the structure of the grooved heat insulation panel of the present invention will be described with reference to the drawings.
FIG. 1 is an example of a grooved heat insulation panel of the present invention having a face material and a groove having an inclination. FIG. 2 shows an example in which the groove sidewall has an inclined portion having a face material provided with a gradient between the foamed resin exposed portion and the panel surface.
In the figure, 1 is a foamed resin heat insulating material, 2 and 2 'are face materials, 3 is a groove, 4 is a foamed resin exposed portion on the groove side wall, 4' is a foamed resin exposed portion having an inclination, and 5 is a face material on the groove side wall. An inclined portion 6 has a resin that covers the exposed portion of the foamed resin on the side wall of the groove.
[0014]
For the foamed resin heat insulating material 1 of the present invention, a hard synthetic resin foam is used. Specific examples of the synthetic resin foam include rigid polyurethane foam, rigid isocyanurate foam, extruded or bead-molded polystyrene foam, rigid polyethylene foam, and phenol foam. Particularly preferred is rigid polyurethane foam.
[0015]
The face materials 2 and 2 'laminated on the surface of the foamed resin heat insulating material are paper such as kraft paper, paper treated with water proof or water repellent, plastic films such as polyethylene and polypropylene, aluminum foil, or paper Laminates such as laminates with plastic films, laminates between plastic films, and laminates of aluminum and plastic films. The same face material may be laminated on both sides of the heat insulating material, or different materials may be used. Preferred face materials are those using paper or paper / polyethylene film laminate on one side and aluminum foil or aluminum foil / polyethylene film laminate on the other side. In addition, about the surface which does not shape a groove | channel, a plywood, a gypsum board, etc. may be used as a face material. Further, a small hole may be provided in the face material to give air permeability as desired. In the case of providing a small hole, for example, it may be provided on the outdoor side surface of the heat insulating panel for a cold region and on the indoor side surface for a hot and humid region.
[0016]
A heat insulating panel in which a foamed resin heat insulating material and a face material are laminated is provided with a plurality of grooves 3 extending on the entire length in the longitudinal direction of the panel on at least one surface thereof in a state where the face material is in close contact. When the groove is provided only on one surface, the surface on which the groove is provided is determined depending on the construction method and purpose, but generally the surface is provided on the outer wall side.
[0017]
The groove 3 has a depth of 3 to 15 mm, preferably 5 to 10 mm, and a width of 150 to 500 mm, preferably 200 to 300 mm. In the case of a groove deeper than 15 mm, it is difficult to maintain the groove shape. Grooves shallower than 3 mm are insufficient for the diffusion of wet air. Further, when the groove width is smaller than 150 mm, the diffusion of wet air becomes insufficient unless a large number of grooves are provided, and the large number of groove formations increases the amount of the coated hot melt resin used. When it is larger than 500 mm, it is difficult to maintain the groove shape.
The length of the panel is not particularly limited, but is generally used at a constant length of 1820 mm or the like. However, the length corresponding to the floor height can be freely designed as required.
[0018]
In one aspect of the present invention, the grooves are provided symmetrically in the width direction so that the grooved heat insulation panel can be divided into two equal parts of ½ width. In this case, when dividing into two equal parts, a groove is formed so that the groove does not come to the center part of the original panel which becomes a new end.
[0019]
As a method of pressure compression, a heat insulation panel with or without a face plate that has been manufactured continuously is pressed with a roll on a line to continuously form a groove, and then this is cut into a predetermined length. Alternatively, the insulating panel cut to a predetermined length may be pressed and compressed in a press machine to be grooved.
In addition, the pressure compression processing may be performed separately from the production line for the non-grooved heat insulation panel, or may be incorporated online into the continuous production line for the heat insulation panel.
[0020]
The grooved insulation panel 12 of the present invention is advantageously used for wall or roof insulation. However, the use is not limited to walls or roofs, and can be used freely for floors and the like.
[0021]
The grooved heat insulation panel of the present invention is generally attached to the outside of the pillar as shown in FIG. 3, but can also be used for an attachment method in which it is inserted into the space of the pillar or the stud. The exterior material is attached to the outside of the heat insulation panel, but in the case of the conventional heat insulation panel, the water vapor that has permeated from the room does not escape and accumulates on the surface of the heat insulation material, and condensation from the outside is caused by cold air from the outside. It had to occur. For this reason, as shown in FIG. 3, the ventilation trunk edge 9 is attached to the outside of the heat insulating material, and the exterior material is attached thereon, thereby securing a moisture escape path between the surface of the heat insulating material and the exterior material.
When the grooved heat insulation panel of the present invention is used, in any of the above construction methods, the high humidity air is diffused by the groove extending in the length direction provided in the heat insulation panel. Can be used, or at least a ventilator edge that is thinner and therefore less expensive than before can be used to ensure a sufficient escape path.
[0022]
Furthermore, since the heat insulating panel of the present invention does not have a hard exterior material or a reinforcing material, cutting and other processing can be performed without any problem, and processing and correction can be freely and easily performed according to the dimensions of the construction site. Moreover, it has sufficient handling strength and retains light weight.
[0023]
An exterior material 15 such as a ceramic siding material, a metal plate, an ALC plate, and an extrusion-molded cement plate is generally provided on the outside of the grooved heat insulating panel of the present invention directly or as needed through a thin rim body edge 9. Can be attached. Further, in order to reinforce the wall surface and protect the heat insulation panel, a hard board such as plywood, particle board, molded cement board, fiber board or the like can be attached as the exterior base material 16 just outside the grooved heat insulation panel of the present invention. . In this case, the above-described exterior material may be further attached thereto, mortar may be applied, or tile construction may be performed.
[0024]
As usual, an interior base material 7 such as gypsum board or plywood or an interior finishing material 7 such as decorative gypsum board or plywood can be attached to the inner wall side. These plate materials may be directly attached on the heat insulating material, or may be attached by providing an air layer between the heat insulating material.
[0025]
【Example】
Hereinafter, the grooved heat insulating panel of the present invention will be described with reference to examples.
Example 1: Insulated panel with groove in which groove side wall is inclined FIG. 1 is a sectional view of the insulated panel with groove of the present invention. The heat insulation panel has a width of 910 mm, a length of 3030 mm, a thickness of 40 mm, and two grooves of 240 mm width (a) per width. The foamed resin heat insulating material 1 has a rigid polyurethane foam with a density of 35 kg / m ³ , the face material 2 has an aluminum foil / polyethylene film laminated face material, the face material 2 ′ has a kraft paper / polyethylene film laminated face material, and the groove 3. A synthetic rubber-based hot melt resin was used as the resin for covering the inclined side wall portion 4 ′. The sloped wall has a slight gradient.
Production of polyurethane foam, processing of the grooves and coating of the resin on the side walls of the grooves were performed as follows.
[0026]
A rigid polyurethane foam was continuously foam-molded by a conventional method, and a polyurethane foam sandwich panel was produced by laminating kraft paper / polyethylene film laminate on one side and aluminum foil / polyethylene film laminate on the other side. That is, the polyurethane foam raw material prepared for foaming from the mixing head is laid down on the face material (craft paper / polyethylene film laminate) that flows continuously on the conveyor belt, and foamed on this face material while being foamed on this face material. The other face material fed from the roll was covered. Foaming was completed while adjusting the thickness of the foam to 40 mm with multistage rolls from the outside of both face materials.
[0027]
Subsequently, foam is applied from the face material to the upper surface, that is, the paper material side, by four blades (slitters) fixedly installed at a position corresponding to the boundary line between the portion to be compressed and not compressed. A cut with a depth of 10 mm is continuously made. This polyurethane foam sandwich panel was passed through between a pressing roll and a flat roll formed with two protrusions with a height of 10 mm and a width of 240 mm provided at the tip of the polyurethane foam sandwich panel, and an aluminum foil / polyethylene film. Grooves having continuous sidewalls were formed on the laminate face material side.
Subsequently, while further feeding the panel, the hot melt resin “Evergrip” (made by Aron Evergrip Limited: softening point 116.5 ° C.) melted by the resin coating device (hotmelt applicator) provided downstream thereof is thermally insulated. It apply | coated to the panel side wall part with the application quantity of 200 g / sheet. The hot melt resin was quickly solidified by blowing cold air with a cooling device, thereby completing the groove shaping.
In addition, small holes having a diameter of 1 mm at a pitch of 25 mm were provided on the other side of the craft paper / polyethylene film surface. Next, both side surfaces were trimmed so as to have a constant width of 910 mm, and further cut to a length of 3030 mm to obtain a grooved heat insulating panel of the present invention.
[0028]
Example 2: Insulated panel with grooves having inclined portions in which groove side walls have face members FIG. 2 is a cross-sectional view of a heat insulating panel with grooves having inclined portions in which groove side walls have face members. About the heat insulation panel, the same thing as Example 1 was used.
Production of the polyurethane foam having the face material was carried out in the same manner as in Example 1, and the processing of the grooves and the formation of the inclined portions were carried out as follows.
[0029]
In the same manner as in Example 1, the slit was cut by a slitter. In addition, the cut | interruption was provided in the boundary part of a groove bottom face part and a groove | channel side wall part. This polyurethane foam sandwich panel was passed through between a pressing roll and a flat roll formed with two protrusions with a height of 10 mm and a width of 240 mm provided at the tip of the polyurethane foam sandwich panel, and an aluminum foil / polyethylene film. Pressed continuously to the laminate face material side.
[0030]
Subsequently, an inclined portion of the groove side wall portion is formed using a pressing roller installed at an angle of 20 ° (β) with respect to the horizontal plane at a position corresponding to the upper portion of the wall surface of each pressing portion downstream thereof. Formed.
Subsequently, the hot melt resin “Ever grip” (manufactured by Aron Ever Grip Limited, Inc .: softening point 116) melted by the same resin coating apparatus (hot melt applicator) as that of Example 1 provided downstream while feeding the panel further. 0.5 ° C.) was applied to the side wall of the heat insulating panel at an application amount of 100 g / sheet. The hot melt resin was quickly solidified by blowing air with a cooling device, thereby completing the groove shaping.
[0031]
FIG. 3 shows an example of the mounting state of the grooved heat insulation panel of the present invention. This panel is fixed to the outside of the columns and the studs, and further, a thin ventilator edge is fixed to the outside. An exterior material is attached to the outside of the ventilator edge.
[0032]
【The invention's effect】
The grooved heat insulation panel of the present invention manufactured by the method of the present invention is used for air circulation in which wet air is diffused between the heat insulation material and the exterior material or the exterior base material just by performing the construction in the same manner as before. A passage can be provided, and condensation on the surface of the heat insulating material can be effectively prevented. Moreover, it retains the original light weight and workability of the foamed resin heat insulating material, and is easy to handle including construction. In particular, since the groove side surfaces are covered with resin, this grooved heat insulation panel does not intrude moisture such as condensed water, so excellent heat insulation performance is maintained for a long time, and the groove shape is also maintained for a long time. .
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of one embodiment of a grooved heat insulation panel of the present invention.
FIG. 2 is a sectional view of another embodiment of the grooved heat insulation panel of the present invention.
FIG. 3 is a cross-sectional view showing the relationship between a grooved heat insulation panel and an exterior material in a construction example in which an exterior material is attached to the grooved heat insulation panel of the present invention via a ventilator edge.
[Explanation of symbols]
1: Foamed resin insulation,
2, 2 ': Face material,
3: Groove
4: Exposed portion of foam resin on the side wall of the groove,
4 ′: Foamed resin exposed portion having an inclination,
5: Inclined portion having a face material on the groove side wall portion 6: Resin for covering the exposed portion of the foamed resin on the groove side wall portion,
7: Interior base material or interior finish material,
8: Pillar,
9: Vent trunk edge,
11: Air diffusion passage,
12: Insulated panel with grooves,
15: Exterior material.

Claims (4)

In a heat insulating panel with a groove in which a groove extending in the length direction is provided on the surface of a foamed resin heat insulating material having a face material , the groove cuts more than the thickness of the face material on both side portions corresponding to the groove bottom boundary portion , And compressing and compressing the groove bottom surface portion, the surface material of the groove bottom portion is positioned lower than the surface material on both sides thereof, and a step is formed between both surface materials. A heat-insulating panel with a groove, in which the exposed portion of the foamed resin is covered with a hot melt resin.   The grooved heat insulating panel according to claim 1, wherein the groove side wall portion includes a foamed resin exposed portion and an inclined portion having a face material provided with a gradient between the exposed portion and the panel surface.   The grooved heat insulation panel according to claim 1 or 2, wherein the groove has a depth of 3 to 15 mm and a groove width of 150 to 500 mm. The grooved heat insulating panel according to any one of claims 1 to 3 , wherein the face material is paper, aluminum, or a laminate of these and polyethylene resin.

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