WO2021240762A1

WO2021240762A1 - Production method of thermal insulation panel

Info

Publication number: WO2021240762A1
Application number: PCT/JP2020/021275
Authority: WO
Inventors: 正矢野; 英行谷
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2020-05-29
Filing date: 2020-05-29
Publication date: 2021-12-02

Abstract

This production method of thermal insulation panel produces thermal insulation panels 1, 1 by cutting a panel body 10 in half in the thickness direction, the panel body being formed in such a manner that: a first board 11 and a second board 12 are arranged so as to be spaced apart from each other in the panel thickness direction, the boards respectively having opposing surfaces 11a, 12a along which vacuum thermal insulation materials 16, 16 are fixed; and then a foam resin composition 14 is supplied between the first board and the second board to form a foam resin layer 15 therebetween.

Description

Insulation panel manufacturing method

The present invention relates to a method for manufacturing a heat insulating panel.

Conventionally, as a heat insulating panel, a heat insulating panel containing a vacuum heat insulating material has been known.
For example, in Patent Document 1 below, a vacuum heat insulating material is embedded in a heat insulating material made of hard urethane foam or the like to form a core material, and an outer plate and an inner plate made of aluminum are bonded to both sides of the core material. A heat insulating panel formed by pasting the material as a panel material is disclosed.

Japanese Unexamined Patent Publication No. 10-114245

However, in the method for manufacturing a heat insulating panel described in Patent Document 1, when the vacuum heat insulating material is embedded in the heat insulating material made of rigid urethane foam or the like to form the core material, until the foamed resin composition is cured. It is necessary to cure each panel, and further improvement is desired.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a heat insulating panel capable of efficiently manufacturing a heat insulating panel containing a vacuum heat insulating material.

In order to achieve the above object, in the method for manufacturing a heat insulating panel according to the present invention, the first board and the second board to which the vacuum heat insulating material is fixed are spaced apart from each other along the facing surfaces in the panel thickness direction. A heat insulating panel is manufactured by supplying a foamed resin composition between the first board and the second board in a state of being vacant and dividing the panel body on which the foamed resin layer is formed into two in the thickness direction. It is characterized by.

The method for manufacturing the heat insulating panel according to the present invention has the above-mentioned configuration, so that the heat insulating panel containing the vacuum heat insulating material can be efficiently manufactured.

(A) and (b) schematically show an example of a method for manufacturing a heat insulating panel according to an embodiment of the present invention, (a) is a schematic side view, and (b) is an X-ray in (a). It is a schematic plan view corresponding to the X-ray arrow view. (A) and (b) are schematic side views schematically showing an example of the manufacturing method of the heat insulating panel. (A) and (b) schematically show an example of a heat insulating panel manufactured by using the same method for manufacturing a heat insulating panel, (a) is a schematic plan view, and (b) is Y in (a). -It is a schematic vertical sectional view corresponding to the Y line arrow view.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
In some figures, some of the detailed reference numerals attached to other figures are omitted.
1 to 3 are diagrams schematically showing an example of a method for manufacturing a heat insulating panel according to the present embodiment and an example of a heat insulating panel manufactured by using the same.

In the method for manufacturing a heat insulating panel according to the present embodiment, as shown in FIG. 1A, the first board 11 and the second board 12 are arranged at intervals in the panel thickness direction. A step of supplying the foamed resin composition 14 between the board 11 and the second board 12 is provided. Further, the manufacturing method includes a step of fixing the vacuum

heat insulating materials

16 and 16 along the

back surfaces

11a and 12a which are facing surfaces of the first board 11 and the second board 12, respectively. Further, in the same manufacturing method, as shown in FIGS. 2A and 2B, the foamed resin composition 14 is supplied between the first board 11 and the second board 12 to form the foamed resin layer 15. The panel body 10 is divided into two in the thickness direction to manufacture the

heat insulating panels

1 and 1.

With the above configuration, the

heat insulating panels

1 and 1 containing the vacuum

heat insulating materials

16 and 16 can be manufactured by foaming and curing the foamed resin composition 14 and then dividing the foam resin composition 14 into two parts. As a result, the curing time can be shortened as compared with the case where the foamed resin composition 14 needs to be cured until it is cured for each panel, and the

heat insulating panels

1 and 1 can be efficiently manufactured. can do.
In the present embodiment, as shown in FIG. 3A, the manufacturing method is configured to manufacture a substantially square plate-shaped heat insulating panel 1 that is long in one direction.

The heat insulating panel 1 may be fixed to a mounting base such as a ceiling base, a roof base, a floor base, an inner wall base, an outer wall base, etc. of a building such as a residence. Further, the heat insulating panel 1 may be constructed so as to form an interior finish surface or an interior base surface of a building. Further, the construction target of the heat insulating panel 1 may be an existing ceiling surface, a wall surface, or the like, or may be used for a relocated building such as a unit house. Further, the heat insulating panel 1 is not limited to the one used for such a building, and may be used for other structures such as a cold storage and a heat storage. The thickness dimension, the length dimension, and the width dimension of the heat insulating panel 1 may be appropriately set according to the object in which the heat insulating panel 1 is used, the required heat insulating property, and the like.

The first board 11 and the second board 12 may be an inorganic board such as gypsum board or a wood board such as plywood, but in the present embodiment, it is a hard foamed resin board. With such a configuration, the weight of the heat insulating panel 1 can be reduced, and the heat insulating property can be improved. Further, the foamed resin composition 14 enters into a large number of bubble cells opened on the

back surfaces

11a and 12a of the first board 11 and the second board 12, and delamination is less likely to occur. In the present embodiment, the first board 11 and the second board 12 are formed of a resin composition having the same resin main component as the foamed resin composition 14 constituting the foamed resin layer 15. With such a configuration, the affinity between the first board 11 and the second board 12 and the foamed resin layer 15 is good, that is, the compatibility in each layer can be improved, and the adhesiveness can be improved. .. As a result, delamination is less likely to occur, and the heat insulating panel 1 having relatively high strength can be efficiently manufactured.

The resin composition constituting the first board 11 and the second board 12 and the foamed resin composition 14 constituting the foamed resin layer 15 may be a polyurethane resin composition, and may be flame-retardant depending on the use of the heat insulating panel 1. It may be a sex polyurethane resin composition. That is, the first board 11 and the second board 12 may be rigid polyurethane foam boards.
Such a polyurethane resin composition may be mainly composed of a polyisocyanate compound having two or more NCO (isocyanate) groups and a polyol compound having two or more OH (hydroxyl) groups. As the resin main component of the polyurethane resin composition constituting the first board 11, the second board 12, and the foamed resin layer 15, the same type of polyol may be adopted. Examples of the polyol used as the main component of these resins include polyether polyols, polymer polyols, and polyester polyols. Further, the polyol used as the main component of the resin may be a combination of at least two of a polyether polyol, a polymer polyol and a polyester polyol. Further, the polyol used as the main component of the resin may have a functional group number of 3 to 8 and a molecular weight in the range of 500 to 1000. Further, the polyisocyanate adopted as the main component of the resin may be diphenylmethane diisocyanate (MDI). Further, the polyurethane resin composition may contain, in addition to these polyisocyanate compounds and polyol compounds, a catalyst (amine compound, etc.), a foaming agent (water, fluorocarbon, etc.), a foam stabilizer (silicone oil, etc.), and the like. Further, the polyurethane resin composition may further contain various additives such as a flame retardant, a filler, and an inorganic filler. Further, this polyurethane resin composition may have a foaming ratio of about 10 to 30 times.

Further, the first board 11, the second board 12, and the foamed resin layer 15 may be formed of the foamed resin composition 14 having the same structure. With such a configuration, the homogeneity of each layer of the heat insulating panel 1 can be improved. The resin constituting the first board 11, the second board 12, and the foamed resin layer 15 is not limited to the polyurethane resin, and may be a polystyrene resin, a polyethylene resin, a polypropylene resin, a phenol resin, an epoxy resin, or the like.
Further, the first board 11 and the second board 12 have the same thickness dimension, length dimension, and width dimension. Further, the first board 11 and the second board 12 may have the same configuration. With such a configuration, the heat insulating panel 1 (panel body 10) can be manufactured without distinguishing between the first board 11 and the second board 12.

The length dimension and the width dimension of the first board 11 and the second board 12 are the same as the length dimension and the width dimension of the heat insulating panel 1.
Further, the thickness dimension of the first board 11 and the second board 12 is set to be less than 1/2 of the thickness dimension of the heat insulating panel 1 as shown in FIG. 2 (b). The thickness dimensions of the first board 11 and the second board 12 may be appropriately set so that the vacuum heat insulating material 16 included in the heat insulating panel 1 is located substantially at the center in the thickness direction of the heat insulating panel 1. In the illustrated example, the vacuum heat insulating material 16 is provided so as to be offset toward the first board 11 (second board 12) in the thickness direction of the heat insulating panel 1, but the present invention is not limited to this aspect. Further, the surfaces of the first board 11 and the second board 12 may be appropriately coated or painted with a sheet material.

The vacuum heat insulating material 16 has a substantially rectangular plate shape that is long in one direction. The thickness dimension of the vacuum heat insulating material 16 may be an appropriate dimension according to the thickness dimension of the heat insulating panel 1 and from the viewpoint of desired heat insulating performance, cost and the like. In the illustrated example, the thickness dimension of the vacuum heat insulating material 16 is substantially the same as the thickness dimension of the first board 11 and the second board 12, but the dimension is not limited to such a dimension. Further, the dimensions along the panel longitudinal direction and the dimensions along the panel width direction of the vacuum heat insulating material 16 may be appropriate dimensions from the viewpoint of desired heat insulating performance, cost and the like. The vacuum heat insulating material 16 may be provided so that the area occupied by the vacuum heat insulating material 16 is ½ or more when the heat insulating panel 1 is viewed in the panel thickness direction. Further, in the figure, an example in which one vacuum heat insulating material 16 is included in the heat insulating panel 1 is shown, but a configuration in which a plurality of vacuum heat insulating materials 16 are included may be used. For example, a plurality of vacuum heat insulating materials 16 may be provided on both or one of the longitudinal direction and the width direction of the heat insulating panel 1.

As shown in FIG. 3B, the vacuum heat insulating material 16 has a first one surface in the thickness direction of the sealing portions 19 on the peripheral edges of the

packaging materials

18 and 18 provided on both sides of the core material 17 in the thickness direction. It is configured to be bent so as to be along the board side surface 16a facing the board 11 (second board 12) side. In this vacuum heat insulating material 16, the core material 17 is covered with gas

barrier packaging materials

18 and 18 and vacuum sucked, and the peripheral edge portion of the

packaging materials

18 and 18 to be the sealing portion 19 is sealed by heat welding or the like, and the four sides are sealed. The seal portion 19 may be formed by bending along the side surface 16a of the board. The core material 17 may be made of a foam such as open cell urethane foam, styrene foam, or phenol foam using a material having a relatively low thermal conductivity. Alternatively, the core material 17 may be a crushed material of various foam materials, a powder or granular material such as silica, alumina, or pearlite, or a fiber body such as glass fiber, glass wool, rock wool, or cellulose fiber. good. Further, the various foams, powders and fibers described above may be mixed and used as the core material 17. The packaging material 18 may be a metal film such as aluminum having a gas barrier property. Alternatively, a protective layer such as a resin film is provided on the outer layer side, a gas barrier layer such as a metal film or a metal vapor deposition layer is provided in the middle, and a heat weldable layer such as a resin film having heat welding property is provided on the inner layer side (core material 17 side). The laminated film (sheet) may be used as the packaging material 18.

The vacuum heat insulating material 16 may be fixed to the

back surfaces

11a and 12a of the first board 11 and the second board 12 with an adhesive, an adhesive material, or the like. The vacuum heat insulating material 16 on the first board 11 side and the vacuum heat insulating material 16 on the second board 12 side have the same configuration as each other. In the present embodiment, the seal portion 19 is brought into contact with the

back surfaces

11a and 12a of the first board 11 and the second board 12, respectively, to fix the vacuum heat insulating material 16. With such a configuration, the contact of the foamed resin composition 14 (see FIG. 1 (a)) with the seal portion 19 of the vacuum heat insulating material 16 can be suppressed, and the seal portion 19 due to the temperature rise during foaming can be suppressed. Deterioration can be suppressed. As a result, it is possible to prevent the heat insulating performance from being lowered due to the deterioration of the sealing property of the sealing portion 19 of the vacuum heat insulating material 16.
The vacuum heat insulating material 16 is not limited to the one having the above-mentioned structure, and may have various other structures.

In the present embodiment, in the same manufacturing method, a spacer 13 is interposed between the first board 11 and the second board 12, and the first board 11 and the second board 12 are arranged at intervals in the panel thickness direction. I try to do it. Further, as shown in FIGS. 1A and 1B, the spacer 13 is interposed so as to be located at the four corners of the vacuum

heat insulating materials

16 and 16. With such a configuration, the spacers 13 provided at the four corners of the vacuum

heat insulating materials

16 and 16 can make the thickness dimension of the panel body 10 uniform, and the heat insulating material is divided into two in the thickness direction. It is also possible to make the thickness dimensions of the

panels

1 and 1 uniform. Further, as shown in FIG. 3A, the columnar body 13A in which the spacers 13 provided so as to be located at the four corners on the divided side surface which is one surface in the thickness direction of the divided

heat insulating panels

1 and 1 is divided. The divided side surface 13a of the above will be exposed. This makes it possible to grasp the position where the vacuum heat insulating material 16 is provided in the embedded shape. Further, for example, it is possible to suppress damage (vacuum breakage) of the vacuum heat insulating material 16 when the heat insulating panel 1 is attached to the attachment target by a fixing tool such as a screw or a nail. That is, the fixing tool can be fastened to a position where the vacuum heat insulating material 16 of the heat insulating panel 1 is not provided in an embedded shape.

The spacer 13 is embedded in the foamed resin layer 15 with the axial direction along the panel thickness direction. The spacer 13 may be cylindrical, but in the present embodiment, it is columnar (square columnar in the figure). Further, the spacer 13 may be formed of a wood-based material or the like, but in the present embodiment, the spacer 13 is formed of a resin composition having the same resin main component as the foamed resin composition 14 constituting the foamed resin layer 15. It is supposed to be. With such a configuration, the affinity with the foamed resin layer 15 is good and the adhesiveness can be improved as described above. The spacer 13 may be a rigid polyurethane foam formed from a polyurethane resin composition containing a polyol of the same type as the foamed resin composition 14. Further, the spacer 13 may be formed of the foamed resin composition 14 having the same structure as the foamed resin composition 14 constituting the foamed resin layer 15.
In the present embodiment, the spacers 13 at the four corners are provided so as to be located between the vacuum

heat insulating materials

16 and 16. That is, the spacers 13 are provided at positions overlapping the four corners of the vacuum

heat insulating materials

16 and 16 when viewed in the panel thickness direction. The mode in which the spacer 13 is provided so as to be located at the four corners of the vacuum

heat insulating materials

16 and 16 is not limited to such a mode, and each of the vacuum

heat insulating materials

16 and 16 can be grasped at the four corners. The mode may be provided so as to be in contact with the outside of the corner portion.
Further, the spacer 13 may be fixed to the four corners of the vacuum heat insulating material 16 or the first board 11 or the second board 12 outside each corner with an adhesive, an adhesive material, or the like, and is placed without being fixed. It may be a thing. Further, in addition to the mode in which the spacer 13 is provided so as to be located at the four corners of the vacuum heat insulating material 16, the mode may be provided in a substantially central portion or the like as seen in the thickness direction of the vacuum heat insulating material 16. Further, the dimension of the spacer 13 along the panel thickness direction may be an appropriate dimension according to the thickness dimension of the panel body 10 which is divided into two in the thickness direction to form the

heat insulating panels

1 and 1.

Next, each step of an example of the method for manufacturing a heat insulating panel according to the present embodiment will be described.
In the same manufacturing method, as shown in FIG. 1A, one of the first board 11 and the second board 12 (the first board 11 in the example) is attached to the back surface 11a to which the vacuum heat insulating material 16 is fixed. It is placed on the base (lower mold) 2 with the side facing upward. Further, the spacers 13 are arranged so as to be located at the four corners of the vacuum heat insulating material 16 fixed to the first board 11. The spacer 13 may be fixed to the four corners of the vacuum heat insulating material 16 or the back surface 11a of the first board 11 outside each corner before the first board 11 is placed on the base 2.
Then, the foamed resin composition 14 is supplied to the back surface 11a side of the first board 11. The supply amount of the foamed resin composition 14 per unit area may be an appropriate amount so that the foamed resin layer 15 has a desired thickness and density. Further, an appropriate supply nozzle for supplying the foamed resin composition 14 may be supplied while being relatively moved with respect to the first board 11. Further, when the foamed resin composition 14 is supplied, the

end face types

4 and 4 are attached to the first board 11 so as to form the side end faces of both sides or four circumferences of the panel body 10 (see FIG. 2A) in the width direction. It may be performed in a state where it is arranged so as to be in contact with both sides in the width direction or the side end faces of the four circumferences.

Further, after the foamed resin composition 14 is supplied and before the foamed resin composition 14 is completely foamed and cured, the other of the first board 11 and the second board 12 (in the example, the second board 12) is pressed. ,Deploy. At this time, the spacer 13 is arranged so as to come into contact with the four corners of the vacuum heat insulating material 16 fixed to the back surface 12a of the second board 12 or the back surface 12a on the outside of each corner. Then, while the thickness of the panel body 10 (see FIG. 2A) is restricted to a thickness corresponding to the thickness dimension, the surface side of the second board 12 is pressed by the upper mold 3 to foam the foamed resin composition 14. It may be cured to form the panel body 10. Alternatively, the first board 11 to which the vacuum heat insulating material 16 is fixed and the second board 12 to which the vacuum heat insulating material 16 is fixed are arranged in the

molds

2, 3 and 4 with the spacer 13 interposed therebetween. The foamed resin composition 14 may be supplied via the injection port.

For example, if the foamed resin composition 14 made of the polyurethane resin composition is supplied as described above, the first liquid such as a polyol compound as a main agent and the second liquid such as a polyisocyanate compound as a curing agent react with each other. It gradually foams, the viscosity increases, and it hardens. When the foamed resin composition 14 is foamed and cured in this way, the foamed resin layer 15 and the first board 11 and the second board 12 on both sides thereof are laminated and integrated by the self-adhesiveness to form the panel body 10. .. Further, the foamed resin layer 15 is also formed around the board side surfaces 16a and 16a of the vacuum

heat insulating materials

16 and 16, and the vacuum

heat insulating materials

16 and 16 are fixed and integrated with the foamed resin layer 15. The mode for forming the panel body 10 is not limited to the above-mentioned mode, and various other modes can be adopted.

Then, as shown in FIGS. 3A and 3B, the panel body 10 is divided into two in the thickness direction by the cutting blade 6 of an appropriate cutting machine to create the

heat insulating panels

1 and 1. In the present embodiment, the panel body 10 is divided into two equal parts in the thickness direction to create the

heat insulating panels

1 and 1. With such a configuration, it is possible to create two

heat insulating panels

1 and 1 having substantially the same configuration from one panel body 10. Instead of such an embodiment, the panel body 10 may be divided into two in the thickness direction to create

heat insulating panels

1 and 1 having different thickness dimensions. Further, instead of dividing the panel body 10 into two by the cutting blade 6, the panel body 10 may be divided into two by a heat ray cutter such as a nichrome wire, or may be divided into two by various other modes.

As shown in FIG. 3, each of the

heat insulating panels

1 and 1 divided into two in this way is provided with the first board 11 or the second board 12 on one side in the thickness direction, and the other side in the thickness direction (division section side). The foamed resin layer 15A is provided on the surface. Further, each of the

heat insulating panels

1 and 1 has a configuration in which the divided side surface 13a of the columnar body 13A formed by dividing the spacer 13 into two is exposed on the other side in the thickness direction. That is, each columnar body 13A is provided so as to be located at each of the four corners of the vacuum heat insulating material 16 when viewed in the thickness direction, and these divided side surfaces 13a are each exposed on the other side in the thickness direction.
An appropriate sheet material may be attached or painted on the partial cross-sectional side of the heat insulating panel 1. Further, instead of the above-mentioned mode in which the spacer 13 is interposed, an appropriate thickness regulating portion may be provided on the molding die side to form the panel body 10. Each step of the method for manufacturing a heat insulating panel according to the present embodiment is not limited to the above-described embodiment, and various other modifications are possible.

1 Insulation panel 10 Panel body 11 1st board 11a Back side (opposing surface)
12 2nd board 12a Back side (opposite side)
13 Spacer 14

Foam resin composition

15, 15A Foam resin layer 16 Vacuum heat insulating material 16a Board side surface (one side in the thickness direction)
17 Core material 18 Packaging material 19 Seal part

Claims

The first board and the second board to which the vacuum heat insulating material is fixed are arranged along the respective facing surfaces at intervals in the panel thickness direction, and between the first board and the second board. A method for manufacturing a heat insulating panel, which comprises supplying a foamed resin composition and dividing a panel body on which a foamed resin layer is formed into two in the thickness direction to manufacture a heat insulating panel.
In claim 1,
The first board and the second board are connected to each other in the panel thickness direction by interposing spacers so as to be located at the four corners of the vacuum heat insulating materials fixed to the facing surfaces of the first board and the second board. A method for manufacturing a heat insulating panel, which is characterized by arranging them at intervals.
In claim 1 or 2,
A method for manufacturing a heat insulating panel, wherein the first board and the second board are formed of the same resin composition as the foamed resin composition.
In any one of claims 1 to 3,
The vacuum heat insulating material has a configuration in which the sealing portions of the peripheral edges of the packaging materials provided on both sides of the core material in the thickness direction are bent so as to be along one side in the thickness direction.
A method for manufacturing a heat insulating panel, characterized in that the vacuum heat insulating material is fixed by bringing the seal portion into contact with the facing surfaces of the first board and the second board.