JP2000160723A - Heat insulating structural body, its manufacture, and hood-shaped member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide techniques relating to a heat insulating structural body of high productivity such that demolding time can be reduced during production. SOLUTION: A heat insulating structure has a core 2 having a number of heat insulating foam resin chips and a polyurethane foam layer 3 covering a portion or the whole of the core 2. The heat insulating structural body is thus widely usable as a proper hood, a hood-shaped member such as a roof for a bay window, and also as building members such as walls and roofing. The use of the heat insulating resin foam chips in the core allows a reduction in the amount of resin foam injected to cover the core, thus allowing a reduction in material cost and permitting effective use of the waste of various resin foam generated in a large amount.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a heat insulating structure, a method of manufacturing the same, and an eaves, and more particularly, to a heat insulating structure used for building materials and the like, a method of manufacturing the same, and an eave-like member using the heat insulating structure.

[0002]

2. Description of the Related Art As a heat insulating material used for building materials, a foamed resin material such as a foamed polyurethane which is an organic heat insulating material is frequently used. In recent years, because of the strong demand for energy saving, the use of heat insulating materials around the walls, roofs, and other areas that make up openings other than roofs, such as windows, doorways, eaves provided on the top of porches, and the upper and lower parts of bay windows Insulation is also being used.

[0003] For example, an eave is used as a heat insulating material by arranging foamed polyurethane at an intermediate portion between a surface material forming a roof portion and a surface material forming a lower portion (eave portion). This is because such foamed polyurethane contains closed cells, so that it has excellent heat insulating properties as a heat insulating material, and also has excellent lightness and airtightness. The size of this eave is generally, for example, 400 to 3000 mm in length and 400 to 600 mm in width.
The cross section is almost trapezoidal with a one-sided flow, and the root portion of the eaves connected to the structure constituting the house has a thickness of about 1
The thickness of the tip portion that protrudes from the outer wall surface of the building while being inclined at 00 to 200 mm is about 50 to 100 mm.
The outer skin of the eaves is made of thin steel plate, metal such as aluminum casting, etc., and the inside is filled with injected and foamed polyurethane resin, so it is quiet without rain noise and it is lightweight and lightweight. Eaves using foamed polyurethane as a heat insulating material are often used as building members because they are structurally strong and have excellent heat insulating properties and other functions.

[0004]

However, the foamed polyurethane used as the heat insulating material in this case is mainly a heat insulating material having closed cells, and large internal heat is generated due to the reaction at the base of the thick eaves. Since heat is difficult to escape, 30 to 4
Currently, it takes 0 minutes, and the productivity was not always high. In the case of foamed polyurethane containing open cells, the demolding time is somewhat shortened, but it is still 15
It took ~ 20 minutes. This is a phenomenon generally applied to the production of a relatively thick heat insulating structure having high heat insulating properties, and there has been a strong demand for improvement in productivity.

Accordingly, an object of the present invention is to solve the above-mentioned problems of the prior art and to provide a technology relating to a highly productive heat insulating structure capable of shortening the demolding time in production.

[0006]

The above object is achieved by the invention described in each claim. That is, the characteristic structure of the heat insulating structure according to the present invention is that it has a core material having a large number of heat insulating resin foam chips, and a foamed resin layer covering a part or the whole thereof. With such a configuration, even when used as a thick heat-insulating structure, since the heat-insulating resin foam chip is used for the core material, the amount of resin injected when manufacturing the heat-insulating structure is small. As a result, the foaming reaction time is shortened, and the generated reaction heat is also reduced, so that the demolding time can be greatly reduced, and a heat-insulating structure having high productivity can be obtained. Moreover, internal stress is generated when the foamed resin layer injected outside the core material foams, but since the core material is composed of a large number of heat-insulating resin foam chips, a large number of gaps are open cells. Since it acts in the same manner, unlike a foamed resin containing closed cells, the core material has excellent shape retention, and the heat insulating structure itself does not undergo a dimensional change with time. Therefore, such a heat-insulating structure includes an original eave, an eave-like member such as a bay window roof, a wall,
It can be widely used as building materials such as roofing materials. Furthermore, since the heat-insulating resin foam chip is used as the core material, the amount of the foamed resin injected for covering the core material can be reduced, and the material cost can be reduced. Waste material can be effectively used, and an excellent effect can be exhibited for waste disposal.

In the heat insulating structure according to the present invention, the core material comprises a bag containing a large number of the heat insulating resin foam chips, and the bag is an aggregate of the heat insulating resin foam chips. Is preferably divided into a plurality of blocks. With this configuration, the shape of the core material is easily determined, and it is easy to press and mold the core material into a predetermined shape, which is convenient. Further, when the aggregate of the heat-insulating resin foam chips is divided into a plurality of blocks, when the core material is transported to the building site, the entire resin chips are less likely to be unevenly distributed in a certain direction, which is convenient. .

In the heat insulating structure according to the present invention, it is preferable that the heat insulating resin foam chip has a diameter of 1 to 50 mm and the foamed resin layer is made of rigid foamed polyurethane. With such a configuration, the core material can be easily formed into a predetermined shape, and the shape retention after forming is excellent, which is convenient. Further, when the hard foamed polyurethane is injected, the adhesiveness to the core material is good, and the bonding between the two is strong, which is preferable. In addition, the hard foamed polyurethane layer is convenient because it has excellent heat insulating properties. The size of the heat-insulating resin foam chip is less than 1 mm in diameter or 50 mm.
If it exceeds mm, it is difficult to form and process a core material having a predetermined size. The size of the heat-insulating resin foam chip is 10 to 10 from the viewpoint of ease of molding and processing.
It is more preferable to make the diameter about 30 mm.

Further, the characteristic structure of the method for manufacturing a heat insulating structure according to the present invention is characterized in that a core material having a large number of heat insulating resin foam chips is arranged inside a frame constituting an outer shell, and the core is provided from outside the outer shell. The object is to inject a foamed resin so as to cover a part or the whole of the core material, and to integrally form the core material and the outer shell. With such a configuration, even when a thick heat insulating structure is manufactured, since the heat insulating resin foam chip is used for the core material, the amount of resin injected when manufacturing the heat insulating structure is reduced. It is possible to reduce the foaming reaction time and to reduce the heat generated by the reaction, so that the demolding time can be greatly reduced and a heat-insulating structure with high productivity can be manufactured. Moreover, internal stress is generated when the foamed resin layer injected outside the core material foams, but since the core material is composed of a large number of heat-insulating resin foam chips, a large number of gaps are open cells. Since it acts in the same manner, unlike a foamed resin containing closed cells, the core material has excellent shape retention, and the heat insulating structure itself does not undergo a dimensional change with time. Therefore, such a heat insulating structure can produce a high-quality heat insulating structure that can be widely used as a building member such as an original eave, an eave-like member such as a roof member of a bay window, a wall, a roof material, and the like. Furthermore, since the heat-insulating resin foam chip is used as the core material, the amount of the injected polyurethane resin can be reduced, so that the material cost can be reduced. An excellent effect can be exhibited also for material processing.

Furthermore, as a method of manufacturing a heat insulating structure according to the present invention, a large number of the heat insulating resin foam chips are housed and sealed in a bag, and the heat insulating resin foam chips housed in the bag are enclosed. Is preferably divided into a plurality of blocks to manufacture the core material. In this case, the shape as the core material is easily determined, and it is easy to press and mold into a predetermined shape, which is convenient. In addition, when the assembly of the heat-insulating resin foam chips is divided into a plurality of blocks, when the core material is transported to the construction site, a heat-insulating structure in which the entire resin chips are hardly unevenly distributed in a certain direction is manufactured. it can.

Further, according to the method of manufacturing a heat insulating structure according to the present invention, the heat insulating resin foam chip may have a size of 1 to 50.
It is preferable to use a foamed resin layer having a diameter of mm, and to form the foamed resin layer by injecting a hard foamed polyurethane foam stock solution composition. With this configuration, the core material can be easily formed into a predetermined shape and the shape retention after the formation is excellent, so that it is convenient when manufacturing the heat insulating structure. Also, when the raw foamed polyurethane foam composition is injected, it has good adhesion to the core material, and the bonding between the two is strong. It is convenient because the material can be manufactured.

Furthermore, a characteristic configuration of the eave-shaped member according to the present invention is that the eave-shaped member is provided with the heat-insulating structure of claim 1 or 2 and can be mounted so as to protrude outside the building. With such a configuration, since the heat insulating structure having high productivity and excellent function is provided, the eaves are low in production cost and excellent in heat insulation and other functions, which is preferable. In the present invention, the eaves-like member is used to mean a concept including not only the original eaves but also a building member having the same function as the eaves such as a roof of a bay window.

[0013]

Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows an external shape of an eaves A as an example of a heat insulating structure, and FIG. 2 shows a vertical cross-sectional structure of a substantially central portion thereof. The outer shell 1 of the eaves A is made of a thin steel plate, the tapered tip 1a is closed, and the root 1b is expanded to form an open frame. As shown in FIG. 2, an overhanging portion 1c for connection to the building is formed on the expanding edge of the root portion 1b.
This part is omitted to avoid complication. The unfoamed polyurethane can be injected from an injection hole 1d formed in the root portion 1b of the outer shell 1. A core material 2 having a heat-insulating foamed polyurethane chip 2a is inserted into the inside surrounded by the outer shell 1, and the outside is surrounded by a hard foamed polyurethane 3 injected.

As shown in FIGS.
It comprises a large number of heat-insulating foamed polyurethane chips 2a having a diameter of about 50 mm and an outer shell 2b of a bag covering the same, and is sewn at several places through the outer skin 2b to separate the polyurethane chips 2a into several blocks. The structure is attached. That is, when the heat-insulating foamed polyurethane chip 2a accommodated in the core material 2 is transported / moved, it is preferable that the whole is not unevenly distributed. By providing the sewn portions 2c at several places, the heat-insulating foamed polyurethane chip 2a is provided. The structure of 2a is divided into several blocks so that it is difficult to move the whole. The outer skin 2b of the bag is formed of a non-woven fabric or the like, but the material of the outer skin 2b is not limited to the non-woven fabric in the practice of the present invention, and various fibers, paper, resin, composite materials of resin and other materials, and the like can be used. Any material can be used as long as it can hold and transport a large number of heat-insulating foamed polyurethane chips 2a inside. Various shapes such as a net shape, a mesh shape, and a cloth shape can be used.

Next, a method of manufacturing the eaves A using the heat insulating structure shown in FIG. 1 will be described below. The core 2 shown in FIGS. 3 and 4 is created in advance. The core material 2 has a size corresponding to the shape of the eaves A, that is, can be inserted and arranged inside the eaves A, and the maximum thickness of the unfoamed hard polyurethane to be injected is 100 m.
m or less.
A heat-insulating foamed polyurethane chip having a diameter of about 1 to 50 mm is put into a bag made of a nonwoven fabric having one open end. Insulation foam polyurethane chip size is 1m
If the diameter is less than m or exceeds 50 mm, it is difficult to form and process a core material having a predetermined size.
The size of the heat-insulating foamed polyurethane chip 2a is more preferably set to a size of about 10 to 30 mm in diameter from the viewpoint of ease of molding and processing. This heat-insulating foamed polyurethane chip can use a waste material that is originally to be discarded, such as an off-gauge portion or a defective portion, when producing a foamed polyurethane heat-insulating material. Further, instead of the heat-insulating foamed polyurethane chips, other heat-insulating foamed resins such as heat-insulating foamed polystyrene chips may be used. For example, it is possible to use a large amount of waste polystyrene used for packaging materials, toro boxes, trays, and the like. Even if a little paper, resin, wood chips, etc. adhere to the heat-insulating foamed resin, there is no problem at all. If the shape is too large, it may be appropriately crushed and used.

When the heat-insulating foamed polyurethane chip has been put into the core, the core is pressed and molded so as to have a predetermined shape, and the open end of the core is sewn. Close in a way. Thereafter, a seam for connecting the front and back surfaces of the core material is formed at an appropriate place so that the injected heat-insulating foamed polyurethane chip is not unevenly distributed during transportation. In this case, the seam does not necessarily need to be joined so that the front and back of the core material are in close contact. Since the core material 2 contains a large number of heat-insulating foamed resin chips 2a therein, voids between the heat-insulating foamed resin chips 2a act as open cells, so that the air inside is effectively discharged by pressurization. ,Pressurization·
Exhibits shape retention by molding. In this regard, if an integral foamed resin containing closed cells is used as the core material, it tends to return to its original shape due to its own elasticity even when pressed and molded, so it can exhibit shape retention. Although it is difficult, according to the present embodiment, there is no such a defect, and a core material having a substantially predetermined size can be surely formed.

Next, as shown in FIG. 3A, a core material 2 is fixed to a central side wall of the outer shell 1 made of a thin steel plate of the eaves A.
This fixation may be performed by applying an adhesive or attaching an adhesive tape, or may be arranged such that polyurethane having a low reactivity is injected in advance and the core material is floated from above, and One or two or more engaging projections may be formed on the inner side wall in advance, and the projections may be fixed by piercing the side surfaces of the core material 2. A mechanical method may be used in which a loop is formed in advance and this is hooked and fixed to the projection. In short, the core material 2 may be temporarily held on the side wall in the outer shell 1 until the injection of the unfoamed hard polyurethane is completed.

After that, unfoamed hard polyurethane is injected from the open end side of the outer shell 1 formed in an expanded shape. In this case, it is preferable to uniformly inject the unfoamed hard polyurethane around the core material 2. Therefore, in order to keep the posture of the core material 2 constant, a holding jig or a holding jig may be appropriately used. Injection of the rigid polyurethane foam stock solution composition is generally performed by mixing a polyol component containing an isocyanate component and a foaming agent, and filling the resulting mixture into a molding cavity as a foamed composition. Usual conventional means can be used.

[0019]

EXAMPLE: Approximate width 400 mm, length 3 fixed by a mold
000 mm, thickness at the tip 100 mm, thickness at the root 2
For a 200 mm eave outer frame, width 200 mm, length 250
A core material having a size of 0 mm and a thickness of 70 mm and containing various heat-insulating foam resin chips of 1 to 50 mm inside a bag-shaped nonwoven fabric is adhered to one end side wall inside the eave at a position as shown in FIG. With the tape fixed, the open end side of the root portion was directed upward, and a hard polyurethane resin was injected from here with a foaming agent while mixing.
Immediately after the injected polyurethane resin foamed and generated heat, the foaming pressure was reduced to a demoldable foaming pressure. During this time, the demolding time is 7
It took about 10 minutes. As described above, according to the present invention, the demolding can be performed in a shorter time than expected compared to the demolding time according to the related art. This is considered to be due not only to a decrease in the reaction amount due to a decrease in the amount of the injected unfoamed polyurethane but also to a synergistic result taking into account the cooling effect of the encapsulated core material.

[Other Embodiments] (1) Various positions other than the positions shown in FIG. 2 are conceivable for the position of the core material in the outer shell 1 of the eaves A. For example, FIG.
The core material may be arranged at a position as shown in (a) to (f). Various shapes of the core material can be considered according to the shape of the outer frame. FIG. 5 (a) shows the bottom of the core fixed to the front end of the outer frame, FIG. 5 (b) shows one of the surfaces of the core fixed to one end of the outer frame, and FIG. The whole core material is made substantially similar to the cross-sectional shape of the eaves, and one side surface of the core material is fixed to the front end side of the outer frame. In this case, if the unfoamed resin is applied from both sides of the core material by an open method using a spray or the like, the resin can be easily injected around the core material and the filling operation becomes easier. When injection is performed by a spray method, the demolding time is about 1 to 2 minutes.

FIG. 3D shows an arrangement in which the proportion of the core material is increased and the core material is fixed so as to be filled at the front end side of the outer frame.
In (e), the arrangement ratio of the core material is lower than that in (d). An unfoamed resin is injected into the front end side of the outer frame in advance, and after the core material is charged, the unfoamed resin is injected again. (F) is an arrangement in which the unfoamed resin is injected into the front end side of the outer frame in advance, and the floating of the unfoamed resin is prevented using a suitable holding jig. Inject.

In any of the examples shown in FIGS. 5A to 5F, the demolding time is reduced to 1/2 to 1/3 or less as compared with the conventional method in which the entire unfoamed resin is injected from the beginning. It was possible to shorten the time. 5B, 5D and 5E.
In the case of, the foaming pressure of the resin injected after the core material is placed also reaches the core material, so this pressure may affect the outer frame later, so the air inside the core material can be exhausted when the injected resin foams A pipe that communicates with the outside may be connected from the core material to the outside.

(2) In the above embodiment, an example was shown in which a nonwoven fabric was used for the outer skin of the bag constituting the core material. Instead of this, an aluminum foil, a polyethylene film, and a polyamide (nylon) film were used. A laminated material may be used. Since the outer cover is excellent in confidentiality, it is preferable to reduce the pressure inside to easily maintain the shape of the core material.

(3) In the above embodiment, an example is shown in which a nonwoven fabric is used for the outer skin of the bag constituting the core material. Alternatively, an inexpensive polyethylene film may be used.

(4) The outer shell of the bag constituting the core material is
It may be a net shape of 10 mm size. In this case, the adhesion with the hard polyurethane to be injected is improved, which is convenient.

(5) In the above embodiment, an example was shown in which the core material was constituted by a large number of heat-insulating foamed resin chips housed in a bag. However, a large number of heat-insulating foamed resins were simply used without using a bag. A chip to which a chip is fixed with an adhesive may be used as a core material. In this case, if the individual resin chips are joined and formed by a spray method using an emulsion adhesive, it can be manufactured at low cost and is convenient.

(6) In the above-described embodiment, the sewn portions 2c are provided at several places so that the polyurethane chips 2a accommodated in the core material 2 are not unevenly distributed when being transported and moved. Foamed polyurethane chip 2
Although the whole of a was divided into several blocks,
The method of separating the whole heat-insulating foamed polyurethane chip into several blocks is not limited to this. The bag structure has a plurality of rooms from the beginning, and the heat-insulating foamed polyurethane chips 2a are put into each small room. It may be sealed.

[Brief description of the drawings]

FIG. 1 is an external perspective view of an eaves according to an embodiment of the present invention.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is an external perspective view of a core material.

FIG. 4 is a sectional view taken along line IV-IV of the core member of FIG. 3;

FIG. 5 is a schematic cross-sectional view of various eaves according to another embodiment.

[Explanation of symbols]

 2 core material 2a heat-insulating foam resin chip 3 foam resin layer

Claims (4)

[Claims] 1. A heat insulating structure comprising a core material having a large number of heat insulating resin foam chips, and a foam resin layer covering a part or all of the core material. 2. The heat-insulating resin foam chip has a thickness of 1 to 50.
The heat insulating structure according to claim 1, wherein the heat insulating structure has a diameter of mm and the foamed resin layer is made of hard foamed polyurethane. 3. A core material having a large number of heat-insulating resin foam chips is disposed inside a frame constituting an outer shell, and a foaming resin is injected from outside the outer shell so as to cover a part or the whole of the core material. And a method of manufacturing a heat insulating structure in which the core material and the outer shell are integrally formed. 4. An eaves-like member comprising the heat-insulating structure according to claim 1 or 2 and protruding and attached to the outside of a building.