JP2001073478A - Heat insulating material and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat insulating material particularly excellent in heat insulating performance and workability, and its manufacturing method. SOLUTION: This heat insulating material 15 comprises a heat insulating base material 16 formed of inorganic fiber fitted between wall backing columns 5, 8, and first recessed parts 20a, 20b are formed at the heat insulating base material 16 at least in the positions of the fitted columns 5, 8. The heat insulating material 15 is manufactured through a process of adding and laminating a binder maily composed of thermosetting resin, on defiferized inorganic fiber to form the heat insulating base material 16, a process of forming the first recessed parts 20a, 20b, and a process of heating and hardening in the formed state.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat insulating material having excellent heat insulating properties and sound absorbing properties and a method of manufacturing the same, and more particularly to a heat insulating material used in a residential building and a method of manufacturing the same.

[0002]

2. Description of the Related Art Generally, in a building such as a house, a wall is
Various outer wall materials are provided on the outside of the room on the wall foundation consisting of vertical frame materials such as pillars and studs and horizontal frame materials such as horizontal waist edges, and rock wool and glass wool are placed in the space surrounded by the wall foundation. A construction method is used in which a heat insulating material is filled to increase heat insulation and sound absorption.

One example of the above-described heat insulating material will be described with reference to FIGS. 13 to 15. This heat insulating material 1 wraps a heat insulating base material 2 made of an inorganic fiber such as rock wool or glass wool with a moisture proof moisture proof sheet 3, Moreover, it is comprised in the shape of a highly elastic mat which has the ear parts 4 and 4 which the moisture-proof sheet 3 extended to the both longitudinal end parts of the back surface. The moisture-proof sheet 3 on the front side of the heat insulating material 1 is provided with well-known moisture-permeable holes 12 irregularly.

[0004] The heat insulating material 1 is disposed between the pillar 5 and the stud 6, and the ears 4, 4 are brought into close contact with the pillar 5 and the stud 6, respectively. The heat insulating material 1 is attached between the pillar 5 and the stud 6. The heat insulating material 1 is similarly attached between the stud 6 and the following post 8 to enhance heat insulation and sound insulation.

[0005]

However, as shown in the figure, the lug 4 of the heat insulating material 1 is provided with lugs 4 composed of only the moisture-proof sheet 3 having no heat insulating base material 2 and columns 5, 8 and studs. Since it is only in direct contact with 6, the portion may serve as a thermal bridge, which may cause inconvenience that desired high heat insulation and sound insulation cannot be obtained.

[0006] As shown in the figure, in the case of a wall base provided with a strut 9 between the pillars 5 and 8 with the studs 6 interposed therebetween, the strut 9 projects to the indoor side 10 when the heat insulating material 1 is attached. For this reason, the corresponding portion of the heat insulating material 1 which comes into contact with the bracing 9 is strongly crushed, but since the heat insulating material 1 protrudes toward the indoor side 10, the heat insulating material 1 is inclined obliquely as shown by a dashed line in FIG. Must be cut to shape.

[0007] However, this cutting work is troublesome,
If not cut into the oblique shape accurately, there may be gaps between the braces 9 and the cut surface 11, looseness of the heat insulating material 1 may occur, and the heat insulating base material 2 may be scattered from the cut surface 11 to cause inconveniences. May be.

An object of the present invention is to solve the above-mentioned problems and to provide a heat insulating material having particularly excellent heat insulating properties and workability, and to provide a manufacturing method by which this heat insulating material can be easily manufactured. Is what you do.

[0009]

Means for Solving the Problems In order to achieve the above-mentioned object, a first invention according to the present invention is directed to a heat insulating material comprising a heat insulating base of inorganic fibers disposed between pillars of a wall foundation constituting a wall. And at least on the insulating base material at the position to be attached to the pillar,
A first concave portion is formed.

According to a second aspect of the present invention, between the pillars of the wall foundation constituting the wall, the heat insulating base material at a position in contact with the projection of the wall foundation, which is an obstacle to the heat insulating material, is fitted with the projection. The third invention is characterized in that two concave portions are formed, and the third invention is characterized in that at least one surface of the heat insulating base material is covered with a moisture-proof sheet.

Further, a fourth invention is a method of manufacturing a heat insulating material comprising a heat insulating base material of inorganic fibers disposed between pillars of a wall base constituting a wall body, wherein the opened inorganic fibers are cured by thermosetting. Adding a binder containing a resin as a main component and laminating to form a heat insulating substrate; forming at least a first concave portion in the heat insulating substrate at a position to be attached to the pillar; And a step of heating and curing the material.

A fifth aspect of the present invention is a method for manufacturing a heat insulating material comprising a heat insulating base material of inorganic fibers disposed between pillars of a wall base constituting a wall, wherein a thermosetting resin is applied to the opened inorganic fibers. A step of forming a heat insulating base material by adding and laminating a binder as a main component, and a step of forming a heat insulating base between pillars of the wall base constituting the wall body, the position being in contact with the protrusion of the wall base which is an obstacle to the heat insulating material. The method according to the sixth aspect of the present invention is characterized in that the method comprises the steps of: forming, in a material, a second concave portion that fits with the protrusion, and heating and curing the heat-insulating substrate after the molding. Is characterized by including a step of covering at least one surface with a moisture-proof sheet.

[0013]

According to the first aspect of the present invention, when the heat insulating material is installed between the columns, the first concave portion having the heat insulating base directly contacts the columns, so that there is no thermal bridge as in the prior art. Heat insulation and sound insulation.

According to the second aspect of the present invention, since the heat insulating material is present in the second concave portion which fits with the projection of the wall base which hinders the attachment of the heat insulating material to the wall base, the heat insulating material is cut with a blade or the like. Work is eliminated, and installation work of the heat insulating material is simplified.
According to the third aspect, there is an effect that scattering of a heat insulating base material such as rock wool can be prevented.

Further, according to the fourth aspect, a heat insulating material having the first concave portion having the heat insulating base material can be easily manufactured. Fifth
According to the invention of the sixth aspect, the heat insulating material having the second concave portion that fits into the projection of the wall base which hinders the attachment of the heat insulating material to the wall base can be easily manufactured. A heat insulating material that can prevent scattering of the material can be easily obtained.

[0016]

Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing a heat insulating material of a first example according to the present invention, FIG. 2 is a cross-sectional view showing the same mounting state, and FIG.
Is a perspective view showing a heat insulating material of a second example, FIG. 4 is a cross-sectional view showing the same mounting state, FIG. 5 is a perspective view showing a heat insulating material of a third example, and FIG. FIG. 7 is a cross-sectional view showing the same mounting state, FIG. 8 is a cross-sectional view taken along line A-I, ro-ro and ha-ha of FIG. 7, and FIG. First
FIG. 10 is a perspective view of a main part showing a manufacturing method of the second example, FIG. 10 is a perspective view of a main part showing a manufacturing method of the third example, FIG. It is a principal part perspective view which shows the manufacturing method of four examples.

The heat insulating material 15 of the first example will be described. As shown in FIGS. 1 and 2, the heat insulating material 15 is prepared by adding a binder mainly composed of a thermosetting resin such as a phenol resin to a heat insulating base material 16 made of an inorganic fiber such as rock wool or glass wool. It is cured and molded into a rectangle having a thickness of, and is configured in a mat shape, a felt shape, a board shape, or the like. Hereinafter, the heat insulating material 15 to be described includes a mat-like, felt-like, or board-like structure. For example, the mat-like heat insulating material 15 made of rock wool is formed to have a bulk density of 40 kg / m ³ and a thickness of 100 mm.

A second angular recess 18 is formed linearly in the center of the one surface 17 of the heat insulating material 15 along the longitudinal direction.
Are formed linearly to form first concave portions 20a and 20b having the heat insulating base material 16, respectively.
As described later, a and 20b are fitted and fitted to one surface of the pillars 5 and 8. This first recess 20
a, 20b and the second recess 18 are formed by the heat insulating material 1 as shown in the figure.
It is necessary that the heat-insulating base material 16 exist at a predetermined thickness without extending to the other surface 21 of the fifth heat-insulating material 5, and it is preferable that the heat-insulating base material 16 of at least about の of the thickness of the heat-insulating material 15 remains. . In addition, the second concave portion 18 is provided with the first concave portion 2 at both ends.
The shape is slightly narrower than that of Oa and 20b, as described later, because the second recess 18 fits with the stud 6 that is narrower than the columns 5 and 8.

The heat insulating material 15 is wrapped in the moisture-proof sheet 3 except for the upper and lower end faces 22. The moisture-proof sheet 3 may be a sheet material having excellent moisture impermeability.
Plastic sheets such as polypropylene, polyvinyl chloride and polyvinylidene chloride, sheets obtained by depositing aluminum on these sheets, and metal foil structures such as aluminum foil are preferred. Although not shown, the entire surface including the upper and lower end surfaces 22 may be wrapped with a sheet material. Insulation base material 16
Is preferably an inorganic fiber such as rock wool or glass wool described above, but an organic cellular heat insulating material such as a polystyrene resin or a polyol resin may be used. Note that, similarly to the above-described conventional example, the moisture-proof sheet 3 on the one surface 17 side of the heat insulating material 15 is provided with well-known moisture-permeable holes 12 irregularly. Hereinafter, the heat insulating material of each example to be described will not be described in each case, but similarly, a penetration hole is provided. Further, the moisture-proof sheet 3 is not necessarily required on both sides 17 and 21 of the heat insulating material 15; the indoor side 10 is required, and the opposite outdoor side 17 may be omitted, and so on.

The method of attaching the heat insulating material 15 of the first example will be described with reference to FIG.
One surface 21 side of the heat insulating material 15 faces the indoor side 10, and the first concave portion 20 b of the heat insulating material 15 is fitted to the column 5, the second concave portion 18 is fitted to the stud 6, and the first concave portion 20 a is fitted to the column 8. In addition, a wall base in which a heat insulating material 15 is attached to columns and studs that are sequentially adjacent to each other is configured to enhance the heat insulating property and the sound absorbing property.

The heat insulating material 25 of the second example will be described. As shown in FIG. 4, the heat insulating material 25 is mounted on a wall base where no stud 6 is provided between the pillars 5 and 8, and accordingly, the first heat insulating material 25 is used.
The shape is narrower than the heat insulating material 15 of the example. The other configuration is the same as that of the first example, and thus the same reference numerals are given and the description is omitted.

A third example of the heat insulating material 27 will be described. The heat insulating material 27 is an example in which the heat insulating material 25 is deformed.
As shown in the figure, the first concave portion 20 is located near each end of the one surface 17 of the heat insulating base material 16 so as to correspond to the positions of the pillars 5 and 8 to be attached.
a and 20b are respectively formed. Other configurations are
Since this is the same as the first example, the same reference numerals are given and the description thereof is omitted.

A heat insulating material 30 of a fourth example will be described. As shown in FIG. 7, the heat insulating material 30 has a structure in which a stud 6 is provided between the pillars 5 and 8 and is attached to a wall base where a bracing 9 is disposed between the pillars 5 and 8. There is a feature in the configuration that can cope with this. That is, as shown in FIG. 6, a horn-shaped inclined recess 31 is formed obliquely from the upper end of the first recess 20 b provided on the one surface 17 side of the heat insulating material 30 to the lower end of the first recess 20 a. The other parts are the same as those in the first example, and thus the same reference numerals are given and the description will be omitted.

The mounting method of the fourth example will be described with reference to FIG. 7. One surface 17 of the heat insulating material 30 faces the columns 5 and 8, the first concave portion 20 b of the heat insulating material 30 is positioned on the column 5, and the second concave portion 18 is positioned on the column 5. The first recesses 20 a are fitted to the pillars 8, respectively.
Further, the inclined concave portion 31 formed in the heat insulating material 30 and the columns 5, 8
When the bracing 9 arranged between the fittings is fitted, the bracing 9 does not become a particular obstacle, the construction can be performed smoothly and smoothly, and the heat insulating material 30 is sequentially provided between the adjacent columns or columns. An attached wall base can be configured.

Next, a method for manufacturing a heat insulating material according to the present invention will be described. The example shown in FIG. 9 shows a main part of a step 35 of manufacturing the heat insulating material 15 of the first example, and a binder mainly containing a thermosetting resin such as a phenol resin is opened in a known step not shown. A laminate 36 is formed by adding the inorganic fiber such as rock wool and laminating the same. The laminate 36 is sent onto a mold 38 arranged at predetermined intervals on a belt 37 to be transported in the next manufacturing process 35, and the laminate 36 sent onto the mold 38 is left unmolded as it is. Together with the frame 38, it is transferred to a heating device 39.

The laminate 36 that has entered the heating device 39 is provided with square protrusions 40a, 40b, and 41 projecting from the mold 38 by curing the phenol resin on the mold 38.
6, that is, the angular second concave portion 18 and the extension portion 19 along the longitudinal direction at the central portion and both end portions of the one surface 42, respectively.
A laminate 36 is formed in which the first concave portions 20a and 20b made of are formed in a straight line. Then, by covering the entire surface including the upper and lower end surfaces 43 of the laminate 36 with the moisture-proof sheet 3 in order to prevent the dew condensation of the product and the scattering of the rock wool, the heat insulating material 15 wrapped with the moisture-proof sheet 3 is obtained. . As described above, the heat insulating material 15 needs the moisture-proof sheet 3 on one side facing the indoor side, but does not need to provide the moisture-proof sheet 3 on the opposite side facing the outdoor side or the moisture-permeable hole 12 in the same. Are arbitrary. Hereinafter, the same applies.

The formwork 38 is provided with angular projections 40a, 40b and 41, which extend in the longitudinal direction at the rear end thereof, at both ends and the center of the flat surface 44 in order to obtain the heat insulating material 15. The central projection 41 is formed narrow. Further, the formwork 38 is arranged upward on the belt 37 to be conveyed.
The mold 38 may be installed so as to cover the stacked body 36 to be transferred.

In the heat insulating material 25 of the second example, the first concave portions 20a and 20b having the extending portions 19 are provided at both ends without providing the second concave portion 18 at the center. For this reason, although not shown, in order to manufacture the heat insulating material 25, the mold 38 has a narrow width, and has a configuration in which angular projections 40a, 40a extending in the rear longitudinal direction are provided at both ends. Use a good one. Further, similarly to the above, the formwork 38 may be either upward or downward.

FIG. 10 is different from the manufacturing method using the formwork 38 in that three roll-shaped heaters 47a and 47 are provided.
This is an example in which the heat insulating materials 15 and 25 are made using the b and 47c, and the heaters 47a, 47b and 47 are provided at intervals from above on the laminate 36 installed on the belt 37 during transfer.
c abuts, and the heat cures the phenol resin, and the second concave portion 18 and the first concave portions 20a, 20
0b are provided respectively.

Then, the heat insulating base material 16 is transferred to the heating device 39 by the transferring belt 37,
9 heats the entire heat insulating base material 16 and cures the phenolic resin, thereby forming the angular second concave portions 18 and the first concave portions 20a and 20a along the longitudinal direction at the central portion and both end portions of the one surface 42, respectively.
A laminate 36 in which Ob is formed in a straight line is produced. Further, the heat insulating material 15 in which the entire surface including the upper and lower end surfaces 43 of the laminate 36 is wrapped with the moisture-proof sheet 3 is obtained.

In order to make the heat insulating material 25, the heat insulating base material 16 is made narrower, and in order to interrupt the operation of the central heater 47b, it is lifted upward or the heater 47b is removed, so that both ends are removed. Only the heaters 47a and 47c need to be operated, and in the other steps, the desired heat insulating material 25 is obtained in the same manner as described above.

FIG. 11 shows an example in which the heat insulating material 30 of the fourth example is formed, and the second concave portion 18 and the first concave portion
The transfer belt 37 is stopped with respect to the heat-insulating base material 16 that has been heated and cured by the a and 20b, and the rod-shaped heater 48 is inclinedly contacted from the upper end side of the first concave portion 20b to the lower end side of the first concave portion 20a. The phenol resin is cured by the heat of the heater 48, and the second recess 18 and the first recess 20 are formed on one surface 17.
An inclined concave portion 31 intersecting with a and 20b is formed. Further, the heat insulating material 30 in which the entire surface including the upper and lower end surfaces 43 of the laminate 36 is wrapped with the moisture-proof sheet 3 is obtained.

In the case of the heat insulating material 30, although not shown,
When the mold 38 is provided with the projections 40a, 40b, and 41 and the inclined projection 49 extending from the upper end of the projection 40b to the lower end of the projection 40a, the intended heat insulating material 30 is heated by one use of the mold 38. It can be cured and the process can be omitted.

FIG. 12 shows an example different from the above-mentioned heat insulating material 30, in which an inclined projection 49 from the upper end of the projection 40b to the lower end of the projection 40a is heated and hardened by a roll-shaped heater 50.

Although not shown, the first concave portions 20a and 20b provided at both ends and the like may be formed by cutting with a cutter or the like by post-processing after the laminate 36 is cured by heating. That is.

[0036]

According to the heat insulating material of the present invention, the first and second concave portions of the heat insulating material which come into contact with the pillars and the studs are filled with a heat insulating base material of an inorganic fiber such as rock wool. Unlike the ears with only a moisture-proof sheet, there is no thermal bridge in the wall, and it is excellent in heat insulation and sound insulation.

In the heat insulating material, a concave portion is formed on the wall base which fits into the projection of the wall base which is an obstacle to installation of the heat insulating material. The installation work of the heat insulating material is simplified. Furthermore, since the heat insulating material is covered with the moisture-proof sheet on the entire surface, the heat insulating material can prevent scattering of the heat insulating base material such as rock wool and has an effect of eliminating the cause of dew condensation.

Further, according to the present invention, the first and second concave portions having the heat insulating base material are provided at both end portions or the like, and the wall base material is fitted with the protrusions of the wall base which hinder installation of the heat insulating material. A heat insulating material having a concavity can be easily manufactured, and a heat insulating material that can prevent scattering of the heat insulating base material can also be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a first example of a heat insulating material according to the present invention.

FIG. 2 is a cross-sectional view showing the state of attachment.

FIG. 3 is a perspective view showing a heat insulating material of a second example.

FIG. 4 is a cross-sectional view showing the state of attachment.

FIG. 5 is a perspective view showing a heat insulating material of a third example.

FIG. 6 is a perspective view showing a heat insulating material of a fourth example.

FIG. 7 is a cross-sectional view showing the state of attachment.

FIG. 8 is a cross-sectional view taken along a line ii, a line, and a line in FIG. 7;

FIG. 9 is a perspective view of an essential part showing a manufacturing method of a first example according to the present invention.

FIG. 10 is an essential part perspective view showing a manufacturing method of a second example.

FIG. 11 is a perspective view of an essential part showing a manufacturing method of a third example.

FIG. 12 is an essential part perspective view showing a manufacturing method of a fourth example.

FIG. 13 is a cross-sectional view showing a state of attachment of a conventional heat insulating material.

FIG. 14 is a perspective view showing a mounting state of a brace.

FIG. 15 is an explanatory diagram showing a cut state of a heat insulating material.

[Explanation of symbols]

 5,8 pillar 15,25 Insulation material 16 Insulation base material 20a, 20b First recess

Claims (6)

[Claims] 1. A heat insulating material comprising an inorganic fiber heat insulating base material disposed between pillars of a wall base constituting a wall body, wherein at least a heat insulating base material at a position to be attached to the pillar has a first recess formed therein. Insulation material characterized by being. 2. A second concave portion, which fits with the projection, is formed in the heat insulating base material at a position in contact with the projection of the wall foundation, which is an obstacle to the heat insulating material, between the pillars of the wall foundation constituting the wall body. The heat insulating material according to claim 1, wherein the heat insulating material is provided. 3. The heat insulating material according to claim 1, wherein at least one surface of the heat insulating base material is coated with a moisture-proof sheet. 4. A method for producing a heat insulating material comprising a heat insulating base material of inorganic fibers disposed between pillars of a wall foundation constituting a wall body, wherein the opened inorganic fibers are mainly composed of a thermosetting resin. Adding a binder and laminating to form a heat insulating substrate; forming at least a first concave portion in the heat insulating substrate at a position to be attached to the pillar; heating and curing the heat insulating substrate in the molded state And a process for producing a heat insulating material. 5. A method for producing a heat insulating material comprising a heat insulating base material of inorganic fibers disposed between pillars of a wall base constituting a wall body, wherein the opened inorganic fibers are mainly composed of a thermosetting resin. A step of forming a heat insulating base material by adding a binder and laminating, between the pillars of the wall base forming the wall, the heat insulating base material at a position in contact with the protrusion of the wall base which becomes an obstacle to the heat insulating material, A method for manufacturing a heat insulating material, comprising: a step of forming a second concave portion to be fitted with a projection; and a step of heating and curing the heat insulating base material after the forming. 6. The method according to claim 4, further comprising the step of covering at least one surface of the heat insulating base material with a moisture-proof sheet.
A method for producing the heat insulating material according to the above.