JP2007230228A - Method for production of heat insulating board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a heat insulating board, wherein lowering of a temperature in a bath can be much more suppressed and keeping a space for storing a cover becomes easy by reducing thickness and weight under maintaining a heat insulation property at the same level or higher than the so far conventional one and also maintaining rigidity with no deformation. <P>SOLUTION: The dies 26 is moved to the combining direction, whereby the sheet like resin 22 containing a vacuum heat insulating material 1 is held in a cavity formed in the die under combined state. Air is introduced from a nozzle 27, whereby softened sheet like resin 22 is expanded to the outer direction and pressed to the inner surface of the cavity of the die to form a heat insulating board having a predetermined shape. In this stage, a hot-melt adhesive 25 is previously coated on a surface of the vacuum heat insulating material 1, and thus the sheet like resin 22 and the vacuum heat insulating material 1 are adhered to each others. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a heat insulating board used as a heat insulating bath lid, a cold insulation box, or the like that can maintain a hot water temperature in a bathtub for a long time.

The bath lid is generally a resin single lid, a combination lid, or a folding lid. Among them, the folding lid needs to be thin because it needs flexibility, and has almost no heat insulation performance. On the other hand, in the case of a single lid and a combination lid, there are many products that use a resin material. As a resin-made bath lid, both sides of a product provided with a hollow portion (air heat insulating layer) between two resin plates and a resin-based heat insulating material as described in Patent Documents 1 and 2 are resin plates. Sandwiched products are common.

  As the above sandwich-type bath lid, Patent Literature 1 discloses an upright bath lid and Patent Literature 2 discloses a float-type bath lid.

JP 2003-225173 A JP 2005-230149 A

  The sandwich-type bath lid has better heat insulation than the hollow-type bath lid. However, since the thermal conductivity is generally about 0.028 to 0.036 W / m · K, the bath lid is thickened to obtain sufficient heat insulation. Therefore, both of the top-type bath lid as in Patent Document 1 and the float-type bath lid of Patent Document 2 have a problem of taking up space when standing in a bathroom.

  In addition, a bath lid using a vacuum heat insulating material having a very high heat insulating property in combination with a resin heat insulating material is also commercially available. For example, Matsushita Electric has incorporated a vacuum heat insulating material (trade name: U-Vacua) into a bath lid. Since the vacuum heat insulating material itself is not rigid and bends when used as a bath lid, this product is reinforced by sandwiching it with another resin heat insulating material. Therefore, although the heat insulating property is sufficiently improved, the thickness of the entire bath lid is not so much as that of the conventional product, and there is no change in the problem of the place in the bathroom.

  Furthermore, a cold box has been conventionally known. The general structure of a cold box is a foamed resin board formed into a box shape. However, the foamed resin board itself is not sufficient in terms of strength, and is too thick to obtain the required strength.

  The present invention relates to a method for producing a heat insulating board used as a part of a bath lid or a cold box, and the first invention is the two sheets of softened resin that are softened between a pair of molds. A vacuum heat insulating material is set between the sheet-like resins, and then the mold is closed to wrap the vacuum heat-insulating material with the two sheet-like resins, and further supply air into the closed mold. The sheet-like resin was pressed against the mold cavity and molded.

  In the second invention, the softened cylindrical resin is faced between a pair of molds, a vacuum heat insulating material is set in the inner space of the cylindrical resin, and then the mold is closed to close the mold by the cylindrical resin. A vacuum heat insulating material is wrapped, and air is supplied into a closed mold so that the cylindrical resin is pressed against the mold cavity and molded.

  In the first and second aspects of the invention, a part of the surface of the vacuum heat insulating material is preliminarily coated with a hot melt, a hot melt sheet, a heat-weldable resin sheet such as polyethylene, or a double-sided adhesive tape. By wearing it, the vacuum heat insulating material wrapped inside the resin after molding will not move.

  3rd invention is the manufacturing method of the heat insulation board which encloses a vacuum heat insulating material, sets a vacuum heat insulating material in a metal mold | die, pours the melted resin around this vacuum heat insulating material, The whole surface of a vacuum heat insulating material Were covered with resin so as to be integrated.

  4th invention is the manufacturing method of the heat insulation board which encloses a vacuum heat insulating material, Comprising: A vacuum heat insulating material is inserted in the bottomed flat box-shaped resin box, and the opening part of this box is sealed with the resin material. I tried to do it. In the fourth invention, the space between the inner wall of the box and the vacuum heat insulating material may be filled with foam.

  5th invention is the manufacturing method of the heat insulation board which encloses a vacuum heat insulating material, Comprising: A vacuum heat insulating material is pinched | interposed between two resin surface materials, The foam is filled in the space | gap part around a vacuum heat insulating material, The two surface materials are connected by ribs.

  In 5th invention, the structure which arrange | positions a vacuum heat insulating material in the space formed by providing a rib on one side of the said surface material, or using a surface material with a rib can be considered. Further, a convex rib is formed on one of the two surface materials, a concave rib is formed on the other, and the concave and convex ribs are fitted to form the space, and the space is further partitioned. A plurality of ribs may be provided in tandem or intersecting, and the vacuum heat insulating material may be disposed in each of the spaces thus subdivided. Alternatively, the two surface materials may be formed in the same shape with ribs, and the two surface materials may be butted or fitted together.

  According to the 1st invention and the 2nd invention, the heat insulation board which was lightweight and thin and excellent in the heat insulation effect can be fabricated. Therefore, it exhibits excellent effects as a bath lid and a cold box. Moreover, even if it is a simple plate shape, a sufficient cold insulation effect can be exhibited only by leaning on the inner wall surface of the cold insulation vehicle, and the storage capacity can be ensured because the thickness is thin.

  In the third invention, since the molten resin is poured around the vacuum heat insulating material and the entire surface of the vacuum heat insulating material is covered with the resin and integrated, the number of manufacturing steps can be reduced. In addition, the thickness of the heat insulation board can be adjusted freely depending on the design of the mold, and it is easy to reduce the thickness. Further, since the entire surface of the vacuum heat insulating material is seamlessly covered with the resin material, the side surface resin material has the same effect as the rib and has a structure that is not easily bent.

  In addition, when two or more vacuum heat insulating materials are used and are arranged at a distance from each other, and molten resin is poured therein, the molten resin enters the gap formed between the vacuum heat insulating materials. Thus, a rib is formed, and the bending resistance is further improved.

  In the fourth invention, a vacuum heat insulating material is inserted into an envelope-shaped resin box and the envelope opening is sealed with a resin material. Can be provided. Moreover, heat insulation can be further improved by filling the space between the inner wall of the box and the vacuum heat insulating material with a foam.

  In the fifth invention, a vacuum heat insulating material is sandwiched between two resin surface materials, a void is filled in the space around the vacuum heat insulating material, and the two surface materials are connected by ribs. It is possible to provide a heat-insulating board that is thin and difficult to bend and has high heat insulating properties as compared with the above products. Further, if a rib is provided on one surface of the surface material or a surface material with a rib is used and a vacuum heat insulating material is disposed in a space formed by the rib, the heat insulating property can be further enhanced.

  Further, by forming a convex rib on one of the two surface materials and a concave rib on the other, and forming the space by fitting these concave and convex ribs, the mutual displacement between the surface materials is achieved. Can be prevented. Further, by providing a plurality of ribs for further partitioning the space in series or intersecting, and by disposing a vacuum heat insulating material in each of the subdivided spaces, the bending resistance is further improved, and the vacuum heat insulation is provided. A heat insulation board can be manufactured without being influenced by the size of the single material.

  Further, by covering the outer peripheral portion of the heat insulating board with an elastic resin, there is an effect that a gap is not formed when the heat insulating boards are hardly damaged and arranged.

  The vacuum heat insulating material used for the heat insulating board of the present invention is a material in which the heat insulating material is covered with a resin film having a high barrier property, and the periphery of the internal heat insulating material is sealed after vacuum treatment. As the internal heat insulating material, fiber heat insulating materials such as glass wool and rock wool, and resin heat insulating materials such as urethane foam and polyethylene foam are used. The heat conductivity of the vacuum heat insulating material is as excellent as 1/5 to 1/20 of the fiber-based and resin-based heat insulating materials.

  In the first aspect of the present invention, the heat insulating board is manufactured by blow molding. This will be described with reference to the drawings. 1 is a perspective view illustrating a method for manufacturing a heat insulation board, FIG. 2 is a cross-sectional view in a state where a mold is closed, FIG. 3 is a perspective view of a vacuum heat insulating material, and FIG. 4 is a perspective view of a cold insulation box using the heat insulation board. It is.

  In FIG. 1, softened resin is stored in the resin supply portion 20 of the box, and the softened resin 22 from a pair of slit-shaped discharge ports 21 and 21 formed on the bottom surface of the box 20 has a predetermined shape in a sheet shape. It has a structure that flows down at a speed.

Further, the vacuum heat insulating material 1 is suspended and supported on the lower surface of the box 20 via jigs 23 and 23. The vacuum heat insulating material 1 may be supported by the jig 24 from below. As shown in FIG. 3, a hot melt 25 is preferably applied to the surface of the vacuum heat insulating material 1 in advance so that the sheet-like resin 22 and the vacuum heat insulating material 1 are not separated during blow molding described later.
It should be noted that a double-sided tape or the like may be used instead of the hot melt 25 so that the vacuum heat insulating material 1 does not rattle after blow molding.

  Further, molds 26, 26 are disposed on the outside of the sheet-like resins 22, 22 so as to be able to advance and retract laterally, and are formed between the jigs 23, 23 when the molds 26, 26 are closed. An air blow nozzle 27 for feeding air into the cavity is provided.

  In the above, when the molds 26 and 26 are moved in the mold alignment direction from the state shown in FIG. 1, the sheet-like resins 22 and 22 are contained in the cavities formed in the mold aligned state as shown in FIG. Is held in a state in which the vacuum heat insulating material 1 is wrapped. When air is blown from the nozzle 27 from this state, the softened sheet-like resins 22 and 22 swell outward and are pressed against the inner surface of the cavity of the mold to be formed into a heat insulating board 30 having a predetermined shape. At this time, as described above, since the hot melt 25 is applied to the surface of the vacuum heat insulating material 1 in advance, the sheet-like resin 22 and the vacuum heat insulating material 1 are bonded.

  FIG. 4 shows a cold insulation box in which the heat insulating board 30 formed by the above process is configured as a side plate, a bottom plate, and a top plate. For example, the heat insulating board 30 may be attached to the inner wall of the storage portion of the cold-reserved vehicle.

FIG. 5 is a perspective view showing a second aspect of the present invention, and also in this second aspect, a heat insulating board is manufactured by blow molding.
That is, in this embodiment, the cylindrical softened resin (parison) 32 flows down from the drum-shaped resin supply unit 31. The vacuum heat insulating material 1 faces the softened cylindrical resin 32, and the molds 26 and 26 are closed while being stretched left and right by a rod-shaped stretching jig 33, and air is blown into the mold cavity from the nozzle 27. As described above, a heat insulating board in which the vacuum heat insulating material 1 is wrapped is obtained.
In addition, the resin protruding to the outside of the mold is cut and reused.

  In the third aspect of the present invention, molten resin is poured around the vacuum heat insulating material, and the entire surface of the vacuum heat insulating material is covered with the resin to integrate the bath lid. Specifically, a vacuum heat insulating material is suspended in an injection mold, and a thermoplastic molten resin is poured into the mold, or a vacuum heat insulating material immersed in the molten resin is sandwiched between compression molds. , Cool and solidify to produce insulation board

  The bath lid as an example of the heat insulation board manufactured in this way is shown in FIG. FIG. 6A is a plan view and FIG. 6B is a cross-sectional view of a bath lid. As shown in the figure, the vacuum heat insulating material 1 is completely covered with the resin material 2. According to this manufacturing method, the resin / film forming the vacuum heat insulating material 1 and the melted and solidified resin material 2 are welded in one shot. For this reason, the number of manufacturing steps can be reduced.

  In addition, the thickness of the bath lid can be adjusted freely depending on the design of the mold, and it is easy to make it thinner. Furthermore, since the entire surface of the vacuum heat insulating material is seamlessly covered with the resin material, the side surface resin material has the same effect as the rib, and has a structure that is difficult to bend when used in a bathtub.

  In this embodiment, two or more vacuum heat insulating materials can be used, arranged in the mold at a distance from each other, and the molten resin can be poured. By setting it as such a manufacturing method, molten resin approachs also into the clearance gap formed between vacuum heat insulating materials, a rib is formed, and a bending resistance improves further.

  FIG. 7 is a perspective view showing another aspect of the heat insulating bath lid. In this aspect, the vacuum heat insulating material 1 is inserted into the envelope-shaped resin box 3, and the main body opening 3a is sealed with the resin material 4 serving as a lid. A block-shaped foam 11 may be filled between the inner wall of the box 3 and the vacuum heat insulating material 1.

  If a heat insulation bath lid is manufactured according to this aspect, it is possible to provide a bath cap that is thin and hard to bend as compared with conventional products and that has high heat insulation properties.

  FIG. 8 is a perspective view showing another aspect of the heat insulating bath lid. In this embodiment, the vacuum heat insulating material 1 is sandwiched between the two resin surface materials 5 and 6, and the void around the vacuum heat insulating material is filled with a foam (not shown). And a bath lid is manufactured by connecting between the two surface materials 5 and 6 with the rib 6a. The other two sides of the surface material 6 that do not have the ribs 6a can be covered with an elastic resin described later.

  In this drawing, the surface material 6 is a surface material with ribs 6a, but a resin material independent of the surface materials 5 and 6 may be separately prepared for the ribs. The ribs 6a may be provided on only two opposite sides of the surface material 6 as shown in the figure, but may be provided on all four sides. By attaching the rib 6a, it is possible to provide a bath cap that is thin and difficult to bend compared to conventional products and that has a high thermal insulation property.

  FIG. 9 is a perspective view showing a modification of another embodiment of the heat insulating bath lid. In this modification, the surface material 5 is provided with convex ribs 5a, while the surface material 6 is provided with concave ribs 6a. Contrary to this figure, the surface material 5 side may be a concave rib and the surface material 6 side may be a convex rib. The vacuum heat insulating material 1 is put in a space formed by fitting the convex rib 5a and the concave rib 6a, and the periphery thereof is filled with the foam 11.

  Finally, the heat insulating bath lid is manufactured by thermally fusing or bonding the resin surface material 5 and the rib 6a. When the bath lid is manufactured by fitting the concave and convex ribs, it is possible to prevent the surface materials 5 and 6 from being displaced from each other at the time of manufacturing.

  As can be said for the present invention as a whole, it is basically efficient to provide the rib in the width direction when it is put on the bathtub, but it may also be provided in the length direction, and as described above, the four sides May be provided continuously.

  FIG. 10 is a perspective view showing another modification of another embodiment of the heat insulating bath lid. In this modification, the space formed by the surface materials 5 and 6 and the rib 6a is provided by crossing a plurality of ribs 6b and 6c for further partitioning. The vacuum heat insulating material 1 and a foam (not shown) are respectively put in the space thus subdivided and integrated.

  The arrangement and number of the ribs 6b and 6c can be freely set in consideration of the size of the vacuum heat insulating material 1 and the like. For example, as shown in FIG. 11, the ribs 6b and 6c are formed on the respective surface materials. However, the other rib 6b may be inserted into one rib 6c to form a cut.

  It is also possible to eliminate the rib 6b and add several ribs (not shown) parallel to the rib 6c. Moreover, the vacuum heat insulating material 1 and the surface materials 5 and 6 can be made more difficult to bend by attaching them with an adhesive.

  Various other modifications can be considered for the method for manufacturing a heat insulating board of the present invention. For example, in FIG. 8, both of the two surface materials 5 and 6 can be formed in the same shape with ribs, and the edge of these two surface materials can be abutted to form a bath lid. Further, the two surface materials 5, 6 are respectively formed into a shape with a lunch box body-like shape and a lunch box-shaped peripheral rib, and both surface materials are fitted to the lunch box so as to cover the bath lid. It can also be manufactured.

  FIG. 12 is a front view showing an example of the entire bath lid. The heat insulating bath lid 10 manufactured by each of the manufacturing methods described above is composed of the surface material 5 containing the vacuum heat insulating material and the foam. It can be covered with the elastic resin 7. The elastic resin 7 may cover the entire outer periphery, or may cover a part as shown in the figure. By covering the outer peripheral portion, there are effects such that the bath lid does not break when dropped, and there is no gap between the bath lid and the bathtub when placed in the bathtub.

  The heat insulation board of the present invention manufactured by the manufacturing method described above ensures heat insulation equivalent to or higher than that of the conventional one, has rigidity that does not cause bending, and is thin and lightweight. For this reason, for example, a drop in hot water temperature in the bathtub can be further suppressed, a space for placing the lid can be easily secured, and the insulated bath lid is easy to handle for children and the elderly.

The perspective view explaining the manufacturing method which concerns on the 1st aspect of a heat insulation board. Sectional view with mold closed Perspective view of vacuum insulation Perspective view of a cold insulation box using an insulation board The perspective view explaining the manufacturing method which concerns on the 2nd aspect of a heat insulation board. (A) Top view and (b) Cross section of a bath lid as an insulation board The perspective view which shows another aspect of the bath lid as an insulation board The perspective view which shows another aspect of the bath lid as an insulation board The perspective view which shows another aspect of the bath lid as an insulation board The perspective view which shows another aspect of the bath lid as an insulation board The perspective view which shows another Example of a rib shape Front view showing an example of the entire bath lid

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Vacuum heat insulating material, 2 ... Resin material, 3 ... Resin box, 3a ... Main body opening part, 4 ... Resin cover material, 5, 6 ... Resin surface material, 5a, 6a, 6b, 6c ... Rib, DESCRIPTION OF SYMBOLS 7 ... Elastic resin, 10 ... Thermal insulation bath lid, 11 ... Foam, 20 ... Resin supply part, 21 ... Slit-like discharge port, 22 ... Softened sheet-like resin, 23, 24 ... Jig, 25 ... Hot melt, 26 DESCRIPTION OF SYMBOLS ... Die, 27 ... Nozzle, 30 ... Thermal insulation board, 31 ... Drum-shaped resin supply part, 32 ... Softened cylindrical resin (parison), 33 ... Stretching jig.

Claims (15)

Two sheets of softened resin are exposed between a pair of molds, a vacuum heat insulating material is set between the two softened sheets of resin, and then the molds are closed to close the two sheets of resin. A method for manufacturing a heat insulating board, comprising: encapsulating the vacuum heat insulating material with a sheet-shaped resin, and further pressing the sheet-shaped resin against a cavity of the mold by supplying air into a closed mold. A soft cylindrical resin is placed between a pair of molds, a vacuum heat insulating material is set in an inner space of the cylindrical resin, and then the mold is closed to enclose the vacuum heat insulating material with the cylindrical resin. A method for manufacturing a heat insulating board, characterized in that the tubular resin is pressed against a cavity of a mold by supplying air into a further closed mold. A method for manufacturing a heat insulation board that encloses a vacuum heat insulating material, in which a vacuum heat insulating material is set in a mold, a molten resin is poured around the vacuum heat insulating material, and the entire surface of the vacuum heat insulating material is covered with the resin. A method for producing a heat insulating board, characterized by integrating. A method for manufacturing a heat insulating board that includes a vacuum heat insulating material, wherein the vacuum heat insulating material is inserted into a bottomed flat box-shaped resin box, and the opening of the box is sealed with a resin material. A method of manufacturing an insulation board. The method for manufacturing a heat insulation board according to claim 4, wherein the space between the inner wall of the box and the vacuum heat insulation material is filled with a foam. A method of manufacturing a heat insulation board that encloses a vacuum heat insulating material, sandwiching the vacuum heat insulating material between two resin surface materials, filling the void around the vacuum heat insulating material with foam, and further, two surfaces The manufacturing method of the heat insulation board characterized by connecting between materials with a rib. In the manufacturing method of the heat insulation board of Claim 6, a rib is provided in the single side | surface of the said surface material, or a surface material with a rib is used, and a vacuum heat insulating material is arrange | positioned in the space formed by this rib. A method of manufacturing a heat insulation board characterized by the above. In the manufacturing method of the heat insulation board of Claim 6 or Claim 7, a convex rib is formed in one of the two surface materials, and a concave rib is formed in the other. And manufacturing the heat insulation board, wherein the space is formed. The method for manufacturing a heat insulation board according to any one of claims 6 to 8, wherein a plurality of ribs for further partitioning the space are provided in tandem or intersecting, and the vacuum heat insulation is provided in each of the subdivided spaces. A method for manufacturing a heat insulating board, characterized by disposing a material. The method for manufacturing a heat insulating board according to any one of claims 6 to 9, wherein the two surface materials are formed in the same shape with ribs, and the two surface materials are abutted together. Manufacturing method of heat insulation board. 10. The method for manufacturing a heat insulating board according to claim 6, wherein the two surface materials are formed in a shape with a peripheral rib in a lunch box body shape and a lunch box lid shape, respectively, and both surface materials are formed. The manufacturing method of the heat insulation board characterized by making it fit. The method for manufacturing a heat insulating board according to any one of claims 1 to 11, wherein an outer peripheral portion of the heat insulating board is covered with an elastic resin. 3. The method of manufacturing a heat insulation board according to claim 1, wherein a resin sheet that can be preliminarily applied with hot melt, affixed with a hot melt sheet, or heat-welded, such as polyethylene, on a part of the surface of the vacuum heat insulating material. A method for producing a heat insulating board, characterized by comprising attaching an adhesive or a double-sided adhesive tape. The method for manufacturing a heat insulation board according to any one of claims 1 to 13, wherein two or more of the vacuum heat insulating materials are used and spaced apart from each other. . The method for manufacturing a heat insulating board according to any one of claims 1 to 14, wherein the heat insulating board is a bath lid or a cold box.

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