JP2008073600A - Method of manufacturing heat insulating sheet, and heat insulating sheet - Google Patents

Method of manufacturing heat insulating sheet, and heat insulating sheet Download PDF

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JP2008073600A
JP2008073600A JP2006254750A JP2006254750A JP2008073600A JP 2008073600 A JP2008073600 A JP 2008073600A JP 2006254750 A JP2006254750 A JP 2006254750A JP 2006254750 A JP2006254750 A JP 2006254750A JP 2008073600 A JP2008073600 A JP 2008073600A
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sheet
heat insulating
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insulating layer
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Hiroshi Kawate
浩 川手
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a heat insulating sheet capable of being immediately wound or folded without degrading heat insulating effect, and the heat insulating sheet. <P>SOLUTION: This invention relates to the heat insulating sheet 1 and the method of the heat insulating sheet 1, comprising: a sheet like base material 2 consisting of nonwoven cloth; a heat insulating layer 3 formed on at least one surface of the sheet like base material 2; and an adhesive layer 4 provided on another surface of the sheet like base material 2 or the upper surface of the heat insulating layer 3 and having an adhesive 4a and an adhesive protective sheet 4b pasted separably from the adhesive material 4a, wherein the heat insulating layer 3 has a heat insulating coating film formed by applying a heat insulating coating material 6 comprising a mixture of hollow beads and an acrylic resin to be applied on the sheet like base material 2 and removing water and drying by the irradiation with far infrared light or a microwave, and the adhesive layer 4 is formed by applying the adhesive 4a on the sheet like base material 2 or the heat insulating layer 3 and covering with the adhesive protective sheet 4b. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、断熱シートの製造方法及び断熱シートに関する。
The present invention relates to a method for manufacturing a heat insulating sheet and a heat insulating sheet.

従来、建造物の屋根や外壁等に断熱処理を施す場合、塗装業者が、直接、断熱処理を必要とする箇所に、断熱塗材の塗装作業を行なう。しかし、このような塗装作業を行なった場合、塗装後に断熱塗材が乾燥するまでに時間がかかり、この間、次の作業が出来ないという問題があった。また、塗装作業時に塗料がタレ落ちたり、乾燥中に塵埃が付着して、塗装品質が悪化したり、断熱効果が低下するという問題があった。   Conventionally, when a heat treatment is performed on a roof, an outer wall, or the like of a building, a painter directly performs a coating operation of a heat insulating coating material on a place requiring the heat treatment. However, when such a painting operation is performed, there is a problem that it takes time until the heat insulating coating material is dried after painting, and the next operation cannot be performed during this time. In addition, there are problems in that the paint drops during the painting operation, dust adheres during drying, the coating quality deteriorates, and the heat insulation effect decreases.

これらの問題を解決すべく、特許文献１に記載されているように、断熱塗材を予め、柔軟なシートの一面全面に塗布した断熱シートを用いることで、塗装作業を不要とし簡単な施工で断熱を行なうことが出来るようになった。   In order to solve these problems, as described in Patent Document 1, by using a heat insulating sheet in which a heat insulating coating material is applied to the entire surface of a flexible sheet in advance, no painting work is required and simple construction can be performed. Insulation can be performed.

しかし、このような断熱シートには、以下に説明する課題があった。   However, such a heat insulating sheet has a problem described below.

実用新案登録第３０４６１６７号公報Utility Model Registration No. 3046167

特許文献１に記載の断熱シートは、シートに断熱塗材を塗布した後、断熱塗材を硬化させるため、自然乾燥または空気を吹付けること（送風）により乾燥させる。   The heat insulating sheet described in Patent Document 1 is dried by natural drying or air blowing (air blowing) in order to cure the heat insulating coating material after applying the heat insulating coating material to the sheet.

しかし、自然乾燥の場合にはおよそ２４時間もかかり、空気を吹付けることによる強制乾燥の場合でも、１時間〜２時間はかかる。この間、完全に乾燥するまでは、断熱シートを広げたまま放置しなければならず、断熱シートを巻き取ったり折畳んだりすることが出来ないため、断熱シートの製造場所の確保が必要となり、断熱シートの大量生産ができない。   However, in the case of natural drying, it takes about 24 hours, and even in the case of forced drying by blowing air, it takes 1 to 2 hours. During this time, the insulation sheet must be left unfolded until it is completely dried, and the insulation sheet cannot be wound or folded. Mass production of sheets is not possible.

また、強制乾燥の場合には、空気を吹付けるので、乾燥過程で塗装ムラが生じたり、表面に気泡が発生してしまい、塗装品質が劣化し、ひいては、断熱効果の低下につながる。   Further, in the case of forced drying, since air is blown, coating unevenness occurs during the drying process, or bubbles are generated on the surface, resulting in deterioration of the coating quality and eventually leading to a decrease in the heat insulating effect.

本発明は、このような従来の問題点に鑑みてなされたものであって、断熱効果が低下することなく、すぐに巻いたり折畳んだりすることが可能な断熱シートの製造方法及び断熱シートを提供することにある。
The present invention has been made in view of such conventional problems, and includes a method for manufacturing a heat insulating sheet and a heat insulating sheet that can be immediately wound or folded without lowering the heat insulating effect. It is to provide.

本発明の断熱シートの製造方法は、不織布からなるシート状基材と、前記シート状基材の少なくとも一方の面に形成された断熱層と、前記シート状基材の他方の面、または、前記断熱層の上面に設けられ、粘着材と前記粘着材から離脱可能な粘着材保護シートを有する接着層とから構成される断熱シートの製造方法であって、中空ビーズとアクリル系樹脂との混合物からなる断熱塗材を、前記シート状基材に塗布し、遠赤外線もしくはマイクロ波を照射して抜水により断熱塗膜を形成し、前記断熱層とする断熱層形成工程と、前記断熱層形成工程の前に、前記シート状基材に前記粘着材を塗布し、または、前記断熱層形成工程の後に、前記シート状基材もしくは前記断熱層に前記粘着材を塗布し、前記粘着材を前記粘着材保護シートで覆い、前記接着層とする接着層形成工程とを含むことを特徴とする。   The method for producing a heat-insulating sheet of the present invention includes a sheet-like substrate made of a nonwoven fabric, a heat-insulating layer formed on at least one surface of the sheet-like substrate, and the other surface of the sheet-like substrate, or A method for producing a heat insulating sheet provided on an upper surface of a heat insulating layer and comprising an adhesive material and an adhesive layer having an adhesive protective sheet that can be detached from the adhesive material, comprising a mixture of hollow beads and acrylic resin The heat insulating coating material is applied to the sheet-like base material, far infrared rays or microwaves are applied to form a heat insulating coating film by draining, and the heat insulating layer forming step and the heat insulating layer forming step The adhesive material is applied to the sheet-like base material before or after the heat-insulating layer forming step, the adhesive material is applied to the sheet-like base material or the heat-insulating layer, and the adhesive material is attached to the adhesive material. Cover with a protective sheet, Characterized in that it comprises an adhesive layer forming step of the serial adhesive layer.

また、本発明の断熱シートは、不織布からなるシート状基材と、前記シート状基材の少なくとも一方の面に形成された断熱層と、前記シート状基材の他方の面、または、前記断熱層の上面に設けられ、粘着材と前記粘着材から離脱可能な粘着材保護シートを有する接着層とから構成される断熱シートであって、前記断熱層は、前記シート状基材に塗布される中空ビーズとアクリル系樹脂との混合物からなる断熱塗材を、遠赤外線もしくはマイクロ波の照射により抜水し、断熱塗膜を形成したものであり、前記接着層は、前記シート状基材もしくは前記断熱層に前記粘着材を塗布し、前記粘着材保護シートで覆ったものであることを特徴とする。   Further, the heat insulating sheet of the present invention is a sheet-like base material made of a nonwoven fabric, a heat insulating layer formed on at least one surface of the sheet-like base material, and the other surface of the sheet-like base material, or the heat insulating material. A heat insulating sheet provided on the upper surface of the layer and comprising an adhesive material and an adhesive layer having an adhesive protective sheet that can be detached from the adhesive material, wherein the heat insulating layer is applied to the sheet-like substrate A heat insulating coating material comprising a mixture of hollow beads and acrylic resin is drained by irradiation with far infrared rays or microwaves to form a heat insulating coating, and the adhesive layer is formed of the sheet-like substrate or the above The adhesive material is applied to a heat insulation layer and covered with the adhesive material protective sheet.

このように、シート状基材に断熱塗材を塗布後、当該塗布面に、遠赤外線もしくはマイクロ波を照射して抜水し、断熱層を形成するようにしたので、遠赤外線やマイクロ波の特性により、塗布された断熱塗材の内部から水分が蒸発し、塗装ムラや気泡の発生なく、しかも、早期に乾燥させることができる。つまり、品質の維持された断熱シートが製造されるとともに、断熱シートの製造効率を向上させられる。   Thus, after applying the heat insulating coating material to the sheet-like base material, the application surface is irradiated with far infrared rays or microwaves to drain water and form a heat insulating layer. Due to the characteristics, moisture evaporates from the inside of the applied heat-insulating coating material, so that coating unevenness and bubbles do not occur and can be dried at an early stage. That is, a heat insulating sheet having a maintained quality can be manufactured and the manufacturing efficiency of the heat insulating sheet can be improved.

また、断熱塗材は、アクリル系樹脂をバインダーとしているので、弾力性、伸縮性に富み、塗装しやすく、断熱層は、弾力性・柔軟性に優れる。更に、断熱塗材をシート状基材に塗布した場合、不織布であるシート状基材がつなぎの役割を果たすので、断熱層がシート状基材に形成されても劣化がしにくく、耐久性に優れ、折り曲げや巻き取りをしても、シート状基材から断熱層が剥離することがない。   Further, since the heat insulating coating material uses an acrylic resin as a binder, it is rich in elasticity and stretchability, is easy to paint, and the heat insulating layer is excellent in elasticity and flexibility. Furthermore, when the heat insulating coating material is applied to the sheet-like base material, the sheet-like base material that is a non-woven fabric plays a role of linking. It is excellent and the heat insulating layer does not peel off from the sheet-like base material even if it is bent or wound.

また、前記中空ビーズは、アクリルビーズであり、前記アクリル系樹脂は、スチレンアクリル酸アルキルエステル共重合物エマルジョンであってもよい。   The hollow beads may be acrylic beads, and the acrylic resin may be a styrene acrylic acid alkyl ester copolymer emulsion.

その際、前記断熱層に含まれる中空ビーズの重量比率は、３０〜７０％とすることが望ましい。   At that time, the weight ratio of the hollow beads contained in the heat insulating layer is preferably 30 to 70%.

このように、同じアクリル系材料同士を混合することで、バインダーとしてのアクリル系エマルジョンが、中空ビーズを抱き込みやすい状態が生まれ、中空ビーズの重量比率の大きい、すなわち、断熱効果の高い断熱層が形成される。   Thus, by mixing the same acrylic materials, an acrylic emulsion as a binder is apt to embrace the hollow beads, and the weight ratio of the hollow beads is large, that is, a heat insulating layer having a high heat insulating effect. It is formed.

また、前記断熱層形成工程では、前記断熱塗材が所定厚みに塗布された前記シート状基材を、前記マイクロ波もしくは遠赤外線の照射炉内に通過させた後、前記断熱層が形成されたシート状基材を巻き取ってもよい。   Further, in the heat insulating layer forming step, the heat insulating layer is formed after the sheet-like base material coated with the heat insulating coating material is passed through the microwave or far infrared irradiation furnace. You may wind up a sheet-like base material.

このように、断熱塗材の乾燥時間を待たず、次々に断熱シートを製造して、巻き取ることが出来るので、製造された断熱シートの保管場所をとらない。   Thus, since the heat insulation sheet can be manufactured and wound up one after another without waiting for the drying time of the heat insulation coating material, the storage place of the manufactured heat insulation sheet is not taken up.

また、前記断熱シートの接着材側の面は、建築物の内外壁、自動車・航空機・列車等の車体の内外表面、カーテンウォールの内外壁のいずれかに、貼着されてもよい。   Further, the surface on the adhesive material side of the heat insulating sheet may be attached to any of the inner and outer walls of a building, the inner and outer surfaces of a vehicle body such as an automobile, aircraft, and train, and the inner and outer walls of a curtain wall.

上述したように本発明の断熱シートは、耐久性・柔軟性を有するので、建築物の内外壁や車体の内外表面やカーテンウォールの内外壁といった、平面のみならず曲面をも有する部分の断熱に好適である。
As described above, since the heat insulation sheet of the present invention has durability and flexibility, it is suitable for heat insulation of portions having curved surfaces as well as flat surfaces such as inner and outer walls of buildings, inner and outer surfaces of vehicle bodies, and inner and outer walls of curtain walls. Is preferred.

本発明の断熱シートの製造方法及び断熱シートによれば、シート状基材に断熱塗材を塗布後、当該塗布面に、遠赤外線もしくはマイクロ波を照射して、断熱層を形成するようにしたので、遠赤外線やマイクロ波の特性により、塗布された断熱塗材の内部から水分が蒸発し、塗装ムラや気泡の発生なく、しかも、早期に乾燥させることができる。つまり、品質の維持された断熱シートが製造されるとともに、断熱シートの製造効率を向上させられる。   According to the method for manufacturing a heat insulating sheet and the heat insulating sheet of the present invention, after applying the heat insulating coating material to the sheet-like substrate, the application surface is irradiated with far infrared rays or microwaves to form a heat insulating layer. Therefore, due to the characteristics of far-infrared rays and microwaves, moisture evaporates from the inside of the applied heat-insulating coating material, so that coating unevenness and bubbles do not occur and can be dried quickly. That is, a heat insulating sheet having a maintained quality can be manufactured and the manufacturing efficiency of the heat insulating sheet can be improved.

また、断熱塗材は、アクリル系樹脂をバインダーとしているので、弾力性、伸縮性に富み、塗装しやすく、断熱層は、弾力性・柔軟性に優れる。更に、断熱塗材をシート状基材に塗布した場合、不織布であるシート状基材がつなぎの役割を果たすので、断熱層がシート状基材に形成されても劣化がしにくく、耐久性に優れ、折り曲げや巻き取りをしても、シート状基材から断熱層が剥離することがない。
Further, since the heat insulating coating material uses an acrylic resin as a binder, it is rich in elasticity and stretchability, is easy to paint, and the heat insulating layer is excellent in elasticity and flexibility. Furthermore, when the heat-insulating coating material is applied to the sheet-like base material, the sheet-like base material that is a non-woven fabric plays a role of linking, so that even if the heat-insulating layer is formed on the sheet-like base material, it is difficult to deteriorate and is durable. It is excellent and the heat insulating layer does not peel off from the sheet-like substrate even if it is folded or wound.

以下、図面を参照して、本発明の断熱シートの製造方法及び当該製造方法により製造された断熱シートの実施例について説明する。   Hereinafter, with reference to drawings, the example of the manufacturing method of the heat insulation sheet of the present invention and the heat insulation sheet manufactured by the manufacturing method is explained.

図１は、本発明の断熱シートの構造の一実施例を示す部分断面図である。図１（ａ）に示す断熱シート１ａの構造は、不織布からなるシート状基材２、シート状基材２の一方の面に形成された断熱層３、シート状基材２の他方の面に設けられ、粘着材４ａと粘着材４ａから離脱可能な粘着材保護シート４ｂを有する接着層４とから構成されている。尚、本実施例のシート状基材２は約１００μｍ、断熱層３は約６００μｍ、粘着材４ａは約１００μｍ、粘着材保護シート４ｂは約１００μｍとなっている。   FIG. 1 is a partial cross-sectional view showing an example of the structure of the heat insulating sheet of the present invention. The structure of the heat insulation sheet 1a shown to Fig.1 (a) is the sheet-like base material 2 which consists of a nonwoven fabric, the heat insulation layer 3 formed in one surface of the sheet-like base material 2, and the other surface of the sheet-like base material 2 The adhesive layer 4 is provided and includes an adhesive material 4a and an adhesive material protective sheet 4b that can be detached from the adhesive material 4a. In this embodiment, the sheet-like substrate 2 is about 100 μm, the heat insulating layer 3 is about 600 μm, the adhesive 4a is about 100 μm, and the adhesive protective sheet 4b is about 100 μm.

断熱層３は、セラミックビーズ、アクリルビーズ等の中空ビーズと、バインダー（結合材）としてアクリル系樹脂を混ぜて得られた断熱塗材を、シート状基材２の一方の面に塗布して抜水乾燥させて、断熱塗材の塗膜を形成することで得られる。尚、本実施例の断熱層３は、断熱塗材中の水分を抜くだけで塗膜が形成されるようになっている。   The heat insulating layer 3 is formed by applying a heat insulating coating material obtained by mixing hollow beads such as ceramic beads and acrylic beads and an acrylic resin as a binder (binding material) to one surface of the sheet-like substrate 2. It is obtained by drying with water to form a coating film of a heat insulating coating material. In addition, the heat insulation layer 3 of a present Example forms a coating film only by draining the water | moisture content in a heat insulation coating material.

かかる断熱層３は、アクリル系樹脂中に中空ビーズが抱き込まれた状態となるので、断熱効果を有するようになる。また、断熱塗材は、アクリル系樹脂をバインダーとしているので、弾力性、伸縮性があって、塗装しやすく、断熱層３は、弾力性・柔軟性に優れる。更に、断熱塗材をシート状基材２に塗布した場合、不織布であるシート状基材２がつなぎの役割を果たすので、断熱層３がシート状基材２に形成されても劣化がしにくく、耐久性に優れ、折り曲げや巻き取りをしても、シート状基材２から断熱層３が剥離することがない。   The heat insulating layer 3 has a heat insulating effect because the hollow beads are embedded in the acrylic resin. Further, since the heat insulating coating material uses an acrylic resin as a binder, it has elasticity and stretchability and is easy to paint, and the heat insulating layer 3 is excellent in elasticity and flexibility. Furthermore, when the heat-insulating coating material is applied to the sheet-like base material 2, the sheet-like base material 2, which is a non-woven fabric, plays a role of linking, so that even if the heat-insulating layer 3 is formed on the sheet-like base material 2, it is difficult to deteriorate. The heat insulating layer 3 is not peeled off from the sheet-like substrate 2 even if it is excellent in durability and folded or wound.

接着層４は、シート状基材２の他方の面に、粘着材４ａを塗布し、その上を粘着材保護シート４ｂで覆うことで形成される。   The adhesive layer 4 is formed by applying an adhesive material 4a to the other surface of the sheet-like substrate 2 and covering the upper surface with an adhesive material protective sheet 4b.

そして、このような構造の断熱シート１ａは、断熱対象物の形状に合わせて、切断等の加工を行い、粘着材保護シート４ｂを粘着材４ａから剥離して、粘着材４ａの面を断熱対象物に直接、貼着するだけで、断熱対象物への断熱施工が完了するので、施工の簡略化が実現され、コストの低減に繋がる。   And the heat insulation sheet 1a of such a structure processes a cutting | disconnection etc. according to the shape of the heat insulation target object, peels the adhesive material protection sheet 4b from the adhesive material 4a, and heat-insulates the surface of the adhesive material 4a. By simply sticking directly to the object, the heat insulation construction to the object to be insulated is completed, so that the construction is simplified and the cost is reduced.

しかも、シート状基材２は約１００μｍという薄さの不織布であり、断熱層３は、アクリル系樹脂をバインダーとして、約６００μｍの薄さに形成されていることから、断熱シート１ａは、全体として薄く、弾力性・柔軟性に優れ、折り曲げ加工しても劣化しない。   Moreover, the sheet-like substrate 2 is a nonwoven fabric having a thickness of about 100 μm, and the heat insulating layer 3 is formed to a thickness of about 600 μm using an acrylic resin as a binder. It is thin, excellent in elasticity and flexibility, and does not deteriorate even when bent.

よって、この断熱シート１ａは、建築物の内外壁や、平板のみならず、曲面を有する自動車・航空機・列車等の車体の内外表面や、カーテンウォールの内外壁の断熱施工に好適である。尚、本明細書において、パネルには、平板のみならず、上記自動車・航空機・列車等の車体の曲面を有するものも含まれる。   Therefore, this heat insulating sheet 1a is suitable not only for the inner and outer walls of buildings and flat plates, but also for the heat insulating construction of inner and outer surfaces of car bodies such as automobiles, aircraft and trains having curved surfaces, and inner and outer walls of curtain walls. In the present specification, the panel includes not only a flat plate but also a panel having a curved surface of a vehicle body such as the automobile, aircraft, or train.

ここで、本実施例の断熱シート１ａは、断熱層３の形成工程、すなわち、シート状基材２に断熱塗材を塗布後、断熱塗材から抜水して断熱塗膜を形成する断熱層形成工程において、遠赤外線もしくはマイクロ波を照射して、断熱層３の断熱効果を低下させることなく、断熱塗材中の水分を早期に抜き断熱塗膜を形成することに特徴がある。   Here, the heat insulation sheet 1a of a present Example is the heat insulation layer which forms the heat insulation coating film by draining water from a heat insulation coating material after apply | coating a heat insulation coating material to the formation process of the heat insulation layer 3, ie, the sheet-like base material 2. In the formation process, far infrared rays or microwaves are irradiated to remove moisture in the heat insulating coating material at an early stage without lowering the heat insulating effect of the heat insulating layer 3, thereby forming a heat insulating coating film.

従来、断熱層３の形成に際しては、自然乾燥か、空気を吹付けることによる強制乾燥が行なわれていた。しかし、自然乾燥方法の場合は、完全に固化するまでには２４時間かかり、断熱シート１ａの製造工程において大きな時間ロスが発生する。また、強制乾燥方法を採用した場合でも、最低１〜２時間かかる上に、送風により断熱層３に塗装ムラが生じる。また、乾燥工程で水分蒸発する際に、内部からではなく表面から水分が蒸発するため、断熱層３に気泡が発生する。このように、自然乾燥や強制乾燥の場合には、断熱効果が低下しやすく、断熱シート１ａの品質劣化を招く。   Conventionally, when the heat insulating layer 3 is formed, natural drying or forced drying by blowing air has been performed. However, in the case of the natural drying method, it takes 24 hours to completely solidify, and a large time loss occurs in the manufacturing process of the heat insulating sheet 1a. Further, even when the forced drying method is adopted, it takes at least 1 to 2 hours, and coating unevenness is generated in the heat insulating layer 3 by air blowing. In addition, when moisture evaporates in the drying process, moisture evaporates from the surface rather than from the inside, and bubbles are generated in the heat insulating layer 3. Thus, in the case of natural drying or forced drying, the heat insulating effect tends to be reduced, leading to quality deterioration of the heat insulating sheet 1a.

そこで、本実施例の断熱シート１ａの製造方法では、シート状基材２に断熱塗材を塗布後、当該塗布面に、遠赤外線もしくはマイクロ波を照射して抜水し、断熱塗膜を形成するようにしたので、遠赤外線やマイクロ波の特性により、塗布された断熱塗材の内部から水分が蒸発し、塗装ムラや気泡の発生なく、しかも、早期に乾燥させることができる。つまり、品質の維持された断熱シート１ａが製造されるとともに、断熱シート１ａの製造効率を向上させられる。   Therefore, in the manufacturing method of the heat insulating sheet 1a of the present embodiment, after the heat insulating coating material is applied to the sheet-like substrate 2, the applied surface is drained by irradiating far infrared rays or microwaves to form a heat insulating coating film. Therefore, due to the characteristics of far infrared rays and microwaves, moisture evaporates from the inside of the applied heat insulating coating material, and it is possible to dry quickly without generating coating unevenness and bubbles. That is, the heat insulation sheet 1a with maintained quality can be manufactured and the production efficiency of the heat insulation sheet 1a can be improved.

例えば、所定速度で走行しているベルトコンベヤ上に、シート状のシート状基材２を広げて、ベルトコンベヤの始端に設けられたポンプや漏斗等の塗材押し出し機から、シート状基材２上に断熱塗材を塗布し、ベルトコンベヤの途中経路に設けられた所定長さの照射炉内を、断熱塗材が塗布されたシート状基材２が通過するようにし、照射炉を通過後、シート状基材２上に断熱層３が形成された断熱シート１ａを、ベルトコンベヤの終端に設置されたローラーによって順次、巻き取れば、断熱塗材の乾燥時間を待たず、次々に断熱シート１ａを製造して、ロール状にまとめることが出来、製造された断熱シート１ａの保管場所をとらない。   For example, the sheet-like base material 2 is spread on a belt conveyor running at a predetermined speed, and the sheet-like base material 2 is supplied from a coating material extruder such as a pump or a funnel provided at the starting end of the belt conveyor. After applying the heat insulating coating material on the upper part of the belt conveyor, the sheet-like base material 2 coated with the heat insulating coating material passes through the irradiation furnace of a predetermined length provided in the middle path of the belt conveyor. If the heat insulating sheet 1a in which the heat insulating layer 3 is formed on the sheet-like base material 2 is sequentially wound up by a roller installed at the end of the belt conveyor, the heat insulating sheets are successively formed without waiting for the drying time of the heat insulating coating material. 1a can be manufactured and put together in a roll shape, and the storage place of the manufactured heat insulation sheet 1a is not taken.

しかも、遠赤外線もしくはマイクロ波の照射によって抜水し、断熱塗膜を形成するので、塗装ムラが発生せず、また内部から水分を蒸発させるので気泡ができず、断熱層３の断熱効果は低下しない。   In addition, water is extracted by irradiation with far infrared rays or microwaves to form a heat insulating coating, so that coating unevenness does not occur, and moisture is evaporated from the inside, so that no bubbles are formed and the heat insulating effect of the heat insulating layer 3 is reduced. do not do.

つまり、本発明の断熱シートの製造方法によれば、断熱シートの断熱効果が低下することなく、断熱シートの製造効率を向上させ、大量生産が可能になるとともに、製造された断熱シートの保管の省スペース化が図られる。   That is, according to the method for manufacturing a heat insulating sheet of the present invention, the heat insulating effect of the heat insulating sheet is not lowered, the manufacturing efficiency of the heat insulating sheet is improved, mass production becomes possible, and the storage of the manufactured heat insulating sheet can be performed. Space saving is achieved.

尚、断熱シート１ａを製造する場合、接着層４の形成工程は、断熱層３の形成前でもよいし、形成後でもよい。   In addition, when manufacturing the heat insulation sheet 1a, the formation process of the contact bonding layer 4 may be before formation of the heat insulation layer 3, and may be after formation.

また、先の実施例では、断熱層３が、シート状基材２の一方の面に形成された場合について説明したが、図１（ｂ）の断熱シート１ｂに示すように、断熱層３が、シート状基材２の両面に形成されていてもよく、その場合、一方の面に形成された場合と比較して、断熱効果がより高まる。   Moreover, in the previous Example, although the case where the heat insulation layer 3 was formed in one surface of the sheet-like base material 2 was demonstrated, as shown to the heat insulation sheet 1b of FIG.1 (b), the heat insulation layer 3 is shown. Moreover, you may form in the both surfaces of the sheet-like base material 2, and the heat insulation effect increases more in that case compared with the case where it forms in one side.

所定の同一厚みの断熱層３を、一方の面に形成させた場合と、両面に分けて形成させた場合とでは、基本的に断熱効果は変わらないはずであるが、一方の面のみに厚く、断熱塗材を塗布した場合は、その分、断熱塗膜が形成されるまでの時間がかかり、断熱シートの製造上、現実的ではない。   The heat insulating effect should not basically change between the case where the heat insulating layer 3 having the same thickness is formed on one surface and the case where the heat insulating layer 3 is formed separately on both surfaces, but is thick only on one surface. When the heat insulating coating material is applied, it takes time until the heat insulating coating is formed, which is not realistic in the production of the heat insulating sheet.

従って、図１（ａ）に示した断熱シート１ａよりも断熱効果を向上させた断熱シートを製造したい場合には、図１（ｂ）の断熱シート１ｂの構造を採用するのが好適である。この場合、接着層４は、断熱層３の形成後、一方の断熱層３の上面に形成されることになる。   Therefore, when it is desired to manufacture a heat insulating sheet having a heat insulating effect improved compared to the heat insulating sheet 1a shown in FIG. 1A, it is preferable to adopt the structure of the heat insulating sheet 1b shown in FIG. In this case, the adhesive layer 4 is formed on the upper surface of one heat insulating layer 3 after the heat insulating layer 3 is formed.

また、断熱シートの構造は、図１（ｃ）の断熱シート１ｃに示すように、シート状基材２の一方の面に断熱層３が形成され、更に、当該断熱層３の上面に、接着層４が形成されていてもよい。この場合、不織布からなるシート状基材２が、表側に現われるので、シート状基材２に予め着色したり、模様を印刷することで、断熱効果を有する壁紙として使用することが可能となる。尚、この場合も、接着層４は、断熱層３の形成後に形成される。
In addition, as shown in the heat insulating sheet 1c in FIG. 1C, the heat insulating sheet has a structure in which a heat insulating layer 3 is formed on one surface of the sheet-like substrate 2 and is further bonded to the upper surface of the heat insulating layer 3. The layer 4 may be formed. In this case, since the sheet-like base material 2 made of a non-woven fabric appears on the front side, the sheet-like base material 2 can be used as wallpaper having a heat insulating effect by previously coloring or printing a pattern. In this case as well, the adhesive layer 4 is formed after the heat insulating layer 3 is formed.

次に、図２を参照しながら、本発明による断熱シートの製造方法の一実施例について説明する。尚、本実施例で製造される断熱シートの構造は、図１（ａ）に示した断熱シート１ａの構造と同様である。また、図２には、本実施例で断熱シート１ａを製造するための製造装置１０が示されている。   Next, an embodiment of a method for manufacturing a heat insulating sheet according to the present invention will be described with reference to FIG. In addition, the structure of the heat insulation sheet manufactured by a present Example is the same as that of the structure of the heat insulation sheet 1a shown to Fig.1 (a). Moreover, the manufacturing apparatus 10 for manufacturing the heat insulation sheet 1a by the present Example is shown by FIG.

この断熱シート１ａの製造方法は、不織布からなるシート状基材２をボビンから繰り出す繰り出し工程、セラミックビーズ、アクリルビーズ等の中空ビーズと、バインダー（結合材）としてアクリル系樹脂を混ぜて作製された断熱塗材６をシート状基材２の少なくとも一方の全面に所定の略均一厚さとなるように塗布し、これを遠赤外線もしくはマイクロ波照射炉内に通過させて抜水により断熱塗膜を形成し、断熱層３とする断熱層形成工程、断熱層形成工程の前または後に、シート状基材２に粘着材４ａを塗布し、粘着材４ａを粘着材保護シート４ｂで覆い接着層４とする接着層形成工程と、から構成される。   The heat insulating sheet 1a is produced by mixing a sheet-like base material 2 made of nonwoven fabric from a bobbin, a hollow bead such as ceramic beads and acrylic beads, and an acrylic resin as a binder (binding material). The heat insulating coating material 6 is applied to the entire surface of at least one of the sheet-like base materials 2 so as to have a predetermined substantially uniform thickness, and this is passed through a far infrared or microwave irradiation furnace to form a heat insulating coating film by draining water. The adhesive material 4a is applied to the sheet-like substrate 2 before or after the heat insulating layer forming step and the heat insulating layer forming step to form the heat insulating layer 3, and the adhesive material 4a is covered with the adhesive material protective sheet 4b to form the adhesive layer 4. An adhesive layer forming step.

尚、シート状基材２に接着層４を形成する場合には、接着層形成工程は、断熱層形成工程の前でも後でもよいが、図１（ｂ），（ｃ）の断熱シート１ｂ，ｃのように、断熱層３の上面に接着層４を形成する場合には、接着層形成工程は、必然的に断熱層形成工程の後となる。
In addition, when forming the contact bonding layer 4 in the sheet-like base material 2, although the contact bonding layer formation process may be before or after a heat insulation layer formation process, the heat insulation sheet 1b of FIG.1 (b), (c), When the adhesive layer 4 is formed on the upper surface of the heat insulating layer 3 as in c, the adhesive layer forming step is necessarily after the heat insulating layer forming step.

以下、図２の製造装置１０を用いて断熱シート１ａを製造する際の具体的実施例を説明する。   Hereinafter, the specific Example at the time of manufacturing the heat insulation sheet 1a using the manufacturing apparatus 10 of FIG. 2 is described.

まず、断熱塗材６を作製する。本実施例の断熱塗材６は、表１に示すように、アクリル系樹脂エマルジョン、中空ビーズ、成膜助剤・チタン・体質顔料・着色顔料・消泡剤・粘性調整剤・可塑剤等の添加剤、及び、水を、同表に示す重量比率割合で混合し、均一になるまで撹拌して得た。尚、このとき、撹拌しやすいように、場合によっては加熱により所定の温度で撹拌してもよい。   First, the heat insulating coating material 6 is produced. As shown in Table 1, the heat-insulating coating material 6 of this example includes acrylic resin emulsion, hollow beads, film forming aids, titanium, extender pigments, colored pigments, antifoaming agents, viscosity modifiers, plasticizers, etc. The additive and water were mixed at a weight ratio shown in the same table and stirred until uniform. In addition, at this time, in order to facilitate stirring, in some cases, stirring may be performed at a predetermined temperature by heating.

Figure 2008073600
Figure 2008073600

本実施例では、表１におけるアクリル系樹脂エマルジョンは、スチレンアクリル酸アルキルエステル共重合物エマルジョン（ＢＡＳＦジャパン株式会社製）を用いた。また、成膜助剤は、テキサノールを用いた。   In this example, the acrylic resin emulsion in Table 1 was a styrene acrylic acid alkyl ester copolymer emulsion (manufactured by BASF Japan Ltd.). Further, texanol was used as a film forming aid.

また、断熱機能の実現のために混合される中空ビーズは、平均粒子径２０〜５０μｍのマイクロビーズ（松本油脂製薬株式会社）を用いた。また、チタンは、二酸化チタンルチル型を、体質顔料は、タルクを用いた。尚、チタン及び体質顔料は、中空ビーズを固めるために加えられるものである。   Moreover, the microbead (Matsumoto Yushi Seiyaku Co., Ltd.) with an average particle diameter of 20-50 micrometers was used for the hollow bead mixed in order to implement | achieve a heat insulation function. Titanium dioxide rutile type was used for titanium and talc was used for extender pigment. Titanium and extender are added to solidify the hollow beads.

また、消泡剤は、カルシウム炭酸塩を、粘性調整剤は、高沸点オイルを、可塑剤は、防腐剤をそれぞれ用いた。尚、これらはいずれも、環境問題に配慮し、非ホルムアルデヒド系の材料を使用している。   The antifoaming agent used was calcium carbonate, the viscosity modifier used high boiling oil, and the plasticizer used preservative. All of these use non-formaldehyde materials in consideration of environmental problems.

そして、本実施例では、最終的に中空ビーズの重量比率が５０％となるように各成分を配合し、粘度を、シート状基材２に塗布しやすい、２０００〜８０
００ｃｐｓに調整して作製された断熱塗材６を、原料タンク１１に投入する。尚、この原料タンク内に直接、上記の材料が投入され、撹拌が行なわれることで断熱塗材６が作製されてもよい。 And in a present Example, each component is mix | blended so that the weight ratio of a hollow bead may finally be 50%, and a viscosity is easy to apply | coat to the sheet-like base material 2, 2000-80
The heat insulating coating material 6 adjusted to 00 cps is put into the raw material tank 11. Note that the heat insulating coating material 6 may be manufactured by directly charging the material into the raw material tank and performing stirring.

一方、シート状基材２は、予め、断熱塗材６の塗布面とは反対側の面に、粘着材４ａを塗布し、更に粘着材保護シート４ｂで覆って接着層４を形成した状態のものが用意され、断熱塗材６の塗布面を上にして、ボビン１２からガイドロール１３に案内されて、所定速度で走行するベルトコンベア（図示せず）のコンベア面上に繰り出される。   On the other hand, the sheet-like base material 2 is in a state in which the adhesive layer 4a is previously applied to the surface opposite to the application surface of the heat insulating coating material 6 and further covered with the adhesive material protection sheet 4b to form the adhesive layer 4. A thing is prepared, the coating surface of the heat insulation coating material 6 is turned up, it is guided by the guide roll 13 from the bobbin 12, and is drawn out on the conveyor surface of a belt conveyor (not shown) that runs at a predetermined speed.

本実施例のシート状基材２は、リンテック(株）製の、厚さ１００μｍ、巾１〜１．２ｍｍのロール状の不織布を使用している。また、粘着材４ａは、リンテック(株）製の粘着材をシート状基材２に塗布して得られたものであり、厚さは１００μｍである。また、粘着材保護シート４ｂは、粘着材４ａの乾燥防止・保護のため、粘着材４ａに貼着される剥離材付きシートであり、厚さ１００μｍのものである。   The sheet-like base material 2 of this example uses a roll-shaped nonwoven fabric having a thickness of 100 μm and a width of 1 to 1.2 mm manufactured by Lintec Corporation. Moreover, the adhesive material 4a was obtained by apply | coating the adhesive material made from Lintec Corporation to the sheet-like base material 2, and thickness is 100 micrometers. Moreover, the adhesive material protection sheet 4b is a sheet with a release material attached to the adhesive material 4a in order to prevent and protect the adhesive material 4a from drying, and has a thickness of 100 μm.

断熱塗材６は、原料タンク１１から圧縮により下方に繰り出され、シート状基材２の上に載置するように供給される。尚、本実施例のように断熱塗材６を載置する場合も、本明細書の「塗布」に含むものとする。   The heat insulating coating material 6 is fed downward from the raw material tank 11 by compression and supplied so as to be placed on the sheet-like substrate 2. Note that the case where the heat insulating coating material 6 is placed as in this embodiment is also included in the “application” of the present specification.

本実施例の断熱塗材６は、上記のように、アクリル系樹脂エマルジョンをバインダーとして、水分が断熱塗材６の約１／３を占めるので、弾力性・伸縮性があり、シート状基材２上に塗布しやすい。   As described above, the heat insulating coating material 6 of the present example has an elastic resin emulsion as a binder, and moisture occupies about 1/3 of the heat insulating coating material 6, so that it has elasticity and elasticity, and is a sheet-like substrate. 2 easy to apply.

シート状基材２上に載置された断熱塗材６は、スクレーパ１４によって、所定の均一厚さになるように平坦化され、その後、断熱塗材６が塗布されたシート状基材２は、照射炉１５へ送り込まれる。   The heat insulating coating material 6 placed on the sheet-like base material 2 is flattened by the scraper 14 so as to have a predetermined uniform thickness, and then the sheet-like base material 2 to which the heat insulating coating material 6 is applied is And sent to the irradiation furnace 15.

本実施例の照射炉１５は、遠赤外線ヒーターであり、断熱塗材６の塗布面から所定距離離間した位置から、遠赤外線が照射される。また、照射炉１５の長さは、４０ｍであり、照射炉１５の始点から終点までの通過時間は、ベルトコンベアを０．５ｍ／分の速度で走行させた場合、約３分となっている。   The irradiation furnace 15 of this embodiment is a far-infrared heater, and irradiates far-infrared rays from a position separated from the application surface of the heat insulating coating material 6 by a predetermined distance. The length of the irradiation furnace 15 is 40 m, and the passing time from the start point to the end point of the irradiation furnace 15 is about 3 minutes when the belt conveyor is run at a speed of 0.5 m / min. .

照射炉１５の通過時間と照射炉１５の長さは、照射炉１５内の温度と、遠赤外線の照射量と、ベルトコンベアの走行速度と、断熱塗材６の塗布厚との関係で決められることになる。例えば、照射炉１５内の温度が高いほど、照射量が多いほど、通過時間は短く、照射炉１５の長さは短くて済む。逆に、走行速度が遅いほど、塗布厚が厚いほど、通過時間は長く、照射炉１５の長さは長くなる。   The passing time of the irradiation furnace 15 and the length of the irradiation furnace 15 are determined by the relationship among the temperature in the irradiation furnace 15, the amount of far-infrared irradiation, the running speed of the belt conveyor, and the coating thickness of the heat insulating coating material 6. It will be. For example, the higher the temperature in the irradiation furnace 15 and the larger the irradiation amount, the shorter the passing time and the shorter the length of the irradiation furnace 15. Conversely, the slower the traveling speed, the thicker the coating thickness, the longer the passage time and the longer the irradiation furnace 15.

尚、遠赤外線ヒータに代えて、電子レンジの仕組みを利用したマイクロ波ヒーターが用いられてもよい。   Instead of the far infrared heater, a microwave heater using a microwave mechanism may be used.

シート状基材２に載置された断熱塗材６に含まれる全体の約１／３の水分が、照射炉１５内で抜水されることによって、シート状基材２に、断熱塗膜からなる断熱層３が固着形成され、断熱シート１ａが作製される。このようにして作製された断熱シート１ａは、順次、ガイドロール１６に案内されて、巻き取り機１７によって巻き取られる。尚、本実施例の断熱層３の厚さは、６００μｍである。   About 1/3 of the total water contained in the heat insulating coating material 6 placed on the sheet-like base material 2 is drained in the irradiation furnace 15, so that the sheet-like base material 2 has a heat insulating coating film. The heat insulation layer 3 to be formed is fixedly formed, and the heat insulation sheet 1a is produced. The heat insulating sheet 1 a thus produced is sequentially guided by the guide roll 16 and wound up by the winder 17. In addition, the thickness of the heat insulation layer 3 of a present Example is 600 micrometers.

尚、本実施例では、先に、接着層４がシート状基材２に形成されていたが、シート状基材２に断熱層３が固着形成されて巻き取り機１７によって巻き取られたものを、再度、ボビン１２に通し、ベルトコンベア上に繰り出して、粘着材４ａを塗布し、その上に粘着材保護シート４ｂを覆うことで、接着層４が形成されてもよい。   In this embodiment, the adhesive layer 4 was previously formed on the sheet-like base material 2, but the heat-insulating layer 3 was fixedly formed on the sheet-like base material 2 and wound up by the winder 17. May be passed through the bobbin 12 again and fed onto the belt conveyor to apply the adhesive material 4a and cover the adhesive material protective sheet 4b thereon, whereby the adhesive layer 4 may be formed.

以上説明した製造装置１０によって断熱シート１ａを製造した場合、シート状基材２に断熱塗材６を塗布した後、断熱塗材６の抜水、すなわち、乾燥を、遠赤外線もしくはマイクロ波を照射することによって行なうようにしたので、自然乾燥や送風による強制乾燥と比較して、早期に断熱層３を形成することができる。   When the heat insulating sheet 1a is manufactured by the manufacturing apparatus 10 described above, after the heat insulating coating material 6 is applied to the sheet-like base material 2, the heat insulating coating material 6 is drained, that is, dried, irradiated with far infrared rays or microwaves. Therefore, the heat insulation layer 3 can be formed earlier than natural drying or forced drying by blowing air.

また更に、自然乾燥の場合には、表面から水分が蒸発するため、気泡ができやすいが、遠赤外線もしくはマイクロ波の照射により抜水乾燥させる場合には、遠赤外線やマイクロ波の特性上、断熱塗材６の内部から水分が蒸発するので、気泡ができにくく、品質の維持された断熱シート１ａが製造される。   Furthermore, in the case of natural drying, water bubbles evaporate from the surface, so bubbles are likely to be formed. However, in the case of draining and drying by irradiation with far infrared rays or microwaves, heat insulation is performed due to the characteristics of far infrared rays and microwaves. Since moisture evaporates from the inside of the coating material 6, it is difficult to form bubbles, and the heat insulating sheet 1 a having a maintained quality is manufactured.

本実施例の製造装置１０によれば、自然乾燥で２４時間かかるところを、３分で抜水乾燥させることができるので、製造装置１０のベルトコンベアを所定速度で駆動させながら、照射炉１５を通過して作製された断熱シート１ａを順次、巻き取り機１７で巻き取ることができる。従って、断熱シート１ａの製造効率が向上し、大量生産が可能になるとともに、製造された断熱シート１ａの保管の省スペース化が図られる。
According to the manufacturing apparatus 10 of the present embodiment, the place where natural drying takes 24 hours can be drained and dried in 3 minutes, so that the irradiation furnace 15 is operated while the belt conveyor of the manufacturing apparatus 10 is driven at a predetermined speed. The heat insulating sheets 1a produced by passing through can be sequentially wound up by the winder 17. Therefore, the manufacturing efficiency of the heat insulating sheet 1a is improved, mass production becomes possible, and space saving of storage of the manufactured heat insulating sheet 1a is achieved.

次に、作製された断熱シート１ａの断熱層３の断熱効果を確認するため、以下の実験を行なった。まず、先に作製された断熱塗材６（以下、試料Ｓという）の塗膜について、日射反射率を求めた。その得られた日射反射率を表２に示す。尚、試料Ｓを乾燥させ、塗膜が形成された後の、断熱塗材成分の重量比率は、アクリル系樹脂エマルジョンが４４％であり、中空ビーズが５０％であり、その他の添加剤が６％となる。   Next, in order to confirm the heat insulation effect of the heat insulation layer 3 of the produced heat insulation sheet 1a, the following experiment was conducted. First, the solar reflectance was calculated | required about the coating film of the heat insulation coating material 6 (henceforth sample S) produced previously. The obtained solar reflectance is shown in Table 2. The weight ratio of the heat insulating coating material component after the sample S was dried and the coating film was formed was 44% for the acrylic resin emulsion, 50% for the hollow beads, and 6 for other additives. %.

Figure 2008073600
Figure 2008073600

これより、０．６ｍｍ厚の試料Ｓの膜で、特に近赤外領域で隠ぺい率試験紙の白地上と黒地上での反射率に差異が認められた。すなわち、黒地上の反射率が低下している。このことは、試料Ｓの０．６ｍｍ膜厚では近赤外領域の光は通過しており、素地の黒地に吸収されていることを意味している。また、試料Ｓの日光反射率は９０％以上であり、紫外線を含む太陽光の９０％以上を反射させるので、建物等の構造物の外壁に塗布した場合、当該構造物の劣化を防止することが出来る。   Accordingly, in the film of the sample S having a thickness of 0.6 mm, a difference was observed in the reflectance between the white ground and the black ground of the concealment rate test paper particularly in the near infrared region. That is, the reflectance on the black ground is reduced. This means that in the 0.6 mm film thickness of the sample S, light in the near infrared region passes and is absorbed by the black background. Moreover, since the sunlight reflectance of the sample S is 90% or more and 90% or more of sunlight including ultraviolet rays is reflected, when applied to the outer wall of a structure such as a building, the structure is prevented from being deteriorated. I can do it.

本実施例の断熱塗材６は、アクリル系樹脂エマルジョン（スチレンアクリル酸アルキルエステル共重合物エマルジョン）と、アクリルビーズという、同じアクリル系材料同士を混合していることにより、親和性が高くなるので、バインダーとしてのアクリル系樹脂エマルジョンに、中空ビーズをより多く抱き込み、含有させることが出来、本実施例のように、抜水乾燥後の断熱塗材の中空ビーズの重量比率を５０％以上とすることが出来る。これにより、より断熱効果の高い断熱層３を形成することが出来る。   Since the heat insulating coating material 6 of the present embodiment has a high affinity by mixing the same acrylic material called acrylic resin emulsion (styrene acrylic acid alkyl ester copolymer emulsion) and acrylic beads. The acrylic resin emulsion as a binder can contain more hollow beads and can be contained. As in this example, the weight ratio of the hollow beads of the heat-insulating coating material after draining and drying is 50% or more. I can do it. Thereby, the heat insulation layer 3 with a higher heat insulation effect can be formed.

尚、本実施例では、最終的に中空ビーズの重量比率が５０％となるように、各成分を配合したが、断熱性の向上のためには、中空ビーズの重量比率が３０〜７０％となるように、各成分の調整が行なわれることが望ましい。当該比率が３０％未満である場合には、断熱効果が十分に得られない。また７０％より高い場合には、バインダーとの親和性が低くなり、均一な断熱塗材が作製されず、基材への付着性が弱くなる。   In this example, each component was blended so that the weight ratio of the hollow beads was finally 50%. However, in order to improve heat insulation, the weight ratio of the hollow beads was 30 to 70%. Thus, it is desirable to adjust each component. When the ratio is less than 30%, a sufficient heat insulating effect cannot be obtained. On the other hand, if it is higher than 70%, the affinity with the binder is lowered, a uniform heat insulating coating material is not produced, and the adhesion to the substrate is weakened.

更に、試料Ｓの塗膜について、熱伝導率を測定し、遮断効果の程度を確認した。表３は、試料Ｓの熱伝導率の測定結果を示す。   Furthermore, about the coating film of the sample S, the heat conductivity was measured and the grade of the interruption | blocking effect was confirmed. Table 3 shows the measurement results of the thermal conductivity of Sample S.

Figure 2008073600
Figure 2008073600

ちなみに、「漆喰」の熱伝導率は「０．６」、「石膏プラスター」の熱伝導率は「０．５」、「石膏ボード」の熱伝導率は「０．７１〜０．１」、「コンクリート」の熱伝導率は「１．４０」であるのに対し、試料Ｓの熱伝導率は表３より「０．１２１（Ｋｃａｌ／ｈ・ｍ・℃）」である。また、断熱性の高い「保温レンガ」の熱伝導率は「０．１２」である。したがって、この試料Ｓは、熱伝導率が比較的低い部類の塗装材料と言える。   By the way, the thermal conductivity of “Plastic” is “0.6”, the thermal conductivity of “Gypsum plaster” is “0.5”, and the thermal conductivity of “Gypsum board” is “0.71-0.1”, The thermal conductivity of “concrete” is “1.40”, whereas the thermal conductivity of sample S is “0.121 (Kcal / h · m · ° C.)” from Table 3. Moreover, the thermal conductivity of the “thermal brick” having high heat insulation is “0.12”. Therefore, it can be said that this sample S is a class of coating material having a relatively low thermal conductivity.

次に、亜鉛めっき銅板及びコンクリート板に対する試料Ｓの接着強度を評価した、その結果を表４に示す。   Next, the adhesion strength of the sample S to the galvanized copper plate and the concrete plate was evaluated, and the results are shown in Table 4.

Figure 2008073600
Figure 2008073600

表４によれば、試料Ｓの接着強度は、対鋼板が１．７Ｎ／ｍｍ２、対コンクリートが１．５Ｎ／ｍｍ２である（ＪＩＳ規格は、０．５Ｎ／ｍｍ２以上である）。このことから、この試料Ｓは、ＪＩＳ規格を十分に満足する接着強度を有する。 According to Table 4, the adhesive strength of the sample S, versus steel sheet 1.7 N / mm 2, pairs concrete is 1.5N / mm 2 (JIS standard is 0.5 N / mm 2 or higher). Therefore, this sample S has an adhesive strength that sufficiently satisfies the JIS standard.

本実施例の断熱塗材６の塗膜は、更に、以下の効果も有している。すなわち、この断熱塗材によれば、スチレンアクリル酸アルキルエステル共重合物エマルジョンをバインダーとして用いることで、元々、本材料に備わっている防水性、接着性が発揮されるとともに、被膜性、弾力性も有するので、より亀裂の出来にくい衝撃、振動に強い断熱層３が形成される。また、塗膜を劣化させるあらゆる障害に対して驚異的に対抗し、抜群の耐久性を発揮することができる。   The coating film of the heat insulating coating material 6 of the present example also has the following effects. That is, according to this heat insulating coating material, by using the styrene acrylic acid alkyl ester copolymer emulsion as a binder, the waterproofness and adhesiveness originally provided in the material are exhibited, and the film property and elasticity are also provided. Therefore, the heat-insulating layer 3 that is more resistant to impacts and vibrations, which are more difficult to crack, is formed. In addition, it can remarkably counteract any obstacle that deteriorates the coating film, and exhibits excellent durability.

また、本実施例の断熱塗材６を壁に０．９ｍｍ厚塗布すると、屋根・天井・壁を通過する音が約１０デシベル低下し、静かな環境が確保できる。また、本実施例の断熱塗材６は環境にやさしい水溶性で、シックハウス症候群の原因物質を含まない。また、当該断熱塗材６の塗膜は３層〜４層（０．６ｍｍ〜０．９ｍｍ）形成されることで、水の浸入を防ぐことができる。   Further, when the heat insulating coating material 6 of this embodiment is applied to the wall by a thickness of 0.9 mm, the sound passing through the roof, ceiling, and wall is reduced by about 10 decibels, and a quiet environment can be secured. Moreover, the heat insulating coating material 6 of the present embodiment is water-soluble and is free of causative substances for sick house syndrome. Moreover, the infiltration of water can be prevented by forming 3 to 4 layers (0.6 mm to 0.9 mm) of the heat insulating coating material 6.

また、当該断熱塗材６は、幅広い塗装適性を持っているので、当然、不織布への塗布も容易である。また、刷毛ローラー・吹付け・鏝など幅広い塗布方法にも対応することができる。   Moreover, since the said heat insulation coating material 6 has a wide coating suitability, naturally, application | coating to a nonwoven fabric is also easy. Moreover, it can respond to a wide range of application methods such as brush rollers, spraying, and wrinkles.

そして、このような断熱塗材６をシート状基材２に塗布して、抜水乾燥させ、断熱層３を形成して出来た断熱シート１ａの施工対象は、例えば、工場、一般倉庫、保冷倉庫、研究所、学校、集会所、体育館等の大きな建物の屋根の外装及び内装であったり、冷凍コンテナ、ドライコンテナ、保冷車、穀物サイロ、冷凍冷蔵倉庫、貯蔵タンク、畜産舎、車両（自動車・航空機・電車等）の内外装、カーテンウォール、プラントの配管（ＬＰガス・蒸気）であったり、鉄、コンクリート、発泡コンクリート、木材、瓦、スレート、サイデング、レンガ、タイル、アルミ、ステンレス、ブロック、石膏ボード等、幅広く、平面、曲面を問わず、利用できる。
And such a heat insulation coating material 6 is apply | coated to the sheet-like base material 2, and it drains and dries, and the construction object of the heat insulation sheet 1a formed by forming the heat insulation layer 3 is a factory, a general warehouse, cold storage, for example The exterior and interior of the roofs of large buildings such as warehouses, research institutes, schools, meetinghouses, gymnasiums, etc.・ Aircraft, trains, etc.), curtain walls, plant piping (LP gas / steam), iron, concrete, foamed concrete, wood, tile, slate, siding, brick, tile, aluminum, stainless steel, block It can be used widely regardless of whether it is flat or curved, such as plasterboard.

次に、本実施例で作製された断熱シート１ａの断熱層３の断熱効果を確認するため、以下の実験を行なった。まず、シーラー（下地用塗料）に中空ビーズを添加した断熱塗材を作製する。尚、後述する試料ａを除き、先に作製された断熱塗材６と同様である。   Next, in order to confirm the heat insulation effect of the heat insulation layer 3 of the heat insulation sheet 1a produced in the present Example, the following experiment was conducted. First, a heat insulating coating material in which hollow beads are added to a sealer (base coating material) is produced. In addition, it is the same as that of the heat insulation coating material 6 produced previously except the sample a mentioned later.

図３（ａ）の見取り図及び（ｂ）の平面図に示す実験装置１８は、１．０ｍｍ厚のアルミニウム板製の直方体状の箱体１９と、箱体１９の開口部を覆う図示しないアルミニウム製の蓋体と、箱体１９の内部を２つの略等しい２５０ｍｍ×２５０ｍｍ×２５０ｍｍの空間イ、ロに２分する位置（中央部）に設けられ、１．０ｍｍ厚のアルミニウム板製の仕切板２０ａ，ｂと、空間イの中央部にセットされる熱源２１と、Ａ，Ｂ，Ｃ，Ｄの位置（いずれも底面からの高さは１２５ｍｍ）に設置される、温度計等の温度検出器とから構成される。尚、熱源２１は、４０Ｗの白熱電球を使用した。   The experimental apparatus 18 shown in the plan view of FIG. 3 (a) and the plan view of FIG. 3 (b) includes a rectangular parallelepiped box 19 made of an aluminum plate having a thickness of 1.0 mm and an aluminum (not shown) covering the opening of the box 19. A partition plate 20a made of an aluminum plate having a thickness of 1.0 mm is provided at a position (center portion) that divides the inside of the box body 19 into two substantially equal spaces of 250 mm × 250 mm × 250 mm and b. , B, a heat source 21 set in the center of the space A, and a temperature detector such as a thermometer installed at positions A, B, C, D (all of which are 125 mm from the bottom) Consists of The heat source 21 was a 40 W incandescent bulb.

仕切板２０ａ，ｂは、互いに２５ｍｍの空隙Ｓを設けて設置され、仕切板２０ａ，ｂの両方又は片方の、仕切板同士が対向する面（内側面）全面に渡り、断熱塗材を塗布し、塗膜が形成される。   The partition plates 20a and 20b are installed with a gap S of 25mm between them, and a heat insulating coating material is applied over the entire surface (inner side surface) of both or one of the partition plates 20a and 20b facing each other. A coating film is formed.

塗布される断熱塗材は、表５に示されるように、シーラーに添加される中空ビーズの重量比率（対シーラー）を５０％に調整したものを仕切板２０ａにのみ１．０ｍｍ厚塗布した試料ａ，ｂと、仕切板２０ａ，ｂの両方にそれぞれ１．０ｍｍずつ塗布した試料ｃと、仕切板２０ａに３．０ｍｍ、仕切板２０ｂに２．５ｍｍ塗布した試料ｄと、仕切板２０ａ，ｂの両方にそれぞれ５．０ｍｍずつ塗布した試料ｅである。尚、本実験に使用した中空ビーズは、試料ａがセラミックビーズ、試料ｂ〜ｅがアクリルビーズである。   As shown in Table 5, the heat insulating coating material to be applied is a sample in which the weight ratio of the hollow beads added to the sealer (vs. sealer) is adjusted to 50% and applied to the partition plate 20a only by 1.0 mm thick. Sample c applied to both a and b and partition plates 20a and 20b each by 1.0 mm, Sample d applied to partition plate 20a and 3.0 mm to partition plate 20b, and partition plates 20a and b Sample e was applied to both of each by 5.0 mm. In the hollow beads used in this experiment, the sample a is a ceramic bead and the samples be to e are acrylic beads.

Figure 2008073600
Figure 2008073600

また、比較参考のために、グラスウールを仕切板２０ａ，ｂの両方に貼り付けた試料Ｉと、アルミニウム製の仕切板２０ａ，ｂに替えて、３ｍｍ厚のガラス板を空隙を２５ｍｍ設けて２枚合わせた試料ＩＩも用意する。   In addition, for comparison purposes, instead of the sample I in which glass wool is pasted on both of the partition plates 20a and 20b and the aluminum partition plates 20a and 20b, two 3mm thick glass plates with a space of 25mm are provided. A combined sample II is also prepared.

各試料につき、実験装置１８を密閉した状態で、熱源２１を駆動させ、Ａ〜Ｄの温度検出器の値を測定する。   For each sample, with the experimental apparatus 18 sealed, the heat source 21 is driven and the values of the temperature detectors A to D are measured.

熱源を駆動させると同時に測定を開始し、測定開始から１５分経過するまでは５分おき、１５分〜６０分経過するまでは１５分おき、６０分〜１８０分経過するまでは４０分おきに各温度を測定した。各試料での測定結果を表す表とグラフを図４〜図１０に示す。   Measurement is started at the same time as the heat source is driven, every 5 minutes until 15 minutes have passed since the start of measurement, every 15 minutes until 15 to 60 minutes have passed, and every 40 minutes until 60 to 180 minutes have passed. Each temperature was measured. The table | surface and graph showing the measurement result in each sample are shown in FIGS.

そして、測定結果及び以下の数式に基づいて、各試料の断熱効果δを算出した。尚、このδ（％）の数値が高いほど、断熱効果が高いと言える。   And based on the measurement result and the following numerical formula, the heat insulation effect (delta) of each sample was computed. It can be said that the higher the numerical value of δ (%), the higher the heat insulation effect.

（数１）
δ＝１−（Ｄ−α）／（Ａ−α）
Ａ：空間イの温度
Ｄ：空間ロの温度
α：実験時の平均温度 (Equation 1)
δ = 1− (D−α) / (A−α)
A: Space temperature D: Space temperature α: Average temperature during the experiment

各試料について求めたＡ−Ｄ，Ｂ−Ｃ，α，δを表す表とグラフを図１１に示す。   FIG. 11 shows a table and a graph representing AD, BC, α, and δ determined for each sample.

図１１の表とグラフにより、以下のことが考察される。まず、試料ａと試料ＩＩを比較すると、試料ａのほうが断熱効果が高い（δの数値が大きい）ことが分かる。次に、試料ａと試料ｂとを比較すると、セラミックビーズを中空ビーズとして使用した試料ａよりも、アクリルビーズを中空ビーズとして使用した試料ｂのほうが、断熱効果が高い。つまり、中空ビーズとしては、アクリルビーズを断熱塗材に使用するほうが、断熱層３の断熱効果が高く、本発明の断熱シートの製造方法及び当該製造方法を用いた断熱シートに好適である。   The following is considered from the table and graph of FIG. First, comparing sample a and sample II, it can be seen that sample a has a higher heat insulation effect (the value of δ is larger). Next, when comparing sample a and sample b, sample b using acrylic beads as hollow beads has a higher heat insulation effect than sample a using ceramic beads as hollow beads. That is, as the hollow beads, it is preferable to use acrylic beads for the heat insulating coating material because the heat insulating effect of the heat insulating layer 3 is high, and the heat insulating sheet manufacturing method of the present invention and the heat insulating sheet using the manufacturing method are suitable.

次に、試料ｂと試料ｃとを比較すると、仕切板２０ａの一面にのみアクリルビーズを塗布している試料ｂよりも、仕切板２０ａ，ｂの二面にアクリルビーズを塗布した試料ｃのほうが、断熱効果が高く、δが約７％も向上している。   Next, comparing sample b and sample c, sample c in which acrylic beads are applied to two surfaces of partition plates 20a and 20b is more than sample b in which acrylic beads are applied only to one surface of partition plate 20a. The heat insulation effect is high, and δ is improved by about 7%.

更に、試料ｄ，ｅと、膜厚を大きくしていくに従って、δの数値は大きくなり、膜厚が５ｍｍ−５ｍｍの試料ｅでは、δが９０％以上となり、試料Ｉのグラスウール並みの断熱効果が得られる結果となった。本実施例のアクリルビーズによって作製された断熱塗材を仕切板の両面に５ｍｍずつ塗布した時と塗布しなかった時の断熱効果の差を温度差に換算すると、約５０℃となる。   Further, as the film thickness is increased with the samples d and e, the numerical value of δ increases, and in the sample e with a film thickness of 5 mm-5 mm, δ is 90% or more, which is the heat insulation effect equivalent to the glass wool of the sample I. Was obtained. When the difference in the heat insulating effect when the heat insulating coating material produced by the acrylic beads of this example is applied to both sides of the partition plate by 5 mm and when it is not applied is converted to a temperature difference, it is about 50 ° C.

このように、本実施例の断熱塗材により形成される断熱層３は、合計厚みが大きくなればなるほど、絶大な断熱効果が発揮されると言える。   Thus, it can be said that the heat insulation layer 3 formed with the heat insulation coating material of a present Example exhibits a great heat insulation effect, so that total thickness becomes large.

従って、断熱効果の高い断熱シートを製造したい場合には、シート状基材２の一方の面に断熱塗材を塗布するよりは、両面に塗布したほうが合計厚みが稼げるので、図１（ｂ）のような構造を採用するのが好適である。また、一方の面に同じ厚さを塗布するよりは、両面に分けて塗布したほうが、一面当たりの塗布厚が薄くて済むので、その分、抜水乾燥する時間が早まり、断熱シートの製造効率アップにつながる。
Therefore, when it is desired to manufacture a heat insulating sheet having a high heat insulating effect, the total thickness can be increased by applying the heat insulating coating material on one surface of the sheet-like base material 2 rather than applying the heat insulating coating material on one surface. It is preferable to adopt such a structure. Also, rather than applying the same thickness on one side, it is better to apply the coating separately on both sides, so that the coating thickness per side can be reduced, so that the time for draining and drying is increased, and the production efficiency of the insulation sheet is increased accordingly. Leading up.

本発明にかかる断熱シートの構造の一実施例を示す部分断面図である。It is a fragmentary sectional view showing one example of the structure of the heat insulation sheet concerning the present invention. 本発明にかかる断熱シートの製造方法の一実施例を示す図である。It is a figure which shows one Example of the manufacturing method of the heat insulation sheet concerning this invention. 断熱効果を確認するための実験装置の見取り図と平面図である。It is a sketch and a plan view of an experimental apparatus for confirming the heat insulation effect. 試料ａの実験結果を表す表とグラフである。It is the table | surface and graph showing the experimental result of the sample a. 試料ｂの実験結果を表す表とグラフである。It is the table | surface and graph showing the experimental result of the sample b. 試料ｃの実験結果を表す表とグラフである。It is the table | surface and graph showing the experimental result of the sample c. 試料ｄの実験結果を表す表とグラフである。It is the table | surface and graph showing the experimental result of the sample d. 試料ｅの実験結果を表す表とグラフである。It is the table | surface and graph showing the experimental result of the sample e. 試料Ｉの実験結果を表す表とグラフである。2 is a table and a graph showing experimental results of Sample I. 試料ＩＩの実験結果を表す表とグラフである。It is a table | surface and a graph showing the experimental result of the sample II. 試料ａ〜ｅ，Ｉ，ＩＩの実験結果をまとめて表す表とグラフである。It is the table | surface and graph which represent collectively the experimental result of sample ae, I, and II.

符号の説明Explanation of symbols

１：断熱シート
２：シート状基材
３：断熱層
４：接着層
４ａ：粘着材
４ｂ：粘着材保護シート
１０：製造装置
１１：原料タンク
１２：ボビン
１３：ロール
１４：スクレーパ
１５：照射炉
１６：ガイドロール
１７：巻き取り機
１８：実験装置
１９：箱体
２０：仕切板
２１：熱源 DESCRIPTION OF SYMBOLS 1: Thermal insulation sheet 2: Sheet-like base material 3: Thermal insulation layer 4: Adhesive layer 4a: Adhesive material 4b: Adhesive material protection sheet 10: Manufacturing apparatus 11: Raw material tank 12: Bobbin 13: Roll 14: Scraper 15: Irradiation furnace 16 : Guide roll 17: Winder 18: Experimental device 19: Box 20: Partition plate 21: Heat source

Claims (8)

不織布からなるシート状基材と、前記シート状基材の少なくとも一方の面に形成された断熱層と、前記シート状基材の他方の面、または、前記断熱層の上面に設けられ、粘着材と前記粘着材から離脱可能な粘着材保護シートを有する接着層とから構成される断熱シートの製造方法であって、
中空ビーズとアクリル系樹脂との混合物からなる断熱塗材を、前記シート状基材に塗布し、遠赤外線もしくはマイクロ波を照射して抜水により断熱塗膜を形成し、前記断熱層とする断熱層形成工程と、
前記断熱層形成工程の前に、前記シート状基材に前記粘着材を塗布し、または、前記断熱層形成工程の後に、前記シート状基材もしくは前記断熱層に前記粘着材を塗布し、前記粘着材を前記粘着材保護シートで覆い、前記接着層とする接着層形成工程と、
を含むことを特徴とする断熱シートの製造方法。
A pressure-sensitive adhesive provided on a sheet-like substrate made of nonwoven fabric, a heat insulating layer formed on at least one surface of the sheet-like substrate, and the other surface of the sheet-like substrate, or the upper surface of the heat insulating layer. And a method for producing a heat insulating sheet comprising an adhesive layer having an adhesive protective sheet that can be detached from the adhesive,
Heat insulation coating material comprising a mixture of hollow beads and acrylic resin is applied to the sheet-like base material, and a heat insulating coating film is formed by draining water by irradiating far infrared rays or microwaves to form the heat insulating layer. A layer forming step;
Before the heat insulating layer forming step, the adhesive material is applied to the sheet-like base material, or after the heat insulating layer forming step, the adhesive material is applied to the sheet-like base material or the heat insulating layer, An adhesive layer forming step of covering the adhesive material with the adhesive material protective sheet and making the adhesive layer;
The manufacturing method of the heat insulation sheet characterized by including.
前記中空ビーズは、アクリルビーズであり、
前記アクリル系樹脂は、スチレンアクリル酸アルキルエステル共重合物エマルジョンである
ことを特徴とする請求項１に記載の断熱シートの製造方法。
The hollow beads are acrylic beads,
The said acrylic resin is a styrene acrylic acid alkylester copolymer emulsion. The manufacturing method of the heat insulation sheet | seat of Claim 1 characterized by the above-mentioned.
前記断熱層に含まれる中空ビーズの重量比率を、３０〜７０％とする
ことを特徴とする請求項２に記載の断熱シートの製造方法。
The weight ratio of the hollow beads contained in the heat insulating layer is 30 to 70%. The method for manufacturing a heat insulating sheet according to claim 2, wherein the weight ratio is 30 to 70%.
前記断熱層形成工程では、
前記断熱塗材が所定厚みに塗布された前記シート状基材を、前記マイクロ波もしくは遠赤外線の照射炉内に通過させた後、前記断熱層が形成されたシート状基材を巻き取る
ことを特徴とする請求項１から請求項３のいずれかに記載の断熱シートの製造方法。
In the heat insulation layer forming step,
Winding the sheet-like substrate on which the heat-insulating layer is formed, after passing the sheet-like substrate on which the heat-insulating coating material is applied to a predetermined thickness, through the microwave or far-infrared irradiation furnace. The manufacturing method of the heat insulation sheet in any one of Claims 1-3 characterized by the above-mentioned.
不織布からなるシート状基材と、前記シート状基材の少なくとも一方の面に形成された断熱層と、前記シート状基材の他方の面、または、前記断熱層の上面に設けられ、粘着材と前記粘着材から離脱可能な粘着材保護シートを有する接着層とから構成される断熱シートであって、
前記断熱層は、
前記シート状基材に塗布される中空ビーズとアクリル系樹脂との混合物からなる断熱塗材を、遠赤外線もしくはマイクロ波の照射により抜水し、断熱塗膜を形成したものであり、
前記接着層は、
前記シート状基材もしくは前記断熱層に前記粘着材を塗布し、前記粘着材保護シートで覆ったものである
ことを特徴とする断熱シート。
A pressure-sensitive adhesive provided on a sheet-like base material made of a nonwoven fabric, a heat-insulating layer formed on at least one surface of the sheet-like base material, the other surface of the sheet-like base material, or an upper surface of the heat-insulating layer And an adhesive layer having an adhesive material protective sheet that can be detached from the adhesive material,
The thermal insulation layer is
The heat insulating coating material composed of a mixture of hollow beads and acrylic resin applied to the sheet-like base material is drained by irradiation with far infrared rays or microwaves to form a heat insulating coating,
The adhesive layer is
The heat-insulating sheet, wherein the pressure-sensitive adhesive material is applied to the sheet-like substrate or the heat-insulating layer and covered with the pressure-sensitive adhesive protective sheet.
前記中空ビーズは、アクリルビーズであり、
前記アクリル系樹脂は、スチレンアクリル酸アルキルエステル共重合物エマルジョンである
ことを特徴とする請求項５に記載の断熱シート。
The hollow beads are acrylic beads,
The heat insulation sheet according to claim 5, wherein the acrylic resin is a styrene acrylic acid alkyl ester copolymer emulsion.
前記断熱層に含まれる中空ビーズの重量比率は、３０〜７０％である
ことを特徴とする請求項６に記載の断熱シート。
The weight ratio of the hollow beads contained in the heat insulation layer is 30 to 70%. The heat insulation sheet according to claim 6.
前記断熱シートの接着材側の面は、
建築物の内外壁、自動車・航空機・列車等の車体の内外表面、カーテンウォールの内外壁のいずれかに、貼着される
ことを特徴とする請求項５から請求項７のいずれかに記載の断熱シート。 The surface of the heat insulating sheet on the adhesive side is
It is affixed on either the inner or outer wall of a building, the inner or outer surface of a car body such as an automobile, aircraft or train, or the inner or outer wall of a curtain wall. Insulation sheet.
JP2006254750A 2006-09-20 2006-09-20 Method of manufacturing heat insulating sheet, and heat insulating sheet Pending JP2008073600A (en)

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JP2010248852A (en) * 2009-04-20 2010-11-04 Sekisui Chem Co Ltd Heat insulating structure of opening and method for heat insulation of opening using the heat insulating structure
KR101134260B1 (en) * 2009-11-20 2012-05-17 선종우 Interior Decoration panel
CN103740291A (en) * 2013-12-24 2014-04-23 上海奇想青晨新材料科技股份有限公司 Pre-coating film and preparation method thereof
JP2018017242A (en) * 2016-07-25 2018-02-01 仁敏 小綿 Process of manufacture of heat insulation sheet and manufacturing installation for the same
CN108368372A (en) * 2015-12-09 2018-08-03 株式会社造梦者53 Thermal insulation film and thermal insulation coating composition
CN108424729A (en) * 2018-05-11 2018-08-21 东莞市古川胶带有限公司 A kind of black one-faced tapes and preparation method thereof with heat insulating function
KR20210133005A (en) * 2020-04-28 2021-11-05 정금필 Pent roof manufacturing method for awning and tent
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JP2010248852A (en) * 2009-04-20 2010-11-04 Sekisui Chem Co Ltd Heat insulating structure of opening and method for heat insulation of opening using the heat insulating structure
KR101134260B1 (en) * 2009-11-20 2012-05-17 선종우 Interior Decoration panel
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CN108424729A (en) * 2018-05-11 2018-08-21 东莞市古川胶带有限公司 A kind of black one-faced tapes and preparation method thereof with heat insulating function
KR20210133005A (en) * 2020-04-28 2021-11-05 정금필 Pent roof manufacturing method for awning and tent
KR102487929B1 (en) * 2020-04-28 2023-01-11 정금필 Awning curtain manufacturing method and awning curtain using same
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