JP2008280785A - Heat insulating panel and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a heat insulating panel in which sound insulating performance is improved. <P>SOLUTION: The heat insulating panel comprises a foamed polystyrene board having fine recesses and projections formed on a whole front surface by shaving the surface by a wire of a heat cutter, a glass fiber sheet bonded to a rear surface of the foamed polystyrene board, and grid-like sash bars projecting on a front surface of the foamed polystyrene board. A mountain/valley part including a plurality of mountains and valleys formed by a mold, arranged alternately in vertical and horizontal directions, and extending straight may be formed instead of the fine peaks and troughs. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a heat insulating panel, and more particularly, to a heat insulating panel with improved sound insulation performance and a method for manufacturing the same.

In general, there is known an architectural formwork that has a structure in which a crosspiece is assembled to a polystyrene foam plate and can be used both as a concrete formwork and an interior base material. That is, after pouring concrete and forming a wall, it is left as it is without removing a formwork and used as a heat insulation panel. The expanded polystyrene plate is obtained by adding a foaming agent to polystyrene and expanding it with steam, and has a structure in which many fine closed cells are surrounded by a thin polystyrene resin film, and is lightweight (16-30 kg / m ³ ). Excellent heat insulation. Patent Document 1 discloses a structure of a foamed polystyrene foam for construction.

  An example of a conventional heat insulation panel is shown in FIGS. FIG. 9A is a front view of a heat insulating panel 50a for a doorway wall. The heat insulation panel 50a for the doorway wall is a foamed polystyrene plate 1 provided with a grid-like pier 2 and a pier 2 as upper, lower, left and right frames. FIG. 9B is a front view of a heat insulating panel 50b for a slab floor. The heat insulation panel 50b for the slab floor is only the lattice-shaped pier 2 and is not provided with a pier as an outer frame. FIG. 10 is an enlarged view of the DD cross-sectional view of FIG. The pier 2 is attached so as to protrude from the front surface of the expanded polystyrene plate 1. The pier 2 is assembled by inserting it into a groove and fixing it with an adhesive. A plaster board 5 made of gypsum is attached to the front surface of the pier 2. Since the crosspiece 2 protrudes, a hollow portion 6 is formed between the surface of the expanded polystyrene plate 1.

For example, the conventional heat insulation panel has an overall thickness of about 40 mm, a foamed polystyrene plate thickness of 30 mm, and a piercing projection of 10 mm, and an overall thickness of about 60 mm. The length was 50 mm, and the protruding amount of the pier was 10 mm. Thus, the protruding amount of the pier was constant and the thickness of the hollow part was small. Therefore, even if a heat insulation panel is stuck, the sound insulation performance between rooms may not be enough. When an insulation panel is affixed to an RC (steel reinforced concrete) wall, etc., the sound in the high frequency region (1-2 kHz) is effectively cut off, but the sound in the low frequency region (125-256 Hz) is conversely thin. For this reason, it may resonate with the plaster board on the surface of the heat insulating panel, which may make it worse than the sound insulation performance of the RC wall alone. For this reason, it is necessary to perform additional work such as placing a sound absorbing material such as urethane fiber in the hollow portion of the heat insulation panel, or changing the thickness of the plaster board from 9.5 mm to 12.5 mm.
Registered Utility Model Publication No. 3017784

  The objective of this invention is providing the heat insulation panel excellent in the sound-insulation performance.

  The heat insulation panel according to claim 1 of the present invention is affixed to a foamed polystyrene plate having fine irregularities formed on the entire front surface formed by shaving the surface with a wire of a heat cutter, and a rear surface of the foamed polystyrene plate. It is characterized by comprising a glass fiber sheet and a grid-like pier protruding from the front surface of the expanded polystyrene plate.

  According to a second aspect of the present invention, there is provided the heat insulation panel according to the second aspect of the present invention, wherein a mountain-valley portion that is formed by a mold and is alternately provided in the vertical direction and the horizontal direction and extends linearly including a plurality of peaks and valleys is provided on the entire front surface. It is characterized by comprising a foamed polystyrene plate, a glass fiber sheet affixed to the rear surface of the foamed polystyrene plate, and a grid-like pier protruding from the front surface of the foamed polystyrene plate.

  According to a third aspect of the present invention, there is provided a method for manufacturing a heat insulating panel, wherein the heat insulating panel is formed by a fine unevenness forming step or a mold for shaving the front surface of a polystyrene foam plate with a wire of a heat cutter, and is provided alternately in the vertical and horizontal directions. A valley-and-valley forming step for forming a linearly-grooved valley-and-valley portion composed of a plurality of peaks and valleys on the front surface of the expanded polystyrene plate, a glass fiber sheet attaching step for adhering a glass fiber sheet to the rear surface of the expanded polystyrene plate, and the foaming And a cross-assembly process in which a cross is protruded with an adhesive and assembled in a lattice shape on the front surface of the polystyrene plate.

  According to the heat insulating panel of the first aspect of the present invention, since the fine irregularities are provided on the entire front surface of the expanded polystyrene plate and the surface area thereof is increased, sound is absorbed and sound transmission loss (TL) can be improved. Since the glass fiber sheet is attached and the strength is improved, the polystyrene foam plate can be thinned. Accordingly, since the hollow portion is thickened, it is possible to secure sound transmission loss (TL) of 40 TL or more in a low frequency region of 125 to 256 Hz, particularly in a frequency region of 125 Hz to 2000 Hz.

  According to the heat insulation panel of the second aspect of the present invention, since the linear crest and valley portions are provided on the entire front surface of the expanded polystyrene plate and the surface area thereof is increased, sound is absorbed and sound transmission loss (TL) can be improved. . Alternating linear peaks and valleys are also effective in sound dispersion because air moves along the peaks and valleys. Since the glass fiber sheet is attached and the strength is improved, the polystyrene foam plate can be thinned. Accordingly, the hollow portion can be made thick, and the sound transmission loss (TL) in the low frequency region of 125 to 256 Hz can be ensured by 40 TL or more.

  According to the manufacturing method of the heat insulation panel which has the process of Claim 3 by this invention, the fine unevenness | corrugation formation process which forms fine unevenness | corrugation with the wire of a heat cutter on the surface of the front surface of a polystyrene foam plate, or the linear form by a metal mold | die Since the mountain valley portion forming step for forming the mountain valley portion, the step of attaching the glass fiber sheet to the rear surface of the expanded polystyrene plate, and the assembly step of the pier are further provided, for the same reason as in claim 1, the sound insulation performance is achieved. Excellent heat insulation panel can be manufactured.

  Embodiments of a heat insulation panel according to the present invention will be described below with reference to the drawings.

FIG. 1 is a sectional view of a heat insulation panel for a door wall according to the present invention. As shown in FIG. 1, the heat insulating panel 70 a for a doorway wall has fine uneven portions 11 on the entire front surface. The dimensions (configuration example A) of the heat insulation panel 70a are, for example, 2360 mm in height, 600 mm in width, and 48 mm in thickness. The expanded polystyrene plate 1 is obtained by expanding beads about 40 times with steam. A glass fiber sheet 10 is pasted on the rear surface of the expanded polystyrene plate 1 to increase the strength. The thickness (L1) of the expanded polystyrene plate 1 is 28 to 30 mm. L1 is not limited to this, and can be as thin as 25 mm. The thickness (L2) of the hollow portion 6 was 20 mm. L2 is not limited to this, and may be 15 to 20 mm (1.5 to 2 times the conventional value). In the configuration example A, the total thickness (L; L = L1 + L2) is 48 mm. The pier 2 was a square having a cross section of 20 × 25 mm. Seven piers 2 were arranged in a lattice pattern at intervals of 78 mm, and fixed to the grooves of the expanded polystyrene plate 1 with an adhesive. A plaster board 5 is attached to the front surface of the pier 2. The glass fiber sheet 10 had a thickness of about 0.2 mm, a weight of about 160 g / m ² , and a mesh size of 4 mm × 4 mm. The glass fiber sheet 10 ensures the strength of the expanded polystyrene plate 1 and has good adhesion to concrete.

  The fine concavo-convex portion 11 can be processed by first forming the foamed polystyrene plate 1 that has been slightly thickened with a mold, and then cutting the entire front surface with a heat cutter. The wire of the heat cutter is heated to about 200 to 300 degrees by energization. The length of the wire of the heat cutter was adjusted to the width of the expanded polystyrene plate 1. That is, the fine irregularities 11 are formed by fusing the surface of the expanded polystyrene plate 1 with a heat cutter wire. The fine irregularities 11 have an effect that a coating (2 to 3 microns) of closed cells (30 to 50 microns in the embodiment) is cut open, the surface melts and is rough, and the sound is reflected and partly absorbed. There is.

  FIG. 2 is a cross-sectional view of a heat insulation panel for a slab floor according to the present invention. The heat insulation panel 70b for the slab floor has the fine irregularities 11 on the entire front surface. Moreover, the glass fiber sheet 10 is stuck on the rear surface of the expanded polystyrene plate 1 to increase the strength. The dimensions (configuration example B) of the heat insulating panel 70b are, for example, a height of 2490 mm, a width of 600 mm, and a thickness of 60 mm. The crosspiece 2 has a cross section of 25 × 45 mm. The pier 2 may use 35 × 35 mm. The thickness (L1) of the expanded polystyrene plate 1 was 25 to 30 mm. L1 is not limited to this, and one having a plate thickness of 35 mm may be used. The thickness (L2) of the hollow portion 6 was set to 35 mm. L2 is not limited to this, and may be about 25 mm.

  FIG. 3 is a cross-sectional view of a heat insulating panel for a door wall according to the present invention. The heat insulation panel 70c for the doorway wall has a mountain valley portion 12 on the entire front surface. The dimensions (Configuration Example C) of the heat insulation panel 70c were the same as those in Configuration Example A, and the height was 2360 mm, the width was 600 mm, and the thickness was 48 to 50 mm. However, a mountain valley portion 12 is provided on the front surface in place of the fine uneven portion 11. The total thickness (L) of the heat insulation panel 70c is calculated from L = L1 + L2-L3. The thickness (L1) of the expanded polystyrene plate 1 is 38 to 40 mm including the height 10 mm of the peak 13 of the valley 12 and the thickness (L2) of the hollow part 6 including the depth 10 mm of the valley 14 of the valley 12. Since 20 mm and the thickness (L3) of the mountain valley portion 12 are 10 mm, L is 48 to 50 mm. The valley 12 is not limited to 10 mm and may be about 15 mm. The thickness of the hollow portion 6 is secured about twice that of the prior art. In terms of strength, the thickness (L1) of the expanded polystyrene plate 1 may be 38 mm to 35 mm (base 25 mm + mountain valley 10 mm), and the overall thickness (L) may be 45 mm. The pier 2 was a square having a cross section of 20 × 25 mm. Seven piers 2 were arranged in a lattice pattern at intervals of 78 mm, and fixed to the grooves of the expanded polystyrene plate 1 with an adhesive. A glass fiber sheet 10 was attached to the rear surface of the expanded polystyrene plate 1.

  On the front surface of the expanded polystyrene plate 1, a mountain valley portion 12 in which a plurality of peaks 13 and valleys 14 linearly extend is provided on the surface. The mountain valley portion 12 was formed by a mold of the expanded polystyrene plate 1. As for the depth of the mountain valley part 12, 10-15 mm is desirable, and a surface area can be increased significantly by this. In the configuration example C, the depth of the mountain valley portion 12 is about 10 mm. Since the air moves in the direction of low air pressure along the straight mountain-and-valley portion 12, the mountain-and-valley portions 12 are alternately arranged in the vertical direction and the horizontal direction, so that the sound is absorbed and dispersed.

  FIG. 4 is a cross-sectional view of a heat insulation panel for a slab floor according to the present invention. The dimensions (Configuration Example D) of the heat insulation panel 70d for the slab floor are, for example, a height of 2490 mm, a width of 600 mm, and a thickness of 50 to 55 mm. As the pier 2, for example, one having a cross section of 35 × 35 mm was used, and five bars were arranged in a lattice shape at intervals of 108 mm. The thickness (L1) of the expanded polystyrene plate 1 was set to 35 mm together with 10 mm of the mountain valley portion 12. In the configuration example D, the thickness (L1) of the expanded polystyrene plate 1 is 35 to 40 mm, the thickness (L2) of the hollow portion 6 including 10 mm of the mountain valley portion 12 is 25 mm, and the thickness (L3) of the mountain valley portion 12 is 10 mm. It is. The total thickness (L; L = L1 + L2-L3) of the heat insulation panel 70b is 50 to 55 mm.

  FIG. 5 is a front view of FIG. In the mountain valley portion 12, the mountain valley portion 12a extending in the vertical direction and the mountain valley portion 12b extending in the horizontal direction are alternately arranged in the vertical direction. This is to disperse the sound. FIG. 3 shows a cross-sectional view taken along line FF in FIG.

  FIG. 6 is a partial cross-sectional view showing an example of use of a heat insulating panel of a door wall and a slab floor. In the case where the heat insulation panel is also used as a formwork panel, for example, the concrete 4 is poured between the heat insulation panels 70 a to form the door boundary wall 40. Even if the concrete 4 is hardened, the heat insulating panel 70a is left without being removed. A plaster board 5 is attached to the surface. The heat insulation panel 70b is arrange | positioned when forming the slab floor 45 which partitions the downstairs and the room upstairs. When a heat insulating panel is used for the RC wall, the sound transmission loss (TL) is evaluated as to how much the sound generated in the room A is transmitted to the room B or the sound generated in the room C is transmitted to the room B.

  FIG. 7 is a graph showing the sound insulation performance of the heat insulation panel according to the present invention. The horizontal axis represents frequency and the vertical axis represents sound transmission loss (TL). In FIG. 7, the sound insulation performance curve 60 shows the sound transmission loss (TL) of the RC wall having a thickness of 200 mm when the heat insulation panel is not attached to the wall. The sound insulation performance curve 61 is a sound transmission loss (TL) of the door boundary wall 40, and is a value using a heat insulating panel 70a (Configuration Example A) in which the thickness of the hollow portion 6 is 20 mm. The plaster board 5 has a thickness of 9.5 mm. The sound insulation performance curve 62 is a sound transmission loss (TL) of the slab floor, and is a value using a heat insulating panel 70b (Configuration Example B) in which the thickness of the hollow portion 6 is 35 mm. The plaster board 5 has a thickness of 9.5 mm. The unit of sound transmission loss (TL) is dB, and the larger the value, the better the sound insulation performance. The frequency (Hz) on the horizontal axis is evaluated from 125 to 2000 Hz in the audible region indicated by the symbol A. When the sound transmission loss (TL) is 55 or more, it is a level that cannot be heard normally, when TL is 55, it is hardly heard, and when TL is 40, it is a level that can be heard small.

  The sound insulation performance curves 61 and 62 are both excellent in sound insulation performance because the sound transmission loss (TL) rises to near 70 at a frequency near 2000 Hz as compared to the sound insulation performance curve 60 of an RC wall without a heat insulation panel. Is shown. On the other hand, at a frequency of 125 to 1000 Hz of the sound insulation performance curve 61, the sound insulation performance is lower than that of the RC wall to which the heat insulation panel is not attached, but 40 (TL) or more can be secured. It should be noted that the plaster board 5 acts as a mass and the hollow portion 6 acts as a spring, and the resonance point is located at the lower left of FIG.

  It is desirable that the sound transmission loss (TL) can be secured to 60 or more at a frequency of 1000 Hz and 40 or more at a frequency of 125 Hz. Therefore, it is preferable that the thickness of the hollow portion 6 is 20 mm. Since the thickness of the hollow portion 6 of the sound insulation performance curve 61 of the configuration example A is 20 mm and the thickness of the hollow portion 6 of the sound insulation performance curve 62 of the configuration example B is 35 mm, the thickness of the hollow portion 6 is reduced. In FIG. 7, the sound insulation performance curve moves to the right and the sound insulation performance deteriorates. Although the configuration example C and the configuration example D in which the mountain valley portion 12 is provided on the front surface are not shown in the graph, the effect of the mountain valley portion 12 is improved by 1 to 2 dB compared to the configuration example A and the configuration example B.

  FIG. 8 is a process diagram showing the manufacturing process of the heat insulation panel according to the present invention. As shown in FIG. 8, the fine uneven portion forming step or the mountain valley forming step (S15) is carried out by selecting either, and the fine uneven portion forming step is performed by fusing the front surface with a heat cutter wire. Then, in the step of forming fine irregularities, the mountain valley portion forming step is a step of forming a mountain valley portion 12 in which a plurality of peaks 13 and valleys 14 extend linearly with a mold. The mountain valley portions 12 are alternately arranged in the vertical and horizontal directions of the front surface and have a depth of 10 to 15 mm. The glass fiber sheet attaching step (S16) is a step of attaching the glass fiber sheet to the rear surface of the expanded polystyrene plate 1 with an adhesive. The crosspiece assembling step (S17) is a step in which a crosspiece is protruded from the front surface of the expanded polystyrene plate 1 with an adhesive and assembled in a lattice shape. Since the glass fiber sheet is stuck, the strength can be maintained even if the thickness of the expanded polystyrene plate 1 is reduced, and the hollow portion of the pier can be increased without increasing the overall thickness of the heat insulating panel.

  Although the heat insulation panel by this invention demonstrated the case where it used as a heat insulation panel combined with a formwork, it is suitable also as a heat insulation panel which improves the sound-insulation property at the time of renovation.

It is sectional drawing of the heat insulation panel for doorway walls by this invention. (Configuration example A) It is sectional drawing of the heat insulation panel for slab floors by this invention. (Configuration example B) It is sectional drawing of the heat insulation panel for doorway walls by this invention. (Configuration example C) It is sectional drawing of the heat insulation panel for slab floors by this invention. (Configuration example D) FIG. 4 is a front view of FIG. 3. It is a fragmentary sectional view which shows the usage example of a heat insulation panel. It is a graph which shows the sound insulation performance of the heat insulation panel by this invention. It is process drawing which shows the manufacturing process of the heat insulation panel by this invention. It is a front view of the conventional heat insulation panel. (A) is a heat insulation panel for doorway walls, (B) is a front view of the heat insulation panel for slab floors. FIG. 10 is a sectional view taken along the line DD of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Expanded polystyrene board 2 Pier 4 Concrete 5 Plaster board 6 Hollow part 10 Glass fiber sheet 11 Fine uneven part 12 Mountain valley part 12a Mountain valley part 12b extended in the vertical direction Mountain valley part 13 extended in the horizontal direction 13 Mountain 14 Valley 40 Door wall 45 Slab floor 50a 50b Thermal insulation panel (conventional)
60 Sound insulation performance curve when there is no RC wall insulation panel 61 Sound insulation performance curve when the insulation panel of Configuration Example A is used 62 Sound insulation performance curve when the insulation panel of Configuration Example B is used 70a to 70d invention)
S15-S17 Each manufacturing process

Claims (3)

A foamed polystyrene plate having fine irregularities formed on the entire front surface by cutting the surface with a wire of a heat cutter,
A glass fiber sheet attached to the rear surface of the expanded polystyrene plate;
A heat-insulating panel comprising: a lattice-shaped pier protruding from the front surface of the expanded polystyrene plate. An expanded polystyrene plate provided on the entire surface of the front surface has a crest and trough portion that is formed by a mold and that is alternately provided in the longitudinal direction and the lateral direction and that extends in a straight line consisting of a plurality of crests and troughs,
A glass fiber sheet affixed to the rear surface of the expanded polystyrene plate;
A heat-insulating panel comprising: a lattice-shaped pier protruding from the front surface of the expanded polystyrene plate. Foam polystyrene is formed by a micro unevenness forming process that cuts the surface of the front surface of the expanded polystyrene plate with a heat cutter wire or a mold, and is alternately provided in the vertical and horizontal directions and extends in a straight line consisting of a plurality of peaks and valleys. Yamaya part formation process to be formed on the front surface of the plate,
A glass fiber sheet pasting step of pasting a glass fiber sheet on the rear surface of the expanded polystyrene plate;
A method for manufacturing a heat insulating panel, comprising: a clerk assembling step in which a pier is projected with an adhesive and assembled in a lattice shape on the front surface of the expanded polystyrene plate.

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