JP2010242975A - Insulating material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an insulating material dispensing with a flange-shaped lug section, and reducing gas leakage caused by folding of the lug section and heat leakage from a butting section, and maintaining insulating performance with the passage of time. <P>SOLUTION: The vacuum insulating material 1 has a structure wherein a core material 3 is fitted in an opening of a frame body 4 and the opening of the frame body 4 is covered with a barrier film 2 as an envelope material capable of sticking to the frame body 4, and a connection section capable of mutually connecting is arranged at a peripheral edge section of the frame body 4. Further, energy director 8 is scatterably arranged on a sticking section of the barrier film 2 on upper and lower surfaces of the frame body 4, and the core material 3 is formed by a board-shaped molded body made of glass fibers bound with a binder. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a heat insulating material in which a core material is housed in a jacket material and a method for manufacturing the same.

  In recent years, consumer electronics products have been required to save energy. In order to meet such demands, high-performance vacuum insulation is used inside the main body of home appliances.

  The said vacuum heat insulating material is comprised by the core material and the jacket material which wraps a core material, for example as disclosed by patent document 1. The jacket material here may be any material as long as the core material can be accommodated and the inside can be maintained in a vacuum, but a laminated bag such as a film is preferably used.

  A protrusion (ear) is formed on the outer peripheral edge of the outer cover material of the vacuum heat insulating material.

JP 2003-269689 A

  When this ear part is bent in consideration of handling and mounting on home appliances, if the laminate film is bent forcibly at the ridgeline part of the core material, a hole such as a crack opens in that part, causing gas leakage and vacuum insulation The internal pressure of the material increases and the heat insulation performance decreases.

  On the other hand, when a plurality of the vacuum heat insulating materials are used side by side, the heat insulating performance of the home electric appliance with the vacuum heat insulating material itself deteriorates due to heat leakage from the butt portion.

  Moreover, when mounting a heat insulating material on a product, a mounting place may be limited or a heat insulating material may not be mounted with other components. If the edge of the insulation becomes thicker than the core due to the folding of the ears, the shape of the product body must be increased or the internal capacity must be reduced in order to mount the insulation. There is a concern that it must be done. Moreover, when a heat insulating material is mounted on a thin product, there is a concern that the main body does not enter or the main body becomes thick.

  Therefore, in view of the above problems, an object of the present invention is to provide a heat insulating material that can eliminate an ear part, eliminate a gas leak caused by bending of the ear part, and can suppress a heat leak from a butt part.

  Another object of the present invention is to provide a heat insulating material that can be mounted even in a narrow space, and also to provide a heat insulating material that does not require bending of the ear portion.

  In the heat insulating material of Claim 1 in this invention, an ear | edge part is not formed by covering a frame with a covering material, and generation | occurrence | production of the gas leak by bending of the said ear | edge part can be prevented. Further, since the gap between the abutting portions of the heat insulating material is not formed by the engagement of the respective engaging portions provided on the peripheral edge portion of the frame body, the heat leak from the abutting portion can be suppressed small. In addition, a uniform molten state can be brought about by the energy directors scattered on the upper and lower surfaces of the frame, and a stable welding strength can be obtained. Furthermore, since the heat generated in the welded portion is abrupt and can be welded in a short time, the resin is hardly deteriorated. In addition, gas generation due to organic substances does not occur, the degree of vacuum is maintained, and the heat insulating performance is maintained over time.

  In the heat insulating material according to claim 2 of the present invention, by using the adsorbent having a sheet-like structure, the inclusions contained in the core material are effectively adsorbed to ensure the stability at the time of the inside of the heat insulating material. Therefore, thinness can be maintained.

  In the heat insulating material according to claims 3 and 4 of the present invention, the core material can be easily compressed and the thickness can be reduced.

  In the heat insulating material according to the fifth aspect of the present invention, the ear fold is not required by narrowing the ear width to such an extent that it does not get in the way when the product is mounted. As a result, stress on the jacket material due to the bending of the ear portion is eliminated, deterioration of the heat insulating performance due to leakage or destruction of the vapor deposition surface can be prevented, and mounting in a narrow space is also possible.

  In the heat insulating material according to the sixth aspect of the present invention, by making the adsorbent into a sheet-like structure, the contact area with the core material is widened, and the inclusions contained in the core material can be adsorbed effectively.

  In the manufacturing method of the heat insulating material of Claim 7 in this invention, the content contained in a core material is effective by inserting the adsorbent of a sheet-like structure in a jacket material and vacuum-sealing with a core material. It can be adsorbed on the surface of the heat insulating material to ensure the stability of the degree of vacuum inside the heat insulating material, so that the thinness can be maintained.

  According to the first aspect of the present invention, it is possible to provide a heat insulating material that can eliminate the ear part, eliminate the gas leak due to the bending of the ear part, and suppress the heat leak from the butt part. In addition, the adhesion between the jacket material and the frame is strengthened, gas leakage can be suppressed, gas generation due to organic substances does not occur, the degree of vacuum is maintained, and the heat insulation performance is maintained over time.

  According to Claim 2 of this invention, the heat insulating material which can be mounted also in a small space can be provided.

  According to the third and fourth aspects of the present invention, the thinness of the vacuum heat insulating material is maintained.

  According to the fifth aspect of the present invention, it is possible to provide a heat insulating material that can be mounted in a narrow space and does not require bending of the ear portion.

  According to the sixth aspect of the present invention, the inclusions contained in the core material can be effectively adsorbed to maintain thinness.

  According to the seventh aspect of the present invention, a heat insulating material that can be mounted in a narrow space can be obtained.

It is a disassembled perspective view which shows the structure of the heat insulating material in 1st Example of this invention. It is a longitudinal cross-sectional view of a heat insulating material same as the above. It is a longitudinal cross-sectional view of the modification of a heat insulating material same as the above. It is a longitudinal cross-sectional view which shows the state before heat-sealing a barrier film to a frame in another modification of a heat insulating material same as the above. It is a perspective view which shows the state before heat-sealing the heat insulating material in 2nd Example of this invention. It is a longitudinal cross-sectional view of a heat insulating material same as the above. It is a longitudinal cross-sectional view of the modification of a heat insulating material same as the above.

  Hereinafter, preferred embodiments of the heat insulating material and the manufacturing method thereof according to the present invention will be described with reference to the accompanying drawings. In addition, in each Example, the same code | symbol is attached | subjected to the same location, Since description of a common part overlaps, it abbreviate | omits as much as possible.

  The heat insulating material in the first embodiment of the present invention will be described with reference to FIGS. 1 and 2. In the figure, the vacuum heat insulating material 1 is composed of a frame body 4, a core material 3, and a barrier film 2 as a covering material that covers the upper surface and the bottom surface of the frame body 4. The frame body 4 is a molded product made of a synthetic resin material, and has a rectangular frame shape formed so that a rectangular opening 5 is opened up and down at the center thereof.

  The core material 3 is made of glass wool formed in a board shape, and the vertical and horizontal dimensions thereof are set so as to be properly accommodated in the opening 5 of the frame body 4. As a method for forming glass wool into a board-like molded body, there are a method using a binder and a method not using it. In the method using a binder, the glass wool is bound to the glass fiber by a binder to form a board-like molded body. Advantages in the case of using a binder include that the core material 3 can be easily formed into a molded body, and the handleability when inserting the barrier bag is improved. On the other hand, in a method without using a binder, glass wool is heated and compressed to form a board-like molded body. Advantages of not using a binder include that gas generation due to organic substances does not occur, the degree of vacuum is maintained, and the heat insulation performance is maintained over time.

  The barrier film 2 as the covering material may be any material as long as it has a gas barrier property and can maintain a vacuum inside with the frame body 4 in which the core material 3 is inserted. A laminated film such as a plastic film having a metal deposited on its surface is used. Of the layers constituting the barrier film 2, the innermost layer (the frame body 4 side) is in contact with the upper and lower surfaces 4 a of the frame body 4 and can be heat sealed.

  In the manufacturing process of the vacuum heat insulating material 1, the core material 3 is inserted into the opening 5 of the frame body 4, and then the upper and lower surfaces 4 a and 4 a of the frame body 4 are closed (closed) with the barrier film 2, It is formed by putting in a vacuum chamber and evacuating, and heat sealing the periphery of the frame 4 and the barrier film 2 to seal the inside of the opening 5.

  Next, FIG. 3 shows a modified embodiment in which heat leakage in the frame body 4 is suppressed to a low level. That is, the peripheral part of the frame 4 is provided with a concave part 6 and a convex part 7 as engaging parts that can be engaged with each other. In the figure, a concave portion 6 is provided on one outer peripheral surface of the frame 4, and a convex portion 7 is provided on the other outer peripheral surface facing the outer peripheral surface. When the plurality of vacuum heat insulating materials 1 are arranged, the concave portions 6 and the convex portions 7 are engaged with the concave portions 6 and the convex portions 7 provided in the respective vacuum heat insulating materials 1 so that the respective vacuum heat insulating materials are engaged. The material 1 can be connected. Therefore, when a plurality of the vacuum heat insulating materials 1 are arranged, there is no gap in the butt portion of each vacuum heat insulating material 1, so that heat leak from the butt portion can be suppressed small. When one piece of vacuum heat insulating material 1 is rolled into a cylindrical shape, even if the concave portion 6 and the convex portion 7 are engaged with each other, there is no gap in the butt portion, so that heat leaks from the butt portion. It can be kept small. In addition, as a requirement of the engaging portions such as the concave portion 6 and the convex portion 7, the position, shape, and the like are particularly limited as long as they are suitable for connecting the butt portions of the vacuum heat insulating material 1. For example, the peripheral part of the frame 4 may be formed into a hook shape that engages with each other.

  Furthermore, the modified embodiment which suppressed the gas leak in the heat seal part of the frame 4 and the barrier film 2 small is shown in FIG. In this structure, energy directors 8 are provided on the upper and lower surfaces 4a and 4a of the frame body 4 that is the part to which the barrier film 2 is attached, in which the opening 5 is opened. The frame 4 and the barrier film 2 are heat sealed using this energy director 8. That is, the barrier film 2 and the frame body 4 are welded by heating the position where the energy director 8 is provided from above the barrier film 2 with a heater and eluting the energy director 8.

  In general, when the flat surfaces are welded to each other, the melted position of the resin becomes non-uniform, and a uniform and stable welding strength cannot be obtained. At the same time, the heat generation temperature rise at the welded portion is slow and time consuming, which not only results in poor efficiency but also leads to deterioration of the resin. However, by providing the energy director 8, the position where the resin melts always becomes the apex of the triangle and becomes constant, and a uniform molten state can be obtained, and stable welding strength can be obtained. Furthermore, since the heat generated in the welded portion is abrupt and can be welded in a short time, the resin is hardly deteriorated. Therefore, according to this embodiment, welding of the heat seal part between the barrier film 2 and the frame body 4 becomes strong, and gas leakage can be suppressed to a small value.

  The vacuum heat insulating material 1 obtained in this way has no flange-shaped ears formed when the barrier films 2 are heat-sealed, so that it is easy to transport and handle without bending the ears. At the same time, generation of cracks due to excessive bending of the ear is eliminated.

  As described above, in the vacuum heat insulating material 1 of the first embodiment, the frame body 4 is formed by the barrier film 2 as an outer covering material that can be attached to the frame body 4 by fitting the core material 3 into the opening 5 of the frame body 4. The opening 5 is covered, and the peripheral portion of the frame 4 is provided with a concave portion 6 and a convex portion 7 as engaging portions that can be engaged with each other.

  If it does in this way, a flange-like ear | edge part will not be formed by sticking the barrier film 2 to the frame 4, and generation | occurrence | production of the gas leak by bending of the said ear | edge part can be prevented. Moreover, since a clearance is not made in the butting part of the vacuum heat insulating material 1 by engagement of each engaging part provided in the peripheral part of the frame body 4, the heat leak from the said butting part can be suppressed small. As described above, it is possible to provide the vacuum heat insulating material 1 that can eliminate the flange-shaped ear portion, eliminate the gas leak due to the bending of the ear portion, and suppress the heat leak from the butt portion.

  Moreover, in the vacuum heat insulating material 1 of the first embodiment, energy directors 8 are provided on the upper and lower surfaces 4a and 4a of the frame body 4 in the portion where the barrier film 2 is attached.

  In this way, it is possible to bring about a uniform melted state by the energy director 8 provided to be scattered on the upper and lower surfaces 4a, 4a of the frame body 4, and to obtain a stable welding strength. Furthermore, since the heat generated in the welded portion is abrupt and can be welded in a short time, the resin is hardly deteriorated. By the above, welding with the barrier film 2 and the frame 4 becomes strong, and gas leak can be suppressed small.

  Furthermore, in the first embodiment, the core material 3 is a board-like molded body made of glass fibers bound by a binder.

  If it does in this way, the core material 3 can be easily made into a molded object, and the handleability at the time of barrier bag insertion will improve.

  In the first embodiment, the core material 3 is a board-shaped molded body made of glass fibers that are heated and compressed without using a binder.

  In this way, gas generation due to organic substances does not occur, the degree of vacuum is maintained, and the heat insulating performance is maintained over time.

  The heat insulating material in the second embodiment of the present invention will be described with reference to FIGS. FIG. 5 shows the vacuum heat insulating material 10 before sealing, and FIG. 6 is a cross-sectional view of the vacuum heat insulating material 10 in a completed state. In the figure, 10 is a flat vacuum heat insulating material disposed in, for example, a refrigerator or a cooking appliance, and this is a vacuum for the core material 11, the moisture adsorbing material 12, and the core material 11 and the moisture adsorbing material 12. It is comprised with the barrier film 13 as a jacket material packaged in a state.

  For the core material 11, for example, a plastic nonwoven fabric such as polyethylene terephthalate formed in a sheet shape or a paper glass wool (glass fiber) is used. As will be described later, the core material 11 is not bound by a binder or the like so as to be thinned by compression when evacuated. For the core material 11, a material having a small fiber diameter, a high porosity, and a thin thickness is suitable. For example, a polypropylene nonwoven fabric or an acrylic nonwoven fabric may be used.

  The moisture adsorbing material 12 has a structure in which films are laminated on both surfaces of a base material in which calcium chloride is supported on a carrier made of a thermoplastic resin formed in a sheet shape and natural pulp. In addition, for example, a sheet-like carrier having zeolite, silica gel or the like supported thereon may be used, as long as it can adsorb contents such as liquid components and volatile gas components contained in the core material 11. .

  The barrier film 13 before vacuum sealing is formed into a bag shape having three sides heat sealed and only one side opened, and the core material 2 and the moisture adsorbing material 12 are inserted and sealed from this opening. At this time, the outer peripheral edge of the heat-sealed barrier film 13 becomes an ear portion 14 as a flange-shaped sealing portion. The barrier film 13 may be any material as long as it is heat-sealable and has a gas barrier property and can maintain a vacuum inside the core material 11 and the moisture adsorbing material 12 inserted. A laminated film such as a plastic film deposited on is used.

  In the manufacturing process of the vacuum heat insulating material 10, after inserting the moisture adsorbing material 12 together with the core material 11 dried at a high temperature into the barrier film 13, it is put into a vacuum chamber and evacuated to heat-seal the opening of the barrier film 13. Then, it is formed by sealing. As an insertion mode of the moisture adsorbing material 12, in addition to inserting the core material 11 in a layer form like the vacuum heat insulating material 10 in FIG. 6, in the barrier film 13 like the vacuum heat insulating material 10A shown in FIG. The moisture adsorbing material 12 may be inserted into a gap formed by shifting the core material 11. In the vacuum heat insulating material 10 </ b> A, the moisture adsorbing material 12 is arranged side by side with the core material 11, whereby the thickness thereof can be made thinner than that of the vacuum heat insulating material 10.

  Next, the operation of the above configuration will be described. Since the core 11 uses a plastic nonwoven fabric such as polyethylene terephthalate formed in a sheet shape having a thickness of 1 to 3 mm, or a paper wool made of paper, etc., the core material 11 is shrunk by vacuum sealing, and its thickness is reduced to a sheet shape. Even if the thickness of the moisture adsorbing material 12 is taken into consideration, the thickness of the vacuum heat insulating material 10 as a whole is 1 to 3 mm. Accordingly, the thinness of the vacuum heat insulating material is maintained.

  Here, when the moisture adsorbent 12 is not used, the moisture in the core 11 that could not be removed by the high-temperature drying or vacuuming process of the core 11 ensures the stability of the vacuum degree inside the vacuum heat insulating material. It may not be possible. Also, conventionally used adsorbents such as lime and silica gel cannot maintain the thinness of the vacuum heat insulating material. In order to avoid the above points, by using the sheet-like moisture adsorbent 12, the moisture contained in the core 11 is effectively adsorbed, and the vacuum stability of the vacuum degree inside the vacuum heat insulating material 10 is stable. Can be secured. Therefore, since the thinness can be maintained, it is possible to obtain the vacuum heat insulating material 10 that can be mounted in a narrow space and has higher heat insulating properties.

  By the way, the outer peripheral edge of the barrier film 13 constituting the vacuum heat insulating material 10 is heat-sealed to form a flange-like ear portion 14, but when the ear portion 14 is bent, the ridgeline of the core material 11 is formed. When the barrier film 13 is forcibly bent at the portion, a hole such as a crack is opened at the portion, gas leakage occurs, the internal pressure of the vacuum heat insulating material 10 rises, and the heat insulation performance deteriorates. For example, when mounting a heat insulating material on a rice cooker, a mounting place may be limited or a heat insulating material may not be mounted with other components. That is, if the thickness of the peripheral edge of the heat insulating material becomes thicker than the thickness of the core material 11 by folding the ear, the shape of the product body is increased in order to mount the heat insulating material, and conversely the internal capacity is increased. There is concern about the problem of having to make it smaller.

  In order to avoid these problems, in the vacuum heat insulating materials 10 and 10A in the second embodiment, the width of the ear portion 14 is set to 8 mm or less, and the ear folding is unnecessary. As a result, there is no stress on the barrier film 13 due to the bending of the ears 14, and it is possible to prevent the heat insulation performance from being deteriorated due to leakage or destruction of the vapor deposition surface, and to obtain the vacuum heat insulating material 10 that can be mounted in a narrow space. Can do. On the other hand, by reducing the width of the ears, there is an advantage that the core material area can be increased with respect to the outer dimensions of the heat insulating material, and the heat insulating area is increased.

  As described above, the vacuum heat insulating material 10 according to the second embodiment is a heat insulating material formed by sealing the core material 11 and the moisture adsorbing material 12 into the barrier film 13 as a covering material in a predetermined state, The core material 11 is formed by molding at least one kind selected from plastic nonwoven fabric or inorganic fiber into a sheet shape, the moisture adsorbing material 12 forms a sheet-like structure, and the total thickness is 1 to 3 mm. It is characterized by that.

  In this way, by using the moisture adsorbing material 12 having a sheet-like structure, it is possible to effectively adsorb the moisture contained in the core material 11 and ensure the stability of the heat insulation inside the diameter. , Can retain thinness. Therefore, the vacuum heat insulating material 10 that can be mounted in a narrow space can be provided.

  In the second embodiment, the plastic nonwoven fabric is any one of a polyethylene terephthalate nonwoven fabric, a polypropylene nonwoven fabric, and an acrylic nonwoven fabric.

  Further, the second embodiment is characterized in that the inorganic fiber is a paper-made glass fiber and is not bound.

  If it does in this way, core material 11 will be easy to compress and thickness can be made thin. Therefore, the thinness as a vacuum heat insulating material is maintained.

  Further, the second embodiment is characterized in that the width of the ear portion 14 at the periphery of the barrier film 13 is 8 mm or less.

  By doing so, it is not necessary to fold the ear by narrowing the width of the ear to such an extent that it does not get in the way when the product is mounted. As a result, stress on the jacket material due to the bending of the ear portion 14 is eliminated, deterioration of the heat insulating performance due to leakage or destruction of the vapor deposition surface can be prevented, and mounting in a narrow space is also possible. As described above, it is possible to provide the vacuum heat insulating materials 10 and 10A that can be mounted in a narrow space and do not need to bend the flange-shaped ear portion 14.

  Furthermore, in the second embodiment, the moisture adsorbing material 12 is characterized in that any one of zeolite, calcium chloride, and silica gel is supported on a sheet-like carrier.

  In this way, by making the moisture adsorbing material 12 into a sheet-like structure, the contact area with the core material 11 is widened, and the moisture contained in the core material 11 can be adsorbed effectively. Accordingly, moisture contained in the core material 11 can be effectively adsorbed and thinness can be maintained.

  In the second embodiment, the core material 11 made of any one of a sheet-like polyethylene terephthalate nonwoven fabric, a polypropylene nonwoven fabric, and an acrylic nonwoven fabric, or a sheet-like glass fiber that has been made, and a moisture adsorbing material 12 are put into the barrier film 13. Provided is a method for producing a vacuum heat insulating material 10, 10A, which is inserted and vacuum-sealed.

  In this way, by inserting the moisture adsorbing material 12 having a sheet-like structure into the barrier film 13 together with the core material 11 and vacuum-sealing, the moisture contained in the core material 11 is effectively adsorbed, and heat insulation Since the stability of the degree of vacuum inside the material can be ensured, the thinness can be maintained. Therefore, the vacuum heat insulating materials 10 and 10A that can be mounted in a narrow space can be obtained.

  The present invention is not limited to the above embodiments, and can be modified without departing from the spirit of the present invention. For example, the vacuum heat insulating material as the heat insulating material in the present embodiment can be applied to any product. The barrier film 2 can also be attached to the frame 4 using an adhesive or the like.

1 Vacuum insulation (insulation)
2 Barrier film (coating material)
3 Core material 4 Frame body 5 Opening part 6 Concave part (engagement part)
7 Convex part (engagement part)
8 Energy Director
10, 10A Vacuum insulation (insulation)
11 Core
12 Moisture absorbing material
13 Barrier film (coating material)
14 Ear

Claims (7)

  A core member is fitted into the frame body, and the frame body is covered with an outer cover material. Engaging engagement portions are provided at the peripheral edge of the frame body, and energy directors are placed on the upper and lower surfaces of the frame body. The heat insulating material is characterized in that the core material is a molded body that does not use a binder.   A heat insulating material in which a core material and an adsorbent material are housed in a jacket material in a predetermined state, wherein the core material is formed by molding at least one kind selected from a nonwoven fabric or a fiber, A heat insulating material characterized in that the adsorbent has a sheet-like structure and has a thickness of 1 to 3 mm.   The heat insulating material according to claim 2, wherein the non-woven fabric is one of polyethylene terephthalate, polypropylene, and acrylic.   The heat insulating material according to claim 2, wherein the fibers are glass fibers and are not bound.   The heat insulating material according to claim 2, wherein the edge of the outer periphery of the jacket material has a predetermined width or less.   The heat-insulating material according to claim 2, wherein the adsorbent is made by supporting any one of zeolite, calcium chloride, and silica gel on a carrier.   A method for producing a heat insulating material, in which a polyethylene terephthalate non-woven fabric, a polypropylene non-woven fabric, an acrylic non-woven fabric, or a core material made of paper-made fibers and an adsorbent material are inserted into a jacket material and vacuum sealed.

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