JP2016173142A - Heat insulator, core material, refrigerator, and heat insulator manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat insulator for improving the productivity and suppressing the reduction of a thermal insulation performance, a core material constituting this heat insulator, a refrigerator having that heat insulator, and a manufacturing method for that heat insulator.SOLUTION: A heat insulator 10 has a core material 11 constituted by winding a nonwoven fabric 13 continuing in a zone shape, and the nonwoven fabric 13 is constituted of resin fibers. An external capsule 12 is the so-called laminate material, in which a metal or a metal oxide is evaporated on a resin film of one layer or two layers, for example, and has an air-tightness having eliminated the permeability of gases.SELECTED DRAWING: Figure 1

Description

  Embodiments of the present invention relate to a heat insulating material, a core material constituting the heat insulating material, a refrigerator including the heat insulating material, and a method for manufacturing the heat insulating material.

  Conventionally, the heat insulating material comprised by accommodating the core material which has a heat insulation function in an outer packaging material is considered (for example, refer patent document 1). In the technical field related to this type of heat insulating material, in recent years, it has been considered to form a core material of a heat insulating material by forming a non-woven fabric with fibers and laminating a large number of non-woven fabrics. However, the work of laminating a large number of nonwoven fabrics takes time. Moreover, since each nonwoven fabric is sheet-like, its handling is difficult. Therefore, in the heat insulating material which comprises a core material by laminating many nonwoven fabrics, the improvement of the productivity is calculated | required. Moreover, a sheet-like nonwoven fabric lacks rigidity. Therefore, for example, when forming the vacuum heat insulating material by accommodating the core material in the outer packaging material and evacuating it, the nonwoven fabric is compressed, the contact area between the fibers increases, and the heat insulating performance decreases. .

JP 2006-105286 A

  This embodiment can improve productivity, and can suppress the fall of heat insulation performance, the core material which comprises this heat insulating material, the refrigerator provided with this heat insulating material, and this heat insulating material A manufacturing method is provided.

The heat insulating material which concerns on this embodiment is provided with the core material comprised by winding the nonwoven fabric continuous in strip shape in the continuous state. The said nonwoven fabric is comprised with the resin fiber.
The method for manufacturing a heat insulating material according to the present embodiment is a method for manufacturing a heat insulating material including a core material, and a non-woven fabric that is continuous in a strip shape is formed from resin fibers, and this non-woven fabric is wound in a continuous state. Thus, the core material is formed.

Sectional drawing which shows the structural example of the heat insulating material which concerns on this embodiment Sectional view showing a configuration example of the core material Sectional drawing which shows the structural example of a nonwoven fabric The figure which shows an example of the manufacturing method of a heat insulating material Schematic perspective view showing the heat insulation box of the refrigerator Schematic perspective view showing the vacuum insulation panel assembly of the refrigerator The figure which shows the modification of the heat insulating material

  Hereinafter, an embodiment will be described with reference to the drawings. A heat insulating material 10 illustrated in FIG. 1 has a configuration in which a core material 11 constituting a main portion thereof is accommodated in an outer packaging material 12. As illustrated in FIG. 2, the core material 11 is configured by winding a long nonwoven fabric 13 that is continuous in a band shape. The outer packaging material 12 constitutes a surface portion of the heat insulating material 10. The outer packaging material 12 is, for example, a so-called laminate material in which a metal or metal oxide is vapor-deposited on one or two or more resin films, and has airtightness that eliminates gas permeability. In this case, the outer packaging material 12 is configured in a bag shape that can accommodate the core material 11. The outer packaging material 12 containing the core material 11 is sealed after the inside is depressurized to a pressure close to vacuum. Thereby, the outer packaging material 12 containing the core material 11 is formed as the vacuum heat insulating material 10.

  As illustrated in FIG. 3, the nonwoven fabric 13 has a configuration in which a first nonwoven fabric layer 13 a and a second nonwoven fabric layer 13 b are laminated. The first nonwoven fabric layer 13a is a sheet-like nonwoven fabric layer made of relatively hard fibers such as felt. The second nonwoven fabric layer 13b is a sheet-like nonwoven fabric layer made of resin fibers. In this case, the nonwoven fabric 13 has a configuration in which one first nonwoven fabric layer 13a is sandwiched between two second nonwoven fabric layers 13b. The first nonwoven fabric layer 13a is harder and more rigid than the second nonwoven fabric layer 13b. The nonwoven fabric 13 has a configuration in which the first nonwoven fabric layer 13a is a main component and a second nonwoven fabric layer 13b is added to the first nonwoven fabric layer 13a.

  The second nonwoven fabric layer 13b is formed of resin fibers that are randomly intertwined. In this case, the second nonwoven fabric layer 13b is formed by an electrospinning method. The resin fiber produced by the electrospinning method is a thin fiber having a fiber diameter of about 0.1 nm to 10 μm, and a long fiber having a length that is, for example, 1000 times or more of the outer diameter. Moreover, the resin fiber produced | generated by the electrospinning method does not have a linear form as a whole, but makes a curved shape that is randomly curved. For this reason, the resin fibers are entangled with each other.

  In this case, the resin fiber is formed of an organic polymer having a density lower than that of glass. The resin fibers can be made lighter by forming the resin fibers with a polymer having a density lower than that of glass. Resin fibers are polystyrene, polycarbonate, polymethyl methacrylate, polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyoxymethylene, polyamideimide, polyimide, polysulfane, polyethersulfane, polyetherimide, polyether 1 type or 2 types selected from ether ketone, polyphenylene sulfide, modified polyphenylene ether, syndiotactic polystyrene, liquid crystal polymer, urea resin, unsaturated polyester, polyphenol, melamine resin, epoxy resin and copolymers containing these It can be formed by blending the above polymers.

  When the resin fiber is formed by an electrospinning method, the polymer is made into a solution. Examples of the solvent include isopropanol, ethylene glycol, cyclohexanone, dimethylformamide, acetone, ethyl acetate, dimethylacetamide, N-methyl-2-pyrrolidone, hexane, toluene, xylene, methyl ethyl ketone, diethyl ketone, butyl acetate, tetrahydrofuran, dioxane, A volatile organic solvent such as pyridine or water can be used. Further, the solvent may be one kind selected from the above solvents, or a plurality of kinds may be mixed. In addition, the solvent applicable to this embodiment is not limited to the said solvent. The said solvent is an illustration to the last.

  When the resin fibers are formed by the electrospinning method, the entanglement between the fibers can be increased, so that the non-woven fiber sheet, that is, the second non-woven fabric layer 13b can be formed simultaneously with the spinning. Moreover, since the fiber diameter of a micro order can be obtained from a micro order by forming a resin fiber by the electrospinning method, it is possible to make the thickness of the 2nd nonwoven fabric layer 13b per sheet very thin. The heat insulating material 10 has a structure in which the sheet-like second nonwoven fabric layer 13 b is wound in the core material 11.

  In addition, by decreasing the volume of the gap between the entangled fibers, the number of the gaps is increased, and the heat insulation is improved. Therefore, the fiber diameter of the resin fiber is preferably about 5 μm or less, more preferably 1 μm or less, that is, a nano-order fiber diameter. And it is preferable to maintain the porosity of the 2nd nonwoven fabric layer 13b at least 60 to 90 percent. Thereby, the strength can be improved while maintaining heat insulation. Moreover, the heat conductivity of the heat insulation panel formed of resin fibers is preferably 2.2 mW / mK or less, more preferably 1.1 mW / mK or less.

  In addition, various inorganic fillers such as silicon oxide, metal hydroxide, carbonate, sulfate, and silicate may be added to the resin fiber. By adding an inorganic filler to the resin fiber, strength can be improved while maintaining heat insulation. Examples of the inorganic filler to be added include wollastonite, potassium titanate, zonotlite, gypsum fiber, aluminum porate, MOS (basic magnesium sulfate), aramid fiber, carbon fiber, glass fiber, talc, mica, glass flake, etc. It is done.

  Next, an example of the manufacturing method of the heat insulating material 10 mentioned above is demonstrated. That is, as illustrated in FIG. 4, a strip-shaped long nonwoven fabric 13 including the first nonwoven fabric layer 13a and the second nonwoven fabric layer 13b is formed. And the core material 11 is formed by winding this nonwoven fabric 13 from an edge part. At this time, the nonwoven fabric 13 is preferably wound at least 100 times or more, more preferably several hundred times or more, or several thousand times or more. Thereby, the core material 11 in which the nonwoven fabric 13 forms at least 100 layers or more can be obtained, and the heat insulation performance can be improved.

  And the core material 11 obtained by winding the nonwoven fabric 13 is accommodated in the outer packaging material 12. At this time, the nonwoven fabric 13 has a main portion constituted by a first nonwoven fabric layer 13a having a certain degree of rigidity. Therefore, the wound nonwoven fabric 13 has a certain degree of springiness, that is, a property of returning to a cylindrical shape. Therefore, the wound nonwoven fabric 13 is not flattened by its own weight, and maintains a state in which a cavity is formed at the center.

  And the inside of the outer packaging material 12 which accommodated the core material 11 is evacuated. Thereby, the core material 11 is compressed and the flat heat insulating material 10 is obtained. At this time, as described above, the nonwoven fabric 13 constituting the core material 11 has a certain degree of springiness. Therefore, the evacuation of the outer packaging material 12 is advanced against the spring property of the nonwoven fabric 13. Therefore, it can be avoided that the nonwoven fabric 13 is excessively compressed, and that the second nonwoven fabric layer 13b is excessively compressed and the porosity is reduced.

  According to the heat insulating material 10 which concerns on this embodiment, the core material is comprised by winding the elongate nonwoven fabric 13 continuous in a strip shape in the state which continued without cut | disconnecting. And the nonwoven fabric 13 wound in this way contains the resin fiber. That is, according to the heat insulating material 10, the core material 11 is configured by winding the nonwoven fabric 13. Therefore, unlike the structure in which a large number of non-woven fabrics are laminated, productivity can be improved. Moreover, the core material 11 comprised by winding the nonwoven fabric 13 has a certain amount of spring property. Therefore, it is possible to suppress a decrease in heat insulation performance due to overcompression of the nonwoven fabric 13.

  Moreover, according to the heat insulating material 10, by further winding the nonwoven fabric 13 100 times or more, in other words, by forming the core material 11 by forming 100 or more layers, the heat insulating performance can be further improved. it can. Moreover, according to the heat insulating material 10, the resin fiber which comprises the nonwoven fabric 13 is shape | molded by the electrospinning method. Therefore, the nonwoven fabric 13 with extremely high heat insulating performance can be realized, and as a result, the heat insulating performance of the heat insulating material 10 can be further improved.

  Moreover, according to the heat insulating material 10, it is a heat insulation panel formed with the resin fiber which comprises the nonwoven fabric 13, and can further improve a heat insulation performance because heat conductivity shall be 2.2 mW / mK or less. .

Next, a refrigerator using the heat insulating material 10 will be described with reference to FIGS. 5 and 6.
As shown in FIG. 5, the refrigerator includes a heat insulating box 41 having an open front surface. In the refrigerator, a refrigeration cycle (not shown) is attached to the heat insulating box 41. The refrigerator also includes a partition plate (not shown) that partitions the heat insulating box 41 into a plurality of storage chambers, a heat insulating door (not shown) that covers the front surface of the storage chamber, and a drawer (not shown) that moves back and forth inside the storage chamber. . The heat insulating box 41 of the refrigerator has an outer box 42, an inner box 43, and a vacuum heat insulating panel set 50 sandwiched between the outer box 42 and the inner box 43. The outer box 42 is formed of a steel plate, and the inner box 43 is formed of a synthetic resin.

  The vacuum heat insulation panel set 50 is divided | segmented corresponding to each wall part of the heat insulation box 41 of a refrigerator. Specifically, the vacuum heat insulating panel set 50 is divided into a left wall panel 51, a right wall panel 52, a ceiling panel 53, a rear wall panel 54, and a bottom wall panel 55 as shown in FIG. The left wall panel 51, the right wall panel 52, the ceiling panel 53, the rear wall panel 54, and the bottom wall panel 55 are all made of the heat insulating material 10 described above. The left wall panel 51, the right wall panel 52, the ceiling panel 53, the rear wall panel 54 and the bottom wall panel 55 are assembled as a vacuum heat insulating panel set 50 and sandwiched between the outer box 42 and the inner box 43. A gap formed between the left wall panel 51, the right wall panel 52, the ceiling panel 53, the rear wall panel 54, and the bottom wall panel 55 constituting the vacuum heat insulation panel set 50 between the outer box 42 and the inner box 43. Is sealed with a heat insulating seal member (not shown). The seal member is formed of, for example, a foamable resin.

  Thus, the refrigerator has the vacuum heat insulation panel set 50 which comprises the heat insulation box 41. FIG. The vacuum heat insulating panel set 50 is configured by the heat insulating material 10 described above. Therefore, high heat insulation performance can be secured while further reducing the thickness and weight.

  The heat insulating material which concerns on this embodiment is provided with the core material comprised by winding the nonwoven fabric continuous in strip shape in the continuous state. And the said nonwoven fabric is comprised with the resin fiber. According to this embodiment, compared with the structure which laminates many nonwoven fabrics, productivity can be improved and the fall of heat insulation performance can be suppressed.

  This embodiment is presented as an example and is not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. This embodiment and its modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  For example, the heat insulating material may include a plurality of core materials. The heat insulating material 20 illustrated in FIG. 7 is configured to include four core materials 21 a to 21 d having the same shape and size in one outer bag material 22. Any of these core materials 21a to 21d has the same configuration as the core material 11 described above. As described above, by providing an even number of core materials in one outer bag material 22, it is possible to obtain a single heat insulating material 20 having a rectangular shape as a whole.

  Moreover, the heat insulating material 30 illustrated in FIG. 7 is a structure provided with the three core materials 31a-31c of the same shape and magnitude | size in the one outer bag material 32. FIG. All of these core materials 31a to 31d have the same configuration as the core material 11 described above. Thus, by providing an odd number of core members in one outer bag member 32, the shape of the heat insulating member 30 as a whole can be changed to a shape other than a rectangular shape. Therefore, for example, the shape of the entire heat insulating material can be changed as appropriate in accordance with the shape of the attachment target portion of the heat insulating material.

  Moreover, the heat insulating material 40 illustrated in FIG. 7 is a structure provided with several core material 41a-41c of a different shape and a size in one outer bag material 42. All of these core materials 41 a to 41 c have the same configuration as the core material 11 described above. Here, although the core material which concerns on this embodiment has spring property as above-mentioned, the tendency for the strength of the spring property to become so small that a core material is large and a core material is small is seen. That is, the larger core material tends to be crushed, and the smaller core material tends to be less crushed. Therefore, according to the heat insulating material 40, the degree of difficulty in being crushed or the degree of being crushed differs depending on the portion where each of the core materials 41a to 41c is arranged. Therefore, the compressibility in each portion during vacuuming can be varied. it can. Therefore, the thickness of the heat insulating material 40 can be varied depending on the part.

  Moreover, the heat insulating material which concerns on this embodiment is applicable besides a refrigerator. Moreover, the fiber which comprises a nonwoven fabric may be glass fiber instead of a resin fiber. Further, the heat insulating material may not be evacuated.

  In the drawings, 10, 20, 30, and 40 are heat insulating materials, 13 is a nonwoven fabric, 11, 21a to 21b, 31a to 31c, and 41a to 41c are core materials, and 100 is a refrigerator.

Claims (10)

A core material configured by winding a continuous nonwoven fabric in a strip shape in a continuous state,
The said nonwoven fabric is the heat insulating material comprised by the resin fiber.   The heat insulating material according to claim 1, wherein the nonwoven fabric forms 100 or more layers.   The said resin fiber is a heat insulating material of Claim 1 or 2 shape | molded by the electrospinning method.   The heat insulating material according to any one of claims 1 to 3, wherein the resin fiber has a thermal conductivity of 2.2 mW / mK or less.   The heat insulating material according to any one of claims 1 to 4, comprising a plurality of the core materials.   The core material with which the heat insulating material of any one of Claim 1 to 5 is equipped.   A refrigerator provided with the heat insulating material of any one of Claim 1 to 5. A method of manufacturing a heat insulating material including a core material,
A non-woven fabric that is continuous in a strip shape is formed from resin fibers,
The manufacturing method of the heat insulating material which forms the said core material by winding the said nonwoven fabric in the continuous state.   The manufacturing method of the heat insulating material of Claim 8 which forms the said core material by winding the said nonwoven fabric 100 times or more.   The manufacturing method of the heat insulating material of Claim 8 or 9 which shape | molds the said resin fiber by the electrospinning method.

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