JP2023039769A - Surface material for foaming heat insulation board and foaming heat insulation board - Google Patents

Abstract

To suppress the expansion of a foaming heat insulation board caused by the stagnation of a gas generated from a foaming heat insulation material at combustion between the board and the foaming heat insulation material, and to suppress the occurrence of poor appearance at integral processing with the foaming heat insulation material.SOLUTION: In a surface material for foaming heat insulation board 1 having aluminum foil 2 and a resin film 3 formed at one face side of the aluminum foil, a thickness of the surface material for foaming heat insulation board is equal to or thicker than 25 μm and equal to or thinner than 80 μm, and stick rigidity from the aluminum foil side with the foaming heat insulation material integrated with a surface at a side opposite to the aluminum foil of the resin film as a foaming heat insulation material side is equal to or higher than 6.1 N/Φ1 mm. The surface at the side opposite to the aluminum foil of the resin film constitutes an outermost surface of the surface material for foaming heat insulation board, and a push-in elasticity modulus of the resin film is equal to or higher than 1000 MPa.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present disclosure relates to a foam insulation board surface material and a foam insulation board using the same.

A heat insulating board is used as a heat insulating material used in buildings and the like. Due to the stability of power supply and demand, soaring energy prices, environmental considerations, etc., it is expected that the use of insulation boards in buildings will increase more than ever. Therefore, many techniques related to foam insulation boards containing foam insulation have been proposed (Patent Literature 1 and Patent Literature 2).

Conventionally, a metal foil such as an aluminum foil may be attached to the surface of the foamed heat insulating material. The purpose of using the metal foil is to suppress the combustion of the foam insulation by the heat shielding effect of the metal foil, and to prevent the heat insulating gas such as fluorine gas enclosed in the foam insulation from the outside by the barrier effect of the metal foil. to suppress leakage.

Patent No. 6823394 JP 2018-171885 A

In the case of a foam insulation board in which metal foil is attached to the front and back surfaces of a foam insulation material as a surface material, the insulating gas contained in the foam insulation material stays between the surface material and the foam insulation material during combustion, Foam insulation boards may expand. In this case, the heat insulating gas remaining between the surface material and the foam insulation material expands, causing the metal foil to peel off and the metal foil to lose its heat ray reflectivity, exposing the foam insulation material to high temperatures. Materials may burn. Furthermore, if the strength of the surface material is low, the surface material cannot withstand the stress applied to the surface material due to the expansion of the foam insulation board, cracks may occur in the surface material, and the foam insulation material may burn from the cracks. In addition, expansion of the foam insulation board causes appearance defects and requires replacement. In particular, in recent years, increasing the thickness of the foam insulation board has been studied in order to further improve the heat insulation. In this case, as the volume of the foamed heat insulating material increases, the amount of gas generated from the foamed heat insulating material during combustion also increases, and there is a risk that the aforementioned expansion of the foamed heat insulating board will become more pronounced.

In addition, the surface material for the foamed insulation board is also required to suppress appearance defects when integrated with the foamed insulation material.

The present disclosure has been made in view of the above circumstances, and can suppress expansion of the foam insulation board due to retention of gas generated from the foam insulation material during combustion, A main object of the present invention is to provide a surface material for a foam insulation board that can suppress appearance defects during integration processing with a foam insulation material.

One embodiment of the present disclosure is a foam insulation board surface material having an aluminum foil and a resin film disposed on one side of the aluminum foil, wherein the foam insulation board surface material has a thickness of The resin film has a thickness of 25 μm or more and 80 μm or less, and a piercing strength from the aluminum foil side when the resin film is integrated with the foamed heat insulating material with the surface opposite to the aluminum foil side as the foamed heat insulating material side is 6. 1 N/Φ1 mm or more, the surface of the resin film opposite to the aluminum foil constitutes the outermost surface of the foam insulation board surface material, and the indentation elastic modulus of the resin film is 1000 MPa or more. It is a surface material for boards.

An embodiment of the present disclosure includes a foam insulation material and the above-described surface material for a foam insulation board disposed on at least one surface side of the foam insulation material, wherein the surface material for a foam insulation board includes: In the foamed heat insulating board, the resin film is arranged so as to face the foamed heat insulating material.

The present disclosure is capable of suppressing the expansion of the foam insulation board due to the gas generated from the foam insulation material during combustion staying between the foam insulation material and the appearance defect during integration processing with the foam insulation material. There is an effect that it is possible to provide a foam insulation board surface material that can suppress the

1 is a schematic cross-sectional view illustrating a surface material for a foam insulation board of the present disclosure; FIG. 1 is a schematic cross-sectional view illustrating a foam insulation board of the present disclosure; FIG. 1 is a schematic cross-sectional view illustrating a surface material for a foam insulation board of the present disclosure; FIG. FIG. 2 is a schematic cross-sectional view illustrating an insulation board using a conventional foam insulation board surface material.

Embodiments of the present disclosure will be described below with reference to the drawings and the like. However, the present disclosure can be embodied in many different modes and should not be construed as limited to the description of the embodiments exemplified below. In addition, in order to make the description clearer, the drawings may schematically show the width, thickness, shape, etc. of each part compared to the actual form, but this is only an example and limits the interpretation of the present disclosure. not something to do. In addition, in this specification and each figure, the same reference numerals may be given to the same elements as those described above with respect to the existing figures, and detailed description thereof may be omitted as appropriate.

In this specification, when expressing a mode of arranging another member on top of a certain member, when simply describing “above” or “below”, unless otherwise specified, 2 includes both cases in which another member is arranged directly above or directly below, and cases in which another member is arranged above or below a certain member via another member. In addition, in this specification, when expressing a mode in which another member is arranged on the surface of a certain member, when simply describing “on the surface side” or “on the surface”, unless otherwise specified, It includes both the case of arranging another member directly above or directly below so as to be in contact with it, and the case of arranging another member above or below a certain member via another member.

FIG. 4 is a schematic cross-sectional view of a foam insulation board using a conventional foam insulation board surface material. The foam insulation board surface material 51 in the foam insulation board 100 shown in FIG. In such a heat insulating board 100, there is a concern that the heat insulating gas generated from the foam heat insulating material 61 stays between the surface material 51 and the foam heat insulating material 61 during combustion, causing the surface material 51 to swell and peel off. be.
Moreover, if the strength of the surface material is low, it may not be able to withstand the stress applied to the surface material due to the expansion of the foam insulation board, cracks may occur in the surface material, and the foam insulation material may burn from the cracks. Furthermore, conventional surface materials for foamed insulation boards may cause appearance defects such as streaks and wrinkles when integrated with a foamed insulation material.

The inventors who faced such a problem found the surface material for the foam insulation board shown below as a result of earnest investigation, and solved the above-mentioned problem.
In the following, the surface material for a foam insulation board and the foam insulation board according to the present disclosure will be described in detail.

A. Surface Material for Foam Insulation Board FIG. 1 is a schematic cross-sectional view showing an example of the surface material for foam insulation board of the present disclosure. As shown in FIG. 1 , the foam insulation board surface material 1 of the present disclosure has an aluminum foil 2 and a resin film 3 arranged on one side of the aluminum foil 2 . Furthermore, the foam insulation board surface material 1 has a thickness of 25 μm or more and 80 μm or less, and when the surface of the resin film 3 opposite to the aluminum foil 2 is the foam insulation material side and integrated with the foam insulation material, The piercing strength from the aluminum foil 2 side (that is, the piercing strength measured by the method described in Examples) is 6.1 N/Φ1 mm or more, and the surface of the resin film 3 opposite to the aluminum foil 2 is a foam insulation board. The indentation elastic modulus of the resin film 3 constituting the outermost surface 1A of the surface material 1 is 1000 MPa or more.

FIG. 2 is a schematic cross-sectional view showing an example of a foam insulation board provided with a foam insulation board surface material of the present disclosure. As shown in FIG. 2, the foam insulation board 10 includes a foam insulation board 11 and the foam insulation board surface material 1 disposed on at least one surface of the foam insulation board 11. The surface material 1 is arranged so that the resin film 3 faces the foamed heat insulating material 11 side. It is preferable that the outermost surface 1</b>A of the surface material 1 for foam insulation board on the side of the resin film 3 is in direct contact with the foam insulation material 11 .

In the present disclosure, the resin film forming the outermost surface of the foam insulation board surface material has a predetermined indentation elastic modulus, so that it has excellent adhesion to the foam insulation material during combustion (at high temperatures). Therefore, it is possible to withstand the stress applied to the surface material due to the expansion of the insulation gas during combustion, and it is possible to suppress the retention of the insulation gas between the surface material and the foam insulation material, thereby suppressing the expansion of the foam insulation board. can do.
Furthermore, the surface material for foam insulation board of the present disclosure has a resin film, and has a predetermined thickness and the above-mentioned puncture strength, so that appearance defects such as streaks and wrinkles when integrated with the foam insulation material are prevented. Also, during combustion (at high temperatures), it has the strength to withstand the stress applied to the surface material due to the expansion of the insulating gas in the foam insulation material and the thermal expansion of the foam insulation material itself. Therefore, cracks and the like are less likely to occur.

In particular, when the thickness of the foam insulation is increased in order to further improve the heat insulation, there is a risk that the amount of insulating gas generated from the foam insulation during combustion will increase. Expansion of the foam insulation board can be suppressed.

Insulation boards are also required to meet noncombustible certification acquisition requirements in a heat generation test using a cone calorimeter conforming to ISO5660-1:2002. A cone calorimeter is a device that heats a sample with a cone-shaped heater, ignites and burns it with a spark igniter, and measures the oxygen concentration in the generated gas.
According to the cone calorimeter, as evaluation of combustibility, total calorific value, maximum heat generation rate, combustion time from ignition to extinction, weight retention rate (weight percentage after test based on weight before test), etc. can be measured. Even when such a heat generation test is performed using a foam insulation board, it is thought that the gas generated when the foam insulation material burns will be generated between the foam insulation material and the surface material, causing the foam insulation board to swell. be done. If the insulation board expands and deforms during the exothermic test, the surface material may peel off, exposing the foam insulation to high temperatures and burning the foam insulation. Also, it comes into contact with the spark igniter, making measurement impossible. Therefore, even if the insulating board is flame-retardant or non-combustible, it cannot be measured due to expansion during the exothermic test, and the non-combustible certification requirements cannot be met.

On the other hand, in the present disclosure, the adhesion between the foam insulation board surface material and the foam insulation material is excellent. Therefore, even during the exothermic test, it is possible to suppress the gas generated from the foam insulation board from staying between the foam insulation board surface material and the foam insulation board, and to suppress the expansion of the foam insulation board. can. Therefore, it is possible to suppress peeling of the surface material and contact with the spark igniter even in the exothermic test, and it is possible to obtain a foam insulation board that satisfies the requirements for acquiring noncombustible certification and is certified to be noncombustible in the event of a fire. can.

The foam insulation board surface material of the present disclosure has an aluminum foil 2 and a resin film 3 arranged on one side of the aluminum foil 2 .

1. Thickness The thickness of the foam insulation board surface material of the present disclosure is 25 μm or more, preferably 30 μm or more, and particularly preferably 35 μm or more. If the thickness is too thin, poor appearance tends to occur during integration processing with the foamed heat insulating material. Furthermore, when the surface material is stressed by the expansion of the insulating gas in the foam insulation and the thermal expansion of the foam insulation itself at high temperatures, cracks are likely to occur. On the other hand, the thickness of the foam insulation board surface material is 80 μm or less, preferably 70 μm or less, and particularly preferably 60 μm or less. If the thickness is too thick, it is disadvantageous in terms of cost. In the present disclosure, the "thickness of the foam insulation board surface material" is the total thickness of the layers constituting the foam insulation board surface material.

2. Pierce strength The surface material for a foamed insulation board of the present disclosure has a piercing strength from the aluminum foil side when integrated with the foamed insulation material with the surface opposite to the aluminum foil of the resin film as the foamed insulation material side (i.e., The puncture strength measured by the method described in Examples) is 6.1 N/Φ1 mm or more, preferably 7.0 N/Φ1 mm or more, and particularly preferably 8.0 N/Φ1 mm or more. If the piercing strength is too low, poor appearance tends to occur during processing for integration with the foamed heat insulating material. Furthermore, cracks are more likely to occur when the surface material is stressed at high temperatures. On the other hand, the puncture strength is, for example, 30 N/Φ1 mm or less, and may be 20 N/Φ1 mm or less.

In the present disclosure, the method described in the Examples can be adopted as the method for measuring the puncture strength. Regardless of the type of foam insulation, the stress required for needles to penetrate the foam insulation is much smaller than the stress required for needles to penetrate the surface material. The puncture strength when integrated with the material does not depend on the type of foam insulation material. Therefore, the piercing strength when the surface material and the foamed heat insulating material are integrated can be used as an index of the piercing strength of the surface material.

3. Indentation Elastic Modulus In the surface material for a foamed insulation board of the present disclosure, the resin film forming the outermost surface has an indentation elastic modulus of 1000 MPa or more at room temperature (25° C.). The outermost surface of this foam insulation board surface material (hereinafter also referred to as the outermost surface on the resin film side) is the surface that comes into contact with the foam insulation material when it is made into a foam insulation board. (At high temperatures), the resin becomes easier to flow, and the adhesion to the foamed heat insulating material is reduced. As a result, gas tends to remain between the foamed heat insulating material and the surface material, and the foamed heat insulating material may swell and the surface material may peel off, exposing the foamed heat insulating material to a high temperature and burning the foamed heat insulating material.

The indentation modulus is preferably 2000 MPa or more. On the other hand, the indentation modulus is, for example, 100000 MPa or less, preferably 10000 MPa or less.

As a method for measuring the indentation modulus, for example, the method described in Examples can be adopted.

4. Configuration Each configuration of the foam insulation board surface material of the present disclosure will be described below.

(1) Resin film The surface material for foam insulation board of the present disclosure has a resin film. By having the resin film, it is possible to suppress wrinkles or the like in the aluminum foil during integral processing with the foamed heat insulating material. In the present disclosure, the resin film constitutes one outermost surface of the foam insulation board surface material.

In the present disclosure, the resin contained in the resin film forming the outermost surface (the resin film in contact with the foamed heat insulating material) preferably has a glass transition temperature of 60° C. or higher, particularly preferably 70° C. or higher. This is because, when the glass transition temperature is equal to or higher than the above value, sufficient heat resistance is obtained, so that there is little change in state even at high temperatures, and the adhesion between the resin film and the foamed heat insulating material is less likely to decrease.
The glass transition temperature (Tg) can be determined by a measurement method based on JIS K7121 using, for example, a differential calorimeter (DSC, manufactured by Shimadzu Corporation, model number: DSC-60).

In the present disclosure, the resin contained in the resin film constituting the outermost surface (resin film in contact with the foamed heat insulating material) is not particularly limited as long as the indentation elastic modulus satisfies the above range. For example, polyethylene terephthalate (PET ), nylon, polybutylene terephthalate (PBT), and the like. In the present disclosure, PET is more preferably used among the above resins. A biaxially oriented PET film is particularly preferred.

In addition, the resin film may be previously subjected to a corona treatment on one side or both sides which will be the outermost surface of the surface material. This is because the indentation modulus of elasticity of the resin film can be set within the above range. The resin film may be unstretched, or may be uniaxially or biaxially stretched.

The thickness of the resin film is not particularly limited as long as the thickness of the foam insulation board surface material is within the above range.

(2) Aluminum foil In the present disclosure, the aluminum foil is arranged on one side of the resin film. The thickness of the aluminum foil is not particularly limited as long as the thickness of the surface material for the foam insulation board is within the above range. If it is at least the above value, the strength of the surface material is increased, which is preferable. On the other hand, the thickness is, for example, 50 μm or less, and 35 μm or less is preferable in terms of cost.

Furthermore, the ratio of the thickness of the aluminum foil to the total thickness of the surface material for foam insulation board of the present disclosure (thickness of aluminum foil / total thickness of surface material for foam insulation board) is, for example, 0.075 or more. and may be 0.25 or more. If it is at least the above value, it is preferable because the strength of the surface material is increased. On the other hand, it is, for example, 0.70 or less, and may be 0.54 or less.

(3) Other configurations The foam insulation board surface material of the present disclosure may include layers other than the aluminum foil and the resin film. FIG. 3 is a schematic cross-sectional view showing another example of the foam insulation board surface material of the present disclosure. A foam insulation board surface material 1 shown in FIG. 3 has a reinforcing layer 4 disposed between an aluminum foil 2 and a resin film 3 .

(a) Reinforcement layer The foam insulation board surface material of the present disclosure includes a reinforcement layer between the aluminum foil and the resin film to increase the thickness to the above value or more, or to increase the puncture strength to the above value or more. may have. As the reinforcing layer, a layer whose rigidity can be improved by increasing its thickness or a layer having relatively high rigidity can be used, and examples thereof include resin. Examples of resins include polyethylene terephthalate (PET), nylon, polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), and the like. Nylon is preferred because of its high puncture strength.

(b) Adhesive layer The foam insulation board surface material of the present disclosure has an adhesive layer between the aluminum foil and the resin film, between the resin film and the reinforcing layer, between the aluminum foil and the reinforcing layer, etc. may be placed.

Conventionally known adhesives (for example, pressure-sensitive adhesives, thermoplastic adhesives, curable adhesives) can be used as materials for such an adhesive layer.

5. Others It is preferable that the surface material for a foam insulation board of the present disclosure has flexibility. The foam insulation board facing material of the present disclosure is placed on at least one side of a foam insulation board and used to make a foam insulation board.

B. Foam insulation board The foam insulation board of the present disclosure includes a foam insulation and the foam insulation board surface material disposed on at least one surface side of the foam insulation board, and the foam insulation board surface The material is arranged so that the resin film faces the foamed heat insulating material.

FIG. 2 is a schematic cross-sectional view showing an example of the foam insulation board of the present disclosure. Note that FIG. 2 has already been described in the above section "A. Surface material for foam insulation board", so the description is omitted here.

The foam insulation board of the present disclosure has the foam insulation board surface material described above, so that the heat insulating gas can be suppressed from stagnation between the foam insulation board and the foam insulation board surface material during combustion. , expansion can be suppressed. Therefore, it becomes a foam insulation board that can satisfy the noncombustible certification requirements in the exothermic test. In addition, the foam insulation board of the present disclosure can suppress appearance defects during manufacturing. Each configuration of the foam insulation board in the present disclosure will be described below.

1. Surface material for foam insulation board The surface material for foam insulation board in the present disclosure may be arranged on at least one surface of the foam insulation board, for example, may be arranged on one surface of the foam insulation board, It may be arranged on both sides of the foam insulation board.

Since the foam insulation board surface material has been described in detail in the above section "A. Foam insulation board surface material", the description is omitted here.

2. Foam Insulation Material The foam insulation material in the present disclosure is composed of a rigid material having heat insulation properties. As the foam heat insulating material, a foam heat insulating material generally used for heat insulating boards can be used, and examples thereof include rigid urethane foam and phenol foam. Fluorocarbon-based gases such as CFCs (chlorofluorocarbons), HCFCs (hydrochlorofluorocarbons), and HFCs (hydrofluorocarbons) are examples of the heat-insulating gas enclosed in the internal bubbles.

Rigid urethane foams also include isocyanurate foams, which are formed primarily through the reaction of hydroxyl groups (OH groups) and isocyanate groups and are generally included in the definition of rigid urethane foams. A rigid urethane foam can be formed using, for example, a polyol compound having a hydroxyl group (OH group), an isocyanate compound having an isocyanate group, a foaming agent, and the like. The polyol compound is not particularly limited, and for example, polyether polyol, polyester polyol, polyether ester polyol, etc. can be used. A polyol compound may be used individually by 1 type, and may be used in combination of 2 or more type. Examples of isocyanate compounds that can be used include aliphatic or aromatic polyisocyanates having two or more isocyanate groups, mixtures thereof, and modified polyisocyanates obtained by modifying them.

Phenolic foams can be formed using, for example, phenolic resins, blowing agents, curing agents, and the like.

As the foaming agent, for example, a fluorine-based foaming agent can be used. Specifically, fluorocarbon materials with low thermal conductivity, particularly hydrofluorocarbon (HFC) class materials, can be used. The raw material of the foam insulation material may contain, for example, catalysts, additives, flame retardants, and the like.

The shape of the foamed heat insulating material in plan view is not particularly limited, and for example, it can be cut into an arbitrary shape such as a rectangular shape, a polygonal shape, a circular shape, and the like.

3. Foam insulation board In the foam insulation board of the present disclosure, the surface material for the foam insulation board should be arranged on at least one side of the foam insulation. For example, (i) the foam insulation board surface material described above may be arranged on both surface sides of the foam insulation material, and (ii) the foam insulation board surface material described above may be disposed on one surface side of the foam insulation material. may be arranged and the other side of the foam insulation may be exposed, or (iii) the foam insulation board surface material may be arranged on one side of the foam insulation and the other side of the foam insulation Another surface material may be arranged on the surface side of the .

As the above-mentioned other surface materials, surface materials that are generally used as surface materials for heat insulating boards can be used, such as glass paper, plastic sheet, moisture-proof paper, calcium carbonate paper, resin-impregnated paper, and coated paper. , nonwoven fabrics, and the like.

(1) Thickness The thickness of the foam insulation board of the present disclosure is, for example, 10 mm or more, preferably 50 mm or more. If the value is equal to or more than the above value, the gas generated from the foamed heat insulating material during the exothermic test increases as the volume of the foamed heat insulating material increases, so that the effects of the present invention can be obtained more remarkably.
On the other hand, the thickness of the foam insulation board of the present disclosure is generally 200 mm or less, preferably 100 mm or less.

(2) Ash Content The foam insulation board of the present disclosure has an ash content of, for example, 10% by mass or more and 90% by mass or less when heated to 600°C. As a method for measuring the ash content, for example, the method described in Examples can be adopted. If it is at least the above value, the ratio of the aluminum foil in the foam insulation board is sufficient, and the strength of the surface material can be increased, which is preferable. On the other hand, if the value is equal to or less than the above value, it is preferable in terms of cost.

4. Others As a method for manufacturing the foam insulation board, a general method for manufacturing an insulation board can be used. For example, using a mold (foam molding mold) consisting of a lower mold and an upper mold, in which a cavity of a foam insulation material with a desired thickness is formed, the foam insulation board surface material of the present disclosure is applied to the bottom surface of the cavity of the lower mold. The surface material for the back surface is placed with the resin film facing upward, and the foamed heat insulating material composition is injected into the cavity while the temperature is adjusted to, for example, 120°C. Then, the upper mold of the mold in which another surface material for a foamed insulation board of the present disclosure is set so that the resin film faces downward is placed on the lower mold to close the mold, and the foamed insulation composition is placed in the cavity. After foaming, the molded article is demolded. The closed cell ratio is preferably 10 to 40%. The closed cell ratio in the present invention is a value measured according to ASTM D2856. The rigid urethane foam used for the foam insulation has self-adhesiveness and adheres to the surface material by the integrated foaming method described above. For the purpose of improving adhesion, a general adhesive may be used on the surface of the surface material that is in contact with the foamed heat insulating material.

The foam insulation board according to the present disclosure can be used, for example, as a heat insulating material for use in buildings and the like.

Note that the present disclosure is not limited to the above embodiments. The above embodiment is an example, and any device that has substantially the same configuration as the technical idea described in the claims of the present disclosure and achieves the same effect is the present invention. It is included in the technical scope of the disclosure.

Examples and comparative examples are shown below to describe the present disclosure in more detail.

[Example 1]
(Manufacturing surface materials for foam insulation boards)
An aluminum foil having a thickness of 9 μm was prepared. A PET film having a thickness of 12 μm was prepared as a resin film. A PET film having a thickness of 12 μm was prepared as a reinforcing layer. This was adhered via an adhesive layer to produce a 39 μm-thick surface material for a foam insulation board having a layer structure of PET (12 μm)/PET (12 μm)/aluminum foil (9 μm).

(Manufacture of foam insulation board)
Using a mold (foam molding mold) consisting of a lower mold and an upper mold, in which a cavity of foam insulation material with the desired thickness is formed, the obtained surface material for foam insulation board is applied to the bottom surface of the cavity of the lower mold. A foam insulation composition (polyol compound, isocyanate compound and fluorine-based foam) for forming a rigid urethane foam is placed in the cavity while the film is facing upward and the surface material for the back surface is placed and the temperature is adjusted to 120 ° C. agent) was injected. Then, another foam insulation board surface material is prepared, and the upper mold set so that the resin film faces downward is placed over the lower mold to close the mold, and the foam insulation composition is placed in the cavity. After foaming, the molded product was removed from the mold to obtain a foamed heat insulating board with a thickness of 50 mm.

[Example 2]
For a foam insulation board with a thickness of 52 μm having a layer structure of PET (12 μm) / nylon (25 μm) / aluminum foil (9 μm) in the same manner as in Example 1 except that nylon with a thickness of 25 μm was used as the reinforcing layer A surfacing material was manufactured. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 3]
An aluminum foil having a thickness of 12 µm was prepared. Also, a PET film having a thickness of 12 μm was prepared as a resin film. These were adhered via an adhesive layer to produce a 27 μm-thick foam insulation board surface material having a layer structure of PET (12 μm)/aluminum foil (12 μm). Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 4]
Surface material for foam insulation board with a thickness of 42 μm having a layer structure of PET (12 μm) / PET (12 μm) / aluminum foil (12 μm) in the same manner as in Example 1 except that an aluminum foil with a thickness of 12 μm was used. manufactured. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 5]
A layer of PET (12 μm)/nylon (25 μm)/aluminum foil (12 μm) was formed in the same manner as in Example 1, except that a 12 μm thick aluminum foil was used and a 25 μm thick nylon was used as the reinforcing layer. A surface material for a foam insulation board having a thickness of 55 μm having a structure was manufactured. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 6]
An aluminum foil with a thickness of 35 µm was prepared. A PET substrate having a thickness of 12 μm was prepared as a resin film. These were adhered via an adhesive layer to produce a foam insulation board surface material having a layer structure of PET (12 μm)/aluminum foil (35 μm) and having a thickness of 50 μm. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 7]
65 μm thick having a layer structure of PET (12 μm) / PET (12 μm) / aluminum foil (35 μm) in the same manner as in Example 1, except that an aluminum foil with a thickness of 35 μm was used instead of an aluminum foil with a thickness of 9 μm. of the surface material for foam insulation boards. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

[Example 8]
78 μm thick having a layer structure of PET (12 μm) / nylon (25 μm) / aluminum foil (35 μm) in the same manner as in Example 2, except that an aluminum foil with a thickness of 35 μm was used instead of an aluminum foil with a thickness of 9 μm. of the surface material for foam insulation boards. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

(Comparative example 1)
A foam insulation board surface material having a layer structure of PE film (35 μm) / PE film (15 μm) / aluminum foil (20 μm) and having a thickness of 70 μm was attached to both sides of a foam insulation material made of rigid urethane foam. A foam insulation board was prepared.

(Comparative example 2)
A foam insulation board was prepared by attaching aluminum foil (30 μm) to both sides of a foam insulation material made of rigid urethane foam via a coating agent.

(Comparative Example 3)
A surface material for a foam insulation board having a layer structure of PE film (40 μm)/kraft paper (170 μm)/PE film (20 μm)/aluminum foil (7 μm)/primer layer and having a thickness of 240 μm is made of hard urethane foam. A foam insulation board attached to both sides of the foam insulation was prepared.

(Comparative Example 4)
Foam insulation with a thickness of 21 μm having a layer structure of PET (12 μm) / aluminum foil (6 μm) in the same manner as in Example 3 except that an aluminum foil with a thickness of 6 μm was used instead of an aluminum foil with a thickness of 12 μm. A surface material for boards was produced. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

(Comparative Example 5)
Foam insulation with a thickness of 24 μm having a layer structure of PET (12 μm) / aluminum foil (9 μm) in the same manner as in Example 3, except that an aluminum foil with a thickness of 9 μm was used instead of the aluminum foil with a thickness of 12 μm. A surface material for boards was produced. Further, a foamed thermal insulation board was obtained in the same manner as in Example 1 except that the obtained surface material for foamed thermal insulation board was used.

<Puncture Strength>
The pierce strength from the aluminum foil side of the foam insulation board (that is, the integrated product of the foam insulation board surface material and the foam insulation material) in Examples 1 to 8 and Comparative Examples 1 to 5 was measured by the following method. Tables 1 and 2 show the results. As a test piece, an integrated surface material and foamed heat insulating material (hard urethane foam) was cut into a size of 50 mm×50 mm. The test piece was fixed, and a semicircular needle with a diameter of 1.0 mm and a tip shape radius of 0.5 mm was pierced into the center at a speed of 50 ± 5 mm per minute, and the maximum stress until the needle penetrated was measured. got

<Indentation modulus>
The indentation elastic modulus of the resin film was measured as follows for the foam insulation board surface materials of Examples 1 to 8 and Comparative Examples 1 to 5. Tables 1 and 2 show the results. The indentation modulus was measured by the following measuring method.
(Measuring method)
Ultra micro load hardness in accordance with ISO 14577:2015, in which a Vickers indenter (a square pyramidal diamond indenter with a facing angle of 136°) is attached to the cross section of the sample in an environment of about 23 ° C and about 60% RH. A method of measuring the indentation modulus using a testing machine was used. The measurement was performed at an indentation speed of 0.1 μm/sec, an indentation depth of 2 μm, a holding time of 5 seconds, and a withdrawal speed of 0.1 μm/sec. Pico Dentor HM500 (manufactured by Fisher Instruments) was used as the ultra-micro load hardness tester. For one condition, at least five samples were measured and the average of those measurements was taken as the indentation modulus value for that condition. The cross-section of the above sample is the exposed cross-section of the sample cut out from the surface material, fixed by fixing the outer periphery with a curable resin-based adhesive, and cutting the fixed sample in the thickness direction with a diamond knife. In addition, the thickness of each film when calculating the indentation elastic index was measured by optical microscope observation of the cut cross section.

The heat insulating boards obtained in Examples 1 to 8 and Comparative Examples 1 to 5 were evaluated as follows. Tables 1 and 2 show the results.
<Cone calorimeter test evaluation>
The resulting heat insulating board was subjected to a heat build-up evaluation test using a cone calorimeter test in accordance with ISO5660-1:2002. The amount of radiant heat was set at 50 kW/m ² . Those that satisfy all of the noncombustible certification acquisition requirements (requirements (i) to (iii) below) were evaluated as ◯, and those that did not satisfy even one were evaluated as x. A cone calorimeter C-3 manufactured by Toyo Seiki Seisakusho was used as the apparatus.
(1) The total calorific value for 20 minutes after the start of heating shall be 8 MJ/m ² or less (2) For 20 minutes after the start of heating, there shall be no cracks or holes penetrating to the rear surface which are harmful for fire prevention (3) Start of heating For the next 20 minutes, the heat release rate must not exceed 200 kw/ ^m2 continuously for 10 seconds or longer.

<Appearance evaluation>
The appearance of the obtained heat insulating board was visually observed and evaluated according to the following evaluation criteria.
Evaluation criteria ⊚: no wrinkles or streaks ∘: some wrinkles. No streaks Δ: Some wrinkles. In addition, there are both streaks where aluminum does not fold into the foam insulation material. ×: Wavy wrinkles on the entire surface and streaks where aluminum folds into the foam insulation material.

<Ash residue evaluation>
A measurement sample was taken from the obtained foamed insulation board, and the ash residue when heated to 600° C. was measured by the following method. Tables 1 and 2 show the results. A measurement sample was obtained by cutting from the heat insulating board integrated with the surface material. After measuring the mass of the measurement sample using a simultaneous thermogravimetric/differential thermal analyzer (TG-DTA), in an aluminum pan and in an air atmosphere, from room temperature to 600 ° C. at a heating rate of 10 ° C./min. After the temperature was raised, the sample was heated at 600° C. for 30 minutes to incinerate the measurement sample, and the mass after heating to the mass before heating was expressed as a percentage. As the thermogravimetric/differential thermal simultaneous analysis apparatus, TG8120 manufactured by Rigaku Corporation was used.

As shown in Tables 1 and 2, the foam insulation board surface materials of Examples 1 to 8 can obtain foam insulation boards that meet the requirements for acquiring noncombustible certification in the cone calorimeter test, and foam insulation materials It was possible to suppress the appearance defect at the time of integration processing with. On the other hand, the foam insulation board surface materials of Comparative Examples 1 and 3 have a PE resin film on the foam insulation material side, so the indentation elastic modulus is low. The material burned and did not meet the requirements for obtaining non-combustible certification. It is considered that this is because gas accumulated between the surface material and the foamed heat insulating material, causing swelling and peeling of the surface material. In addition, the foam insulation board using the foam insulation board surface material of Comparative Example 2 had a poor appearance because it did not have a resin film. Since the surface materials for foamed insulation boards of Comparative Examples 4 and 5 had low strength, poor appearance occurred when integrated with the foamed insulation.

REFERENCE SIGNS LIST 1 ... surface material for foam insulation board 2 ... aluminum foil 3 ... resin film 4 ... reinforcing layer 10 ... insulation board

Claims (7)

A surface material for a foam insulation board, comprising an aluminum foil and a resin film disposed on one side of the aluminum foil,
The foam insulation board surface material has a thickness of 25 μm or more and 80 μm or less, and when the surface of the resin film opposite to the aluminum foil is integrated with the foam insulation material, the above The piercing strength from the aluminum foil side is 6.1 N / Φ1 mm or more,
The surface of the resin film opposite to the aluminum foil constitutes the outermost surface of the foam insulation board surface material,
A surface material for a foam insulation board, wherein the indentation modulus of the resin film is 1000 MPa or more. The surface material for a foamed insulation board according to claim 1, wherein the resin contained in the resin film has a glass transition temperature of 60°C or higher. The surface material for a foam insulation board according to claim 1 or 2, wherein the resin film contains polyethylene terephthalate. The ratio of the thickness of the aluminum foil to the thickness of the foam insulation board surface material (thickness of the aluminum foil/thickness of the foam insulation board surface material) is 0.075 or more and 0.70 or less. A surface material for a foam insulation board according to any one of claims 1 to 3. foam insulation;
and the surface material for a foam insulation board according to any one of claims 1 to 4, which is arranged on at least one surface side of the foam insulation material,
The foam insulation board surface material is arranged such that the resin film faces the foam insulation board. The foam insulation board according to claim 5, wherein the foam insulation board has a thickness of 10 mm or more. The foam insulation board according to claim 5 or 6, wherein the ash content when heated to 600°C is 10% by mass or more and 90% by mass or less.

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