JP2899743B2 - Thermal insulation panel and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a structural heat insulating panel used for walls, floors, and the like, and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a heat insulating structure applied to a roof, a roof, a wall, a floor, etc. of a building, a heat insulating board made of a synthetic resin foam such as a rigid polyurethane foam as a core material is used as a pillar, a stud, a rafter, a large tree. Conventionally, a structure in which the structure is assembled to a frame such as a joist and covered with an exterior material or an interior material, or a structure in which a rigid polyurethane foam or the like is sprayed on a plywood fixed to the frame and foamed on site is generally known.

Incidentally, the heat insulation board needs to be measured and cut in accordance with the frame of a place to be installed at a construction work site, and the work is troublesome and the workability is extremely poor. In addition, if the cutting is not accurate, there is a possibility that a gap is formed between the frame and the heat insulating effect, and that the heat insulating effect is reduced.

On the other hand, a structure in which a rigid polyurethane foam or the like is sprayed and foamed in-situ does not cause a gap between the frame and the frame, but the raw material such as the rigid polyurethane foam scatters around during the spraying. It is necessary to cover the whole thing with a sheet or the like, and the installation work is very troublesome.

In order to solve such inconveniences, there has been proposed a heat insulating structure which does not require a measuring operation or a cutting operation at a construction site, and does not require an installation operation of a sheet or the like covering the entire building. For example, in a heat insulation panel described in Japanese Utility Model Laid-Open No. 53-65616, a frame is formed in advance in consideration of a frame at a construction site, and face materials are fixed to both surfaces of the frame. Then, a heat insulating foam layer of a rigid polyurethane foam is foamed and formed in the frame body to manufacture a heat insulating panel.

[0006]

By the way, in a heat insulating panel in which a heat insulating foam layer of a rigid polyurethane foam is foamed in a frame body having face materials fixed to both sides, when foaming the heat insulating foam, the foaming pressure is opposed to the foaming pressure. It is necessary to press down the face material on both sides of the frame with a large press machine in order to do so. For this reason, in manufacturing, an expensive and wide installation space is required, and furthermore, a person who can operate a press machine is required.
There are various problems, such as the necessity of safety measures for preventing accidents accompanying the operation of the press machine.

An object of the present invention is to provide a heat insulating foam from the periphery of a face material.
The problem is that the bulges out and the burrs are formed.
It has excellent insulation and moisture resistance,
An object of the present invention is to provide a thermal panel and a manufacturing method thereof. Another object of the present invention is that the measuring work and the cutting work at the construction site are unnecessary, and the work of setting the sheets and the like covering the entire building is also unnecessary, so that the construction can be easily performed in a short time,
It is an object of the present invention to provide a heat insulating panel that can easily form a ventilation layer as a measure for preventing dew condensation, has desired characteristics, and has a good appearance. Still another object of the present invention is to provide a method for manufacturing a heat insulating panel which can be manufactured easily, safely and inexpensively.

[0008]

The heat insulation panel of the present invention comprises:
It is used as a structural member of a building, at least the outer periphery is constituted by a wooden frame, one surface is closed by a flat plate,
A frame having the other surface opened, and a heat-insulating foam layer of a synthetic resin foamed on a flat plate in the frame with a thickness smaller than the thickness of the frame or with the same thickness as the thickness of the frame. And the periphery bites between the wooden frame and the heat insulating foam layer
And a face material covering the surface of the heat insulating foam layer .

Further, in the heat insulating panel of the present invention, the face material
However, it may be made to have a moisture-proof property or a moisture-permeable property .

[0010] manufacturing process of the heat insulation panels of the present invention, the cross-sectional
Applied to the manufacture of thermal panels , at least the outer periphery is composed of a wooden frame, one surface is closed by a flat plate, the other surface is open in the frame body, kraft paper, core paper,
Moisture proof paper, a nonwoven fabric, a plastic film, or a plastic-based microporous film laminated with a nonwoven fabric with a thin paper or nonwoven fabric as a base and a metal foil or a plastic film laminated thereon, and having breathability and moisture permeability, and A surface material selected from a moisture-permeable surface material having waterproofness, and a peripheral edge of the surface material is brought into contact with the inner surface of the wooden frame.
So as to hold a holding lid on the frame with a predetermined interval between the flat plate and the flat plate, and to provide a heat insulating foam layer in a space in the frame between the flat plate and the face material. layer
The edge of the face material is bitten between the and the wooden frame, and the
The foam is foamed so that the surface of the foam layer is covered with the face material . Further, in the method for manufacturing a heat insulating panel according to the present invention, the holding lid is formed of a plate-shaped main body having a size that fits into the space in the frame, and a reinforcing material fixed to a top surface of the main body by a framework. The lid may be locked to the wooden frame by a locking tongue fixed to the reinforcing member.

In the production of the above-mentioned heat insulating panel, for example,
At least the outer periphery is constituted by a wooden frame, one surface is closed by a flat plate, and a frame body in which the other surface is opened, a bed placed such that the flat plate side is a lower side, and the flat plate and A holding lid locked to the frame by, for example, the locking tongue so as to form a closed space between the holding frame and the wooden frame; A manufacturing apparatus comprising: a plurality of pressing bars; and a plurality of clamp levers each having an engaging portion for locking an upper surface of each of the pressing bars at one end and the other end pivotally connected to the bed. used.

[0012]

According to the heat insulating panel of the present invention, the surface of the heat insulating foam layer is covered with the face material. By adopting a material having appropriate properties such as moisture proof property or moisture permeability property as the face material, it becomes possible to provide a heat insulating panel having desired properties. In the present invention, since the periphery uses a face material that has been cut between the wooden frame and the heat insulation foam layer, the heat insulation foam does not protrude from the peripheral edge of the face material, and burrs are not formed. An insulating panel having extremely excellent moisture-proof properties is provided. In the heat insulation panel of the present invention, the measuring work and the cutting work at the construction site are unnecessary, and the installation work of the sheet or the like covering the entire building is of course unnecessary.

In the method for manufacturing a heat insulating panel according to the present invention, when the hard synthetic resin or the like injected into the space between the flat plate and the face material is foamed and solidified, the face material is pressed against the holding lid by the foaming pressure. However, the peripheral portion bent to the flat plate side is pressed against the inner surface side of the wooden frame, and bites between the wooden frame and the heat insulating foam layer to prevent the heat insulating foam layer from protruding. Also,
Since the heat insulating foam layer adheres to the face material but does not adhere to the holding lid, there is no need to attach a polyethylene film or the like for release to the inner surface of the holding lid, thereby improving workability.

An apparatus used for manufacturing a heat insulating panel according to the present invention includes a bed on which a frame is placed, a holding lid held by a locking piece on the frame, and a horizontal cover on an upper surface of the frame. Since it is mainly composed of a plurality of holding bars to be bridged and a plurality of clamp levers attached to the bed and locking the upper surface of the holding bar,
It is cheaper than conventional large presses, requires less installation space, and does not require skilled work.

[0015]

4 to 6 are a plan view, a longitudinal side view and a lateral side view showing an example of an apparatus used for manufacturing the heat insulating panel of the present invention. 4 to 6, the manufacturing apparatus mainly includes a bed 1, a holding lid 2, a plurality of holding bars 3, and a plurality of clamp levers 4 pivotally attached to the bed 1.

The bed 1 comprises a frame (a wooden frame 5 and a flat plate 6 fixed to one surface thereof by means of gluing, nailing, or the like) with the flat plate 6 facing down. The size of the bed 1 in plan view is larger than the size of the wooden frame 5 in plan view. The wooden frame 5 has two vertical frames 5a, 5a and two horizontal frames 5a.
b, 5b, and a crosspiece 5c at the center connecting the horizontal frames 5b, 5b, and has a rectangular shape in plan view.

Here, the holding lid 2 is a reinforcing member in which a wooden square bar, an iron square pipe, an aluminum square pipe, etc. are framed on the upper surface of a main body 2a made of a transparent vinyl chloride plate, a plywood, an appropriate metal plate or the like. The material 2b is fixed. The planar shape of the holding lid 2 is within the frame on one side of the wooden frame 5, that is, the vertical frame 5a, the crosspiece 5c, the upper and lower horizontal frames 5b,
5b, which fits into a vertically elongated rectangular frame body space 5d surrounded by 5b. 4 to 6, for convenience of explanation, the holding cover 2 is fitted only in the frame on one side of the wooden frame 5, but the two holding lids may be fitted in both frames at the same time. it can.

The holding lid 2 has a reinforcing member 2 as a locking portion.
The plurality of locking tongue pieces 2c fixed to b are locked on the upper surface of the vertical frame 5a of the wooden frame 5 and the crosspiece 5c. Thereby, the main body 2
The lower surface of a is fitted and held in a vertically-long rectangular frame surrounded by the vertical frame 5a, the crosspiece 5c, and the upper and lower horizontal frames 5b, 5b with a predetermined gap between the flat plate 6 and the lower surface. In this state, the upper surface of the reinforcing member 2b substantially matches the upper surface of the wooden frame 5.

In the present embodiment, each holding bar 3 is made of a square pipe made of iron or the like, and abuts on the upper surface of the reinforcing member 2b of the holding lid 2 to be laterally attached to the upper surface of the frame (that is, the upper surface of the wooden frame 5). When the bed 1 is placed, both ends thereof have a length protruding to the left and right sides of the bed 1.

Each of the clamp levers 4 has a locking portion 4a for locking the upper surface of the holding bar 3, which is bent at one end into an L-shape. It is fixed to both ends of the projecting support shaft 7. The clamp lever 4 is usually made of a metal material such as steel. In the present embodiment, a plurality of pairs are provided at intervals of 500 to 800 mm in the longitudinal direction of the bed 1 so that the holding bars 3 are laid horizontally near the center and both ends of the wooden frame 5 in the longitudinal direction. 3 pairs) are provided.

Next, a method for manufacturing a heat insulating panel using the above-described apparatus for manufacturing a heat insulating panel will be described with reference to each operation process shown in FIGS. 7 (a) and 7 (b). First, a wooden frame 5 composed of a pair of opposed vertical frames 5a, 5a, a pair of similarly opposed horizontal frames 5b, 5b, and a central crosspiece 5c connecting the respective horizontal frames 5b, 5b is provided with one of them. A plate to which the flat plate 6 is fixed so as to cover the surface is prepared. Here, the vertical frame 5a, the horizontal frame 5b, and the crosspiece 5c of the wooden frame 5 are 20 × 45 to 50 × 1.
Square wood of about 20 mm is used, and they are connected to each other by using dowel joints or connection fittings.
Functions as a stud or rafter by itself. Flat plate 6
Is a plywood, a gypsum plate, a metal plate, or the like having a thickness of about 9 to 12 mm, which serves as a general interior or exterior base material and an exterior material. Is fixed by The flat plate 6 may be larger than the outline of the wooden frame 5.

The wooden frame 5 with the flat plate 6 thus prepared
As shown in FIG. 7 (a), the flat body 6 is placed on the bed 1 with the flat plate 6 down, and the vertical frame 5a, the crosspiece 5c and the upper and lower horizontal frames 5b are viewed from the opened upper surface. , 5b are respectively disposed in the left and right vertically elongated rectangular frame body spaces 5d. Here, the face material 8 is the space 5d in the frame body.
It is slightly larger than the vertical rectangle inside. In the present embodiment, the vertical width of the face material 8 is equal to the vertical width of the in-frame space 5d along the vertical frame 5a, and the horizontal width of the face material 8 is
The width is slightly wider than the width of the space 5d inside the frame along the line b. The width of the frame space 5d w, the distance between the flat plate 6 and the holding lid 2 when fitted into the frame space 5d of the presser lid 2 when is h, the width W _S of the surface material 8,

[0023]

## EQU1 ## It is assumed that w <W _S <w + 2h (for w and h, see FIG. 7B).

In the above embodiment, only the width of the face material 8 is set to be slightly wider than the width of the space 5d inside the frame along the horizontal frame 5b, but the height of the face material 8 is also reduced to the vertical frame 5a. It can be made equal to the vertical width of the inside space 5d of the frame. In this case, although not shown, each peripheral portion 8
A cut is made so that a, 8a, 8a, 8a can be bent, and the face material 8 is set in the space 5d in the frame in a state where the respective peripheral edges 8a, 8a, 8a, 8a are bent toward the flat plate 6 side.

Here, the face material 8 is made of kraft paper, core paper, thin paper, non-woven fabric or the like as a base material, and a metal foil such as an aluminum foil is adhered, laminated or vapor-deposited on the base material, or a polyethylene film, a polypropylene film or the like. Moisture proof paper on which a plastic film is adhered and laminated, or a nonwoven fabric, a plastic film, or the like can be used. In addition,
The moisture-permeation resistance of this moisture-proof paper is 60 m ² · h · mmHg / g.
It is preferable to make the above. Further, as the face material 8, for example, a moisture-permeable face material that is air-permeable and moisture-permeable and also waterproof can be used in which a nonwoven fabric is laminated on a plastic-based microporous film.

Subsequently, as shown in FIG.
The retaining lid 2 is fitted and inserted into the inside space 5d of the frame on one side from above, and the locking tongue 2c is engaged with the vertical frame 5a of the wooden frame 5 and the upper surface of the crosspiece 5c. The holding bars 3, 3, 3 are laid horizontally, and the upper surface of each holding bar 3 is locked by the locking portion 4 a of the clamp lever 4. In this case, the pair of left and right clamp levers 4 connected to each other by the support shaft 7 are rotated upward together, and the locking portions 4a are positioned upward. Slide 3 to engage.

By such a preparation operation, the holding lid 2 covers the face material 8 and has a predetermined interval between the pressing lid 2 and the flat plate 6, that is, a predetermined interval corresponding to the thickness of the heat insulating foam layer to be formed. It is fitted and held in the space 5d inside the frame on one side.
Therefore, as shown in FIG. 7C, a synthetic resin is injected into a space between the flat plate 6 and the face material 8. In this case, the longitudinal center or the lateral center of the vertical frame 5a of the wooden frame 5 is
Nozzle (outer diameter 6-8mm, inner diameter 5-5) of synthetic resin foaming machine
6 mm) injection hole 5 with a diameter of about 8 to 10 mm
e is formed to penetrate in the lateral direction in advance, and this injection hole 5 is formed.
Liquid or foam-like synthetic resin is injected from the nozzle 9 of the foaming machine inserted in e. The location and number of the injection holes 5e are appropriately selected according to the injection range of the synthetic resin.

As the synthetic resin to be injected, a synthetic resin which is injected in the form of a liquid or foam and solidifies by foaming, for example, rigid polyurethane foam, urethane-modified polyisocyanurate foam, polyisocyanurate foam, phenol foam, low-density communicating polyurethane foam, etc. Although a rigid or semi-rigid synthetic resin foam can be used, in this example, a rigid polyurethane foam was generally used.

The rigid polyurethane foam injected into the space between the flat plate 6 and the face material 8 is foamed and solidified in a short time, and is formed in the space of the space 5 d in the frame between the flat plate 6 and the holding lid 2. 10 are formed, adhered to the flat plate 6, the face material 8, the vertical frame 5a of the wooden frame 5, the crosspiece 5c, and the horizontal frames 5b, 5b and integrated therewith (see FIG. 7D). At this time, each peripheral portion 8a, 8 of the face material 8 installed in the space 5d in the frame body.
Since a, 8a and 8a are bent toward the flat plate 6, the vertical frame 5a and the crosspiece 5 are formed by the foaming pressure of the rigid polyurethane foam.
(c) It is pressed against the inner surfaces of the horizontal frames 5b, 5b and bites between these and the heat insulating foam layer 10 to prevent the heat insulating foam layer 10 from protruding. In addition, since the heat insulating foam layer 10 does not adhere to the press cover 2 due to the presence of the face material 8, it is not necessary to attach a polyethylene film or the like for release to the inner surface of the press cover 2 and workability is good. In particular,
The width WS of the face material 8 is appropriately set (after the hard polyurethane foam is injected, the end of the face material 8 is set in the middle of the thickness of the frame (thickness of the frame 5)). Thus, the adhesion between the vertical frame 5a and the heat insulating foam layer 10 is ensured (see the α portion in FIG. 7D).

After foaming the heat insulating foam layer 10 in the space 5d inside the frame on one side of the wooden frame 5, foaming the heat insulating foam layer 10 is also performed in the space 5d on the other side of the frame by the same procedure, and the work is completed. Then, each holding bar 3 is removed from the clamp lever 4 and the holding lid 2 is removed to obtain the heat insulating panel 11.

FIGS. 1 to 3 show a heat insulating panel 11 obtained by the above-described manufacturing method. As shown in FIG. 8, the heat insulating panel 11 is attached to a frame of a wooden building, for example. A wall is constituted (note that in FIG. 8, the above-mentioned heat-insulating panel and heat-insulating panels of various other shapes are indicated by reference numeral 11). Here, the heat insulation panel 11
Insulation foam layer 10 in wooden frame 5 covered on one side with flat plate 6
Since foaming is formed, measurement and cutting work at the construction site are unnecessary, and installation work of sheets and the like covering the entire building is also unnecessary, so that construction can be easily performed in a short time.

In the heat insulating panel 11, both side edges 8a, 8a of the face material 8 covering the surface of the heat insulating foam layer 10 bite between the vertical frame 5a and the pier 5c of the wooden frame 5 and the heat insulating foam layer 10, respectively. And both side edges 8a of the face material 8,
Since the heat insulating foam layer 10 does not protrude from 8a to form burrs, the appearance is good and the commercial value is high.

Further, in the heat insulating panel 11, since the heat insulating foam layer 10 is formed so as to have a thickness smaller than that of the wooden frame 5 with the back surface being in close contact with the flat plate 6, there is a space layer on the front side of the heat insulating foam layer 10. . Therefore, by forming ventilation holes and ventilation notches communicating with the space layer in, for example, the horizontal frames 5b and 5b of the wooden frame 5, it is possible to easily form a ventilation layer as a measure for preventing dew condensation, The generation of mold and mites due to moisture can be effectively prevented.

The above-described heat insulating panel 11 and the method of manufacturing the same according to the present embodiment constitute not only a heat insulating panel 11 having a rectangular shape in plan view that can be applied to a heat insulating wall of a wooden building, but also a heat insulating wall in a lower part of a roof. The present invention can also be applied to a triangular or trapezoidal heat insulating panel in plan view. In this case, face material 8
Is a large one similar to a triangular or trapezoidal planar shape in the wooden frame 5 and is provided with cuts in its corners, so that the wooden frame and the heat insulating foam layer 10 and the peripheral edge bites.

[0035]

As described above, the heat insulating panel according to the present invention is formed by foaming the heat insulating foam layer in the frame, so that there is no gap and the heat insulating property is excellent. In addition, by adopting a material having appropriate properties such as moisture-proof property or moisture-permeable property as a surface material covered by the surface of the heat-insulating foam layer, a heat-insulating panel having desired characteristics can be provided.

Further , in the present invention, the face material having a structure in which the periphery is cut between the wooden frame and the heat insulating foam layer is used .
Thus, the heat insulating foam does not protrude from the peripheral edge of the face material to form burrs, and a heat insulating panel having extremely excellent heat insulating and moisture proof properties can be provided. Further, as described above , the face material covering the surface of the heat insulating foam layer does not protrude from the peripheral edge of the face material and does not form burrs, so that the appearance is good and the commercial value can be increased.

Further, the method for manufacturing a heat insulating panel according to the present invention does not require a large-sized press device, and is excellent in workability. Furthermore, when synthetic resin such as hard polyurethane injected into the space in the wooden frame between the flat plate and the face material is foamed and solidified,
Although the face material is pressed by the holding lid by the foaming pressure, the peripheral portion bent to the flat plate side is pressed to the inner surface side of the wooden frame, so that it is in a state of being bitten between the wooden frame and the heat insulating foam layer, The protrusion of the heat insulating foam layer can be prevented. In addition, since the heat insulating foam layer adheres to the face material but does not adhere to the holding lid, there is no need to attach a polyethylene film or the like for release to the inner surface of the holding lid, which improves workability,
Insulated panels can be easily manufactured.

The apparatus used for manufacturing the heat insulating panel of the present invention is inexpensive, has a small installation space, and does not require any skilled work as compared with a conventional large press machine. In addition, it can be manufactured at low cost.

[Brief description of the drawings]

FIG. 1 is a perspective view of a heat insulating panel according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of the heat insulating panel of FIG.

FIG. 3 is a longitudinal sectional view of the heat insulating panel of FIG. 1;

FIG. 4 is a plan view showing an example of an apparatus for manufacturing the heat insulating panel of FIG.

FIG. 5 is a side view of the device of FIG.

6 is a front view of the device of FIG.

FIGS. 7A to 7D are cross-sectional views showing respective working steps of a method of manufacturing a heat insulating panel according to an embodiment of the present invention.

FIG. 8 is a schematic front view of a wooden building showing an application example and another embodiment of the heat insulating panel according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Bed 2 Holding lid 2a Main body 2b Reinforcement material 2c Locking tongue piece 3 Holding bar 4 Clamp lever 4a Locking part 5 Wooden frame 5a Vertical frame 5b Horizontal frame 5c Crosspiece 5d Inside frame 5e Injection hole 5f Vent hole 5g Vent notch 6 Flat plate 7 Support shaft 8 Face material 8a Each peripheral part 9 Nozzle 10 Heat insulation foam layer 11 Heat insulation panel

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04B 1/76 E04B 1/76 V 1/80 1/80 V // B32B 21/08 B32B 21/08 B29K 105: 04 105: 20 711: 14 B29L 9:00 31:10

Claims (4)

(57) [Claims] 1. A heat insulating panel used as a structural member of a building, wherein at least the outer periphery is constituted by a wooden frame, one surface is closed by a flat plate, and the other surface is open; On a flat plate in the frame, a heat-insulating foam layer of a synthetic resin foamed and formed with a thickness smaller than the thickness of the frame, or the same thickness as the thickness of the frame , and a peripheral edge of the wooden frame and the heat-insulating foam layer. Bite in between
A heat insulating foam layer covering the surface of the heat insulating foam layer . 2. The face material has a moisture-proof property or a moisture-permeable property.
The heat insulation panel according to claim 1, wherein: 3. A claim for use as a structural member of a building
Item 3. The method for manufacturing a heat-insulating panel according to Item 1 or 2, wherein a kraft paper, a core, and a core are provided in which at least the outer periphery is constituted by a wooden frame, one surface is closed by a flat plate, and the other surface is open. It is made of paper, tissue paper, nonwoven fabric, etc. as a base material, and has breathability and moisture permeability made by laminating a nonwoven fabric to a moisture-proof paper, nonwoven fabric, plastic film, or plastic-based microporous film laminated with a metal foil or plastic film. And a water-permeable moisture-permeable surface material , wherein the peripheral edge of the surface material is the inner wall of the wooden frame.
It is installed so as to be in contact with the surface, holds the holding lid on the frame at a predetermined interval between the flat plate, and a heat insulating foam layer in a space in the frame between the flat plate and the face material. The peripheral edge of the face material between the foam layer and the wooden frame
And the surface of the foam layer is
A method for manufacturing a heat insulating panel , wherein foaming is performed so as to be covered more . 4. The press cover is fitted into the space in the frame.
Fixed on a plate-shaped main body and its upper surface with a frame
And the holding lid is formed by a locking tongue fixed to the reinforcing material.
And being locked to a wooden frame.
Manufacturing method of thermal insulation panel.