JP3364898B2 - Insulation panel manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a heat insulating panel used as a building panel such as a ceiling panel or a wall panel.

[0002]

2. Description of the Related Art Conventionally, when forming a heat insulating panel by providing a heat insulating material 5 made of foamed resin on the inner surface side of a face material 2, the face material 2 is attached to one side as shown in FIG. 3 (a). The frame body 1 is installed below the heating body 3 with the face material 2 on the lower side, and after heating the upper surface of the face material 2 with heat of far infrared rays or the like emitted from the heating body 3, As shown in (b), the foamed resin 4 is injected into the inside of the frame body 1, and then, as shown in FIG. The frame body 1 is installed on the lower side, and the foamed resin 4 inside the frame body 1 is heated and foamed by the heat emitted from the heating body 3, and the heat insulation is performed by the foamed resin 4 as shown in FIG. 3D. A process for forming the material 5 is performed.

[0003]

However, in the method of manufacturing the heat insulating panel as described above, the heating element 3 above the frame 1 is provided.
Since the upper surface of the face material 2 and the foamed resin 4 are heated by the heat emitted from the heater 3, the gap between the heating body 3 and the face material 2 or the foamed resin 4 is increased, and the heating body 3 and the face material 2 or the foamed resin 4 are separated from each other. The heat released from the heating element 3 is taken by the air between them, and therefore, in order to heat the face material 2 and the foamed resin 4 to a desired temperature,
There are problems that the heating time by the heating body 3 becomes long, and the electric capacity consumed by the heating body 3 becomes large and the energy cost becomes high.

Further, in the method of manufacturing the heat insulating panel as described above, the foamed resin 4 is heated by the heat released from the heating body 3 above the frame 1, so that the surface of the foamed resin 4 separated from the heating body 3 is heated. It becomes difficult to supply sufficient heat to the portion close to the surface material 2, so that the foamability of the portion of the foamed resin 4 near the surface material 2 decreases and the adhesion between the surface material 2 and the foamed resin 4 (the heat insulating material 5). There was a problem that it decreased.

Further, in the method of manufacturing the heat insulating panel as described above, since the face material 2 and the foamed resin 4 are heated by the heat emitted from the heating body 3 above the frame body 1, the frame body which does not need to be heated. Heat is also supplied to 1, and when the wooden frame 1 is used by this heat, the frame 1 is deformed such as warped or twisted due to evaporation of water in the frame 1. There was a problem.

The present invention has been made in view of the above points, and it is possible to shorten the heating time by the heating element and reduce the electric capacity consumed by the heating element to reduce the energy cost. In addition, the foamability of the foamed resin can be improved and the adhesion between the face material and the foamed resin can be improved, and even if a wooden frame is used, deformation such as warping or twisting does not occur in the frame. It is an object of the present invention to provide a method for manufacturing a heat insulating panel that can be made into.

[0007]

According to a first aspect of the present invention, there is provided a method for manufacturing a heat insulating panel, in which a face material 2 is attached to one surface of a frame body 1 and a heating body 3 is attached to the face material 2 inside the frame body 1.
Are contacted with each other to heat the face material 2 with the heating body 3, and then the foamed resin 4 is injected into the inside of the frame body 1 to heat and foam the foamed resin 4 by the heat of the heated face material 2 and the heat insulating material. 5 is formed.

According to a second aspect of the present invention, in addition to the structure of the first aspect, a method of manufacturing a heat insulating panel uses a wooden frame body as the frame body 1 and a frame body 1 as the heating body 3. It is characterized by using a heating element having an outer size smaller than the inner size.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below. The frame body 1 is formed by combining a frame member 1a formed of a wooden square or the like into a square shape in a plan view,
If necessary, a reinforcing member 1b made of wooden lumber or the like may be installed between the opposing frame members 1. As the face material 2, a plate material that has been conventionally used as a building material can be used, and examples thereof include gypsum board and particle board.

The foamed resin 4 may be any as long as it foams to become the heat insulating material 5. For example, a resin prepared by blending a foaming agent or a curing catalyst with phenol resin or urethane resin is used. be able to. As the foaming agent, Freon R-11, R-113, methylene chloride or the like can be used alone or in combination. As the curing catalyst, sulfuric acid, hydrochloric acid, phosphoric acid or the like can be used as the inorganic acid, and benzenesulfonic acid, toluenesulfonic acid, phenolsulfonic acid or the like can be used as the organic acid. In addition, a foam stabilizer, a flame retardant and the like can be added as required. The mixing ratio of the phenol resin or urethane resin, the foaming agent, and the curing catalyst is determined in consideration of the reactivity of the foamed resin 4, the density of the heat insulating material 5 after foaming, and, for example, phenol resin is 100%. The foamed resin 4 can be prepared by mixing 18 parts by weight of the foaming agent and 23 parts by weight of the curing catalyst.

Next, the manufacturing process of the heat insulating panel will be described. First, the inner surface of the face material 2 (the surface facing the inside of the heat insulating panel) is attached to one side of the frame body 1 with an adhesive or the like so that the frame material 1a and the reinforcing material 1b of the frame body 1 and the face material 2 are attached. A panel body 6 having a recess 7 surrounded by the inner surface of is formed. Next, the panel body 6 is set so that the frame body 1 is located on the upper side of the face material 2 and the recess 7 is opened to the upper side, and then the frame body 1 is set as shown in FIG. Inner recess 7
The inner surface of the face material 2 is heated to 25 to 135 ° C. by the heating body 3 by contacting the inner surface of the inner surface material 2 with a heating body 3 formed of a planar heater or the like over substantially the entire surface for 1 to 10 seconds. .

In this way, the heating element 3 is brought into contact with the inner surface of the surface material 2 and only the surface material 2 is heated by the heating element 3,
Since there is no air between the heating element 3 and the face material 2 that deprives the heat emitted from the heating element 3, the heat emitted from the heating element 3 can be efficiently supplied to the face material 2, and thus the surface material can be efficiently supplied. The heating time of the heating element 3 for heating the heating element 2 to a desired temperature can be made shorter than that of the conventional example, and the electric capacity consumed by the heating element 3 to heat the face material 2 to the desired temperature is It can be made smaller than the conventional example.

For example, when a plaster board having a thickness of 12 mm is used as the face material 2 and a heating body 3 having a surface temperature of 215 ° C. is used, heating of the face material 2 of the conventional example shown in FIG. In the method, the surface temperature of the inner surface of the face material 2 is set to 2
It takes about 20 seconds to raise the temperature from 6 ° C. to 100 ° C. (the distance between the face material 2 and the heating body 3 is 66 mm), whereas the method for heating the face material 2 of this embodiment shown in FIG. Then, it takes only about 10 seconds to raise the surface temperature of the inner surface of the face material 2 from 26 ° C. to 136 ° C. Therefore, the heating method of this embodiment requires the face material 2 more than the conventional example. The time for heating to the temperature can be shortened.

In the method for heating the face material 2 of this embodiment, a gypsum board having a thickness of 12 mm (the surface temperature of the inner surface before heating is 26 ° C.) as the face material 2 and the surface temperature of the heating body 3 are The surface temperature of the inner surface of the face material 2 when the heating time of the face material 2 is set to 10 seconds using 215 ° C. each (the face material 2 with respect to the elapsed time from the end of heating)
Table 1 shows the changes in the surface temperature of the inner surface of.

[0015]

[Table 1]

As the heating element 3, it is preferable to use a heating element whose outer size is smaller than the inner dimension of the frame body 1, whereby the heating body 3 does not come into contact with the frame body 1 and the frame body 1 is heated. It is possible to prevent the frame body 1 from being deformed by warping, twisting or the like due to the heat of the heating body 3 not evaporating the moisture of the frame body 1 by the heat of the heating body 3. The heating body 3 and the frame body 1 may have a size such that they do not come into contact with each other. For example, between the inner surface of the frame material 1a of the frame body 1 and the side surface of the reinforcing material 1b and the end surface of the heating body 3 of 5 to 10 mm. Each size of the frame body 1 and the heating body 3 can be set to such a size that a gap (indicated by T in FIG. 2) can be formed.

Next, the foamed resin 4 is sprayed from the spray nozzle 8 installed above the panel body 6 into the recess 7 inside the frame 1 to inject the foamed resin 4 into the recess 7. Since the foamed resin 4 is sprayed in a substantially conical shape having the apex of the spray nozzle 8 as shown by an imaginary line in FIG. The foamed resin 4 can be injected in a uniform amount over the entire surface. The injection amount of the foamed resin 4 is determined by the following expression A.

Injection amount (g / m ² ) = t × a × 1.25 × 10 ³ ... A In this formula A, t (m) is the average thickness of the heat insulating material 5 formed after foaming, a (kg / m ² ) is the density of the heat insulating material 5, 1.2
5 is an evaporation coefficient due to a foaming agent, water and the like. Then, the foamed resin 4 injected into the recess 7 is heated and foamed by the heat of the face material 2 heated before the injection of the foamed resin 4 by the heating body 3, and the adhesive force by the self-adhesiveness of the foamed resin 4 is obtained. The heat insulating material 5 fixed to the inner surface of the face material 2 in the recess 7 (frame 1)
Thus, the heat insulating panel of the present invention is formed. When this heat insulating panel is used as a ceiling panel or a floor panel, it is possible to use the one in which the face material 2 is attached to only one side of the frame body 1 as shown in FIG. When used, the face member 2 may be attached to the other side of the frame 1 as shown in FIG. 1 (d).

As described above, according to the present invention, the foamed resin 4 injected into the recess 7 is heated and foamed by the heat of the face material 2 which is heated before the injection of the foamed resin 4. The heat required for foaming is supplied from the face material 2 to the portion close to the face material 2 more efficiently and more efficiently than the above-mentioned conventional example. Therefore, the foamability of the foamed resin 4 near the face member 2 (foaming speed and The foaming ratio) can be improved more than that of the conventional example, and the foaming property of the foamed resin 4 is increased, so that the adhesion (adhesiveness) between the face material 2 and the foamed resin 4 (heat insulating material 5) can be improved. Further, it is possible to form a heat insulating panel having a uniform heat insulating property.

In the above embodiment, when the foamed resin 4 is not sufficiently foamed only by the heat from the face material 2, the foamed resin 4 is injected into the recess 7 and then the panel body 6 is filled. The foamed resin 4 may be heated from above by a heating body such as an infrared heater.

[0021]

As described above, according to the invention described in claim 1 of the present invention, the face material is attached to one surface of the frame body, and the face material is brought into contact with the face material inside the frame body to heat the face material. Then, the foamed resin is injected inside the frame and the foamed resin is heated and foamed by the heat of the heated face material to form the heat insulating material. By heating the material with the heating element, the heat emitted from the heating element is not taken by the air between the heating element and the surface material, and the heat emitted from the heating element is efficiently supplied to the surface material. Therefore, the heating time by the heating body for heating the face material and the foamed resin to a desired temperature can be shortened, and the electric capacity of the heating body consumed when heating the face material and the foamed resin can be reduced. It can be made smaller to reduce the energy cost of producing insulation panels. Is shall.

Further, according to the present invention, by heating the face material and then injecting the foamed resin into the inside of the frame body, heat can be sufficiently supplied from the face material to a portion of the foamed resin close to the face material. It is possible to improve the foamability of the portion close to the resin face material and improve the adhesion between the face material and the foam resin and the heat insulating material by improving the foamability of the foam resin face material. As a result, a heat insulating panel having uniform heat insulating performance can be formed.

In the invention according to claim 2 of the present invention, since the wooden frame is used as the frame and the heating body having the outer size smaller than the inner size of the frame is used as the heating body,
When heating the surface material with the heating element, it is possible to prevent the heating element from coming into contact with the wooden frame, so it becomes difficult for the frame to be heated by the heat emitted from the heating element, and the wooden frame is Even if it is used, it is possible to prevent the frame body from being deformed such as warping or twisting due to the heat of the heating body.

[Brief description of drawings]

FIG. 1A to FIG. 1D are cross-sectional views showing an embodiment of the present invention.

FIG. 2 is a plan view of FIG. 1 (a) above.

3A to 3D are cross-sectional views showing a conventional example.

[Explanation of symbols]

1 frame 2 face materials 3 heating body 4 Foam resin 5 insulation

─────────────────────────────────────────────────── ─── Continuation of the front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 44/00-44/60

Claims (2)

(57) [Claims] 1. A face material is attached to one surface of a frame body, a heating body is brought into contact with the face material inside the frame body to heat the face material with the heating body, and then a foaming resin is injected inside the frame body. A method for manufacturing a heat insulating panel, characterized in that the foamed resin is heated and foamed by the heat of the heated face material to form a heat insulating material. 2. The manufacturing of the heat insulation panel according to claim 1, wherein a wooden frame is used as the frame, and a heating body having an outer size smaller than an inner size of the frame is used as the heating body. Method.