JP3706777B2

JP3706777B2 - Insulation manufacturing method

Info

Publication number: JP3706777B2
Application number: JP25211399A
Authority: JP
Inventors: 浩規中川; 泰章村田
Original assignee: Nichias Corp
Current assignee: Nichias Corp
Priority date: 1999-09-06
Filing date: 1999-09-06
Publication date: 2005-10-19
Anticipated expiration: 2019-09-06
Also published as: JP2001073478A

Description

【０００１】
【発明の属する技術分野】
本発明は、断熱性と吸音性に優れた断熱材及びその製造方法に係り、特に住宅建築に使用する断熱材及びその製造方法に関するものである。
【０００２】
【従来の技術】
一般に住宅などの建物の場合、壁体は、柱や間柱などの縦枠材や横胴縁などからなる横枠材で構成される壁下地に、室外側に各種の外壁材を設け、壁下地に囲まれた空間にロックウールやグラスウールなどの断熱材を充填して断熱性や吸音性を高める工法が採用されている。
【０００３】
上記する断熱材の１例を図１３〜図１５により説明すると、この断熱材１は、ロックウールやグラスウールのような無機質繊維の断熱基材２を防湿性の防湿シート３で包み、また、裏面の長手両端部に防湿シート３を延出させた耳部４，４を有する弾力性に富むマット状に構成している。なお、断熱材１の表面側の防湿シート３には、周知の透湿穴１２が不規則的に設けられている。
【０００４】
そして、この断熱材１を柱５と間柱６の間に配し、各耳部４，４を柱５と間柱６にそれぞれ密に当接させた上、所定間隔ごとにステープル７を施し、断熱材１を柱５と間柱６間に取付けている。間柱６と続く柱８の間も同様に断熱材１を取付けて断熱性や遮音性を高めている。
【０００５】
【発明が解決しようとする課題】
しかしながら、図示するように、断熱材１の耳部４には、断熱基材２が存在しない防湿シート３のみの構成の耳部４が柱５，８及び間柱６と直接接触するだけであるため、その部分が熱橋となって目的とする高い断熱性や遮音性が得られない不都合の原因となることがある。
【０００６】
また、図示するように、間柱６を介在させた柱５，８間に筋かい９を設けた壁下地の場合、断熱材１を取付ける際、室内側１０に筋かい９が突出するために筋かい９と当接する断熱材１の該当部分を強く押潰すが、断熱材１は室内側１０に突出するため、図１５の一点鎖線で示すように断熱材１を筋かい９の斜め形状に合わせてカットしなければならない。
【０００７】
しかし、このカット作業は面倒であるし、正確に斜め形状にカットしないと、筋かい９とカット面１１の間に隙間が空いたり、断熱材１に弛みが生まれたり、カット面１１から断熱基材２が飛散するなどの不都合の原因となることがある。
【０００８】
本発明は、上記する課題を解決するものであり、断熱性と施工性に特に優れた断熱材であり、また、この断熱材が簡易に製造できる製造方法を提供することを目的とするものである。
【０００９】
【課題を解決するための手段】
上記する目的を達成するため、本発明に係る第１の発明は、壁体を構成する壁下地の柱間に配する無機質繊維の断熱基材からなる断熱材であり、柱および／または間柱と接触する断熱材の凹部に断熱基材を充填させ、壁体内に熱橋を設けない構造としたことを特徴とする断熱材の製造方法であって、開綿した無機質繊維に熱硬化性樹脂を主成分とするバインダーを添加して積層させて断熱基材を成形する工程と、柱と嵌合する位置に合わせて、断熱基材の表面にロール状および／または棒状のヒーターにより凹部を形成させる工程と、凹部が形成された断熱基材を、加熱装置により加熱・硬化する工程とからなることを特徴としている。
【００１０】
第２の発明は、断熱基材の少なくとも片面に防湿シートを被覆する工程を含むことを特徴としている。
【００１１】
【作用】
本発明に係る第１の発明によれば、断熱基材を有する第１凹部を設ける断熱材や壁下地に断熱材の取付けに障害となる壁下地の突起部と嵌合し合う第２凹部を有する断熱材が簡易に製造でき、第２の発明によれば、断熱基材の飛散が防げる断熱材が簡易に得られる。
【００１２】
【発明の実施の形態】
本発明の実施形態を図面を参照して説明する。図１は、本発明に係る第１例の断熱材を示す斜視図、図２は、同取付け状態を示す横断面図、図３は、第２例の断熱材を示す斜視図、図４は、同取付け状態を示す横断面図、図５は、第３例の断熱材を示す斜視図、図６は、第４例の断熱材を示す斜視図、図７は、同取付け状態を示す横断面図、図８は、図７のイ−イ、ロ−ロ及びハ−ハの各断面図、図９は、本発明に係る第１例の製造方法を示す要部斜視図、図１０は、第２例の製造方法を示す要部斜視図、図１１は、第３例の製造方法を示す要部斜視図、図１２は、第４例の製造方法を示す要部斜視図である。
【００１３】
第１例の断熱材１５を説明する。図１及び図２に示すように、この断熱材１５は、ロックウールやグラスウールのような無機質繊維の断熱基材１６にフェノール樹脂などの熱硬化性樹脂を主成分とするバインダーを添加して所定の厚みを有する長方形に硬化・成形させてあり、マット状やフェルト状或いはボード状などに構成してある。以下、説明する断熱材１５には、マット状やフェルト状或いはボード状構成のものを含むものとする。例えば、ロックウールからなるマット状の断熱材１５は、嵩密度４０ｋｇ／ｍ^３、厚さ１００ｍｍに成形してある。
【００１４】
そして、断熱材１５の一面１７の中央部に長手方向に沿って角状の第２凹部１８が直線状に形成され、また、両端部に同様に長手方向に沿って延出部１９が直線状にそれぞれ形成されて断熱基材１６を有する第１凹部２０ａ，２０ｂが構成され、この第１凹部２０ａ，２０ｂが、後記するように、柱５，８の一面と嵌合し合って取付ける構成としてある。この第１凹部２０ａ，２０ｂと第２凹部１８は、図示するように断熱材１５の他面２１まで延びることなく、断熱基材１６が所定の厚みで存在することが必要であり、少なくとも断熱材１５の厚さの略１／３程度の断熱基材１６が残ることが好ましい。なお、第２凹部１８は、両端部の第１凹部２０ａ，２０ｂに比べ若干幅狭な形状としてあるが、これは、後記するように、第２凹部１８が柱５，８より幅狭な間柱６と嵌合し合うためである。
【００１５】
また、断熱材１５は、上・下端面２２を除いて防湿シート３で包んであり、防湿シート３は、不透湿性能に優れたシート材であればよく、ポリエチレン、ポリプロピレン、ポリ塩化ビニル、ポリ塩化ビニリデンなどのプラスチックシート、これらのシートにアルミを蒸着したシート、アルミ箔などの金属箔構成のものが好ましい。また、図示省略するが、上・下端面２２を含む全面をシート材で包むようにしてもよい。断熱基材１６は、上記するロックウールやグラスウールなどの無機質繊維が好ましいが、ポリスチレン樹脂やポリオール樹脂などの有機質の気泡状断熱材を用いてもよい。なお、上述する従来例と同様に、この断熱材１５の一面１７側の防湿シート３には、周知の透湿穴１２が不規則的に設けられている。以下、説明する各例の断熱材もその都度説明を省くが、同様に浸透穴が設けられている。また、防湿シート３は、必ずしも断熱材１５の両面１７、２１に必要なものではなく、室内側１０は必要であり、反対の室外側の一面１７は省いてもよく、以下同様である。
【００１６】
上記する第１例の断熱材１５の取付け方法を図２により説明すると、間柱６を介在させた柱５，８間に断熱材１５の一面２１側を室内側１０に向け、断熱材１５の第１凹部２０ｂを柱５に、第２凹部１８を間柱６に、第１凹部２０ａを柱８にそれぞれ嵌合させ、順次隣接し合う柱や間柱に断熱材１５を取付けた壁下地を構成し、その断熱性や吸音性を高めている。
【００１７】
第２例の断熱材２５を説明する。この断熱材２５は、図４に示すように柱５，８の間に間柱６を設けない壁下地に取付ける構成であり、それだけ上記第１例の断熱材１５に比べ幅狭な形状を特徴としている。その他の構成は、第１例と同じであるため、同じ符号を付け、その説明を省略する。
【００１８】
第３例の断熱材２７を説明する。この断熱材２７は、上記断熱材２５を変形させた例であり、図５に示すように、取付ける柱５，８の位置に対応するように断熱基材１６の一面１７の各端部寄りに第１凹部２０ａ，２０ｂがそれぞれ形成してある。その他の構成は、第１例と同じであるため、同じ符号を付け、その説明を省略する。
【００１９】
第４例の断熱材３０を説明する。この断熱材３０は、図７に示すように柱５，８の間に間柱６を設けると共に、柱５，８の間に筋かい９を配した壁下地に取付ける構成であり、この筋かい９に対応できる構成に特徴がある。つまり、図６に示すように、断熱材３０の一面１７側に設けた第１凹部２０ｂの上端側から第１凹部２０ａの下端側に至って角状の傾斜凹部３１を斜めに形成してある。その他は、上記第１例と同じであるため、同じ符号を付け、その説明を省略する。
【００２０】
上記第４例の取付け方法を図７により説明すると、柱５，８に断熱材３０の一面１７側を向け、断熱材３０の第１凹部２０ｂを柱５に、第２凹部１８を間柱６に、第１凹部２０ａを柱８にそれぞれ嵌合させる。さらに、断熱材３０に形成した傾斜凹部３１と柱５，８の間に配した筋かい９を嵌合させると、この筋かい９が特に障害になることはなく、スムーズに無理のない施工ができ、順次隣接し合う柱や柱間などに断熱材３０を取付けた壁下地が構成できる。
【００２１】
次に、本発明に係る断熱材の製造方法を説明する。図９に示す例は、第１例の断熱材１５を製造する工程３５の要部を示し、図示省略した公知の工程でフェノル樹脂などの熱硬化性樹脂を主成分とするバインダーを開綿したロックウールなどの無機質繊維に添加させて積層した積層物３６が作られる。積層物３６は、次の製造工程３５の移送するベルト３７上に所定の間隔に配置された型枠３８上に送られ、型枠３８上に送られた積層物３６は、そのままの状態で型枠３８と一緒に、加熱装置３９に移送される。
【００２２】
加熱装置３９に入った積層物３６は、型枠３８上においてフェノル樹脂の硬化により型枠３８に突設した角状の突起部４０ａ，４０ｂ及び４１が積層物３６の一面４２、つまり、一面４２の中央部と両端部にそれぞれ長手方向に沿う角状の第２凹部１８と延出部１９からなる第１凹部２０ａ，２０ｂが直線状に形成された積層物３６が作られる。そして、製品の結露防止とロックウールの飛散を防止するために積層物３６の上・下端面４３を含めて全面を防湿シート３で覆うことで、防湿シート３で包んだ断熱材１５が得られる。なお、この断熱材１５には、上述するように室内側となる一面に防湿シート３が必要であるが、反対の室外側となる一面に防湿シート３、或いはこれに透湿穴１２を設けるかは何れも任意である。以下、同様である。
【００２３】
上記型枠３８は、断熱材１５を得るために、平らな表面４４の両端部と中央部にそれぞれ後方長手方向に延びる角状の突起部４０ａ，４０ｂ及び４１が突設してあり、中央部の突起部４１が、幅狭に形成してある。また、型枠３８は、移送するベルト３７に上向きに配置されているが、反対に型枠３８を下向きにして、移送させる積層物３６上に型枠３８を被せるように設置してもよい。
【００２４】
第２例の断熱材２５では、中央部に第２凹部１８を設けずに、両端部に延出部１９からなる第１凹部２０ａ，２０ｂが設けられている。このため、図示省略するが、この断熱材２５の製造には、型枠３８は幅狭で、かつ両端部にそれぞれ後方長手方向に延びる角状の突起部４０ａ，４０ａが突設された構成のものを使用するとよい。また、上記と同様に、型枠３８は上向き或いは下向きの何れであってもよい。
【００２５】
図１０は、上記型枠３８を使用する製造方法と異なり、３つのロール状のヒーター４７ａ，４７ｂ，４７ｃを使用して断熱材１５，２５を作る例であり、移送中のベルト３７に設置された積層物３６に上方から間隔をあけて設けたヒーター４７ａ，４７ｂ，４７ｃが当接し、その熱でフェノル樹脂を硬化させ、断熱基材１６の一面１７に第２凹部１８と第１凹部２０ａ，２０ｂがそれぞれ設けられている。
【００２６】
そして、この断熱基材１６は、移送するベルト３７によって加熱装置３９に移送され、加熱装置３９により断熱基材１６全体が加熱され、フェノル樹脂の硬化によって、一面４２の中央部と両端部にそれぞれ長手方向に沿う角状の第２凹部１８と第１凹部２０ａ，２０ｂが直線状に形成された積層物３６が作られる。また、積層物３６の上・下端面４３を含めて全面を防湿シート３で包んだ断熱材１５が得られる。
【００２７】
断熱材２５を作るには、断熱基材１６を幅狭にし、また、中央部のヒーター４７ｂの作動を中断させるため、上方に持上げたり、或いはヒーター４７ｂを取外したりして、両端部のヒーター４７ａ，４７ｃのみを作動させればよく、その他の工程は、上記と同様にして所望の断熱材２５が得られる。
【００２８】
図１１は、第４例の断熱材３０を作る例であり、一面１７に角状の第２凹部１８と第１凹部２０ａ，２０ｂが加熱硬化させた断熱基材１６に対し、その移送ベルト３７を止め、第１凹部２０ｂの上端側から第１凹部２０ａの下端側に至って棒状のヒーター４８を傾斜状に当接させ、ヒーター４８の熱によりフェノル樹脂を硬化させ、一面１７に第２凹部１８と第１凹部２０ａ，２０ｂに交差する傾斜凹部３１が形成される。また、積層物３６の上・下端面４３を含めて全面を防湿シート３で包んだ断熱材３０が得られる。
【００２９】
上記断熱材３０の場合、図示省略するが、型枠３８に突起部４０ａ，４０ｂ及び４１と共に、突起部４０ｂの上端から突起部４０ａの下端に至る傾斜突起部４９を設けると、この型枠３８の一度の使用で目的の断熱材３０を加熱硬化でき、その工程を省くことができる。
【００３０】
図１２は、上記断熱材３０と異なる例であり、突起部４０ｂの上端から突起部４０ａの下端に至る傾斜突起部４９をロール状のヒーター５０により加熱硬化させている。
【００３１】
また、図示省略するが、両端部などに設ける第１凹部２０ａ，２０ｂは、積層物３６を加熱硬化した後の後加工によりカッターなどでカットして形成してもよいことは勿論のことである。
【００３２】
【発明の効果】
本発明の断熱材によれば、柱及び間柱と接触する断熱材の第１・第２の凹部には、ロックウールなどの無機質繊維の断熱基材が充填させてあり、従来のような防湿シートのみの耳部と異なり、壁内に熱橋がなくなり、断熱性や遮音性に優れる。
【００３３】
断熱材には、壁下地に断熱材の取付けに障害となる壁下地の突起部と嵌合し合う凹部が形成してあるため、筋かいがあっても断熱材をカットすることもなくなり、断熱材の取付け施工が簡易となる。さらに、断熱材には、防湿シートが全面に被覆してあるため、ロックウールなどの断熱基材の飛散が防げるし、結露の原因がなくなるなどの効果がある。
【００３４】
また、本発明によれば、両端部などに断熱基材を有する第１・第２の凹部を設けたり、壁下地に断熱材の取付けに障害となる壁下地の突起部と嵌合し合う凹部を有する断熱材が簡易に製造でき、断熱基材の飛散が防げる断熱材も簡易に製造できる。
【図面の簡単な説明】
【図１】本発明に係る第１例の断熱材を示す斜視図。
【図２】同取付け状態を示す横断面図。
【図３】第２例の断熱材を示す斜視図。
【図４】同取付け状態を示す横断面図。
【図５】第３例の断熱材を示す斜視図。
【図６】第４例の断熱材を示す斜視図。
【図７】同取付け状態を示す横断面図。
【図８】図７のイ−イ、ロ−ロ及びハ−ハの各断面図。
【図９】本発明に係る第１例の製造方法を示す要部斜視図。
【図１０】第２例の製造方法を示す要部斜視図。
【図１１】第３例の製造方法を示す要部斜視図。
【図１２】第４例の製造方法を示す要部斜視図。
【図１３】従来例の断熱材の取付け状態を示す横断面図。
【図１４】筋かいの取付け状態を示す斜視図。
【図１５】断熱材のカット状態を示す説明図。
【符号の説明】
５，８柱
１５，２５断熱材
１６断熱基材
２０ａ，２０ｂ第１凹部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat insulating material having excellent heat insulating properties and sound absorbing properties and a method for manufacturing the same, and more particularly to a heat insulating material used for residential construction and a method for manufacturing the same.
[0002]
[Prior art]
In general, in the case of a building such as a house, the wall body is provided with various external wall materials on the outside of the wall, which is composed of vertical frame materials such as columns and studs, and horizontal frame materials such as horizontal torso edges. A method of improving heat insulation and sound absorption by filling a space surrounded by heat insulation such as rock wool or glass wool is adopted.
[0003]
An example of the above-described heat insulating material will be described with reference to FIGS. 13 to 15. This heat insulating material 1 wraps a heat insulating base material 2 made of inorganic fibers such as rock wool and glass wool with a moisture-proof moisture-proof sheet 3, and the back surface. It has the shape of a mat that is rich in elasticity and has ears 4 and 4 in which a moisture-proof sheet 3 is extended at both longitudinal ends. In addition, the moisture-proof sheet 3 on the surface side of the heat insulating material 1 is provided with known moisture-permeable holes 12 irregularly.
[0004]
And this heat insulating material 1 is arranged between the pillar 5 and the interposition pillar 6, and each ear | edge part 4 and 4 is made to contact | abut to the pillar 5 and the interposition pillar 6, respectively, Furthermore, the staple 7 is given for every predetermined space | interval, and heat insulation is carried out. The material 1 is attached between the column 5 and the inter-column 6. Similarly, the heat insulating material 1 is attached between the inter-column 6 and the following column 8 to enhance the heat insulating property and the sound insulating property.
[0005]
[Problems to be solved by the invention]
However, as shown in the figure, the ears 4 of the heat insulating material 1 are only in direct contact with the pillars 5, 8 and the intermediary pillars 6 because the ears 4 having only the moisture-proof sheet 3 without the heat-insulating base material 2 exist. The part may become a thermal bridge, which may cause inconvenience that the desired high heat insulation and sound insulation cannot be obtained.
[0006]
Further, as shown in the figure, in the case of a wall base provided with a brace 9 between columns 5 and 8 with interposing a pillar 6, the brace 9 protrudes into the indoor side 10 when the heat insulating material 1 is attached. Although the corresponding part of the heat insulating material 1 that abuts against the paddle 9 is strongly crushed, the heat insulating material 1 protrudes to the indoor side 10, so the heat insulating material 1 is matched to the diagonal shape of the brace 9 as shown by the one-dot chain line in FIG. Must be cut.
[0007]
However, this cutting work is cumbersome, and if it is not cut accurately into an oblique shape, there is a gap between the brace 9 and the cut surface 11, a slack in the heat insulating material 1, or a heat insulating base from the cut surface 11. This may cause inconvenience such as scattering of the material 2.
[0008]
The present invention solves the above-mentioned problems, is a heat insulating material particularly excellent in heat insulating properties and workability, and aims to provide a manufacturing method in which this heat insulating material can be easily manufactured. is there.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, a first invention according to the present invention is a heat insulating material comprising a heat insulating base material of inorganic fibers disposed between columns of a wall base constituting a wall body, and A method of manufacturing a heat insulating material, characterized in that a heat insulating base material is filled in a concave portion of a heat insulating material to be contacted and a thermal bridge is not provided in a wall body, and a thermosetting resin is applied to the opened inorganic fiber. A step of forming a heat-insulating base material by adding and laminating a binder as a main component and forming a concave portion on the surface of the heat-insulating base material with a roll-shaped and / or rod-shaped heater in accordance with the position where the pillar is fitted. It consists of a process and the process of heating and hardening the heat insulation base material in which the recessed part was formed with a heating apparatus.
[0010]
2nd invention is characterized by including the process of coat | covering a moisture-proof sheet | seat on the at least single side | surface of a heat insulation base material.
[0011]
[Action]
According to the first invention of the present invention, the heat insulating material provided with the first concave portion having the heat insulating base material or the second concave portion that fits with the projection of the wall base material that obstructs the attachment of the heat insulating material to the wall base material. The heat insulating material which can have can be manufactured easily, and according to 2nd invention, the heat insulating material which can prevent scattering of a heat insulating base material is obtained easily.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing a heat insulating material of a first example according to the present invention, FIG. 2 is a cross-sectional view showing the attached state, FIG. 3 is a perspective view showing a heat insulating material of the second example, and FIG. FIG. 5 is a perspective view showing the heat insulating material of the third example, FIG. 6 is a perspective view showing the heat insulating material of the fourth example, and FIG. 7 is a cross sectional view showing the same mounting state. FIG. 8 is a cross-sectional view of each of II, roll, and ha ha in FIG. 7, FIG. 9 is a perspective view of a main part showing a first example manufacturing method according to the present invention, and FIG. FIG. 11 is a perspective view of a main part showing a manufacturing method of the third example, and FIG. 12 is a perspective view of a main part showing a manufacturing method of the fourth example.
[0013]
The heat insulating material 15 of the first example will be described. As shown in FIGS. 1 and 2, this heat insulating material 15 is obtained by adding a binder mainly composed of a thermosetting resin such as a phenol resin to a heat insulating base material 16 of an inorganic fiber such as rock wool or glass wool. It is cured and molded into a rectangular shape having a thickness of 5 mm, and is formed into a mat shape, felt shape, board shape, or the like. Hereinafter, the heat insulating material 15 to be described includes a mat shape, a felt shape, or a board shape. For example, the mat-like heat insulating material 15 made of rock wool is molded to a bulk density of 40 kg / m ³ and a thickness of 100 mm.
[0014]
And the square 2nd recessed part 18 is formed in linear form along the longitudinal direction in the center part of the one surface 17 of the heat insulating material 15, and the extension part 19 is linear along the longitudinal direction similarly to both ends. The first recesses 20a and 20b each having the heat insulating base material 16 are formed, and the first recesses 20a and 20b are fitted and attached to one surface of the columns 5 and 8, as will be described later. is there. The first concave portions 20a and 20b and the second concave portion 18 do not extend to the other surface 21 of the heat insulating material 15 as shown in the drawing, and the heat insulating base material 16 needs to exist with a predetermined thickness, and at least the heat insulating material. It is preferable that the heat insulating base material 16 having a thickness of about 1/3 of 15 remains. The second recess 18 has a slightly narrower shape than the first recesses 20a and 20b at both ends. However, as will be described later, this is because the second recess 18 is narrower than the columns 5 and 8. This is because it fits together.
[0015]
Moreover, the heat insulating material 15 is wrapped with a moisture-proof sheet 3 except for the upper and lower end surfaces 22, and the moisture-proof sheet 3 may be a sheet material having excellent moisture-impervious performance, such as polyethylene, polypropylene, polyvinyl chloride, A plastic sheet such as polyvinylidene chloride, a sheet obtained by vapor-depositing aluminum on these sheets, or a metal foil structure such as an aluminum foil is preferable. Although not shown, the entire surface including the upper and lower end surfaces 22 may be wrapped with a sheet material. The heat insulating substrate 16 is preferably an inorganic fiber such as rock wool or glass wool described above, but an organic cellular heat insulating material such as polystyrene resin or polyol resin may be used. As in the conventional example described above, the moisture proof sheet 3 on the one surface 17 side of the heat insulating material 15 is provided with known moisture permeable holes 12 irregularly. Hereinafter, although the description of the heat insulating material of each example to be described is omitted each time, a penetration hole is similarly provided. Further, the moisture-proof sheet 3 is not necessarily required for the both surfaces 17 and 21 of the heat insulating material 15, the indoor side 10 is necessary, the opposite outer surface 1 may be omitted, and so on.
[0016]
The mounting method of the heat insulating material 15 of the first example described above will be described with reference to FIG. 2. The one surface 21 side of the heat insulating material 15 is directed to the indoor side 10 between the columns 5 and 8 with the intermediary columns 6 interposed therebetween. 1 recess 20b is connected to the pillar 5, the second recess 18 is fitted to the intermediary pillar 6, and the first recess 20a is fitted to the pillar 8, respectively. The heat insulation and sound absorption are improved.
[0017]
The heat insulating material 25 of the second example will be described. As shown in FIG. 4, the heat insulating material 25 is configured to be attached to a wall base without the intermediary column 6 between the columns 5 and 8, and thus has a narrower shape than the heat insulating material 15 of the first example. Yes. Since other configurations are the same as those of the first example, the same reference numerals are given and the description thereof is omitted.
[0018]
The heat insulating material 27 of the third example will be described. The heat insulating material 27 is an example in which the heat insulating material 25 is deformed. As shown in FIG. 5, the heat insulating material 27 is close to each end portion of the one surface 17 of the heat insulating base material 16 so as to correspond to the positions of the columns 5 and 8 to be attached. First recesses 20a and 20b are respectively formed. Since other configurations are the same as those of the first example, the same reference numerals are given and the description thereof is omitted.
[0019]
The heat insulating material 30 of the fourth example will be described. As shown in FIG. 7, the heat insulating material 30 has a structure in which an intermediary column 6 is provided between columns 5 and 8 and is attached to a wall base having a brace 9 disposed between the columns 5 and 8. There is a feature in the configuration that can respond to. That is, as shown in FIG. 6, the angular inclined recess 31 is formed obliquely from the upper end side of the first recess 20 b provided on the one surface 17 side of the heat insulating material 30 to the lower end side of the first recess 20 a. Others are the same as those in the first example, so the same reference numerals are given and the description thereof is omitted.
[0020]
The attachment method of the fourth example will be described with reference to FIG. 7. The one surface 17 side of the heat insulating material 30 is directed to the columns 5 and 8, the first concave portion 20 b of the heat insulating material 30 is directed to the pillar 5, and the second concave portion 18 is directed to the intermediate pillar 6. The first recess 20a is fitted to the column 8 respectively. Furthermore, when the brace 9 arranged between the inclined recess 31 formed in the heat insulating material 30 and the columns 5 and 8 is fitted, the brace 9 is not particularly obstructed, and the construction is smooth and easy. In addition, it is possible to configure a wall base in which the heat insulating material 30 is attached to the columns adjacent to each other or between the columns.
[0021]
Next, the manufacturing method of the heat insulating material which concerns on this invention is demonstrated. The example shown in FIG. 9 shows the main part of the process 35 for manufacturing the heat insulating material 15 of the first example, and a binder mainly composed of a thermosetting resin such as phenol resin is opened in a known process not shown. A laminate 36 is made by adding and laminating to inorganic fibers such as rock wool. The laminate 36 is fed onto a formwork 38 arranged at a predetermined interval on a belt 37 to be transferred in the next manufacturing process 35, and the laminate 36 sent onto the formwork 38 is left as it is. Along with the frame 38, it is transferred to the heating device 39.
[0022]
In the laminate 36 that has entered the heating device 39, the square protrusions 40 a, 40 b, and 41 projecting from the mold 38 by curing the phenolic resin on the mold 38 are formed on one surface 42 of the laminate 36, that is, one surface 42. A laminate 36 is formed in which first concave portions 20a and 20b each formed of a rectangular second concave portion 18 and an extending portion 19 along the longitudinal direction are formed linearly at the central portion and both end portions, respectively. And in order to prevent dew condensation of a product and scattering of rock wool, the heat insulating material 15 wrapped with the moisture-proof sheet 3 is obtained by covering the entire surface including the upper and lower end surfaces 43 of the laminate 36 with the moisture-proof sheet 3. . The heat insulating material 15 requires the moisture-proof sheet 3 on one surface on the indoor side as described above, but is the moisture-proof sheet 3 on the other surface on the opposite side or the moisture-permeable hole 12 provided on the opposite surface? Are arbitrary. The same applies hereinafter.
[0023]
In order to obtain the heat insulating material 15, the mold 38 has angular projections 40 a, 40 b, and 41 extending in the rear longitudinal direction at both ends and the center of the flat surface 44, respectively. The projecting portion 41 is formed narrow. Further, although the mold 38 is arranged upward on the belt 37 to be transferred, it may be installed so that the mold 38 is placed on the laminate 36 to be transferred with the mold 38 facing downward.
[0024]
In the heat insulating material 25 of the second example, the first concave portions 20a and 20b including the extending portions 19 are provided at both ends without providing the second concave portion 18 at the central portion. For this reason, although not shown in the drawings, for the manufacture of the heat insulating material 25, the mold frame 38 has a narrow width, and angular projections 40a, 40a extending in the rear longitudinal direction are provided at both ends. Use a good one. Similarly to the above, the formwork 38 may be either upward or downward.
[0025]
FIG. 10 is an example of making the heat insulating materials 15 and 25 using three roll-shaped heaters 47a, 47b and 47c, which is different from the manufacturing method using the mold 38, and is installed on the belt 37 being transferred. The heaters 47a, 47b, 47c provided at intervals from above are contacted with the laminate 36, the phenol resin is cured by the heat, and the second recess 18 and the first recess 20a, 20b are provided.
[0026]
And this heat insulation base material 16 is transferred to the heating apparatus 39 by the belt 37 to transfer, and the heat insulation base material 16 whole is heated by the heating apparatus 39, and hardening of phenol resin is carried out to the center part and both ends of the one surface 42, respectively. A laminate 36 is formed in which the angular second recesses 18 along the longitudinal direction and the first recesses 20a and 20b are linearly formed. Moreover, the heat insulating material 15 in which the entire surface including the upper and lower end surfaces 43 of the laminate 36 is wrapped with the moisture-proof sheet 3 is obtained.
[0027]
In order to make the heat insulating material 25, the heat insulating base material 16 is narrowed, and in order to interrupt the operation of the central heater 47b, it is lifted upward or the heater 47b is removed, and the heaters 47a at both ends are removed. , 47c only need to be operated, and in other processes, the desired heat insulating material 25 is obtained in the same manner as described above.
[0028]
FIG. 11 is an example of making the heat insulating material 30 of the fourth example, and the transfer belt 37 for the heat insulating base material 16 in which the square second concave portion 18 and the first concave portions 20a and 20b are heat-cured on one surface 17. The rod-shaped heater 48 is brought into contact with the slope from the upper end side of the first recess 20b to the lower end side of the first recess 20b, the phenol resin is cured by the heat of the heater 48, and the second recess 18 is formed on the one surface 17. And the inclined recessed part 31 which cross | intersects the 1st recessed parts 20a and 20b is formed. Moreover, the heat insulating material 30 in which the entire surface including the upper and lower end surfaces 43 of the laminate 36 is wrapped with the moisture-proof sheet 3 is obtained.
[0029]
In the case of the heat insulating material 30, although not shown in the drawings, when the mold 38 is provided with an inclined protrusion 49 extending from the upper end of the protrusion 40 b to the lower end of the protrusion 40 a together with the protrusions 40 a, 40 b and 41, the mold 38. The desired heat insulating material 30 can be heat-cured with one use, and the process can be omitted.
[0030]
FIG. 12 is an example different from the heat insulating material 30, and the inclined protrusion 49 extending from the upper end of the protrusion 40 b to the lower end of the protrusion 40 a is heated and cured by the roll heater 50.
[0031]
In addition, although not shown in the drawings, the first recesses 20a and 20b provided at both ends may be formed by cutting with a cutter or the like by post-processing after the laminate 36 is heat-cured. .
[0032]
【The invention's effect】
According to the heat insulating material of the present invention, the first and second recesses of the heat insulating material that comes into contact with the pillars and the inter-columns are filled with a heat insulating base material of inorganic fibers such as rock wool, and a conventional moisture-proof sheet Unlike the ears only, there is no thermal bridge in the wall, and it has excellent heat insulation and sound insulation.
[0033]
The heat insulation material has a recess that fits into the protrusion on the wall base that interferes with the installation of the heat insulation on the wall base, so there is no need to cut the heat insulation even if there is a brace. The installation work of the material becomes simple. Further, since the heat insulating material is covered with the moisture-proof sheet, the heat insulating base material such as rock wool can be prevented from being scattered and the cause of condensation can be eliminated.
[0034]
In addition, according to the present invention, the first and second recesses having the heat insulating base material are provided at both ends or the like, and the recesses that fit with the protrusions of the wall base that obstruct the attachment of the heat insulating material to the wall base. The heat insulating material which has can be manufactured easily, and the heat insulating material which can prevent scattering of a heat insulating base material can also be manufactured easily.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a heat insulating material of a first example according to the present invention.
FIG. 2 is a cross-sectional view showing the mounting state.
FIG. 3 is a perspective view showing a heat insulating material of a second example.
FIG. 4 is a cross-sectional view showing the mounting state.
FIG. 5 is a perspective view showing a heat insulating material of a third example.
FIG. 6 is a perspective view showing a heat insulating material of a fourth example.
FIG. 7 is a cross-sectional view showing the mounting state.
8 is a cross-sectional view taken along the lines II, ROLL, and HA of FIG. 7;
FIG. 9 is a main part perspective view showing the manufacturing method of the first example according to the present invention.
FIG. 10 is a main part perspective view showing the manufacturing method of the second example.
FIG. 11 is a perspective view of relevant parts showing a manufacturing method of a third example.
FIG. 12 is a main part perspective view showing a manufacturing method of the fourth example.
FIG. 13 is a cross-sectional view showing a state of attachment of a heat insulating material of a conventional example.
FIG. 14 is a perspective view showing an attached state of the brace.
FIG. 15 is an explanatory diagram showing a cut state of the heat insulating material.
[Explanation of symbols]
5,8 Pillars 15, 25 Heat insulation material 16 Heat insulation base materials 20a, 20b First recess

Claims

It is a heat insulating material composed of an inorganic fiber heat insulating base material placed between pillars of the wall base constituting the wall body. A method of manufacturing a heat insulating material characterized by having a structure without a bridge,
  Adding a binder mainly composed of a thermosetting resin to laminated inorganic fibers and laminating them to form a heat insulating substrate;
  A step of forming a concave portion on the surface of the heat-insulating base material with a roll-shaped and / or rod-shaped heater in accordance with a position where the column is fitted,
  A method of manufacturing a heat insulating material, comprising: a step of heating and curing a heat insulating base material in which a concave portion is formed by a heating device.

The method for manufacturing a heat insulating material according to claim 1, further comprising a step of covering the moisture-proof sheet on at least one surface of the heat insulating base material.