JP4371943B2 - Insulating panel manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a heat insulating panel, and more specifically, in a space formed by a pair of surface plates and a frame member mounted between side portions of both surface plates, and having 5 carbon atoms. The present invention relates to a method for manufacturing a heat insulating panel formed by injecting and filling foam heat insulating material such as foamed urethane foam using saturated hydrocarbons.

Conventionally, in this type of panel manufacturing method, there is known a method in which a polyol-based stock solution containing a foaming agent and a polyisocyanate-based stock solution are mixed, and this mixed composition is injected between a pair of face plates to be foamed and filled. It has been. In this manufacturing method, CC1 ₃ F Freon was used as a foaming agent, but since CC1 ₃ F Freon is the main cause of “ozone hole”, its use is prohibited.

Instead of the above-mentioned CC1 ₃ F Freon, C ₂ H ₃ FCl ₂ (CCl ₂ F—CH ₃ ) Freon, which hardly destroys ozone, has been used, but now it is prohibited to use.

  Other alternative blowing agents include fluorine-containing hydrocarbons or hydrocarbons. Of these, fluorine-containing hydrocarbons do not destroy ozone, but are causative substances for global warming and are not suitable for use. On the other hand, hydrocarbons do not destroy ozone and are not caused by global warming, but those with low boiling points may ignite or explode.

  Therefore, as a means for solving the above problems, high-boiling hydrocarbons, particularly saturated hydrocarbons having 5 carbon atoms, are used as substitute blowing agents for Freon.

  However, the alternative foaming agent composed of saturated hydrocarbons having 5 carbon atoms is flammable, unlike conventional fluorocarbon foaming agents, so that the foaming agent vaporized inside the panel and the air inside the panel during the panel manufacturing process. There is a risk of explosion in the panel during foaming.

For this reason, conventionally, a foam heat insulating material is foamed while supplying an inert gas into the panel during foaming / injection (see, for example, Patent Document 1).
JP-A-7-96528 (Claims)

  However, in the conventional method for manufacturing a heat insulation panel, since the foam heat insulating material is injected while supplying an inert gas into the panel, the injection speed and the injection amount of the foam heat insulating material are significantly reduced by the inert gas, There was a problem that the production efficiency was lowered.

  This invention has been made in view of the above circumstances, and uses a foaming agent that does not cause environmental destruction such as ozone layer destruction and global warming, but is flammable and requires careful handling. It is an object of the present invention to provide a method for manufacturing a heat insulating panel capable of improving the production efficiency.

In order to solve the above problems, the invention according to claim 1 is formed of a pair of surface plates, a frame member mounted between the side portions of the both surface plates, and the both surface plates and the frame member. A heat insulating panel manufacturing method comprising a foamed heat insulating material using a saturated hydrocarbon having 5 carbon atoms injected and filled into a space as a foaming agent, wherein the above table is formed in a treatment temperature atmosphere for foaming the foamed heat insulating material. Installing and holding the panel assembled with the face plate and the frame material, injecting an inert gas having a temperature lower than the processing temperature into the space of the panel and replacing the space with the inert gas, and the inert gas. After the step of replacing, the step of injecting and filling the foamed heat insulating material into the space is provided.

  In the present invention, it is preferable that a plurality of panels are stacked in advance and the inert gas is injected into the space of the stacked panels before the inert gas replacement step.

In addition, a plurality of panels in which the surface plate and the frame material are combined are stacked, and at that time, a surface plate is inserted between the panels, and the height between the surface plates is greater than the thickness of the panel. It is preferable that the spacer is disposed and that the difference between the spacer height and the panel thickness is 0.1 mm or more and less than 1.0 mm . The reason is that if the difference is less than 0.1 mm, there is a possibility that a gap is hardly formed between the surface plate and the frame member, and the gas cannot be discharged to the outside, and the difference is 1.0 mm or more. When there is a gap, there is a risk that the surface plate and the frame material will be displaced and the shape of the formed panel may collapse, and the foaming agent will leak out from the gap when the foaming agent is injected and filled. .

Further, it is preferable to provide a gas vent hole in the corner portion of the frame member in the panel, and to discharge the gas generated by the injection of the inert gas used for replacement and the foam heat insulating material from the gas vent hole. Item 4 ).

Further, while injecting an inert gas into the space from the hole provided on the frame member in the panel, it is better to inject the foam insulation preferably (claim 5). In this case, a thin film material having flexibility is provided on the space portion side of the frame material so as to close the injection hole for the inert gas and the foam heat insulating material, and only the lower part of the film material is provided on the frame material. bonded is provided, when the foam insulation is foamed-filled in the space, who closes the hole by the film material is preferably (claim 6).

In addition, the saturated hydrocarbon having 5 carbon atoms can be cyclopentane (Claim 7 ), and the inert gas can be nitrogen gas (Claim 8 ).

(1) According to the invention described in claims 1, 7 and 8, the panel space is inert before being injected and filled with the foam heat insulating material containing a saturated hydrocarbon having 5 carbon atoms as the blowing agent. Since the gas is injected and the space is replaced with the inert gas, the inert gas can be replaced in a short time. Furthermore, by making the temperature of the inert gas lower than the processing temperature for foaming the foam heat insulating material, it is possible to prevent air from entering the panel space from the outside due to the expansion of the inert gas after replacement. . Therefore, heat insulation panel using foaming agent that prevents mixing of oxygen and foaming agent in the panel space, does not cause environmental destruction such as ozone layer destruction and global warming, but is flammable and requires careful handling. In manufacturing, it is possible to improve the safety and production efficiency.

  (2) According to the invention described in claim 2, before the inert gas replacement step, by stacking a plurality of panels in advance and injecting the inert gas into the space of the stacked panels, After replacing the plurality of panels with inert gas in a state where they are held by their own weight without being caused by external force, it is possible to inject and foam the foam insulation. Therefore, the second and subsequent panels from the top are pressed by the upper panel, and the swelling and detachment of the surface plate due to the internal pressure of the panel caused by the inert gas replacement and the foaming insulation material injection process at a high flow rate are performed. In addition, the heat insulation panel can be manufactured easily and efficiently.

(3) According to the invention described in claim 3, each panel is pressed not only by the panel but also by the weight of the surface plate and the spacer, and the inert gas replacement and the foaming insulating material injection process are performed at a higher flow rate. It can be carried out. Furthermore, by setting the height of the spacers arranged between the surface plates to be equal to or greater than the thickness of the panel, it is the spacers that support the weight of the panels after they are laid flat. Only when the panel is swelled by the internal pressure in the process of injecting the active gas and injecting the foam heat insulating material, the number of panels that can be stacked can be increased and the working efficiency can be improved. In addition, when an expansion is caused by the internal pressure generated during the inert gas replacement and the foam heat insulating material injection, an appropriate gap is generated between the surface plate and the frame member, whereby the gas inside the panel can be released to the outside. In this case, by the difference in thickness of the height and the panel of the spacer smaller than 1.0mm or 0.1 mm, it is possible to effectively discharge the gas inside the panel, it is possible to prevent deformation of the panel .

(4) According to the invention described in claim 4 , gas is generated by injecting a gas vent hole at the corner portion of the frame member in the panel and injecting an inert gas and a foam heat insulating material used for replacement from the gas vent hole. Can be prevented from being deformed by an inert gas, and the quality of the heat insulation panel can be improved.

(5) According to the invention described in claim 5, the inert gas is injected into the space from the hole provided in the frame member of the panel and the foamed heat insulating material is injected, so that the injection hole is also used as a non-injection. Active gas and foam insulation can be injected. Therefore, it is possible to inject and fill the foam heat insulating material after replacing the space in the panel with the inert gas only by providing the minimum necessary injection holes in the frame material of the panel. In this case, a thin film material having flexibility is provided on the space portion side of the frame material so as to close the injection holes for the inert gas and the foam heat insulating material, and only the lower part of the film material is adhered to the frame material. When the foam insulation material is foamed and filled in the space, the pores are blocked by the membrane material, thereby preventing the foam insulation from being exposed to the outside and improving the appearance of the panel. (Claim 6 ).

  Hereinafter, the best embodiment of a method for manufacturing a heat insulation panel according to the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a schematic cross-sectional view showing an example of a flat stacked state of heat insulating panels in the method for manufacturing a heat insulating panel according to the present invention, FIG. 2 is an enlarged cross-sectional view of the main part of FIG. 1, and FIG. FIG. 4 is an enlarged cross-sectional view taken along line II in FIG. 3 (a), and FIG. 5 (b) is a cross-sectional view of the main part of the heat insulation panel. FIG. 6 is a flowchart showing the manufacturing process of the heat insulation panel, and FIG. 7 is a schematic plan sectional view (a) showing the replacement state of the inert gas in the manufacturing process of the heat insulation panel and the schematic plan view showing the injection state of the foam heat insulating material. It is sectional drawing (b).

  As shown in FIGS. 3 to 5, the heat insulation panel P includes a pair of surface plates 10 made of steel plates, and a straight frame material 20 made of plastic, for example, made of vinyl chloride, which is mounted between the side portions of both surface plates 10. And the corner frame member 21 and the foam heat insulating material 40 injected and filled in the space 30 formed by the both surface plates 10 and the frame members 20 and 21.

  In this case, the bent pieces 11 bent at the side portions of the surface plate 10 have a slight gap in the fitting grooves 22 provided at the upper and lower ends of the straight frame member 20 and the corner frame member 21, respectively. The surface plate 10 and the frame members 20 and 21 are fixed by being inserted.

  Further, the side surface of the straight frame member 20 is provided with a concave portion or a convex portion (indicated in the drawing, the concave portion 23) provided for joining the heat insulating panels P to each other. The concave line portion 23 is formed in a tapered shape in which the opening side is expanded. In addition, when providing a protruding item | line part, the front-end | tip is formed in a narrow taper shape.

An insulative gas, for example, nitrogen (N ₂ ) gas and an injection hole 25 for the foam heat insulating material 40 are provided in the bottom 24 of the recess 23 in the middle of the straight frame member 20 configured as described above. Yes. Further, on the space side, that is, the inner side of the straight frame member 20, a flexible thin film member 50 is disposed so as to close the injection hole 25. This film material 50 is formed of, for example, a paper material, and only the lower part thereof is bonded to the straight frame member 20 with, for example, an adhesive 51 so that the upper end side can be freely displaced ( (See FIG. 4). Therefore, when N ₂ gas which is an inert gas is injected into the space 30 or when the foam heat insulating material 40 is injected, the N ₂ gas is supplied into the space 30 of the heat insulation panel P through the injection holes 25. When use nozzles 60 or foam insulation supply nozzle 70 is inserted, film material 50, as indicated by two-dot chain lines in FIG. 4 (a), N ₂ gas or displaced inwardly of the space 30 Allows injection of foam insulation 40. When the foam heat insulating material 40 is injected and foamed / filled, the foam heat insulating material 40 is filled from below, so that the membrane material 50 is pushed from the lower side by the foam heat insulating material 40 to open the injection hole 25. It is blocked (see FIG. 5). Thereby, exposure to the exterior of the foam heat insulating material 40 is prevented.

Further, the side surface of the corner frame member 21 is provided with a concave strip portion or a convex strip portion (showing the concave strip portion 23 </ b> A in the drawing) connected to the concave strip portion or the convex strip portion provided in the straight frame member 20. Yes. Similarly to the concave strip portion 23 of the straight frame member 20, the concave strip portion 23A is also formed in a tapered shape in which the opening side is expanded. Each corner frame member 21 is provided with a gas vent hole 26. By providing the vent holes 26 in the corner frame member 21 in this way, N ₂ gas injected into the space of the heat insulating panel P is uniformly supplied into the space 30 and the space 30 is replaced with N ₂ gas. After that, the N ₂ gas used for replacement can be discharged to the outside from the gas vent hole 26, and the gas generated when the foam heat insulating material 40 is injected into the space 30 can be discharged to the outside. . Therefore, the swelling and detachment of the surface plate 10 due to the panel internal pressure can be prevented.

  On the other hand, the foam heat insulating material 40 is formed of a mixed composition of a polyol-based stock solution having water, a polyisocyanate-based stock solution, and a saturated hydrocarbon having 5 carbon atoms such as cyclopentane as a foaming agent. The foam heat insulating material 40 formed in this way is injected and filled into the space 30 of the heat insulating panel P from the foam heat insulating material supply nozzle 70 connected to a mixing device (not shown).

  The polyol stock solution is prepared by mixing and preparing a polyol (polyhydric alcohol), a foam stabilizer, a flame retardant, and other auxiliary agents. Of these, polyol is a raw material that has the greatest influence on the properties of polyurethane foam. Further, the foam stabilizer makes the bubbles uniform or stable and is formed of, for example, a silicon-based surfactant. The catalyst is an auxiliary agent used to promote various reactions during the formation of polyurethane foam, and to produce a foam suitable for the purpose while balancing resination and foaming. For example, a tertiary amine, an organic tin compound or Metal salts of organic acids are used. In addition, flame retardants are used to make foams flame retardant. Phosphoric acid esters and halogenated phosphoric acid esters are used as additive-type flame retardants, and inorganic compounds such as aluminum hydroxide are used to further increase flame retardancy. Are used together. In addition, for example, a crosslinking agent, a colorant, a filler, a stabilizer, or a plasticizer is used as another auxiliary agent used as necessary.

  The foaming agent is a gas source at the time of molding, and has cyclopentane and water, which are alternative chlorofluorocarbons. The foaming pressure can be adjusted by appropriately selecting the ratio of this cyclopentane and the carbon dioxide (CO2) produced by the reaction of water and isocyanate.

  On the other hand, the polyisocyanate-based stock solution is prepared by mixing and preparing polyisocyanate and other auxiliary agents such as a surfactant.

  Next, an example of a procedure for manufacturing the heat insulation panel will be described with reference to the flowcharts shown in FIGS. 1, 2, 7, and 6.

First, as shown in FIG. 1, the temporary assembly panel P0 in which the straight frame member 20 and the corner frame member 21 are mounted between the side portions of the pair of surface plates 10 is placed between the lower base board 80 and the upper base board 81. The aluminum base plate 82 (hereinafter referred to as the flat plate 82) covered with vinyl chloride and the aluminum spacer 83 are stacked in a multistage manner, and are projected from the lower base plate 80 and the upper base plate 81. The flanges 84 and 85 are fixed by the connecting bolt 86 and the nut 87 (step 6-1). The reason why the surface of the flat plate 82 is coated with vinyl chloride is to prevent the surface of the flat plate 82 from being damaged by contact with the temporary assembly panel P0. After the temporary assembly panels P0 are stacked in this manner, the temporary assembly panels P0 stacked in multiple stages are loaded into the processing chamber 100. The processing temperature atmosphere in the processing chamber 100 is set to about 35 ° C. At this time, the height dimension of the spacer 83 is appropriately changed according to the thickness dimension of the heat insulating panel P to be manufactured. In this case, the flat plate 82 is made larger than the surface plate 10 of the temporary assembly panel P0, and the height of the spacers 83 arranged between the flat plates 82 is slightly higher than the thickness of the temporary assembly panel P0, and the difference between them. Gap S is provided. In this case, the gap S, it is better to set the less than 0.1 mm 1.0 mm. Here, the lower base board 80 and the upper base board 81 are fixed by connecting bolts 86 and nuts 87. However, the upper base board 81 does not hold down the uppermost temporary assembly panel P0, and a plurality of temporary assemblies. The panels P0 may be stacked.

Next, the temporarily assembled temporary panel P0 is moved horizontally by a moving mechanism (not shown) to adjust the position of the injection hole 25 and the N ₂ gas supply nozzle 60 (step 6-2). In this case, it is possible to align the injection openings 25 and N ₂ gas supply nozzle 60 by moving the N ₂ gas supply nozzle 60 only in the vertical direction. Then, FIG. 7 (a), the injection hole 25 to insert the _{N 2} gas supply nozzle 60, injected _{N 2} gas under the processing temperature in the space 30 of the temporary assembly panel P0, space 30 Is replaced with N ₂ gas (step 6-3). In addition, the supply amount of N ₂ gas at this time is 1000 L / min or more. At this time, since the N ₂ gas is at a temperature lower than the processing temperature, that is, lower than 35 ° C., after being injected into the panel space 30, the N ₂ gas expands and actively prevents air from entering the space 30 from the outside. be able to. The N ₂ gas used for the replacement is discharged to the outside through the gas vent hole 26 provided in the panel corner portion, that is, the corner frame member 21. Thereby, the swelling and detachment of the surface plate 10 due to the panel internal pressure are prevented. At this time, in the case where the upper part of the uppermost temporary assembly panel P0 is not pressed, N ₂ gas is not injected into the space 30 of the uppermost temporary assembly panel P0, but immediately before the injection of the foam insulation 40 described later. Inject N ₂ gas manually. The pressing of the temporary assembly panel P0 is performed by an air bag when the temporary assembly panel P0 is moved to a place where the foaming heat insulating material 40 is injected.

Next, the temporary assembly panel P0 that has been stacked and replaced with N ₂ gas is moved horizontally by a moving mechanism (not shown) to adjust the position of the injection hole 25 and the foam insulation supply nozzle 70 (step 6). -4). At this time, the foam heat insulating material supply nozzle 70 can be moved only in the vertical direction to align the foam heat insulating material supply nozzle 70 with the injection hole 25. And as shown in FIG.7 (b), the foam heat insulating material supply nozzle 70 is inserted in the hole for injection | pouring, and the foam heat insulating material 40 {specifically, it has the said water in the space 30 of temporary assembly panel P0. A polyol-based stock solution, a polyisocyanate-based stock solution, and a mixed composition of cyclopentane as a foaming agent} are injected, foamed and filled (step 6-5). The gas generated in the step of injecting the foam heat insulating material 40 is discharged from the gas vent hole 26 to the outside. Thereby, the swelling and detachment of the surface plate 10 due to the panel internal pressure are prevented.

  In the step of injecting the foam heat insulating material 40, the polyol stock solution, the polyisocyanate stock solution, and the cyclopentane are respectively weighed in a predetermined ratio, for example, cyclopentane: polyol stock solution: polyisocyanate stock solution, for example, 5 After mixing at a ratio of 5: 75: 100, the pressure is adjusted to a predetermined pressure, supplied to the mixing device, stirred and mixed at a predetermined ratio by the mixing device, and then the mixed composition is supplied to the foam insulation. It inject | pours between a pair of surface boards 10 arrange | positioned from the nozzle 70 at appropriate intervals, it foams, and it hardens | cures after that, and a heat insulating material (foam | foam) is shape | molded. In addition, it is more preferable to set the processing temperature atmosphere (room temperature in the processing chamber 100) at the time of injection | pouring of a mixed composition to the foaming temperature (for example, 35 degreeC).

  In addition, since it is necessary to inject | pour the optimal quantity of foam heat insulating materials 40 according to the height dimension of the heat insulation panel P which is a different dimension, ie, the temporary assembly panel P0, the dimension of the heat insulation panel P previously set, ie, the temporary assembly panel P0. A predetermined amount of foam heat insulating material 40 is injected into the space 30 from the foam heat insulating material supply nozzle 70 based on a control signal that stores information on the height dimension and panel temperature, for example, a control signal from a central processing unit (CPU). . Or, when temporarily assembling the temporary assembly panel P0, for example, according to the dimension of the heat insulation panel P (the height dimension of the temporary assembly panel P0) on each flat plate 82 or the straight frame member 20 on which the temporary assembly panel P0 is stacked. A bar code is provided, for example, a bar code, and before injecting the foam insulation 40, the panel temperature is detected by a temperature sensor, the bar code information is read, and the detection signal is transmitted to the CPU. The CPU compares the detection signal with information stored in advance, sends the control signal to a foaming machine (not shown), and sends a predetermined amount of foam insulation 40 from the foam insulation supply nozzle 70 to the space 30. Inject into.

  As described above, the foam heat insulating material 40 is injected into the space 30 of the temporary assembly panel P0, foamed and filled, and then waited for about 2 to 5 minutes (step 6-6). During this standby, leakage of cyclopentane to the outside of the panel that occurs after foaming and filling of the foam heat insulating material 40 into the panel exists only at the place where the injection process is performed. Therefore, by providing various safety equipment such as exhaust equipment, static electricity removal equipment, and combustible gas detection equipment (not shown) at the place where the injection process is performed, high safety of the entire panel manufacturing equipment can be maintained. And after foaming and filling, after waiting for about 2-5 minutes and confirming safety, the produced heat insulation panel P is carried out to a predetermined place.

It is a schematic sectional drawing which shows an example of the flat stacked state of the heat insulation panel in the manufacturing method of the heat insulation panel which concerns on this invention. It is a principal part expanded sectional view of FIG. It is a perspective view which shows an example of the heat insulation panel in this invention. FIG. 4 is an enlarged cross-sectional view (a) taken along line II of FIG. 3 and a view (b) taken along line II in (a). It is principal part sectional drawing of a heat insulation panel. It is a flowchart which shows the manufacturing process of a heat insulation panel. It is a schematic plane sectional view (a) which shows the substitution state of the inert gas in the manufacturing process of a heat insulation panel, and a schematic plane sectional view (b) which shows the injection | pouring state of a foam heat insulating material.

Explanation of symbols

P Insulation panel P0 Temporary assembly panel S Gap 10 Surface plate 20 Straight frame member 21 Corner frame member 25 Injection hole 26 Gas vent hole 30 Space 40 Foam insulation material 50 Film material 100 Processing chamber

Claims (8)

A pair of surface plates, a frame member mounted between the side portions of the both surface plates, and a saturated hydrocarbon having 5 carbon atoms injected and filled into a space formed by the both surface plates and the frame member. A method for producing a heat insulating panel comprising a foam heat insulating material as a foaming agent,
A panel assembled with the surface plate and the frame material is installed and held in a processing temperature atmosphere for foaming the foam heat insulating material, and an inert gas lower than the processing temperature is injected into the space of the panel. Replacing with an inert gas;
After the step of replacing with the inert gas, the step of injecting and filling the foam insulation into the space;
The manufacturing method of the heat insulation panel characterized by having. In the manufacturing method of the heat insulation panel of Claim 1,
Prior to the inert gas replacement step, a plurality of panels are stacked in advance, and the inert gas is injected into the space of the stacked panels. In the manufacturing method of the heat insulation panel of Claim 1 or 2,
A plurality of panels in which the surface plate and the frame material are combined, and a surface plate is inserted between the panels, and a spacer having a height greater than the thickness of the panel is interposed between the surface plates. A method for manufacturing a heat insulating panel, wherein the difference between the height of the spacer and the thickness of the panel is 0.1 mm or more and less than 1.0 mm. In the manufacturing method of the heat insulation panel in any one of Claim 1 thru | or 3,
A heat insulating panel characterized in that a gas vent hole is provided in a corner portion of the frame material in the panel, and an inert gas used for replacement and a gas generated by injection of the foam heat insulating material are discharged from the gas vent hole to the outside. Manufacturing method. In the manufacturing method of the heat insulation panel in any one of Claim 1 thru | or 4,
The manufacturing method of the heat insulation panel characterized by inject | pouring an inert gas in a space from the hole provided in the frame material in the said panel, and inject | pouring a foam heat insulating material. In the manufacturing method of the heat insulation panel of Claim 5,
A thin film material having flexibility is provided on the space portion side of the frame material so as to close the injection hole for the inert gas and the foam heat insulating material, and only the lower part of the film material is adhered to the frame material. A method for manufacturing a heat insulating panel, comprising: providing the foamed heat insulating material in the space and filling and filling the space with the film material. In the manufacturing method of the heat insulation panel in any one of Claim 1 thru | or 6,
The method for producing a heat-insulating panel, wherein the saturated hydrocarbon having 5 carbon atoms is cyclopentane. In the manufacturing method of the heat insulation panel in any one of Claim 1 thru | or 6,
The method for manufacturing a heat insulating panel, wherein the inert gas is nitrogen gas.

Images