JP4665064B2 - Heat insulator - Google Patents

Description

The present invention, which by forming a plurality of convex portions, to a heat insulator suitably used particularly in the insulation, such as catalytic converters and mufflers of motor vehicles.

  For example, since a heat insulator is often installed in an empty space below the vehicle floor of an automobile, the bead cannot be sufficiently protruded to avoid interference with a fuel tube or the like, or the bead is placed on the entire plate surface. Since it may not be formed, it is common to ensure rigidity by increasing the thickness of the heat insulator. It is also known to form irregularities in order to increase rigidity (see Patent Document 1).

Japanese Patent Laid-Open No. 2002-60878

However, even if rigidity can be ensured, it cannot be said to be sufficient in terms of heat insulation and vibration resistance .

Therefore, the present invention solves such problems, and an object of the present invention is to provide a heat insulator that is excellent in heat insulation, vibration resistance, and the like while ensuring rigidity .

For this reason, the present invention is a heat insulator formed with a large number of convex portions, and the two plate bodies are interspersed with at least two or more types of convex portions on the two plate bodies. A material corresponding to the purpose is interposed therebetween, and one type of convex portion of two or more types of convex portions is formed to improve rigidity, and at least two of the one plate body are formed. By fitting and joining the other types of convex portions of the other plate to the other types of convex portions of the above-mentioned types of convex portions, the other types of convex portions of the other plate body as described above 2 It is characterized by joining the plate bodies.

The present invention can provide a heat insulator excellent in heat insulation and vibration resistance while ensuring rigidity .

It is a perspective view of the heat insulator in the state where the convex part is not formed. It is a fragmentary perspective view of the heat insulator after forming the convex part of a 1st embodiment. It is a fragmentary top view of the heat insulator after forming the convex part of a 1st embodiment. It is a partial vertical side view of a heat insulator. It is a fragmentary perspective view of the heat insulator after forming the convex part of a 2nd embodiment. It is a fragmentary top view of the heat insulator after forming the convex part of a 2nd embodiment. It is a partial vertical side view of the heat insulator of the four-layer structure which is 3rd Embodiment.

  Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. In the first embodiment, a heat insulator that can be suitably used for heat insulation of a catalytic converter, a muffler and the like of an automobile among composite materials formed with a large number of convex portions will be described as an example. 1 is a perspective view of the heat insulator 1 in a state where the convex portions 2A and 2B are not formed, FIG. 2 is a partial perspective view of the heat insulator 1 after forming the convex portions 2A and 2B, and FIG. It is a partial top view of the heat insulator 1 after forming 2B.

  The heat insulator 1 is particularly suitable for heat insulation of catalytic converters and mufflers of automobiles, and is formed by laminating two rectangular aluminum plates 1A and 1B and forming them upward in a mountain shape. A plurality of beads 3 having a predetermined width project from the plate surface at intervals in the longitudinal direction so as to cross the plate surface. Except for the side edges 4 and 5 formed along both sides of the heat insulator 1, a large number of convex portions 2 </ b> A and 2 </ b> B projecting upward are formed on most of the plate surface of the heat insulator 1. Yes. The heat insulator 1 is attached to the vehicle body by inserting a bolt into a mounting hole 5B formed in the vertical piece 5A of the one side edge 5.

Next, a method for manufacturing the heat insulator 1 will be described. First, two aluminum plates 1A and 1B are stacked and set in a press mold apparatus to form a large number of convex portions 2A and 2B. To do. Although the convex portion 2A has a regular hexagonal shape in plan view, the vertical section passing through the apex forming the diagonal has an arc shape, and the convex portion 2B is the center of the flat plate portion 2C. It is formed in the part and has a cylindrical shape.

In this case, in the present embodiment, the two protrusions 2A and 2B are formed by press molding while feeding the two sheets 1A and 1B sequentially or collectively and simultaneously the two sheets 1A and 1B. The two plate bodies 1A and 1B are joined by fitting and joining one kind of convex portions 2B to each other . In this case, after forming one convex portion 2A or 2B while sequentially feeding, You may make it press-mold the other convex part 2B or 2A. Rigidity can also be increased by joining the one type of convex portions 2B.

  Then, the heat insulator 1 is formed with different thickness lamination, the upper plate body 1A has a thickness of 0.125 mm, and the lower plate body 1B has a thickness of 0.3 mm, as shown in FIG. The width W1 of the convex portion 2A is 10 mm to 16 mm, the base width W2 is 11 mm to 17 mm, the planar dimension (C / 2) is 1 mm, and the height H of the convex portion 2A is the height H of the convex portion. / The width of the protrusions 2A is set to 1.2 mm to 3.2 mm so that the width W1 of the protrusions is 12% to 20%, and the interval between the protrusions 2A that is twice the plane dimension (C / 2) It is 75% or less of W2.

  And as shown in FIG. 3, the convex part 2B is the same as the convex part 2A, for example, the base width W2 is the center part of the flat plate part 2C which has 11-17 mm, for example, is 4 mm in diameter, and is the same as the height of the convex part 2A. Form to height.

  The arrangement of the convex portions 2A and 2B is as shown in FIG. 3, but more specifically, two convex portions 2A having a regular hexagonal shape in plan view are vertically arranged at intervals of a dimension C. Then, an arrangement pattern in which a cylindrical convex portion 2B is formed at the central portion of the same hexagonal flat plate portion 2C at the lower position is repeatedly formed in the vertical direction. Then, the arrangement pattern is repeatedly formed on the left and right sides of the arrangement pattern at positions where the projections 2A are shifted by one half.

The convex portion 2B is joined with the lower plate 1B protruding over the upper plate 1A, and a cylinder in which, for example, a round punch portion becomes a die portion at a downstream position in the press die apparatus. The plate bodies 1A and 1B are pushed into the grooves, and an interlock is formed in a state in which the lower plate body 1B protrudes from the upper plate body 1A by further pressurization. Thus , the two plate bodies 1A and 1B are joined at the convex portion 2B portion in such a manner that the convex portion 2B of the plate body 1B is fitted to the convex portion 2B of the plate body 1A. The part 2B is formed so that the upper edge peripheral part 2BB protrudes upward, and rigidity is achieved.

  Next, based on FIG. 5 which is a partial perspective view of the heat insulator 1 after forming the convex portions 20A and 20B and FIG. 6 which is a partial plan view of the heat insulator 1 after forming the convex portions 20A and 20B, A second embodiment will be described. The arrangement pattern of the convex portions 20A and 20B formed on the heat insulator 1 is the same as that of the first embodiment, but the convex portion 20A has a circular shape in plan view, and a vertical cross section has an arc shape. The convex portion 20B is formed in the central portion of the flat plate portion 20C and has a cylindrical shape.

  However, in the second embodiment, similarly to the first embodiment, the width W3 of the convex portion 20A is set to 10 mm to 16 mm, the base width W2 is set to 11 mm to 17 mm, and the plane dimension (C / 2). Is 1 mm, and the height H of the convex portion 20A is 1.2 mm to 3.2 mm so that the height H of the convex portion / the width W3 of the convex portion is 12% to 20%. The interval between the convex portions 20A that is twice C / 2) is 75% or less of the base width W4.

  When the protrusions 2A, 2B, 20A, and 20B are formed as in the first and second embodiments described above, even a single 0.3 mm-thick aluminum plate is made of 0.5 mm-thick aluminum. The rigidity equal to or higher than that of the plate body can be exhibited. Therefore, in the heat insulator 1, even when the beads cannot be sufficiently projected or when the beads cannot be formed on the entire plate surface, the heat insulator 1 is formed by forming the convex portions 2A, 2B, 20A, 20B. The required rigidity can be ensured without increasing the plate thickness, and an increase in weight and an increase in cost can be avoided. In particular, if the flat plate portion is not left in a straight line between the convex portions, the dynamic directionality is lost, and the rigidity can be greatly improved. Moreover, rigidity is further improved by the convex parts 2B and 20B formed in the flat plate parts 2C and 20C.

As in the first embodiment, the convex portion 20B is joined with the lower plate projecting over the upper plate. For example, the round punch portion is joined to the cylindrical groove serving as the die portion. The interlock is formed in a state in which the plate is pushed in and the lower plate projects from the upper plate by further pressurization. As a result, the two plate bodies are joined at the convex portion 20B portion in such a manner that the convex portion 20B of the lower plate body is fitted to the convex portion 20B of the upper plate body. 20B is formed so that the peripheral edge of the upper end protrudes upward, and rigidity is achieved.

  Moreover, the heat insulator 1 which is particularly excellent in heat insulation and vibration resistance can be provided by stacking the two plates with different thicknesses. In addition, according to the above embodiment, the area ratio which the said convex part 2B (or 20B) including the flat plate part 2C (or 20C) occupies is a half of the convex part 2A (or 20A), Comprising: By reducing the area ratio occupied by the convex portions 2B (or 20B), the rigidity can be further increased.

In the first and second embodiments described above, the heat insulator 1 is manufactured by laminating two plates, but a four-layer structure or a three-layer structure may be used instead of such a two-layer structure. First, based on FIG. 7, the four-layer structure according to the third embodiment will be described. An inorganic binder 31 as an adhesive is attached to the back surface (inner surface) of a plate body 10A having a thickness of 0.35 mm made of aluminum. A thickness of 0.05 mm is applied, and an inorganic powder 32 having a low thermal conductivity (excellent in heat insulation performance) is attached to a thickness of 0.1 mm on the back surface (inner side surface) of the plate 10A to which the inorganic binder 31 is applied. This inorganic powder 32 is excellent in heat insulation, lightweight, low density (density is 0.03 g / cm ³ or more to 0.1 cm ³ ), nonflammable, for example, silica powder (silica fine particles) having a particle size of 100 μm or less. However, other inorganic powders may be used. In the present embodiment, the inorganic binder 31 uses a water slurry of silica fine particles having a particle diameter of 100 nm or less, for example, which can form a particularly heat-resistant coating film.

Then, one plate body 10A is processed as described above, and this one plate body 10A and the other plate body 10B made of aluminum having a thickness of 0.35 mm are combined with a press mold apparatus and are fed in little by little. However, the vertical section passing through the apexes forming a diagonal shape in the plan view has a circular arc shape, or the convex section 33A and the cylindrical convex section 33B in which the vertical section has a circular shape and the vertical section has an arc shape. Press molding. And in the downstream position in this press die apparatus, plate body 10A, 10B is pushed into the cylindrical groove | channel where a round punch part becomes a die part, and lower plate body 10B is made into upper plate body 10A by further pressurization. An interlock is formed in an overhanging state. Thus , the two plate bodies 10A and 10B are joined at the convex portion 33B portion in such a manner that the convex portion 33B of the plate body 10B is fitted to the convex portion 33B of the plate body 10A. The part 33B is formed so that the upper end peripheral edge part 33BB protrudes upward, thereby achieving rigidity.

  The convex portions 33A and 33B of the third embodiment are formed on the two plate bodies 10A and 10B with the same arrangement pattern and size as the convex portions 2A and 2B and 20A and 20B of the first and second embodiments. It is formed. The flat plate portion 33C is also formed on the two plate bodies 10A and 10B with the same arrangement pattern and size as the 2C and 20C of the first and second embodiments.

  Thus, the heat insulator 1 which was further excellent in heat insulation and vibration resistance can be provided by interposing a material with low thermal conductivity between the two plates 10A and 10B. According to the theoretical calculation value, when the temperature of the heat source is 400 ° C., the surface temperature of the heat insulator 1 is about 26 ° C., and a considerable heat insulating performance is exhibited.

Next, the fourth embodiment will be described. In the fourth embodiment, instead of the inorganic powder 32 in the third embodiment described above, the particle size is low in thermal conductivity (excellent in heat insulation performance). Is a form using granular hollow ceramic beads of 20 μm to 75 μm. The hollow ceramic beads is excellent in heat insulating properties, (～0.42Cm ³ hereinafter density 0.25 g / cm ³ or higher) Lightweight hollow, having heat resistance (melting point 1600 ° C.).

First, a granular hollow ceramic bead 34 having a low thermal conductivity is attached to the back surface (inner surface) of the plate 10A coated with the inorganic binder 31 with a thickness of 0.1 mm, and the one plate 10A and the other plate 10A. The two convex portions 33A and 33B are press-molded while being sequentially fed to the body 10B with a press die device, and a cylinder in which the round punch portion becomes a die portion at a downstream position in the press die device. The plate bodies 10A and 10B are pushed into the grooves, and the interlock is formed in a state in which the lower plate body 10B protrudes from the upper plate body 10A by further pressurization. Thus , the two plate bodies 10A and 10B are joined at the convex portion 33B portion in such a manner that the convex portion 33B of the plate body 10B is fitted to the convex portion 33B of the plate body 10A. The part 33B is formed so that the upper end peripheral edge part 33BB protrudes upward, thereby achieving rigidity.

  According to the theoretical calculation value, the surface temperature of the heat insulator 1 of the fourth embodiment manufactured in this way is about 52 ° C. when the temperature of the heat source is 400 ° C., and exhibits a considerable heat insulating performance. To do.

Next, in place of the inorganic powder 32 and the hollow ceramic beads 34 in the third and fourth embodiments, the thermal conductivity is low (excellent in heat insulation performance), and the thickness is 0.025 mm excellent in adhesion and heat resistance. A fifth embodiment using the polyimide film will be described below. This fifth embodiment does not use inorganic powder or hollow ceramic beads. That is, the convex portions 33A and 33B are press-molded while the polyimide film is interposed between the one plate body 10A and the other plate body 10B while being sequentially fed together by a press mold apparatus. At the downstream position in the press mold apparatus, the plate body 10A, 10B is pushed into the cylindrical groove where the round punch portion becomes the die portion, and the lower plate body 10B is moved to the upper plate body 10A by further pressurization. An interlock is formed in an overhanging state. Thus , the two plate bodies 10A and 10B are joined at the convex portion 33B portion in such a manner that the convex portion 33B of the plate body 10B is fitted to the convex portion 33B of the plate body 10A. The part 33B is formed so that the upper end peripheral edge part 33BB protrudes upward, thereby achieving rigidity.

  According to the theoretical calculation value, the surface temperature of the heat insulator 1 of the fifth embodiment manufactured as described above is about 158 ° C. when the temperature of the heat source is 400 ° C., and exhibits a considerable heat insulating performance. To do.

  In the sixth embodiment in which the heat insulation performance is further improved, the heat insulator 1 is manufactured using a polyimide film having a thickness of 0.125 mm. The surface temperature of the heat insulator 1 is calculated according to theoretical calculation values. When the temperature of the heat source is 400 ° C., the temperature is about 59 ° C., and the heat insulation performance exceeding that of the fifth embodiment is exhibited.

  In addition, the surface temperature of the heat insulator 1 according to the theoretical calculation value is not a heat insulator 1 having a structure of two or more layers as described above, but a single layer structure with a plate made of aluminum having a thickness of 0.35 mm. When the temperature of the heat source is 400 ° C., the surface temperature of the heat insulator 1 is about 388 ° C. in a two-layer structure of two plates having a thickness of 0.35 mm made of aluminum. Further, in a three-layer structure of three plates made of aluminum and having a thickness of 0.35 mm, the surface temperature of the heat insulator 1 is also about 386 ° C., and the heat insulation performance is inferior.

  In addition, according to the above embodiment, two types of convex portions are formed on a pair of plate bodies and at least one type of convex portion is joined, but three or more types of convex portions are formed. In addition, not only the shape, size, arrangement pattern, etc. of the protrusions described in the above embodiment, various forms are conceivable, and in particular, the arrangement (position) and number of protrusions to be joined should be selected appropriately. The intended purpose is achieved.

In all the embodiments described above, two types of convex portions are formed by press molding with a press mold apparatus and at least one type of convex portion is joined. After forming one convex part 2A, 20A, 33A by roll processing while letting a plate pass between a pair of rollers with irregularities formed, the other convex part 2B, 20B, 33B is simultaneously formed by pressing. The projections 2B, 20B, 33B of the two plates 1A, 1B, 10A, 10B may be joined to each other, and one projection 2A, 20A, 33A and the other projection may be joined by roll processing. The portions 2B, 20B, 33B may be formed and at the same time, the convex portions 2B, 20B, 33B of the two plates 1A, 1B, 10A, 10B may be joined by roll processing.

  Further, instead of joining the other convex portions 2B, 20B, 33B, the two plates 1A, 1B, 10A, 10B may be joined by spot welding, spot FSW (friction stir welding), or other joining means. Good.

  For car wheel apron, toe board, cowl panel, etc., composite materials with excellent vibration suppression performance and sound insulation performance are required. However, vibration suppression performance and sound insulation performance are required between the plates 10A and 10B. Depending on the purpose of the enhancement, for example, a film-like synthetic resin material, rubber, metal foil, etc. are interposed to form a convex portion and provide an appropriate composite material by joining the two plates 10A and 10B. can do. Furthermore, it is possible to provide a composite material that can be applied to parts other than automobiles, such as aircraft and ships.

As described above, the present invention can provide a heat insulator excellent in heat insulation, vibration resistance, etc., and the technology relating to this heat insulator can be applied to automobile wheel apron, toe board, cowl panel, etc., and other than automobiles. It can also be applied to uses required for materials.

  Although the embodiments of the present invention have been described above, various alternatives, modifications, and variations can be made by those skilled in the art based on the above description, and the present invention is not limited to the various alternatives described above without departing from the spirit of the present invention. It includes modifications or variations.

DESCRIPTION OF SYMBOLS 1 Heat insulator 1A, 1B Plate body 2A, 20A Convex part 2B, 20B Convex part 10A, 10B Plate body 31 Inorganic binder 32 Inorganic powder 33A, 33B Convex part 34 Hollow ceramic beads

Claims (1)

A heat insulator formed with a large number of convex portions, and according to the purpose between the two plate bodies so that at least two kinds of the convex portions are scattered on the two plate bodies. It is formed with a material interposed, and one type of convex portion of two or more types of convex portions is formed to improve rigidity, and at least two types of convex portions of one plate body The two plate bodies are joined by fitting and joining other types of convex portions of the other plate body to other types of convex portions of the other plate body. A heat insulator characterized by that .

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