JP5286392B2 - Insulating material and manufacturing method thereof - Google Patents

Description

  The present invention relates to a heat insulating material applied to a floor under a building, a ceiling, a wall, a roof, and the like, and a method for manufacturing the same.

  Generally, a heat insulating material is applied to a floor, a ceiling, a wall, a roof, and the like of a building such as a house. For example, in the case of under the floor, a heat insulating material is arranged between a large draw or a joist, and a base plywood or the like is installed on the heat insulating material.

  As a heat insulating material, for example, a heat insulating material obtained by extrusion foaming a foam material containing polypropylene, waste paper and starch (see Patent Documents 1 and 2), a heat insulating material using a foamed synthetic resin such as polystyrene foam (see Patent Document 3). ), Foamed resin heat insulating materials such as polystyrene resin and polyurethane resin (see Patent Document 4) and the like are known.

  The heat insulating material described in Patent Document 1 is manufactured by integrally forming a plurality of foams obtained by extruding a foam material from a plurality of small holes and foaming the same into a plate shape. As described above, other methods for manufacturing a heat insulating material by integrally forming a plurality of foams in a plate shape have been proposed (see Patent Documents 5 to 7).

  On the other hand, the heat insulating materials described in Patent Documents 2 to 4 are manufactured by extruding a foam material into a plate shape.

Japanese Patent No. 4069255 JP 2003-41041 A JP 2006-291461 A JP 2008-196270 A Japanese Patent No. 3393341 Special table 2004-500998 gazette JP 2007-204590 A

  When constructing insulation materials as described above, between support materials installed at intervals (e.g., between the large and the joists in the case of the floor, between the rafters in the case of the roof, and between the pillars and studs in the case of the wall) The heat insulating material is held on the support material by fitting the heat insulating material between the two. Thereby, attachment of a heat insulating material is facilitated and construction efficiency is improved. By the way, when constructing a heat insulating material, if conditions about the direction and posture at the time of installing the heat insulating material are increased, the effectiveness is reduced.

  This invention is made | formed in view of this problem, and it aims at providing the heat insulating material which can improve workability, and its manufacturing method.

  In order to achieve the above-mentioned object, the invention according to claim 1 is characterized in that a plurality of rod-like foams obtained by extruding and foaming a foam material are oriented in one direction and integrated, and in a direction orthogonal to the one direction. A heat insulating material that is fitted and held between a pair of support members at a pair of mating surfaces that are positioned, wherein the fitting surface has an intermediate portion in the fitting direction at a front portion and a rear portion in the fitting direction. The foam is disposed so as to be located on the outer side, and the arrangement interval of the foams in the intermediate part in the fitting direction is wider than the arrangement interval in the front part and the rear part in the fitting direction. And

  The invention according to claim 2 is the invention according to claim 1, wherein the fitting surface vicinity range on the fitting surface side is such that the arrangement interval of the intermediate part in the fitting direction is the front part in the fitting direction. And the center interval between the fitting surface vicinity ranges is equal to the arrangement interval between the middle portion in the fitting direction and the front portion and the rear portion in the fitting direction. It is characterized by becoming.

  The invention according to claim 3 is the foam according to the invention according to claim 1 or 2, wherein a plurality of the foams are aligned in the direction perpendicular to the fitting direction by aligning the positions in the fitting direction. The row has a shape in which a plurality of rows are stacked in the fitting direction, and the arrangement interval of the foam rows in the middle portion in the fitting direction is the same as that of the foam rows in the front portion and the rear portion in the fitting direction. It is wider than the arrangement interval.

  The invention according to claim 4 is a method for manufacturing a heat insulating material according to any one of claims 1 to 3, wherein a foam material is extruded and foamed to form a plurality of the foams and welded together. An extrusion foaming step of forming an intermediate molded body in which the arrangement interval of the intermediate portion in the fitting direction is wider than the arrangement interval of the front portion and the rear portion in the fitting direction; A roll forming step of pressing the fitting surface with a roller so that a front portion and a rear portion in the fitting direction are located on an inner side than an intermediate portion.

  The invention according to claim 5 is a method of manufacturing a heat insulating material according to any one of claims 1 to 3, wherein a foam material is extruded and foamed to form a plurality of foams and welded together. An extrusion foaming step of forming an intermediate molded body in which the arrangement interval of the intermediate portion in the fitting direction is equal to the arrangement interval of the front portion and the rear portion in the fitting direction, and the fitting direction with respect to the intermediate molded body The fitting surface is formed by pressing the fitting surface with a roller so that the front part and the rear part in the fitting direction are located on the inner side than the intermediate part of the intermediate part, and the fitting is more than the arrangement interval of the intermediate part in the fitting direction. A roll forming step of narrowing the arrangement interval between the front part and the rear part in the opposite direction.

According to the invention which concerns on Claim 1, the fitting surface fitted by a support material is the shape which bulges so that the intermediate part of a fitting direction may be located outside the front part and rear part of a fitting direction. Therefore, if there is no other restriction on the direction of the fitting direction, it can be smoothly fitted between the pair of support members in either the front or back direction. Therefore, workability can be improved.
In addition, there is a direction in the indoor / outdoor direction, and when installation from the indoor side and installation from the outdoor side are mixed, installation from both sides may be difficult. Since the mating fitting surface has the above shape, it can be smoothly fitted from both the indoor side and the outdoor side. Therefore, also in this case, workability can be improved.
In addition, since the arrangement interval of the foam in the middle portion in the fitting direction is wider than the arrangement interval in the front portion and the rear portion in the fitting direction, the middle portion in the fitting direction has the foam arrangement density (unit The area occupied by the foam per area) is lower than the arrangement density of the front and rear parts in the mating direction, making it more flexible, facilitating mating at the time of construction and good elasticity after mating. A generating force is generated and held between the pair of support members. Further, the rigidity can be ensured on both the front and rear sides in the fitting direction in which the arrangement interval of the foam is narrow and the arrangement density is high.

  According to the invention which concerns on Claim 2, the arrangement | positioning space | interval of a foam is equal in the center range which exists between the fitting surface vicinity ranges by the intermediate part of a fitting direction, and the front part and rear part of a fitting direction. . Therefore, the arrangement density of the foam in the center range, which has relatively little influence on the fitting, can be increased as a whole, and the rigidity can be increased.

  According to the invention of claim 3, a plurality of foam rows, in which a plurality of foams are aligned in a direction perpendicular to the fitting direction by aligning the positions in the fitting direction, are laminated in a plurality of rows in the fitting direction. This is a shape, and the foam arrangement interval in the foam row in the middle part in the fitting direction is wider than the foam arrangement interval in the front and rear foam rows in the fitting direction. Therefore, it is relatively easy to vary the arrangement density.

  According to the invention according to claim 4, in the extrusion foaming step, the intermediate molded body in which the foam arrangement interval in the intermediate portion in the fitting direction is wider than the foam arrangement interval in the front and rear portions in the fitting direction. In the roll forming process, the fitting surface is pressed with a roller so that the front part and the rear part in the fitting direction are located inside the intermediate part in the fitting direction. Since it forms, the arrangement | positioning space | interval of the foam of the intermediate part of a fitting direction can be enlarged as the fitting surface side.

  According to the invention of claim 5, in the extrusion foaming step, an intermediate molded body in which the foam arrangement interval at the intermediate portion in the fitting direction is equivalent to the foam arrangement interval at the front and rear portions in the fitting direction. In the roll forming process, the fitting surface is pressed with a roller so that the front part and the rear part in the fitting direction are located inside the intermediate part in the fitting direction. In order to make the foam arrangement interval in the front part and the rear part in the fitting direction narrower than the foam arrangement interval in the middle part in the fitting direction, the foam in the front part and the rear part in the fitting direction Can be made smaller toward the fitting surface side.

It is a perspective view which shows the floor structure as a construction example of the heat insulating material which concerns on 1st Embodiment of this invention. It is a front view before the fitting to the support material which shows the heat insulating material which concerns on 1st Embodiment of this invention. It is a front view after the fitting to the support material which shows the heat insulating material which concerns on 1st Embodiment of this invention. It is a front view which shows the intermediate molded object after the extrusion foaming process of the heat insulating material which concerns on 1st Embodiment of this invention. It is a side view of the manufacturing apparatus which performs the roll forming process of the heat insulating material which concerns on 1st Embodiment of this invention. It is a rear view of the manufacturing apparatus which performs the roll forming process of the heat insulating material which concerns on 1st Embodiment of this invention. It is a front view which shows the heat insulating material which concerns on 1st Embodiment of this invention. The measured value of the space | gap of the heat insulating material which concerns on 1st Embodiment of this invention is shown, (a) is a figure which shows a measured position, (b) is a measured value, (c) is a diagram of a measured value. It is a front view which shows the modification of the heat insulating material which concerns on 1st Embodiment of this invention. It is a front view which shows the intermediate molded object after the extrusion foaming process of the heat insulating material which concerns on 2nd Embodiment of this invention. It is a front view which shows the heat insulating material which concerns on 2nd Embodiment of this invention. The measured value of the space | gap of the heat insulating material which concerns on 2nd Embodiment of this invention is shown, (a) is a figure which shows a measured position, (b) is a measured value, (c) is a diagram of measured value.

  Hereinafter, the heat insulating material which concerns on 1st Embodiment of this invention is demonstrated with reference to FIGS.

  FIG. 1 is a perspective view showing a floor structure as a construction example of a heat insulating material 10 according to the first embodiment. The heat insulating material 10 is a support material 110 having a rectangular cross section such as a large drawing or joist extending in parallel with each other. 110.

  As shown in FIG. 2, the heat insulating material 10 includes a plurality of rod-like foams 11 formed by extruding and foaming a foam material, aligned in a certain orientation direction (one direction: a direction orthogonal to the plane of FIG. 2), and in this orientation direction. It is formed in a plate shape having a plate thickness direction in one orientation orthogonal direction and a plate width direction in another orientation orthogonal direction orthogonal to the plate thickness direction. Yes.

  The heat insulating material 10 is fitted at both ends in the plate width direction between the support surfaces 111 and 111 of the support materials 110 and 110 which extend in parallel with each other and face each other so that the state shown in FIG. 2 is changed to the state shown in FIG. More specifically, in a direction perpendicular to the plane including the center line of both the support members 110 and 110 (in the direction of the arrow Z shown in FIG. 2) in a posture along the plate thickness direction in this direction. Will be combined. The heat insulating material 10 has a plate width larger than the distance between the support surfaces 111 and 111, and is held between the pair of support materials 110 and 110 by the elastic force generated by being crushed during fitting. Here, the direction Z perpendicular to the plane including the center line of each of the support members 110, 110 extending in parallel with each other is defined as the fitting direction of the heat insulating material 10, and thus the fitting direction in the heat insulating material 10 is the plate thickness direction. Become.

  A pair of large surfaces 15 and 15 on both sides in the plate thickness direction, that is, the fitting direction, of the heat insulating material 10 has a flat shape that is generally orthogonal to the plate thickness direction. In addition, the pair of fitting surfaces 16 and 16 located at both ends in the plate width direction have the plate thickness direction, that is, the intermediate portion in the fitting direction, located outside the plate thickness direction, that is, the front portion and the rear portion in the fitting direction. It has an arc shape that bulges out like this. Specifically, the fitting surfaces 16 and 16 are equal so that the center in the plate thickness direction is located on the outermost side in the plate width direction, and the larger surfaces 15 and 15 are located on the inner side in the plate width direction. It consists of a pair of inclined surfaces 17 and 17 which incline. The heat insulating material 10 is fitted and held between the pair of support materials 110 and 110 by the pair of fitting surfaces 16 and 16 positioned in a direction orthogonal to the orientation direction of the foam 11 described above. In the heat insulating material 10, the minimum width on the both large surfaces 15, 15 side between the fitting surfaces 16, 16 is slightly smaller than the distance between the support surfaces 111, 111. Is larger than the distance between the support surfaces 111 and 111.

Here, as the foam material used for molding the foam 11, it is preferable to use a material containing polyolefin resin, cellulose, and starch.
Examples of the polyolefin resin include polyethylene resin and polypropylene resin.
As the cellulose, used paper such as newspapers and magazines can be used as a raw material. Waste paper is used after being pulverized to a desired size by a pulverizer.
As starch, corn starch (corn starch), wheat starch, rice starch, etc. can be used.

The proportion of each component in 100% by mass of the foamed material is preferably 30 to 50% by mass of polyolefin resin, preferably 10 to 40% by mass of cellulose, and 20 to 40% of starch. It is preferable that it is mass%.
Moreover, you may make the foaming material contain various additives used for heat insulating materials, such as antioxidant, a fungicide, and a pigment, as needed.
Since the heat insulating material 10 of the present embodiment includes cellulose (waste paper) and starch, sufficient consideration is given to the environment.

  The heat insulating material 10 is formed as follows, for example.

  First, the above-mentioned paper foam material is foamed while being extruded from a die having a plurality of pores of an extruder, so that a plurality of cylindrical rod-like (strand-shaped) foam bodies 11 corresponding to the number of pores are in the same direction. The large number of foams 11 extruded in a bundle from the die are welded together by the melt adhesiveness immediately after foaming to be integrated into a collective state (extrusion). Foaming process). By this extrusion foaming step, a plate-like intermediate molded body 10A shown in FIG. 4 is formed. In the case of foaming, it is preferable to use water as a foaming agent.

  The die of the extrusion molding machine used in the above extrusion foaming process has a plurality of fine pore rows (more specifically, 11 rows) composed of a plurality of circular pores having a cross-sectional shape aligned in the thickness direction of the intermediate molded body 10A. ), A shape formed at an equal pitch in the thickness direction. Assuming that the pore row at the center position in the plate thickness direction is a reference row (first row), odd rows on both sides in the plate thickness direction (specifically, the reference row and every other row arranged in the plate thickness direction from the reference row) The first row, the third row, and the fifth row) have the same number of pores. On the other hand, those adjacent to the reference row on both sides in the plate thickness direction, and even rows on both sides in the plate thickness direction, which are alternately arranged for these (specifically, the second row, the fourth row, the sixth row) The pore rows of the odd-numbered rows are shifted by approximately half a pitch in the plate width direction so that one pore is arranged between adjacent odd-numbered pores, and the number of pores is the same and the odd-numbered rows. It is one less than the pore array of.

  In the die, the arrangement interval of the pores in the central predetermined range (about ３) in the plate width direction of the intermediate molded body 10A is constant in the plate width direction at the same interval as the plate thickness direction. On the other hand, the arrangement interval in the plate width direction of the pores in the one side predetermined range (about 1/3) and the other side predetermined range (about 1/3) of the intermediate formed body 10A is set at the center in the plate thickness direction. All the arrangement intervals in the plurality of rows are wider than the arrangement interval in the center predetermined range in the plate width direction, and the arrangement intervals are gradually increased toward the end side in the plate width direction. Further, in the predetermined range on one side and the predetermined range on the other side, the expansion rate of the arrangement interval in the plate width direction of the plurality of pores in the center in the plate thickness direction is the largest in the reference row in the plate thickness direction, and the plate thickness direction The end portion of the plate is gradually smaller, and the end portions in the plate thickness direction are the same as the central predetermined range in the plate width direction and are equally spaced. That is, in the predetermined range on the one side and the predetermined range on the other side, the pores are formed so as to gradually become rougher in the outer side in the plate width direction in the reference row in the center in the plate thickness direction.

  As a result, as shown in FIG. 4, the intermediate molded body 10 </ b> A molded by the extrusion foaming process also has a plurality of foam rows composed of a plurality of foam bodies 11 aligned in the plate thickness direction, and the like in the plate thickness direction. It is formed with a pitch. Assuming that the foam row at the center position in the plate thickness direction is a reference row (first row), odd rows on both sides in the plate thickness direction (specifically, the reference row and every other row arranged in the plate thickness direction from the reference row) The first row, the third row, and the fifth row) have the same number of foams 11 in the foam row. On the other hand, those adjacent to the reference row on both sides in the plate thickness direction, and even rows on both sides in the plate thickness direction, which are alternately arranged for these (specifically, the second row, the fourth row, the sixth row) This foam row is shifted from the odd-numbered row by approximately a half pitch in the plate width direction so that one foam 11 is arranged between the adjacent foams 11, 11 in the odd-numbered row, and the number of foams 11 is , All the same and one less than the odd number of foam rows.

  Further, in the intermediate molded body 10A, the arrangement interval of the foams 11 in the plate width direction in a predetermined (about ３) central range X1 in the plate width direction is also constant at the same interval as the plate thickness direction. On the other hand, the disposition interval in the plate width direction of the foam 11 in the one side range X2 in the plate width direction (about ３) and the other side range X3 in the plate width direction (about ３) is: The arrangement intervals in the plurality of rows in the center in the plate thickness direction are all wider than the central range X1 in the plate width direction, and the arrangement intervals in the plate width direction gradually increase toward the end side in the plate width direction. Further, in the one-side range X2 and the other-side range X3, the expansion rate of the arrangement interval in the plate width direction of the plurality of rows of foams 11 in the center in the plate thickness direction is the largest in the reference row in the plate thickness direction center, and the plate thickness direction The end portion in the plate thickness direction gradually decreases, and the end portions in the plate thickness direction are the same as the central range X1 in the plate width direction and are equally spaced. That is, in the extrusion foaming step, intermediate molding in which the disposition interval in the plate width direction of the foam 11 in the intermediate portion in the fitting direction is wider than the disposition interval in the plate width direction of the foam 11 in the front portion and the rear portion in the fitting direction. The body 10A is molded.

  In FIG. 4, in the one-side range X <b> 2 in the plate width direction, the odd-numbered foams 11 on the one side in the plate thickness direction are connected by the center of the same order in the plate width direction, and are indicated by a one-dot chain line. The center of the thing of the same order is tied to the board width direction of the foam 11 of the even-numbered row | line | column of one side, and it has shown with the dashed-dotted line. Similarly, in the one-side range X2 in the plate width direction, the odd-numbered rows of foams 11 on the other side in the plate thickness direction are connected with the centers of the same order in the plate width direction and are indicated by a one-dot chain line. The centers of the same order in the plate width direction of the even-numbered foams 11 are connected by a one-dot chain line. The above relationship is also apparent from these alternate long and short dash lines.

  In other words, the width in the plate width direction of the gaps 20 between the foams 11 and 11 adjacent in the plate width direction in the one side range X2 and the other side range X3 in the plate width direction is a plurality of rows in the center in the plate thickness direction. Are all wider than the width of the gap 20 in the central range X1, and gradually become wider toward the end in the plate width direction. Further, in the one-side range X2 and the other-side range X3, the expansion ratio of the width in the plate width direction of the gaps 20 between the adjacent foams 11, 11 in the plurality of rows in the center in the plate thickness direction is the reference row in the center in the plate thickness direction. And the width in the plate width direction of the gap 20 on the end side in the plate thickness direction is the width in the plate width direction of the gap 20 in the central range X1 in the plate width direction. It is the same and is the same width.

  In other words, since the length of the gap 20 in the plate thickness direction is constant, the two foams 11 adjacent to each other in the plate width direction in the one side range X2 and the other side range X2 in the plate width direction. 11, and the opening area of the gap 20 surrounded by the two foams 11, 11 adjacent to each other in the plate thickness direction is the center of the opening area of the gap 20 in the plurality of rows in the center in the plate thickness direction. It is wider than the opening area of the gap 20 in the range X1, and gradually becomes wider toward the end in the plate width direction. In addition, the enlargement ratio of the opening area of the gap 20 in the one side range X2 and the other side range X3 is the largest in the reference row at the center in the plate thickness direction, and gradually decreases toward the end in the plate thickness direction. The opening area of the gap 20 at the end of the plate is substantially the same as the opening area of the gap 20 in the central range X1 in the plate width direction.

  Then, as shown in FIGS. 5 and 6, a pair of parallel rollers 200 and 200 having a cylindrical outer peripheral surface on the upstream side are rotated, and in contact between them on both sides in the plate thickness direction. As described above, the intermediate molded body 10A described above is continuously passed. Subsequently, a pair of parallel rollers 202, 202 composed of two tapered surfaces 201, 201 which are located on the downstream side and whose outer peripheral surface has a larger diameter toward both sides in the axial direction are rotated. The intermediate molded body 10A is continuously passed so as to be in contact with both sides. In this way, the intermediate molded body 10A is heated and pressed by the pair of rollers 200, 200 and the pair of rollers 202, 202. Here, the two taper surfaces 201 and 201 of the roller 202 have the same taper ratio and the same axial length, and the boundary position between them is arranged at the center position between the rollers 200 and 200.

  Then, a pair of substantially flat large surfaces 15 and 15 are formed on both sides in the thickness direction of the intermediate molded body 10A by the pair of upstream rollers 200 and 200, and the intermediate molded body is formed by the pair of downstream rollers 202 and 202. A pair of chevron-shaped fitting surfaces 16 and 16 are formed on both sides in the plate width direction of 10A to form the plate-shaped heat insulating material 10 shown in FIG. 7 (roll forming step). The pair of chevron-shaped fitting surfaces 16, 16 have a mirror-symmetric shape with respect to the center in the thickness direction. That is, in the roll forming process, the fitting surfaces 16 and 16 are pressed by the rollers 202 and 202 so that the front part and the rear part in the fitting direction are located on the inner side of the intermediate molded body 10A with respect to the intermediate part in the fitting direction. Form.

  In addition, as shown in FIG. 7, the heat insulating material 10 has a pair of large surfaces 15 and 15 formed on the foams 11 in the foam row located at both ends in the plate thickness direction. In the foam 11, the cross section orthogonal to the length direction has a rounded isosceles triangle shape with corners forming an arc shape. Moreover, a pair of fitting surfaces 16 and 16 will be formed in the foam 11 located in the both ends of the board width direction of all the odd-numbered foam rows, and, as a result, these foams 11 are long. The cross section orthogonal to the vertical direction forms a rounded triangular shape with the corners forming an arc shape except for the foam 11 in the foam row at the center in the thickness direction. Further, in the foam 11 at both ends of the foam row at the center in the plate thickness direction, the cross section perpendicular to the length direction forms a fan shape. The other foams 11 except those that form the pair of large surfaces 15 and 15 and those that form the pair of mating surfaces 16 and 16 maintain the shape in the extrusion foaming process described above, and are adjacent to each other. When the objects to be welded are compressed and crushed at the time of welding, the cross section perpendicular to the length direction forms a rounded rhombus shape with corners forming an arc shape. In the heat insulating material 10, a gap 20 is formed between the foams 11 adjacent to each other in the plate width direction and four continuous foams 11 between the foams 11 adjacent to each other in the plate thickness direction. Is formed. That is, the space | gap 20 is surrounded by the round corner part of the four foams 11 located in the four directions.

  The heat insulating material 10 molded in the roll forming process is also formed with a plurality of foam rows made of foams 11 aligned in the plate thickness direction at equal pitches in the plate thickness direction. Assuming that the foam row at the center position in the plate thickness direction is a reference row (first row), odd rows on both sides in the plate thickness direction (specifically, the reference row and every other row arranged in the plate thickness direction from the reference row) The first row, the third row, and the fifth row) have the same number of foams 11 in the foam row. On the other hand, those adjacent to the reference row on both sides in the plate thickness direction, and even rows on both sides in the plate thickness direction, which are alternately arranged for these (specifically, the second row, the fourth row, the sixth row) The foam rows of the odd-numbered rows are shifted by about a half pitch in the plate width direction so that one foam 11 is arranged between the adjacent foams 11, 11 in the odd-numbered rows, and the number of the foams 11 is All are the same and one less than the odd number of foam rows. That is, the heat insulating material 10 has a shape in which a plurality of foams 11 formed by aligning a plurality of foams 11 in the fitting direction and arranged in parallel in a direction perpendicular to the fitting direction are laminated in the fitting direction. Eggplant.

  As for the heat insulating material 10, the arrangement | positioning space | interval of the plate | board width direction of the foam 11 in the center range X11 of predetermined (about 1/3) of the plate | board width direction is constant at the same space | interval as the plate | board thickness direction. On the other hand, a predetermined (about ３) one-side fitting surface vicinity range X12 on the one fitting surface 16 side in the plate width direction and a predetermined (about ３) on the other fitting surface 16 side in the plate width direction. ) The arrangement interval in the plate width direction of the foam 11 with respect to the other-side mating surface vicinity range X13 is wider than the arrangement interval in the center range X11 in the plate width direction. Moreover, the width gradually becomes wider toward the end in the plate width direction. In addition, the expansion rate of the arrangement interval in the plate width direction of the foam 11 in the one-side fitting surface vicinity range X12 and the other-side fitting surface vicinity range X13 is the largest in the reference row at the center in the plate thickness direction. The distance between the foams 11 on the end side in the plate thickness direction is the same as the arrangement interval in the central range X11 in the plate width direction and is constant.

  Also in FIG. 7, the center of the odd-numbered foams 11 on one side in the plate thickness direction in the plate width direction on the one side fitting surface vicinity range X12 in the same order in the plate width direction (crushed in the roll forming step) Is shown by a one-dot chain line connecting the centers of the same order in the plate width direction of the foams 11 in the even-numbered rows on one side in the plate thickness direction. Similarly, in the one-side fitting surface vicinity range X12, the center of the same order is connected to the plate width direction of the odd-numbered foams 11 on the other side in the plate thickness direction, and is indicated by a one-dot chain line. The centers of the same order in the plate width direction of the even-numbered foams 11 are connected by a one-dot chain line. The above relationship is also apparent from these alternate long and short dash lines.

  In other words, in the heat insulating material 10, the arrangement interval in the plate width direction of the foam 11 at the intermediate portion in the fitting direction is wider than the arrangement interval in the plate width direction of the front and rear foams 11 in the fitting direction. . In particular, in the fitting surface vicinity ranges X12 and X13 on the fitting surface 16 side, the disposition interval in the plate width direction of the foam 11 at the intermediate portion in the fitting direction is the plate of the foam 11 at the front and rear portions in the fitting direction. In the center range X11 which is wider than the arrangement interval in the width direction and is between the fitting surface vicinity ranges X12 and X13 on both sides, the plate width is between the middle portion in the fitting direction and the front and rear portions in the fitting direction. Directional spacing is the same. As a result, in the fitting surface vicinity ranges X12 and X13 on the fitting surface 16 side, the arrangement intervals in the plate width direction of the foams 11 in the foam row at the middle part in the fitting direction are the front part and the rear part in the fitting direction. It is wider than the arrangement interval in the plate width direction of the foam 11 in the foam row.

  In other words, the width in the plate width direction of the gap 20 between the foams 11 and 11 adjacent in the plate width direction in the one side fitting surface vicinity range X12 and the other side fitting surface vicinity range X13 in the plate width direction is The plurality of rows in the center in the thickness direction are all wider than the center range X11 and gradually become wider toward the end in the plate width direction. In addition, the expansion ratio of the width in the plate width direction of the gap 20 between the adjacent foams 11 and 11 in the one side fitting surface vicinity range X12 and the other side fitting surface vicinity range X13 is a reference row in the center in the plate thickness direction. Is the largest and gradually decreases toward the end in the plate thickness direction, and the end in the plate thickness direction has the same width as the central range X11 in the plate width direction.

  Furthermore, in other words, since the length of the gap 20 in the plate thickness direction is constant in the heat insulating material 10, in the one side fitting surface vicinity range X12 and the other side fitting surface vicinity range X13 in the plate width direction, The opening area of the gap 20 surrounded by the two foams 11 and 11 adjacent in the plate width direction and the two foams 11 and 11 adjacent in the plate thickness direction between them is the center in the plate thickness direction. Are all wider than the central range X11, and gradually become wider toward the end in the plate width direction. In addition, the enlargement ratio of the opening area of the gap 20 in the one-side fitting surface vicinity range X12 and the other-side fitting surface vicinity range X13 is the largest in the reference row at the center in the plate thickness direction, and is closer to the end portion side in the plate thickness direction. It gradually decreases, and the opening area of the gap 20 on the end side in the plate thickness direction is the same as the gap 20 in the central range X11 in the plate width direction and has a substantially constant area.

  FIG. 8 shows measured values of the opening area of the gap 20 in the one-side fitting surface vicinity range X12. 8 (a) to 8 (c), the central part is a space 20 formed by the foam row in the reference row in the center in the plate thickness direction and the second row on both sides in the plate thickness direction. The middle part in FIG. 8 (c) shows the gap 20 formed by the second row, the third row, and the fourth row of foam rows, and the lower end in FIGS. 8 (a) to 8 (c) The voids 20 formed by the foam rows of the fourth row, the fifth row and the sixth row are respectively shown. In addition, No. 2 in FIGS. 1-No. No. 8 shows No. 8 shown in FIG. 1-No. 8 voids are shown. From these measured values, it can be seen that the opening area of the gap 20 has the above relationship. In addition, the opening area of the gap 20, that is, the arrangement interval in the plate width direction of the foam 11 is larger toward the center side in the fitting direction, and the middle part in the fitting direction (the middle part and the middle part) is fitted. It can be seen that the opening area of the gap 20, that is, the arrangement interval of the foam 11 in the plate width direction becomes larger toward the surfaces 16 and 16.

  According to the heat insulating material 10 according to the first embodiment described above, the pair of fitting surfaces 16 and 16 fitted to the support materials 110 and 110 have a middle portion in the fitting direction at the front portion in the fitting direction. Since it has a shape that bulges so as to be located outside the rear part, it fits smoothly between the pair of support members 110, 110 in either the front or back direction unless there are other restrictions on the direction of the fitting direction. Can be combined. Therefore, workability can be improved.

  Moreover, since the disposition interval in the plate width direction of the foam 11 at the intermediate portion in the fitting direction is wider than the disposition interval in the plate width direction at the front portion and the rear portion in the fitting direction, the intermediate portion in the fitting direction is In addition, the arrangement density of the foam 11 (the area occupied by the foam 11 per unit area) is lower than the arrangement density of the front part and the rear part in the fitting direction, and the support material 110, The fitting to 110 becomes easy, and after fitting, a good elastic force is generated and held between the support members 110 and 110. Moreover, the rigidity of the heat insulating material 10 can be ensured on both the front and rear sides in the fitting direction in which the arrangement interval of the foam 11 is narrow and the arrangement density is high.

  Further, in the central range X11 between the fitting surface vicinity ranges X12 and X13, the arrangement interval in the plate width direction of the foam 11 is equal between the middle portion in the fitting direction and the front and rear portions in the fitting direction. Yes. Therefore, the arrangement density of the foams 11 in the central range X11 that has relatively little influence on fitting can be increased as a whole, and the rigidity of the heat insulating material 10 can be further increased.

  Further, a plurality of foams 11 are aligned in a direction perpendicular to the mating direction by aligning the positions in the mating direction, and a plurality of foam rows are stacked in the mating direction, and the mating direction The disposition interval in the plate width direction of the foams 11 in the foam row at the middle part of the foam is wider than the disposition interval in the plate width direction of the foams 11 in the front and rear foam rows in the fitting direction. Therefore, it is relatively easy to partially vary the arrangement density.

  Further, in the extrusion foaming step, intermediate molding in which the disposition interval in the plate width direction of the foam 11 in the intermediate portion in the fitting direction is wider than the disposition interval in the plate width direction of the foam 11 in the front portion and the rear portion in the fitting direction. The body 10A is to be molded, and a pair of mating surfaces are formed on the intermediate molded body 10A so that the front part and the rear part in the mating direction are located on the inner side in the roll forming step than the intermediate part in the mating direction. In order to form the heat insulating material 10 by a continuous strand extrusion post-forming method formed by pressing the rollers 16 and 16 with rollers 202 and 202, the arrangement interval in the plate width direction of the foam 11 at the intermediate portion in the fitting direction is set to the fitting surface. 16, 16 can be larger.

  Moreover, since many voids 20 are formed between the foams 11, in addition to the heat insulation performance of the foams 11 themselves, the heat insulation performance is improved by these voids 20.

  In addition, when there is a direction in the indoor / outdoor direction and a case where construction is performed from the indoor side and a case where construction is performed from the outdoor side, there is a possibility that the construction from both sides may be difficult. Since the fitting surfaces 16 and 16 fitted in are formed in the above shape, the fitting surfaces 16 can be smoothly fitted from both the indoor side and the outdoor side. Therefore, also in this case, workability can be improved.

  That is, for example, in the case of the heat insulating material 10 constructed on the roof, the ventilation groove 30 may be formed only on one large surface 15 side as in the modification shown in FIG. 10 is constructed with this groove 30 facing upward. In such a heat insulating material 10, the fitting surfaces 16, 16 have the above-described shape even when the support material 110 such as a rafter is constructed from the indoor side or from the outdoor side. Therefore, it can be smoothly fitted to both constructions. On the other hand, in the conventional one in which the fitting surface is inclined so that the one side in the plate thickness direction is located on the inner side in the plate width direction, only the fitting with the narrow side of the plate width as the head can be performed. The construction from both the indoor side and the outdoor side becomes difficult.

  In addition, in the heat insulating material 10 of 1st Embodiment, without providing the center range X21 in which the arrangement | positioning space | interval of the foam 11 of the board width direction is constant, in the whole range of the board width direction, the foam 11 of the foam 11 is so far away from the center position. The arrangement interval in the plate width direction may be gradually increased.

  The heat insulating material according to the second embodiment of the present invention will be described mainly with reference to FIGS. 10 to 12 with a focus on differences from the first embodiment.

  In the second embodiment, in the die used in the extrusion foaming process, the arrangement interval of the pores in the entire range is the same in both the plate thickness direction and the plate width direction and is constant.

  As a result, in the intermediate molded body 10A molded in the extrusion foaming process, as shown in FIG. 10, the arrangement interval of the foams 11 in the entire range is the same in both the plate thickness direction and the plate width direction. Yes. In other words, the width in the plate width direction and the width in the plate thickness direction of the gap 20 are constant over the entire range, and the opening area of the gap 20 is also constant over the entire range. That is, in the extrusion foaming process, the foam material is extruded and foamed to form a plurality of foams 11 and welded together, so that the spacing between the foams 11 at the middle part in the fitting direction and the front and rear parts in the fitting direction are An intermediate molded body 10A having the same arrangement interval of the foams 11 is molded.

  Then, similar to the first embodiment, the intermediate molded body 10A is pressed by a pair of parallel rollers 200, 200 shown in FIGS. 5 and 6, and a pair of flat large surfaces on both sides in the plate thickness direction. 15 and 15 are formed and pressed by a pair of parallel rollers 202 and 202 to form a pair of mountain-shaped fitting surfaces 16 and 16 on both sides in the plate width direction, and the plate-shaped heat insulating material 10 shown in FIG. (Roll forming process).

  Then, in the heat insulating material 10 formed in this roll forming step, the arrangement interval of the foams 11 in the plate thickness direction is constant, and the foam in a predetermined (about 2/3) central range X21 in the plate width direction. The arrangement interval of 11 in the plate width direction is constant at the same interval as the plate thickness direction. On the other hand, a predetermined (about 1/6) one-side fitting surface vicinity range X22 on one fitting surface 16 side in the plate width direction and a predetermined (about 1/6) other-side fitting on the other fitting surface 16 side. With respect to the arrangement interval in the plate width direction of the foam 11 in the vicinity surface range X23, the arrangement intervals of the reference row at the center in the plate thickness direction are all equal to the arrangement interval in the center range X21 in the plate width direction. And the arrangement | positioning space | interval of the plate width direction of the foam 11 of the other row | line | column except the reference | standard row | line | column of the plate | board thickness direction center is narrower than the arrangement | positioning space | interval of the plate width direction of the center range X21 of the plate width direction as a whole, And the arrangement | positioning space | interval becomes narrow gradually toward the edge part side of a board width direction. In addition, the reduction rate of the arrangement interval in the plate width direction of the foam 11 in the one-side fitting surface vicinity range X22 and the other-side fitting surface vicinity range X23 gradually increases toward the end in the plate thickness direction. . In FIG. 11, the center of the foams 11 in the same order in the plate width direction of the even-numbered rows of foams 11 on one side in the plate thickness direction in the one-side fitting surface vicinity range X22 in the plate width direction (crushed in the roll forming step) Represents the center before crushing).

  That is, the heat insulating material 10 according to the second embodiment has the fitting surface 16 in the roll forming process such that the front and rear portions in the fitting direction are located on the inner side relative to the intermediate portion in the fitting direction with respect to the intermediate molded body 10A. , 16 by pressing with rollers 202, 202, the width of the foam 11 in the front part and the rear part in the fitting direction rather than the arrangement interval in the width direction of the foam 11 in the middle part in the fitting direction. Narrow the direction spacing. In particular, in the fitting surface vicinity ranges X22 and X23 on the fitting surface 16 side, the front and rear foams 11 in the fitting direction are more than the arrangement interval in the plate width direction of the foams 11 in the middle part in the fitting direction. In the central range X21 between the fitting surface vicinity ranges X22 and X23 on both sides, the arrangement width in the plate width direction is narrow, and the plate width is between the middle portion in the fitting direction and the front and rear portions in the fitting direction. Directional spacing is the same. As a result, in the fitting surface vicinity ranges X22 and X23 on the fitting surface 16 side, the front portion in the fitting direction and the disposition interval in the plate width direction of the foam 11 in the foam row in the middle portion in the fitting direction The arrangement | positioning space | interval of the board width direction of the foam 11 in the foam row | line | column of a rear part is narrow.

  In other words, in the heat insulating material 10 of 2nd Embodiment, between the foams 11 and 11 adjacent to the board width direction in the one side fitting surface vicinity range X22 and the other side fitting surface vicinity range X23 in the board width direction. The widths of the gaps 20 in the plate width direction are all narrower than the center range X11 except for the reference row at the center in the plate thickness direction, and gradually become narrower toward the end side in the plate width direction. In addition, the reduction ratio of the width in the plate width direction of the gap 20 between the adjacent foams 11 and 11 in the one side fitting surface vicinity range X22 and the other side fitting surface vicinity range X23 is the end side in the plate thickness direction. It is getting bigger gradually.

  In other words, also in the heat insulating material 10 of the second embodiment, since the length of the gap 20 in the plate thickness direction is constant, the one side fitting surface vicinity range X22 and the other side fitting surface in the plate width direction. Opening area of the gap 20 surrounded by the two foams 11 and 11 adjacent in the plate width direction and the two foams 11 and 11 adjacent in the plate thickness direction between them in the vicinity range X23 The voids 20 in the other foam rows except for the gap 20 in the reference row at the center in the plate thickness direction are all narrower than the center range X21 and gradually narrow toward the end in the plate width direction. In addition, the reduction ratio of the opening area of the gap 20 in the one-side fitting surface vicinity range X22 and the other-side fitting surface vicinity range X23 gradually increases toward the end side in the plate thickness direction.

  The measured value of the opening area of the space | gap 20 in the heat insulating material 10 of 2nd Embodiment is shown in FIG. 12 (a) to 12 (c), the central portion is a space 20 formed by the foam row in the reference row at the center in the plate thickness direction and the second row on both sides in the plate thickness direction. The middle part in FIG. 12 (c) shows the gap 20 formed by the second row, the third row and the fourth row of foam rows, and the lower end in FIG. 12 (a) to FIG. 12 (c), The voids 20 formed by the fourth row, the fifth row and the sixth row of foams are respectively shown. In addition, No. 2 in FIGS. 1-No. 5 is No. 5 shown in FIG. 1-No. 5 voids are shown. From this measured value, it can be seen that the gap 20 has the above relationship, and that the difference in the arrangement interval of the foam 11 between the intermediate portion in the fitting direction, the front portion, and the rear portion is large. Recognize.

  According to the heat insulating material 10 according to the second embodiment described above, in the extrusion foaming step, the disposition interval in the plate width direction of the foam 11 in the intermediate part in the fitting direction and the front part and the rear part in the fitting direction. The intermediate molded body 10A having the same arrangement interval in the plate width direction of the foam 11 is formed. In the intermediate forming body 10A, in the roll forming step, the intermediate molded body 10A is more in the fitting direction than the intermediate portion in the fitting direction. By forming the fitting surfaces 16 and 16 with the rollers 202 and 202 so that the front part and the rear part are located on the inner side, than the arrangement interval in the plate width direction of the foam 11 at the intermediate part in the fitting direction. In order to narrow the arrangement interval in the plate width direction of the foam 11 at the front portion and the rear portion in the fitting direction, the arrangement interval in the plate width direction of the foam 11 between the intermediate portion in the fitting direction, the front portion, and the rear portion. The difference can be increased.

In addition, the above embodiment is applicable also between the rafters of a roof, or between pillars of a wall.
In addition to the above, a synthetic resin foam material such as polystyrene or polypropylene can be used as the foam material.

DESCRIPTION OF SYMBOLS 10 Heat insulating material 10A Intermediate molded object 11 Foam 16 Fit surface 20 Gap 110 Support material 202 Roller

Claims (5)

A plurality of rod-like foams obtained by extruding and foaming a foam material are integrated by being oriented in one direction, and fitted between a pair of support materials at a pair of fitting surfaces located in a direction orthogonal to the one direction. A heat insulating material that is held together,
The fitting surface bulges so that the middle part in the fitting direction is located outside the front part and the rear part in the fitting direction,
A heat insulating material characterized in that an arrangement interval of the foams in an intermediate portion in the fitting direction is wider than an arrangement interval in a front portion and a rear portion in the fitting direction. In the vicinity of the fitting surface on the fitting surface side, the arrangement interval of the intermediate portion in the fitting direction is wider than the arrangement interval of the front portion and the rear portion in the fitting direction,
The central range between the fitting surface vicinity ranges is such that the arrangement interval is equal between an intermediate part in the fitting direction and a front part and a rear part in the fitting direction. The described insulation. The foam row formed by aligning the plurality of foams in the fitting direction and arranged in parallel in the direction perpendicular to the fitting direction has a shape in which a plurality of rows are laminated in the fitting direction,
2. The arrangement interval of the foam rows in the middle portion in the fitting direction is wider than the arrangement interval of the foam rows in the front portion and the rear portion in the fitting direction. Or the heat insulating material of 2. It is a manufacturing method of the heat insulating material according to any one of claims 1 to 3,
An intermediate molding in which a foam material is extruded and foamed to form and weld a plurality of foams, and the arrangement interval at the intermediate portion in the fitting direction is wider than the arrangement interval at the front and rear portions in the fitting direction. An extrusion foaming process for shaping the body;
A roll forming step of pressing the fitting surface with a roller so that a front portion and a rear portion in the fitting direction are located on the inner side of the intermediate molded body than an intermediate portion in the fitting direction;
The manufacturing method of the heat insulating material characterized by having. It is a manufacturing method of the heat insulating material according to any one of claims 1 to 3,
A foam material is extruded and foamed to form a plurality of the foams and welded together, and the arrangement interval of the intermediate portion in the fitting direction is equal to the arrangement interval of the front and rear portions in the fitting direction. An extrusion foaming process for forming a molded body;
The fitting surface is formed by pressing the fitting surface with a roller so that a front portion and a rear portion in the fitting direction are located on an inner side than an intermediate portion in the fitting direction with respect to the intermediate molded body. A roll forming step of narrowing the arrangement interval of the front part and the rear part in the fitting direction than the arrangement interval of the intermediate part;
The manufacturing method of the heat insulating material characterized by having.

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