JP5571610B2 - Vacuum insulation material manufacturing method, vacuum insulation material and refrigerator equipped with the same - Google Patents

Description

  The present invention relates to a method for manufacturing a vacuum heat insulating material in consideration of formability and energy saving, a vacuum heat insulating material, and a refrigerator including the same.

  Conventionally, the following Patent Documents 1 to 4 are disclosed as literature well-known inventions related to a vacuum heat insulating material in which a vacuum space having a low thermal conductivity is formed to improve heat insulation, a manufacturing method thereof, and a refrigerator equipped with a vacuum heat insulating material. There is.

  In Patent Document 1, the binder (binder) concentration in the thickness direction of the core material that forms the core of the vacuum heat insulating material is made different between the core material surface and the central portion of the thickness, so that heat conduction of the solid component of the binder can be achieved. Relying on the influence of thermal crosslinking. As a result, the degree of coupling of the core materials differs in the thickness direction, and the exhaust resistance during vacuum exhaust in the manufacturing process can be reduced. Thus, an example in which the exhaust time is shortened and the productivity is improved is shown.

On the other hand, conventionally, in the vacuum heat insulating material using glass fiber or the like as a core material, the binder used for the core material acts as a thermal cross-link between the glass fibers, so as to cope with the problem of deteriorating the heat insulating performance. There exists patent document 2. FIG.
Patent Document 2 discloses that a core material is plastically deformed by transferring a temperature region from an elastic deformation region to a plastic deformation region by applying pressure while heating the core material to a melting point of about 400 to 500 ° C. without using a binder. A vacuum heat insulating material excellent in heat insulating performance that maintains the shape of the material and suppresses thermal crosslinking is shown.

  Patent Document 3 discloses that a vacuum insulation material is shaped by constraining a core material made of glass wool with a bag-like sheet material that can be held in a compressed state, and shaping the vacuum insulation material with improved performance as a glass wool alone. The body is shown.

  In Patent Document 4, an inorganic fiber aggregate (for example, an aggregate of glass fibers) that has not been subjected to binder treatment or heat molding treatment is covered with an inner bag made of a synthetic resin film, and the outer bag outside the inner bag is covered. The example which applied the vacuum heat insulating material which reduced the internal pressure by carrying out pressure reduction sealing and suppressed the repulsive force with respect to the atmospheric pressure of an inorganic fiber aggregate | assembly to a refrigerator is shown.

JP 2004-11707 A Japanese Patent Laid-Open No. 2005-220954 JP 2005-207556 A JP 2006-112439 A

  By the way, in recent years, various industries have promoted energy saving of various so-called electric appliances including home appliances such as a refrigerator for home use as part of global environmental protection. Due to such a recent trend, vacuum heat insulating materials having high heat insulating properties are being used more frequently than ever in the refrigerator for home use in order to improve the heat insulating performance of the cold box.

  However, because of the importance of energy saving of products, the energy consumed in the manufacturing process of the vacuum heat insulating material is not necessarily energy saving and is not carefully considered. In addition, there are many cases in which the appearance quality and design properties of products are impaired due to an increase in the area and number of vacuum heat insulating materials used in products.

  About the vacuum heat insulating material of patent document 1, a core material is shape | molded by apply | coating a binder (binder) to glass fiber, and heat-pressing. As a result, since a hardened layer is formed on the surface of the core material, the surface property (flatness) of the vacuum heat insulating material is good, and there is an advantage that the external dimension accuracy is high because it is cut into a predetermined dimension after molding. .

  However, it is a manufacturing method that uses enormous heat energy (heated to 200 ° C or higher) to form a core material using a binder (binder), and greenhouse gas emissions are excessive, giving consideration to the environment. It is missing. Moreover, since the binder exists as a solid content between the glass fibers of the core material, there is a problem that the heat insulation performance is deteriorated because this becomes thermal crosslinking. Furthermore, since it is solidified by the binder, the strength of the vacuum heat insulation itself is increased, and there is a difficulty in that the degree of freedom in shape when the vacuum heat insulating material is bent is low.

  On the other hand, the vacuum heat insulating material shown in Patent Document 2 does not use a binder, but it is necessary to heat to a temperature near the softening point of glass (melting point: 400 to 500 ° C.) in order to form glass fibers. As with Patent Document 1, there is an inconvenience that enormous heat energy is used to form the core material.

  Further, since the glass fibers are pressed while being heated to the vicinity of the softening point (melting point), the glass fibers are in close contact with each other, and the glass fibers may be fused depending on how the conditions vary. Therefore, there is a problem that the influence of heat transfer of the solid (glass fiber) is large, resulting in deterioration of heat insulation performance and resistance during evacuation. In addition, since the glass fibers of the core material are in close contact with each other, the elastic modulus is increased and the flexibility is reduced, and the degree of freedom in shape when the vacuum heat insulating material is bent is insufficient as in Patent Document 1.

Moreover, about the vacuum heat insulating material shown by patent document 3, as a means to shape glass wool (glass fiber) in a compression state, the enormous amount which is a subject of patent documents 1 and 2 is used by using the sheet material of a shape restraint material. Solves heat energy consumption. However, there is a problem in surface flatness such that variation in glass fiber basis weight (glass fiber density) peculiar to glass wool appears as irregularities on the surface of the vacuum heat insulating material.
In addition, since glass wool is bulky (mass volume ratio is large), when compressing in the thickness direction, the end often bulges in the extending direction, and it is difficult to obtain the accuracy of the external dimensions of the vacuum heat insulating material There is.

  Moreover, about the vacuum heat insulating material shown by patent document 4, the synthetic resin film is used as an inner bag as a means to make an inorganic fiber aggregate into a compression state like patent document 3, and the problem of patent documents 1 and 2 is shown. It solves the enormous heat energy consumption and the freedom of shape. However, as in Patent Document 3, there still remains a problem that the surface flatness as a vacuum heat insulating material is low and the external dimension accuracy is poor.

  As described above, the vacuum heat insulating material that conventionally employs a binder (binder) or a core material that is not molded by heating has been considered environmentally in terms of manufacturing process and material, but the appearance quality of the vacuum heat insulating material is The present condition is inferior to the core material formed by binder or heating.

  In view of the above-mentioned actual situation, the present invention suppresses heat energy consumption, provides a method of manufacturing a vacuum heat insulating material having good surface flatness and external dimension accuracy, and has a degree of freedom, a vacuum heat insulating material, and a refrigerator provided with the same. With the goal.

To achieve the above object, the manufacturing method of the vacuum heat insulating material according to the first of the present invention, by overlapping a fiber aggregate formed by laminating without using a binder fiber material in the thickness direction of single wall or a plurality of layers Vacuum insulation comprising: a core material comprising: an adsorbent that adsorbs moisture and gas components of the core material; an inner bag that houses the core material and the adsorbent; and an outer bag that houses the inner bag. A method of manufacturing a material, the compression step of compressing the core material so as to be in a predetermined first density range, and the core material being predetermined in a state of being held in a second density range lower than the first density range A cutting step of cutting into the outer dimensions, an inner bag packaging step of sealing the core material with the inner bag while maintaining the second density range in the cutting step, and a core sealed with the inner bag on the outer bag A bagging step for inserting a material, and the core released from sealing of the inner bag Comprising a vacuum packaging process is evacuated sealed with said outer bag being maintained at the second density range.

Vacuum heat insulating material according to a second aspect of the present invention, a core formed by a laminated fiber aggregate superimposed single layer or plural layers without using a binder fiber material in the thickness direction, the moisture of the core material and an adsorbent for adsorbing gas components, and the bag inner housing and said adsorbent and said core material, a vacuum heat insulating material comprising an outer bag for accommodating the inner bag therein, Tokoro said core member and compressed so that the first density range of the constant, the cut into a predetermined outer dimensions while maintaining the lower second density range than the first density range, holding the second density range at the time of cutting The core material sealed with the inner bag is inserted into the outer bag to release the sealing of the inner bag while maintaining the second density range, and is evacuated and sealed with the outer bag. It has stopped.

The refrigerator according to the third aspect of the present invention includes the vacuum heat insulating material according to the second aspect of the present invention.

  ADVANTAGE OF THE INVENTION According to this invention, while suppressing heat energy consumption, the surface flatness and the external dimension precision are favorable, the manufacturing method of the vacuum heat insulating material which has a shape freedom degree, a vacuum heat insulating material, and a refrigerator provided with this are realizable.

It is a front view of the refrigerator of embodiment concerning this invention. It is AA sectional view taken on the line of the refrigerator of FIG. It is ZZ sectional view taken on the line of the refrigerator of FIG. 2 is a cross-sectional view showing a vacuum heat insulating material of Embodiment 1. FIG. (a) is a figure which shows the manufacturing method of the vacuum heat insulating material of Embodiment 1, (b) is a figure which shows an example of the manufacturing method of the vacuum heat insulating material of a comparative example (conventional). (a) is a side view conceptually showing the core material compression step of Embodiment 1, (b) is a side view conceptually showing a second core material cutting step and an inner bag packaging step, (c) ) Is a side view conceptually showing the inner bag packaging step. (a) is a figure which shows the state before compression of the glass wool which makes the core material which laminated | stacked the conventional glass fiber, (b) is a compression direction when the glass wool which makes the core material which laminated | stacked the conventional glass fiber is compressed. It is the figure which showed the state which raise | generates lamination | stacking shift | offset | difference in the direction which is not. (a) is a sectional side view showing a state in which the core material has expanded and restored before the conventional evacuation, and (b) shows one end of the inner bag in which the core material of Embodiment 1 is sealed. It is a sectional side view which shows the operation | work which opens. (a) is a plan view of the inner bag showing the notch portion of the inner bag that is the outer packaging material of the core material of the vacuum heat insulating material, and (b), (c), (d) are the cuts of the inner bag, respectively. It is the A section enlarged view of (a) which expands and shows an example of easy seal release means, such as a notch part. It is the figure which put together the measurement result of the vacuum heat insulating material of Embodiment 1, 2, and the vacuum heat insulating material of Comparative Examples 1-4.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a front view of a refrigerator 1 according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along line AA of the refrigerator 1 of FIG.
In the refrigerator 1 of the embodiment, a refrigerator compartment 2, an ice making chamber 3a, an upper freezer compartment 3b, a freezer compartment 4, and a vegetable compartment 5 are arranged from the top to the bottom.

A door for opening and closing the front opening of the refrigerator 1 is disposed on the front side of the refrigerating room 2 (front side of the sheet of FIG. 1).
Specifically, in the refrigerator compartment 2, the refrigerator compartment doors 6a and 6b supported by the hinges 10 and the like are rotated to open and close the front opening.

All the doors of the chambers 3a, 3b, 4, 5 other than the refrigerator doors 6a, 6b are drawer type doors.
The ice making room 3a and the upper freezing room 3b are provided with an ice making room door 7a and an upper freezing room door 7b that can be pulled out, and the freezing room 4 is provided with a lower freezing room door 8 that can be pulled out. Similarly, the vegetable compartment door 9 is provided in the vegetable compartment 5 so that it can be pulled out.
When each of the drawer type doors 7a to 9 is pulled out, the container forming the storage space of each of the chambers 3a to 5 is pulled out together with the door.

As shown in FIG. 2, packings 11 are fixed to the doors 6 a to 9 along the front outer peripheral edges of the chambers 2 to 5 of the box 1 </ b> H that forms the storage space of the refrigerator 1. The packing 11 hermetically seals between each door 6a-9 and the front outer periphery of each chamber 2-5.
The packing 11 is an elastic body made of, for example, butadiene rubber, and is deformed along the box 1H of the refrigerator 1 and the doors 6a to 9 by being elastically deformed. To do. In addition, the material of the packing 11 will not be limited if the airtight function demonstrated can be fulfill | performed.

  In addition, the box body 1H of the refrigerator 1 is provided with a partition heat insulation wall 12 in order to partition and insulate between different storage temperature zones of the refrigerating room 2, the ice making room 3a, and the upper freezing room 3b. The partition heat insulating wall 12 is a heat insulating wall having a thickness of about 30 to 50 mm, and each of various heat insulating materials such as styrofoam, foam heat insulating material (urethane foam), and vacuum heat insulating material 50e is used alone, or a plurality of heat insulating walls are used. It is manufactured by combining heat insulating materials.

  For example, the partition heat insulation wall 12 is comprised with the expanded polystyrene 33 and the vacuum heat insulating material 50e. The partition heat insulating wall 12 may be filled with a foam heat insulating material 23 such as rigid urethane foam, and is not particularly limited to the foamed polystyrene 33 and the vacuum heat insulating material 50e.

  On the other hand, the ice making chamber 3a and the upper freezing chamber 3b and the lower freezing chamber 4 are in the same freezing temperature zone, so there is no need for heat insulation, and the partition member 13 for partitioning is not a partition heat insulating wall for partitioning and insulating. Is provided. On the front surface of the partition member 13, a receiving surface for the packing 11 of the ice making chamber 3 a and the upper freezing chamber 3 b and the lower freezing chamber 4 is formed.

  A partition heat insulation wall 14 is provided between the lower freezer compartment 4 and the vegetable compartment 5 having different cooling temperatures to partition and insulate. The partition heat insulation wall 14 is a heat insulation wall having a thickness of about 30 to 50 mm, similar to the partition heat insulation wall 12, and is made of styrofoam, foam heat insulation (urethane foam), vacuum heat insulation 50 or the like.

For example, the partition heat insulating wall 14 is composed of expanded polystyrene 33 and a vacuum heat insulating material 50. The partition heat insulating wall 14 may be filled with a foam heat insulating material 23 such as rigid urethane foam, and is not particularly limited to the foamed polystyrene 33 and the vacuum heat insulating material 50.
Basically, a partition heat insulating wall that partitions and insulates adjacent rooms is installed on a member that partitions the chambers having different storage temperature zones such as refrigeration and freezing.

In addition, although the inside of the box body 1H illustrated the case where each storage room of the refrigerator compartment 2, the ice making room 3a, the upper stage freezer room 3b, the lower stage freezer room 4, and the vegetable room 5 was respectively arranged from the top, The arrangement is not particularly limited to this.
In addition, the refrigerator doors 6a and 6b, the ice making door 7a, the upper freezer door 7b, the lower freezer door 8, and the vegetable door 9 shown in FIG. 1 are also opened and closed by rotation, opened and closed by drawers, and divided into doors. The number is not particularly limited to this.

A box 1H shown in FIG. 2 includes an outer box 21 made of, for example, several millimeters of steel plate that forms an outer plate, and an inner box 22 made of resin such as polypropylene that forms a storage space for stored items. I have.
In a space formed by the outer box 21 and the inner box 22 of the box body 1H, a heat insulating portion for insulating the storage chambers 2 to 5 and the outer space G in the box body 1H is provided. A vacuum heat insulating material 50 having a high heat insulating property is disposed on either the outer box 21 side or the inner box 22 side in the heat insulating portion, and a foam heat insulating material 23 such as hard urethane foam (see FIG. 2) in a space other than the vacuum heat insulating material 50. Filling).

<Refrigeration cycle>
As shown in FIG. 2, in order to cool each room, such as the refrigerator compartment 2, the ice making room 3a, the upper and lower freezing rooms 3b and 4 and the vegetable room 5 of the refrigerator 1, the ice making room 3a, the upper and lower stages On the back (rear) side of the freezer compartments 3b and 4, there is provided a cooler (evaporator) 28 that absorbs heat by evaporating the refrigerant and cools the interior.

  A cooler (evaporator) 28, a compressor 30, a condenser 31, and a capillary tube (not shown) are connected to form a refrigeration cycle in which refrigerant circulates. Above the cooler 28, a blower 27 that circulates the cold air cooled by the cooler 28 in the refrigerator 1 and keeps it at a predetermined low temperature is disposed.

<Inside light 45>
An interior lamp 45 having a case 45a protruding toward the upper foamed heat insulating material 23 is arranged on a part of the top surface of the inner box 22 of the box 1H, and when the user opens the door of the refrigerator 1 The interior is bright and easy to see. The interior light 45 is not particularly limited as long as it can brightly illuminate the interior such as an LED (Light Emitting Diode), a light bulb, a fluorescent lamp, and a xenon lamp.

The arrangement of the interior lamp 45 reduces the thickness of the foam heat insulating material 23 between the case 45a and the outer box 21 (the thickness dimension is reduced) and the heat insulating performance is lowered. A highly heat-insulating vacuum heat insulating material 50a is disposed to ensure heat insulating performance. Needless to say, the interior light 45 does not have to be in the illustrated position.
<Control unit>

  A recessed portion 40 for housing an electrical component 41 mounted on a control board, a power supply board, and the like for controlling the operation of the refrigerator 1 is provided in the rear portion of the top surface of the box 1H. A cover 42 is provided to cover the electrical component 41 mounted on a control board, a power supply board, and the like disposed in the recess 40.

  The height of the cover 42 is set to the same height as the top surface of the outer box 21 or substantially the same height in consideration of the appearance design property relating to the merchantability and securing the internal volume that is the (storage) capacity of the refrigerator 1. Although not particularly limited, when the height of the cover 42 protrudes upward from the top surface of the outer box 21, it is desirable that the cover 42 be within a range of 10 mm.

  Thus, since the recessed part 40 is formed in the state which only the space which accommodates the electrical component 41 in the foam heat insulating material 23 side is depressed, in order to ensure the thickness which has predetermined heat insulation in this state, it is inevitably content. Product (capacity of refrigerator 1) is sacrificed. On the other hand, if the internal volume (capacity of the refrigerator 1) is increased, the thickness of the foam heat insulating material 23 between the recess 40 and the inner box 22 becomes thin, and a predetermined heat insulating performance cannot be ensured. Here, since the heat transfer coefficient is inversely proportional to the thickness of the foam heat insulating material 23, the heat insulating performance is proportional to the thickness of the foam heat insulating material 23.

<Arrangement of vacuum insulation>
Therefore, in the refrigerator 1 shown in FIG. 2, a vacuum heat insulating material 50 a having a higher heat insulating property than the foam heat insulating material 23 is provided on the surface of the recess 40 facing the foam heat insulating material 23 to secure and enhance the heat insulating performance. . The vacuum heat insulating material 50a is formed in a substantially Z shape so as to straddle the case 45a of the internal light 45 and the electrical component 41 at a position along the inner surface of the outer box 21a projected from the inside to the external space G. It is said.
The cover 42 is made of a fire-resistant steel plate in consideration of fire from the outside or a case where the electrical component 41 mounted on the control board, the power supply board or the like is ignited for some reason.

On the other hand, since the compressor 30 and the condenser 31 disposed at the lower back of the box 1H are components that generate a large amount of heat, the inner box 22 of the compressor 30 and the condenser 31 is prevented in order to prevent heat from entering into the cabinet. A vacuum heat insulating material 50b having a high heat insulating property is disposed on the projection surface to the side.
FIG. 3 is a cross-sectional view of the refrigerator 1 in FIG. 1 taken along the line ZZ.
The vacuum heat insulating material 50 is arrange | positioned at the inner surface of the outer box 21c of the side part of the box 1H (refer FIG. 1). In the example of FIG. 3, the vacuum heat insulating material 50 c disposed on the inner surface of the outer box 21 b on the back surface of the box 1 </ b> H is provided so as to cover the outer box 21 b on the back surface of the box 1 </ b> H and is bent in a substantially U shape. ing.

(Embodiment 1)
Next, the vacuum heat insulating material 50 in Embodiment 1 of this invention is demonstrated.
FIG. 4 is a cross-sectional view showing the vacuum heat insulating material 50 according to the first embodiment of the present invention. In FIG. 4, the adsorbent 54 is shown enlarged.
The vacuum heat insulating material 50 includes a core material 51, an inner bag 52 for holding the core material 51 in a compressed state, and a jacket material having a gas barrier layer that covers the core material 51 held in a compressed state by the inner bag 52. 53 and an adsorbent 54 that adsorbs moisture (H ₂ O) and gas components (N ₂ , O ₂ , CO _2, etc.) inside the jacket material 53.

  The peripheral portion of the jacket material 53 that covers the core material 51, the inner bag 52, and the adsorbent 54 is welded to form a welded portion 53c, which seals the inside of the jacket material 53. The vacuum heat insulating material 50 is used by bending the welded portion 53c toward the main body side in the use state.

  In the vacuum heat insulating material 50 of the first embodiment, glass wool having an average fiber diameter of 4 μm is used as the core material 51 as a laminate of inorganic fibers not bonded or bound with a binder (binder) or the like. Glass wool is an aggregate of glass fibers obtained by laminating glass fibers in a layer so that the mass per unit volume (hereinafter referred to as basis weight) is a predetermined value by a centrifugal method. Glass wool is cotton-like because it is not molded with a binder (binder) or the like, and is characterized by a large bulk density (mass volume ratio).

The inner bag 52 is not particularly limited as long as it is a heat-weld synthetic resin film, but in the first embodiment, a high-density polyethylene film is used.
In addition, although the case where a high density polyethylene film is used as the inner bag 52 is illustrated, it may be a synthetic resin film that can be thermally welded, and is not limited to a high density, but a polyethylene film, polypropylene (polypropylene), polybutylene It is good also as films, such as a terephthalate (polybutylene terephthalate).

The jacket material 53 has a predetermined gas barrier property, and is formed of a multilayer laminate film in which several kinds of films such as synthetic resins are laminated and bonded together. The covering material 53 is not particularly limited as long as it has gas barrier properties and can be heat-welded and can maintain (hold) a predetermined degree of vacuum.
In the first embodiment, the outer covering material 53 is a laminated film having a four-layer structure including a surface protective layer, a first gas barrier layer, a second gas barrier layer, and a heat welding layer. As a specific configuration, for example, the surface protective layer is a synthetic resin film such as polyamide, polypropylene, polyethylene terephthalate, or the like.

  The jacket material 53 is preferably a biaxially stretched film formed by stretching in the biaxial direction in consideration of gas barrier properties, hygroscopicity, and the like. As the first and second gas barrier layers, a biaxially stretched type film having a gas barrier film made of metal, metal oxide, inorganic material or the like is preferable, for example, polyethylene terephthalate, ethylene vinyl alcohol copolymer (Ethylene- Vinylalcohol). There are films such as -Copolymer) and polyvinyl alcohol. Note that a metal foil layer may be provided on one or both of the first and second gas barrier layers of the jacket material 53.

As the heat welding layer of the jacket material 53, the strength at the time of heat welding is required. The heat-welded layer is often a film such as polyethylene, such as low density, medium density, high density, and linear low density, or polypropylene, polybutylene terephthalate. The film of each layer is bonded by a dry laminating method through a two-component curable urethane adhesive, but the adhesive and the bonding method are not particularly limited thereto.
Note that the laminate structure of the jacket material 53 is not limited to a four-layer structure, and may be a three-layer, five-layer, or a plurality of other layers as long as a predetermined performance can be secured as a vacuum heat insulating material. Not.

  As the adsorbent 54, a physical adsorption type synthetic zeolite was used, but the adsorbent 54 is not particularly limited thereto. If water and gas (at least oxygen, nitrogen, carbon dioxide) are adsorbed, water molecules and gas molecules can be captured by pore-type physical adsorption or chemical reaction ionic bonds or covalent bonds. Either of the types of chemical reaction type adsorption that adsorbs bismuth may be used. However, it is naturally impossible to use a material that is highly reactive and that alters the material constituting the vacuum heat insulating material 50 or generates a by-product.

<Method of manufacturing vacuum heat insulating material 50>
Next, the manufacturing method of the vacuum heat insulating material 50 of Embodiment 1 is demonstrated.
FIG. 5 (a) shows a method for manufacturing the vacuum heat insulating material 50 of Embodiment 1, and FIG. 5 (b) shows an example of a method for manufacturing a vacuum heat insulating material of a comparative example (conventional).

First, the manufacturing process of the vacuum heat insulating material 50 of Embodiment 1 is demonstrated using Fig.5 (a).
As shown in FIG. 5A, a glass wool 51a which is a material of the core material 51 and has a predetermined basis weight is supplied, and the core material of the vacuum heat insulating material 50 to be manufactured in the first core material cutting step 101. The glass wool 51a is cut, that is, roughly cut to a size that is slightly larger than the outer size of 51.

Subsequently, in the core material laminating step 102, the glass wool 51a is laminated in a plurality of layers according to the required thickness of the vacuum heat insulating material 50.
Glass wool 51a may be a single layer, and in this case, core material lamination step 102 is not performed.

Subsequently, in the core material drying step 103, the core material 51 laminated in a plurality of layers is passed through a high-temperature drying furnace for a necessary time to remove moisture and reduce the amount of moisture brought into the core material 51. In addition, you may employ | adopt the batch type which puts the core material 51 in a high temperature drying furnace for required time.
FIG. 6A is a side view conceptually showing the core material compression step 104 of the first embodiment, and FIG. 6B conceptually shows a second core material cutting step 105 and an inner bag packaging step 106. FIG. 6C is a side view conceptually showing the inner bag packaging step 106.

  Subsequently, in the core material compressing step 104 in FIG. 5A, as shown in FIG. 6A, in order to average the variation in the basis weight of the glass wool 51a, they are laminated and dried by the compression devices 104a and 104b. The core material 51a is compressed to a density range (A) described later (see arrow α1 in FIG. 6A).

Subsequently, as shown in FIG. 6 (b), the core material 51 is conveyed in the second core material cutting step 105 so as to have a density range (B) (details will be described later) lower than the density range (A). 105a, 105b and 105c are transported and restrained to obtain a density range (B). And it cut | disconnects so that it may become the finished product shape of the core material 51 of the vacuum heat insulating material 50 in the state which hold | maintained the external size of the glass wool 51a of the density range (B) pressed by the conveyors 105b and 105c in the density range (B). Cutting with blades 105d, 105e, and 105f. At this time, the adsorbent 54 is introduced into the core material 51 by an adsorbent introduction process (not shown).
In FIG. 6B, the cutting blade 105f is provided on at least one of the front side of the paper in FIG. 6B and the back side of the paper in FIG. 6B with the conveyors 105b and 105c interposed therebetween. .

  Subsequently, in the inner bag packaging step 106, as shown in FIG. 6 (c), the inner bag film 52a with the front end 52a1 welded is transferred from the rollers r1 and r2 to the density range (B) by the conveyors 106a and 106b. It is supplied to the core material 51 which is conveyed in a held state. Then, in the state where the density range (B) is maintained, the periphery of the inner bag film 52a covered with the core material 51 by the heat welding devices 106c and 106d is heat-welded so as to cover the core material 51 and seal the density range. A core material 51 is obtained that is held in a sealed state by the inner bag 52 while holding (B).

  Subsequently, in the bag filling process 107, the core material 51 sealed with the inner bag 52 is inserted into the jacket material 53, and the inside of the jacket material 53 is evacuated, so that the inside of the vacuum packaging machine having a vacuum chamber (not shown). In At this time, in order to efficiently evacuate the inside of the jacket material 53 and the core material 51 before putting into the vacuum packaging machine, the jacket in a state where the core material 51 compressed by the inner bag 52 is inserted. The material 53 may be sufficiently warmed to about 100 ° C.

Subsequently, in the inner bag opening step 108, one end of the inner bag 52 is opened while the density range (B) is maintained so that the inside of the core material 51 is evacuated while the density range (B) is maintained. Let
Subsequently, in the evacuation process 109, the inside of the vacuum chamber in which the core material 51 in the inner bag 52 having one end opened is placed in the outer jacket material 53 while maintaining the density range (B). Evacuate.

Subsequently, in the vacuum packaging step 110, after reaching a predetermined degree of vacuum, the opening of the jacket material 53 is thermally welded to complete the vacuum heat insulating material 50.
At this time, the core material 52 introduced into the jacket material 53 in the bag filling process 107 is charged into the vacuum packaging machine 107 in the bag filling process 107, and then from the inner bag opening process 108 to the vacuum packaging process 110 in the density range (B ) Is held.

  On the other hand, the comparative example (conventional) shown in FIG. 5B is similar to the core material cutting step 101 to the core material drying step 103 in the first embodiment from the core material cutting step 201 to the core material drying step 203. However, the inner bag packaging process 204 of the comparative example (conventional) is different from the inner bag packaging process 106 of the first embodiment in that the density range (B) is not maintained. The bag filling process 205 of the comparative example (conventional) is the same as the bag filling process 107 of the first embodiment.

However, the inner bag opening process 206 to the vacuum packaging process 208 of the comparative example (conventional) are different from the inner bag opening process 206 to the vacuum packaging process 208 of the first embodiment in that the density range (B) is not maintained.
That is, unlike the comparative example (conventional), the first embodiment compresses the core material 51 so as to be in the density range (A) in the core material compression step 104, and is lower than the density range (A). Thus, the second core material cutting step 105, the inner bag packaging step 106, and the inner bag opening step 108 to the vacuum packaging step 110 are characterized.

The flatness of the core material 51 of the vacuum heat insulating material 50 is improved by compressing the core material 51 so that the density range (A) is higher than the density range (B) when vacuuming.
Also, in the second core material cutting step 105, the core material 51 is cut so as to have a finished product shape of the vacuum heat insulating material 50 while keeping the outer size of the core material 51 in the density range (B) lower than the density range (A). To do. And the precision of the outer diameter dimension of the vacuum heat insulating material 50 can be made high by hold | maintaining the subsequent inner bag packaging process 106 and the inner bag opening process 108-the vacuum packaging process 110 in a density range (B).

<Details of Core Material Compression Step 104 to Inner Bag Packaging Step 106 of Embodiment 1>
The reason why the density range (B) is maintained in the second core material cutting step 105 and the inner bag packaging step 106 will be described in detail with reference to FIG.
FIG. 7A is a view showing a state before compression of the glass wool 51a forming the core material 51 laminated with the conventional glass fibers, and FIG. 7B is a glass wool forming the core material 51 laminated with the conventional glass fibers. It is the figure which showed the state which raise | generates lamination | stacking deviation in the direction (direction orthogonal to a compression direction) which is not a compression direction when 51a is compressed.

As shown in FIG. 7A, the glass wool 51a, which is the material of the core material 51, has a cotton shape in which glass fibers are simply laminated as described above, and has a large bulk density (mass volume ratio). The bulkiness is increased by laminating the layers.
Here, it is assumed that the outer dimension in the extending direction (left-right direction in FIG. 7A) orthogonal to the thickness direction of the glass wool 51a is cut into S.

  When the glass wool 51a cut into the outer dimension S is enclosed in the inner bag 52 and compressed by the compression devices 104a and 104b, the side end face 51a1 is uncompressed when compressed in the direction of the arrow α2 as shown in FIG. In many cases, the position is shifted from the original position. That is, the side end face 51a1 of the glass wool 51a protrudes from the original position before compression by X1 and X2 during compression.

That is, in the conventional manufacturing method, since the core material 51 is cut into a predetermined outer dimension in advance and then packed and compressed in the inner bag 52, the end surface 51a1 of the core material 51 is formed as shown in FIG. There was a phenomenon in which X1 and X2 minutes shifted from the original position before compression.
This is one of the causes that have deteriorated the external dimension accuracy of the vacuum heat insulating material 50 conventionally.

Therefore, in the present invention, as described above, after setting the density range (B) on the glass wool 51a forming the core material 51, the glass wool 51a is cut to have a predetermined outer dimension of the core material 51.
Here, an example of the process from the core material compression process 104 to the inner bag packaging process 106 shown in FIG.

  6A, in the core material compression step 104, the glass wool 51a laminated by the compression devices 104a and 104b is compressed so as to be in the density range (A). At this time, since it compresses to about 70% of the final thickness of the vacuum heat insulating material 50, the partial displacement of the glass wool 51a constituting the core material 51 (vacuum heat insulating) Variation of the glass fiber density in the material 50) is corrected, and in the final state of the vacuum heat insulating material 50, the flatness of the outer surface can be improved.

Thereafter, as shown in FIG. 6B, the core material 51 is conveyed by the conveyors 105a, 105b, and 105c so that the density range (B) is lower than the density range (A). In the core material cutting step 105 of FIG. 2, the cutting blades 105d, 105e, so that the outer size of the core material 51 becomes the finished product shape of the vacuum heat insulating material 50 in the state of the density range (B) lower than the density range (A). Cut at 105f.
Then, as shown in FIG. 6 (c), in the inner bag packaging step 106 of FIG. 5 (a), the inner bag film 52a is supplied, and the conveyor 106a, so as to keep the density range (B) of the core material 51, While being transported by 106b, it is thermally welded by the thermal welding devices 106c and 106d to be in a sealed state.

  Here, in the state of the density range (B) lower than the density range (A), the outer size of the core material 51 is cut so as to be the finished product shape of the vacuum heat insulating material 50, and the subsequent steps are also performed in the density range (A ) It is considered that the accuracy of the external dimensions of the vacuum heat insulating material 50 of the final product is increased by carrying out in the state of the lower density range (B).

In addition, although the conveyor system was illustrated as an example of the process in the first embodiment, the method is particularly limited as long as it can satisfy the density range (A) and the density range (B) of the core material 51 and can be cut into a desired size. Not what you want. For example, a dedicated jig may be used.
However, when the conveyor system is adopted, as shown in FIG. 6, the work process can be performed by a flow operation, and therefore the work is easy and efficient, so the conveyor system is desirable.

<Details from inner bag opening process 108 to vacuum packaging process 110>
Details of the process from the inner bag opening process 108 to the vacuum packaging process 110 will be described including the effects.
Before evacuation, it is necessary to open one end of the inner bag 52 in which the core material 51 is sealed. However, as in the conventional process, the inner bag 52 is once pulled out, and one end of the inner bag 52 is removed with scissors or a cutter. When it is cut and opened, the work is usually performed so that a portion close to the cut portion of the inner bag 52 is kept in close contact (valve effect).

FIG. 8 is a view for explaining the vacuum packaging process, and FIG. 8 (a) is a side sectional view showing a state in which the core material 51 has expanded and restored before the conventional evacuation. FIG. 8B is a side sectional view showing an operation of opening one end of the inner bag 52 in which the core material 51 of the first embodiment is sealed.
However, the close contact is released depending on the way of work, and the core material 51 may expand and be restored as shown in FIG. In this state, as described above, the side end surface 51a1 of the core member 51 is displaced (see dimensions X1 and X2 in FIG. 7B).

On the other hand, in the present invention, since the core material 51 is already sealed with the inner bag 52 when the core material 51 is put into the vacuum packaging machine in the bag filling step 107 of FIG. 5A, the density range (A ) It is held in a lower density range (B).
5A, one end of the welded portion of the inner bag 52 is opened. At this time, the core material 51 is held in the density range (B) lower than the density range (A) by the holding plates 108a and 108b as shown by an arrow α3 in FIG. 8B so that the core material 51 is not restored. doing.

FIG. 9A is a plan view of the inner bag 52 showing a cutout portion 52b of the inner bag 52 that is an outer packaging material of the core material 51 of the vacuum heat insulating material 50. FIGS. FIG. 9D is an enlarged view of part A of FIG. 9A, showing an example of easy-seal release means such as a notch 52b of the inner bag 52 in an enlarged manner.
In FIG. 9, it is assumed that the core material 51 is accommodated in the inner bag 52, and the periphery of the inner bag 52 is welded and sealed by a welding portion 52c.

  In the inner bag opening step 108, in order to easily open one end of the inner bag 52, in the present invention, as shown in FIG. 9A, a notch 52 b or the like is formed in a part of the inner bag 52 (welded portion 52 c). It is provided so that the 52H portion shown in FIG. 8B can be cut (opened) just by being pulled as indicated by an arrow α4.

  As for the shape of the notch 52b, there are easy-seal releasing means such as a notch 52b1 as shown in FIG. 9B and a V-cut 52b2 as shown in FIG. 9C. However, the shape is not limited to these shapes. is not. That is, any easy sealing releasing means such as a notch that triggers the inner bag 52 to be cut may be used, as long as a U-shaped cut, a saw blade cut, and other similar effects can be obtained. When the portion 52H is pulled in the direction of the arrow α4, it is desirable that the portion be cut linearly in a direction orthogonal to the pulling direction as indicated by line C in FIG.

  The material of the inner bag 52 is not particularly limited as long as it can be heat-welded with a uniaxially stretched polyethylene film or polypropylene film. For example, Hybron (trade name) manufactured by Mitsui Chemicals, which is a straight-cut film, can be used.

Further, if an easily openable material is selected as the material of the inner bag 52, the inner bag 52 can be provided with the same easy opening property even if the notchless is eliminated. For example, a large number (for example, 1,500 to 2,000 holes / cm ² ) of reverse cone-shaped non-through holes are processed on the entire surface of the film, or an end portion of the film as shown in FIG. There are easy-sealing releasing means such as those in which fine holes (pores) or friction scratches 52b3 are applied to the (seal part).

Others are not particularly limited as long as they are easily openable. For example, as an easily openable material, there is a film subjected to magic cut or magic cut straight processing (both trade names) manufactured by Asahi Kasei Packs. In the first embodiment, a uniaxially stretched high-density polyethylene film provided with a V-cut 52b2 (see FIG. 9C) is used. In addition, the uniaxial stretching direction of the uniaxial stretching type high-density polyethylene film in FIG. 9 is the C-line direction.
Thereby, it is possible to smoothly cut along the line C shown in FIG. 9 by pulling the 52H portion of FIG. 8B in the direction of the arrow α4.
Thereafter, after the evacuation step 109, in the vacuum packaging step 110, the edge portion of the outer covering material 53 is thermally welded by the heat welding portions 110a and 110b, and the outer covering material 53 is sealed.

In the first embodiment, the density range (A) of the core material 51 in the core material compression step 104 of FIG. 5A is 280 kg / m ³ , and the density range of the core material 51 in the second core material cutting step 105 ( B) was set to 140 kg / m ³ respectively. With the manufacturing method of the first embodiment, the core material 51 is manufactured with a width of 500 mm, a length of 1500 mm, and a thickness of 15 mm (as design values). The width and length are both within ± 1 mm, and the thickness is ± 0. It was within a dimensional error range of 0.5 mm, and no large irregularities were seen on the surface of the vacuum heat insulating material 50, and flatness was ensured.

Moreover, when the thermal conductivity of the vacuum heat insulating material 50 obtained in Embodiment 1 was measured, 0.82 (mW / m · K) was displayed. The measurement of the thermal conductivity was carried out using a thermal conductivity measuring device HC-074 manufactured by Eihiro Seiki with an average temperature of the hot plate of 24 ° C.
In FIG. 10, the figure which put together the measurement result of the vacuum heat insulating material 50 of Embodiment 1, 2 and the vacuum heat insulating material of Comparative Examples 1-4 is shown.

According to the first embodiment, in the vacuum heat insulating material 50, the core material 51 formed by superimposing a fiber assembly in which fiber materials are laminated in the thickness direction without using a binder (binder) on a single layer or a plurality of layers is temporarily provided. Thus, by compressing in a non-heated state so as to be in a predetermined density range (A), the variation consisting of a portion having a large basis weight (glass fiber density) and a portion having a small basis weight (glass fiber density), which is peculiar to the fiber material laminate, is averaged. be able to.
Therefore, the surface unevenness | corrugation when evacuating and using the vacuum heat insulating material 50 can be decreased.

  Further, by cutting into a predetermined dimension while being held in a density range (B) lower than the density range (A), the core material 51 is sealed with the inner bag 52 while maintaining the density range (B) at the time of cutting. Since the cut surface can be kept straight or cut, a core material 51 with good external dimension accuracy can be obtained, and vacuum packaging with high external dimension accuracy can be achieved by vacuum packaging while maintaining the density range of the core material 51. 50 can be provided.

  Further, the inner bag 52 is provided with an easy-seal releasing means such as a notch in a part of the welded portion 52c in order to release the seal once before evacuation so that the inner bag 52 is easily cut. Since the core material 51 is vacuum-packed while maintaining the compressed state, the sealing can be easily released by attaching easy-seal releasing means such as a notch to a part of the welded portion 52c of the inner bag 52.

  Furthermore, the inner bag 52 is made of an easily openable material that can be easily cut by pulling in the vacuum exhaust direction. As a result, vacuum packaging is performed while maintaining the compressed state of the core material 51, so that the inner bag 52 is easily opened using a material that is easy to open. Furthermore, it is possible to give the tearing portion linearity by giving directionality to this material.

In addition, when the core material 51 is processed, a process that consumes enormous heat energy such as a heating press is not performed, and thus it is possible to contribute to protection of the global environment in the manufacturing process. Further, since no binder (binder) is used for the core material 51, the inorganic fiber aggregates do not leave solid components that cause resistance during vacuum evacuation or thermal crosslinking.
Accordingly, it is possible to provide the vacuum heat insulating material 50 with improved evacuation efficiency and high heat insulation performance.

  Thus, the vacuum heat insulating material 50 has good dimensional accuracy and surface flatness. Therefore, even if it adheres to the inner surface of the steel plate of the outer box 21 (21a, 21b) such as the refrigerator 1 or the freezer shown in FIG. It is difficult to provide a product with high appearance quality (design) with high heat insulation performance.

(Embodiment 2)
In the second embodiment, the density range (A) of the core material 51 in the core material compression step 104 in FIG. 5A is set to 370 kg / m ³ , and the second core material cutting step 105 (see FIG. 5A). Except for setting the density range (B) of the core material 51 to 260 kg / m ³ , a vacuum heat insulating material 50 having the same outer dimensions was manufactured in the same manufacturing process as in the first embodiment.

As a result, both the width and length are within ± 0.5 mm and the thickness is within the dimensional error range of ± 0.5 mm, and flatness is not observed on the surface of the vacuum heat insulating material 50 as in the first embodiment. Was secured. The thermal conductivity of the vacuum heat insulating material 50 obtained in the second embodiment is 0.84 (mW / m · K). The measurement of the thermal conductivity was performed under the same conditions as in the first embodiment.
In the second embodiment, the same effects as those in the first embodiment are obtained.

(Comparative Example 1)
In Comparative Example 1, the density range (A) of the core material 51 in the core material compression step 104 in FIG. 5A is set to 260 kg / m ³ , and the second core material cutting step 105 (see FIG. 5A). Except that the density range (B) of the core material 51 was set to 100 kg / m ³ , vacuum heat insulating materials having the same outer dimensions were manufactured in the same manufacturing process as in the first embodiment.

  As a result, the width dimension error varied ± 2.5 mm, and the length dimension error varied ± 3.2 mm. The thickness dimension error was ± 1.5 mm, and many small irregularities were observed on the surface of the vacuum heat insulating material 50. The heat conductivity of the vacuum heat insulating material 50 obtained in Comparative Example 1 is 0.87 (mW / m · K). The measurement of thermal conductivity was performed under the same conditions as in the first embodiment.

  The width dimension error ± 2.5 mm of the vacuum heat insulating material of Comparative Example 1 is larger than the width dimension error ± 0.5 to 1 mm of the vacuum heat insulating material 50 of Embodiments 1 and 2, and the vacuum of Comparative Example 1 The length dimensional error ± 3.2 of the heat insulating material is larger than the length dimensional error ± 0.5 to 1 mm of the vacuum heat insulating material 50 of the first and second embodiments. Further, the thickness dimensional error ± 1.5 mm of the vacuum heat insulating material of Comparative Example 1 is larger than the thickness dimensional error ± 0.5 mm of the vacuum heat insulating material 50 of the first and second embodiments. Therefore, the vacuum heat insulating material of Comparative Example 1 is inferior in outer dimensional accuracy compared to the first embodiment.

The vacuum heat insulating material of Comparative Example 1 has many small irregularities on the surface, and is inferior in surface flatness as compared with the vacuum heat insulating material 50 having good surface flatness of Embodiments 1 and 2.
Moreover, the heat conductivity of the vacuum heat insulating material of Comparative Example 1 is 0.87 (mW / m · K), and the heat conductivity of the vacuum heat insulating material 50 of Embodiments 1 and 2 is 0.82 to 0.84 (mW / m). The vacuum heat insulating material of Comparative Example 1 is inferior to the vacuum heat insulating material 50 of Embodiments 1 and 2 in terms of heat insulating properties.

(Comparative Example 2)
In Comparative Example 2, the density range (A) of the core material 51 in the core material compression step 104 in FIG. 5A is set to 390 kg / m ³ , and the second core material cutting step 105 (see FIG. 5A). Except that the density range (B) of the core material 51 was set to 100 kg / m ³ , vacuum heat insulating materials having the same outer dimensions were manufactured in the same manufacturing process as in the first embodiment.

As a result, the vacuum heat insulating material of Comparative Example 2 had a width dimensional error of ± 2.2 mm and a length dimensional error of ± 2.9 mm. The thickness error was ± 0.5 mm, and no irregularities were found on the surface of the vacuum heat insulating material.
The heat conductivity of the vacuum heat insulating material obtained in Comparative Example 2 was 1.2 (mW / m · K). The measurement of thermal conductivity was performed under the same conditions as in the first embodiment.

As shown in FIG. 10, the vacuum heat insulating material of Comparative Example 2 has a thickness dimension error of ± 0.5 mm, which is equivalent to the vacuum heat insulating material 50 of Embodiments 1 and 2, and has surface flatness according to Embodiment 1. 2 is equivalent to the vacuum heat insulating material 50.
However, the vacuum heat insulating material of Comparative Example 2 has a width dimension error (± 2.2 mm) and a length method error (± 2.9 mm), and the width and length dimensions of the vacuum heat insulating material 50 of the first and second embodiments. It was found to be inferior to the error (± 0.5 to 1 mm).
Furthermore, the heat conductivity of the vacuum heat insulating material of Comparative Example 2 is 1.2 (mW / m · K), and the heat conductivity of the vacuum heat insulating material 50 of Embodiments 1 and 2 is 0.82 to 0.84 ( mW / m · K), which is insulative and inferior to the vacuum heat insulating material 50 of the first and second embodiments.

(Comparative Example 3)
In Comparative Example 3, the core material 51 is not compressed in the core material compression step 104 in FIG. 5A, and the density range of the core material 51 in the second core material cutting step 105 (see FIG. 5A) (B The vacuum heat insulating material 50 having the same outer dimensions was manufactured in the same manufacturing process as in the first embodiment except that only 260 kg / m ³ was set.

As a result, as shown in FIG. 10, both width and length width dimension errors were within ± 0.5 mm, but thickness dimension error was ± 1.3 mm, and small irregularities on the surface of the vacuum heat insulating material. Many were seen.
The thermal conductivity of the vacuum heat insulating material of Comparative Example 3 was 0.88 (mW / m · K). In addition, about the measurement of heat conductivity, it carried out on the same conditions as Embodiment 1. FIG.

The vacuum heat insulating material of Comparative Example 3 was compared with the vacuum heat insulating material 50 of Embodiments 1 and 2, and as shown in FIG. It was found that the surface flatness was inferior to the thickness dimensional error (± 0.5 mm) and surface flatness of the vacuum heat insulating material 50 of Embodiments 1 and 2 in terms of surface flatness.
Furthermore, the heat conductivity of the vacuum heat insulating material of Comparative Example 3 is 0.88 (mW / m · K), and the heat conductivity of the vacuum heat insulating material 50 of Embodiments 1 and 2 is 0.82 to 0.84 (mW). / M · K), which is insulative and inferior to the vacuum heat insulating material 50 of the first and second embodiments.

(Comparative Example 4)
As Comparative Example 4, a vacuum heat insulating material 50 was manufactured by a conventional manufacturing method.
The conventional manufacturing method of Comparative Example 4 will be described with reference to FIG.
First, in the core material cutting step 201, glass wool 51a which is a material of the core material 51 and has a predetermined basis weight is supplied and cut into the outer size of the core material 51 of the vacuum heat insulating material 50 to be manufactured. Thereafter, in the core material lamination step 202, the glass wool 51a is laminated in a plurality of layers according to the required thickness of the vacuum heat insulating material 50. Then, in the core material drying step 203, the moisture of the laminated core material 51 is removed, and the amount of moisture brought into the core material 51 is reduced. The steps up to here are the same as those in the first and second embodiments.

  Thereafter, the adsorbent 54 is introduced into the core material 51 by an adsorbent injection process (not shown), and then the inner bag 52 in a state where the thickness of the core material 51 is about 20 mm in the inner bag packaging process 204. The film is supplied and the core material 51 is covered and sealed. Thereby, the core material 51 about 20-30 mm in thickness is obtained.

  This core material 51 is inserted into the jacket material 53 in the bagging process 205, and put into a vacuum packaging machine having a vacuum chamber in order to make the inside of the jacket material 53 in a vacuum state. At this time, in order to efficiently evacuate the inside of the jacket material 53 and the core material 51 before putting into the vacuum packaging machine, the jacket in a state where the core material 51 compressed by the inner bag 52 is inserted. The material 53 may be sufficiently warmed to about 100 ° C.

Then, in the inner bag opening step 206, as shown in FIG. 8A, one end of the inner bag 52 is opened so as to be evacuated to the inside of the core material 51, and in the vacuum chamber 207 Is evacuated.
After reaching a predetermined degree of vacuum, the vacuum insulating material 50 is completed by thermally welding the opening of the jacket material 53 in the vacuum packaging step 208.

  In these steps, as shown in comparison with FIG. 5A, the core material 52 in the inner bag packaging step 204 is not constrained to maintain the density range. Further, the core material 51 put into the jacket material 53 in the bagging process 205 is not restricted so as to keep the density range in particular after being put into the vacuum packaging machine. In addition, the cutting process of the core material 51 in a constrained state that maintains the density range as in the second core material cutting process 105 in FIG. 5A of the first embodiment is not performed.

  In the manufacturing method of Comparative Example 4, when the outer dimensions of the core material 51 were manufactured with the target width of 500 mm, length of 1500 mm, and thickness of 15 mm, as shown in FIG. 10, the width dimension error (deviation) was ± 3 mm, long The dimensional error varied widely as ± 5 mm. The thickness dimension error was ± 1.2 mm, but relatively unevenness was observed on the surface of the vacuum heat insulating material 50. The thermal conductivity of the vacuum heat insulating material 50 obtained in Comparative Example 4 was 0.84 (mW / m · K). Note that the measurement of thermal conductivity was performed under the same conditions as in the first embodiment.

As shown in FIG. 10, the vacuum heat insulating material 50 of Comparative Example 4 is greatly inferior to the vacuum heat insulating materials 50 of Embodiments 1 and 2 in terms of width, length, and thickness dimensional errors (deviations).
Moreover, it turned out that the vacuum heat insulating material 50 of the comparative example 4 is inferior to the vacuum heat insulating material 50 of Embodiment 1, 2 by surface flatness.
However, the vacuum heat insulating material 50 of Comparative Example 4 has a thermal conductivity of 0.84 (mW / m · K) and is substantially equivalent to the vacuum heat insulating material 50 of the first and second embodiments. The same performance as the vacuum heat insulating materials 50 of 1 and 2 was shown.

(Embodiment 3)
When the vacuum heat insulating material 50 of Embodiment 1 was apply | coated to the side surface inner surface of the outer case 21 of the refrigerator 1, and the hot-melt-adhesive agent which is not shown in figure was apply | coated and stuck on the whole bonding surface of the vacuum heat insulating material 50, 20 refrigerators 1 were produced. The side surface of the outer box 21 of the refrigerator 1 was flat, and no defects such as undulations due to unevenness occurred. In addition, the vacuum heat insulating material 50 was pressed with respect to the outer box 21 by the pressure higher than usual at the time of affixing so that the corrugation by the vacuum heat insulating material 50 may generate | occur | produce easily.
According to the third embodiment, the heat insulating performance of the refrigerator 1 can be ensured, the flatness of the outer surface of the refrigerator 1 is maintained, and the refrigerator 1 having a good design property and high merchantability can be realized.

(Comparative Example 5)
The vacuum heat insulating material 50 of Comparative Example 4 is applied to the inner surface of the side surface of the outer box 21 of the refrigerator 1 and a hot melt adhesive (not shown) is applied to the entire attachment surface of the vacuum heat insulating material 50 and pasted. When 20 units were manufactured, one wavy pattern consisting of small irregularities was generated on the side surface of the outer box 21 of the refrigerator 1. As in the third embodiment, the vacuum heat insulating material 50 was pressed against the outer box 21 at a pressure higher than usual at the time of pasting so that the waving due to the vacuum heat insulating material 50 was easily generated.
Therefore, the refrigerator 1 of the comparative example 5 cannot guarantee the flatness of the outer surface, and has a problem in terms of design.

  In addition, in the said embodiment, although what sealed after sealing the core material 51 in the inner bag 52 was illustrated in the outer covering material 53, if the shape of the molded body of the core material 51 can be maintained, it will not necessarily be an inner bag. The core material 51 may be inserted into the jacket material 53 without being sealed after being stored in the core 52. In this case, it is desirable to keep the core material 51 accommodated in the inner bag 52 in the density range (B) in the bag filling step 107 of FIG.

1 Refrigerator 50 Vacuum heat insulating material 51 Core material 52 Inner bag 52b Notch (easy-sealing release means)
52b1 notch (easy seal release means)
52b2 V-cut (easy seal release means)
52b3 Hole processing and friction scratch processing (easy seal release means)
52c Welded part (sealed)
53 Jacket material (outer bag)
54 Adsorbent 104 Core material compression process (compression process)
104a, 104b Compressor 105 Second core material cutting step (cutting step)
106 Inner bag packaging process 106c, 106d Thermal welding device 107 Bag filling process 108 Inner bag opening process (sealing release process)
108a, 108b Holding plate 109 Vacuum exhausting process 110 Vacuum packaging process A Density range (first density range)
B density range (second density range)

Claims (6)

A core formed by a laminated fiber aggregate superimposed single layer or plural layers without using a binder fiber material in the thickness direction, an adsorbent which adsorbs moisture and gas components of the core material, the core A vacuum heat insulating material manufacturing method comprising an inner bag for storing a material and the adsorbent, and an outer bag for storing the inner bag therein,
A compression step of compressing the core material to a predetermined first density range;
A cutting step of cutting the core material into a predetermined outer dimension in a state of being held in a second density range lower than the first density range;
An inner bag packaging step for sealing the core material with the inner bag while maintaining the second density range in the cutting step;
A bagging step of inserting a core material sealed with the inner bag into the outer bag;
A vacuum packaging step of evacuating and sealing the outer core with the outer bag after the core material released from the sealing of the inner bag is held in the second density range. The inner bag is provided with easy-seal release means that is easy to release the seal in a part of the welded portion that forms the seal,
The method for producing a vacuum heat insulating material according to claim 1, further comprising: a seal release step for releasing the seal of the inner bag between the bag filling step and the vacuum packaging step. A core formed by a laminated fiber aggregate superimposed single layer or plural layers without using a binder fiber material in the thickness direction, an adsorbent which adsorbs moisture and gas components of the core material, the core A vacuum heat insulating material comprising an inner bag for storing the material and the adsorbent, and an outer bag for storing the inner bag therein,
And compressed so that the first density range of Jo Tokoro the core material, cut into a predetermined outer dimensions while maintaining the lower second density range than the first density range, the first at the time of cutting 2 The core material sealed with the inner bag while maintaining the density range is inserted into the outer bag to release the sealing of the inner bag while maintaining the second density range, and evacuated. A vacuum heat insulating material characterized by being sealed with the outer bag. 4. The vacuum heat insulating material according to claim 3 , wherein easy sealing release means is provided in a part of the welded portion of the inner bag, which is easy to cut when the seal is released. Wherein the first density range is 280~370kg / ^{m 3,} the vacuum heat insulating material according to claim 3 or claim 4 second density range is characterized by a 140~260kg / ^{m 3.} Refrigerator having a vacuum heat insulating material according to claims 3 to any one of claims 5.

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