JP5968942B2 - Thermal barrier - Google Patents

Description

  The present invention relates to a thermal barrier of the type comprising a closed cell. Insulation barriers are used, for example, to insulate commercial and home dwellings.

  Thermal insulation products are used as physical thermal barriers in many applications to prevent or reduce energy transfer. Depending on the application, the heat insulating barrier may work to prevent heat transfer, and depending on the application, the barrier may be used as a soundproofing material or a sound insulating material for reducing the intensity of sound.

  Several forms for insulating thermal energy include radiant thermal insulation achieved using reflective materials that reflect thermal energy, conductive thermal insulation to prevent heat passing through objects such as walls, and one side of an object such as walls. Convective insulation is included to reduce heat transfer by heating the air or other medium.

  Thermal insulation batts using materials such as foam, fiberglass, wool or polyester are a common type of thermal insulation used in buildings. These are effective in reducing heat conduction, but are not necessarily effective in reducing heat transfer by convection and radiation. By providing the heat insulating bat with the reflecting foil, it is possible to improve the effectiveness of the heat insulating bat to reduce heat transfer due to radiation.

  A further type of thermal insulation includes the use of a sheet of closed air cells structure (also known as a “bubble pack” used to package objects). By providing the reflective foils on both sides of the closed cell sheet, the heat insulation performance against the radiant heat of the sheet is improved.

  Insulation barriers such as those described above are effective in reducing heat transfer across the insulation barrier, the larger the size of the closed air cell, the greater the insulation expressed as a measure of the so-called “R grade” of the insulation barrier. Improves. The problem with such a thermal barrier with a closed air cell is that the size of the air cell cannot be made too large. This is because the air cell is not self-supporting, causing the cell membrane to collapse and reducing the effective heat insulation capacity of the heat insulation barrier. In addition, large air cells are less effective (effective) to insulate against heat transfer by convection. This is because if the volume of gas inside a large air cell is large, turbulent flow is generated and heat transfer by convection is promoted.

  The thermal barrier of the present invention has been developed to address these problems.

  According to the present invention, the thermal barrier comprises a cell layer having a plurality of closed cells. The cell layer is attached to the reinforcing layer, and the plurality of closed cells are formed in a plurality of cell groups. Closed cells in each cell group are separated by at least one partition.

  Preferably, collectively, each cell group forms a substantially annular structure. The annular structure can include an oval shape to a circular shape. The annular structure of the cell group can have a width of about 20-35 mm. Preferably, this width is 20 to 35 mm in diameter. More preferably, the annular structure has a diameter of about 25-35 mm, and in one embodiment 28 mm.

  Preferably, a closed cell is a closed air cell, i.e. a closed cell filled with air. However, it is clear that gases other than air can be used to fill the closed cell. For example, carbon dioxide may be used to fill a closed cell. Carbon dioxide has a lower thermal conductivity than air and is a nonflammable gas that can replace oxygen in the event of a fire, so it can upgrade the fire rating of the thermal barrier.

  Each cell group may comprise a reasonable number of separate closed cells. In one embodiment, this reasonable number is two, i.e. a pair of closed cells. However, depending on the embodiment, it may be possible to provide an even number of closed cells or an odd number of closed cells. Of course, each cell group may include 2, 3, 4, 5, 6, 7, 8, or more closed cells.

  Depending on the number of closed cells in one cell group, the shape of the closed cells may be semicircular, quarter-circular, or fan-shaped with various sector angles. In embodiments where one cell group has two cells and a substantially annular structure, the closed cell has a length greater than the width. In some embodiments, closed cells may be formed in different shapes depending on the number of distinct closed cells in a cell group. Within one cell glue, each closed cell is separated from other closed cells by one or more partitions.

  The partition wall is formed as a wall between the closed cells, and the thickness of the partition wall is approximately 1.0 to 4.0 mm, and thus the separation distance between the closed cells is defined. The partition walls are formed during the process of forming a cell layer structure having a plurality of closed cells. This molding process may be a vacuum suction extrusion forming process. The cell layer having a plurality of closed cells may be made using a plastic material, and in one embodiment is made from polyethylene. More specifically, the cell layer having a plurality of closed cells (closed cell layer) may be a mixture of low density polyethylene (LDPE), high density polyethylene (HDPE), and nanoclay.

  An advantage of the thermal barrier of the present invention is that a cell group having a plurality of separate closed cells effectively creates a large closed cell structure. The “effective” large closed cell structure increases the “effective” air volume of the closed cell and then improves the thermal insulation performance due to the closed cell layer. Since at least one partition in each cell group strengthens the cell group, the risk of cell collapse is reduced.

  The plurality of cell groups are separated by 2 to 5 mm. Preferably, each cell group is separated from the other cell groups by a distance of 3.0 mm.

  Preferably, a reinforcing layer is laminated on one side surface of the cell layer. In a preferred embodiment, two reinforcing layers are provided on each side of the cell layer, and the cell layer is sandwiched between these two reinforcing layers. In one embodiment, the reinforcing layer may be only a reflective layer such as a foil layer. Preferably, two layers that are reflective layers are provided on both sides of the cell layer. Reflective properties can be provided by providing one or both reinforcing layers with aluminum foil or other suitable metal foil. In other embodiments or in addition to this embodiment, the reinforcing layer may be a more structural substrate such as a woven product. The reinforcement layer may be made from a high density polyethylene (HDPE) woven fabric product and may be reinforced with glass fibers or fiber yarns to improve its durability.

  In the following, embodiments incorporating all aspects of the present invention are described by way of example only with reference to the accompanying drawings.

It is the schematic which shows the heat insulation barrier which concerns on one embodiment of this invention. FIG. 2 is an enlarged plan view showing “Area A” of the heat insulation barrier described in FIG. 1. It is side sectional drawing which shows a heat insulation barrier. It is a schematic plan view which shows the mold type | mold used for formation of a heat insulation barrier.

  1 to 3 show a thermal barrier 10 having a cell layer 12 (see FIG. 3) having a plurality of closed cells 20. The cell layer 12 is disposed between the two reinforcing layers 14.

  The plurality of closed cells 20 are formed in a plurality of cell groups 30, and the plurality of closed cells in each cell group are separated by a partition wall 22. The closed cell may be filled with an air cell, ie air. However, a gas other than air can be used to fill the closed cell, or an additive can be mixed into the gas / air.

  By collecting and grouping multiple closed cells and separating them with bulkheads, the size including height is effective without the disadvantages of turbulence as in the case of a large single air cell. Insulating cell structure is formed. Dividing a large and effective cell into multiple segments can increase the height and effective cell size while maintaining laminar flow within this “effective” large cell, ie, a group of cells. it can. Therefore, the heat resistance, that is, the R grade can be upgraded as compared with a sheet in which small closed cells are evenly distributed. When the effective size of the cell structure is enlarged, the thickness of the heat insulating barrier, in other words, the gap between the reinforcing layer and the reinforcing layer increases. This improves the degree of heat resistance that can be achieved by each cell group.

  The partitions 22 between the closed cells 20 in one group serve as pillars that impart structural rigidity to the cell group. Each cell group is provided with at least one partition wall. However, two or more partition walls may be used depending on the structure of the cell group.

  Therefore, when the “effectiveness” of the cell structure is improved, the heat insulating property of the heat insulating barrier 10 is improved. The partition walls provide rigidity to the cell group and reduce the possibility of the cells collapsing.

  1 and 2, each cell group 30 forms a cell structure 35, the shape of the cell structure 35 is substantially annular, and each cell group has two closed cells 20. It is shown. The annular structure of each cell group 30 is “effective” and corresponds to a large air cell. The annular structure 35 has an elliptical shape, an oval shape, a circular shape, or a shape between them, and this annular shape distributes a substantially constant pressure over the entire circumference of the annular shape, so that the cell structure The body is formed.

  In the illustrated embodiment, each cell group 30 has a pair of separate adjacent closed cells 20. Here, the term "separate" means that these cells are closed cells but are not allowed to move air between them.

  The closed cells 20 in one cell group 30 are arranged at an interval closer than the interval between the closed cells of different groups.

  The partition wall 22 is disposed between adjacent surfaces of a pair of closed cells in one cell group, in other words, between adjacent cell walls. 3 has the form of a gap between the cell walls 24 of adjacent closed cells 20. The gap may itself contain air / gas that is intentionally or accidentally filled during the cell layer forming process. Alternatively, the partition may be formed as a solid wall between adjacent cells.

  The cell group has a width of about 20 mm to 35 mm. The cell group has an annular structure as shown, and its width is a diameter d of 20 mm to 35 mm.

  The measured value d of the diameter is a value obtained by measuring the plurality of outer cell walls 24 of each cell group 30 from the outside. When stationary, the cell has a height h of about 5 mm to 15 mm, more specifically around 8 mm.

  Taking into account the manufacturing and measurement tolerances of the insulation barrier in a stationary state (ie, when there is no compression or expansion), the diameter of the annular structure of the cell group of the illustrated embodiment is about 25-30 mm. More specifically, it is about 28 mm.

  Depending on the number of closed cells in a group, the shape and size of the closed cells vary. In the pair of semicircular closed cells 20 in the illustrated embodiment, the length of each semicircular cell is greater than its width.

  The thickness t of the partition wall 22 measured from substantially the center of the cell wall 24 is about 2.0 to 3.0 mm, and more specifically about 2.5 mm.

  The separation distance between the cell groups may be different, but ideally is a distance that does not interfere with other cell groups 30 that are as close together as possible to upgrade the R rating. Therefore, the distance between the cell groups is suitably between 1 mm and 6 mm. In the accompanying drawings, the separation distance g between cell groups is shown as about 2.0 mm.

  The partition wall is formed as a wall between closed cells adjacent to each other in one cell group during the molding process of the cell layer 12. The molding process used may be any known process for forming closed air cells or bubble wraps, but is often a vacuum suction extrusion process using plastic materials.

  FIG. 4 is a schematic plan view showing a mold 40 used for forming the cell layer 12 into a sheet shape. A plastic material, such as polyethylene, is extruded as a first membrane 25 onto a mold 40 having a plurality of mold recesses 42, and air is sucked from the cell recesses through the vacuum holes 43, whereby the first membrane 25 is , Pulled into the mold recess 42 and shaped into the shape of the mold recess 42 that matches the “bubble” shape of the closed cell 20. The first membrane 25 forms a substantial part of the closed cell structure.

  Next, the second membrane 27 made of polyethylene is extruded onto the mold, and the mold recess 42 is closed and attached to the first layer, whereby a plurality of closed cells in which air / gas is confined are sealed. Is formed.

  In the process of forming the heat insulation barrier 10, the partition walls 45 arranged across the mold recess 42 form the partition walls 22 in each cell group 30. This is achieved by tightly attaching the first membrane 25 onto the partition wall 45 as the first membrane 25 is vacuumed into the mold recess 42. Therefore, when the molded product is cooled and removed from the mold, partition walls are formed between the adjacent closed cells. The partition wall 45 divides the mold recess 42 into two separate sections, each section having its own vacuum suction hole 43, each section forming an adjacent closed cell within the cell group 30. To do.

  After the cell layer 12 is formed by the process described above, a reinforcing layer is formed on one or both sides of the cell layer 12 to provide a framework and reinforcement for the final product of the thermal barrier. Specifically, the reinforcing layer 14 is laminated on both side surfaces of the cell layer, and one or both of the reinforcing layers 14 have a reflecting material or a reflecting layer 16 for improving the radiation heat insulating property of the heat insulating barrier 10. May be.

  The reflective properties of the reinforcing layer 14 can be provided by an aluminum foil or other metal foil 16 provided on one or both reinforcing layers. These reinforcing layers may be formed from woven fabric products made of high density polyethylene (HDPE) and may be reinforced with glass fibers or fiber yarns to improve their durability.

  The simplest form of cell layer 12 may be formed from polyethylene, although it may be formed from polyethylene. In one embodiment, the polyethylene mixture includes low density polyethylene (LDPE), high density polyethylene (HDPE), and nanoclay. Nanoclay further protects the cell layer from puncturing and tearing.

  In a preferred embodiment, the thermal barrier comprises the following multiple layers. These layers include a cell layer 12, an LDPE layer (not shown) coated on the reinforcing layer 14 for attaching the reinforcing layer to the cell layer, and a reinforcing layer in the form of a woven fabric substrate made of HDPE. 14 and a tie layer (not shown) including LDPE mixed with an additive for attaching the woven fabric layer 14 made of HDPE to the reflective layer 16.

  Although a pair of closed cells 20 are shown in each cell group 30 in the drawing, a larger number of closed cells may be formed in each cell group 30. The number of closed cells depends on the size of the cell group, but in addition to two, where the number of closed cells is the minimum for each group, the number of closed cells is three, four, five, There may be one, six, seven, eight, or more numbers. Accordingly, in each cell group, one partition wall is provided between the closed cells adjacent to each other, and this means that the plurality of recesses 42 in the mold 40 have a plurality of partition walls. Means that a plurality of partition walls are formed. Also, the closed cells vary in shape and size according to the number of closed cells in each group, and may have a sector shape having a sector shape from a quarter circle to various sector angles.

  In order to improve the fire resistance of the thermal barrier, a flame retardant additive may be added to the plastic extrudate forming the first and second membranes of the cell layer 12. In addition, a flame retardant may be coated on the HDPE woven fabric reinforcing layer 14. Here, the flame retardant is composed of a mixture obtained by adding a flame retardant additive to LDPE.

  Alternatively, a flame retardant additive may be added to the HDPE yarn used to weave the HDPE woven fabric reinforcement layer.

  Further, as described above, when carbon dioxide is injected into the closed air cell as a gas, it acts as a flame retardant / extinguishing agent because carbon dioxide replaces oxygen during a fire.

  The thermal barrier 10 may include a plurality of cell layers 12. The thermal barrier 10 includes, for example, two cell layers. One cell layer covers the other cell layer to form a double cell layer, and reinforcing layers 14 are provided on both sides of the double cell layer. As a result, the R grade of the heat insulation barrier is further upgraded.

  The thermal barrier described herein provides superior thermal insulation properties because each group of closed cells provides a wider and more effective thermal insulation region. Furthermore, since the closed cell is stable and has a rigid structure, the thermal barrier is reliable and reliable in use. The thermal barrier can effectively prevent heat from being transferred by conduction, convection and radiation.

Claims (3)

An insulation barrier,
Comprising a cell layer attached to the reinforcing layer, comprising a plurality of cell grooves having a substantially circular contour ;
Wherein each of the plurality of cell groups are formed by a plurality of closed cells which are separated from one another by at least one partition wall, the heat insulating barrier. Each cell group, 2, 3, 4, 5, 6, 7 or is formed by eight the number of closed cell, insulating barrier according to claim 1. The thermal barrier according to claim 1 or claim 2, wherein the substantially circular profile has a diameter of about 20 to 35 mm.

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