JP6091692B1 - 無機繊維積層体、それを用いた真空断熱材、及びその製造方法 - Google Patents
無機繊維積層体、それを用いた真空断熱材、及びその製造方法 Download PDFInfo
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Abstract
Description
《態様1》
高面密度部分及び低面密度部分を有する第1の無機繊維マットと、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを少なくとも含む無機繊維積層体であって、
前記第1の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は前記第2の無機繊維マットの高面密度部分が積層されており、かつ前記第2の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は前記第2の無機繊維マットの高面密度部分が積層されている、真空断熱材の芯材用の無機繊維積層体。
《態様2》
前記第1の無機繊維マットの前記高面密度部分及び前記低面密度部分が、その長さ方向にわたって互いに隣接する帯状の領域を形成しており、かつ
前記第2の無機繊維マットの前記高面密度部分及び前記低面密度部分が、その長さ方向にわたって互いに隣接する帯状の領域を形成している、
態様1に記載の無機繊維積層体。
《態様3》
前記第1の無機繊維マットにおいて、前記高面密度部分が、その幅方向における中央の帯状の領域であり、かつ前記低面密度部分が、前記中央の帯状の領域の両側に隣接する帯状の領域であり、かつ
前記第2の無機繊維マットにおいて、前記低面密度部分が、その幅方向における中央の帯状の領域であり、かつ前記高面密度部分が、前記中央の帯状の領域の両側に隣接する帯状の領域である、
態様2に記載の無機繊維積層体。
《態様4》
前記第1の無機繊維マットの前記高面密度部分及び前記低面密度部分が互いに分離しており、かつ/又は前記第2の無機繊維マットの前記高面密度部分及び前記低面密度部分が互いに分離している、態様1〜3のいずれか一項に記載の無機繊維積層体。
《態様5》
態様1〜4のいずれか一項に記載の無機繊維積層体及び前記無機繊維積層体を封入する外皮を含む、真空断熱材。
《態様6》
高面密度部分と低面密度部分とを有する第1の無機繊維マットを準備する工程;
高面密度部分と低面密度部分とを有する第2の無機繊維マットを準備する工程;及び
前記第1の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層し、かつ第2の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層する工程
を含む、無機繊維積層体の製造方法。
《態様7》
前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、無機繊維マットの面密度分布を測定することを含む、態様6に記載の方法。
《態様8》
前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、以下を含む、態様6に記載の方法。
無機繊維マット原反の面密度分布を測定すること;及び
前記無機繊維マット原反を切断して、高面密度部分及び低面密度部分を有する第1の無機繊維マットと、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを得ること。
《態様9》
前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、以下を含む、態様6に記載の方法。
無機繊維マット原反を高面密度部分及び低面密度部分を与えて形成すること;及び
前記無機繊維マット原反を切断し、高面密度部分及び低面密度部分を有する第1の無機繊維と、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを与えること。
《態様10》
前記第1の無機繊維マットを切断して、前記第1の無機繊維マットの高面密度部分と低面密度部分とを分離すること;
前記第2の無機繊維マットを切断して、前記第2の無機繊維マットの高面密度部分と低面密度部分とを分離すること
をさらに含む、態様8又は9に記載の方法。
本発明の無機繊維積層体は、高面密度部分及び低面密度部分を有する第1の無機繊維マットと、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを少なくとも含む。この無機繊維積層体では、第1の無機繊維マットの低面密度部分に、第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分が積層されており、かつ第2の無機繊維マットの低面密度部分に、第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分が積層されている。本発明の無機繊維積層体で用いられる無機繊維は、バインダーを含まない無機繊維、例えば真空断熱材の芯材に用いられる無機繊維であることが好ましい。
本発明の真空断熱材は、上記の無機繊維積層体と、無機繊維積層体を封入する外皮を含む。外皮は、通常は、熱融着層、バリア層、及び保護層を含み、かつその端部において対向している熱融着層を互いに熱融着させて封止部を形成し、芯材を封入する。各層を、接着剤の層で共に接着させることができる。また、各層間及び/又は各層の内部に、吸着剤、吸湿剤等を含有させることもできる。
本発明の無機繊維積層体の製造方法は、高面密度部分と低面密度部分とを有する第1の無機繊維マットを準備する工程、高面密度部分と低面密度部分とを有する第2の無機繊維マットを準備する工程、及び第1の無機繊維マットの低面密度部分に、第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層し、かつ第2の無機繊維マットの低面密度部分に、第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層する工程を含む。ここで、積層は、オンラインで連続的に行ってもよく、又はオフラインでバッチ式で行ってもよい。
1a 第1の無機繊維マットの高面密度部分
1b 第1の無機繊維マットの低面密度部分
2 第2の無機繊維マット
2a 第2の無機繊維マットの高面密度部分
2b 第2の無機繊維マットの低面密度部分
10 無機繊維積層体
100 無機繊維マット原反
100a 無機繊維マット原反の高面密度部分
100b 無機繊維マット原反の低面密度部分
Claims (10)
- 高面密度部分及び低面密度部分を有する第1の無機繊維マットと、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを少なくとも含む無機繊維積層体であって、
前記第1の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は前記第2の無機繊維マットの高面密度部分が積層されており、かつ前記第2の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は前記第2の無機繊維マットの高面密度部分が積層されている、無機繊維積層体。 - 前記第1の無機繊維マットの前記高面密度部分及び前記低面密度部分が、その長さ方向にわたって互いに隣接する帯状の領域を形成しており、かつ
前記第2の無機繊維マットの前記高面密度部分及び前記低面密度部分が、その長さ方向にわたって互いに隣接する帯状の領域を形成している、
請求項1に記載の無機繊維積層体。 - 前記第1の無機繊維マットにおいて、前記高面密度部分が、その幅方向における中央の帯状の領域であり、かつ前記低面密度部分が、前記中央の帯状の領域の両側に隣接する帯状の領域であり、かつ
前記第2の無機繊維マットにおいて、前記低面密度部分が、その幅方向における中央の帯状の領域であり、かつ前記高面密度部分が、前記中央の帯状の領域の両側に隣接する帯状の領域である、
請求項2に記載の無機繊維積層体。 - 前記第1の無機繊維マットの前記高面密度部分及び前記低面密度部分が互いに分離しており、かつ/又は前記第2の無機繊維マットの前記高面密度部分及び前記低面密度部分が互いに分離している、請求項1〜3のいずれか一項に記載の無機繊維積層体。
- 請求項1〜4のいずれか一項に記載の無機繊維積層体及び前記無機繊維積層体を封入する外皮を含む、真空断熱材。
- 高面密度部分と低面密度部分とを有する第1の無機繊維マットを準備する工程;
高面密度部分と低面密度部分とを有する第2の無機繊維マットを準備する工程;及び
前記第1の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層し、かつ第2の無機繊維マットの低面密度部分に、前記第1の無機繊維マット及び/又は第2の無機繊維マットの高面密度部分を積層する工程
を含む、無機繊維積層体の製造方法。 - 前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、無機繊維マットの面密度分布を測定することを含む、請求項6に記載の方法。
- 前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、以下を含む、請求項6に記載の方法。
無機繊維マット原反の面密度分布を測定すること;及び
前記無機繊維マット原反を切断して、高面密度部分及び低面密度部分を有する第1の無機繊維マットと、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを得ること。 - 前記第1の無機繊維マットを準備する工程及び/又は前記第2の無機繊維マットを準備する工程が、以下を含む、請求項6に記載の方法。
無機繊維マット原反を高面密度部分及び低面密度部分を与えて形成すること;及び
前記無機繊維マット原反を切断し、高面密度部分及び低面密度部分を有する第1の無機繊維と、高面密度部分及び低面密度部分を有する第2の無機繊維マットとを与えること。 - 前記第1の無機繊維マットを切断して、前記第1の無機繊維マットの高面密度部分と低面密度部分とを分離すること;
前記第2の無機繊維マットを切断して、前記第2の無機繊維マットの高面密度部分と低面密度部分とを分離すること
をさらに含む、請求項8又は9に記載の方法。
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