JP6517551B2 - Method of manufacturing vacuum insulation panel, vacuum insulation panel, core material, refrigerator - Google Patents

Description

  An embodiment of the present invention relates to a method of manufacturing a vacuum insulation panel, a vacuum insulation panel manufactured by the method, a core material constituting the vacuum insulation panel, and a refrigerator including the vacuum insulation panel.

  BACKGROUND ART Conventionally, a heat insulating material configured by housing a core material having a heat insulating function in an outer packaging material has been considered (see, for example, Patent Document 1). And in the vacuum insulation panel which is an example of this kind of heat insulating material, forming the core material which constitutes the main part from resin fiber is considered. By the way, when providing this kind of vacuum heat insulation panel in a refrigerator, it is calculated | required that the groove part for accommodating a thermal radiation pipe is provided in the surface of a core material, for example. That is, a technique for forming a desired asperity shape on the surface of the core material is required.

JP, 2006-105286, A

  In this embodiment, even when the core material is formed of resin fibers, a method of manufacturing a vacuum insulation panel capable of forming a desired uneven shape on the surface of the core material, and vacuum insulation manufactured by this manufacturing method A refrigerator, a panel, a core material constituting the vacuum insulation panel, and the vacuum insulation panel is provided.

  A manufacturing method of a vacuum insulation panel concerning this embodiment is a method of manufacturing a vacuum insulation panel provided with a core material which consists of resin fibers, and discharges a resin solution which melted resin used as a raw material of the above-mentioned resin fiber from a nozzle Thereby forming a core material forming process for forming the core material. Then, in the core material forming process, projections and recesses are formed on the surface of the core material by adjusting the discharge mode of the resin solution.

A schematic cross-sectional view showing a vacuum insulation panel according to an embodiment The figure which shows an example of the manufacturing method of a vacuum insulation panel The figure which shows the structural example of the uneven | corrugated shape of a vacuum heat insulation panel (the 1) The figure which shows the structural example of the uneven | corrugated shape of a vacuum heat insulation panel (the 2) Typical perspective view showing the heat insulation box of the refrigerator Schematic perspective view showing the vacuum insulation panel set of the refrigerator Sectional drawing which shows the structural example of the wall part of the refrigerator in which the vacuum insulation panel was integrated (the 1) Sectional drawing which shows the structural example of the wall part of the refrigerator in which the vacuum insulation panel was integrated (the 2)

  Hereinafter, an embodiment will be described based on the drawings. The vacuum heat insulation panel 10 illustrated in FIG. 1 includes the core material 11 constituting the main part in the outer packaging material 12. The core material 11 is composed of resin fibers 13. The outer packaging material 12 constitutes a surface portion of the vacuum heat insulation panel 10. The outer packaging material 12 is, for example, a so-called laminate material in which metal or metal oxide is vapor-deposited on one or two or more resin films, and has low gas permeability and high airtightness. The outer packaging material 12 containing the core material 11 is sealed after the pressure inside thereof is reduced to a pressure close to a vacuum. Thereby, the outer packaging material 12 which contains the core material 11 is formed as the vacuum heat insulation panel 10 in which the inside was pressure-reduced. And the convex part 20 and the recessed part 21 are provided in the surface of the core material 11, in other words, the surface of the vacuum heat insulation panel 10. As shown in FIG.

  The resin fibers 13 are formed by an electrospinning method. The resin fibers 13 formed by the electrospinning method are fine fibers having an average fiber diameter of about 1 μm, and long fibers having a length of 1000 times or more the outer diameter. Further, the resin fibers 13 are not entirely linear but randomly crimped and crimped. Therefore, the resin fibers 13 are easily entangled with each other, and easily form a non-woven fabric. By using the electrospinning method, the spinning of the resin fiber 13 and the formation of the non-woven fabric can be performed simultaneously. As a result, the core material 11 can be easily formed in a short number of steps.

  Moreover, the resin fiber 13 can easily secure an extremely thin average fiber diameter of nanometer to micrometer by utilizing the electrospinning method. In the case of the conventional glass fiber, the fiber length is short and the entanglement between the fibers is small. Therefore, when glass fiber is used, it becomes difficult to maintain it in the non-woven fabric state. Moreover, in the case of glass fiber, it is generally difficult to simultaneously perform the spinning of the glass fiber and the formation of the non-woven fabric.

  The resin fibers 13 forming the core material 11 are formed in a circular or elliptical cross section with a substantially uniform cross section. The resin fibers 13 forming the core material 11 are formed of an organic polymer having a density smaller than that of glass. By forming the resin fibers 13 of a polymer having a density smaller than that of glass, the resin fibers 13 can be reduced in weight. The core material 11 may be blended with two or more types of resin fibers 13. As an example of the core material 11 formed by blending, polystyrene fiber and aromatic polyamide resin (registered trademark: Kepler) are used. In addition to the above, the core material 11 is polycarbonate, polymethyl methacrylate, polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyoxymethylene, polyamideimide, polyimide, polysulfone, polyethersulfane, It is selected from polyether imide, polyether ether ketone, polyphenylene sulfide, modified polyphenylene ether, syndiotactic polystyrene, liquid crystal polymer, urea resin, unsaturated polyester, polyphenol, melamine resin, epoxy resin and copolymers containing these, etc. It can be formed by blending one or more polymers.

  When the fiber material 13 is formed by electrospinning, the above-mentioned polymer is made into a solution. As the solvent, for example, isopropanol, ethylene glycol, cyclohexanone, dimethylformamide, acetone, ethyl acetate, dimethylacetamide, N-methyl-2-pyrrolidone, hexane, toluene, xylene, methyl ethyl ketone, diethyl ketone, butyl acetate, tetrahydrofuran, dioxane, Volatile organic solvents such as pyridine and water can be used. Moreover, as a solvent, 1 type chosen from the said solvent may be sufficient, and multiple types may be mixed. In addition, the solvent applicable to this embodiment is not limited to the said solvent. The said solvent is an illustration to the last.

  Even in the case where the core material 11 is constituted by mixed spinning, the resin fibers 13 are all set so that the outer diameter d is d <1 μm. By blending a plurality of types of resin fibers 13 in this manner, it is possible to achieve the heat insulating properties, weight reduction, and strength improvement of the core material 11. As the volume of the voids formed between the intertwined resin fibers 13 decreases, the number of voids in the core material 11 increases. As the number of voids between the resin fibers 13 increases, the heat insulation can be improved. Therefore, it is preferable that the core material 11 reduce the outer diameter d of the fibers of the resin fiber 13 constituting the core material to the order of nanometers such as d <1 μm. By reducing the outer diameter d of the resin fibers 13 as described above, the volume of the voids formed between the resin fibers 13 decreases while the number thereof increases. By reducing the diameter in this manner, the volume of the voids formed between the entangled resin fibers 13 is further reduced, the number thereof is further increased, and the heat insulation of the core material 11 can be improved.

  The resin fibers 13 may be added with various inorganic fillers such as, for example, silicon oxides, metal hydroxides, carbonates, sulfates, and silicates. By adding the inorganic filler to the resin fiber 13 as described above, the strength can be improved while maintaining the heat insulating property of the core material 11. Specifically, as the inorganic filler to be added, wollastonite, potassium titanate, zonotolite, gypsum fiber, aluminum pole, MOS (basic magnesium sulfate), aramid fiber, carbon fiber, glass fiber, talc, mica, glass flake Etc. can also be used.

  Next, the manufacturing method of said vacuum-insulation panel 10 is demonstrated. As shown in FIG. 2, the apparatus for manufacturing a vacuum insulation panel 10 includes a plurality of nozzles 101 and a plurality of return electrodes 102. The nozzle 101 and the return electrode plate 102 face each other. A high voltage of, for example, several kV or more is applied between the nozzle 101 and the return electrode plate 102. That is, an electric field is formed between the nozzle 101 and the counter electrode plate 102 by the high voltage applied. Then, the manufacturing apparatus includes the placement unit 103 between the nozzle 101 and the return electrode plate 102. A sheet material 12 s that forms the outer packaging material 12 is placed on the placement unit 103. The plurality of nozzles 101 are arranged in a matrix above the placement unit 103. Each of the nozzles 101 is configured to be swingable, and the discharge direction of the resin solution can be adjusted. Further, the plurality of return electrodes 102 are arranged such that a matrix or a plurality of long return electrodes 102 are arranged in parallel below the mounting portion 103. The placement unit 103 may be configured of, for example, a conveyance belt. Moreover, the structure of a manufacturing apparatus is not restricted to this structure, A various structure is employable.

  The resin as the raw material of the resin fiber 13 is dissolved in a solvent having compatibility with the resin, and supplied to the respective nozzles 101. The resin solution supplied to each nozzle 101 is jetted from the respective nozzles 101 toward the sheet material 12s at high pressure. At this time, as described above, an electric field by high voltage is formed between the nozzle 101 and the return electrode plate 102. The solution of the resin jetted from the nozzle 101 is refined by the application of a high voltage and is charged, so it is randomly attracted from the nozzle 101 to the return electrode plate 102 electrostatically while containing fluctuations. In addition, when the resin solution injected at high pressure is injected from the nozzle 101, the solvent is vaporized. Therefore, it becomes fine fibrous and adheres to the sheet material 12s in a random shape. As a result, the core material 11 in which the fine resin fibers 13 are randomly intertwined is formed on the surface of the sheet material 12s on the nozzle 101 side.

  Also, the resin fibers 13 are jetted from the nozzle 101 in a random and random manner, that is, in an irregular state. Therefore, the resin fibers 13 turn irregularly when being jetted from the nozzle 101, and are formed in a random crimped shape that is not straight as a whole. As a result, the resin fibers 13 entangle each other irregularly and firmly to constitute the core material 11. In addition, the resin fibers 13 may have a spiral shape when being jetted from the nozzle 101. The spiral shaped resin fibers 13 are firmly entangled with other resin fibers 13 and contribute to the improvement of the strength of the core material 11. Furthermore, the resin fibers 13 are continuously jetted from the nozzle 101. Therefore, the resin fibers 13 to be formed become one fiber that is substantially continuous until the injection from the nozzle 101 is completed. As a result, the resin fibers 13 become very long filaments having a fiber length of 1000 times or more with respect to the outer diameter of the fibers.

  When the resin fiber 13 is formed by the electrospinning method, the fiber has a continuous sufficient length without interruption. Therefore, not only entanglement with other fibers but also entanglement of resin fiber 13 by electrospinning is continuously entwined due to its length and irregular shape due to turning during formation. As a result, the resin fiber 13 by the electrospinning method forms the core material 11 also by the strong entanglement of one fiber itself. Thereby, the core material 11 of a more stable shape can be formed.

  In addition, when forming the core material 11, before forming the core material 11 into a film, it is good to mask the edge part of the sheet material 12s beforehand with the masking tape which is not shown in figure, for example. Thereby, it can avoid that the core material 11 is formed in the edge part of 12 s of sheet materials. The end portion of the sheet material 12s is a portion sealed when forming the sheet material 12s as the outer packaging material 12. Therefore, if the resin fibers 13 exist in this portion, the degree of sealing is impaired, and the degree of vacuum of the vacuum insulation panel 10 can not be maintained. In addition, the sheet material 12s includes a conductive metal layer, and is susceptible to the action of an electric field. Therefore, the core material 11 can be efficiently formed on the surface of the sheet material 12s.

  In the core material forming process shown at the top of FIG. 2, the manufacturing apparatus forms the projections 20 and the recesses 21 on the surface of the core material 11 by adjusting the discharge mode of the resin solution from the nozzle 101. In this case, the manufacturing apparatus can adjust at least one of the discharge amount of the resin solution, the discharge angle of the resin solution, and the strength of the electric field applied to the resin solution as a discharge mode of the resin solution from the nozzle 101 Is configured. The adjustment of the discharge amount of the resin solution can be performed, for example, by adjusting the pressure applied to the resin solution when discharging the resin solution from the nozzle 101. That is, the core material 11 is obtained by increasing the discharge amount of the resin solution from the nozzle 101 corresponding to the portion where the convex portion is desired to be formed and reducing the discharge amount of the resin solution from the nozzle 101 corresponding to the portion where the concave portion is desired to be formed. The desired asperity shape can be formed on the surface of the.

  Further, adjustment of the discharge angle of the resin solution can be performed, for example, by adjusting each nozzle 101 by swinging each nozzle 101. That is, each nozzle 101 is swung toward the portion where the convex portion is to be formed, and the desired unevenness shape is formed on the surface of the core material 11 by reducing or eliminating the nozzles 101 toward the portion where the concave portion is to be formed. be able to. Further, adjustment of the strength of the electric field applied to the resin solution can be performed by adjusting the magnitude of the voltage applied between each nozzle 101 and each counter electrode plate 102. That is, the magnitude of the voltage applied between the nozzle 101 and the counter electrode plate 102 corresponding to the portion where the convex portion is to be formed is increased, and the magnitude of the voltage applied between the nozzle 101 and the counter electrode plate 102 corresponding to the portion where the concave portion is desired to be formed. By reducing the thickness, it is possible to form a desired uneven shape on the surface of the core material 11. In addition, it is possible to form uneven | corrugated shape with high precision by combining the adjustment of the discharge amount of the resin solution, the adjustment of the discharge angle of the resin solution, and the adjustment of an electric field suitably.

  In the vacuuming process shown in the middle of FIG. 2, the core material 11 having the concavo-convex shape formed by the core material forming process is accommodated in the bag-like outer packaging material 12. Then, the inside of the outer packaging material 12 containing the core material 11 is decompressed and sealed. Thereby, the vacuum heat insulation panel 10 in which the inside was pressure-reduced is obtained. In addition, it is difficult to form the convex part and recessed part which were clearly divided on the surface of the core material 11 only by the core material formation process shown at the uppermost step of FIG. That is, in the core material forming process, the amount of the resin fibers 13 in the portion where the convex portion is desired to be formed is relatively large, and the amount of the resin fiber 13 in the portion where the concave portion is desired is relatively decreased Is formed. Then, the lump of the resin fiber 13 is accommodated in the outer wrapping material 12 and the pressure is reduced inside, so that the convex part 20 and the concave part 21 clearly separated appear on the surface of the core material 11 and hence the vacuum heat insulation panel 10. That is, the portion where the amount of resin fiber 13 is relatively large forms the convex portion 20 with vacuuming, and the portion where the amount of resin fiber 13 is relatively small forms the concave portion 21 as vacuuming.

  According to the method of manufacturing the vacuum insulation panel 10 according to the present embodiment, the core material forming process of forming the core material 11 by discharging the resin solution in which the resin which is the raw material of the resin fiber 13 is dissolved from the nozzle 101 of the manufacturing apparatus. The convex portion 20 and the concave portion 21 are formed on the surface of the core material 11 by adjusting the discharge mode of the resin solution. According to this manufacturing method, even in the case where the core material 11 is formed of the resin fibers 13, it is possible to form a desired uneven shape on the surface of the core material 11.

  The resin fibers 13 may be formed, for example, by melt spinning. The melt spinning method is a method of obtaining the resin fiber 13 by heating and melting the raw material of the resin fiber 13 and extruding it into air or water through a nozzle and cooling.

  Next, the structural example of the vacuum heat insulation panel 10 manufactured by the above-mentioned manufacturing method is demonstrated. In the vacuum heat insulation panel 10 illustrated in FIG. 3, the convex portion 20 and the concave portion 21 are formed linearly along the longitudinal direction or the short side direction of the vacuum heat insulation panel 14. The width D2 of the recess 21 is smaller than the width D1 of the protrusion 20. Moreover, the vacuum heat insulation panel 10 illustrated in FIG. 4 has the 1st recessed part 21a and the 2nd recessed part 21b as the recessed part 21. As shown in FIG. The first recess 21 a corresponds to the recess 21 in the vacuum insulation panel 10 illustrated in FIG. 3. The second recess 21 b is additionally provided on the protrusion 20. That is, the vacuum heat insulation panel 10 illustrated to FIG. 4 adds the 2nd recessed part 21b to the convex part 20 of the vacuum heat insulation panel 10 illustrated to FIG. The first recess 21a and the second recess 21b have different widths D2 and D3. In this case, the width D3 of the second recess 21b is smaller than the width D2 of the first recess 21a. And the depth of the 2nd crevice 21b is deeper than the depth of the 1st crevice 21a. The first recess 21 a and the second recess 21 b are also formed linearly along the longitudinal direction or the short direction of the vacuum heat insulation panel 10. The vacuum insulation panel 10 illustrated in FIGS. 3 and 4 is provided in a refrigerator as described later in detail.

Next, a refrigerator using the above-mentioned vacuum heat insulation panel 10 will be described based on FIG. 5 and FIG.
The refrigerator 40 is equipped with the heat insulation box 41 which the front surface opened, as shown in FIG. The refrigerator 40 has a refrigeration cycle (not shown) attached to the heat insulation box 41. Further, the refrigerator 40 is provided with a partition plate (not shown) for dividing the heat insulation box 41 into a plurality of storage rooms, a heat insulation door (not shown) covering the front of the storage room, and a drawer (not shown) There is. The heat insulation box 41 of the refrigerator 40 has an outer box 42, an inner box 43, and a vacuum insulation panel set 50 sandwiched between the outer box 42 and the inner box 43. The outer box 42 is formed of a steel plate, and the inner box 43 is formed of a synthetic resin.

  The vacuum insulation panel set 50 is divided corresponding to each wall of the insulation box 41 of the refrigerator 40. Specifically, the vacuum insulation panel set 50 is divided into a left wall panel 51, a right wall panel 52, a ceiling panel 53, a back wall panel 54 and a bottom wall panel 55 as shown in FIG. The left wall panel 51, the right wall panel 52, the ceiling panel 53, the back wall panel 54, and the bottom wall panel 55 are all formed of the above-described vacuum insulation panel 10. The left wall panel 51, the right wall panel 52, the ceiling panel 53, the back wall panel 54 and the bottom wall panel 55 are assembled as a vacuum insulation panel set 50 and sandwiched between the outer case 42 and the inner case 43. A clearance formed between the left wall panel 51, the right wall panel 52, the ceiling panel 53, the rear wall panel 54, and the bottom wall panel 55 constituting the vacuum insulation panel set 50 between the outer box 42 and the inner box 43 Is sealed by a heat insulating sealing member (not shown). The seal member is formed of, for example, a foamable resin.

  Thus, the refrigerator 40 has the vacuum heat insulation panel set 50 which comprises the heat insulation box body 41. As shown in FIG. The vacuum insulation panel set 50 is configured of the vacuum insulation panel 10 described above. Therefore, high thermal insulation performance can be secured while further reducing the thickness and weight.

  FIG. 7 shows a state in which the vacuum insulation panel 10 illustrated in FIG. 3 is incorporated between the outer case 42 and the inner case 43. That is, the heat dissipation pipe 30 is provided in the recess 21 of the vacuum heat insulation panel 10. The heat radiation pipe 30 constitutes a part of the refrigeration cycle provided in the refrigerator, and releases heat when the high temperature / high pressure refrigerant discharged from the compressor flows. By utilizing the heat radiation from the heat radiation pipe 30, problems such as condensation can be avoided. In this case, a foamed heat insulating material 60 made of, for example, urethane is provided between the vacuum heat insulating panel 10 and the inner box 43. However, the foam heat insulating material 60 may not be provided.

  FIG. 8 shows a state in which the vacuum insulation panel 10 illustrated in FIG. 4 is incorporated between the outer case 42 and the inner case 43. That is, in this case, the heat radiation pipe 30 is provided in the second recess 21 b which is narrower and deeper than the plurality of recesses provided in the vacuum heat insulation panel 10. In the present embodiment, the heat dissipation pipe 30 is provided in the second recess 21 b which is the narrowest and the deepest among the plurality of recesses provided in the vacuum heat insulation panel 10. Also, in this case, the outer case 42 has a bead portion 70 for improving the strength of the outer case 42. Thereby, the outer case 42 also has the convex part 42a and the recessed part 42b.

  The convex portion 20 of the vacuum heat insulation panel 10 is opposed to the convex portion 42 a of the outer case 42. The recess 21 of the vacuum heat insulation panel 10 is opposed to the recess 42 b of the outer case 42. According to this configuration, the bead portion 70 can improve the strength of the outer case 42. Moreover, positioning of the vacuum heat insulation panel 10 with respect to the outer case 42 can be performed correctly by fitting of convex parts, and fitting of recessed parts. Further, the adhesion between the surface of the vacuum heat insulation panel 10 and the inner surface of the outer case 42 is improved, and the heat insulation performance can be improved. Also in this case, the foam heat insulating material 60 may not be provided.

  A manufacturing method of a vacuum insulation panel concerning this embodiment is a method of manufacturing a vacuum insulation panel provided with a core material which consists of resin fibers, and discharges a resin solution which melted resin used as a raw material of the above-mentioned resin fiber from a nozzle Thereby forming a core material forming process for forming the core material. Then, in the core material forming process, projections and recesses are formed on the surface of the core material by adjusting the discharge mode of the resin solution. According to this manufacturing method, even when the core material is formed of resin fibers, it is possible to form a desired uneven shape on the surface of the core material.

  This embodiment is presented as an example and is not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The present embodiment and the modifications thereof are included in the scope and the gist of the invention, and are included in the invention described in the claims and the equivalent scope thereof.

  For example, the core material 11 may have a configuration in which a plurality of non-woven fiber layers made of resin fibers 13 are laminated. In this case, the core material 11 may have, for example, several hundred to several thousand or more fiber layers laminated.

  In the drawing, 10 is a vacuum heat insulation panel, 11 is a core material, 12 is an outer packaging material, 13 is a resin fiber, 20 is a convex portion, 21 is a concave portion, 21a is a first concave portion, 21b is a second concave portion, 40 is a refrigerator, 101 Indicates a nozzle.

Claims (15)

A method of manufacturing a vacuum insulation panel comprising a core material made of resin fiber, comprising:
It has a core material forming process of forming the core material by discharging from a nozzle a resin solution in which a resin as a raw material of the resin fiber is dissolved
The manufacturing method of the vacuum heat insulation panel which forms a convex part and a recessed part in the surface of the said core material by adjusting the discharge aspect of the said resin solution in the said core material formation process.   In the core material forming step, at least one of the discharge amount of the resin solution, the discharge angle of the resin solution, and the strength of the electric field applied to the resin solution is adjusted as a discharge mode of the resin solution. The manufacturing method of the vacuum insulation panel of item 1.   The manufacturing method of the vacuum heat insulation panel of Claim 1 or 2 which forms the said convex part and the said recessed part in linear form.   The manufacturing method of the vacuum heat insulation panel in any one of Claim 1 to 3 which makes the width | variety of the said recessed part narrower than the width | variety of the said convex part.   The manufacturing method of the vacuum heat insulation panel in any one of Claim 1 to 4 which forms 1st recessed part and 2nd recessed part in which each differs in width as said recessed part.   The manufacturing method of the vacuum heat insulation panel of Claim 5 which makes the width | variety of said 2nd recessed part narrower than the width | variety of said 1st recessed part.   The manufacturing method of the vacuum heat insulation panel of Claim 5 or 6 which makes the depth of a said 2nd recessed part deeper than the depth of a said 1st recessed part.   The method for producing a vacuum insulation panel according to any one of claims 1 to 7, wherein the resin fiber is formed by an electrospinning method.   The method for producing a vacuum insulation panel according to any one of claims 1 to 7, wherein the resin fiber is formed by a melt spinning method.   The vacuum insulation panel manufactured by the manufacturing method in any one of Claims 1-9.   The core material with which the vacuum insulation panel according to claim 10 is provided.   A refrigerator comprising the vacuum insulation panel according to claim 10.   The refrigerator according to claim 12, wherein the recess comprises a heat radiation pipe.   The refrigerator according to claim 13, wherein the heat dissipation pipe is provided in a narrowest recess of the plurality of recesses provided in the vacuum heat insulation panel. The vacuum insulation panel is provided between an inner case and an outer case,
The outer box has a protrusion and a recess,
The refrigerator according to any one of claims 12 to 14, wherein the convex portion of the vacuum heat insulation panel faces the convex portion of the outer case, and the concave portion of the vacuum heat insulation panel faces the concave portion of the outer case.

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