JP6539676B2 - 脆い断熱材をポリイソシアヌレート内に封入する方法 - Google Patents
脆い断熱材をポリイソシアヌレート内に封入する方法 Download PDFInfo
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- JP6539676B2 JP6539676B2 JP2016560470A JP2016560470A JP6539676B2 JP 6539676 B2 JP6539676 B2 JP 6539676B2 JP 2016560470 A JP2016560470 A JP 2016560470A JP 2016560470 A JP2016560470 A JP 2016560470A JP 6539676 B2 JP6539676 B2 JP 6539676B2
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- SYRHIZPPCHMRIT-UHFFFAOYSA-N tin(4+) Chemical class [Sn+4] SYRHIZPPCHMRIT-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1271—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed parts being partially covered
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/24—Structural elements or technologies for improving thermal insulation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
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Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Civil Engineering (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Ceramic Engineering (AREA)
- Building Environments (AREA)
- Polyurethanes Or Polyureas (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Thermal Insulation (AREA)
- Laminated Bodies (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Description
本発明の実施は、必ずしも、本明細書に記載された方法により封入される脆い断熱材の選択により限定されるわけではない。1つ以上の実施形態では、脆い断熱材は、それらを包み込むポリウレタン又はポリイソシアヌレート発泡体より高い断熱性を提供する。1つ以上の実施形態では、脆い断熱材は、それらを包み込むポリウレタン又はポリイソシアヌレート発泡体より低い熱伝導性を有する。1つ以上の実施形態では、脆い断熱材は、砕けやすい成分を含む。
この明細書全体を通して、発泡途上の発泡体に対する言及がなされ得る。この用語は、ポリウレタン及びポリイソシアヌレート発泡体(これらの用語は、一般的には、以下に記載されるように、本明細書において互換的に使用され得る)が、イソシアネート含有化合物を含む第1の流れと、イソシアネート反応性化合物を含む第2の流れとを混合することにより形成されるとの理解を伴って使用される。従来の専門用語を使用して、第1の流れ(すなわち、イソシアネート含有化合物を含む流れ)を、A側流、A側反応物質流、又は単にA流と呼ぶことができる。同様に、第2の流れ(すなわち、イソシアネート反応性化合物を含む流れ)を、B側流、B側反応物質流、又は単にB流と呼ぶことができる。いずれにしても、1つ以上の力学的及び/又は熱力学的特性に基づいて、経時的に発泡する発泡体を生成する反応が起こる。したがって、別途記載のない限り、発泡途上の発泡体という用語は、それらが硬化前に存在する場合、ポリウレタン及び/又はポリイソシアヌレート反応物質の混合物を意味すると理解されるであろう。硬化とは、反応混合物が、明らかに動かない(例えば、もはや流れない)場合を言う。
1つ以上の実施形態では、A側流は、イソシアネート含有化合物のみを含有していてもよい。1つ以上の実施形態では、多数のイソシアネート含有化合物が、A側に含まれていてもよい。他の実施形態では、A側流はまた、他の成分を含有していてもよく、これには例えば、限定するものではないが、難燃剤、界面活性剤、発泡剤、及び他の非イソシアネート反応性成分が挙げられる。1つ以上の実施形態では、A側に添加される補完成分は、非イソシアネート反応性である。
1つ以上の実施形態では、B側流は、イソシアネート反応性化合物のみを含んでもよい。1つ以上の実施形態では、多数のイソシアネート反応性化合物が、B側流に含まれていてもよい。他の実施形態では、B側流はまた、他の成分を含有していてもよく、これには例えば、限定するものではないが、難燃剤、界面活性剤、発泡剤、及び他の非イソシアネート含有成分が挙げられる。特定の実施形態では、B側は、イソシアネート反応性化合物と発泡剤とを含む。これらの又は他の実施形態では、B側はまた、難燃剤、触媒、乳化剤/可溶化剤、界面活性剤、充填材、防かび剤、帯電防止物質、水、及び当技術分野において従来から存在する他の成分を含んでいてもよい。
イソシアネートとポリオールとの間の重合反応、及び、ポリイソシアヌレート発泡体が所望される場合、遊離イソシアネート基間の三量体化反応を開始させると考えられている触媒が利用されてもよい。一部の触媒は、両反応を促進するが、2つ又はそれ以上の触媒を利用して、両反応を達成してもよい。有用な触媒としては、アルカリ金属とカルボン酸又はフェノールとの塩、例えば、オクタン酸カリウム等;濃縮フェノール、オキソ化合物、及び二級アミンの単核又は多核マンニッヒ塩基(二級アミンは、場合により、アルキル基、アリール基、又はアラルキル基により置換されている);三級アミン、例えば、ペンタメチルジエチレントリアミン(PMDETA)、2,4,6−トリス[(ジメチルアミノ)メチル]フェノール、トリエチルアミン、トリブチルアミン、N−メチルモルホリン、及びN−エチルモルホリン;塩基性窒素化合物、例えば、テトラアルキルアンモニウム水酸化物、アルカリ金属水酸化物、アルカリ金属フェノレート、及びアルカリ金属アルコラート;並びに、有機金属化合物、例えば、カルボン酸のスズ(II)塩、スズ(IV)化合物、及び有機鉛化合物(例えば、鉛ナフテネート及び鉛オクタノエート)が挙げられる。
界面活性剤、乳化剤、及び/又は可溶化剤もまた、ポリウレタン及びポリイソシアヌレート発泡体の製造において、発泡剤とイソシアネート及びポリオール成分との適合性を増大させるために利用されてもよい。界面活性剤は、2つの目的で提供され得る。第一に、界面活性剤は、全ての成分が完全に反応するように、全ての成分を乳化/可溶化するのに役立ち得る。第二に、界面活性剤は、気泡の核形成及び気泡の安定化を促進し得る。
難燃材は、特に、発泡体がペンタン異性体等の可燃性発泡剤を含有する場合、ポリウレタン及びポリイソシアヌレート発泡体の製造に使用されてもよい。有用な難燃剤としては、トリ(モノクロロプロピル)ホスフェート(別名トリス(クロロ−プロピル)ホスフェート)、トリ−2−クロロエチルホスフェート(別名トリス(クロロ−エチル)ホスフェート)、ホスホン酸、メチルエステル、ジメチルエステル、及びジエチルエステルが挙げられる。米国特許第5,182,309号は、有用な発泡剤を示すとして、参照により本明細書に組み込まれる。
有用な発泡剤としては、イソペンタン、n−ペンタン、シクロペンタン、アルカン、(シクロ)アルカン、ヒドロフルオロカーボン、ヒドロクロロフルオロカーボン、フルオロカーボン、フッ素化エーテル、アルケン、アルキン、二酸化炭素、ヒドロフルオロオレフィン(HFO)、及び希ガスが挙げられる。
イソシアヌレートは、6員環を形成する3つのイソシアネートの三量体反応生成物である。(イソシアネート含有化合物又はA側により提供される)NCO基と、(イソシアネート含有化合物又はB側により提供される)イソシアネート反応性基との当量比を、インデックス又はISOインデックスと呼ぶことができる。イソシアネート反応性基当量に対するNCO当量が等しい場合、インデックスは、1.00であり、インデックス100と呼ばれる。この混合物は、化学量論的に等しいと言える。イソシアネート反応性基当量に対するNCO当量の比が大きくなると、インデックスは大きくなる。インデックスが約150を上回る材料は、多くのポリウレタン結合が存在しても、三量体化され得ないポリイソシアヌレート発泡体として一般的に公知である。インデックスが約150を下回ると、発泡体は、幾らかのイソシアヌレート結合が存在する場合でも、ポリウレタン発泡体として一般的に公知である。本明細書の目的で、ポリイソシアヌレート及びポリウレタンへの言及は、具体的なISOインデックスが言及されない限り、互換的に使用されるであろう。
上記のように、本発明の1つ以上の実施形態により製造される発泡体は、脆い断熱材を包被するのに利用され、この発泡体としては、ポリウレタン及び/又はポリイソシアヌレート発泡体が挙げられる。当技術分野において一般的に理解されているように、発泡体は、気泡の縁及び面を形成する固体の支柱又はプレートの相互結合ネットワークを含み得る気泡構造である。また、これらの気泡構造は、1つ以上の実施形態では、0.8未満、他の実施形態では0.5未満、及び他の実施形態では0.3未満の「相対密度」により定義されてもよい。当業者であれば理解するであろうように、「相対密度」は、気泡壁を形成する固体の密度で割った、気泡材料の密度を意味する。相対密度が大きくなると、気泡壁は厚くなり、孔空間は収縮し、ある時点において、気泡構造から、分離した孔を含有する固体と定義された方がよいものに変化する。
一実施形態では、脆い断熱材を封入する方法は、予め形成された建築板を提供することと、1つ以上の脆い断熱材を該板上に位置付けすることと、脆い断熱材を少なくとも部分的に覆うように、かつ発泡途上の発泡体が該建築板と少なくとも部分的に結合するように、該発泡途上の発泡体を該脆い断熱材の上をおおうように堆積させることと、を含む。
本発明の第2の実施形態では、脆い断熱材を封入する方法は、発泡途上の発泡体をフェーサ材料上に堆積させることと、1つ以上の脆い断熱材を該発泡途上の発泡体上に位置付けすることと、その後、該脆い断熱材を少なくとも部分的に覆うように、かつ該予め堆積させた発泡途上の発泡体と結合するように、更なる発泡途上の発泡体を該脆い断熱材の上に堆積させることと、を含む。
第3の実施形態において、脆い断熱材を封入する方法は、1つ以上のスペーサをフェーサ材料上に位置付けすることと、その後、1つ以上の脆い断熱材を該スペーサ上に位置付けすることと、更にその後、発泡途上の発泡体を該脆い断熱材及び該フェーサ上に堆積させることと、を含む。
Claims (16)
- 断熱材を封入する方法であって、
i.予め形成された1枚の板を提供することと、
ii.1つ以上の断熱材を提供することと、
iii.接着剤を前記断熱材に、前記板に、又は前記断熱材及び前記板の両方に塗工することと、
iv.前記断熱材を前記板上に位置付けすることと、
v.前記断熱材の上方から発泡途上の発泡体を供給することにより、前記断熱材を覆うように、かつ前記発泡途上の発泡体が前記板と少なくとも部分的に結合するように、前記断熱材の上面の上に前記発泡途上の発泡体を堆積させることと、
vi.前記発泡途上の発泡体上にフェーサを適用することと、
を含む、方法。 - 前記位置付けする工程及び前記堆積させる工程を、統合したプロセスにおいて連続的に行い、前記位置付けする工程及び前記堆積させる工程を、別々の区別した工程として行う、請求項1に記載の方法。
- 前記板は、ポリイソシアヌレート又はポリウレタンの板である、請求項1又は2に記載の方法。
- 前記堆積させる工程は、予備硬化複合材を形成し、前記方法は、前記予備硬化複合材を加熱する工程を更に含む、請求項1〜3のいずれか一項に記載の方法。
- 前記加熱する工程を、ラミネータ内で行う、請求項4に記載の方法。
- 前記予め形成された1枚の板を提供することは、前記予め形成された1枚の板をコンベア上に配置することを含み、
前記位置付けする工程、前記堆積させる工程、及び前記加熱する工程を前記コンベア上で連続的に行うことを特徴とする、請求項4又は5に記載の方法。 - 前記位置付けする工程は、2つ以上の断熱材を前記板上に位置付けし、前記2つ以上の断熱材は、前記2つ以上の断熱材の間に隙間を提供するように位置付けされる、請求項1〜6のいずれか一項に記載の方法。
- 前記断熱材は、真空断熱パネル又は調整大気断熱パネルである、請求項1〜7のいずれか一項に記載の方法。
- 断熱材を封入する方法であって、
i.フェーサ材料を提供することと、
ii.前記フェーサの上面上にスペーサを位置付けすることと、
iii.前記フェーサの上面上に位置付けされた前記スペーサ上に前記断熱材を位置付けすることと、
iv.前記断熱材を発泡途上の発泡体で完全に包み込むように、発泡途上の発泡体を堆積させることと、を含む、方法。 - 前記スペーサは、前記フェーサ若しくは前記断熱材に、又は前記フェーサ及び前記断熱材の両方に接着又は固定されている、請求項9に記載の方法。
- 前記フェーサは、前記スペーサを位置付けする工程中及び前記断熱材を位置付けする工程中に、発泡途上の発泡体を実質的に含まない、請求項9に記載の方法。
- 前記発泡途上の発泡体は、ポリイソシアヌレート又はポリウレタンの発泡途上の発泡体である、請求項9〜11のいずれか一項に記載の方法。
- 前記フェーサは第1のフェーサであり、
前記発泡途上の発泡体上に第2のフェーサを適用して予備硬化複合材を形成する工程と、前記予備硬化複合材を加熱する工程とを更に含む、請求項9〜12のいずれか一項に記載の方法。 - 前記スペーサは、前記断熱材と前記フェーサとの間に、0.64cm〜5.08cmのギャップを提供し、前記スペーサは、布である、請求項9〜13のいずれか一項に記載の方法。
- 前記断熱材は、真空断熱パネル又は調整大気断熱パネルである、請求項9〜14のいずれか一項に記載の方法。
- 前記フェーサ材料を提供することは、前記第1のフェーサをコンベア上に配置することを含み、
前記スペーサを位置付けする工程、前記断熱材を位置付けする工程、前記堆積させる工程、前記第2のフェーサを適用して予備硬化複合材を形成する工程、及び前記加熱する工程を前記コンベア上で連続的に行うことを特徴とする、請求項13に記載の方法。
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