JP6804776B2 - Manufacturing method of heat insulating wall material for ventilation duct of building - Google Patents

Description

The present invention relates to a heat insulating wall material for a ventilation duct provided in a building and a method for manufacturing the same.

In general, ventilation ducts such as kitchen exhaust ducts, air conditioning ducts, and chimneys of buildings are provided with heat insulating materials for heat resistance and heat retention.
This type of ventilation duct insulation is made of foamed resin or nonflammable fibers. For example, the heat insulating material for a ventilation duct of Patent Document 1 is made of glass fiber felt.

JP-A-2018-112329

The heat insulating material made of glass fiber felt in the ventilation duct of a building is difficult to form into a desired wall shape, and even if it is formed, it is difficult to independently maintain the wall shape.
In view of such circumstances, an object of the present invention is to provide a heat insulating wall material for a ventilation duct that can be formed into a desired wall shape and can be self-supporting and retain its shape.

In order to solve the above problems, the present invention is a heat insulating wall material in a ventilation duct of a building.
The heat insulating molded body is provided with a heat insulating molded body formed into a predetermined wall shape along the flow path of the ventilation duct, and the heat insulating molded body is a stacking compressed body obtained by stacking and compressing defibrated bodies of glass fibers, and the stacking It is characterized by containing an inorganic binder cured product which is diffused in the compressed body and joins the defibrated bodies to each other.
As a result, a heat insulating wall material for a ventilation duct having high self-supporting shape retention can be obtained.
Density of the stack before compression to the solution繊体are stacked ^is preferably 100kg / ^{m 3} ~200kg / m 3 approximately.
The density of the stacking compact in thermal insulation molded body ^is preferably 200kg / ^{m 3} ~250kg / m 3 approximately.
In the stacked compressed body, a large number of streaky portions extending in the thickness direction are dispersed in the in-plane direction, and it is preferable that the defibrated bodies are entangled with each other in each streaky portion.
The thickness direction refers to a direction connecting an inner surface (a surface facing the flow path) and an outer surface of the heat insulating wall material. The in-plane direction refers to a direction along a surface orthogonal to the thickness direction, or a direction along the inner surface or the outer surface. Preferably, the stack is compressed in the thickness direction to become the stack compress.

It is preferable that the heat insulating wall material for a ventilation duct further includes a surface layer sheet covering the surface of the heat insulating molded body, and the surface layer sheet is directly adhered to the heat insulating molded body by an inorganic binder cured product on the surface. The surface may be the outer surface of the heat insulating molded product, the inner surface, or the flow path drawing surface.

The method of the present invention is a method for manufacturing a heat insulating wall material provided in a ventilation duct of a building.
A stacked body is produced by stacking defibrated bodies of glass fibers.
The stack is coated or impregnated with an inorganic binder.
Then, by heating and compression molding the stacked body, a heat insulating molded body having a predetermined wall shape along the flow path of the ventilation duct is produced.

When the inorganic binder is cured, it becomes the inorganic binder cured product.
The inorganic binder is preferably made of a thermosetting inorganic binder.
It is preferable to form a large number of streaky portions on the stacked body before the application or impregnation of the inorganic binder by needle punching or the like. Since the defibrated bodies are intertwined with each other in the streaky part, it is possible to prevent the stacked bodies from coming apart. Further, the combination of the entanglement in the streaky portion and the joining with the inorganic binder further enhances the self-supporting shape retention of the heat insulating molded product.

It is preferable that the pressing force in the heating and compression molding is 0.1 MPa to 0.7 MPa, the heating temperature is 100 ° C. to 400 ° C., and the molding time is 3 minutes to 30 minutes. As a result, a heat insulating wall material for a ventilation duct having good self-standing shape retention and an appropriate hardness and thickness can be obtained.
Before the heating and compression molding, the content of the inorganic binder in the stack is high in both side portions of the stack and low in the central portion in the thickness direction of the stack, and by the heating and compression molding. It is preferable that the inorganic binder is diffused over the entire area of the stack. In particular, it is preferable that diffusion from the double-sided side portion to the central portion is promoted.
As a result, the defibrated bodies constituting the stacked body are evenly joined. As a result, the self-supporting shape retention of the heat insulating molded product is further enhanced.
Before the heating and compression molding, the abundance of voids (void portions) in the stack is low in both side portions of the stack, corresponding to the distribution of the inorganic binder, in the thickness direction of the stack. Even if it is high in the central portion of the above, the voids are substantially uniformly dispersed over the entire area of the heat insulating molded product due to the diffusion of the inorganic binder during the heating and compression molding.
It is preferable to directly cover the surface of the stacked body after coating or impregnating the inorganic binder with the surface layer sheet, and perform the heating and compression molding in that state. By the heating and compression molding, the surface layer sheet and the heat insulating molded body are joined and integrated. The inorganic binder serves as a means for joining the surface layer sheet. Separately, no adhesive or the like for joining the surface layer sheets is required. The surface layer sheet may undergo deterioration such as wrinkles and changes in hardness due to heating and compression treatment.

According to the present invention, it is possible to obtain a heat insulating wall material for a ventilation duct that can be formed into a desired shape and can independently hold the shape.

FIG. 1 is a cross-sectional view of a ventilation duct for a building according to the first embodiment of the present invention. FIG. 2 is a perspective view of the ventilation duct for a building. FIG. 3 is an exploded perspective view of the ventilation duct for a building. FIG. 4 is an explanatory view explanatoryly showing an enlarged cross-sectional structure of the heat insulating wall material of the ventilation duct for a building. 5 (a) to 5 (h) are explanatory views of the manufacturing process of the heat insulating wall material. FIG. 6 is a plan sectional view of a chimney which is a ventilation duct for a building according to a second embodiment of the present invention. FIG. 7 is a perspective view of the chimney. FIG. 8 is a side sectional view of a kitchen exhaust hood, which is a ventilation duct for a building according to a third embodiment of the present invention. FIG. 9 is an exploded perspective view of the heat insulating wall material of the kitchen exhaust hood as viewed from the rear.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 5 show the first embodiment of the present invention.
1 and 2 show a ventilation duct 1 for a building. The building may be a house, an office building, or a factory. The ventilation duct 1 for a building may be a kitchen exhaust duct, an air conditioning duct, or a chimney (smoke exhaust duct).
The ventilation duct 1 for a building has, for example, a cylindrical shape.

As shown in FIGS. 1 and 3, the ventilation duct 1 for a building includes a heat insulating wall material 2 and an inner surface member 3. The heat insulating wall material 2 includes a pair of heat insulating molded bodies 10 and a surface layer sheet 4. The heat insulating molded body 10 is molded according to the wall shape of the ventilation duct 1 for a building. For example, each heat insulating molded body 10 has a half-divided cylindrical shape. The two heat insulating molded bodies 10 are combined to form a cylindrical heat insulating wall material 2.
Although not shown, an adhesive tape or an adhesive is used as a means for joining the heat insulating molded bodies 10.

As shown in FIG. 4, the heat insulating molded product 10 includes a product-compressed product 11 and an inorganic binder cured product 12. The stacked compaction body 11 is a product obtained by compressing a large number of glass fiber defibrated bodies 11a and a stacked stacking body 11x.
The glass fiber contains SiO ₂ as a main component, and may also contain Al ₂ O ₃ , Fe ₂ O ₃ , TiO ₂ , CaO, Na ₂ O, and the like. The content of SiO _{2 in} the glass fiber is preferably about 50 to 98 wt%, more preferably about 60 to 95 wt%, and even more preferably about 70 to 95 wt%.
The defibrated body 11a of the glass fiber is preferably a long fiber, and its average length is usually 10 mm or more, preferably 20 mm or more, more preferably 30 mm or more, still more preferably 50 mm or more. The average diameter of the defibrated body 11a is usually about 2 to 30 μm, preferably about 5 to 30 μm, more preferably about 5 to 20 μm, and even more preferably about 5 to 15 μm.
Density of solution繊体11a is stack before compression stacked 11x (Fig. 5 (d)) is preferably 100kg ^{/ m 3} ~200kg ^/ m 3 approximately.
The density of stacking compression body 11 in the heat-insulating molded body 10 is preferably 200kg ^{/ m 3} ~250kg ^/ m 3 approximately.

The cured inorganic binder 12 is a cured inorganic binder 12a (FIG. 5 (e)) coated / impregnated on the stack 11x. The defibrated bodies 11a are bonded to each other via the cured inorganic binder 12. The inorganic binder cured product 12 is substantially uniformly dispersed over the entire area of the heat insulating molded product 10.
Preferably, the inorganic binder 12a is a thermosetting inorganic binder that is a liquid material at the time of coating and impregnation and is irreversibly cured by heating.
Examples of the main component of the inorganic binder 12a include silica, aluminum silicate and other clay minerals. The weight mixing ratio of silica and aluminum silicate is, for example, silica: aluminum silicate = 50:50 to 10:90.
Further, the inorganic binder 12a before curing also contains water and other liquids. The viscosity of the inorganic binder 12a can be adjusted by adjusting the amount of a liquid such as water. The aluminum silicate may be hydrous aluminum silicate.

The ratio of the defibrated body 11a to the heat insulating molded body 10 is preferably about 80 wt% to 90 wt%.
The ratio of the inorganic binder cured product 12 to the heat insulating molded product 10 is preferably 10 wt% to 20 wt%.
In the heat insulating molded body 10, the remainder except for the defibrated body 11a and the cured inorganic binder 12 is mostly occupied by voids (void portions or air layers). The volume ratio of the voids (void portions) in the heat insulating molded product 10 is preferably about 0.1 vol% to 10 vol%, and more preferably about 0.5 vol% to 5 vol%. The voids are substantially uniformly dispersed inside the heat insulating molded product 10.

A large number of streaky portions 13 are formed in the stacked compressed body 11 and thus the heat insulating molded body 10. Each of these streaky portions 13 extends in the thickness direction (diametrical direction, vertical direction in FIG. 4) of the heat insulating molded body 10, and also extends in the in-plane direction (circumferential direction and axial length direction, left and right in FIG. 4) of the heat insulating molded body 10. And the paper surface orthogonal method), and preferably arranged at substantially uniform intervals. In each streak portion 13, the defibrated bodies 11a are intertwined with each other. The arrangement interval d ₁₃ of the streaky portion 13 is preferably about d ₁₃ = 0.1 mm to 10 mm, and more preferably about d ₁₃ = 0.5 mm to 5 mm.

The outer peripheral surface (surface) of the heat insulating molded body 10 is covered with a surface layer sheet 4 such as an aluminum glass cloth. The surface layer sheet 4 is directly adhered to and integrated with the heat insulating molded body 10 by an inorganic binder appearing on the outer peripheral surface of the heat insulating molded body 10. Separately, no adhesive for joining the surface layer sheet 4 is used.

An inner surface member 3 is provided on the inner peripheral surface of the heat insulating wall material 2. The inner surface member 3 is composed of, for example, a metal tube having a circular cross section. The internal space of the inner surface member 3 serves as a flow path for flow target fluids such as kitchen exhaust air, air conditioning air, and chimney exhaust gas.
The metal pipe may be a spiral pipe made of galvanized steel plate or a stainless steel pipe. The material of the inner surface member 3 is not limited to metal, and may be resin, ceramics, paper, wood, or the like. The inner surface member 3 may be formed of a sheet similar to the surface layer sheet 4, and may be directly adhered to and integrated with the heat insulating molded body 10 by an inorganic binder appearing on the inner peripheral surface (surface) of the heat insulating molded body 10.

The building ventilation duct 1 is manufactured as follows.
As shown in FIG. 5A, glass fiber 2a as a material is prepared.
As shown in FIG. 5B, the glass fiber 2a is defibrated to obtain a defibrated body 11a. By depositing the defibrated body 11a, a stacked body 11x is formed.
As shown in FIG. 5C, a needle punching device 5 having a large number of needles 5a is used to perform needle punching on the stacked body 11x. A protruding barb 5c is formed on the needle 5a. The defibrated bodies 11a are entangled with each other by the high-speed reciprocating movement of the needle 5a. As a result, as shown in FIG. 5D, the stacking body 11x becomes mat-shaped, and a large number of streaky portions 13 extending in the thickness direction of the stacking body 11x are formed.
The stack 11x at this stage has no shape retention and can be easily deformed by gravity or other external force.

Subsequently, as shown in FIG. 5 (e), the inorganic binder 12a is applied to both surfaces (upper surface and lower surface in the same figure) of the stack 11x. The coating is preferably carried out with a roller. It may be applied by spraying.
Instead of coating, the stack 11x may be impregnated with the inorganic binder 12a by immersing the stack 11x in an inorganic binder tank. In this case, it is preferable that the upper surface side portion and the lower surface side portion of the stacking body 11x are immersed in the inorganic binder tank by half or less of the thickness of the stacking body 11x, respectively. It is preferable that a non-impregnated layer of the inorganic binder 12a is formed in the central portion of the stacking body 11x in the thickness direction. As a result, a void (air layer) can be secured in the stack 11x.
Therefore, in the stage from coating or impregnation to compression molding described later, the content of the inorganic binder 12a in the stacking body 11x is high in the double-sided side portions (upper surface side portion and lower surface side portion) of the stacking body 11x, and the stacking body It is low in the central part in the thickness direction of 11x. Further, the abundance rate of voids (void portions) in the stacking body 11x is low in the both side portions of the stacking body 11x and high in the central portion of the stacking body 11x in the thickness direction.

As shown in FIG. 5 (f), the surface layer sheet 4 is attached to the upper surface (the surface facing the outer peripheral side of the ventilation duct 1) of the stacked body 11x after coating or impregnation. The surface layer sheet 4 is directly adhered to the stack 11x by the inorganic binder 12a appearing on the upper surface of the stack 11x.

As shown in FIG. 5 (f), dies 6 and 7 having mold surfaces 6a and 7a corresponding to the finished shape (half-split cylinder shape) of the heat insulating molded body 10 are separately prepared. A heater 8 is incorporated in at least one of the molds 6 and 7. In the figure, the heater 8 is composed of a plurality of rod-shaped heaters, but the heater 8 is not limited to this, and may be a plate heater or the like.

The stack 11x is set between the molds 6 and 7.
Subsequently, as shown in FIG. 5 (g), the dies 6 and 7 are closed, and the stack 11x is pressurized while being heated by the heater 8 to be compression-molded. It is preferable to use an air cylinder for pressurization.
The pressing force in the heating and compression molding steps is preferably about 0.1 MPa to 0.7 MPa. The heating temperature is preferably about 100 ° C. to 400 ° C. The molding time (duration of application of the pressing force and heating) is preferably about 3 to 30 minutes.
As a result, the stacking body 11x is compressed in the thickness direction to become the stacking compressed body 11. Preferably, the thickness of the stacking compact 11 is compression-molded so as to be about one-half to four-fifths of the thickness of the stack 11x before compression.
Further, the heating increases the fluidity of the inorganic binder 12a, and further causes boiling, vaporization, and dissipation of the liquid component of the inorganic binder 12a. In this process, the solid component of the inorganic binder 12a is diffused over the entire area of the stack 11x to form the cured inorganic binder 12.
Further, the voids (voids or air layers) in the stack 11x are reduced by the compression of the stack 11x, and the inside of the stack 11 is reduced by the diffusion of the inorganic binder 12a and the vaporization / dissipation of the liquid component. Voids are spread over the entire area of.
After that, as shown in FIG. 5 (h), the mold is removed.

As a result, the heat insulating molded body 10 having at least a part of the wall shape (half-split cylinder shape) of the duct 1 is formed. The self-supporting shape-retaining property of the heat-insulating molded body 10 is ensured by evenly joining the defibrated bodies 11a over the entire area of the heat-insulating molded body 10 via the cured inorganic binder 12. Further, since the defibrated bodies 11a are entangled with each other in the streaky portion 13, it is possible to more reliably prevent the stacked compressed body 11 from coming apart, and further enhance the self-supporting shape retention of the heat insulating molded body 10. it can.
By using glass fiber as the main material of the heat insulating molded body 10, the heat insulating property and heat resistance of the heat insulating molded body 10 can be ensured.
Further, by using an inorganic binder instead of an organic binder as the binder, the heat resistance, fire resistance, and heat insulating property of the heat insulating molded product 10 can be ensured. In addition, the voids are uniformly dispersed over the entire area of the heat insulating molded body 10, so that the heat insulating property is further enhanced.
The surface layer sheet 4 is integrally laminated on the outer peripheral surface (surface) of the heat insulating molded body 10. The surface layer sheet 4 is directly bonded to the heat insulating molded body 10 by the inorganic binder cured product 12 on the outer peripheral surface (surface) of the heat insulating molded body 10. Since the inorganic binder cured product 12 serves as a joining means for the surface layer sheet 4, a separate joining means such as an adhesive is not required.

A pair of the heat insulating molded bodies 10 having a half-split cylinder shape are produced.
The pair of heat insulating molded bodies 10 are put on both side portions of the separately prepared inner surface member 3.
Further, the pair of heat insulating molded bodies 10 are joined by a joining means such as an adhesive tape or an adhesive. As a result, the cylindrical heat insulating wall material 2 is obtained.
In this way, the ventilation duct 1 for a building is obtained. The inner surface member 3 functions to prevent the defibrator 11a from scattering from the inner peripheral surface of the heat insulating wall material 2. The surface layer sheet 4 functions to prevent the defibrator 11a from scattering from the outer peripheral surface of the heat insulating wall material 2.
According to the embodiment of the present invention, the shape of the heat insulating molded body 10 and the shape of the heat insulating wall material 2 can be arbitrarily set by preparing molds corresponding to the wall shapes of various ventilation ducts for buildings.

Next, other embodiments of the present invention will be described. In the following embodiments, the same reference numerals are given to the drawings for configurations that overlap with the above-described embodiments, and the description thereof will be omitted.
<Second Embodiment>
6 and 7 show a second embodiment of the present invention.
The ventilation duct for a building in the second embodiment is a chimney 20 installed inside or on an outer wall of a building having a boiler, a generator, or the like. Exhaust gas from the boiler, generator, etc. is discharged from the chimney 20.
The chimney 20 has, for example, a square cylinder shape. Each of the four walls of the chimney 20 contains a heat insulating molded body 22 as a main component. Each heat insulating molded body 22 is molded into a flat plate shape so as to correspond to the shape of each wall of the chimney 20. Since it has a flat plate shape, it is easy to manufacture a molding die, and the manufacturing cost of the heat insulating molded body 22 can be reduced. The internal structure, composition, and the like of the heat insulating molded body 22 are the same as those of the heat insulating molded body 10 of the first embodiment.
A square cylinder-shaped heat insulating wall material 21 is composed of four heat insulating molded bodies 22. A lining 23 made of a metal plate is provided on the inner surface of the heat insulating wall material 21.
The surface layer sheet 4 (see FIG. 1) is not provided on the outer surface (surface) of the heat insulating wall material 21.

<Third Embodiment>
6 to 7 show a third embodiment of the present invention.
The ventilation duct for a building in the third embodiment is a kitchen exhaust hood 30. The kitchen exhaust hood 30 includes a heat insulating wall material 30a and an inner surface member 35. The heat insulating wall material 30a includes a plurality of substantially plate-shaped heat insulating molded bodies 31 to 33. The curved plate-shaped heat insulating molded body 31 constitutes the upper wall portion and the front wall portion of the kitchen exhaust hood 30. A pair of heat insulating molded bodies 32 form a pair of side wall portions of the kitchen exhaust hood 30. The square plate-shaped heat insulating molded body 33 constitutes the rear wall portion of the kitchen exhaust hood 30. A hole 33c is formed in the heat insulating molded body 33 for the rear wall portion. The internal structure, composition, and the like of the heat insulating molded bodies 31 to 33 are the same as those of the heat insulating molded body 10 of the first embodiment. The surface layer sheet 34 is directly adhered and integrated with the outer surface (surface) of the heat insulating molded bodies 31 to 33.

These heat insulating molded bodies 31 to 33 are assembled so as to have a hood shape, and the heat insulating wall material 30a of the kitchen exhaust hood 30 is formed. An inner surface member 35 made of a metal plate is provided on the inner surface of the heat insulating wall material 30a via an adhesive (not shown). The inner surface member 35 is composed of a sheet similar to the surface layer sheet 4, and is directly adhered to and integrated with the heat insulating molded body 31 to 33 by an inorganic binder appearing on the inner peripheral surface (surface) of the heat insulating molded body 31 to 33. You may. Further, as shown by the alternate long and short dash line in FIG. 8, the exhaust pipe 36 is inserted into the hole portion 32c and connected to the internal space of the hood 30.
As described above, according to the present invention, it is possible to give an arbitrary shape to the heat insulating wall material according to the wall shape of the ventilation duct for a building.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.
For example, the ventilation duct for a building is not limited to the kitchen exhaust hood, the air conditioning duct, and the chimney, and may be a ventilation duct or the like.
The defibrated body 11a is not limited to long fibers, but may be short fibers.
The inorganic binder 12a is not limited to a thermosetting binder, and may be, for example, a water-curable binder that is cured by a hydration reaction or the like. The inorganic binder 12a may be melted by heating to join the defibrated bodies 11a to each other, and then cured by cooling. The inorganic binder 12a may contain a dispersion medium or a solvent. The dispersion medium or solvent may be vaporized during heating. The dispersion medium or solvent may be water.
The surface layer sheet 4 may be provided on the inner surface (duct flow path defining surface) of the wall-shaped heat insulating molded body. The surface layer sheet 4 may be directly adhered to the heat insulating molded product by an inorganic binder on the inner surface of the heat insulating molded product.

The present invention can be applied to, for example, ventilation ducts such as kitchen exhaust ducts, air conditioning ducts, and chimneys in buildings.

1 Ventilation duct for buildings 2 Insulation wall material 2a Glass fiber 4 Surface sheet 10 Insulation molded body 11 Stacked compressor 11a Defibered body 11 x Stacked body 12 Inorganic binder cured product 12a Inorganic binder 13 Streaks 20 Chimney (for buildings) Ventilation duct)
21 Insulation wall material 22 Insulation molded body 30 Kitchen exhaust hood (ventilation duct for buildings)
30a Insulation wall material 31-3 Insulation molded body 34 Surface sheet 36 Exhaust pipe

Claims (3)

It is a method of manufacturing a heat insulating wall material provided in a ventilation duct of a building.
A stacked body is produced by stacking defibrated bodies of glass fibers.
The stack is coated or impregnated with an inorganic binder.
The surface layer sheet is directly covered on the surface of the stacked body after the coating or impregnation of the inorganic binder is applied.
Then, by heating and compression molding the stacked body with the surface layer sheet covered, a ventilation duct having a predetermined wall shape along the flow path of the ventilation duct is produced. Manufacturing method of heat insulating wall material for. The ventilation duct according to claim 1 , wherein the pressing force in the heating and compression molding is 0.1 MPa to 0.7 MPa, the heating temperature is 100 ° C. to 400 ° C., and the molding time is 3 minutes to 30 minutes. Manufacturing method of heat insulating wall material. Before the heating and compression molding, the content of the inorganic binder in the stack was high in both side portions of the stack and low in the central portion in the thickness direction of the stack.
The method for producing a heat insulating wall material for a ventilation duct according to claim 1 or 2 , wherein the inorganic binder is diffused over the entire area of the stacked body by the heating and compression molding.

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