JPH05269905A - Production of heat insulating material - Google Patents

Abstract

PURPOSE:To produce a heat insulating material excellent in durability with high productivity. CONSTITUTION:A non-foamed resin film 4 composed of the same material quality as a thermoplastic foamed resin material 5 is preliminarily bonded to an aluminum foil 3. The non-foamed resin film 4 and the foamed resin material 5 are brought into contact with each other and heated to be fused to integrate the aluminum foil 3 with the surface of the foamed resin material 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a heat insulating material in which an aluminum foil is integrated with the surface of a foamed resin material.

2. Description of the Related Art Conventionally, as a method of manufacturing the above-mentioned heat insulating material, after applying an adhesive to the surface of a foamed resin material, an aluminum foil is laid on the applied surface portion, and the adhesive is cured to form a foamed resin material. A general method is to press the foamed resin material and the aluminum foil in a laminated state until the aluminum foil is completely bonded. In this case, since the surface of the foamed resin material is uneven due to foaming, if it is bonded with a normal adhesive, the foamed resin material and the aluminum foil will come into point contact and bond. Since the adhesiveness is poor, a two-component reactive adhesive containing a foam material is used to foam the foam material in the recesses on the surface of the foam resin material, and bond them in a state of surface contact. Was there.

[0002]

However, in the above method for producing a heat insulating material, in order to bring the foamed resin material and the aluminum foil into surface contact with each other, the foaming material must be sufficiently foamed. It takes time to complete, and in order to increase the foaming rate of the foam material, the viscosity of the adhesive must be kept high. It cannot be shortened, and in the end, the conventional method has a drawback that it takes a long time to integrate the aluminum foil on the surface of the foamed resin material and the productivity is low. It is an object of the present invention to solve the above-mentioned conventional drawbacks and to provide a method of manufacturing a heat insulating material, which can integrate an aluminum foil on the surface of a foamed resin material in a short time and improve productivity.

[0003]

In order to achieve the above-mentioned object, a method for producing a heat insulating material according to the present invention is such that an unfoamed resin film made of the same material as a thermoplastic foamed resin material is previously formed into an aluminum foil. Is adhered to, and the unfoamed resin film and the foamed resin material are brought into contact with each other and heated and heat-fused to integrate an aluminum foil on the surface of the foamed resin material, and its action The effects are as follows.

[0004]

That is, the surface of the unfoamed resin film made of the same material as the thermoplastic foamed resin material is a smooth surface, unlike the surface of the foamed resin material, so that the unfoamed resin film and the aluminum foil are And can be superposed in a surface contact state, and therefore, it is not necessary to include a foaming material in the adhesive for bringing the two into the surface contact state, and the ordinary adhesive is used to bond them. You can As a result, it is possible to eliminate the time required until the foaming of the foamed material, as compared with the conventional case, and when the ordinary adhesive is used, it is not necessary to consider the foaming rate of the foamed material. You can dilute the agent with a solvent to reduce the viscosity,
The time to cure the adhesive can be shortened. Then, since the unfoamed resin film and the aluminum foil are adhered in this way, the unfoamed resin film and the thermoplastic foaming resin material are heated and heat-sealed together, so that Since both may be made of the same material, it is possible to surely integrate them in a short time. Further, the heat fusion cures the contact portion of the foamed resin material with the resin film to form the reinforcing layer, and as a result, the strength of the heat insulating material can be improved as a whole.

[0005]

As described above, when the unfoamed resin film and the aluminum foil are adhered to each other, the time required for foaming the foam material can be eliminated as compared with the conventional case, and the time until the adhesive is cured can be reduced. It can be shortened, and moreover, the unfoamed resin film and the foamed resin material can be surely integrated in a short time, and the strength of the heat insulating material can be improved, so that the heat insulating material with excellent durability is produced. It was possible to provide a method of manufacturing a heat insulating material that can be manufactured with good properties.

[0006]

Embodiments of the present invention will now be described with reference to the drawings.

FIG. 1C shows a heat insulating material 1 manufactured by the manufacturing method according to the present invention. This insulation 1
For example, a tank shell constructed inside a hull or an external structure such as a structure above ground or underground, specifically, liquid propane gas at -46 ° C, liquefied butane gas at -0.6 ° C, -3
This is used to insulate the tank shell provided in the external structure to contain liquefied petroleum gas or low-temperature liquefied gas in a temperature range close to it, such as liquefied ammonia gas at 3.5 ° C. In the example, polyester material 2, aluminum foil 3, unfoamed polystyrene film 4 (an example of a resin film) and foamed polystyrene material 5
(Example of thermoplastic foamed resin material) are laminated in this order. The polyester material 2 is provided as a surface protective layer, and has a role of preventing invasion of water vapor and absorbing a drop impact of an object under construction. And
As is well known, the aluminum foil 3 and the expanded polystyrene material 5 mainly perform heat insulation. The aluminum foil 3 also has a gas barrier property.

The method of manufacturing the heat insulating material 1 is as follows.

As shown in FIG. 1A, the polyester material 2 is bonded to one surface of the aluminum foil 3 and the unfoamed polystyrene film 4 is bonded to the other surface. For the adhesive, a two-component reaction type urethane adhesive is used, and it is diluted with a solvent to reduce the viscosity, and the time to cure is shortened. When the adhesive is cured and they are completely adhered, the polystyrene film 4 is superposed on the expanded polystyrene material 5 and heated under pressure, as shown in FIG. Are heat-sealed and integrated. The heat fusion is performed in the temperature range of the melting point or higher to the melting point + 50 ° C. In this case, the same materials are heat-sealed together, and since the polyester material 2, the aluminum foil 3 and the polystyrene film 4 are integrated by adhesion before heat-sealing, these and the expanded polystyrene material 5 are combined. As compared with the case where they are heat-bonded as separate bodies without being adhered to each other and integrated at one time, they are easier to fuse, and even after the fusion, the polyester material 2, the aluminum foil 3 and the polystyrene film 4 are already formed. Since they are integrated, they can be restrained from each other, and wrinkles due to the difference in the coefficient of thermal expansion of each member can be prevented from occurring.

Next, an example of a production test of the heat insulating material 1 by the above method will be described. [Manufacturing Test Example 1] A polyester material (PET ^{# 16} ) 2 / aluminum foil (AL ^{# 40} ) 3 / Polystyrene film (PS ^{# 30} ) 4 is placed, the temperature is changed by a heat roller from 150 ° C to 250 ° C and integrated by heat fusion, and then peel test, falling ball impact test and thermal conductivity measurement I went. The results are shown in Table 1.
Shown in.

[0011]

[Table 1]

From the above results, it was confirmed that by setting the temperature condition 40 ° C. higher than the melting point, the peel strength was good, the impact resistance was good, and the thermal conductivity did not change.

[Manufacturing Test Example 2] As in Manufacturing Test Example 1,
A polyester material (PET ^{# 16} ) 2 / aluminum foil (AL ^{# 40} ) 3 / EVA-PS copolymer dry-laminated on the surface of extruded polystyrene foam material 5 (trade name: Styrofoam EK manufactured by Dow Kako Co., Ltd.) is placed. The temperature was changed from 100 ° C. to 160 ° C. with a heat roller to integrate them, and then a peel test, a falling ball impact test and a thermal conductivity measurement were performed. The results are shown in Table 2.

[0014]

[Table 2]

The EVA-PS copolymer has a melting point of 110 ° C., and generally heat-bonds at a temperature 10 ° C. to 20 ° C. higher than the melting point. In this case, only the surface material adheres well, but only the adhesion does not form the resin layer under the surface material, and therefore the impact strength is only the strength of the surface material. However, if heat fusion is performed at a temperature 40 ° C to 50 ° C higher than the melting point,
A reinforcing resin layer having a thickness of about 0.5 to about 1 mm is formed under the surface material. As a result, the impact strength is improved, and not only the gas barrier property but also the surface protective layer is fulfilled.

Next, a comparative example to the above [Production Test Example 1] and [Production Test Example 2] will be shown. [Comparative Example 1] A foamed polystyrene material 5 with bead foaming was prepared, and a metal foil laminated film composed of polyester material (PET ^{# 16} ) 5 / aluminum foil (AL ^{# 40} ) 3 / EVA-PS copolymer was placed thereon, and 110 Thermal fusion was performed in the range of ℃ to 150 ℃. In this case, the surface material was adhered, but the styrene beads near the surface material caused tertiary foaming, resulting in swelling and no impact-resistant resin layer was formed.

In the heat insulating material 1 of the present invention, there are polyethylene, vinyl chloride, polystyrene and the like as the thermoplastic foaming resin material, but extruded polystyrene foam is preferable in terms of cost and also in terms of thermal conductivity. The best. As a result, as the surface material of the present invention, a plastic laminate film comprising a sealant layer as the unfoamed resin film / a metal foil composed of the aluminum foil 3 / a protective layer composed of a polyester material 5 is inexpensive and has good productivity.
As the surface material, it is preferable that the sealant layer uses the same resin as the material of the plastic foam. Furthermore, the required performance of the surface material is vapor barrier property,
And since external impact resistance at the time of heat-proof construction is required, the material of the metal foil or metal plate is aluminum, iron, zinc-plated iron plate, nickel, stainless steel, etc., preferably 10 μm to 100 μm thick. is there. Further, it is preferable that a protective film such as a polyester film having a thickness of 12 μm or more is further laminated to protect the metal foil or the like. Further, in order to strengthen the surface layer, a nonwoven fabric such as polystyrene or polystyrene-EVA is pasted instead of the sealant layer, and heat fusion is performed in the same manner to form a fiber reinforced resin layer. It is also possible to form a protective layer having impact resistance. Further, in order to prevent warpage as much as possible, the same surface material may be heat-sealed to the upper and lower surfaces of the foam. As the method for producing the heat insulating material of the present invention, a surface material obtained by dry laminating the above sealant layer / metal foil / protective film is wound around a roller, and a surface material having the foam length is placed on the surface of the plastic foam, followed by heat treatment. It can be easily manufactured by pressing with a roller. This method can be applied not only to a flat plate shape but also to a cover type heat insulating material by moving the heat roller in an arc shape in the same manner.

Next, an example of construction using the heat insulating material 1 will be shown. [Execution example 1] 1 mx with surface material attached to one side by heat fusion
Two 1 m × 100 mm panels were prepared and fixed to the surface of a 10 mm iron plate with bolts assuming a tank shell. Then, the joint spacing between the panels is set to 20 mm and 500 m
The length of m was filled with glass wool (product density: 24 kg / m ³ , thickness: 15 mm), and the length of 500 mm was filled with glass wool (product density: 24 kg / m ³ , thickness: 25 mm). Then, an adhesive tape was attached to the joint surface, and the whole surface was cooled with dry ice from the surface opposite to the tape. When the state of the tape surface was observed 8 hours after cooling, the joint portion (filling density 18 kg / m ³ ) filled with glass wool having a thickness of 15 mm produced dew condensation, and the thickness 2
Joints filled with 5 mm glass wool (filling density 30
(kg / m ³ ) did not cause dew condensation. Further, during cooling, the two panels were warped on the outside air side due to the temperature difference, but in this case, it was confirmed that the surface material did not peel off and the surface material was completely bonded. From this, the packing density of the present invention is 30 kg.
The construction method in which the fibrous cross-section material is filled with a material of not less than / m ³ has no influence on the heat insulation performance. Also, even if glass wool having a product density of 16 kg / m ³ (thickness 50 mm) is filled (filling density 40 kg / m ³ ), the joint is filled well, and 48 kg / mm ³ (thickness 25 mm) is filled (filling density 60 kg / m ^3). ), The joints were not filled well during construction. Thus, the product density of the glass wool filling the joints by way of 16~24kg / m ^3, and packing density, by filling 30kg / m ³ or more,
It was confirmed that the thermal insulation performance of the joints was perfect.

[Working Example 2] The panel used in Working Example 1 is made vertical this time, the tank surface is controlled to -5 ° C using a refrigerator, and the apparatus itself is left in an air-conditioned room at 20 ° C. To fill the joints, change the filling density of the glass wool to fill the joints, and to check the performance of the joints, attach a heat flow meter to the surface of the adhesive tape and measure the amount of heat entering the joints. Then, the apparent thermal conductivity of the glass wool part was calculated back from the data, and the result is shown in FIG.
And shown below. In this case, the product densities of glass wool used were 16 kg / m ³ and 24 kg / m ³ . In both cases, the construction was well filled. However, 48 kg / m ³ could not be filled successfully. As a result it is determined from, by using the glass wool products density 16~24kg / m ^3, and a packing density of not convection occurs if 30kg / m ³ or more, construction method was confirmed to be good. In addition, although extruded polystyrene was used, in the case of another thermoplastic foam, that is, polyethylene foam, the thermal conductivity was as bad as 0.035 kcal / mh ° C, and -55 ° C.
In this case, the foam became brittle, and in the case of vinyl chloride foam, the adhesion to the surface material was poor due to the large cells, and as a result, extruded polystyrene foam was the best.

It should be noted that reference numerals are given in the claims for convenience of comparison with the drawings, but the present invention is not limited to the structures of the accompanying drawings by the entry.

[Brief description of drawings]

[FIG. 1] (a) A diagram showing the manufacturing process of the heat insulating material (b) A diagram showing the manufacturing process of the heat insulating material (c) A sectional view of the heat insulating material

FIG. 2 is a graph showing changes in apparent thermal conductivity.

[Explanation of symbols]

 3 Aluminum foil 4 Unfoamed resin film 5 Thermoplastic foamed resin material

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display area // F16L 59/02

Claims (1)

[Claims] 1. An unfoamed resin film (4) made of the same material as a thermoplastic foamed resin material (5) is adhered to an aluminum foil (3) in advance, and said unfoamed resin film (4) And a foamed resin material (5) are brought into contact with each other, and heated and heat-sealed to each other, and the aluminum foil (3) is integrated with the surface of the foamed resin material (5).