JPH06330575A - Heat-insulating wall panel - Google Patents

Abstract

PURPOSE:To prevent the deformation and shrinkage of a foamed resin by forming a coating layer consisting of a metal on at least one surface of a face material in a heat-insulating wall panel, in which a heat-insulating material composed of the foamed resin is formed onto the face material. CONSTITUTION:The panel P1 of a wall is composed of a frame body 1 consisting of two pairs of framed materials 1a, 1b, a face material 2, a hard urethane foam 3 as a heat-insulating material, a stud 4, etc. An aluminum foil 2b is stuck to the surface of the long-sized fiberboard 2 of the waterproof and weatherproof three layers of the face material 2, and a rear is impregnated and covered with a polyethylene film 2C. In a wall W, the panel P1 is clamped and fixed in a mounting space S2 surrounded by frameworks such as an interior finish material 16, a facing material 17, floor joists 10, a sill 11, etc., by nails 18, etc. Accordingly, a gas such as carbon dioxide, etc., is not permeated through the aluminum foil 2b, and outflow to the outside of carbon dioxide diffused in the cells of the polyurethane foam 3 is prevented, thus obviating the deformation and shrinkage of a foamed resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat insulating wall panel which is arranged on a wall of a house or the like to improve the heat insulating property of the wall.

[0002]

2. Description of the Related Art For example, in the case of a wall of a house in which an interior material and an exterior material are attached to a frame, in order to improve heat insulation,
It is common practice to arrange various building materials for heat insulation in the space formed by the interior material and the exterior material. As such a building material for heat insulation, a heat insulating wall panel 21 in which a frame 22 is filled with a heat insulating material 24 made of foamed resin such as polyurethane has been conventionally known (FIG. 6).
(See (a) and (b)).

The heat insulating material 24 of the heat insulating wall panel 21 is required to have a so-called foam-like structure having many closed cells therein. It is well known that such a foam-like structure can be obtained, for example, by treating a mixture of an isocyanate compound and an active hydrogen-containing compound with a predetermined foaming agent. Until recently, Freon has been generally used as such a foaming agent.

However, in the present day when the destruction of the ozone layer due to the large use and release of CFCs becomes serious, serious restrictions on the use of CFCs, and ultimately a ban on the total use of CFCs are seriously considered. ing. In such a social situation, it is becoming impossible to use CFC as a foaming agent, which has a great influence on the environment.
Therefore, recently, it has been proposed to use water, pentane, or the like as a foaming agent, which is less likely to cause environmental damage, as an alternative to CFCs. However, since pentane has an ignitability and toxicity, it is currently considered that the use of water is more preferable.

Here, the foaming mechanism when water is used as a foaming agent will be briefly described. Usually, when polyurethane is produced by the reaction of an isocyanate compound and an active hydrogen-containing compound, the presence of water as a foaming agent,
This results in the production of carbon dioxide in the product. The generated carbon dioxide gas becomes bubbles and quickly diffuses into the product, and the cooling and curing of the polyurethane proceeds in such a gas diffusion state. As a result, a foamed polyurethane (urethane foam) in which carbon dioxide gas is retained in the cells can be obtained.

[0006]

However, when water is used as the foaming agent, the amount of carbon dioxide gas that escapes to the outside due to the cooling and curing of the polyurethane is larger than that when chlorofluorocarbon is used, and the urethane foam as a whole deforms and contracts. There was a problem of doing. As a result of research, the inventors of the present application
The cause of the contraction was found to be as follows.

That is, carbon dioxide has a smaller molecule than freon, and the inside of the cell, which is the geometrical minimum unit constituting the foam, is in a depressurized state and is crushed by atmospheric pressure to reduce the volume of the cell. The urethane foam as a whole deforms and contracts.

As a measure for avoiding such inconvenience, for example, it is conceivable to increase the density of urethane foam to make the cell wall thicker so as to increase the overall strength. However, if such measures are taken, the voids in the cell occupied in the urethane foam, that is, the ratio of carbon dioxide gas (air phase) retained in the cell, becomes relatively small, and inevitably the heat insulating property deteriorates. Will end up.

Further, in addition to the above-mentioned problem related to the deformation / shrinkage of the foamed resin due to the type of the foaming agent, there is also a problem related to the strength of the heat insulating wall panel 21. That is, in the conventional heat insulating wall panel 21, it is inevitable that the braces 23 as the reinforcing material are obliquely provided in the frame body 22 in order to secure the rigidity to some extent. (See FIGS. 6 (a) and 6 (b)). Further, when adopting the structure in which the braces 23 are provided, it is inevitable that the structure of the heat insulating panel 21 becomes complicated and the manufacturing process itself becomes very troublesome.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a heat insulating wall panel capable of reliably preventing deformation and shrinkage of a foamed resin and having excellent strength. It is in.

[0011]

In order to solve the above problems, in the present invention, in a heat insulating wall panel having a heat insulating material made of foamed resin provided on a face material, at least one surface of the face material is made of metal. Alternatively, the gist is a heat insulating wall panel having a coating layer made of at least one selected from resins.

In this case, the metal is preferably aluminum, the resin is polyethylene, and the face material is preferably a fiber board. Moreover, you may provide the area | region in which the heat insulating material is not formed in the peripheral part of the face material.

[0013]

According to the structure of the present invention, since the covering layer is arranged between the face material and the foamed resin, the outflow of the gas diffused in the foamed resin can be prevented. Therefore, the deformation and shrinkage of the heat insulating material are reliably prevented. Further, in the present invention, since the heat insulating material made of foamed resin is provided on the face material, the strength is excellent. When the heat insulating panel is formed of a face material, a heat insulating material, or the like, the wall magnification of the face material is preferably 0.5 or more, and particularly preferably 1.5 or more. If the wall magnification is less than 0.5, it is difficult to secure the required amount of wall unless the heat insulating panels are separately overlapped and provided with thick braces, and as a result, the construction takes time. When the wall magnification becomes 1.5 or more,
It is easy to secure the required amount of wall in the house, even if only the panel is used alone or only partially.

The surface material used in the present invention includes, for example, fiberboard, sheathing board, gypsum board,
There are pulp cement board, flexible board, MDF, particle board, magnesium carbonate board and the like. Among them, it is particularly preferable to select the fiber board because it is lightweight but excellent in strength, and because many of them use recycled materials made of corrugated waste paper.

The metal used as the covering layer for the face material includes, for example, aluminum, copper, iron, nickel, cobalt, titanium, silicon and lead. Among the metals listed here, it is preferable to select aluminum because it is particularly light and can be easily obtained by a vapor deposition process or the like.

Examples of the resin used as the coating layer include polyethylene, polypropylene, polyvinyl chloride, fluororesin, silicone resin and the like. Among the resins listed here, it is desirable to select polyethylene because it is particularly easy to handle and can easily impregnate a fiberboard.

The thickness of the coating layer is 0.3 μm to 250 μm.
It is desirable that it is m. The reason for this is that a thickness of about 0.3 μm is required in order to prevent pinholes from being generated when the surface material is covered. Further, considering the adhesiveness to the face material, it is not preferable that the thickness exceeds 250 μm. The above applies not only when the coating layer is a resin but also when it is a metal.

It is desirable to provide an area where the heat insulating material is not formed in the peripheral portion of the face material. The reason is,
By providing such a region, the heat insulating wall panel can be easily attached to the frame and the workability is improved. In addition, the presence of such a region also improves the airtightness of the house.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is embodied in a heat insulating wall panel for a wooden house will be described in detail with reference to the drawings.

1 to 4 show three types of heat insulating wall panels (a true wall panel P1, a large wall panel P2, and an opening panel P3) used in this embodiment. Panel P for true wall shown in FIGS. 1 (a) to 1 (c)
1 is basically composed of a frame body 1 composed of two pairs of frame members 1a and 1b, a face material 2, a hard urethane foam 3 as a heat insulating material, a stud 4, and the like.

The face material 2 constitutes the outer side surface of the true wall panel P1 and has an outer shape slightly larger than the frame body 1. In this embodiment, as the face material 2,
A laminated material is used which is obtained by pressing the coating layers 2b and 2c with a water-resistant adhesive on a water-resistant and weather-resistant three-layer long fiberboard 2a. In addition, specifically, "Thermo Ply (trade name, thickness: 3.5 mm, super strength grade)" manufactured by Kokoku Housing Co., Ltd. is used. As shown in FIG. 2, this face material 2 is obtained by attaching an aluminum foil 2b to the surface of a long fiber board 2a and impregnating and coating a polyethylene film 2c on the back surface.

As shown in FIGS. 1 (a) to 1 (c), the frame 1 is fixed to one surface of the face material 2, that is, the surface which becomes the indoor side when the wall W is installed. This frame body 1 gives a certain strength to the true-wall panel P1 when combined with the face material 2, and the rigid urethane foam 3
It is also a framework for hardening the resin into a predetermined shape. As the frame members 1a and 1b forming the frame body 1, a wooden board material is used in this embodiment.

When fixing each of the frame members 1a and 1b to the face member 2, a region where the heat insulating material is not formed in the peripheral portion of the face member 2 (hereinafter simply referred to as "non-formed region R1").
Remain (see FIGS. 1 (a) to 1 (c)).

In the frame body 1 which constitutes the true wall panel P1, a reinforcing material for improving the rigidity of the frame body 1 is provided.
Book studs 4 are arranged parallel to the vertical frame member 1a. A sealing material 5 made of a soft resin is provided on the outer surface of the frame body 1.

Hard urethane foam 3 as heat insulating material
Is a main part of the true wall panel P1 when it exhibits a heat insulating effect. In order to obtain such a rigid urethane foam 3, a procedure of injecting a starting material and a foaming agent into a space S1 formed by the frame 1 and the face material 2 and then applying heat to foam the foam is generally adopted. .

In this example, 140 parts by weight of "diphenylmethane diisocyanate (isocyanate compound)" and 100 parts of "polyol (active hydrogen-containing compound)" were used as starting materials for obtaining the rigid urethane foam 3.
Parts by weight are used. In addition, in this example, 1.7 parts by weight of water was added to the starting material as a foaming agent for foaming the starting material. Then, the kraft paper 6 is adhered to the surface of the hard urethane foam 3 having a density of 46 kg / m ³ thus obtained, that is, the surface which becomes the indoor side during construction.

The large wall panel P2 shown in FIGS. 3 (a) to 3 (c) and the opening panel P3 shown in FIGS. 4 (a) and 4 (b) are the same as the true wall panel P1. It has the same basic configuration.

However, a concave portion 3a for accommodating electric wiring or the like is formed in the central portion of the back surface of the hard urethane foam 3 of the large wall panel P2. Further, the rigid urethane foam 3 is formed with a plurality of ventilation grooves 3b. On the other hand, regarding the opening panel P3, the true wall panel P
Instead of the studs 4 in 1, a plurality of vertical bars 7 are arranged. The large wall panel P2 and the opening panel P
All of 3 are obtained by injecting the starting material and the foaming agent into the space S1 of the frame 1 and heating and foaming.

Next, the heat insulating wall panels P1 and P2 of the present embodiment.
, P3 on the wall W will be described. FIG. 5 exemplifies a shaft assembly (a joist 10, a base 11, a girder 12, and a pipe post 13) which is a portion where the true wall panel P1 is to be installed. An interior material 16 and an exterior material 17 are attached to the frame, respectively, and thereby a wall W in a wooden house is formed. In addition, a ceiling material 1 is provided on the indoor side of the wooden house.
4 and the floor material 15 are arranged. In the wall W, an area surrounded by the interior material 16, the exterior material 17, and the framework such as the joist 10 and the base 11 is an installation space S2 for mounting the true wall panel P1. .

In this embodiment, the frame 1 of the true wall panel P1
Is formed so as to be slightly smaller than the outer shape of the installation space S2 in consideration of convenience in installation. For this reason,
When the true-wall panel P1 is placed in the installation space S2, the shafts such as the joists 10 and the base 11 and the peripheral portion of the face material 2 (that is, the non-formation region R1) are in contact with each other. The true wall panel P1 installed as described above is attached by hitting a nail (for example, SN400) 18 or the like.

Since the method of installing the large wall panel P2 and the opening panel P3 is basically the same as that of the true wall panel P1, the detailed description is omitted here. Now, according to the configuration of this embodiment, the aluminum foil 2b is arranged at the joint portion between the long fiberboard 2a which constitutes the main portion of the face material 2 and the rigid polyurethane foam 3. Since such metal foil is dense and does not allow the permeation of gas such as carbon dioxide gas, as a result, the outflow of carbon dioxide gas diffused in the cells of the rigid polyurethane foam 3 to the outside is surely performed. Can be stopped.

Therefore, it is possible to prevent such a problem that the carbon dioxide gas escapes from the cells of the rigid polyurethane foam 3 and the whole is deformed / contracted. Further, by preventing such a problem, the heat insulating wall panel P1
As a result, the life of .about.P3 itself is extended and its heat insulating effect is reliably maintained for a long period of time.

Further, the heat insulating wall panels P1 to P3 of the present embodiment.
In both cases, the characteristic is that the frame body 1 is fixed to one surface of the face material 2 and a space S1 in the frame body 1 is provided with a heat insulating material made of foamed resin. Therefore, for example, the strength of the heat insulating wall panel is superior to that of the conventional type heat insulating wall panel including only the frame and the heat insulating material.

Further, in these heat insulating wall panels P1 to P3, since the non-formation region R1 for driving the nail 18 into the peripheral portion of the face material 2 is secured, the workability at the time of mounting on the wall W is improved. And the fixing strength is improved. In particular, this can be said to have an advantage, unlike the conventional heat insulating wall panel, which has almost no area for nailing. Further, since the "thermo ply" used as the face material 2 in this embodiment is itself lightweight, there is no possibility that the workability of the heat insulating wall panels P1 to P3 is deteriorated due to the increase in weight. .

In this embodiment, the face material 2 of the true wall panel P1 has a wall magnification of 2.0. As described above, since the true wall panel P1 of this example is excellent in strength, it can be understood that the strength of the wall W can be improved by performing the construction. Of course, it has been confirmed that not only the true wall panel P1 but also the large wall panel P2 and the opening panel P3 have the same strength.

Moreover, these heat insulating wall panels P1 to P3
Has a characteristic that the structure is simple, although they are excellent in strength. Therefore, unlike the conventional heat insulation wall panel that requires bracing, there is no disadvantage that a complicated manufacturing process is required.

The present invention is not limited to the above embodiment, but can be modified, for example, as follows. (A) Not only the coating layers 2b and 2c made of different materials are provided on the front and back sides of the face material 2 as in the embodiment, but the coating layers 2b and 2c made of the same material may of course be provided. Since it is not always necessary to provide the coating layers 2b and 2c on both sides of the face material 2, it is possible to adopt a configuration in which they are provided at least on the joint surface with the heat insulating material 3 in the face material 2. is there.

In any of the above cases, the coating layers 2b and 2c arranged on the joint surface side may be the aluminum foil 2b or the polyethylene film 2c. (B) Face material 2 like the heat insulating wall panels P1 to P3 of the embodiment
It is not limited to providing the coating layers 2b and 2c on only one side of the above, but the coating layers 2b and 2c may be provided on both sides of the face material 2.
Further, in the case of such a configuration, the coating layers 2b and 2c may be further provided on the outer surface of the frame body 1.

(C) For example, instead of the procedure of the above embodiment in which the heat insulating material 3 is injected and foamed with the frame body 1 fixed to the face material 2, for example, the heat insulating material 3 which has been solidified in advance is used as the face material 2. It is also possible to adopt the procedure of disposing the frame 1 after fixing.

(D) If a predetermined wall magnification can be secured, it is of course possible to omit the studs 4 and the vertical bars 7 from the frame body 1 of the heat insulating wall panels P1 to P3. Further, it is possible to further simplify the configuration of the frame body 1 itself including the two pairs of frame members 1a and 1b. Further, in the case of the other example (c), by omitting the frame body 1 as well, the main material of the heat insulating wall panels P1 to P3 may be constituted by the face material 2 and the heat insulating material 3. It is possible.

(E) The foamed resin for forming the heat insulating material 3 may be polyethylene resin, phenol resin, polystyrene resin, urea resin or the like in addition to the polyurethane resin used in the examples. Further, the blowing agent may be replaced with water used in the examples, and may be, for example, CFC substitute, hydrofluorocarbon, hydrocarbon or the like.

(F) The non-formation region R1 for mounting the heat insulating wall panels P1 to P3 does not necessarily have to be provided on the entire peripheral portion, and may be provided, for example, only on the left and right sides of the frame 1 or only on the upper and lower sides.

[0043]

As described above in detail, according to the structure of the heat insulating wall panel of the present invention, it is possible to surely prevent the foamed resin used as the heat insulating material from being deformed and shrunk, and also excellent in strength. It has an excellent effect that it can be achieved.

[Brief description of drawings]

FIG. 1 (a) is a front view showing a true wall panel of an embodiment,
(B) is a sectional view taken along the line A-A, and (c) is its B.
It is a sectional view taken along the line B.

FIG. 2 is a partially enlarged schematic cross-sectional view showing a state near a joint surface between a face material and a foamed resin.

FIG. 3A is a front view showing a large wall panel of an embodiment,
(B) is a sectional view taken along the line C-C, and (c) is its D.
It is sectional drawing in the -D line.

FIG. 4A is a front view showing the opening panel of the embodiment,
(B) is sectional drawing in the EE line.

FIG. 5 is a partially cutaway schematic sectional view for explaining a method of installing a true wall panel.

FIG. 6 (a) is a front view showing a conventional heat insulation wall panel,
(B) is sectional drawing in the FF line.

[Explanation of symbols]

2 ... Face material, 3 ... Hard polyurethane foam as heat insulating material, P1 ... Panel for true wall as heat insulating wall panel, P2 ...
Large-wall panel as heat-insulating wall panel, P3 ... Opening panel as heat-insulating wall panel, 2b ... Aluminum foil as coating layer, 2c ... Polyethylene film as coating layer, R1 ... Area where heat insulating material is not formed ( = Non-formed area).

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yoshihiro Ohara 1122, Kidomachi Rokusha, Ogaki, Gifu Prefecture Ibiden Central Research Institute

Claims (5)

[Claims] 1. A heat insulating wall panel (P1, P2, P3) provided with a heat insulating material (3) made of foamed resin on a face material (2).
In at least one surface of the face material (2), a coating layer (2b, 2) made of at least one selected from metal and resin
Insulation wall panel characterized by having c). 2. The heat insulating wall panel according to claim 1, wherein the metal is aluminum. 3. The heat insulating wall panel according to claim 1, wherein the resin is polyethylene. 4. The heat insulating wall panel according to claim 1, wherein the face material (2) is a fiber board. 5. The region (R1) in which the heat insulating material (3) is not formed is provided in a peripheral portion of the face material (2), as claimed in any one of claims 1 to 4. Insulation wall panels.