KR101636513B1

KR101636513B1 - Manufacturing Method Of Multi-Layer Foamed Heat Insulating Material

Info

Publication number: KR101636513B1
Application number: KR1020140158423A
Authority: KR
Inventors: 노성열; 노규익
Original assignee: 명일폼테크주식회사
Priority date: 2014-11-14
Filing date: 2014-11-14
Publication date: 2016-07-05
Also published as: KR20160057611A

Abstract

The present invention relates to a process for producing a foamed insulation material having a desired thickness by laminating a thin foamed insulation material and a process for producing a foamed insulation material such as extrusion and foaming and a process for laminating and joining the produced foamed insulation material, It is possible to reduce the defective rate as well as to increase the productivity. In addition, without using a chemical adhesive which causes toxic gas or bad odor in the lamination of the foam insulation, it is possible to use the same material as the plastic resin included in the raw material for foam insulation By using the method of mutual bonding by using the plastic resin melt of the components, not only the working environment of the workers can be greatly improved, but also environmentally friendly laminated foamed foam which does not cause any problems in recycling the used foamed insulation after use A method for manufacturing a heat insulating material All.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method for manufacturing a foamed heat insulating material,

The present invention relates to a method of manufacturing a foamed thermal insulating material, and more particularly, to a method of manufacturing a foamed heat insulating material having a thick thickness by stacking a plurality of foamed thermal insulating materials with a thin thickness, To a process for producing a laminated foamed thermal insulating material which can be carried out in a continuous process.

Generally, a heat insulating material is a material that covers the outside of a part to be kept at a constant temperature and minimizes heat loss or heat inflow to the outside. Depending on the temperature used, a heat insulating material having a temperature of about 100 ° C or less, Insulation material of 500 ~ 1,100 ℃, refractory insulation of 1,100 ℃ or more.

As a material of insulation, it is ideal that the thermal conductivity is small. However, in order to compensate for the thermal conductivity which is not very small, the inside of the insulation is formed to be porous so as to utilize the heat insulating property of the air in the pore.

Insulation materials are mainly divided into organic and inorganic materials, such as cork, cotton, felt, carbonized cork, and foamed rubber, which are suitable for use at temperatures below about 150 ° C. As inorganic materials, asbestos, glass wool, quartz cotton, diatomaceous earth, magnesium carbonate powder, magnesia powder, calcium silicate, pearlite and the like are used, and most of them are characterized by being able to withstand use at high temperatures.

Because of its high economic efficiency, the most widely used materials for building interior and exterior materials are plastic foam insulation, foamed with a foaming agent such as polystyrene, polyurethane, polyethylene, etc. The thermal conductivity is about 0.020 to 0.035 W / mk, and the usage limit temperature is about 110 ° C.

As a typical method of producing foam insulation, there are bead method and extrusion method. Foamed insulation material manufactured by bead method is generally known as EPS and is also known as 'Styrofoam' which is a trade name of a specific company. Is a given name because it is made by foaming the insulation to produce the insulation.

Foamed insulation materials produced by the extrusion method are generally known as XPS and also known as 'Starform' or 'Isopink', which is a product name of a specific company. Generally, insulation performance is higher than foamed insulation manufactured by bead method at the same density It has a characteristic that the insulation performance is guaranteed even when it is applied to a portion which is directly exposed to water.

The extrusion method generally comprises a process of mixing plastic raw material, foaming agent and other additives, a process of melting and extruding the raw material, a process of molding the base plate, and a process of foaming the foaming agent.

Conventionally, an in-line type in which a base plate produced by an extrusion apparatus is continuously introduced into a foaming furnace to produce a foamed insulating material, and an in-line type in which a base plate after the extrusion molding process is immediately stored in a specific place without being input to the foaming process, Line type in which the foamed insulation material is produced by injecting it into the furnace. Since the production rate of the base plate of the conventional extrusion apparatus is remarkably lower than the production rate that can be processed in the foaming furnace, the off-line system has been widely used in the on-line system since the productivity of the extrusion apparatus is remarkably increased .

In the case of foamed insulation, as described above, an air layer hole called a cell is formed in order to compensate the thermal conductivity of the insulation. When forming such a cell in the foamed insulation, it is advantageous in terms of thermal conductivity, but the thickness of the foamed insulation is increased There is a problem that the size of the cell is increased when the cell is produced.

When the size of the cell in the foam insulation increases, the foam insulation is shrunk or expanded due to the temperature change. Therefore, the foam insulation is generally produced at a thickness of about 20 to 120 mm. In this case, In order to produce the insulation, a separate joining process was additionally required.

That is, conventionally, once the foaming heat insulating material having been subjected to all processes such as extrusion and foaming is cut to a required size, the adhesive is applied to the surface of the cut foaming heat insulating material, and the foaming heat insulating material cut again is laminated thereon. A non-continuous method of producing foam insulation was used.

However, since the production process such as extrusion and foaming of the foamed insulation material and the combined process of laminating the produced foamed insulation material are not continuously performed, the working speed is lowered and the productivity is greatly lowered, and the production cost due to additional labor costs is increased There was a problem to be done.

In addition, since a bundling process of applying and laminating an adhesive or the like to the foamed thermal insulation material cut in advance is repeatedly performed, there is another problem that the step is inevitably generated between the stacked foamed thermal insulation materials, .

In addition, the adhesive used in the compounding process generally uses a chemical adhesive which releases a toxic gas or a bad odor, so that the working environment is inevitably poor. In addition, the foamed insulating material combined by the chemical adhesive has almost no recycling There is another problem that the resources are wasted and the environment is polluted.

Korean Patent Publication No. 10-2008-0067874 (Published on July 22, 2008)

A problem to be solved by the present invention is to provide a process for producing a foamed heat insulating material such as extrusion and foaming and a process for laminating and joining a produced foamed heat insulating material in a process of producing a foamed heat insulator having a required thickness by laminating foamed heat insulators having a small thickness Which can be continuously produced in an in-line manner, which is high in productivity and capable of lowering a defective ratio.

Another problem to be solved by the present invention is to provide a method of manufacturing a foamed heat insulating material by using a plastic resin having the same material as that of the plastic resin contained in the raw material of the foamed insulating material without using a chemical adhesive which causes toxic gases or bad odors in the lamination of the foamed heat insulating materials. By using the method of applying the melt and mutual bonding, it is possible to greatly improve the work environment of the workers, and also to manufacture an environmentally friendly laminated composite foam insulation which does not cause any problem in recycling the used foam insulation after use .

A method of manufacturing a laminated foamed thermal insulating material for solving the above-mentioned problems comprises the steps of: a) supplying a plurality of unit molded bodies foamed after extrusion molding; b) forming a molten adhesive layer on the upper surface of the unit molded body to be positioned on the lower layer while transferring each of the plurality of unit molded bodies to be supplied, by applying the same plastic resin melt as the plastic resin contained in the raw material of the unit molded body to a predetermined thickness; c) stacking a plurality of unit molded bodies each formed with a hot melt adhesive layer on top of each other to form a laminated foamed thermal insulating material; And d) cutting the laminated foamed insulation material to a predetermined size while transferring the laminated foamed insulation material continuously formed.

In the step b), the same plastic resin melt as that of the plastic resin contained in the raw material of the unit molding is applied in a thickness of 0.01 to 0.03 mm to form a melt adhesive layer.

The step (b) is characterized in that the molten adhesive layer is formed by applying a molten plastic resin heated at a temperature of 130 to 300 ° C.

The step a) may include: a-1) continuously molding a plurality of unit molded bodies through a plurality of extrusion apparatuses after mixing the raw materials; And a-2) continuously foaming and continuously supplying each of the plurality of unit molded bodies.

In the step a-1), a plurality of unit molded bodies are continuously and simultaneously formed through a plurality of vertically disposed extruding apparatuses, and the step b) includes the steps of: And is conveyed so as to have the same horizontal position.

According to the present invention, since a plurality of unit molded bodies manufactured simultaneously by extrusion molding, foaming and the like are successively transferred and stacked up and down, the entire process from mixing of raw materials to manufacturing of unit molded body, formation of laminated combined foamed thermal insulating material, It is possible to reduce the manufacturing cost such as the labor cost as well as the reduction rate of the defective product.

The present invention also provides a method of manufacturing a foamed insulation material having a desired thickness by laminating a unitary molded body having a thin thickness formed with cells having a minute size, There is little change in appearance such as shrinkage or expansion due to abrasion, and deterioration of finishing quality due to steps or the like can be prevented.

In addition, the present invention can be applied to a case where a unitary molded body is stacked upside down without using harmful substances such as chemical adhesives, and a plastic resin melt having the same composition as that of the unitary molded body is coated on the surface of each unit molded body itself, By forming the adhesive layer and bonding them together, no toxic gas or bad odor is generated, so that the working environment is greatly improved. In addition, since the foamed thermal insulation material after use can be recycled, waste of resources and contamination of the environment can be prevented There are advantages.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view showing a step of manufacturing a laminated foamed thermal insulating material according to an embodiment of the present invention. FIG.
2 is a view showing a process line of the laminated foamed thermal insulating material according to an embodiment of the present invention.
3 is a view schematically showing a step of forming a molten adhesive layer according to an embodiment of the present invention.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

FIG. 1 is a view showing a manufacturing step of a laminated foamed thermal insulating material according to an embodiment of the present invention, and FIG. 2 is a view showing a process line of a laminated foamed thermal insulating material according to an embodiment of the present invention.

Referring to FIGS. 1 and 2, a method of manufacturing a laminated foamed thermal insulating material according to an embodiment of the present invention starts with molding a unit molded body 100 using an extrusion apparatus 10 after melting a raw material .

At this time, the extrusion apparatus 10 is provided with a plurality of the plurality of the extrusion apparatuses 10, and then all of the extrusion apparatuses 10 are operated to simultaneously mold a plurality of the unit shaped bodies 100. A plurality of the extrusion apparatuses 10 are shown in FIG. A plurality of the extrusion apparatuses 10 may be positioned at the same height so that the molded unit molded bodies 100 are discharged at the same height, .

Each unit molded body 100 extruded by the plurality of the extruding apparatuses 10 is subjected to a foaming process. The unit molded body 100 discharged from the extruding apparatus 10 is cut, stored separately, It is highly desirable to foam the unit molded body 100 immediately after forming the unit molded body 100 so that the extrusion molding process and the foaming process are continuously performed.

The molten adhesive layer 110 is formed by applying a plastic resin melt to each of the unit molded bodies 100 that have been subjected to the foaming process. Instead of forming the molten adhesive layer 110 on both sides of the unit molded body 100, Is formed only on the upper surface of the unit shaped body 100.

That is, as shown in FIG. 3, when the unit molded body 100 located in the upper layer and the unit molded body 100 located in the lower layer are combined to produce the laminated combined foamed thermal insulating material 200, The molten adhesive layer 110 is formed by applying the plastic resin melt to the upper surface of the substrate 100 only by the application device 40 and then compressed by the roller 30 or the like so that the upper and lower unit molded bodies 100 are combined.

At this time, the plastic resin melt used for forming the melt adhesive layer 110 is not made of a material which is different from the unit molded body 100, but the same plastic resin as the plastic resin used for manufacturing the unit molded body 100 is melted .

Thus, by forming the melt adhesive layer 110 using the same plastic resin melt as the plastic resin used for the raw material of the unit molded body 100, not only the unit molded body 100 of the lower layer and the upper layer constituting the laminated combined foamed insulating material 200, The materials of the melt adhesive layer 110 for bonding the two are made of the same plastic resin, so that not only the quality is excellent but also the later is easily recycled.

On the other hand, in forming the molten adhesive layer 110 by applying the plastic resin melt, the temperature of the plastic resin melt is maintained at about 130 to 300 ° C. so that the surface of the unit molded body 100 to be coated is not excessively damaged .

Also, a laminated composite sheet prepared by coating a resin melt so that the thickness of the melt adhesive layer 110 is about 0.01 to 0.03 mm and being too thinly coated to lower the adhesive force between the upper and lower unit molded bodies 100 or too thick Thereby preventing any influence on the quality of the insulation.

The extrusion molding process, the foaming process, the melt adhesive layer forming process, and the lamination combination process of the unit molded body 100 described above are continuously performed in one sequence, The foaming process, the hot melt adhesive layer forming process, and the lamination and lamination process are carried out while the heat transfer sheet 100 is transferred by using the transfer device 20.

It is also important to arrange the transfer device 20 in an appropriate number at appropriate positions according to the distance between the devices to be subjected to the respective processes, and to maintain a proper transfer speed so that the process does not occur in any process.

As described above, when the extrusion apparatus 10 is disposed in the upper and lower positions, the unit molded body (or the unit molded body) 100 and the melt adhesive layer forming process are carried out while maintaining the respective upper and lower positions, and then the transfer device 20 is arranged so as to combine the unit molded bodies 100 together.

On the other hand, when the extrusion apparatuses 10 are arranged at the same height, the heights of the unit shaped bodies 100 are changed so that the unit shaped bodies 100 can be positioned in the upper and lower layers during the foaming process and the melt adhesive layer formation process The transfer device 20 should be arranged so as to achieve the same horizontal position in the merging process.

On the other hand, as in the present embodiment, it is advantageous from the viewpoints of efficiency and economy that all the processes from the formation of the unit molded body using the raw material to the laminated assembly of the unit molded body are performed successively. However, It may be considered sufficiently to perform the foaming process after the extrusion molding of the molded body separately and to carry out the foaming process and the lamination batch process later by performing the subsequent lamination process or by extruding the unit molded body in advance.

As described above, the laminated composite foam insulating material manufactured through the combination process is cut to a required size through a cutting device, etc., and is packaged in stack units and shipped as a product. Such a cutting process and a packaging process are also continuously performed, It would be desirable for the process to form a sequence.

While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, It will be apparent to those skilled in the art that various modifications, substitutions, and the like can be made without departing from the scope of the present invention.

10 - Extrusion device 20 - Feed device
30 - roller 40 - dispensing device
100 - unit shaped body 110 - hot melt adhesive layer
200 - laminated foam insulation

Claims

a) providing a plurality of unit molded bodies foamed after extrusion molding;
b) forming a molten adhesive layer by applying a plastic resin melt having the same composition as that of the plastic resin contained in the raw material of the unit forming material to the upper surface of the unit molded body to be positioned in the lower layer while transferring each of the supplied plurality of unit molded bodies;
c) stacking a plurality of unit molded bodies each formed with a hot melt adhesive layer on top of each other to form a laminated foamed thermal insulating material; And
d) cutting the laminated foamed foamed insulation material formed to be continuously formed into a predetermined size while being transported,
The step b)
Wherein a molten adhesive layer is formed by applying a plastic resin melt having the same composition as that of the plastic resin contained in the raw material of the unit molding to a thickness of 0.01 to 0.03 mm.

delete

The method according to claim 1,
The step b)
Wherein a molten adhesive layer is formed by applying a molten plastic resin heated at a temperature of 130 to 300 캜 to form a molten adhesive layer.

The method according to claim 1 or 3,
The step a)
a-1) continuously molding each of a plurality of unit molded bodies through a plurality of extrusion apparatuses after mixing the raw materials; And
a-2) continuously foaming and continuously supplying each of the plurality of unit molded bodies to each other.

The method of claim 4,
The step (a-1)
A plurality of unit molded bodies are simultaneously and continuously molded through a plurality of vertically arranged extrusion apparatuses,
The step b)
Wherein the plurality of foamed unit shaped bodies are transported so as to have a different horizontal position and a different vertical position, respectively.