KR20130037640A - Vacuumed insulation marerial, and method and apparatus for manufacturing the same - Google Patents

Abstract

PURPOSE: A vacuum insulation material, a manufacturing method, and a manufacturing device thereof are provided to prevent the degradation of the degree of vacuum with a metal film covering material, and to prevent the spreading of leak heat into the metal film covering material. CONSTITUTION: A vacuum insulation material(1) comprises covering materials(2,3) and an insulation core(4). Two covering materials are composed of a metal film. The insulation core is arranged in a central part between the two covering materials. Thermoplastic resin(5) with thermal resistance is pinched between the covering materials of each end edge part(2a,3a). [Reference numerals] (AA,BB,CC) Heating and pressurizing;

Description

Vacuum insulation material, manufacturing method, and manufacturing apparatus therefor {VACUUMED INSULATION MARERIAL, AND METHOD AND APPARATUS FOR MANUFACTURING THE SAME}

This invention relates to a vacuum heat insulating material, its manufacturing method, and its manufacturing apparatus.

In view of energy saving, in recent years, vacuum insulators have been widely used industrially. This vacuum insulator is filled with a high-performance insulator in a sealed space maintained in a vacuum. Typically, the porous core member of the porous structure is covered with a high-sealing shell such as a plastic film, and the surroundings in a vacuum atmosphere. What was obtained by vacuum sealing by sealing is known.

In this vacuum insulator, in order to maintain the heat insulation performance for a long time, it is necessary to maintain the insulation encapsulation space formed inside the sealed shell material at a high vacuum degree, but even if the seal itself is perfect, the strength of the shell material may be insufficient. Due to secular variation, gases such as air and water vapor gradually penetrate into the outer shell material and invade the inside, and the degree of vacuum decreases in many cases, resulting in deterioration of thermal insulation performance.

Therefore, in order to improve the gas barrier property of the outer cover material itself, the heat insulation structure which used the multilayer film which laminated the aluminum foil and the aluminum vapor deposition film on the base resin film conventionally as an outer cover material is proposed (refer patent document 1 below). ).

However, even in the case of the vacuum insulator using such an outer cover material, when used in a high temperature atmosphere of 90 degreeC or more, for example, heat shrinkage may occur in the resin film which supports a vapor deposition layer, and a crack may arise in a vapor deposition material, and it is very thin In the metal deposition layer, there is a problem in heat resistance and durability, such as deterioration of the layer itself, generation of pinholes, and the like to suppress gas permeation.

In order to escape from such a situation, it is proposed to use the outer skin material of metal foil single body, such as aluminum and stainless steel, as a material with high gas barrier effect, The outer skin material of such a metal foil is an outer skin material. It can be expected to keep the internal vacuum degree stable for a long time.

In order to manufacture the vacuum insulation material which used the metal foil single body as an outer cover material, unlike the conventional simple heat sealing bag for resin outer coverings made of metal, it is necessary to concentrate the heat quantity in a small range in order to fully weld the sealing part of a metal foil outer cover material. Expensive sealing apparatus, such as a welding sealing apparatus, is needed (refer patent document 2 below).

Japanese Patent Application Publication No. 2-54479 Japanese Patent Application Publication No. 2004-90060

However, in the vacuum insulator using the metal foil outer cover material, the gas barrier effect is high, but the thermal conductivity of the metal itself is high. Therefore, in a high temperature environment, heat leak between the surface and the back surface of the vacuum insulator due to heat conduction between the shell materials. Becomes large, and there exists a problem of reducing the heat insulation performance as a whole.

In addition, when using a metal foil shell material, when the core material of the vacuum insulation material is previously wrapped with the outer shell material before the vacuum bag, the method of inserting the core material into the bag of the shell material sealing the three sides of the metal foil outer shell material is used. Workability is not good, there is a problem that the size or shape of the shell material is also limited.

In general, the apparatus for manufacturing a vacuum insulator is capable of manufacturing a vacuum insulator only with a specification relating to a specific size and shape, and reduces the overall equipment cost by increasing the versatility to cope with various sizes, shapes, and the like. However, the improvement of productivity, the reduction of maintenance cost, etc. by automation are not fully considered. As a result, there is a problem that the final manufacturing cost increases.

In addition, in the past, the core material of the vacuum insulator was inserted into the bag of the envelope resin material which was three-way or two-way sealed in advance before vacuum sealing, but this was not good workability. In particular, when it is necessary to place a thermoplastic resin between metal foils, such as the heat insulating material of this invention, workability | operativity is not so good and it is more difficult to produce a vacuum shape material of especially large shape.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and prevents the leakage of heat spread between the metal foil skin materials while preventing the vacuum degree from being lowered by the metal foil skin materials, thereby improving vacuum insulation materials, laser welding devices, and the like. It is an object of the present invention to provide a method for producing a vacuum insulator which can be manufactured without using an expensive sealing device, and a manufacturing apparatus for manufacturing a vacuum insulator in which vacuum insulators of various shapes can be manufactured at low cost.

The vacuum heat insulating material which concerns on this invention is equipped with the two outer skin materials which consist of metal foil, and the heat insulation core material arrange | positioned between the substantially center part of these two outer skin materials, and is at least between the said outer skin materials of each short side part. Each short side portion is thermally welded and sealed in a state where the thermoplastic resin having heat resistance is sandwiched, and the inside is in a vacuum state.

The manufacturing method of the vacuum heat insulating material which concerns on this invention arrange | positions a heat insulation core material in the substantially center between two sheets of metal foil outer materials, and arrange | positions a thermoplastic resin in at least a short side part, and among the four short sides of the said metal foil outer materials, it opposes two sides which oppose. It is heat-welded in air | atmosphere, and the remaining two sides of the said metal foil outer cover material are heat-welded in a vacuum atmosphere, and vacuum sealing is performed.

The apparatus for manufacturing a vacuum insulator according to the present invention is a material in which a vacuum insulator is mounted, and includes a lower encapsulation unit having a heating press member corresponding to an encapsulation position in the periphery and a first encapsulation unit for setting the material. A second chamber including a first sealing unit having a stage and a heating pressing member for thermally welding two sides of short sides of the material of the vacuum insulator between the heating pressing member of the lower sealing unit and the vacuum chamber. It has a 3rd stage which heat pressurizes the vacuum heat insulating material by which the two sides were heat-welded in the said 2nd stage from upper and lower, and efficiently removes and dries air, and has the following vacuum chamber, The heat pressurization of the said lower bag unit is carried out therein. Heating for vacuum sealing by heat-welding the other two sides of the short side part of the material of the said vacuum insulator between members It is equipped with the 4th stage provided with the 2nd sealing unit which has a press member, and the 5th stage which draws out the completed vacuum heat insulating material.

Since the vacuum insulator according to the present invention is sealed by sandwiching a thermoplastic resin having heat insulation and heat resistance such that the metal foil shells do not directly contact each other in the encapsulation portion, the gas barrier property, heat resistance, cost reduction effect, and aging are ensured. It is excellent in resistance to change and the like, and it is possible to suppress a decrease in thermal insulation due to leakage of heat, and to use a thermal welding encapsulation device that has been generally used in the past.

Moreover, the manufacturing method of the vacuum heat insulating material which concerns on this invention performs the heat welding of the two sides which oppose in air | atmosphere in the state which arrange | positioned the heat insulating material and the thermoplastic resin at least at the short side part between the metal foils, and after that, the metal foil and heat insulating material in a vacuum atmosphere. Is encapsulated by vacuuming and heat-sealing, and further thermally welding the remaining two sides, and thus the versatility is high and the automation is easy. Therefore, the equipment cost and maintenance cost can be reduced, and the productivity can be improved. Can be reduced.

The manufacturing apparatus of the vacuum heat insulating material which concerns on this invention can reliably obtain the vacuum heat insulating material of favorable quality by passing through five stages one by one. In particular, in the third and fourth stages having continuous vacuum chambers, the vacuuming and heat drying are performed first in the third stage, and the final vacuum encapsulation is performed in the next fourth stage. Improvement and long life can be aimed at.

(A), (b), (c) is sectional drawing explaining the structure of three different aspects of the sealing part of the vacuum heat insulating material concerning this invention, and their sealing process.
2 is a graph showing the change of the thermal insulation effect by the thickness of the thermoplastic resin in the vacuum insulator according to the present invention, (a) shows a surface temperature of 50 ℃, (b) shows a surface temperature of 100 ℃. .
3 is an explanatory diagram showing a schematic configuration of main parts of a method and a device for manufacturing a vacuum insulator according to the present invention.
It is a side view which shows the structure of the lower sealing unit used by the manufacturing apparatus shown in FIG.
FIG. 5 shows step S3 shown in FIG. 3, which is a side view showing a step of thermally welding the air in the air by sandwiching a thermoplastic resin between two ends of the metal foil envelope.
FIG. 6 is a partial cross-sectional front view which shows the state of the press of step S4 in the 3rd stage shown in FIG. 3, and the vacuum sealing of the remaining two sides of step S5 in the 4th stage.
7 is an enlarged cross-sectional view illustrating the configuration of the small vacuum chamber in FIG. 6 in detail.
FIG. 8 is a front view showing a lower encapsulation unit configuration capable of simultaneously processing four vacuum insulators and an operation in a third stage in FIG. 3.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1: is sectional drawing which shows three processing aspects which use the metal foil as the outer cover material 3 which the heat insulating core material 4 is enclosed, and encapsulates by heat | fever pressurization in a short side part, and obtains the vacuum heat insulating material 1. 1A, 1B, and 1C, the state in which the high-performance heat insulating material as the core material 4 is stored between the two outer shell materials 2 and 3. The short edge parts 2a and 3a of the outer skin materials 2 and 3 shown horizontally on the figure are shown to be sealed by heat welding. In such a bag, the first two sides of the bag may be sealed in the air. However, when the remaining two sides of the bag are encapsulated, it is carried out in a vacuum as described below, and the inside of the shell material becomes a vacuum to obtain a vacuum insulator. have.

Specifically, in the aspect shown in FIG. 1A, one thermoplastic resin 5 is disposed in the middle of only the short sides 2a and 3a of the shell material, and is heated from the outside of the short sides 2a and 3a. By pressurization, the thermal welding which melts the thermoplastic resin 5 and welds short side parts 2a and 3a is performed.

In the aspect shown in FIG.1 (b), the thermoplastic resin 6a, 6b is previously attached to each inside of the short sides 2a, 3a of the upper and lower metal foil outer materials by adhesion | attachment with an adhesive agent or heat welding etc. previously. It seals by heating and pressurizing from the exterior of the short sides 2a and 3a. In this case, since the thermoplastic resin is attached in advance, it is not necessary to position the two metal foil shell materials, and the work can be simplified.

In addition, in the aspect shown to (c) of FIG. 1, although it is similar to the aspect of (b) of FIG. 1, the thermoplastic resins 7a and 7b are previously performed in the front process inside each of the upper and lower metal foil shell materials 2 and 3, respectively. ) Is the same point of mounting by adhesive or thermal welding, but is mounted so as to reach not only the short sides 2a and 3a of the metal foil shell materials 2 and 3 but also the position of the core material 4. Is different. Such a configuration inevitably occurs in the transition portion from the end portion of the core member 4 after the vacuum sealing to the heat welding vacuum sealing portion, for example, when the thin metal foil outer cover materials 2 and 3 are used. It contributes to the reinforcement of the bent part and the part to which the core is in contact.

The thermoplastic resins 7a and 7b may be formed by laminating in advance on the entire surfaces of the shell materials 2 and 3. In this case, the manufacturing process is simplified.

As the thermoplastic resins 5, 6a, 6b, 7a, and 7b used here, it is necessary to have heat insulation and heat resistance, and polyimide is very suitable. In other words, the thermoplastic resins including polyethylene used in conventional shell materials have a glass transition temperature of around 100 ° C., whereas polyimide thermoplastic resins have excellent heat resistance at 250 to 500 ° C., and their thermal conductivity is also low. As 0.16 W / mK, it is about 1/1000 smaller than aluminum metal foil and about half smaller than polyethylene, and is excellent also in heat insulation. Moreover, compared with other thermoplastic resins, it is also excellent that the heat welding with metal foil can be performed on appropriate temperature conditions, and the width | variety of the temperature which can be heat-welded is also excellent.

Next, although aluminum and stainless are used as a metal foil, other metal can also be used as long as it is a material stable in a wide temperature range, and is excellent in malleability. In practical use, in consideration of barrier property, strength, handleability, etc. to the gas for a long time, the thickness thereof is preferably in the range of 60 µm to 200 µm.

Next, the optimum range of the thickness of a thermoplastic resin is demonstrated.

FIG. 2 shows the thickness of the thermoplastic polyimide resin when the thermoplastic polyimide resin is sandwiched between the outer shell material of the aluminum foil having a thickness of 100 탆 and thermally welded to the vacuum insulator short side portion as in the aspect of FIG. As a graph showing the effect of heat insulation according to the present invention, FIG. 2 (a) shows the surface of the short side part according to the thickness change of the thermoplastic polyimide resin when the surface of the short side part is 50 ° C and FIG. 2 (b) is 100 ° C. The temperature change is shown.

The three curves in each graph indicate that the uppermost line has only a weak airflow at the back of natural convection, while the second line has the same forced bottom if there is forced air convection on the back. In addition to phosphorus air convection, since the central part of the back metal foil is cooled and there is a temperature difference between the short side parts, the cases where there is a temperature gradient due to heat conduction are shown.

Comparing these, although it turns out that temperature fall becomes large by the intensity | strength of airflow or cooling of metal foil, the tendency of the heat insulation property (temperature fallability of back surface) by the thickness difference of a thermoplastic polyimide resin is substantially the same. That is, the back temperature rapidly drops to about 110 탆 in thickness and exhibits an adiabatic effect, and then slowly to 250 탆, and thicker than this, and then becomes substantially constant thereafter. Moreover, when the thickness becomes thick more than necessary, considering that it becomes difficult to perform high quality thermal welding, the preferred thickness of the thermoplastic polyimide resin is generally 110 µm or more and 250 µm or less.

In addition, the difference in material and thickness of the metal foil outer cover material having a very high thermal conductivity compared to the thermoplastic resin is negligibly small. In addition, other surface temperature conditions show the same tendency as described above.

When the thermoplastic polyimide resin is formed on each of the inner surfaces of the two sheets of metal foil outer coverings as shown in Figs. 1B and 1C, each thickness is not less than 55 µm and not more than 125 µm, which is half of the aforementioned range. The thickness of the two sheets falls within the range of 110 µm or more and 250 µm or less.

3 schematically shows the main part of a manufacturing apparatus 100 for producing a vacuum insulator according to the present invention, and a manufacturing step using the same. In this manufacturing apparatus 100, the part in which a belt conveyor is provided is set as a stage, and the lower sealing unit demonstrated below is not shown in order to avoid the complicated drawing.

The stage consists of five parts, and in the first first stage 110, the lower sealing unit described later is mounted on the belt conveyor 111 (step S1), and the constituent material of the vacuum insulation material prepared in advance in the lower sealing unit. Is set (step S2).

4 is a front view showing the configuration of the lower encapsulation unit 10. Here, the thing of the two-stage structure which can simultaneously produce two vacuum heat insulating materials is demonstrated.

A post 12 stands in each corner of the base plate 11 that supports the whole, and is mounted on the base plate 11, and the lower support plate 13 corresponds to the post 12. The hole part is formed, and it can raise and lower freely using the support | pillar 12 as a guide.

The lower lower plate 14 incorporating the heater is provided on the lower support plate 13, and the lower heating pressurizing member 15 incorporating the heater is provided on both sides thereof. The lower heating pressurizing member 15 is continuous to be wider than the width of the lower lower plate 14 in the direction perpendicular to the ground. Although each material shown in FIG. 1 is mounted in this state in the laminated state, the height of the bottom heating press member 15 adds 1/2 the thickness of the metal foil outer material and the thickness of an insulating core material rather than the surface height of the bottom lower plate 14. It is desirable to be as high as the height.

The distal end of the post 12 described above is connected to the upper support plate 16, and a lower press plate 17 with a heater is provided on the lower surface of the upper support plate 16, and an upper lower plate with a heater on the upper surface. 18 is provided, and similarly to the lower end, the upper end heating press member 19 incorporating a heater is formed in both sides of the upper lower plate 18. As shown in FIG.

The lower encapsulation unit 10 shown in FIG. 4 is mounted on the belt conveyor 111 of the first stage 110 of FIG. 3, and on the lower lower plate 14 and the upper lower plate 18 of FIG. As in a), the heat insulating core material 4 and the thermoplastic resin 5 overlapping only the short side part are arrange | positioned at the center part between metal foil outer shell materials 2 and 3, and are arrange | positioned.

In the next 2nd stage 120, the upper sealing units 20 and 30 are used, and it has the lifting holder 123 which raises and lowers between the belts of the belt conveyors 121 and 122. As shown in FIG. In addition, since the upper sealing unit is inside, it is not displayed, but is shown in FIG. 5 described later.

The upper sealing unit 20 is attached to the support plate 21 supported by the support structure which is not shown, as shown in FIG. 5 which showed the state seen from the A direction toward the upstream side from the downstream side of FIG. 3 and FIG. It has two heating press members 25 and 26 attached to the shaft 24 driven up and down by the cylinder 23 with the heater 22.

By these, welding of two sides of four sides of a metal foil outer cover material is performed in air | atmosphere by clamping a thermoplastic resin (step S3).

FIG. 5 is a view for explaining a state in which the two sides of the metal foil outer cover material are welded in step S3, and the elevating holder 123 that is lifted between the belt conveyors 121 and 122 is the base plate of the lower sealing unit 10. While supporting the bottom of the lower support plate 13 in the opening of the 11, and by the action of the cylinder 23 of the upper encapsulation unit 20, the heating press members 25, 26 provide the lower encapsulation unit 10. The thermoplastic resin 5 inserted between the two metal foil shell materials 2 and 3 is sandwiched and pressed between the heating and pressing members 19 and 15 of.

At this time, since the heating press members 19 and 15 incorporate a heater and the heater 22 heats the heating press members 25 and 26, the thermoplastic resin 5 is softened, and the two metal foils are pressed by the pressurized pressure. The outer shell materials 2 and 3 are welded firmly.

The cylinder 23 rises after completion | finish of welding, and the lifting holder 123 descends.

The upper encapsulation unit 30 paired with the upper encapsulation unit 20 has a symmetrical configuration with the upper encapsulation unit 20, and corresponding portions of the upper encapsulation unit 20 correspond to 30 units. It is indicated by a reference number.

By simultaneously operating these upper sealing units 20 and 30, welding in the atmosphere of the two sides which oppose a vacuum heat insulating material can be performed simultaneously.

Returning to FIG. 3, the third stage 130 and the fourth stage 150 are stages forming a continuous vacuum chamber.

The third stage 130 is provided with a belt conveyor 134, and the first hermetic door 133 provided outside the wall 131 on the inlet side is opened, and passes through the opening 131a to be lower from the second stage. The sealing unit is conveyed and mounted on the belt conveyor 134.

The elevating holder 135 for elevating through two belts of the belt conveyor 134 is elevated by a cylinder 136 mounted on the lower surface of the bottom wall of the vacuum chamber 132, and the elevating holder 135 ), A press plate 142 which is driven up and down by a cylinder 140 mounted on an upper surface of a ceiling wall of the vacuum chamber 132 is provided.

In addition, a second hermetic door 138 is provided inside the outlet side wall of the third stage 130.

In the third stage, the elevating holder 135 is raised by the operation of the cylinder 136 to support the base plate of the lower encapsulation unit, and the cylinder 140 is operated to lower the press plate 142, thereby at step S3. Pressure is applied from the upper and lower sides of a metal foil in a vacuum atmosphere to the vacuum heat insulating material in the lower side sealing unit in which welding of two sides was performed. Thereby, close_contact | adherence of a metal foil and a heat insulating core material is aimed at (step S4).

The opening 146 formed in the partition wall 145 between the next fourth stage 150 is the third hermetic door 153 provided inside the entrance side of the second hermetic door 138 and the fourth stage 150 described above. ), A closed space is formed, and the closed space is exhausted by the exhaust port 147, thereby becoming the small vacuum chamber 146. The function of this small vacuum chamber is mentioned later.

As can be seen in FIG. 3, the ceiling plate of the walls forming the vacuum chamber 152 of the fourth stage 150 has a cross-sectional shape having a step so that the upper sealing unit can be provided as described later.

Similar to the other stages, the belt conveyor 154 is installed in the vacuum chamber 152 of the fourth stage 150, and the heat insulating material heated and pressurized in the third stage 130 passes through the third hermetic door 153. Are loaded and mounted on the belt conveyor 154. The elevating holder 155, which is moved up and down between two belts of the belt conveyor 154, is lifted and lowered by a cylinder 156 and its shaft 157 mounted on the bottom surface of the bottom wall of the vacuum chamber 152, The highest ascending position of the elevating holder 155 at the time of sealing is indicated by 155 '.

The upper encapsulation unit provided on the ceiling plate of the vacuum chamber 152 of the fourth stage 150 has the same configuration as that shown in FIGS. 3 and 5.

In the fourth stage 150, sealing is performed on the remaining two sides of the state in which the thermoplastic resin is sandwiched between the two metal foil shell materials of the vacuum insulator by the upper sealing units 40 and 50 in the vacuum atmosphere (step S5). ).

The configuration and operation in the third and fourth stages will be described with reference to FIG.

In the third stage 130, the lower sealing unit 10 is loaded on the belt conveyor 134 through the opening 131a of the wall 131 with the first airtight door 133 open. . At the time of carrying in, the second hermetic door 138 serving as the exit to the adjacent stage is closed. In this state, the heat insulating material in which only two sides were welded in the front stage is mounted on the lower lower plate 14 and the upper lower plate 18. As shown in FIG.

First, the first hermetic door 133 and the second hermetic door 138 are closed, and the exhaust is exhausted from the exhaust port 139, whereby the vacuum chamber 132 is evacuated. At this time, the vacuum chamber 152 of the adjacent fourth stage 150 and the small vacuum chamber 146 formed in the partition wall 145 between these vacuum chambers are also evacuated by the exhaust ports 159 and 147 respectively.

In this state, the lower lower plate 14, the lower press plate 17, and the upper lower plate 18 are heated, and the press plate 142 lifted and controlled by the cylinder 140 and its shaft 141 from above. Is lowered, and from below, the elevating holder 135 ascends to the position indicated by 135 'by the cylinder 136 and its shaft 137. As shown in FIG.

When the elevating holder 135 is raised, the lower support plate 13 is raised by passing through the opening of the base plate 11, but the support 12 is installed at the corner of the lower support plate 13, and the lower end is provided. Since the support plate is formed to penetrate the post, the lower support plate 13 and the lower lower plate 14 are pushed together, and the heat insulating material is pressed between the lower lower plate 14 and the lower press plate 17. . Similarly, the heat insulating material is pressed between the upper lower plate 18 and the press plate 142 driven by the cylinder 140.

In this manner, the two heat insulating materials are pressed at the same time, and the metal foil outer cover material and the core material are brought into close contact with each other, so that excess air is eliminated.

When the heating pressurization ends, the cylinders 136 and 140 return to the initial positions, and the second hermetic door 138 and the third hermetic door 153 are opened, and the lower sealing unit 10 is in the vacuum chamber 152. Conveyed onto the belt conveyor 154. In this transfer, since the vacuum chamber 132, the small vacuum chamber 146, and the vacuum chamber 152 are all in a vacuum state, the transfer can be performed without causing a change in the degree of vacuum.

After the lower sealing unit 10 is transferred into the vacuum chamber 152 and the airtight doors 138 and 153 are closed, the vacuum chamber 132 is returned to the standby state and the next lower side is opened by opening the airtight door 133. Carrying in the sealing unit 10 becomes possible.

Here, the structure and function of the small vacuum chamber 146 are demonstrated. As shown in the enlarged cross-sectional view of FIG. 7, the small vacuum chamber 146 is formed in the partition wall 145 between the vacuum chamber 132 and the vacuum chamber 152, and the packing 148 is airtight provided on the contact surface with the partition wall 145. It is a space enclosed by the doors 138 and 153, and the exhaust is exhausted from the exhaust port 147 to be evacuated.

If the small vacuum chamber does not exist and only the airtight door 153 exists, the airtight door 153 is pressurized toward the partition wall 145 when the vacuum chamber 132 is in a vacuum state and the vacuum chamber 152 is in a standby state. While the airtight state of the vacuum chamber 132 can be kept constant, in contrast, when the vacuum chamber 132 is in a standby state and the vacuum chamber 152 is in a vacuum state, a force that opens the airtight door 153 acts as the vacuum chamber 152. Can not maintain the vacuum state.

In addition, if only the airtight door 138 exists, the vacuum state of the vacuum chamber 132 cannot be maintained when the vacuum chamber 132 is in a vacuum state and the vacuum chamber 152 is in a standby state.

On the other hand, as shown in FIG. 7, the vacuum chamber 146 sealed by the two airtight doors 138 and 153 is provided, and the air pressure is always lower than the air pressure of the vacuum chambers 132 and 152, so that even in any pressure relationship, The vacuum chamber state can be maintained. That is, the vacuum chambers 132 and 152 are pressurized toward the partition wall 145 to maintain each vacuum chamber state.

When both of the vacuum chambers 132 and 152 are in the atmospheric state, when the small vacuum chamber 146 is in a slightly reduced pressure state, the two airtight doors 138 and 153 are in close contact with the partition wall 145. In addition, when both vacuum chambers are in a standby state and these airtight doors are opened, the small vacuum chamber 146 may also be in a standby state.

As described above, the vacuum state of the two vacuum chambers can be satisfactorily maintained by forming the vacuum chamber further reduced in pressure between the two vacuum chambers.

Returning to FIG. 6, the remaining two sides of the sealing are performed in the vacuum chamber 152.

As described above, the lower encapsulation unit 10 is transferred onto the belt conveyor 154 in the vacuum chamber 152 with the airtight doors 138 and 153 open.

As shown in FIG. 6, since the installed upper sealing units 40 and 50 are installed in a fixed position, sealing is performed by positioning the lower sealing unit 10 to the position which performs sealing by the belt conveyor 154. do. In FIG. 6, the remaining two short sides of the metal foil envelope are simultaneously encapsulated, but only when the mounting positions of the upper encapsulation units 40 and 50 have a dimensional relationship coinciding with the encapsulation position, simultaneous encapsulation as shown is possible. However, when the mounting positions of the upper sealing units 40 and 50 do not coincide with the sealing position, the heating pressing members 45 and 46 of the upper sealing units 40 and 50 are sealed by controlling the movement of the belt conveyor. The heat sealing is performed by positioning by facing the heating and pressing members 19 and 15 of the unit and pressing the cylinder 43 while heating a short side portion between the two metal foils sandwiched therebetween. At this time, the heating and pressing members 45 and 46 are heated through the shaft 44 by the heat generated by the heater section 42.

Between the heating press members 55 and 56 and the heating press members 19 and 15 of the lower encapsulation unit, which the last one side seal is also heated through the shaft 54 by the heater 52 of the upper encapsulation unit 50, Heat sealing is performed by pressing by the cylinder 53, heating the short side part in which a thermoplastic resin is interposed between two metal foils. Since the vacuum chamber 152 which performs this final sealing turns into a vacuum, the inside of the metal foil outer cover material which sealed four sides becomes a vacuum.

In this manner, the third stage and the fourth stage are continuous vacuum chambers, and in the third stage, the vacuum pressurization and drying of the constituent members of the vacuum insulator are performed simultaneously with the vacuum exhaust in the vacuum insulator 1, and the vacuum is performed in the next fourth stage. By performing the final encapsulation in the atmosphere, not only the vacuum suction and encapsulation work is divided, but also the production efficiency is improved, and the drying process and the encapsulation process can be directly connected to improve the quality maintenance or the degree of vacuum, thereby improving heat insulation.

After completion of the sealing process, the depressurization state in the vacuum chamber 152 is released, and the fourth hermetic door 158 is opened to pass through the opening 151a provided in the wall 151, and the belt conveyor of the next fifth stage 160 ( The vacuum insulator is mounted on 161, and the product of the vacuum insulator is taken out and released by the movement of this belt conveyor and the drawing mechanism not shown.

In the fifth stage, the lower sealing unit is collected after the product is taken out and sent to the first stage. Therefore, it is preferable that the circulation conveyor (not shown) which returns to a 1st stage from a 5th stage is provided, and conveyance is performed automatically.

Since the vacuum insulator manufactured in this way uses a metal foil having high gas barrier performance, the degree of vacuum inside is maintained for a long time, and the welding between the metal foils is carried out by sandwiching a thermoplastic resin having heat insulation. The ashes do not come into contact, and the thermal leakage between the surface and the back is reduced. Moreover, since sealing operation is performed by setting an insulating core material from the beginning, the freedom of the magnitude | size of a product and a shape becomes high.

Although the lower sealing unit for manufacturing two vacuum heat insulating materials simultaneously is used in the Example demonstrated above, the lower sealing unit which made four vacuum heat insulating materials simultaneously can also be used for efficiency.

FIG. 8A is a front view illustrating the lower sealing unit having such a four-stage configuration, and FIG. 8B is a front view illustrating the step of applying pressure in the third stage using the lower sealing unit.

At each corner of the base plate 61 of the four-stage lower encapsulation unit 60, four pillars 80 serving as guides are vertically mounted and fixed to the fourth support plate 71 at the top. In the first support plate 62, the second support plate 65, and the third support plate 68, the support 80 penetrates through the corners, and the support plate 62 can move up and down using the guide. The first lower plate 63, the second lower plate 66, the third lower plate 69, and the fourth lower plate 72 are installed on the upper surfaces of the support plates 62, 65, 68, and 71, respectively. The first press plate 64, the second press plate 67, and the third press plate 70 are provided on the lower surfaces of the support plates 65, 68, and 71, respectively. These lower plates and press plates have a heater built therein so that they can be heated.

In addition, the first support plate 62, the second support plate 65, the third support plate 68, and the fourth support plate 71 each include a first heating pressurizing member having a heater for encapsulation ( 73, the second heating press member 74, the third heating press member 75, and the fourth heating press member 76 are provided.

Next, the process of heat-pressing a vacuum heat insulating material using such a lower sealing unit is demonstrated with reference to FIG. 8 (b).

The vacuum insulators 91, 92, 93, and 94 on which the two sides are welded are positioned on the upper surfaces of the support plates 62, 65, 68, and 71, and the elevating holder 135 is shown as 135 'from below. The heating and pressing of the vacuum insulator 91 is performed between the first lower plate 63 and the first press plate 64 on the first supporting plate 62 pushed up by raising to the position. As the elevating holder 135 is raised, the heating and pressing of the vacuum insulator 92 is performed between the second lower plate 66 and the second press plate 67, and the third lower plate 69 and the third press plate. The heat pressurization of the vacuum heat insulating material 93 is performed between 70, and the heat pressurization of the vacuum heat insulating material 94 is performed between the 4th lower plate 72 and the cylinder-driven press plate 142. As shown in FIG.

In order to perform this heating pressurization safely and reliably, about the 2nd support plate 65 and the 3rd support plate 68 which are pushed up or descend | falled, the fall prevention stopper (to prevent it from falling down any more) 81 and 82 are provided. In addition, overload stoppers 77 and 78 are provided in the first support plate 62 and the second support plate 65 of the lower end portion to which the load is more applied in order to prevent the press force from becoming excessive. They are screwed to each support plate so that they are interchangeable and height adjustable.

As mentioned above, although the heat-welding sealing apparatus specialized for this invention using the metal foil outer shell material was demonstrated, the said apparatus can be used also as a vacuum sealing apparatus of the conventional metal vapor deposition film or a resin outer shell material by a slight design change.

1: vacuum insulation material 2, 3: metal foil outer material
2a, 3a: Short side portion 4: Heartwood
5, 6a, 6b, 7a, 7b: thermoplastic resin 10: lower sealing unit
11: base plate 12: prop
13: lower support plate 14: lower lower plate
15: lower heating pressing member 16: upper support plate
17: lower press plate 18: upper lower plate
19: upper heating pressing member 20, 30: upper sealing unit
21: support plate 22: heater
23: cylinder 24: shaft
25, 26: heating press member 40, 50: upper sealing unit
43: cylinder 44: shaft
45, 46: heating press member 60: four-stage lower sealing unit
61: base plate 62, 65, 68, 71: support plate
63, 66, 69, 72: lower plate 64, 67, 70: press plate
73, 74, 75, 76: heating press member 77, 78: overload prevention stopper
80: prop 81, 82: anti-fall stopper
91, 92, 93, 94: vacuum insulation material 100: manufacturing apparatus
110: first stage 111: belt conveyor
120: second stage 121, 122: belt conveyor
123: elevation holder 130: third stage
131: wall 131a: opening
132: vacuum chamber 133: first hermetic door
134: belt conveyor 135: elevating holder
136: cylinder 137: cylinder axis
138: second hermetic door 139: exhaust port
14O: cylinder 141: cylinder axis
142: press plate 145: partition wall
146: vacuum chamber (opening) 147: exhaust port
148: packing 150: fourth stage
151: wall 151a: opening
152: vacuum chamber 153: third hermetic door
154: belt conveyor 155: lifting lowering
156: cylinder 157: cylinder axis
158: fourth hermetic door 159: exhaust port
160: fifth stage 161: belt conveyor

Claims (14)

Two outer shell material which consists of metal foil, and the heat insulation core material arrange | positioned between the substantially center part of the two outer shell materials, and are heat-resistant between the outer shell material of at least each short side part. A vacuum insulator, wherein the short sides are thermally welded and sealed in a state where the thermoplastic resin is sandwiched, and the inside is in a vacuum state. The method of claim 1,
The said thermoplastic resin is a vacuum heat insulating material in which only one layer is provided only in the edge part of the said outer cover material between the said outer cover materials. The method of claim 1,
The said thermoplastic resin is a vacuum heat insulating material provided only in the edge part of the said outer shell material, respectively in layer form in each inner surface of the said outer shell material. The method of claim 1,
The said thermoplastic resin is a vacuum heat insulating material provided in each layer in the inner surface of the said outer skin material facing each other in the area | region which reaches from the edge part of the said outer skin material to the said heat insulation core material. The method of claim 1,
The said thermoplastic resin is a vacuum heat insulating material provided in the whole inner surface containing the edge part of each said outer skin material. The method according to any one of claims 1 to 5,
The thermoplastic resin is a polyimide having a thickness of 110 μm or more and 250 μm or less. A heat insulation core material is arrange | positioned in the substantially center between two metal foil outer shell materials, and a thermoplastic resin is arrange | positioned at least at the short side part,
Of the four short sides of the metal foil skin material, two opposite sides are thermally welded in the air,
The remaining two sides of the said metal foil outer cover material are heat-welded in a vacuum atmosphere, and vacuum sealing is carried out, The manufacturing method of the vacuum heat insulating material. The method of claim 7, wherein
The step of thermally welding the two sides of the metal foil shell material in a vacuum atmosphere is performed by using two successive vacuum chambers and excluding air by vacuum suction and heat pressurization in the vacuum chambers of all the chambers. The manufacturing method of the vacuum heat insulating material which improves the adhesiveness of a metal foil outer cover material, and performs sealing by the heat welding of two sides in the vacuum chamber of a rear chamber. At the lower plate which mounts the material of the heat insulation core material and the vacuum heat insulating material which consists of a thermoplastic resin at least in a short side part in a substantially central part between a support plate, two metal foils, and the said two metal foils, a press plate, and the sealing position on the said support plate A lower sealing unit having a corresponding heating and pressing member,
A first stage on which the lower encapsulation unit is mounted and which sets the material of the vacuum insulator thereon;
And a second chamber provided with a first upper sealing unit having a heating pressing member for thermally welding two sides of short sides of the material of the vacuum insulator between the heating pressing members of the lower sealing unit and a vacuum chamber therein. A third stage for heating and pressurizing the vacuum insulator heat-welded two sides in the second stage from above and below to efficiently remove and dry air;
A second encapsulation unit having a vacuum chamber connected to the third stage, wherein the second encapsulation unit has a heating press member for thermally welding the other two sides of the short side portions of the material of the vacuum insulator between the pressurizing members of the lower encapsulation unit and vacuum-sealing the second encapsulation unit. A fourth stage provided,
5th stage to draw out the completed vacuum insulation material
Apparatus for producing a vacuum insulator comprising a. 10. The method of claim 9,
The said 1st stage thru | or 5th stage have a conveyor mechanism, respectively, The manufacturing apparatus of the vacuum heat insulating material which made it possible to move the said lower sealing unit one by one. The method of claim 10,
And a circulation conveyance path for returning the lower sealing unit from the fifth stage to the first stage. 10. The method of claim 9,
An apparatus for producing a vacuum insulator, wherein a small vacuum chamber kept at low pressure by the vacuum chamber of the third stage and the vacuum chamber of the fourth stage is further provided. 10. The method of claim 9,
The lower encapsulation unit has a plurality of stages of a support plate, a lower plate, a press plate, and a heating press member, wherein the upper encapsulation unit has a plurality of heating press members, and can manufacture a plurality of vacuum insulation materials at the same time. Apparatus for the production of vacuum insulation. The method of claim 13,
Among the supporting plates of the plurality of stages of the lower sealing unit, the support plate is movable up and down except the uppermost one, and the support is formed so as to form an optimal positional relationship between the lower plate and the press plate at the time of heating and pressing. Apparatus for producing vacuum insulation, provided with stoppers between the plates.

Images