KR20160014530A - Process for producing an insulating board and a vacuum insulation panel - Google Patents
Process for producing an insulating board and a vacuum insulation panel Download PDFInfo
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- KR20160014530A KR20160014530A KR1020150103547A KR20150103547A KR20160014530A KR 20160014530 A KR20160014530 A KR 20160014530A KR 1020150103547 A KR1020150103547 A KR 1020150103547A KR 20150103547 A KR20150103547 A KR 20150103547A KR 20160014530 A KR20160014530 A KR 20160014530A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
- B28B3/022—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form combined with vibrating or jolting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/006—Degassing moulding material or draining off gas during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B9/00—Presses specially adapted for particular purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
- B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L59/00—Thermal insulation in general
- F16L59/06—Arrangements using an air layer or vacuum
- F16L59/065—Arrangements using an air layer or vacuum using vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/304—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
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- Engineering & Computer Science (AREA)
- Quality & Reliability (AREA)
- Mechanical Engineering (AREA)
- Thermal Insulation (AREA)
- General Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
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Abstract
Description
The present invention relates to a heat insulating plate and a method of manufacturing a vacuum insulating material.
BACKGROUND ART Insulation materials such as vacuum insulation materials have been widely used in order to reduce the heat and cooling energy by high thermal insulation such as houses and buildings, and by heat insulation and heat insulation on doors and roofs of automobiles. As the heat insulating material, for example, there can be enumerated an insulating plate in which a heat insulating material including powder such as silica is molded into a plate shape.
As a manufacturing method of an insulating plate, there is known a method of obtaining an insulating plate by press molding (uniaxial molding) a heat insulating material containing powder from a top and a bottom using a molding apparatus. Specifically, for example, there is a method of obtaining an insulating plate by press-molding a heat insulating material containing powder into a plate form from a top and a bottom with a pair of molding plates in a molding die for forming a
However, in this method, since the fluidity of the powder is poor, the air in the heat insulating material is not easily released at the time of press forming, and particularly, the compressed air is likely to remain in the heat insulating plate at the central portion of the heat insulating plate. As a result, when the pressure is released, the compressed air expands, causing cracking in the heat insulating plate, or expansion, resulting in a problem that the density becomes lower than the target value. The problem is particularly likely to occur when an insulating plate having a low density and a relatively low strength of 0.15 to 0.35 g /
If the press time is lengthened and the press pressure is gradually increased, air in the heat insulating material can be sufficiently removed at the time of press forming. However, in this method, productivity is greatly reduced.
As a method of efficiently extracting air in the heat insulating material at the time of press molding, a method is known in which a pair of molding plates for press-molding a heat insulating material in the molding die for forming a molding space are provided in a plurality of exhaust holes (Patent Document 3). In this method, the air in the heat insulating material efficiently escapes through the exhaust hole of the plate during press forming.
However, in the method of
An object of the present invention is to provide a method of manufacturing an insulating plate which can manufacture a heat insulating plate with high productivity while suppressing occurrence of defects such as cracking and expansion and is easy to maintain and repair the molding apparatus and is low in cost, And a method for manufacturing a vacuum insulator using the same.
The present invention provides a method of manufacturing an insulating plate and a vacuum insulating material having the following structures [1] to [9].
[1] A method of manufacturing an insulating plate having a molding step of press-molding a heat insulating material containing powder into a plate shape by a molding apparatus having a top mold and a bottom mold,
Wherein the press molding is performed in a state in which the porous sheet is interposed between the upper mold and the heat insulating material and between the lower mold and the heat insulating material or both of the lower mold and the heat insulating material so as to be in contact with the heat insulating material.
[2] The heat insulating plate according to [1], wherein either or both of the upper and lower molds are in contact with the porous sheet interposed between the heat insulating material and the porous sheet, ≪ / RTI >
[3] The method for producing an insulating plate according to [2], wherein the ratio of the depth and width of the groove formed in the mold surface contacting with the porous sheet (groove depth / groove width) is 0.1 or more.
[4] The porous sheet according to any one of [1] to [3], wherein either or both of the upper and lower molds are in contact with the porous sheet interposed between the heat insulating material and the porous sheet, Wherein the heat insulating plate is made of a metal.
[5] The heat insulating material according to any one of [1] to [4], wherein at least one of the upper and lower molds is in contact with the porous sheet interposed between the heat insulating material and the heat insulating material, Wherein a hole is formed in the insulating layer.
[6] The method for manufacturing an insulating plate according to any one of [1] to [5], wherein the heat insulating material further comprises a binder.
[7] The method of manufacturing an insulating plate according to any one of [1] to [6], wherein the heat insulating material further comprises fibers.
[8] A method for producing an insulating plate according to any one of [1] to [7], wherein an insulating plate having a density of 0.15 to 0.35 g /
[9] The method for manufacturing an insulating plate according to any one of [1] to [8], wherein the heat insulating plate is a core material of vacuum heat insulating material.
[10] A method for producing a vacuum insulation material, comprising the steps of: obtaining an insulating plate by the method for manufacturing an insulating plate according to the above [9]; and vacuum-sealing the obtained insulating plate in an outer bag.
INDUSTRIAL APPLICABILITY According to the method of manufacturing an insulating plate of the present invention, it is possible to manufacture a heat insulating plate with high productivity while suppressing occurrence of defects such as cracking and expansion, and maintenance and repair of the molding apparatus is easy and low cost.
According to the method of manufacturing a vacuum insulator of the present invention, it is possible to manufacture a vacuum insulator with high productivity while suppressing the occurrence of defects such as cracking or expansion in the heat insulating plate.
Fig. 1 is a cross-sectional view showing an example of a molding apparatus used in the method for manufacturing an insulating plate of the present invention.
Fig. 2 is an enlarged cross-sectional view of the vicinity of the side wall of the lower mold in the molding apparatus of Fig. 1;
3 is a cross-sectional view showing a molding step in the method of manufacturing an insulating plate using the molding apparatus shown in Fig.
4 is a cross-sectional view showing a molding step in the method of manufacturing an insulating plate using the molding apparatus of Fig.
5 is a cross-sectional view showing a molding step in a method of manufacturing an insulating plate using another molding apparatus.
Fig. 6 is a cross-sectional view showing a molding step in the method of manufacturing an insulating plate using another molding apparatus. Fig.
Fig. 7 is a cross-sectional view showing a molding step in a method of manufacturing an insulating plate using another molding apparatus. Fig.
8 is a cross-sectional view showing a molding step in a method of manufacturing an insulating plate using another molding apparatus.
9 is a cross-sectional view showing a molding step in a manufacturing method of an insulating plate using another molding apparatus.
10 is a cross-sectional view showing a molding step in a method of manufacturing an insulating plate using another molding apparatus.
11 is a cross-sectional view showing a molding step in a method of manufacturing an insulating plate using another molding apparatus.
Definitions of the following terms apply throughout the present specification and claims.
"Porous sheet" means a sheet-like porous body having a large number of pores and having air permeability capable of allowing air to pass through the pores without allowing the heat insulating material material to escape through the pores thereof .
Means a binder previously applied to the surface of the fumed silica before it is mixed with other components such as porous silica and fibers. Further, fumed silica refers to silica fine particles including amorphous, spherical primary particles free from pores. The fumed silica is obtained by, for example, vaporizing silicon tetrachloride and performing a gas phase reaction in a high temperature hydrogen flame.
The term "radiation inhibitor" refers to a substance that either reflects (scatters) infrared light or absorbs infrared light once and radiates the temperature rise caused by its absorption isotropically so as to dissipate the directionality of the infrared light, Or < / RTI >
"Fiber length D30" means a fiber length at a point of 30% in the cumulative number distribution curve where the total number of fiber length distributions obtained on the number basis is 100%. The " fiber length D90 " means a fiber length of 90% in the cumulative number distribution curve where the total number of fiber length distributions obtained on the number basis is 100%. The fiber length distribution is obtained from a frequency distribution and a cumulative number distribution curve obtained by randomly measuring the length of 50 or more fibers in a photograph observed with an optical microscope.
[First Embodiment]
A method of manufacturing an insulating plate of the present invention is a method having a molding step of obtaining a heat insulating plate by press molding a heat insulating material containing powder into a plate shape by a molding apparatus having a top mold and a bottom mold. Hereinafter, the case of using the
(Molding apparatus)
The
The
The
The planar shape of the
In the
A
In the
The distance d1 (Fig. 2) between the
As the
(Insulation material)
The heat insulating material used in the method for manufacturing an insulating plate of the present invention includes powder. In addition, it is preferable that one or both of the fibers and the binder are contained in the heat insulating material in addition to the powder in terms of obtaining a heat insulating plate of higher strength.
(Powder)
As the powder, a known powder generally used for the insulating plate can be used. Specific examples thereof include fumed silica, porous silica, and radiation suppressing agents. As the powder, it is preferable to include fumed silica in that an insulating plate having sufficient strength is easily obtained.
The powder may be one kind or two or more kinds.
Since fumed silica is a very fine powder, a specific surface area is usually used as an index indicating the particle size.
The specific surface area of the fumed silica is preferably 50 to 400
The specific surface area in the present invention is measured by a nitrogen adsorption method (BET method).
Specific examples of the fumed silica include Aerosil 200 (specific surface area 200 m2 / g, manufactured by Nippon Aerosil Co., Ltd.), Aerosil 300 (specific surface area 300 m2 / g, manufactured by Nippon Aerosil Co., Ltd.) CAB-O-SIL H-300 (specific surface area 300 m < 2 > / g, manufactured by Cabot Japan K.K.), rheol And yarn QS30 (specific surface area 300 m < 2 > / g, manufactured by Tokuyama Co., Ltd.).
The fumed silica may be used alone or in combination of two or more.
The specific surface area of the porous silica is preferably 100 to 800
The porosity of the porous silica is preferably 60 to 90%, more preferably 65 to 85%, and particularly preferably 70 to 80%. When the porosity of the porous silica is not less than the above lower limit value, the heat conductivity of the solid can be reduced, and therefore excellent heat insulating performance is easily obtained. When the porosity of the porous silica is not more than the upper limit, porous silica particles are hardly crushed at the time of molding, and porosity is maintained, so that excellent heat insulating performance tends to be obtained.
The porosity is measured by a nitrogen adsorption method (BJH method).
The average particle diameter of the porous silica is preferably 1 to 300 占 퐉, more preferably 2 to 150 占 퐉, and more preferably 3 to 100 占 퐉, as measured by a laser diffraction scattering method, a Coulter counter method, Particularly preferred. If the average particle diameter of the porous silica is not less than the above lower limit value, porous silica having a high porosity tends to be obtained, and excellent heat insulating performance tends to be obtained. If the average particle diameter of the porous silica is not more than the upper limit value, the density of the heat insulating plate is not excessively increased, and excellent heat insulating performance tends to be obtained.
Specific examples of the porous silica include, for example, M.S.GEL and Sunspear (both manufactured by AGC Co., Ltd.).
The porous silica may be used alone or in combination of two or more.
Examples of the radiation inhibitor include metal particles (aluminum particles, silver particles, gold particles and the like), and inorganic particles (graphite, carbon black, silicon carbide, titanium oxide, tin oxide and potassium titanate).
The radiation inhibitor may be used alone or in combination of two or more.
(bookbinder)
It is preferable that a binder is included in the heat insulating material in that a sufficient strength is easily obtained even when the heat insulating plate is made low, and the powders are hardly penetrated into the pores of the porous sheet by bonding the powder and the components other than the powder and the powder . In particular, it is preferable to use fumed silica as the powder and to give a binder to the surface of the fumed silica in advance to obtain binder-fumed silica. Even if the pressure at the time of molding is low, the binder attached to the surface of the fumed silica bonds the fumed silica with the binder or the binder-modified fumed silica with other materials (porous silica, fiber, etc.).
Even if a binder is added to the porous silica, the effect of the binder is hardly obtained because the binder is absorbed by the porous silica.
The binder may be an organic binder or an inorganic binder. Above all, as the binder, an inorganic binder is preferable because of low thermal conductivity and excellent heat-insulating property.
Examples of the inorganic binder include sodium silicate, aluminum phosphate, magnesium sulfate, magnesium chloride, and the like. Among them, sodium silicate is particularly preferable in view of obtaining an excellent heat insulating property.
Only one kind of binder may be used, or two or more kinds of binders may be used in combination.
(fiber)
If fibers are contained in the heat insulating material, a high-strength heat insulating plate is likely to be obtained. Further, the powder is introduced into the intertwined fibers to form a lump, whereby the powder is less likely to enter the pores of the porous sheet.
As the fiber, a fiber commonly used for a vacuum insulation material can be used, and for example, a resin fiber and an inorganic fiber can be mentioned. Among them, the inorganic fiber is preferable in that when the heat insulating plate is used as the core material of the vacuum heat insulating material, the outgas under vacuum is small, the deterioration of the heat insulating property due to the decrease in the degree of vacuum is easily suppressed, and the heat resistance is excellent.
The fibers may be used alone or in combination of two or more.
Examples of the inorganic fibers include alumina fibers, mullite fibers, silica fibers, glass wool, glass fibers, rock wool, slag wool, silicon carbide fibers, carbon fibers, silica alumina fibers, silica alumina magnesia fibers, silica alumina zirconia fibers , Silica magnesia calcia fiber, and the like.
The fiber length D30 of the fibers used is preferably 100 mu m or more, and more preferably 200 mu m or more. When the fiber length D30 is not less than the above lower limit value, it is easy to suppress occurrence of cracking in the heat insulating plate.
The fiber length D90 of the fibers used is preferably 20 mm or less, more preferably 10 mm or less. If the fiber length D90 is not more than the above upper limit value, the fibers are not excessively entangled with each other, so that they are easily mixed uniformly with the powder, and the effect of the fibers is likely to be obtained.
The diameter (diameter) of the fibers is preferably 10 占 퐉 or less in that the increase in the solid heat transfer due to the fibers can be suppressed. Further, the thickness (diameter) of the fiber is preferably not less than 1 탆, since it is easy to suppress occurrence of cracking in the heat insulating plate.
(Ratio of powder, binder, fiber)
The proportion of the fumed silica in the powder (100 mass%) is preferably 50 to 100 mass%, more preferably 70 to 100 mass%, and particularly preferably 80 to 100 mass%. If the ratio of the fumed silica is not less than the above lower limit value, a heat insulating plate having high strength tends to be obtained.
The proportion of the porous silica in the powder (100 mass%) is preferably 0 to 50 mass%, more preferably 0 to 30 mass%, and particularly preferably 0 to 20 mass%. The larger the ratio of the porous silica, the more easily an insulating plate having excellent heat insulating performance can be obtained. If the proportion of the porous silica is not more than the upper limit value, a heat-insulating plate having high strength tends to be obtained.
In the case where the powder includes binder-fumed silica and porous silica which have been previously provided with a binder on the surface thereof, the ratio M A / M B of the mass M A of the fumed silica and the mass M B of the porous silica before application of the binder is preferably 50/50 or more More preferably 70/30 or more, and particularly preferably 80/20 or more. When the ratio M A / M B is not less than the lower limit value, it is easy to obtain a heat insulating plate having a low density and excellent heat insulating performance and a sufficient strength.
When the powder contains a radiation inhibitor, the proportion of the radiation inhibitor in the powder (100 mass%) is preferably from 3 to 30 mass%, more preferably from 5 to 25 mass%, and particularly preferably from 10 to 20 mass% . If the ratio of the radiation inhibitor is higher than or equal to the lower limit, the effect of the radiation inhibitor is likely to be obtained. When the ratio of the radiation inhibitor is not more than the upper limit value, the increase in the solid heat transfer due to the radiation inhibitor can be suppressed, and therefore excellent heat insulating performance tends to be obtained.
The binder is preferably used in an amount of 0.1 to 15 parts by mass, more preferably 0.5 to 10 parts by mass, and more preferably 1 to 4 parts by mass, relative to 100 parts by mass of the fumed silica before application of the binder, in the case of using binder- Particularly preferred is a mass part. When the ratio of the binder is not less than the lower limit value, it is easy to obtain an insulating plate having a lower density and an excellent heat insulating performance and a sufficient strength. If the proportion of the binder is not more than the upper limit value, the increase in the solid heat transfer by the binder can be suppressed, so that deterioration of the heat insulating performance can be suppressed easily.
When binder fumed silica to which a binder is previously applied on the surface is not used, such as when fumed silica, a binder and other components (porous silica, fiber, etc.) are mixed at the same time, the binder ratio in 100 parts by weight of the powder 0.1 to 15 parts by mass is more preferable, 0.5 to 10 parts by mass is more preferable, and 1 to 4 parts by mass is particularly preferable. When the ratio of the binder is not less than the above lower limit value, it is easy to obtain a heat insulating plate having a low density and excellent heat insulating performance and a sufficient strength. If the ratio of the binder is not more than the upper limit value, the increase in the solid heat transfer by the binder can be suppressed, so that deterioration of the heat insulating performance can be suppressed easily.
The ratio of fibers is preferably from 1 to 30 parts by mass, more preferably from 2 to 20 parts by mass, and particularly preferably from 4 to 10 parts by mass, per 100 parts by mass of the powder. If the ratio of the fibers is not less than the lower limit value, a high-strength insulating plate tends to be obtained. If the ratio of the fibers is not more than the upper limit value, it is possible to suppress the increase of the solid heat transfer due to the fibers, so that deterioration of the heat insulating performance can be suppressed easily.
(Manufacturing method)
Examples of the method of manufacturing the heat insulating plate of the present embodiment include a method having the following mixing step, molding step, and heat treatment step.
Mixing process: Powder and other materials to be used as required are mixed and stirred to obtain an insulating material.
Molding process: Using the
Heat treatment step: The heat insulating plate obtained in the above molding step is heat treated and dried.
(Mixing process)
For example, in the case of using powders, fibers and binders, as a mixing method of the respective components, for example, a method using a V-type mixer or a blender with a stirrer may be used. Among them, a method of using a high-speed stirring device such as a blender with a stirrer is preferable in that the dispersibility of each component becomes good.
In the case of using fumed silica, porous silica and a binder in combination, it is preferable to add binder to the surface in advance to obtain a binder-fumed silica, and then to mix the binder-fumed silica and the porous silica. As a result, the binder can be prevented from being absorbed by the porous silica, so that the amount of the binder used can be reduced.
The timing of mixing the binder is not particularly limited, and for example, fumed silica, porous silica, fibers and a binder may be mixed at the same time.
The binder is preferably dissolved in a solvent and mixed as a binder solution. The solvent used for the binder solution is not particularly limited, and examples thereof include water and ethanol.
The proportion of the binder in the binder solution (100 mass%) is preferably 4 to 60 mass%, more preferably 10 to 50 mass%. When the ratio of the binder is within the above range, the binder is easily given to the powder. As the binder solution, water glass as an aqueous solution of sodium silicate is particularly preferable.
The binder solution may be applied to powder or fiber by spray coating or the like.
(Molding step)
3, a
By using the
The
The
The planar shape of the
The thickness of the
When a glass cloth is used as the
When a metal mesh is used as the
In addition, the number of meshes means the number of meshes existing in one inch.
The
Subsequently, by lowering the
In this example, since the
Thus, air can be efficiently extracted from the heat insulating material M even in a short-time press molding.
The pressure at the time of press forming may be suitably set in accordance with the composition of the heat insulating material M, the thickness of the target heat insulating plate, and the like.
The press time is preferably as short as possible within a range that does not cause problems such as cracking or expansion in the heat insulating plate obtained for the purpose of improving productivity.
(Heat treatment process)
By heat-treating the heat insulating plate obtained in the molding step, the solvent remaining in the heat insulating plate is volatilized, and the binder and the powder and the fiber are bonded together more favorably by the binder.
A method of heat-treating the heat insulating plate is not particularly limited, and examples thereof include a method of heating with a constant temperature drier, an electric furnace or the like.
The density of the insulating plate is preferably 0.15 to 0.35 g / cm3, more preferably 0.17 to 0.30 g / cm3. If the density of the heat insulating plate is not lower than the above lower limit value, the handling property of the heat insulating plate becomes good. Further, in the case of using a vacuum insulator, it is difficult for the heat insulator material to scatter when the heat insulator is pressure-sealed in the outer bag. If the density of the heat insulating plate is less than the upper limit value, excellent heat insulating performance tends to be stably obtained.
(Action effect)
In the conventional manufacturing method of the heat insulating plate as in
On the other hand, in the method of manufacturing the heat insulating plate of the present embodiment, the
In addition, the method for manufacturing the heat insulating plate of the present embodiment can be realized by simply installing the
[Second Embodiment]
In the method of manufacturing an insulating plate of the present invention, one or both of the upper mold and the lower mold is in contact with the porous sheet interposed between the upper and lower molds and the heat insulating material in view of easy removal of air from the heat insulating material more efficiently, It is preferable to use a molding apparatus in which a groove is formed on a mold surface in contact with the mold.
It has been found that it is possible to extend the number of times of use of the sheet as an unexpected effect because the groove is formed on the surface in contact with the porous sheet. Although the detailed reason is unclear, the following presumption is made.
As described above, since the porous sheet is pressed in contact with the powder, the powder remains in the pores gradually and clogs the pores. If there is no groove in the forming die, the air is taken out through the porous sheet, so that if the powder remains in the pores and the pores are closed, the air from the powder in the vicinity of the center becomes difficult to pass through the sheet , The molded body may be deformed or broken or may be easily formed. However, if grooves are formed in the molding die, the distance of permeation of air is short even in the vicinity of the center, so that the air tends to run away, and thus the moldability can be maintained.
Hereinafter, as a concrete example of this embodiment, a case of using the
(Molding apparatus)
The
It is preferable that the
The pitch of the
The depth of the
It is preferable that the ratio of the depth and width of the groove (groove depth / groove width) is 0.1 or more. If the ratio of the groove depth to the width is smaller than 0.1, the porous sheet may adhere to the wall surface of the groove during molding, so that sufficient air venting effect may not be obtained.
The method of forming the
(Manufacturing method)
Examples of the method of manufacturing the heat insulating plate of the present embodiment include a method having the following mixing step, molding step, and heat treatment step.
Mixing process: Powder and other materials to be used as required are mixed and stirred to obtain an insulating material.
Molding process: Using the
Heat treatment step: The heat insulating plate obtained in the above molding step is heat treated and dried.
The mixing process and the heat treatment process can be performed in the same manner as in the first embodiment. The molding process can be carried out in the same manner as in the first embodiment except that the
(Action effect)
In this embodiment, since the plurality of
Since the
[Third embodiment]
In the method of manufacturing an insulating plate of the present invention, it is preferable that at least one of the upper and lower molds is in contact with the porous sheet interposed between the upper and lower molds and the heat insulating material, It is preferable to use a molding apparatus in which the portion in contact with the sheet is porous.
Hereinafter, the case of using the
(Molding apparatus)
The
It is preferable that the through
The pitch of the through
The diameter (diameter) of the through
The opening area of the one through
The method for forming the through
(Manufacturing method)
Examples of the method of manufacturing the heat insulating plate of the present embodiment include a method having the following mixing step, molding step, and heat treatment step.
Mixing process: Powder and other materials to be used as required are mixed and stirred to obtain an insulating material.
Molding process: Using the
Heat treatment step: The heat insulating plate obtained in the above molding step is heat treated and dried.
The mixing process and the heat treatment process can be carried out in the same manner as in the first embodiment. The molding process can be carried out in the same manner as in the first embodiment except that the
(Action effect)
In the present embodiment, since the plurality of through
Since the
[Fourth Embodiment]
The method of manufacturing the heat insulating plate of the present invention may be a method of using the molding apparatus 4 shown in Fig. 7, for example, in the case of forming grooves on the mold surface on the lower mold side in the upper mold. The same parts as those in Fig. 4 in Fig. 7 are denoted by the same reference numerals, and a description thereof will be omitted.
The molding apparatus 4 is provided on the side of the
The
[Fifth Embodiment]
The method for manufacturing the heat insulating plate of the present invention may be a method using the
The
The shape of the plurality of
As shown in Fig. 8, in the state where the
The air that has exited the
[Sixth Embodiment]
The method for manufacturing the heat insulating plate of the present invention may be a method using the
The
9, in the state where the
The air exiting the
[Seventh Embodiment]
Further, the method of manufacturing the heat insulating plate of the present invention is not limited to a method of using a molding apparatus in which the upper mold is of a male mold and the lower mold is of a female mold. For example, the
The
The
10, the
As described above, in the method of manufacturing the heat insulating plate of the present invention, press molding is performed in a state in which the porous sheet is interposed between the upper mold and the heat insulating material, or between the lower mold and the heat insulating material or both, Therefore, air in the heat insulating material tends to be released at the time of press forming. As a result, it is possible to manufacture the heat insulating plate with high productivity while suppressing the occurrence of defects such as cracking and expansion. Further, according to the method for manufacturing an insulating plate of the present invention, even when a low-density insulating plate having a density of 0.15 to 0.3 g /
Further, in the method of manufacturing the heat insulating plate of the present invention, the conventional molding apparatus can be used, and the molding apparatus can be easily maintained.
The method of manufacturing the heat insulating plate of the present invention is particularly effective as a method of manufacturing an insulating plate used as a core material of a vacuum thermal insulating material. The heat insulating plate obtained by the production method of the present invention may be used as a heat insulating material as it is.
[Other Embodiments]
In addition, the method of manufacturing the heat insulating plate of the present invention is not limited to the above-described embodiment.
For example, a method in which the
Further, in the molding process using the
Alternatively, the
Even in the case of using the molding apparatus 4, a method of press molding without arranging the
In the
The method for manufacturing an insulating plate of the present invention is characterized in that in the
When either or both of the upper mold and the lower mold are in contact with the porous sheet interposed between the upper and lower molds and the heat insulating material and a molding apparatus in which the portion in contact with the porous sheet is porous is used, It is not limited to the
For example, a method may be employed in which a molding apparatus in which a plurality of through holes are formed in a lower mold and a porous body is used, and a porous sheet is provided so as to be in contact with a mold surface in which the through holes are formed in the lower mold.
Further, a molding apparatus may be used in which the whole of either or both of the upper mold and the lower mold, or the side in contact with the porous sheet is partially made into a porous body containing porous ceramics. Examples of the material of the porous ceramics include alumina, silicon carbide and the like.
The method of manufacturing the heat insulating plate of the present invention may be a method without a heat treatment step, for example, when the binder solution is not used.
[Method of producing vacuum insulation material]
The method for producing a vacuum insulator of the present invention is a method including a step of obtaining an insulating plate by a method of manufacturing an insulating plate of the present invention and a step of pressure-sealing the obtained insulating plate in an outer bag. The vacuum insulator of the present invention can be manufactured by a known method other than the use of the insulating plate obtained by the method for manufacturing an insulating plate of the present invention.
The step of obtaining the heat insulating plate is as described above.
In the step of obtaining the vacuum insulator, for example, the heat insulating plate is contained in the outer bag, the outer bag is sealed under the reduced pressure condition, and then the vacuum insulator is obtained by returning to the atmospheric pressure condition. Specifically, for example, the following method can be mentioned.
Two sheets of film are superimposed to house an insulating plate in an outer bag sealed in three sides in advance and placed in a vacuum chamber having a heat sealing function, and the inside of the vacuum chamber is decompressed. After the chamber is depressurized to a predetermined pressure, the other open side of the outer bag is heat sealed and sealed, and then the inside of the chamber is returned to atmospheric pressure.
Further, after the heat insulating plate is housed in the outer bag, air in the outer bag is extracted to decompress the inside of the outer bag, and the outer bag is sealed with a heat seal or the like to compress the heat insulating plate in the outer bag.
(Outer pocket)
The outer bag may be one having airtightness and capable of pressure-sealing the heat insulating plate. Examples of the outer bag include a bag containing a gas barrier film and the like. As the gas barrier film, any known vacuum insulator can be used without limitation.
The size and shape of the outer bag are not particularly limited and may be suitably determined in accordance with the size and shape of the heat insulating plate.
The degree of vacuum in the outer bag in the vacuum insulator is preferably 1 x 10 3 Pa or less, more preferably 1 x 10 2 Pa or less, from the point that excellent heat insulating performance is obtained and the life of the vacuum insulator is prolonged.
(Action effect)
According to the method for producing a vacuum insulator of the present invention, since the heat insulating plate is manufactured by the manufacturing method of the heat insulating plate of the present invention and the vacuum insulating material is manufactured by using the heat insulating plate, it is possible to suppress the occurrence of defects such as cracking and expansion in the heat insulating plate The vacuum insulator can be manufactured with high productivity.
In the method of manufacturing a vacuum insulator according to the present invention, a vacuum insulator may be obtained by vacuum-enclosing an insulating bag in an outer bag in an air bag having an air-permeable inner bag.
The inner bag is not particularly limited as long as it has air permeability and can prevent the powder forming the core material from leaking at the time of pressure-sealing. Examples of the inner bag include a bag made of paper material, nonwoven fabric, and the like.
The size and shape of the inner bag are not particularly limited and may be suitably determined in accordance with the size and shape of the heat insulating plate.
As a manufacturing method of the vacuum insulator in the case of using the inner bag, the same method as the above-described method can be adopted except that the heat insulating plate is housed in the inner bag and pressure-sealed in the outer bag.
[Example]
Hereinafter, the present invention will be described in detail by way of examples, but the present invention is not limited to the following descriptions. Examples 1 to 7 are Examples, and 8 to 11 are Comparative Examples.
[Evaluation of insulating plate]
(Presence of breakage)
The obtained insulating plate was visually inspected, and the presence or absence of cracking was judged.
(Evaluation of closing)
The obtained insulating plate was visually confirmed, and the closing of the insulating plate was evaluated based on the following criteria.
(Good): No expansion is observed on the surface of the insulating plate.
× (poor): The surface of the insulating plate shows expansion.
(Quality judgment)
○: There is no crack or expansion in the insulating plate.
B: No cracks are seen in the heat insulating plate, but the surface of the heat insulating plate is expanded.
X: The insulating plate is cracked.
[Example 1]
90 parts by mass of fumed silica (trade name "Aerosil (300)", specific surface area 300
A tray 30 (tray made of aluminum) is provided on the bottom of the
[Example 2]
A heat insulating plate was produced in the same manner as in Example 1 except that the pressing time was changed to 5 minutes.
[Example 3]
As the molding apparatus, a lattice-shaped groove 20 (pitch: 20 mm, depth: 1.5 to 2 mm, width: 2 mm, groove depth / groove width = 0.75 to 1) is formed on the
[Example 4]
As a molding apparatus, a groove-
[Example 5]
The same molding apparatus as in Example 3 was used and a metal mesh (30 mesh length × 150 mesh length, manufactured by Ben Tech Co., Ltd.) was used instead of glass cloth # 470 as the
[Example 6]
The same molding apparatus as in Example 4 was used and a metal mesh (30 mesh length × 150 mesh length, manufactured by Ben Tech Co., Ltd.) was used instead of glass cloth # 470 as the
[Example 7]
The
[Examples 8 to 11]
An insulating plate was produced in the same manner as in Example 1 except that the
Table 1 shows molding conditions and evaluation results of each example.
As shown in Table 1, in Examples 1 to 7 in which the press molding was performed with the porous sheet interposed between the upper mold and the heat insulating material and between the lower mold and the heat insulating material so as to be in contact with the heat insulating material, cracking or expansion A heat insulating plate of a good quality without a heat treatment was obtained. Particularly, in Examples 3 to 6 in which grooves were formed on the mold surface in contact with the porous sheet in the upper mold, a heat insulating plate of good quality was obtained in a very short time.
On the other hand, in Examples 8 and 9 in which the porous sheet was not used, a heat insulating plate of good quality free from cracking or expansion was obtained, but the press time was long and the productivity deteriorated.
In Example 10 in which the porous sheet was not used and the pressing time was 20 minutes, the obtained heat insulating plate was expanded.
In Example 11 in which the porous sheet was not used and the pressing time was set to 15 minutes, the obtained heat insulating plate was cracked.
The heat insulating plate and the vacuum heat insulating material produced by the manufacturing method of the present invention can be applied to places where energy saving is required, and where warming, cold storage, or heat insulation is required. Specifically, for example, housing facilities such as walls, roofs, flooring, piping, and photovoltaic and thermal facilities of houses and buildings; Insulating and cooling areas such as thermostat, water heater, hot water tank, air conditioner, refrigerator, freezer, cold storage high / cold tank, vending machine, cooler box, cold cover, Electronic devices such as notebook computers, liquid crystal projectors, copying machines, batteries, fuel cells, and semiconductor devices; Moving objects such as cars, buses, trucks, cold stores, trains, lorries and ships; It is applicable to piping of plant.
1 to 6: Molding apparatus
10, 10A to 10C, 40:
12, 12A, 50: Lower mold
32, 34, 62, 64: Porous sheet
16: Clearance
18: clearance
20, 24: Home
22: Through hole
42, 56: molded plate
Claims (10)
Wherein the press molding is performed in a state in which the porous sheet is interposed between the upper mold and the heat insulating material and between the lower mold and the heat insulating material or both of the lower mold and the heat insulating material so as to be in contact with the heat insulating material.
Applications Claiming Priority (2)
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JP2014153745 | 2014-07-29 | ||
JPJP-P-2014-153745 | 2014-07-29 |
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KR20160014530A true KR20160014530A (en) | 2016-02-11 |
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KR1020150103547A KR20160014530A (en) | 2014-07-29 | 2015-07-22 | Process for producing an insulating board and a vacuum insulation panel |
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JP (1) | JP2016033419A (en) |
KR (1) | KR20160014530A (en) |
CN (1) | CN105318145A (en) |
GB (1) | GB2531116A (en) |
Cited By (2)
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KR20190097570A (en) * | 2018-02-12 | 2019-08-21 | (주)경안인더스트리 | Insulation·heat insulation board and manufacturingmethod thereof |
KR102434724B1 (en) * | 2022-03-02 | 2022-08-22 | 에프디씨 주식회사 | A explosion panel assembly for a energy storage system having insulation function |
Families Citing this family (6)
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CN106122683A (en) * | 2016-06-27 | 2016-11-16 | 上海熠翌节能技术有限公司 | A kind of muff for exhaustor and manufacture method thereof |
CN106122684A (en) * | 2016-06-27 | 2016-11-16 | 上海熠翌节能技术有限公司 | A kind of muff for smoke ejector and manufacture method thereof |
CN106122682A (en) * | 2016-06-27 | 2016-11-16 | 上海熠翌节能技术有限公司 | A kind of muff for low pressure (LP) cylinder and manufacture method thereof |
CN106015840A (en) * | 2016-06-27 | 2016-10-12 | 上海熠翌节能技术有限公司 | Insulation sleeve for Christmas tree and manufacturing method thereof |
JP6895367B2 (en) * | 2017-11-15 | 2021-06-30 | 住友理工株式会社 | Interior parts and their manufacturing methods |
CN112192710A (en) * | 2020-09-10 | 2021-01-08 | 阜阳市森威保温建材有限公司 | Processing method of homogeneous fireproof insulation board |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2014094563A (en) | 2012-11-07 | 2014-05-22 | Oci Co Ltd | Method for molding core of vacuum insulation panel |
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AU457056B2 (en) * | 1972-01-17 | 1974-12-20 | Abex Corporation | The manufacture of friction elements |
GB2284172B (en) * | 1993-11-25 | 1997-07-30 | Ceramaspeed Ltd | Method of forming compacted layer |
US6986706B1 (en) * | 2004-08-10 | 2006-01-17 | Universal Photonics, Inc. | Polishing pad and method of producing the same |
JP5388603B2 (en) * | 2009-01-29 | 2014-01-15 | 三菱電機株式会社 | Vacuum heat insulating material and heat insulating box equipped with the same |
WO2014030651A1 (en) * | 2012-08-23 | 2014-02-27 | 旭硝子株式会社 | Vacuum heat-insulating material and method for manufacturing vacuum heat-insulating material |
-
2015
- 2015-07-10 JP JP2015138841A patent/JP2016033419A/en active Pending
- 2015-07-22 KR KR1020150103547A patent/KR20160014530A/en unknown
- 2015-07-28 CN CN201510451718.7A patent/CN105318145A/en active Pending
- 2015-07-28 GB GB1513280.6A patent/GB2531116A/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2014094563A (en) | 2012-11-07 | 2014-05-22 | Oci Co Ltd | Method for molding core of vacuum insulation panel |
JP2014094564A (en) | 2012-11-07 | 2014-05-22 | Oci Co Ltd | System for manufacturing core of vacuum insulation panel |
JP2014095471A (en) | 2012-11-07 | 2014-05-22 | Oci Co Ltd | Apparatus for molding core of vacuum insulation material, and vacuum insulation material manufactured thereby |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20190097570A (en) * | 2018-02-12 | 2019-08-21 | (주)경안인더스트리 | Insulation·heat insulation board and manufacturingmethod thereof |
KR102434724B1 (en) * | 2022-03-02 | 2022-08-22 | 에프디씨 주식회사 | A explosion panel assembly for a energy storage system having insulation function |
Also Published As
Publication number | Publication date |
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GB2531116A (en) | 2016-04-13 |
CN105318145A (en) | 2016-02-10 |
JP2016033419A (en) | 2016-03-10 |
GB201513280D0 (en) | 2015-09-09 |
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