KR20190125853A - Vacuum insulation panel and method of preparing the same - Google Patents

Abstract

Disclosed are a vacuum insulation material and a manufacturing method thereof. The vacuum insulation material comprises a first envelope layer and a second envelope layer. A side surface of the first envelope layer and a side surface of the second envelope layer are sealed to each other and the inside between the first envelope layer and the second envelope layer includes a porous core material having a carbon powder and silica under vacuum. The porous core material may have a foamed polystyrofoam obtained by mixing 5 to 15 parts by volume of a first mixed solution including the carbon powder and silica and 85 to 95 parts by volume of styrofoam beads.

Description

Vacuum insulation panel and method of preparing the same

It relates to a vacuum insulator and a method of manufacturing the same.

      Vacuum Insulation Panel (Vacuum Insulation Panel) refers to a heat insulator that removes heat transfer by conduction and convection by using a porous insulation material as a core material in a closed panel and a vacuum inside.

Vacuum insulation may be applied to building materials, refrigerators, and the like, and is widely used as an essential material for passive house designs aimed at minimizing energy consumption.

    The performance of the vacuum insulation material plays an important role in the core material of the porous insulating material related to the thermal conductivity. Examples of the porous insulating material used as the core material include an urethane foam, an organic insulating material such as styrofoam, or an inorganic insulating material such as perlite, glass wool, and ceramic fiber.

    However, these porous insulating materials are often expensive or fail to meet the requirements of good thermal insulation with fire resistance and low thermal conductivity.

    Therefore, there is still a need for a vacuum insulator comprising a porous insulating material as a core material which is inexpensive and has excellent thermal insulation with fire resistance and low thermal conductivity.

     One aspect is to provide a vacuum insulator having excellent heat resistance and low thermal conductivity and having excellent heat insulation even at a thin thickness.

      Another aspect is to provide a method of manufacturing the vacuum insulation.

According to one aspect,

A first envelope layer;

Second envelope layer; And

The side surface of the first skin layer and the side surface of the second skin layer are sealed to each other,

And a porous core material including carbon powder and silica under a vacuum between the first outer layer and the second outer layer.

The porous core material is provided with a vacuum heat insulating material comprising a foamed polystyrofoam foamed by mixing 5 to 15 parts by volume of the first liquid mixture containing carbon powder and silica and 85 to 95 parts by volume of styrofoam beads.

According to another aspect,

Preparing a porous core material including carbon powder and silica; And

Inserting the porous core material between the first shell layer and the second shell layer, and sealing at least three sides of the side of the first shell layer and the second shell layer by heat bonding to manufacture a vacuum insulation material, comprising; vacuum insulation Provided is a method for preparing.

Vacuum insulation according to one aspect, the first shell layer; Second envelope layer; And a porous core material including carbon powder and silica under a vacuum, wherein the side of the first envelope layer and the side of the second envelope layer are sealed to each other, and the interior between the first envelope layer and the second envelope layer is under vacuum. The core material includes foamed polystyrofoam obtained by mixing 5-15 parts by volume of the first mixed solution containing carbon powder and silica and 85-95 parts by volume of styrofoam beads, thereby providing excellent fire resistance and low thermal conductivity and excellent thickness even at a thin thickness. Insulation may be exhibited.

1 is an enlarged schematic cross-sectional view showing a vacuum insulator according to one embodiment.

With reference to the accompanying drawings, it will be described in detail with respect to a vacuum insulator and a method of manufacturing the same according to an exemplary embodiment. The following is presented by way of example, and the present invention is not limited thereto, and the present invention is defined only by the scope of the claims to be described later. In addition, in this specification and drawing, about the component which has a substantially same functional structure, the same code | symbol is attached | subjected and the duplication description is abbreviate | omitted. In this specification, the singular also includes the plural unless specifically stated otherwise in the phrase. As used herein, "comprises" and / or "comprising" or "comprising" means that one or more other components, steps, operations and / or elements are mentioned. It does not exclude the presence or addition of it. The terms first, second, third, fourth, etc. may be used to describe various components, but the components should not be limited by the terms. The terms are only used to distinguish one component from another.

Vacuum insulation according to one embodiment includes a first outer layer; Second envelope layer; And a porous core material including carbon powder and silica under a vacuum, wherein the side of the first envelope layer and the side of the second envelope layer are sealed to each other, and the interior between the first envelope layer and the second envelope layer is under vacuum. The core material may include expanded polystyrene foamed by mixing 5 to 15 parts by volume of the first mixed solution including the carbon powder and silica and 85 to 95 parts by volume of styrofoam beads.

1 is an enlarged schematic cross-sectional view illustrating a vacuum insulator 10 according to one embodiment.

      Referring to FIG. 1, in the vacuum insulator 10, the porous core material 3 is disposed in a vacuum state between the first shell layer 1 and the second shell layer 2, and the first shell layer 1 and the first shell layer 1 are made of vacuum. 2 Both sides of the outer skin layer 2 are comprised by the side sealing part 4 sealed by heat adhesion. In the porous core material 3, a flame retardant coating layer 13 is disposed between the foam particles 12 in which the spirofoam beads are foamed.

The porous core material included in the vacuum insulator is an inorganic porous core material, and since the flame-retardant coating film 13 is disposed on the surface, the porous core material may withstand high temperatures of 1300 ° C. and have even fire resistance over the entire surface of the core material. The porous core material is light in weight, capable of exothermic foaming up to about 1,000% at room temperature, and has environmentally friendly characteristics. In addition, since the porous core material is disposed in a vacuum state between the first shell layer and the second shell layer, the porous core material may be shrunk or pitted when a force is applied from the outside. Furthermore, since the porous core material is compressed in a vacuum state, the porous core material may have excellent heat insulating properties while having a thin thickness of about 1/4 to 1/10 compared to commercially available glass fibers, mineral wool, expanded polystyrene, and the like.

The porous core material may include a foamed polystyrofoam obtained by mixing 5 to 15 parts by volume of the first mixed solution including the carbon powder and silica and 85 to 95 parts by volume of styrofoam beads. For example, the porous core material may include foamed polystyrofoam obtained by mixing 8 to 12 parts by volume of the first mixed solution including the carbon powder and silica and 88 to 92 parts by volume of styrofoam beads.

The first liquid mixture, the carbon powder and silica in a weight ratio of 1: 1, melted at 1300 to 2000 ℃ after cooling and pulverized 10 to 25% by weight of powder; And 75 to 90 wt% of a second mixed solution obtained by mixing a first aqueous solution containing nitric acid and magnesium, a second aqueous solution containing a heating agent and a dispersant, and magnesium carbonate. The first mixed liquid may be, for example, 15 to 20% by weight of powder, which is mixed with the carbon powder and silica in a weight ratio of 1: 1, melted at 1500 to 1800 ° C, cooled and pulverized; And 75% to 85% by weight of a second mixed solution obtained by mixing a first aqueous solution containing nitric acid and magnesium, a second aqueous solution containing a heat generating agent and a dispersing agent, and magnesium carbonate.

The second mixed liquid is a second aqueous solution containing the dispersant; And a third mixed solution in which the first aqueous solution containing nitric acid and magnesium and magnesium carbonate are mixed. The second mixed solution may be prepared separately from the first aqueous solution, and then mixed with the first aqueous solution to provide a vacuum insulation material that maximizes bubble generation and improves dispersibility while performing exothermic reaction, thereby maximizing fire resistance and insulation. have.

The first aqueous solution may be an aqueous solution of 12 to 16 parts by weight of nitric acid and 3 to 6 parts by weight of magnesium based on 100 parts by weight of water. The first aqueous solution may be, for example, an aqueous solution in which 13 to 15 parts by weight of nitric acid and 3 to 5 parts by weight of magnesium are mixed based on 100 parts by weight of water. If nitric acid is added in the content range, it is possible to improve the reactivity with the added magnesium while improving dispersibility in the first aqueous solution.

The second aqueous solution may be an aqueous solution of 4 to 18 parts by weight of sodium oxide, 45 to 54 parts by weight of silica, and 0.3 to 0.6 parts by weight of polyoxyalkyl ether based on 100 parts by weight of water. The second aqueous solution may be, for example, an aqueous solution in which 6 to 10 parts by weight of sodium oxide, 45 to 50 parts by weight of silica, and 0.4 to 0.6 parts by weight of polyoxyalkyl ether are mixed based on 100 parts by weight of water. When sodium oxide reacts with water, it exerts an exothermic function to dehydrate, and when exothermic, magnesium oxide and hydrogen are generated and bubbles are generated by reacting with magnesium contained in the first aqueous solution. When sodium oxide is added in the above content range, the mixed aqueous solution is not denatured and the exothermic action can be performed smoothly. If silica is added within the above content range, the vacuum insulator including the same may maintain excellent thermal insulation. Polyoxyalkyl ether can improve dispersibility as surfactant.

The second mixed solution may further include 5 to 8 parts by weight of potassium methyl siliconate based on 100 parts by weight of the second mixed solution. Potassium methyl silicate can improve the durability by preventing moisture penetration into the porous core material as a water repellent. When potassium methyl silicate is added within the above content range, it is possible to maintain excellent thermal insulation due to improved dispersibility.

The second aqueous solution may further include 0.03 to 0.06 parts by weight of iron oxide based on 100 parts by weight of the second aqueous solution. Iron oxide can be economical and stable in form when added within the above content range as a stabilizer.

The porous core material may have nano cracks and hollows. The porous core material may improve thermal insulation by lowering the thermal conductivity.

The first envelope layer or the second envelope layer may be a layer in which an aluminum film is disposed on the polymer resin sheet. Although it does not restrict | limit about the said polymeric resin sheet, For example, polyethylene, a polypropylene, polyethylene terephthalate, a polycarbonate, etc. are mentioned.

The thickness of the polymer resin sheet may be, for example, 300 ~ 1000 ㎛. The thickness of the aluminum film may be, for example, 30 ~ 60 ㎛. If the polymer resin sheet and the aluminum film satisfy the thickness range, respectively, damage may not occur due to external impact or force, thereby maintaining a vacuum state inside the vacuum insulator, and easily depositing an aluminum film on the polymer resin sheet. Can be.

The aluminum film may be disposed on the polymer resin sheet by a general manufacturing method used in the art, for example, by physical or chemical vapor deposition. The deposition may be carried out, for example, by laminating an aluminum film on a high-spray resin sheet and heating and pressing under a temperature of 50 to 300 ° C. and a pressure of 1 to 30 Kgf / cm ² .

The sealing of the side of the first outer skin layer and the side of the second outer skin layer is similar to that of the heat-sealing bag by, for example, heating and pressing under a temperature of 50 to 300 ° C. and a pressure of 1 to 30 Kgf / cm ² using a heat sealing plate. It can be shaped.

The vacuum insulation may have a heat transmission rate (U value) of 15 kWh / m ² / yr at a thickness of 30 mm or less. The vacuum insulator can satisfy a heat transmission rate (U value) of 15 kWh / m ² / yr even at a thickness of 30 mm or less. In comparison, commercially available glass fibers, mineral wool, expanded polystyrene and the like can meet a thermal permeability (U value) of 15 kWh / m ² / yr at thicknesses of about 180 mm, 170 mm, 160 mm. Therefore, the vacuum insulator according to the embodiment may have excellent thermal insulation even at a thin thickness compared to commercially available glass fibers, mineral wool, expanded polystyrene, and the like.

The vacuum insulator may have a low thermal conductivity of 0.0022 W / mK or less.

According to another embodiment of the present invention, a method of manufacturing a vacuum insulator includes preparing a porous core material including carbon powder and silica; And inserting the porous core material between the first shell layer and the second shell layer, and sealing at least three surfaces of side surfaces of the first shell layer and the second shell layer with heat adhesive to manufacture a vacuum insulation material. . The method of manufacturing the vacuum insulator can economically and easily prepare a vacuum insulator.

The preparing of the porous core material may include preparing a second mixed solution including a first aqueous solution containing nitric acid and magnesium, a second aqueous solution containing a heating agent and a dispersant, and magnesium carbonate; Mixing the carbon powder and silica in a weight ratio of 1: 1 to melt at 1300 to 2000 ° C. to prepare a cooled and pulverized powder; Preparing a powder-containing fourth mixed liquid obtained by mixing 75 to 90% by weight of the second mixed liquid to the prepared 10 to 25% by weight of the powder; And mixing 5 to 15 parts by volume of the powder-containing fourth mixed solution and 85 to 95 parts by volume of styrofoam beads to prepare expanded polystyrofoam heated and foamed at 80 to 100 ° C. in a mold.

The preparing of the second mixed liquid may include mixing a third aqueous solution containing the nitric acid and magnesium and a third mixed solution of magnesium carbonate in a second aqueous solution containing the heat generating agent and the dispersing agent to prepare a mixed liquid; It may include.

The content and role of the materials added in each step are the same as described above, and thus will not be described here.

In the step of manufacturing the vacuum insulator, at least three surfaces of the side surfaces of the first and second skin layers are heat-sealed and then connected to an open one of the side surfaces of the first and second skin layers by a vacuum exhaust pipe. Removing air with a vacuum pump and forming a vacuum; And when the vacuum degree of the formed vacuum rises to a predetermined level or more, sealing the open one surface by heat adhesion and removing the vacuum exhaust pipe.

Hereinafter, examples and comparative examples of the present invention are described. However, the following examples are only examples of the present invention and the present invention is not limited to the following examples.

EXAMPLE

Production Example  1: porous Core material  Produce

1-1. 2nd  Mixed solution manufacturing

13 L of nitric acid and 4 g of magnesium were mixed with 100 L of water to prepare a first aqueous solution. A second aqueous solution was prepared by mixing 8 g of sodium oxide, 48 g of silica and 0.4 g of polyoxyalkyl ether as a dispersant in 100 L of water. To the second aqueous solution was mixed a third liquid mixture of 4 L of the first aqueous solution and 2 g of magnesium carbonate to prepare a second liquid mixture.

1-2. Porosity Core material  Produce

Mixing the carbon powder and silica in a weight ratio of 1: 1 to melt in a heating furnace at a temperature of 1500 ℃ and then separated and cooled by a ball mill in a powder mixture having a particle size of about 1.5 mm in about 20% by weight of the second mixture prepared above 80 wt% was mixed to prepare a powder-containing fourth mixed solution.

Mixing about 90 parts by volume of the styrofoam beads in about 10 parts by volume of the fourth mixture and foaming by heating with steam of about 85 ℃ in the mold, the porous core material of the refractory foamed polystyrofoam panel having a thickness of about 10 cm and having a hollow Was prepared.

Production Example  2: porosity Core material  Produce

The same method as in Preparation Example 1, except that a fifth mixed solution obtained by further mixing 5 g of potassium methyl siliconate as a water repellent was used in the second mixed solution prepared in 1-1 instead of the fourth mixed solution. A porous core material of a refractory expanded polystyrofoam panel about 10 cm thick and having nano cracks and hollows was prepared.

Production Example  3: porosity Core material  Produce

      Except for using the sixth mixed solution prepared by using the third aqueous solution in which 0.05 parts by weight of iron oxide was further added as a stabilizer to the second aqueous solution of 1-1 based on 100 parts by weight of the second aqueous solution instead of the fourth mixed solution. In the same manner as in Preparation Example 1, a porous core material of a refractory expanded polystyrofoam panel having a thickness of about 10 cm and having nano cracks and hollows was prepared.

Example  1-3: Manufacture of vacuum insulation

The first outer skin layer (upper skin layer) of a film (thickness: 400 μm, size: 420 × 420 mm) in which a porous core material of the fire-resistant foamed polystyrofoam panel prepared in Preparation Examples 1 to 3 was respectively deposited on a polyethylene sheet. ) And a second outer skin layer (lower outer skin layer), and at least three surfaces of the side surfaces of the first outer skin layer and the second outer skin layer are heat-sealed and sealed using a heat-sealed plate at a temperature of 200 ° C. and a pressure of 15 Kgf / cm ^2. It was. Subsequently, a vacuum exhaust pipe was connected to an open one of the side surfaces of the first outer layer and the second outer layer, and air was removed by a vacuum pump to form a vacuum. When the degree of vacuum of the formed vacuum rises above a predetermined level, the opened one surface is sealed by thermal bonding using a heat-sealing plate under the same temperature and pressure as above, and the vacuum exhaust pipe is removed to remove the vacuum insulator according to Examples 1 to 3. Prepared.

Evaluation example  1: thermal conductivity evaluation

The thermal conductivity of the vacuum insulator prepared in Example 1 was measured by a plate heat flow meter method. The thermal conductivity measurement method was measured using KS L 9016: 2010 at (20.0 ± 1.0) ° C temperature, (50.0 ± 1.3)% relative humidity.

As a result of measuring the thermal conductivity, it was confirmed that the vacuum insulator prepared in Example 1 had a thermal conductivity of about 0.0022 W / mK. From this, it can be seen that the vacuum insulator prepared in Example 1 may have excellent heat insulation even at a thin thickness.

As mentioned above, although embodiment was described in detail, referring an accompanying drawing, this invention is not limited to a related example. Those skilled in the art to which the present invention pertains clearly reflect various changes or modifications within the scope of the technical idea described in the claims, and of course, the technical scope of the present invention. It is understood to belong to.

1: first outer shell layer (upper shell layer), 2: second outer shell layer (lower shell layer),
3: porous core material, 4: side sealing portion,
10: vacuum insulation,
12: foamed foam with styrofoam beads,
13: flame retardant coating film

Claims (15)

A first envelope layer;
Second envelope layer; And
The side surface of the first skin layer and the side surface of the second skin layer are sealed to each other,
And a porous core material including carbon powder and silica under a vacuum between the first outer layer and the second outer layer.
The porous core material comprises a foamed polystyrofoam foamed by mixing 5 to 15 parts by volume of the first mixture solution containing the carbon powder and silica and 85 to 95 parts by volume of styrofoam beads. The method of claim 1,
The first mixed liquid,
10 to 25% by weight of the powder mixed with the carbon powder and silica in a weight ratio of 1: 1, melted at 1300 to 2000 ° C., cooled and pulverized; And
And a first aqueous solution containing nitric acid and magnesium, a second aqueous solution containing a heat generating agent and a dispersant, and a second mixture of 75 to 90% by weight of magnesium carbonate. The method of claim 2,
The second mixed liquid,
A second aqueous solution containing the dispersant; And
A vacuum heat insulating material which is a liquid which mixed; the 3rd liquid mixture which mixed the said 1st aqueous solution containing nitric acid and magnesium, and magnesium carbonate. The method of claim 2,
The first aqueous solution is a vacuum insulator, which is an aqueous solution of 12 to 16 parts by weight of nitric acid and 3 to 6 parts by weight of magnesium based on 100 parts by weight of water. The method of claim 2,
The second aqueous solution is a vacuum insulator, based on 100 parts by weight of water, 4 to 18 parts by weight of sodium oxide, 45 to 54 parts by weight of silica, and 0.3 to 0.6 parts by weight of polyoxyalkyl ether. The method of claim 2,
The second mixed liquid further comprises 5 to 8 parts by weight of potassium methyl siliconate based on 100 parts by weight of the second mixed liquid, vacuum insulator. The method of claim 1,
The second aqueous solution further comprises 0.03 to 0.06 parts by weight of iron oxide based on 100 parts by weight of the second aqueous solution, vacuum insulator. The method of claim 1,
Wherein said porous core material has nano cracks and hollows. The method of claim 1,
The first shell layer or the second shell layer is a vacuum insulator, a layer in which an aluminum film is disposed on the polymer resin sheet. The method of claim 1,
Wherein said vacuum insulator has a heat transmission rate (U value) of 15 kWh / m 2 / yr at a thickness of 30 mm or less. The method of claim 1,
Wherein the vacuum insulator has a thermal conductivity of 0.0022 W / mK or less. Preparing a porous core material including carbon powder and silica; And
Inserting the porous core material between the first shell layer and the second shell layer, and sealing at least three sides of the side of the first shell layer and the second shell layer by heat bonding to manufacture a vacuum insulation material, comprising; vacuum insulation Manufacturing method. The method of claim 12,
Preparing the porous core material,
Preparing a second mixed solution in which a first aqueous solution containing nitric acid and magnesium, a second aqueous solution containing a heat generating agent and a dispersant, and magnesium carbonate are mixed;
Mixing the carbon powder and silica in a weight ratio of 1: 1 to melt at 1300 to 2000 ° C. to prepare a cooled and pulverized powder;
Preparing a powder-containing fourth mixed liquid obtained by mixing 75 to 90% by weight of the second mixed liquid to the prepared 10 to 25% by weight of the powder; And
And mixing 5 to 15 parts by volume of the powder-containing fourth mixed solution and 85 to 95 parts by volume of styrofoam beads to prepare expanded polystyrofoam heated and foamed at 80 to 100 ° C. in a mold. The method of claim 13,
Preparing the second mixed liquid,
And mixing a third mixed solution obtained by mixing the first aqueous solution containing the nitric acid and magnesium and the magnesium carbonate in a second aqueous solution containing the heat generating agent and the dispersing agent, to prepare a mixed solution. The method of claim 12,
In the step of manufacturing the vacuum insulation,
After sealing at least three sides of the side surfaces of the first outer layer and the second outer layer by heat adhesion, the air is connected to an open one of the side surfaces of the first outer layer and the second outer layer by a vacuum exhaust pipe, and the air is removed by a vacuum pump. Forming a; And
And sealing the open one surface by heat adhesion and removing the vacuum exhaust pipe when the vacuum degree of the formed vacuum rises above a predetermined level.

Images