KR20210118593A - Manufacturing method of thermal insulator - Google Patents

Abstract

Disclosed is a method for manufacturing a thermal insulation material. The method for manufacturing a thermal insulation material of the present invention comprises: a step of manufacturing a vertical non-woven fabric; a first lamination step of laminating ceramic paper and an aluminum foil; and a second lamination step of laminating the ceramic paper on both sides of the vertical non-woven fabric, respectively. According to the present invention, provided can be a method for manufacturing a thermal insulation material which has excellent heat insulation, thermal insulation, sound absorbing performance, and limited combustible performance and prevents volatile materials harmful to human body from being discharged, by being manufactured through lamination of the vertical non-woven fabric, the ceramic paper, and the aluminum foil.

Description

Insulation manufacturing method {MANUFACTURING METHOD OF THERMAL INSULATOR}

The present invention relates to a method for manufacturing an insulating material, and more particularly, to a method for manufacturing an insulating material comprising covering the outside of a building to reduce heat loss or inflow of heat to the outside.

Insulation is a material used for the purpose of keeping heat or blocking heat and belongs to a thermal insulator. Insulation materials are almost essential for the exterior walls of buildings.

Recently, due to the strengthening of energy standards for existing and new buildings, interest and regulations on building insulation materials are increasing as a way to reduce the energy consumed in buildings.

In this regard, Korean Patent Publication No. 2065299 discloses a semi-non-combustible insulating material and a method for manufacturing the same.

Patent Registration No. 2065299 has advantages in that it is excellent in flame retardancy, waterproofness, and heat insulation, and is lightweight and easy to install insulators. The semi-noncombustible heat insulating material disclosed in Korean Patent No. 2065299 includes a heat insulating material layer and a surface layer.

The heat insulating material layer is composed of a polyester polyol, a trimerization catalyst, a urethane catalyst, a blowing agent, and a polyisocyanate. However, since a plurality of materials are mixed in the insulation layer, there is a problem in that it is difficult to recycle in the future. Building waste that is not recycled is a major contributor to environmental pollution.

In addition, the insulating material layer produced by the foaming reaction of various synthetic resins has a problem of generating volatile substances harmful to the human body.

And Patent Publication No. 2065299 manufactures a thermal insulation layer by foaming a foaming composition in a foaming container. The size of the manufactured insulating material is determined by the size of the foam container. Therefore, a large number of foam containers are required to mass-produce the insulation layer. Since there is a limit to the kind of resin that can be continuously foamed, improvement of productivity is required.

Republic of Korea Patent Publication No. 2065299 (Registration Date: 2020.01.06)

It is an object of the present invention to provide a method for manufacturing an insulating material that is recyclable, does not emit volatile substances harmful to the human body, and facilitates mass production while having excellent heat resistance, heat insulation, sound absorption performance and semi-incombustible performance.

The above object, according to the present invention, a manufacturing step of manufacturing a vertical nonwoven; A first laminating step of laminating the ceramic paper and the aluminum foil; and a second laminating step of laminating the ceramic paper on each of both surfaces of the vertical nonwoven fabric.

The manufacturing step is a carding step of making a short fiber into a web; A folding step of overlapping the web in a zigzag form; and a cementing step of putting the web into a dryer so that the overlapping webs are cemented, wherein the short fibers may include low-melting-point fibers that are melted by the heat of the dryer.

The short fiber, 40 to 70% by weight of the low-melting fiber; 20-50% by weight of flame-retardant fibers; and 5 to 15% by weight of other fibers.

The low-melting fiber may be a low-melting polyester fiber, and the flame-retardant fiber may be a flame-retardant polyester fiber.

The thickness of the ceramic paper may be 0.5-5 mm.

The ceramic paper may be coated with an acrylic resin or a urethane resin.

An adhesive is used for the lamination of the first laminating step and the second laminating step, the adhesive includes a polyolefin, polyurethane, polyester or polyamide-based component, and the amount of application of the adhesive is 5 to 20 g/m ² Can be have.

According to the present invention, by laminating a vertical nonwoven fabric, ceramic paper, and aluminum foil, it has excellent heat resistance, heat insulation, sound absorption and semi-incombustible performance, and does not emit volatile substances harmful to the human body. be able to do

In addition, since the low-melting-point fiber and the flame-retardant fiber constituting the vertical nonwoven fabric are made of polyester-based fibers, it is possible to provide a method for manufacturing a heat insulating material that can be recycled.

In addition, by continuously performing the manufacture of the vertical nonwoven fabric, the lamination of the ceramic paper and the aluminum foil, and the lamination of the vertical nonwoven fabric and the ceramic paper, it is possible to provide a method for manufacturing a heat insulator made to facilitate mass production.

1 is a flowchart of a method for manufacturing a heat insulator according to an embodiment of the present invention.
FIG. 2 is a view showing a manufacturing step of the method for manufacturing the heat insulator of FIG. 1 .
3 is a view showing a first laminating step of the method for manufacturing the heat insulator of FIG. 1 .
FIG. 4 is a partially exploded perspective view of the insulator manufactured by the method for manufacturing the insulator of FIG. 1 .
5 is a partial cross-sectional view of the heat insulating material manufactured by the method of manufacturing the heat insulating material of FIG. 1 .

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, in describing the present invention, descriptions of already known functions or configurations will be omitted in order to clarify the gist of the present invention.

The heat insulating material manufacturing method of the present invention, while having excellent heat resistance, heat insulation, sound absorption performance and semi-incombustible performance, is recyclable, does not emit volatile substances harmful to the human body, and is made to facilitate mass production.

1 is a flowchart of a method for manufacturing a heat insulator ( S100 ) according to an embodiment of the present invention.

As shown in FIG. 1 , the method for manufacturing a heat insulator ( S100 ) according to an embodiment of the present invention is configured to include a manufacturing step ( S110 ), a first laminating step ( S112 ) and a second laminating step ( S130 ).

The manufacturing step ( S110 ) is a step of manufacturing the vertical nonwoven fabric 100 . The manufacturing step (S110) is configured to include a carding step (S111), a folding step (S112) and a bonding step (S113).

FIG. 2 is a view showing a manufacturing step (S110) of the method (S100) for manufacturing the heat insulator of FIG. 1 .

As shown in Figure 2, the carding step (S111) is a step of making a short fiber into a web (web). The carding step (S111) is performed through a carding machine (1).

Raw cotton is loosened to some extent by the cotton mill, but there are still a lot of miscellaneous materials other than fibers mixed with it, and the cotton is agglomerated into small lumps. It is necessary to separate the fibers one by one to make them even and parallel, and to collect them to make a sliver.

This process is called a carding process, and the machine used in the carding process is called a carding machine (1) or card. A thin paper-like fiber combed into a card shape is called a web.

The short fibers are configured to include a low-melting-point fiber 110 and a flame-retardant fiber 120 . In more detail, the short fibers may include 40 to 70% by weight of the low-melting fiber 110, 20 to 50% by weight of the flame-retardant fiber 120, and 5 to 15% by weight of other fibers.

As the type of short fibers, polyester, nylon, polypropylene, or rayon may be used. However, polyester fiber is most suitable for providing flame retardancy and recyclability. Therefore, the low-melting-point fiber 110, the flame-retardant fiber 120, and other fibers are provided with polyester-based fibers.

The low-melting fiber 110 is provided with a low-melting polyester fiber. In order to manufacture the vertical nonwoven fabric 100 in the heat insulating material manufacturing method (S100) according to an embodiment of the present invention, a low-melting polyester fiber that can be formed by heat is required. The low-melting polyester fiber may be used in an amount of 40 to 70% by weight depending on the hardness of the product.

When the ratio of the low-melting-point polyester fiber among the short fibers is low, the hardness of the vertical nonwoven fabric 100 to be manufactured is lowered, so that a roll type nonwoven fabric can be manufactured. On the other hand, when the ratio of the low-melting-point polyester fiber among the short fibers is high, the hardness of the vertical nonwoven fabric 100 to be manufactured increases, so that a sheet type nonwoven fabric can be manufactured.

The flame-retardant fiber 120 is provided with flame-retardant polyester fiber. In order to impart flame-retardant performance to the vertical nonwoven fabric 100, flame-retardant polyester fibers must be used in a certain ratio.

Although low-melting polyester has self-extinguishing properties, it does not meet sufficient flame-retardant performance. Therefore, the use of flame-retardant polyester is required. Flame-retardant polyester fibers can be used up to 20-50 wt%.

LOI (Limit Oxygen Index) is mainly used to indicate the degree of flammability in the air, that is, the minimum required oxygen demand for ignition. In general, oxygen makes up 20-22% of the air.

Oxygen in the air is close to 20% in large cities with bad air, and 22% in mountains with many trees. An LOI of 22% or higher usually means that it is not flammable in air. The LOI value of the flame-retardant polyester used is in the range of 18 to 42%.

For other fibers, polyester-based fibers are used. Therefore, all of the short fibers constituting the vertical nonwoven fabric 100 are polyester-based fibers.

Materials used as insulation materials for conventional construction include PU foam, Phenol foam, EPS, XPS, PIR, Glass, and the like. However, materials used as insulation materials for construction in the related art are difficult to be recycled later and are thus buried as waste.

In addition, some of the materials used as conventional building insulation materials generate volatile substances harmful to the human body. The heat insulating material 10 manufactured by the heat insulating material manufacturing method S100 according to an embodiment of the present invention is composed of a nonwoven fabric, a ceramic paper 200 and an aluminum foil 300, and does not discharge substances harmful to the human body.

In addition, in the insulating material 10 manufactured by the insulating material manufacturing method (S100) according to an embodiment of the present invention, since the vertical nonwoven fabric 100 used as the insulating layer is made of a single component, that is, a polyester-based fiber, it is used as a building material. It can be easily recycled.

Therefore, the insulation 10 manufactured by the method for manufacturing an insulation material (S100) according to an embodiment of the present invention minimizes the impact on environmental pollution and does not emit substances harmful to the human body. It is an eco-friendly insulating material (10) that does not adversely affect.

The fineness of the short fibers may be in the range of 1 to 15 denier (denier). When the fineness of low denier is mainly used for products of the same thickness range, the density increases and the sound absorption performance is improved, but there is a problem in that the weight increases.

Conversely, if the fineness of high denier is mainly used for products of the same thickness range, the density is lowered, so there is a problem in that the insulation effect and hardness are lowered. Since the determination of the fineness is also related to the wire standard of the carding machine 1, it is necessary to select an appropriate fineness. The fineness of use suitable for this is suitable for the use of the insulating material 10 in the range of 1 to 10 denier.

The fiber length of the short fiber is used in the range of 38 to 76 mm. In the case of the high-speed carding machine 1, the long fiber may be broken during the carding process. Therefore, it is advantageous that the high-speed carding machine 1 has a short fiber length. On the other hand, it is advantageous that the low-speed carding machine 1 has a long fiber length.

1, when the carding step (S111) is completed, the folding step (S112) is started. The folding step (S112) is a step of overlapping the web in a zigzag form.

As shown in FIG. 2 , the web carded using short fibers moves upwards of the shaker 3 through the apron 2 .

The shaker 3 comprises a pair of rollers. The web is sandwiched between a pair of rollers. The pair of rollers are rotated opposite to each other by a motor (not shown). The web is moved downward by a pair of rotating rollers.

Although not shown in detail, the pair of rollers are continuously reciprocated in the horizontal direction by the reciprocating drive device. The reciprocating drive device may be provided as a linear actuator.

The web is moved downward while being folded back and forth by the shaker (3). The front in FIG. 2 means the dryer 6 side. In FIG. 2, the back means the carding machine (1) side.

As shown in FIG. 2 , a pair of first conveyors 4 are provided under the shaker 3 . The pair of first conveyors 4 are spaced apart from each other in the front-rear direction. A pair of first conveyors 4 guide the descent of the web at the front and back of the web.

A pair of first conveyors 4 form a forward and backward boundary of the web folded back and forth. If the front-back direction spacing of the pair of first conveyors 4 is adjusted, the thickness of the vertical nonwoven fabric 100 may be adjusted.

As shown in FIG. 1 , when the folding step S112 is completed, the bonding step S113 is started. The bonding step (S113) is a step of putting the web into the dryer (6).

As shown in FIG. 2 , a second conveyor 5 is provided under the first conveyor 4 . A second conveyor 5 moves the web to a dryer 6 . The web overlapped in a zigzag form is moved to the dryer 6 in a folded state through the second conveyor 5 .

The temperature inside the dryer 6 may be adjusted within the range of 130 to 220 degrees according to the type of fiber and the ratio of the low-melting-point fiber 110 .

As described above, the short fibers include the low-melting-point fibers 110 that are melted by the heat of the dryer 6 . The low-melting-point fiber 110 is melted by the internal temperature of the high-temperature dryer 6 and serves to entangle the fibers that do not melt at that temperature.

That is, the overlapping webs are bonded by the thermal energy of the dryer 6 . Therefore, it is possible to manufacture the vertical nonwoven fabric 100 without using a separate adhesive.

The vertical nonwoven fabric 100 passed through the dryer 6 maintains the shape of the folded web. The vertical nonwoven fabric 100 passed through the dryer 6 moves to the next step.

The vertical nonwoven fabric 100 passed through the dryer 6 may be cut with a horizontal cutter or wound in a roll shape according to the required specifications before moving to the next step.

A non-woven fabric is manufactured by applying a non-toxic synthetic fiber such as polyester fiber rather than the conventionally widely used foam-type insulation 10 base material, but the non-woven fabrics are adhered in a general Y-axis arrangement (arranged in the direction perpendicular to the wall of the building). Instead, they are joined in a Z-axis arrangement (arranged in a direction parallel to the wall of the building). Therefore, there is an advantage that the air layers capable of heat insulation and sound absorption are constant in the Z-axis as well as in the Y-axis direction.

As shown in Figure 1, when the bonding step (S113) is completed, the first laminating step (S112) is started. The first laminating step ( S112 ) is a step of laminating the ceramic paper 200 and the aluminum foil 300 .

Ceramic paper (200; ceramic paper) may be manufactured in the form of a sheet by mixing a small amount of organic binder with an inorganic material using a ceramic bulk fiber as a basic raw material. The ceramic paper 200 has excellent thermal stability at high temperature, high thermal insulation properties, and good workability because it is flexible while having high strength.

The ceramic paper 200 is manufactured to have a thickness of 0.5 to 5 mm. The thickness of the ceramic paper 200 to be used may vary from 0.5 to 5 mm depending on the thickness of the finally manufactured insulating material 10 and the place of use.

The ceramic paper 200 comprises aluminum trioxide (Al2O3) and silicon oxide (SiO2) as main components. The composition of the ceramic paper 200 may be adjusted according to the required heat-resistant temperature range. Ceramic paper 200 may be used in a heat-resistant temperature range of 500 to 1270 degrees.

In order to improve the tensile strength, rupture strength, and water resistance of the ceramic paper 200, the ceramic paper 200 may be coated with an acrylic resin or a urethane resin.

The aluminum foil 300 is a thinly rolled sheet of aluminum alloy, and a method of rolling a heated aluminum mass while passing it between rolls under pressure to obtain a desired thickness, and a method of continuously casting and cold rolling It is produced. .

The aluminum foil 300 is used to block radiant heat among the three types of heat transfer: radiation, conduction, and convection. Radiant heat accounts for a large portion of the heat transfer in a house.

It is preferable that a hollow layer of a certain width (approximately 25 mm) or more exists between the surface of the heat insulator 10, that is, between the aluminum foil 300 and the exterior material, due to the characteristics of the heat reflective insulator 10 developed for the purpose of blocking radiant heat.

3 is a view showing the first laminating step (S112) of the heat insulating material manufacturing method (S100) of FIG.

As shown in FIG. 3 , the ceramic paper 200 is applied with the adhesive 400 supplied through the adhesive application head H while being unwound along the first roller 8 . The adhesive application head (H) installed in the laminate device 7 is a well-known technology as disclosed in Korean Patent Publication No. 1146291, and a detailed description thereof will be omitted.

The second roller 9 is installed adjacent to the first roller 8 with the ceramic paper 200 having the adhesive 400 applied therebetween.

The second roller 9 rotates in the opposite direction to the first roller 8 to uniform the thickness of the adhesive 400 passing between the first roller 8 and the second roller 9 . That is, the distance between the first roller 8 and the second roller 9 is equal to the thickness of the adhesive 400 passing through the ceramic paper 200 and the second roller 9 .

The ceramic paper 200 and the aluminum foil 300 are adhered by the adhesive 400 while passing between the pair of rollers R1 and R2. The adhered ceramic paper 200 and aluminum foil (hereinafter referred to as 'adhesive sheet (A)') are wound on a roll.

The adhesive 400 may use a polyolefin, polyurethane, polyester, or polyamide-based adhesive resin. In this case, if a polyolefin series is used, a problem may occur in water resistance, so necessary additives should be added.

As a method of performing lamination, various lamination methods such as hot melt spraying, hot melt scattering, and gravure printing can be used. At this time, the application amount of the adhesive 400 is appropriate at a level ^{of 5 to 20 g/m 2 .}

As shown in Figure 1, when the first laminating step (S112) is completed, the second laminating step (S130) is started. The second laminating step (S130) is a step of laminating the ceramic paper 200 on both sides of the vertical nonwoven fabric 100, respectively. The lamination device 7 of FIG. 3 may also be used in the second laminating step (S130).

Briefly, the adhesive sheet A is applied with the adhesive 400 supplied through the adhesive application head H while being unwound along the first roller 8 . The adhesive 400 is applied to the ceramic paper 200 .

The second roller 9 is installed adjacent to the first roller 8 with the adhesive sheet A having the adhesive 400 applied therebetween.

The second roller 9 rotates in the opposite direction to the first roller 8 to uniform the thickness of the adhesive 400 passing between the first roller 8 and the second roller 9 . That is, the distance between the first roller 8 and the second roller 9 is equal to the thickness of the adhesive 400 passing through the adhesive sheet A and the second roller 9 .

The adhesive sheet (A) and the vertical nonwoven fabric 100 are adhered by the adhesive 400 while passing between the pair of rollers R1 and R2. The adhesive sheet (A) and the vertical nonwoven fabric 100 are wound on a roll. In this case, the amount of the adhesive 400 applied is suitable within ^{20 g/m 2 .} This completes the manufacture of the heat insulating material.

4 is a partially exploded perspective view of the heat insulating material 10 manufactured by the heat insulating material manufacturing method ( S100 ) of FIG. 1 . FIG. 5 is a partial cross-sectional view of the heat insulating material 10 manufactured by the heat insulating material manufacturing method S100 of FIG. 1 .

As shown in FIGS. 4 and 5 , in the method for manufacturing a heat insulator ( S100 ) according to an embodiment of the present invention, a ceramic paper 200 layer having excellent non-combustible performance is formed on the heat insulator 10 to provide flame-retardant and semi-non-combustible performance. By laminating the aluminum foil 300 to the outer surface, it is possible to manufacture the insulating material 10 having a heat reflection effect.

According to the present invention, by laminating a vertical nonwoven fabric, ceramic paper, and aluminum foil, it has excellent heat resistance, heat insulation, sound absorption and semi-incombustible performance, and does not emit volatile substances harmful to the human body. be able to do

In addition, since the low-melting-point fiber and the flame-retardant fiber constituting the vertical nonwoven fabric are made of polyester-based fibers, it is possible to provide a method for manufacturing a heat insulating material that can be recycled.

In addition, by continuously performing the manufacture of the vertical nonwoven fabric, the lamination of the ceramic paper and the aluminum foil, and the lamination of the vertical nonwoven fabric and the ceramic paper, it is possible to provide a method for manufacturing a heat insulator made to facilitate mass production.

In the foregoing, specific embodiments of the present invention have been described and shown, but it is common knowledge in the art that the present invention is not limited to the described embodiments, and that various modifications and variations can be made without departing from the spirit and scope of the present invention. It is self-evident to those who have Accordingly, such modifications or variations should not be individually understood from the technical spirit or point of view of the present invention, and modified embodiments should be said to belong to the claims of the present invention.

S100: manufacturing method 1: somen machine
S110: Manufacturing step 2: Apron
S111: Carding stage 3: Shaker
S112: folding step 4: first conveyor
S113: cementation step 5: second conveyor
S120: first lamination step 6: dryer
S130: second lamination step 7: lamination device
10: insulation material 8: first roller
100: vertical non-woven fabric 9: second roller
110: low melting point fiber H: head
120: flame retardant fiber A: adhesive sheet
200: ceramic paper
300: aluminum foil
400: adhesive

Claims (7)

A manufacturing step of manufacturing a vertical nonwoven;
A first laminating step of laminating the ceramic paper and the aluminum foil; and
A method of manufacturing an insulating material comprising a second laminating step of laminating the ceramic paper on each of both surfaces of the vertical nonwoven fabric. According to claim 1,
The manufacturing step is
Carding step of making short fibers into a web;
A folding step of overlapping the web in a zigzag form; and
A cementation step of putting the web into a dryer so that the overlapping webs are cemented,
The short fiber is a method for manufacturing a heat insulating material, characterized in that it comprises a low-melting fiber melted by the heat of the dryer. 3. The method of claim 2,
The short fibers are
40-70% by weight of low-melt fiber;
20-50% by weight of flame-retardant fibers; and
A method of manufacturing an insulating material comprising 5 to 15% by weight of other fibers. 4. The method of claim 3,
The low-melting fiber is a low-melting polyester fiber,
The flame-retardant fiber is a method of manufacturing an insulating material, characterized in that the flame-retardant polyester fiber. According to claim 1,
The thickness of the ceramic paper is a method of manufacturing an insulating material, characterized in that 0.5 ~ 5mm. According to claim 1,
The ceramic paper is an insulating material manufacturing method, characterized in that coated with an acrylic resin or a urethane resin. According to claim 1,
An adhesive is used for the lamination of the first laminating step and the second laminating step,
The adhesive includes a polyolefin, polyurethane, polyester or polyamide-based component,
The method for manufacturing a heat insulating material, characterized in that the amount of the adhesive is applied to 5 ~ 20g / m ^{2 .}

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