KR20210134093A - Polyurethane foam insulation and manufacturing method thereof - Google Patents

Abstract

A polyurethane foam insulation and a manufacturing method thereof of the present invention has an effect wherein an insulation effect is improved, by preventing a layer separation phenomenon of a phase transition material, as the phase transition material can be uniformly distributed. In addition, by manufacturing the phase transition material to a form of a film, the polyurethane foam insulation and the manufacturing method thereof of the present invention has an effect of solving a non-uniform mixing and a clogging phenomenon of a transfer pipe of the phase transition material, and improving a process efficiency as a continuous manufacturing process is enabled. The polyurethane foam insulation comprises: at least one phase transition material-containing film layer; and at least one polyurethane foam insulation layer.

Description

Polyurethane foam insulation and manufacturing method thereof

The present invention relates to a polyurethane foam insulation material and a method for manufacturing the same, and more particularly, a polyurethane foam insulation material having excellent process efficiency due to an easy manufacturing process and improved insulation effect because a phase change material can be uniformly distributed, and manufacturing process thereof it's about how

Phase change materials (PCM) absorb heat when melting from a solid phase to a liquid phase, store it as latent heat while the material exists in a liquid state, and release latent heat when it solidifies, that is, when it is converted from a liquid phase to a solid phase. It is used in the field of heating and cooling, the heat sink of electronic products, the living industry such as clothing, and the food industry.

In order to use a phase change material as an additive for a polymer material, a phase change space is required. When a phase change material is mixed with a polymer material without special treatment, the phase change material migrates to the surface of the polymer material and there is a problem that leakage occurs. In addition, there may be a problem in that the phase change energy is lost because it is not possible to secure a space for the phase change in the polymer material.

Accordingly, an impregnation method for penetrating a phase change material into a structure such as a porous inorganic material may be used.

On the other hand, thermal insulation is essential for efficient use of energy by preventing the movement of heat. In general, more than 40% of the energy heat loss of a building is accounted for by the wall heat loss. Therefore, it is hot in summer and cold in winter, and energy consumption is high and energy is consumed inefficiently. In order to improve the problems of these buildings and to save energy in the building, proper insulation design and construction of insulation materials should be carried out.

Existing insulation materials include Styrofoam and glass fiber. Styrofoam has the advantage of being cheap and easy to purchase, but it is in the form of a panel during transportation, so there is a problem that it cannot transport a large amount of it, and there is a problem in constructability and the thickness is thick. There is a problem in that the space is reduced. In addition, in the event of a fire, not only does the conduction of fire occur quickly, but also there is a disadvantage that it is very dangerous from a fire because toxic gas is generated. Unless a substance is attached, it is difficult to expect pressure resistance or compression resistance, and there is a disadvantage that may cause respiratory diseases in the human body due to dust during use and handling. In this regard, foam insulation materials using polyurethane materials with low thermal conductivity are attracting attention.

As described above, since the phase change material absorbs or releases a certain amount of heat and uses it for a phase change, when the phase change material is used for the insulator, the heat transfer is delayed and the performance of the insulator is improved.

Accordingly, in the prior art, the phase change material was changed to a liquid phase and added to polyol or isocyanate, which is a raw material of polyurethane foam insulation. However, in this case, there was a problem in that the layer separation occurred in the raw material in the tank due to the difference in density and viscosity and the transfer pipe was clogged.

Republic of Korea Patent Publication No. 10-2012-0115027

The first object to be solved by the present invention is to provide a polyurethane foam insulation material having excellent thermal insulation effect by preventing the layer separation of the phase change material and uniformly distributing the phase change material, and a method for manufacturing the same.

In addition, the second problem to be solved by the present invention is to provide a polyurethane foam insulation material having excellent process efficiency and a method for manufacturing the same by forming a phase change material in the form of a film to enable a continuous manufacturing process.

In order to solve the above problems, the present invention is at least one phase change material-containing film layer; And at least one polyurethane foam insulation layer; includes, wherein the phase change material-containing film layer provides a polyurethane foam insulation comprising 10 to 60 parts by weight of the phase change material microcapsules with respect to 100 parts by weight of the binder.

According to a preferred embodiment of the present invention, the phase change material-containing film layer and the polyurethane foam insulation layer may be laminated to form a laminated structure.

According to a preferred embodiment of the present invention, the first phase change material-containing film layer and the second phase change material-containing film layer may be laminated on each of the upper and lower portions of the polyurethane foam insulation layer.

According to a preferred embodiment of the present invention, the first phase change material-containing film layer and the second phase change material-containing film layer may be continuously laminated on any one surface of the upper or lower portion of the polyurethane foam insulation layer.

According to a preferred embodiment of the present invention, the phase change material microcapsule may be impregnated in the pores of the phase change material porous carrier.

According to a preferred embodiment of the present invention, the binder is an aqueous resin emulsion, and the aqueous resin emulsion may be any one or more selected from the group consisting of a polyurethane-based emulsion, a polyvinyl alcohol-based emulsion, and an acrylic-based emulsion.

According to a preferred embodiment of the present invention, it may further include at least one plate layer.

According to a preferred embodiment of the present invention, the face material layer is formed on any one or more of the upper and lower portions of the phase change material-containing film layer, the face material layer may form the outermost layer of the polyurethane foam insulation.

According to a preferred embodiment of the present invention, the following relation 1 may be satisfied.

[Relational Expression 1]

20 ≤ T _I / T _P ≤ 250

(T _I: polyurethane foam heat insulating layer (20), T _P: phase change material-containing film layer 10)

Furthermore, the present invention comprises the steps of: (1) forming a mixed composition comprising 10 to 60 parts by weight of a phase change material microcapsule with respect to 100 parts by weight of a binder; (2) forming a film layer containing a phase change material by applying and drying the mixture composition; and (3) laminating the phase change material-containing film layer and the polyurethane foam insulation layer; provides a polyurethane foam insulation manufacturing method comprising.

According to a preferred embodiment of the present invention, the viscosity of the mixed composition in step (1) may be 4000 ~ 10000 cps.

According to a preferred embodiment of the present invention, the application and drying of step (2) may be performed by applying the mixture composition on a release paper and then drying with hot air.

According to a preferred embodiment of the present invention, the first phase change material-containing film layer and the second phase change material-containing film layer may be laminated on each of the upper and lower portions of the polyurethane foam insulation layer in step (3).

According to a preferred embodiment of the present invention, in step (3), a plate layer may be further laminated on each of the upper portion of the first phase change material-containing film layer and the lower portion of the second phase change material-containing film layer.

The polyurethane foam insulation of the present invention and a method for manufacturing the same have an effect of improving the insulation effect by preventing the phase change material from being separated from each other, so that the phase change material can be uniformly distributed.

In addition, the polyurethane foam insulation of the present invention and its manufacturing method can solve the non-uniform mixing of the phase change material and the clogging of the transfer pipe by manufacturing the phase change material in the form of a film, and the continuous manufacturing process is possible, so the process efficiency is improved there is

1 is a cross-sectional view of a polyurethane foam insulation according to a preferred embodiment of the present invention.
2 is a cross-sectional view of a film layer containing a phase change material according to a preferred embodiment of the present invention.
3 is a cross-sectional view of a polyurethane foam insulation according to a preferred embodiment of the present invention.
4 is a cross-sectional view of a film layer containing a phase change material in which a plate layer is laminated according to an exemplary embodiment of the present invention.
5 is a process flow diagram according to a preferred embodiment of the present invention.
6 is a graph showing the temperature measurement values of Example 2 and Comparative Example 1 of the present invention.
7 is an external image of the polyurethane foam insulation according to a preferred embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those of ordinary skill in the art can easily carry out the present invention.

As described above, the production of an insulating material using a conventional phase change material was made by adding a phase change material to polyol or isocyanate, which is a raw material for polyurethane foam insulation, and in this case, layer separation occurs in the raw material in the tank due to the difference in density and viscosity, and There was a limitation in that the transfer pipe was clogged. In addition, the phase change material was not uniformly distributed, so there was a limitation in that the thermal insulation effect was lowered.

Accordingly, the present invention provides a film layer containing at least one phase change material; And at least one polyurethane foam insulation layer; includes, wherein the phase change material-containing film layer provides a polyurethane foam insulation material containing 20 to 50 parts by weight of the phase change material microcapsules with respect to 100 parts by weight of the binder to solve the above-mentioned limitations searched for.

Accordingly, in the present invention, the phase change material can be uniformly distributed by preventing the layer separation of the phase change material, thereby improving the thermal insulation effect.

1 is a cross-sectional view of a polyurethane foam insulation according to a preferred embodiment of the present invention. Referring to FIG. 1 , it can be seen that the polyurethane foam insulation 1 includes two phase change material-containing film layers 10A and 10B and a polyurethane foam insulation layer 20 .

In addition, Figure 2 is a cross-sectional view of the phase change material-containing film layer 10 according to a preferred embodiment of the present invention. Referring to FIG. 2 , it can be seen that the phase change material-containing film layer 10 is formed in a state in which the phase change material microcapsules 11 are uniformly distributed in the binder 12 .

First, the phase change material-containing film layer 10 will be described.

The phase change material-containing film layer 10 is a film layer in which the phase change material microcapsules 11 are uniformly dispersed in the binder 12 to exist in a uniformly distributed state. can

Phase change materials (PCM) are materials that accumulate heat or release stored heat through a kind of physical change process that changes from one state to another. can These phase change materials exist in either a liquid or a solid state, and when heat is emitted to the outside or heat is absorbed from the outside, their phases are reversibly changed to each other at a predetermined temperature. In this process, the amount of heat released or absorbed does not contribute to the temperature rise of the material but to the phase change, so that the temperature change of the material is relatively small compared to the amount of heat applied. Therefore, even if the ambient temperature drops, the heat retained in the phase change process of the phase change material must be all released to achieve the thermal insulation effect because the temperature change is substantially made.

As the phase change material, those commonly used in the art may be used, and specific examples include organic materials such as tetradecane, octadecane, and nonadecan, which are linear saturated hydrocarbons composed of carbon and hydrogen, and aliphatic or aromatic Compounds propionamide, naphthalene, acetamide, biphenyl, stearic acid, polyglycol, paraffin, palmitic acid, stearic acid, ethylinoserate, campan, 3-heptadecanone, cyanamide, lauric acid, caprolone and the like, and preferably paraffin.

In addition, inorganic substances in the form of hydrates of saturated hydrocarbons having 13 to 28 carbon atoms may be used. Such minerals include, for example, Fe ₂ O ₃ .4SO ₃ .9H ₂ 0, NaNH ₄ SO ₄ .2H ₂ O, NaNH ₄ HPO ₄ .2H ₂ O, NaNH ₄ HPO ₄ .4H ₂ O, FeCl ₃ .2H ₂ O, Na ₃ PO ₄ ·12H ₂ O, Na ₂ SiO ₃ ·5H ₂ O, Ca(NO ₃ ) ₂ ·3H ₂ O, K ₂ HPO ₄ ·3H ₂ O, Na ₂ SiO ₃ ·9H ₂ O, Fe(NO ₃ ) ₃ 9H ₂ O, K ₃ PO ₄ 7H ₂ O, NaHPO ₄ 12H ₂ O, CaCl ₂ 6H ₂ O, Na ₂ SO ₄ 10H ₂ O, Na(CH ₃ COO) 3H ₂ O, etc., polyethylene glycol, some acids and eutectic mixtures with acids, for example, n-octanoic acid, n-octadecane, n-eicoic acid, acetic acid, lactic acid, chloroacetic acid, etc. can be used alone or in mixture of two or more . It is possible to use a single pure material alone as the phase change material, but it is possible to form a eutectic mixture by mixing at least two or more types of phase change materials or to control the degree of hydration to achieve a phase transition with high calorific input and output in a wide temperature range. A phase change material can be obtained.

The phase change temperature range of the phase change material may be preferably 15 ~ 30 ℃.

In addition, the phase change material microcapsule 11 may mean that the phase change material is coated and encapsulated or impregnated in the pores of the porous carrier to be encapsulated, preferably, the phase change material is impregnated in the pores of the porous carrier It may be a hybrid type.

In this case, the porous carrier refers to a material having a plurality of pores formed therein so that the phase change material can provide a space for the phase change process to occur.

The porous carrier includes silica, zeolite, bentonite, activated carbon, alumina, silicon carbide, zirconia, fly ash, and the like, and is not particularly limited thereto as long as it is a porous material having low reactivity. In addition, the porous carrier may include at least one of a sintered body of silica, a sintered body of zeolite, a sintered body of bentonite, a sintered body of activated carbon, a sintered body of alumina, a sintered body of silicon carbide, a sintered body of zirconia, and a sintered body of fly ash. When these ceramic particles are sintered, gaps (voids) are generated between the particles in the ceramic sintered body after sintering. The impregnation efficiency of the phase change material may be further improved by using such a gap.

As described above, the phase change material-containing film layer 10 is formed by evenly distributing the phase change material microcapsules 11 in the binder 12 substrate. The binder 12 may be appropriately selected to be capable of uniformly dispersing the phase change material microcapsules 11 and binding them to form a uniform mixed composition.

According to a preferred embodiment of the present invention, the binder 12 may be an aqueous resin emulsion. More preferably, the aqueous resin emulsion may be at least one selected from the group consisting of a polyurethane-based emulsion, a polyvinyl alcohol-based emulsion, and an acrylic-based emulsion. An emulsion is a thermodynamically unstable system composed of at least two immiscible liquid phases, one liquid phase being dispersed in the other liquid phase.

In the case of using the material as the binder 12, a phenomenon such as layer separation does not occur after mixing, so that the phase change material microcapsules 11 are uniformly distributed in the binder 12 substrate to form a mixed composition. It is possible to solve the difficulties in the manufacturing process such as clogging of the transport pipe in the process, and furthermore, the phase change material microcapsule 11 is uniformly distributed to provide the film layer 10 containing the phase change material with significantly improved insulation. have.

Meanwhile, the phase change material-containing film layer 10 contains 10 to 60 parts by weight of the phase change material microcapsules 11 based on 100 parts by weight of the binder 12 . More preferably, the phase change material microcapsule 11 may be included in an amount of 20 to 50 parts by weight based on 100 parts by weight of the binder 12 . More preferably, the phase change material microcapsule 11 may be included in an amount of 25 to 45 parts by weight based on 100 parts by weight of the binder 12 .

As described above, when the content of the binder 12 and the phase change material microcapsules 11 is within the above range, the phase change material microcapsules 11 are uniformly distributed in the binder 12 base film layer 10 containing the phase change material. can be formed, and thus, by being used together with the polyurethane foam insulation layer 20, it is possible to effectively delay the heat transfer of the insulation layer, thereby further improving the insulation effect of the polyurethane foam insulation material (1) of the present invention. have.

According to a preferred embodiment of the present invention, the thickness of the phase change material-containing film layer 10 may be 0.1 ~ 1.5mm. More preferably, it may be 0.2 ~ 1mm, more preferably 0.25 ~ 1mm.

When the thickness of the phase change material-containing film layer 10 satisfies the above range, an appropriate amount of the phase change material microcapsules 11 can be uniformly distributed, so that the thermal insulation effect is excellent. Since it can be efficiently performed, there is an effect of excellent process efficiency.

If the thickness of the phase change material-containing film layer 10 is less than the above range, the content of the phase change material microcapsules 11 per unit area is low and the thermal barrier performance is lowered, so that the thermal insulation effect may be deteriorated, and if the phase change When the thickness of the material-containing film layer 10 exceeds the above range, there is an advantage that a large amount of phase change material microcapsules 11 per unit area can be contained, but the film layer must be applied and dried several times to form a film layer Process efficiency And there may be a problem that productivity is lowered.

Next, the polyurethane foam insulation layer 20 is demonstrated.

Polyurethane foam insulation layer 20 means a layer (layer) to express the insulation effect made of foamed polyurethane foam. Polyurethane foam insulation layer 20 has excellent thermal insulation properties because the gas for foaming stays inside the polyurethane.

In the past, a liquid phase change material was directly added to polyol and isocyanate, which are raw materials of polyurethane foam, to produce an insulating material. In this case, a layer separation phenomenon occurs due to the difference in density and viscosity. There was a limit to the decrease in In addition, as described above, there was also a difficulty in the manufacturing process due to the clogging of the transfer pipe due to the layer separation of the raw material.

Accordingly, the present invention sought a solution to the above-described limitations by forming the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 as separate layers by forming the phase change material in the form of a film. Accordingly, it is possible to prevent the layer separation of the raw material of the polyurethane foam, so that the polyurethane foam insulation layer 20 with excellent physical properties can be formed, and at the same time, a film layer 10 containing a phase change material formed as a separate film layer is included. By doing so, there is an effect that can improve the thermal insulation effect.

In addition, the thickness of the polyurethane foam insulation layer 20 is preferably 20 ~ 250 mm. According to a preferred embodiment of the present invention, the thickness of the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 preferably satisfy the following relational expression (1).

[Relational Expression 1]

20 ≤ T _I / T _P ≤ 250

(T _I: polyurethane foam heat insulating layer (20), T _P: phase change material-containing film layer 10)

As such, when the thickness of the film layer 10 containing the phase change material compared to the thickness of the polyurethane foam insulation layer 20 satisfies the above relation 1, the microcapsule 11 of the phase change material compared to the thickness of the insulation layer may be included in an appropriate amount, so that the heat insulation layer It can effectively delay the heat transfer of the heat insulation effect can be significantly improved.

On the other hand, the polyurethane foam insulation material (1) is preferably a phase change material-containing film layer (10) and polyurethane foam insulation layer (20) is laminated to form a laminated structure. In this way, the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 are laminated to form a layer-by-layer structure, so that the insulation effect of the polyurethane foam insulation layer 20 is improved. It can be remarkably improved by being supplemented by the phase change material-containing film layer 10 .

In this regard, referring to FIG. 1 , it can be seen that the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 have a laminated structure, and further, between the plurality of phase change material-containing film layers 10 . It can be seen that the polyurethane foam insulation layer 20 is formed to form a sandwich structure.

According to a preferred embodiment of the present invention, a first phase change material-containing film layer (10A) and a second phase change material-containing film layer (10B) may be laminated on each of the upper and lower portions of the polyurethane foam insulation layer 20 . .

In this way, when the polyurethane foam insulation layer 20 is formed between the first phase change material-containing film layer 10A and the second phase change material-containing film layer 10B to form a laminated structure, the upper portion of the polyurethane foam insulation layer 20 And since the phase change material-containing film layer 10 is formed on both the lower portion, the phase change material microcapsules 11 may be evenly distributed on the outside of the polyurethane foam insulation layer 20 . Accordingly, it is possible to effectively delay heat transfer, so that the thermal insulation effect can be further improved.

The present invention is sufficient as long as it includes the above-described laminate structure and layer arrangement, preferably a first phase change material-containing film layer (10A)-polyurethane foam insulation layer (20)- a second phase change material-containing film layer (10B) is one It is also possible to form a structure that is repeatedly stacked several times using the repeating unit of In this case, the number of repetitions of lamination is preferably 1 to 5, and more preferably 1 to 3 times.

On the other hand, in some cases, the first phase change material-containing film layer and the second phase change material-containing film layer may be continuously laminated on any one surface of the upper or lower portion of the polyurethane foam insulation layer. When the film layers containing the phase change material are successively laminated as described above, heat transfer to the corresponding direction can be effectively delayed, and thus the thermal insulation effect can be improved.

According to a preferred embodiment of the present invention, the polyurethane foam insulation (1) may further include at least one face material layer. In this case, the heat insulating effect and the moisture proof effect may be improved by the face material layer.

In addition, the face material layer may be any one or more selected from the group consisting of a non-woven fabric, paper, and aluminum foil. At this time, the meaning that it can be any one or more means any one of nonwoven fabric, paper and aluminum foil when one face material layer is included, but when two or more face material layers are included, each independently selected from nonwoven fabric, paper and aluminum foil means it can be

In this regard, Figure 3 is a cross-sectional view of the polyurethane foam insulation according to a preferred embodiment of the present invention. Referring to FIG. 3 , it can be seen that the polyurethane foam insulation 1 includes a film layer 10A and 10B containing a phase change material, a polyurethane foam insulation layer 20 , and a face material layer 30 .

According to a preferred embodiment of the present invention, the face material layer 30 is formed on any one or more of the upper and lower portions of the phase change material-containing film layer 10, and the face material layer 30 is the polyurethane foam insulation ( The outermost layer of 1) can be achieved.

Specifically, referring to FIG. 3 , it can be seen that the polyurethane foam insulation layer 20 is formed between the phase change material-containing film layers 10A and 10B, and a plurality of face material layers 30 are also formed. One plate layer 30A is formed on the upper portion of the phase change material-containing film layer 10A, and the other plate layer 30B is formed under the phase change material-containing film layer 10B, whereby the plate layers 30A, It can be seen that 30B) can form the outermost layer of the polyurethane foam insulation (1) of the present invention.

In this way, when the face material layer 30 forms the outermost layer of the polyurethane foam insulation material 1, the insulation effect of the polyurethane foam insulation layer 20 positioned in the center of the polyurethane foam insulation material 1 is a film layer containing a phase change material. It can be further improved by the (10) and the face material layer 30, and furthermore, there is an effect that the thermal insulation and moisture-proof effect are excellent.

The thickness of the plate layer 30 may be appropriately selected according to the thickness of the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20, and may be preferably 0.01 to 5 mm. More preferably, it may be 0.02 ~ 2mm, and more preferably, it may be 0.03 ~ 1mm.

When the thickness of the face material layer 30 satisfies the above range, the heat insulating effect and moisture-proof effect of the polyurethane foam insulation 1 can be significantly improved by the face material layer 30 .

On the other hand, the face material layer 30 may be laminated on one surface of the film layer 10 containing the phase change material by a method commonly used in the art, but preferably the film layer 10 containing the phase change material and the face material layer ( 30) by forming the adhesive layer 40 by applying an adhesive between them, the face material layer 30 may be adhered to and laminated on one surface of the phase change material-containing film layer 10 .

4 is a cross-sectional view of the phase change material-containing film layer 10 on which the plate layer 30 is laminated according to a preferred embodiment of the present invention. Referring to FIG. 4 , it can be seen that the plate layer 30 is adhered to and laminated on the film layer 10 containing the phase change material by the adhesive layer 40 .

Further, in order to find a solution to the above-described limitation, the present invention comprises the steps of: (1) forming a mixed composition comprising 20 to 50 parts by weight of a phase change material microcapsule 11 with respect to 100 parts by weight of the binder 12; (2) forming a film layer 10 containing a phase change material by applying and drying the mixture composition; and (3) laminating the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20; provides a polyurethane foam insulation material (1) manufacturing method comprising.

Accordingly, by preventing the layer separation of the raw material and the phase change material, the phase change material can be uniformly distributed, thereby improving the thermal insulation effect. In addition, by manufacturing the phase change material in the form of a film, it is possible to solve the non-uniform mixing of the phase change material and the clogging of the transfer pipe, and a continuous manufacturing process is possible, thereby improving the process efficiency.

Hereinafter, it will be described in detail except for the content overlapping with the above-mentioned content.

5 is a process flow diagram according to a preferred embodiment of the present invention. 5, the polyurethane foam insulation (1) manufacturing method of the present invention (1) to form a mixed composition comprising 10 to 60 parts by weight of the phase change material microcapsule (11) with respect to 100 parts by weight of the binder (12) Steps (S10), (2) applying and drying the mixed composition to form the phase change material-containing film layer 10 (S20) and (3) the phase change material-containing film layer 10 and polyurethane foam insulation layer ( 20) and stacking (S30).

As such, by forming a film layer in which the phase change material microcapsules 11 are uniformly distributed, it is possible to solve the non-uniform mixing of the phase change material and the clogging of the transfer pipe, and the film lamination can be performed continuously. Since the manufacturing process is possible, process efficiency may be improved.

First, the step (S10) of (1) forming a mixed composition including 10 to 60 parts by weight of the phase change material microcapsules 11 with respect to 100 parts by weight of the binder 12 will be described.

The step (1) may provide a composition for forming the phase change material-containing film layer 10 by forming a mixed composition by performing stirring so that the phase change material microcapsules 11 are uniformly distributed in the binder 12 substrate.

According to a preferred embodiment of the present invention, the viscosity of the mixed composition in step (1) may be 4000 ~ 10000 cps. When the viscosity of the mixed composition satisfies the above range, application can be easily performed to an appropriate thickness in the application step of the mixed composition to be described later, thereby improving process efficiency and productivity, and drying the phase change material-containing film layer ( 10) has the effect that it can be performed smoothly so as not to deteriorate the physical properties.

If the viscosity of the mixed composition is less than the above range, the coating thickness is formed as thin as about 100 μm or less in the coating step, and accordingly, the coating has to be repeated several times, so that the process efficiency and productivity may be deteriorated. In addition, if the viscosity of the mixed composition exceeds the above range, it is difficult to remove moisture in the drying step, shrinkage occurs while drying, and cracking of the film occurs, so that the physical properties of the film are reduced as well as the film. There may be a problem in that it cannot be wound in a roll shape.

Meanwhile, in some cases, a thickener may be added in step (1) to adjust the viscosity of the mixed composition as described above. The thickener is an agent that functions to control the viscosity by improving the viscosity, and those commonly used in the art may be used.

In addition, the thickener may be appropriately added in an amount commonly used in the art, but preferably 0.1 to 2 parts by weight based on 100 parts by weight of the binder 12 . More preferably, 0.3 to 1.5 parts by weight may be added based on 100 parts by weight of the binder 12 .

When the thickener is added within the above content range, there is an effect that the viscosity of the mixed composition can be more easily adjusted to 4000 to 10000 cps as described above.

In addition, in some cases, the mixed composition may be formed to further include various additives as long as the properties such as the thermal insulation effect and physical properties of the film layer 10 containing the phase change material are not impaired.

Next, the step (S20) of (2) coating and drying the mixed composition to form the phase change material-containing film layer 10 will be described.

The step (2) is a step of forming a mixture composition including the binder 12 and the phase change material microcapsule 11 and then applying and drying it to form a film form. By performing this, the phase change material-containing film layer 10 ) can be obtained.

According to a preferred embodiment of the present invention, the application and drying of step (2) may be performed by applying the mixture composition on a release paper and then drying with hot air. That is, it is possible to form a film shape by applying the mixture composition on a release paper and then drying it.

In addition, the application and drying may be repeated several times, and preferably, the application-drying may be performed by repeating the repeating unit several times as one repeating unit. For example, the film layer 10 containing the phase change material may be formed by repeatedly performing application and drying, such as 'applying-drying-applying-drying'. In some cases, drying may be performed after repeating application several times. For example, the film layer 10 containing the phase change material may be formed by performing application and drying such as 'apply-apply-apply-dry'.

Next, the step (S30) of (3) laminating the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 will be described.

Through the step (3), the film layer 10 containing the phase change material formed in the step (2) and the polyurethane foam insulation layer 20 are laminated to prepare the polyurethane foam insulation material 1 having a laminate structure.

The lamination may be performed so that the phase change material-containing film layer 10 and the polyurethane foam insulation layer 20 form a layer-by-layer shape.

According to a preferred embodiment of the present invention, the first phase change material-containing film layer (10A) and the second phase change material-containing film layer (10B) on each of the upper and lower portions of the polyurethane foam insulation layer 20 in step (3) ) can be stacked.

In this case, the polyurethane foam insulation layer 20 is formed between the first phase change material-containing film layer 10A and the second phase change material-containing film layer 10B, so that the phase change material-containing film layers 10A and 10B on the outer surface of the heat insulation layer. This is evenly distributed. Accordingly, the heat transfer of the heat insulating layer is delayed by the phase change material, so that the heat insulating effect can be further improved.

The present invention is sufficient as long as it includes the above-described laminate structure and layer arrangement, preferably a first phase change material-containing film layer (10A)-polyurethane foam insulation layer (20)- a second phase change material-containing film layer (10B) is one It is also possible to form a structure that is repeatedly stacked several times using the repeating unit of In this case, the number of repetitions of lamination is preferably 1 to 5 times, and more preferably 1 to 3 times.

In addition, in step (3), a plate layer 30 may be further laminated on each of the upper portion of the first phase change material-containing film layer 10A and the lower portion of the second phase change material-containing film layer 20 . In addition, more preferably, the face material layer 30 may be laminated to form the outermost layer of the polyurethane foam insulation (1).

In this way, when the face material layer 30 is laminated, the insulating effect of the polyurethane foam insulation layer 20 positioned in the center of the polyurethane foam insulation material 1 is achieved by the phase change material-containing film layer 10 and the face material layer 30. can be further improved, and furthermore, there is an effect of showing excellent thermal insulation and moisture-proof effects.

On the other hand, the face material layer 30 may be laminated on one surface of the film layer 10 containing the phase change material by a method commonly used in the art, but preferably the film layer 10 containing the phase change material and the face material layer ( 30) by forming the adhesive layer 40 by applying an adhesive between them, the face material layer 30 may be adhered to and laminated on one surface of the phase change material-containing film layer 10 .

After all, the polyurethane foam insulation of the present invention and its manufacturing method can solve the non-uniform mixing of the phase change material and the clogging of the transfer pipe by forming the phase change material in the form of a film, thereby improving the insulation effect and improving the process efficiency can be

Hereinafter, the present invention will be described in more detail based on examples.

Example 1

A mixed composition was formed with a composition according to Table 1 below, and this was applied on a release paper. A film layer containing a phase change material having a thickness of 0.5 mm was formed by performing application and drying in the order of application-drying-coating-drying. Thereafter, the release paper of the film layer containing the phase change material was removed, and this was laminated on the upper and lower surfaces of the polyurethane foam insulation layer to prepare a polyurethane foam insulation material.

Example 2

A mixed composition was formed with a composition according to Table 1 below, and this was applied on a release paper. A film layer containing a phase change material having a thickness of 0.5 mm was formed by performing application and drying in the order of application-drying-coating-drying. Then, an adhesive was applied to the surface of the film layer containing the phase change material, and a 0.6 mm thick face layer was laminated. The release paper was removed, and this was laminated on the upper and lower surfaces of the polyurethane foam insulation layer to prepare a polyurethane foam insulation material.

Example 3

It was carried out in the same manner as in Example 2, except that a mixed composition was formed with a composition according to Table 1 below.

Comparative Example 1

In the polyurethane foam raw material mixing step, a phase change material was added to form a polyurethane foam insulation layer. After that, a 0.6mm thick cotton layer is laminated on the upper and lower surfaces of the polyurethane foam insulation layer. A polyurethane foam insulation was prepared.

division Example 1 Example 2 Example 3 Binder (parts by weight) 100 100 100 Phase change material microcapsules
(parts by weight) capsule type 30 40 - Hybrid type - - 40 thickener (parts by weight) 1.5 0.3 1.0 mixture viscosity cps 5,000 7,000 6,500 phase transition energy J/g 53 54 46 Binder: PU binder maker (Samyoung Polytech, 40% solids) or PVA water-based binder
Capsule-type phase change material: Ennet (phase transition temperature 24℃, 107~115J/g)
Hybrid phase change material: Korea Institute of Shoes and Leather (phase transition temperature 28℃, 85~90J/g)
Polyurethane foam insulation layer: Woojo Hitech (thermal conductivity 0.018 W/mK)

Experimental Example 1

After cutting the polyurethane foam insulation prepared in Example 2 and Comparative Example in the shape of a cube of 50 cm X 50 cm X 50 cm, the internal temperature change was measured under the temperature conditions shown in Table 2 below through an axial heat dissipation tester, and the measured value is shown in Table 3 below.

Heat storage tester temperature condition Temperature rise (15→35℃) Isothermal (35℃) Cooling (35→15℃) Isothermal (15℃) 20 minutes 3 hours 20 minutes 3 hours

hours (minutes) heat storage tester temperature
(℃) Example 2
(℃) comparative example
(℃) 0 15.0 19.1 16.3 200 34.7 31.0 33.3 400 34.7 18.7 16.2 600 34.7 31.0 33.3 800 15.0 18.7 16.3 1000 34.7 30.9 33.3 1200 15.0 18.6 16.3 1400 34.7 31.0 33.4 1600 15.1 18.7 16.2 1800 34.7 30.9 33.3 2000 15.0 18.6 16.2 2200 34.7 31.0 33.4 2400 15.0 18.6 16.2 2600 34.7 30.9 33.4 2800 15.1 18.7 16.1 3000 34.7 31.0 33.4

Referring to Tables 1 and 3, it can be seen that the temperature change of Example 2 is significantly smaller than that of Comparative Example 1. In this regard, FIG. 6 is a graph showing the temperature measurement values of Example 2 and Comparative Example 1 of the present invention. Referring to FIG. 6 together, it can be seen that the temperature change of Example 2 is significantly smaller than that of Comparative Example 1.

In addition, Figure 7 is an external image of the polyurethane foam insulation according to a preferred embodiment of the present invention. Referring to Figure 7, it can be seen that the appearance of the polyurethane foam insulation of the present invention does not appear cracks or cracks.

Through this, it can be seen that the present invention can provide a polyurethane foam insulation having an excellent thermal insulation effect.

Claims (14)

At least one phase change material-containing film layer; And
At least one polyurethane foam insulation layer;
The phase change material-containing film layer is a polyurethane foam insulation comprising 10 to 60 parts by weight of the phase change material microcapsules based on 100 parts by weight of the binder.
According to claim 1,
Polyurethane foam insulation, characterized in that the film layer containing the phase change material and the polyurethane foam insulation layer are laminated to form a laminated structure.
3. The method of claim 2,
Polyurethane foam insulation, characterized in that the first phase change material-containing film layer and the second phase change material-containing film layer are laminated on the upper and lower portions of the polyurethane foam insulation layer, respectively.
3. The method of claim 2,
Polyurethane foam insulation, characterized in that the first phase change material-containing film layer and the second phase change material-containing film layer are continuously laminated on any one surface of the upper or lower portion of the polyurethane foam insulation layer.
According to claim 1,
The phase change material microcapsule is a polyurethane foam insulation, characterized in that the phase change material is impregnated in the pores of the porous carrier.
According to claim 1,
The binder is an aqueous resin emulsion,
The water-based resin emulsion is polyurethane foam insulation, characterized in that at least one selected from the group consisting of a polyurethane-based emulsion, a polyvinyl alcohol-based emulsion, and an acrylic-based emulsion.
According to claim 1,
It further comprises at least one face material layer,
The face material layer is a polyurethane foam insulation, characterized in that any one or more selected from the group consisting of non-woven fabric, paper, aluminum foil.
8. The method of claim 7,
The face material layer is formed on at least one of the upper and lower portions of the film layer containing the phase change material,
Polyurethane foam insulation, characterized in that the face material layer forms the outermost layer of the polyurethane foam insulation.
According to claim 1,
Polyurethane foam insulation material, characterized in that it satisfies the following Relational Expression 1.
[Relational Expression 1]
20 ≤ T _I / T _P ≤ 250
(T _I: polyurethane foam heat insulating layer (20), T _P: phase change material-containing film layer 10)
(1) forming a mixed composition comprising 10 to 60 parts by weight of the phase change material microcapsules based on 100 parts by weight of the binder;
(2) applying and drying the mixture composition to form a film layer containing a phase change material; And
(3) laminating the film layer containing the phase change material and the polyurethane foam insulation layer; polyurethane foam insulation manufacturing method comprising a.
11. The method of claim 10,
The viscosity of the mixed composition in step (1) is a polyurethane foam insulation manufacturing method, characterized in that 4000 ~ 10000 cps.
11. The method of claim 10,
The application and drying of step (2) is a polyurethane foam insulation manufacturing method, characterized in that it is performed by hot air drying after applying the mixture composition on a release paper.
11. The method of claim 10,
Polyurethane foam insulation manufacturing method, characterized in that the first phase change material-containing film layer and the second phase change material-containing film layer are laminated on each of the upper and lower portions of the polyurethane foam insulation layer in step (3).
14. The method of claim 13,
Polyurethane foam insulation manufacturing method, characterized in that the face material layer is further laminated on each of the upper portion of the first phase change material-containing film layer and the second phase change material-containing film layer in step (3).

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