WO2015033547A1 - Thermal insulation panel and method for producing same - Google Patents

Thermal insulation panel and method for producing same Download PDF

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Publication number
WO2015033547A1
WO2015033547A1 PCT/JP2014/004476 JP2014004476W WO2015033547A1 WO 2015033547 A1 WO2015033547 A1 WO 2015033547A1 JP 2014004476 W JP2014004476 W JP 2014004476W WO 2015033547 A1 WO2015033547 A1 WO 2015033547A1
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WO
WIPO (PCT)
Prior art keywords
heat insulating
binder
airgel particles
base material
insulation panel
Prior art date
Application number
PCT/JP2014/004476
Other languages
French (fr)
Japanese (ja)
Inventor
貴也 丹生
田村 俊樹
遠田 正和
善光 生駒
一真 釘宮
亮介 澤
健太 細井
康博 日高
Original Assignee
パナソニックIpマネジメント株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by パナソニックIpマネジメント株式会社 filed Critical パナソニックIpマネジメント株式会社
Publication of WO2015033547A1 publication Critical patent/WO2015033547A1/en

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/18Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/181Insulating layers integrally formed with the flooring or the flooring elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78Heat insulating elements
    • E04B1/80Heat insulating elements slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742Use of special materials; Materials having special structures or shape
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001Mechanical features of panels
    • E04C2002/004Panels with profiled edges, e.g. stepped, serrated
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • Y02A30/24Structural elements or technologies for improving thermal insulation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B80/00Architectural or constructional elements improving the thermal performance of buildings
    • Y02B80/10Insulation, e.g. vacuum or aerogel insulation

Definitions

  • the present invention relates to a heat insulating panel and a method for manufacturing the same, and more particularly to a heat insulating panel suitable for a floor panel and a method for manufacturing the same.
  • the heat insulation panel provided with a heat insulating material is widely used as a floor panel for floor heating, for example.
  • a heat insulating panel includes a vacuum heat insulating material, a foamed resin, glass wool and the like as a heat insulating material.
  • a heat insulating material occupies a large proportion in the heat insulating panel, its strength is low, and therefore the heat insulating material causes a decrease in the strength of the heat insulating panel.
  • a reinforcing bar or the like is provided in the heat insulating panel together with the heat insulating material (see Japanese Patent Publication No. 2012-246604).
  • the heat insulating material is not disposed at a position occupied by the reinforcing material, which causes a decrease in the heat insulating performance of the heat insulating panel.
  • the heat insulating panel is configured as a floor panel that requires high strength, the ratio of the reinforcing material in the heat insulating panel is increased, so that the heat insulating performance is significantly deteriorated.
  • the reinforcing material is reduced or removed in order to ensure the heat insulating performance, the strength of the heat insulating panel is lowered.
  • This invention is made
  • the heat insulation panel according to the present invention includes a first base material, a second base material facing the first base material with a space therebetween, the first base material, and the second base material.
  • a heat insulating material interposed therebetween, and the heat insulating material contains a plurality of airgel particles and a binder that bonds adjacent airgel particles among the plurality of airgel particles.
  • the method for manufacturing a heat insulating panel according to the present invention includes a step of disposing a mixed material containing a plurality of airgel particles and a binder adhering to each of the airgel particles on a first substrate, A step of placing the base material facing the first base material and superimposing the second base material on the mixed material, and heating the mixed material to adjacent airgel particles among the plurality of airgel particles A step of forming a heat insulating material by adhering with a binder.
  • the heat insulating material containing the airgel particles and the binder has high heat insulating performance and high strength, the heat insulating performance of the heat insulating panel is ensured and the strength of the heat insulating panel due to the heat insulating material. Reduction is suppressed.
  • FIGS. 1A to 1D are cross-sectional views illustrating a manufacturing process of a heat insulating panel according to an embodiment of the present invention. It is a top view which shows the heat insulation panel which concerns on this embodiment. It is sectional drawing which shows the modification of the heat insulation panel which concerns on this embodiment.
  • the heat insulation panel 1 which concerns on this embodiment is the 1st base material 2, the 2nd base material 3 which opposes the 1st base material 2 at intervals, the 1st base material 2, and the 2nd base.
  • the heat insulating material 4 interposed between the materials 3 is provided.
  • the heat insulating material 4 contains a plurality of airgel particles and a binder that bonds adjacent airgel particles among the plurality of airgel particles.
  • the heat insulating material 4 contains airgel particles and a binder, the heat insulating material 4 has high heat insulating performance and high strength. For this reason, while the heat insulation performance of the heat insulation panel 1 is ensured, the strength reduction of the heat insulation panel 1 resulting from the heat insulating material 4 is suppressed.
  • the binder may contain a thermoplastic resin.
  • the binder may contain a thermosetting resin.
  • the heat insulation panel may be configured as a floor panel.
  • the heat insulation panel 1 is the 1st base material 2, the 2nd base material 3 which opposes the 1st base material 2 at intervals, the 1st base material 2, and the 2nd base material. And a heat insulating material 4 interposed therebetween. Furthermore, in this embodiment, the heat insulating panel 1 includes a frame member 6 and a reinforcing member 7.
  • Each of the 1st base material 2 and the 2nd base material 3 is a flat plate-like and planar view rectangular member.
  • each of the 1st base material 2 and the 2nd base material 3 is not restrictive, it is formed from woody materials, such as MDF (medium density fiber board), a plywood, and a thick veneer, for example.
  • each of the 1st base material 2 and the 2nd base material 3 may be formed from a hard resin material.
  • the frame material 6 is interposed between the first base material 2 and the second base material 3.
  • the frame member 6 includes a first frame member 61, a second frame member 62, a third frame member 63, and a fourth frame member 64.
  • Each of these frame members 61 to 64 is a long member.
  • the first frame member 61, the second frame member 62, the third frame member 63, and the fourth frame member 64 are combined in a rectangular frame shape.
  • the first frame member 61 and the second frame member 62 are opposed to each other, and the third frame member 63 and the fourth frame member 64 are opposed to each other.
  • the frame member 6 is made of a woody material such as MDF (medium density fiberboard), plywood, and thick veneer.
  • the frame material 6 may be formed from a hard resin material.
  • the first frame member 61 includes a first fitting portion 81
  • the second frame member 62 includes a second fitting portion 82.
  • the second fitting portion 82 has a shape that fits with the first fitting portion 81.
  • the third frame member 63 includes a third fitting portion 83
  • the fourth frame member 64 includes a fourth fitting portion 84.
  • the fourth fitting portion 84 has a shape that fits with the third fitting portion 83.
  • each of the first fitting portion 81 and the third fitting portion 83 is male
  • each of the second fitting portion 82 and the fourth fitting portion 84 is female. .
  • Reinforcing material 7 is a long member.
  • the reinforcing material 7 divides the space 9 by being disposed in the space 9 surrounded by the first base material 2, the second base material 3, and the frame material 6.
  • the reinforcing material 7 is formed from a woody material such as MDF (medium density fiberboard), plywood, and thick veneer.
  • the reinforcing material 7 may be formed from a hard resin material.
  • the heat insulating material 4 is disposed in a space 9 surrounded by the first base material 2, the second base material 3, and the frame material 6.
  • the heat insulating material 4 is disposed in the space 9 divided by the reinforcing material 7. Thereby, the heat insulating material 4 is interposed between the first base material 2 and the second base material 3.
  • the heat insulating material 4 contains a plurality of airgel particles and a binder.
  • the heat insulating material 4 has high intensity
  • the binder bonds adjacent airgel particles among the plurality of airgel particles. For this reason, the airgel particles are fixed in the heat insulating material 4, thereby further improving the strength of the heat insulating material 4.
  • Airgel particles are particulate airgel.
  • An airgel is a porous substance (porous body) obtained by substituting gas contained in the solvent contained in the gel.
  • the airgel may include a xerogel.
  • the airgel particles contain one or more materials selected from the group consisting of, for example, silica airgel particles, carbon airgel particles, and alumina airgel particles.
  • the airgel particles preferably contain silica airgel particles.
  • Airgel particles are manufactured by a general manufacturing method such as a supercritical drying method or an atmospheric pressure drying method.
  • the shape of the airgel particles is not particularly limited, and may be various shapes.
  • the airgel particles may have an irregular shape such as an angular rock.
  • the airgel particles may have a shape such as a spherical shape, a rugby ball shape, a panel shape, a flake shape, or a fiber shape.
  • the average particle size of the airgel particles is preferably 500 ⁇ m or more.
  • the average particle size is more preferably in the range of 500 ⁇ m to 5 mm, and even more preferably in the range of 500 ⁇ m to 1.5 mm.
  • the major axis of the airgel particles is preferably in the range of 50 nm to 10 mm, and more preferably in the range of 100 ⁇ m to less than 2 mm.
  • the average particle diameter of the airgel particles in the heat insulating material 4 is an arithmetic average value of the diameter in terms of a perfect circle calculated from the cross-sectional area of the airgel particles obtained by the X-ray CT measurement of the heat insulating material 4.
  • the binder is formed in the heat insulating material 4 in the form of dots on the surface of the airgel particles, for example. That is, for example, a binder adheres to a part of the surface of one airgel particle among adjacent airgel particles in a plurality of airgel particles, and the binder adheres to a part of the surface of the other airgel particle, thereby adjoining each other. A binder is interposed between the airgel particles, whereby the adjacent airgel particles are bonded to each other. In this case, since heat conduction through the binder in the heat insulating material 4 is suppressed, the heat insulating performance of the heat insulating material 4 is particularly high.
  • the binder may cover the entire surface of the airgel particles. That is, each of the adjacent airgel particles among the plurality of airgel particles may be covered with the binder, and the adjacent airgel particles may be bonded to each other by contacting the binders on the surface of the adjacent airgel particles. .
  • the airgel particles adjacent to each other among the plurality of airgel particles may be bonded to each other by dispersing the plurality of airgel particles in the matrix composed of the binder.
  • the amount of the binder with respect to 100 parts by mass of the airgel particles in the heat insulating material 4 is not particularly limited, but is preferably in the range of 5 to 100 parts by mass, and more preferably in the range of 15 to 50 parts by mass.
  • the binder can contain a thermosetting resin.
  • the binder may contain only the thermosetting resin, or may contain an appropriate additive together with the thermosetting resin.
  • the difference between the solubility parameter (SP value) in the molten state of the thermosetting resin contained in the binder and the solubility parameter of the airgel particles is preferably 4 or more.
  • the thermosetting resin is bounced on the surface of the airgel particles and hardly spreads, whereby the binder is easily formed in a dot shape.
  • This difference in solubility parameter depends on the type and ratio of functional groups on the surface of the airgel particles, the type and structure of the thermosetting resin (type of functional groups, degree of polymerization, etc.), and the like.
  • the airgel particles are hydrophobic and the thermosetting resin is hydrophilic in a molten state.
  • the upper limit of the SP value difference is not particularly set, but the upper limit may be 20, for example.
  • the SP value in the molten state of the thermosetting resin is calculated from the molecular structure of the thermosetting resin obtained by the atomic group contribution method.
  • the SP value of the airgel particles is calculated by the atomic group contribution method from the molecular structure of the surface treatment agent that modifies the surface of the airgel particles.
  • the thermosetting resin can contain, for example, one or more compounds selected from the group consisting of a phenol resin, a melamine resin, a urea resin, and an epoxy resin.
  • a binder containing a thermosetting resin product number P5510 manufactured by DIC Corporation may be mentioned.
  • the binder may contain a thermoplastic resin instead of a thermosetting resin.
  • the binder may contain only a thermoplastic resin, or may contain an appropriate additive together with the thermoplastic resin.
  • the binder containing the thermoplastic resin may be an emulsion type that can be dispersed in water.
  • the emulsion containing such a binder can contain, for example, one or more materials selected from the group consisting of rubber latex emulsions, acrylic emulsions, and vinyl acetate emulsions.
  • the thermoplastic resin may be a hot melt type.
  • the hot-melt type thermoplastic resin is, for example, one or more compounds selected from the group consisting of ethylene-acrylate copolymer, polyethylene resin, polypropylene resin, polystyrene resin, ethylene-vinyl acetate copolymer, polyamide resin, and polyester resin. Can be contained.
  • thermoplastic resin A specific example of a binder containing a thermoplastic resin is product number 7050 manufactured by Tokyo Ink Co., Ltd.
  • the binder contains a thermoplastic resin, if the thermoplastic resin is softened without being melted at the time of manufacturing the heat insulating material 4, the binder is difficult to spread on the surface of the airgel particles, and the binder is likely to be formed in a dot shape.
  • the decorative layer 11 is provided on the outer surface of the first base member 2, that is, on the surface of the first base member 2 opposite to the heat insulating material 4.
  • the decorative layer 11 include a veneer and an appropriate decorative sheet.
  • a heat insulating layer 10 made of a foamed resin sheet or the like is interposed between the decorative layer 11 and the first base material 2. For this reason, when a human limb etc. touch the surface of the heat insulation panel 1, it is suppressed that a person feels cold.
  • the thickness of the heat insulation layer 10 is preferably in the range of 0.1 to 1 mm, and the heat conductivity of the heat insulation layer 10 is preferably 0.1 W / mK or less.
  • the surface of the first substrate 2 opposite to the heat insulating material 4 may be coated. In FIG. 2, illustration of the heat insulating layer 10 and the decorative layer 11 is omitted.
  • the heat insulating material 4 contains a plurality of airgel particles as described above, the heat insulating material 4 has high heat insulating performance. Moreover, since the heat insulating material 4 contains the binder which adhere
  • the airgel particles are fixed by the binder, the airgel particles are difficult to drop off from the heat insulating material 4, and even if the heat insulating material 4 is cut or perforations are formed in the heat insulating material 4, the airgel particles drop off. Hard to do. For this reason, the handleability and workability of the heat insulating material 4 are high. Even if the heat insulation panel 1 is cut or a perforation is formed in the heat insulation panel 1 during the construction of the heat insulation panel 1, the airgel particles are not easily dropped from the heat insulation panel 1. For this reason, the workability of the heat insulation panel 1 is high.
  • the first frame member 61 since the first frame member 61 includes the first fitting portion 81 and the second frame member 62 includes the second fitting portion 82, the plurality of heat insulating panels 1 are installed. Of the two adjacent heat insulating panels 1, the first fitting portion 81 of one heat insulating panel 1 and the second fitting portion 82 of the other heat insulating panel 1 can be fitted.
  • the third frame member 63 has the third fitting portion 83 and the fourth frame member 64 has the fourth fitting portion 84, when the plurality of heat insulating panels 1 are installed, Of the two heat insulating panels 1 that match, the third fitting portion 83 of one heat insulating panel 1 and the fourth fitting portion 84 of the other heat insulating panel 1 can be fitted. For this reason, the installed heat insulation panel 1 has high load-bearing performance.
  • the heat insulating panel 1 since the heat insulating panel 1 includes the reinforcing material 7 in addition to the high heat insulating material 4, the strength of the heat insulating panel 1 is very high.
  • the heat insulation panel 1 which concerns on this embodiment has high intensity
  • the heat insulation panel 1 may be comprised as a wall panel, a ceiling panel, etc.
  • the heat insulation panel 1 may not include the reinforcing material 7. Even in this case, since the strength of the heat insulation panel 1 is high, the high strength of the heat insulation panel 1 is ensured. Furthermore, since heat conduction through the reinforcing material 7 does not occur, the heat insulating performance of the heat insulating panel 1 is further improved.
  • the heat insulating panel 1 includes the reinforcing material 7 as in the present embodiment, the strength of the heat insulating material 4 is high, so that the amount of the reinforcing material 7 required for reinforcement can be reduced. Therefore, the high heat insulation performance of the heat insulation panel 1 can be maintained by reducing the heat conduction through the reinforcing material 7 in the heat insulation panel 1.
  • each fitting part 81 to 84 is not limited to this embodiment.
  • each of the fitting portions 81 to 84 may have a shape to be fitted by a decision.
  • the frame member 6 may not include the fitting portions 81 to 84, or may include only the first fitting portion 81 and the second fitting portion 82.
  • the first base material 2, the frame material 6 and the reinforcing material 7 are separate members. However, as in the modification shown in FIG. 3, the first base material 2, the frame material 6 and the reinforcing material are used. Each of 7 may be a part of one member. That is, the heat insulating panel 1 may include a member in which the first base material 2, the frame material 6, and the reinforcing material 7 are integrated.
  • the heat insulation panel 1 according to the present embodiment is manufactured, for example, by the following method (see FIGS. 1A to 1D).
  • the first substrate 2 is prepared.
  • the frame material 6 and the reinforcing material 7 are fixed on the first base material 2.
  • the frame member 6 and the reinforcing member 7 are fixed with, for example, an appropriate adhesive, double-sided tape, or the like.
  • the frame member 6 and the reinforcing member 7 may be fixed with a fixing tool such as a nail.
  • the heat insulation panel 1 is provided with the member by which the 1st base material 2, the frame material 6, and the reinforcement material 7 were united, the process of fixing the frame material 6 and the reinforcement material 7 is unnecessary.
  • a member is manufactured by a method including a step of forming a recess in the member by cutting, for example.
  • a mixed material 5 containing a plurality of airgel particles and a binder is prepared.
  • the mixed material 5 may further contain appropriate additives.
  • the binder is preferably in the form of powder, but may be liquid.
  • the mixed material 5 may contain water, and the binder may be dissolved or dispersed in this water.
  • a binder adheres to the airgel particles.
  • a powdery binder adheres to the airgel particles.
  • the binder is preferably in a powder form at normal temperature.
  • a binder becomes easy to be formed in the shape of a dot on the surface of an airgel particle.
  • a method of attaching the binder to the airgel particles in the mixed material for example, a method of stirring the mixed material with a powder mixer is employed.
  • the binder has appropriate tackiness so that it is difficult to aggregate only with the binder and easily adheres to the airgel particles.
  • the mixed material may be mixed while adding a small amount of liquid such as water to the mixed material and drying. Moreover, you may use together the airgel particle to which the binder has adhered, and the airgel particle to which the binder has not adhered.
  • the average particle size of the powdery binder in the mixed material is preferably smaller than the average particle size of the airgel particles in the mixed material. In this case, it becomes easy to adhere the binder to the airgel particles.
  • the ratio of the average particle diameter of the powder binder to the average particle diameter of the airgel particles is preferably in the range of 1/200 to 1/10.
  • the average particle size of each of the powdery binder and the airgel particles in the mixed material is measured by a laser diffraction / scattering method.
  • the mixed material 5 containing a plurality of airgel particles and a binder is disposed in a region surrounded by the frame material 6 on the first base material 2 as shown in FIG. 1B.
  • the height of the mixed material 5 disposed on the first substrate 2 is preferably the same as or slightly higher than that of the frame member 6.
  • the mixed material 5 can be supplied onto the first base material 2 from the quantitative supply device while the first base material 2 is conveyed by a conveyor.
  • the 2nd base material 3 is arrange
  • an appropriate adhesive, a double-sided tape or the like is interposed, so that the frame material 6 and the reinforcing material 7 and the second base material 3 Is preferably adhered.
  • the mixed material 5 is heated. Then, when the binder contains a thermoplastic resin, the binder is softened or melted. Subsequently, when the mixed material 5 is cooled, the binder is solidified so that adjacent airgel particles among the plurality of airgel particles are bonded together with the binder. On the other hand, when the binder contains a thermosetting resin, the airgel particles adjacent to each other among the plurality of airgel particles are bonded with the binder by thermosetting the binder. Thereby, the heat insulating material 4 containing several airgel particle and a binder is formed.
  • the heating conditions of the mixed material 5 are appropriately set according to the binder composition and the like.
  • the heating temperature may be, for example, in the range of 80 to 200 ° C, and preferably in the range of 100 to 190 ° C.
  • the heating time may be, for example, in the range of 1 to 60 minutes, and preferably in the range of 5 to 30 minutes.
  • the heating temperature is preferably in the range of 175 to 185 ° C., and the heating time is preferably in the range of 30 to 60 minutes.
  • the heating temperature is preferably in the range of 85 to 95 ° C., and the heating time is preferably in the range of 30 to 60 minutes.
  • the heat insulation performance of the heat insulating material 4 is improved by increasing the packing density of the airgel particles in the heat insulating material 4, that is, the filling amount per volume.
  • the press pressure at the time of hot pressing may be, for example, in the range of 0.1 to 10 MPa, and preferably in the range of 0.5 to 5 MPa.
  • the heat insulating layer 10 and the decorative layer 11 are sequentially laminated on the outer surface of the first base material 2 (the surface opposite to the heat insulating material 4). Thereby, as shown to FIG. 1D, the heat insulation panel 1 is obtained.

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  • Architecture (AREA)
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Abstract

This thermal insulation panel (1) is provided with: a first base (2); a second base (3) that faces the first base (2) at a distance; and a thermal insulation material (4) that is interposed between the first base (2) and the second base (3). The thermal insulation material (4) contains a plurality of aerogel particles and a binder that bonds adjacent aerogel particles with each other among the aerogel particles.

Description

断熱パネル及びその製造方法Insulation panel and method of manufacturing the same
 本発明は、断熱パネル及びその製造方法に関し、詳しくは床パネルとして好適な断熱パネル及びその製造方法に関する。 The present invention relates to a heat insulating panel and a method for manufacturing the same, and more particularly to a heat insulating panel suitable for a floor panel and a method for manufacturing the same.
 断熱材を備える断熱パネルは、例えば床暖房用の床パネルとして広く用いられている。このような断熱パネルは、断熱材として、真空断熱材、発泡樹脂、グラスウール等を備える。このような断熱材は、断熱パネル中で大きな割合を占めるにもかかわらず、その強度は低いため、断熱材は、断熱パネルの強度低下の要因となる。このため、断熱パネル内には、断熱材と共に、補強のための桟等を設けることが行われている(日本国特許公開番号特開2012-246604号参照)。 The heat insulation panel provided with a heat insulating material is widely used as a floor panel for floor heating, for example. Such a heat insulating panel includes a vacuum heat insulating material, a foamed resin, glass wool and the like as a heat insulating material. Although such a heat insulating material occupies a large proportion in the heat insulating panel, its strength is low, and therefore the heat insulating material causes a decrease in the strength of the heat insulating panel. For this reason, a reinforcing bar or the like is provided in the heat insulating panel together with the heat insulating material (see Japanese Patent Publication No. 2012-246604).
 しかし、断熱パネル内に桟等の補強材を設けると、この補強材の占る位置には断熱材が配置されないため、断熱パネルの断熱性能の低下を招いてしまう。特に断熱パネルが、高い強度が要求される床パネルとして構成される場合には、断熱パネル内の補強材の割合が高くなるため、断熱性能の低下が著しくなってしまう。また、断熱性能を確保するために補強材を減らし、或いは取り除くと、断熱パネルの強度が低下してしまう。 However, if a reinforcing material such as a crosspiece is provided in the heat insulating panel, the heat insulating material is not disposed at a position occupied by the reinforcing material, which causes a decrease in the heat insulating performance of the heat insulating panel. In particular, when the heat insulating panel is configured as a floor panel that requires high strength, the ratio of the reinforcing material in the heat insulating panel is increased, so that the heat insulating performance is significantly deteriorated. Moreover, if the reinforcing material is reduced or removed in order to ensure the heat insulating performance, the strength of the heat insulating panel is lowered.
 本発明は上記事由に鑑みてなされたものであり、断熱材に起因する強度低下が抑制された断熱パネルを提供することを目的とする。 This invention is made | formed in view of the said reason, and it aims at providing the heat insulation panel by which the strength reduction resulting from a heat insulating material was suppressed.
 本発明に係る断熱パネルは、第一の基材と、前記第一の基材と間隔をあけて対向する第二の基材と、前記第一の基材と前記第二の基材との間に介在する断熱材とを備え、前記断熱材が、複数のエアロゲル粒子と、前記複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を接着しているバインダとを含有する。 The heat insulation panel according to the present invention includes a first base material, a second base material facing the first base material with a space therebetween, the first base material, and the second base material. A heat insulating material interposed therebetween, and the heat insulating material contains a plurality of airgel particles and a binder that bonds adjacent airgel particles among the plurality of airgel particles.
 本発明に係る断熱パネルの製造方法は、第一の基材上に、複数のエアロゲル粒子と、前記エアロゲル粒子の各々に付着しているバインダとを含有する混合材料を配置する工程、第二の基材を前記第一の基材と対向させて配置すると共に前記第二の基材を前記混合材料と重ねる工程、及び前記混合材料を加熱して前記複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を前記バインダで接着することで、断熱材を形成する工程を含む。 The method for manufacturing a heat insulating panel according to the present invention includes a step of disposing a mixed material containing a plurality of airgel particles and a binder adhering to each of the airgel particles on a first substrate, A step of placing the base material facing the first base material and superimposing the second base material on the mixed material, and heating the mixed material to adjacent airgel particles among the plurality of airgel particles A step of forming a heat insulating material by adhering with a binder.
 本発明によれば、エアロゲル粒子とバインダとを含有する断熱材が、高い断熱性能を有すると共に高い強度をも有するため、断熱パネルの断熱性能が確保されると共に断熱材に起因する断熱パネルの強度低下が抑制される。 According to the present invention, since the heat insulating material containing the airgel particles and the binder has high heat insulating performance and high strength, the heat insulating performance of the heat insulating panel is ensured and the strength of the heat insulating panel due to the heat insulating material. Reduction is suppressed.
図1A乃至図1Dは、本発明の一実施形態に係る断熱パネルの製造工程を示す断面図である。1A to 1D are cross-sectional views illustrating a manufacturing process of a heat insulating panel according to an embodiment of the present invention. 本実施形態に係る断熱パネルを示す平面図である。It is a top view which shows the heat insulation panel which concerns on this embodiment. 本実施形態に係る断熱パネルの変形例を示す断面図である。It is sectional drawing which shows the modification of the heat insulation panel which concerns on this embodiment.
 本実施形態に係る断熱パネル1は、第一の基材2と、第一の基材2と間隔をあけて対向する第二の基材3と、第一の基材2と第二の基材3との間に介在する断熱材4とを備える。断熱材4は、複数のエアロゲル粒子と、前記複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を接着しているバインダとを含有する。 The heat insulation panel 1 which concerns on this embodiment is the 1st base material 2, the 2nd base material 3 which opposes the 1st base material 2 at intervals, the 1st base material 2, and the 2nd base. The heat insulating material 4 interposed between the materials 3 is provided. The heat insulating material 4 contains a plurality of airgel particles and a binder that bonds adjacent airgel particles among the plurality of airgel particles.
 本実施形態では、断熱材4がエアロゲル粒子とバインダとを含有することで、断熱材4が高い断熱性能を有すると共に高い強度をも有する。このため、断熱パネル1の断熱性能が確保されると共に断熱材4に起因する断熱パネル1の強度低下が抑制される。 In this embodiment, since the heat insulating material 4 contains airgel particles and a binder, the heat insulating material 4 has high heat insulating performance and high strength. For this reason, while the heat insulation performance of the heat insulation panel 1 is ensured, the strength reduction of the heat insulation panel 1 resulting from the heat insulating material 4 is suppressed.
 バインダは、熱可塑性樹脂を含有してもよい。バインダは、熱硬化性樹脂を含有してもよい。 The binder may contain a thermoplastic resin. The binder may contain a thermosetting resin.
 断熱パネルは、床パネルとして構成されてもよい。 The heat insulation panel may be configured as a floor panel.
 本実施形態に係る断熱パネル1の構造について、図1D及び図2を参照して、更に詳しく説明する。 The structure of the heat insulation panel 1 according to the present embodiment will be described in more detail with reference to FIGS. 1D and 2.
 上述の通り、断熱パネル1は、第一の基材2と、第一の基材2と間隔をあけて対向する第二の基材3と、第一の基材2と第二の基材3との間に介在する断熱材4とを備える。更に本実施形態では、断熱パネル1が、枠材6と補強材7とを備える。 As above-mentioned, the heat insulation panel 1 is the 1st base material 2, the 2nd base material 3 which opposes the 1st base material 2 at intervals, the 1st base material 2, and the 2nd base material. And a heat insulating material 4 interposed therebetween. Furthermore, in this embodiment, the heat insulating panel 1 includes a frame member 6 and a reinforcing member 7.
 第一の基材2と第二の基材3の各々は、平板状且つ平面視矩形状の部材である。第一の基材2と第二の基材3の各々は、制限的ではないが、例えば、MDF(中密度繊維板)、合板、厚単板等の木質系材料から形成される。また、第一の基材2と第二の基材3の各々が、硬質樹脂材料から形成されてもよい。 Each of the 1st base material 2 and the 2nd base material 3 is a flat plate-like and planar view rectangular member. Although each of the 1st base material 2 and the 2nd base material 3 is not restrictive, it is formed from woody materials, such as MDF (medium density fiber board), a plywood, and a thick veneer, for example. Moreover, each of the 1st base material 2 and the 2nd base material 3 may be formed from a hard resin material.
 枠材6は、第一の基材2と第二の基材3との間に介在している。本実施形態では、枠材6は、第一の枠材61、第二の枠材62、第三の枠材63及び第四の枠材64を含む。これらの枠材61~64の各々は、長尺な部材である。第一の枠材61、第二の枠材62、第三の枠材63及び第四の枠材64は、矩形の枠型に組み合わされている。第一の枠材61と第二の枠材62とが対向し、第三の枠材63と第四の枠材64とが対向している。枠材6は、例えばMDF(中密度繊維板)、合板、厚単板等の木質系材料から形成される。枠材6が、硬質樹脂材料から形成されてもよい。 The frame material 6 is interposed between the first base material 2 and the second base material 3. In the present embodiment, the frame member 6 includes a first frame member 61, a second frame member 62, a third frame member 63, and a fourth frame member 64. Each of these frame members 61 to 64 is a long member. The first frame member 61, the second frame member 62, the third frame member 63, and the fourth frame member 64 are combined in a rectangular frame shape. The first frame member 61 and the second frame member 62 are opposed to each other, and the third frame member 63 and the fourth frame member 64 are opposed to each other. The frame member 6 is made of a woody material such as MDF (medium density fiberboard), plywood, and thick veneer. The frame material 6 may be formed from a hard resin material.
 第一の枠材61は第一の嵌合部81を備え、第二の枠材62は第二の嵌合部82を備える。第二の嵌合部82は第一の嵌合部81と嵌合する形状を有する。また、第三の枠材63は第三の嵌合部83を備え、第四の枠材64は第四の嵌合部84を備える。第四の嵌合部84は、第三の嵌合部83と嵌合する形状を有する。本実施形態では、第一の嵌合部81及び第三の嵌合部83の各々は雄実であり、第二の嵌合部82と第四の嵌合部84の各々は雌実である。 The first frame member 61 includes a first fitting portion 81, and the second frame member 62 includes a second fitting portion 82. The second fitting portion 82 has a shape that fits with the first fitting portion 81. The third frame member 63 includes a third fitting portion 83, and the fourth frame member 64 includes a fourth fitting portion 84. The fourth fitting portion 84 has a shape that fits with the third fitting portion 83. In the present embodiment, each of the first fitting portion 81 and the third fitting portion 83 is male, and each of the second fitting portion 82 and the fourth fitting portion 84 is female. .
 補強材7は、長尺な部材である。補強材7は、第一の基材2、第二の基材3及び枠材6で囲まれる空間9に配置されることで、この空間9を分割する。補強材7は、例えばMDF(中密度繊維板)、合板、厚単板等の木質系材料から形成される。補強材7が、硬質樹脂材料から形成されてもよい。 Reinforcing material 7 is a long member. The reinforcing material 7 divides the space 9 by being disposed in the space 9 surrounded by the first base material 2, the second base material 3, and the frame material 6. The reinforcing material 7 is formed from a woody material such as MDF (medium density fiberboard), plywood, and thick veneer. The reinforcing material 7 may be formed from a hard resin material.
 断熱材4は、第一の基材2、第二の基材3及び枠材6で囲まれる空間9に配置される。本実施形態では、補強材7によって分割された空間9に、断熱材4が配置されている。これにより、断熱材4が、第一の基材2と第二の基材3との間に介在している。 The heat insulating material 4 is disposed in a space 9 surrounded by the first base material 2, the second base material 3, and the frame material 6. In the present embodiment, the heat insulating material 4 is disposed in the space 9 divided by the reinforcing material 7. Thereby, the heat insulating material 4 is interposed between the first base material 2 and the second base material 3.
 断熱材4は、複数のエアロゲル粒子と、バインダとを含有する。断熱材4がエアロゲル粒子を含有することで、断熱材4が高い強度を有する。バインダは、複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を接着している。このため、断熱材4内でエアロゲル粒子が固定され、これにより、断熱材4の強度が更に向上している。 The heat insulating material 4 contains a plurality of airgel particles and a binder. The heat insulating material 4 has high intensity | strength because the heat insulating material 4 contains an airgel particle. The binder bonds adjacent airgel particles among the plurality of airgel particles. For this reason, the airgel particles are fixed in the heat insulating material 4, thereby further improving the strength of the heat insulating material 4.
 尚、エアロゲル粒子とは、粒子状のエアロゲルのことである。エアロゲルとは、ゲル中に含まれる溶媒を気体に置換して得られる多孔性の物質(多孔質体)である。エアロゲルは、キセロゲルを含んでもよい。 Airgel particles are particulate airgel. An airgel is a porous substance (porous body) obtained by substituting gas contained in the solvent contained in the gel. The airgel may include a xerogel.
 本実施形態では、エアロゲル粒子は、例えばシリカエアロゲル粒子、カーボンエアロゲル粒子及びアルミナエアロゲル粒子からなる群から選択される一種以上の材料を含有する。特にエアロゲル粒子が、シリカエアロゲル粒子を含有することが好ましい。 In the present embodiment, the airgel particles contain one or more materials selected from the group consisting of, for example, silica airgel particles, carbon airgel particles, and alumina airgel particles. In particular, the airgel particles preferably contain silica airgel particles.
 エアロゲル粒子は、例えば超臨界乾燥法、常圧乾燥法などの、一般的な製造方法で製造される。 Airgel particles are manufactured by a general manufacturing method such as a supercritical drying method or an atmospheric pressure drying method.
 エアロゲル粒子の形状は、特に限定されず、種々の形状であってよい。例えばエアロゲル粒子が、角張った岩石状などの不定形の形状を有してもよい。また、エアロゲル粒子が、球状、ラグビーボール状、パネル状、フレーク状、繊維状等の形状を有してもよい。 The shape of the airgel particles is not particularly limited, and may be various shapes. For example, the airgel particles may have an irregular shape such as an angular rock. The airgel particles may have a shape such as a spherical shape, a rugby ball shape, a panel shape, a flake shape, or a fiber shape.
 エアロゲル粒子の平均粒径は、500μm以上であることが好ましい。この平均粒径は、500μm以上5mm以下の範囲内であればより好ましく、500μm以上1.5mm以下の範囲内であれば更に好ましい。エアロゲル粒子の長径は、50nm以上10mm以下の範囲内であることが好ましく、100μm以上2mm未満の範囲内であれば更に好ましい。 The average particle size of the airgel particles is preferably 500 μm or more. The average particle size is more preferably in the range of 500 μm to 5 mm, and even more preferably in the range of 500 μm to 1.5 mm. The major axis of the airgel particles is preferably in the range of 50 nm to 10 mm, and more preferably in the range of 100 μm to less than 2 mm.
 尚、断熱材4中のエアロゲル粒子の平均粒径は、断熱材4のX線CT測定によって得られるエアロゲル粒子の断面積から算出される真円換算の直径の、算術平均値である。 In addition, the average particle diameter of the airgel particles in the heat insulating material 4 is an arithmetic average value of the diameter in terms of a perfect circle calculated from the cross-sectional area of the airgel particles obtained by the X-ray CT measurement of the heat insulating material 4.
 バインダは、断熱材4中で、例えばエアロゲル粒子の表面に点状に形成されている。すなわち、例えば複数のエアロゲル粒子における隣合うエアロゲル粒子のうち一方のエアロゲル粒子の表面の一部にバインダが付着し、このバインダが他方のエアロゲル粒子の表面の一部にも付着することで、隣合うエアロゲル粒子間にバインダが介在し、これにより、隣合うエアロゲル粒子同士が接着されている。この場合、断熱材4中におけるバインダを通じた熱伝導が抑制されるため、断熱材4の断熱性能が特に高くなる。 The binder is formed in the heat insulating material 4 in the form of dots on the surface of the airgel particles, for example. That is, for example, a binder adheres to a part of the surface of one airgel particle among adjacent airgel particles in a plurality of airgel particles, and the binder adheres to a part of the surface of the other airgel particle, thereby adjoining each other. A binder is interposed between the airgel particles, whereby the adjacent airgel particles are bonded to each other. In this case, since heat conduction through the binder in the heat insulating material 4 is suppressed, the heat insulating performance of the heat insulating material 4 is particularly high.
 断熱材4中で、バインダが、エアロゲル粒子の表面全体を覆っていてもよい。すなわち、複数のエアロゲル粒子のうち隣合うエアロゲル粒子の各々が、バインダによって覆われ、且つ隣合うエアロゲル粒子の表面上のバインダ同士が接触することで、隣合うエアロゲル粒子同士が接着されていてもよい。 In the heat insulating material 4, the binder may cover the entire surface of the airgel particles. That is, each of the adjacent airgel particles among the plurality of airgel particles may be covered with the binder, and the adjacent airgel particles may be bonded to each other by contacting the binders on the surface of the adjacent airgel particles. .
 断熱材4中で、バインダで構成される母相中に複数のエアロゲル粒子が分散することで、複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士がバインダで接着されてもよい。 In the heat insulating material 4, the airgel particles adjacent to each other among the plurality of airgel particles may be bonded to each other by dispersing the plurality of airgel particles in the matrix composed of the binder.
 断熱材4中のエアロゲル粒子100質量部に対するバインダの量は、特に制限されないが、5~100質量部の範囲内であることが好ましく、15~50質量部の範囲内であれば更に好ましい。 The amount of the binder with respect to 100 parts by mass of the airgel particles in the heat insulating material 4 is not particularly limited, but is preferably in the range of 5 to 100 parts by mass, and more preferably in the range of 15 to 50 parts by mass.
 バインダは、熱硬化性樹脂を含有することができる。この場合、バインダが、熱硬化性樹脂のみを含有してもよいし、熱硬化性樹脂と共に適宜の添加物を含有してもよい。 The binder can contain a thermosetting resin. In this case, the binder may contain only the thermosetting resin, or may contain an appropriate additive together with the thermosetting resin.
 バインダに含まれる熱硬化性樹脂の溶融状態での溶解度パラメータ(SP値)と、エアロゲル粒子の溶解度パラメータとの差は、4以上であることが好ましい。この場合、熱硬化性樹脂がエアロゲル粒子の表面で弾かれて広がりにくくなり、これによりバインダが点状に形成されやすくなる。この溶解度パラメータの差は、エアロゲル粒子の表面の官能基の種類及び割合、熱硬化性樹脂の種類及び構造(官能基の種類や重合度など)等に依存する。溶解度パラメータの差を大きくするためには、例えばエアロゲル粒子が疎水性であり、熱硬化性樹脂が溶融状態で親水性を有することが、好ましい。このSP値の差の上限は特に設定されないが、例えば上限が20であってもよい。 The difference between the solubility parameter (SP value) in the molten state of the thermosetting resin contained in the binder and the solubility parameter of the airgel particles is preferably 4 or more. In this case, the thermosetting resin is bounced on the surface of the airgel particles and hardly spreads, whereby the binder is easily formed in a dot shape. This difference in solubility parameter depends on the type and ratio of functional groups on the surface of the airgel particles, the type and structure of the thermosetting resin (type of functional groups, degree of polymerization, etc.), and the like. In order to increase the difference in solubility parameter, for example, it is preferable that the airgel particles are hydrophobic and the thermosetting resin is hydrophilic in a molten state. The upper limit of the SP value difference is not particularly set, but the upper limit may be 20, for example.
 尚、熱硬化性樹脂の溶融状態でのSP値は、原子団寄与法によって得られる熱硬化性樹脂の分子構造から算出される。一方、エアロゲル粒子のSP値は、エアロゲル粒子の表面を修飾している表面処理剤の分子構造から原子団寄与法によって算出される。 The SP value in the molten state of the thermosetting resin is calculated from the molecular structure of the thermosetting resin obtained by the atomic group contribution method. On the other hand, the SP value of the airgel particles is calculated by the atomic group contribution method from the molecular structure of the surface treatment agent that modifies the surface of the airgel particles.
 熱硬化性樹脂は、例えばフェノール樹脂、メラミン樹脂、ユリア樹脂及びエポキシ樹脂からなる群から選択される一種以上の化合物を含有することができる。熱硬化性樹脂を含有するバインダの具体的な一例として、DIC株式会社製の品番P5510が挙げられる。 The thermosetting resin can contain, for example, one or more compounds selected from the group consisting of a phenol resin, a melamine resin, a urea resin, and an epoxy resin. As a specific example of a binder containing a thermosetting resin, product number P5510 manufactured by DIC Corporation may be mentioned.
 バインダは、熱硬化性樹脂ではなく、熱可塑性樹脂を含有してもよい。この場合、バインダは、熱可塑性樹脂のみを含有してもよいし、熱可塑性樹脂と共に適宜の添加剤を含有してもよい。 The binder may contain a thermoplastic resin instead of a thermosetting resin. In this case, the binder may contain only a thermoplastic resin, or may contain an appropriate additive together with the thermoplastic resin.
 熱可塑性樹脂を含有するバインダは、水中に分散可能なエマルジョンタイプであってもよい。このようなバインダを含有するエマルションは、例えばゴム系ラテックス系エマルション、アクリル系エマルション、及び酢酸ビニル系エマルションからなる群から選択される一種以上の材料を含有することができる。熱可塑性樹脂は、ホットメルトタイプであってもよい。ホットメルトタイプの熱可塑性樹脂は、例えばエチレン-アクリレート共重合体、ポリエチレン樹脂、ポリプロピレン樹脂、ポリスチレン樹脂、エチレン-酢酸ビニル共重合体、ポリアミド樹脂及びポリエステル樹脂からなる群から選択される一種以上の化合物を含有することができる。熱可塑性樹脂を含有するバインダの具体的な一例として、東京インキ株式会社製の品番7050が挙げられる。バインダが熱可塑性樹脂を含有すると、断熱材4の製造時において熱可塑性樹脂を溶融させずに軟化させれば、バインダがエアロゲル粒子の表面で広がりにくくなり、バインダが点状に形成されやすくなる。 The binder containing the thermoplastic resin may be an emulsion type that can be dispersed in water. The emulsion containing such a binder can contain, for example, one or more materials selected from the group consisting of rubber latex emulsions, acrylic emulsions, and vinyl acetate emulsions. The thermoplastic resin may be a hot melt type. The hot-melt type thermoplastic resin is, for example, one or more compounds selected from the group consisting of ethylene-acrylate copolymer, polyethylene resin, polypropylene resin, polystyrene resin, ethylene-vinyl acetate copolymer, polyamide resin, and polyester resin. Can be contained. A specific example of a binder containing a thermoplastic resin is product number 7050 manufactured by Tokyo Ink Co., Ltd. When the binder contains a thermoplastic resin, if the thermoplastic resin is softened without being melted at the time of manufacturing the heat insulating material 4, the binder is difficult to spread on the surface of the airgel particles, and the binder is likely to be formed in a dot shape.
 本実施形態では、第一の基材2の外面上、すなわち、第一の基材2の断熱材4とは反対側の表面上に、化粧層11が設けられている。化粧層11として、突板、適宜の加飾シート等が挙げられる。本実施形態では、化粧層11と第一の基材2との間に、発泡樹脂シート等からなる断熱層10が介在している。このため、断熱パネル1の表面に人の手足等が触れた場合に、人が冷たさを感じることが抑制される。断熱層10の厚みは0.1~1mmの範囲内であることが好ましく、断熱層10の熱伝導率は0.1W/mK以下であることが好ましい。第一の基材2の、断熱材4とは反対側の表面上に、塗装が施されていてもよい。尚、図2では、断熱層10及び化粧層11の図示を省略している。 In the present embodiment, the decorative layer 11 is provided on the outer surface of the first base member 2, that is, on the surface of the first base member 2 opposite to the heat insulating material 4. Examples of the decorative layer 11 include a veneer and an appropriate decorative sheet. In the present embodiment, a heat insulating layer 10 made of a foamed resin sheet or the like is interposed between the decorative layer 11 and the first base material 2. For this reason, when a human limb etc. touch the surface of the heat insulation panel 1, it is suppressed that a person feels cold. The thickness of the heat insulation layer 10 is preferably in the range of 0.1 to 1 mm, and the heat conductivity of the heat insulation layer 10 is preferably 0.1 W / mK or less. The surface of the first substrate 2 opposite to the heat insulating material 4 may be coated. In FIG. 2, illustration of the heat insulating layer 10 and the decorative layer 11 is omitted.
 本実施形態では、上記のとおり断熱材4が複数のエアロゲル粒子を含有するため、断熱材4が高い断熱性能を有する。また、断熱材4が、複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を接着しているバインダを含有するため、断熱材4が種々の厚みに容易に形成されうる。すなわち断熱材4の厚みを大きくすることが容易である。このため、断熱材4の断熱性能がより向上し得る。更に、断熱材4は、エアロゲル粒子及びバインダを含有することで、高い強度を有する。このため、断熱パネル1の断熱性能が確保されると共に断熱材4に起因する断熱パネル1の強度低下が抑制される。 In this embodiment, since the heat insulating material 4 contains a plurality of airgel particles as described above, the heat insulating material 4 has high heat insulating performance. Moreover, since the heat insulating material 4 contains the binder which adhere | attached the adjacent airgel particle among several airgel particles, the heat insulating material 4 can be easily formed in various thickness. That is, it is easy to increase the thickness of the heat insulating material 4. For this reason, the heat insulation performance of the heat insulating material 4 can improve more. Furthermore, the heat insulating material 4 has high intensity | strength by containing an airgel particle and a binder. For this reason, while the heat insulation performance of the heat insulation panel 1 is ensured, the strength reduction of the heat insulation panel 1 resulting from the heat insulating material 4 is suppressed.
 本実施形態では、バインダがエアロゲル粒子を固定しているため、断熱材4からエアロゲル粒子が脱落しにくく、断熱材4が切断されたり断熱材4に穿孔が形成されたりしてもエアロゲル粒子が脱落しにくい。このため、断熱材4の取り扱い性及び加工性が高い。断熱パネル1の施工時に断熱パネル1を切断したり断熱パネル1に穿孔を形成したりしても、断熱パネル1からエアロゲル粒子が脱落しにくい。このため、断熱パネル1の施工性が高い。 In the present embodiment, since the airgel particles are fixed by the binder, the airgel particles are difficult to drop off from the heat insulating material 4, and even if the heat insulating material 4 is cut or perforations are formed in the heat insulating material 4, the airgel particles drop off. Hard to do. For this reason, the handleability and workability of the heat insulating material 4 are high. Even if the heat insulation panel 1 is cut or a perforation is formed in the heat insulation panel 1 during the construction of the heat insulation panel 1, the airgel particles are not easily dropped from the heat insulation panel 1. For this reason, the workability of the heat insulation panel 1 is high.
 本実施形態では、第一の枠材61が第一の嵌合部81を備え、第二の枠材62が第二の嵌合部82を備えるため、複数の断熱パネル1が設置される際、隣合う二つの断熱パネル1のうち、一方の断熱パネル1の第一の嵌合部81と他方の断熱パネル1の第二の嵌合部82とが嵌合することができる。また、第三の枠材63が第三の嵌合部83を有し、第四の枠材64が第四の嵌合部84を有するため、複数の断熱パネル1が設置される際、隣合う二つの断熱パネル1のうち、一方の断熱パネル1の第三の嵌合部83と他方の断熱パネル1の第四の嵌合部84とが嵌合することもできる。このため、設置された断熱パネル1が、高い耐荷重性能を有する。 In the present embodiment, since the first frame member 61 includes the first fitting portion 81 and the second frame member 62 includes the second fitting portion 82, the plurality of heat insulating panels 1 are installed. Of the two adjacent heat insulating panels 1, the first fitting portion 81 of one heat insulating panel 1 and the second fitting portion 82 of the other heat insulating panel 1 can be fitted. In addition, since the third frame member 63 has the third fitting portion 83 and the fourth frame member 64 has the fourth fitting portion 84, when the plurality of heat insulating panels 1 are installed, Of the two heat insulating panels 1 that match, the third fitting portion 83 of one heat insulating panel 1 and the fourth fitting portion 84 of the other heat insulating panel 1 can be fitted. For this reason, the installed heat insulation panel 1 has high load-bearing performance.
 本実施形態では、断熱パネル1が、強度の高い断熱材4に加えて、補強材7も備えるため、断熱パネル1の強度が非常に高い。 In this embodiment, since the heat insulating panel 1 includes the reinforcing material 7 in addition to the high heat insulating material 4, the strength of the heat insulating panel 1 is very high.
 このように本実施形態に係る断熱パネル1は、高い強度を有するため、床パネルとして構成されることが好ましい。この場合、床パネルの断熱性能が確保されると共に断熱材4に起因する床パネルの強度低下が抑制される。勿論、断熱パネル1が、壁パネル、天井パネル等として構成されてもよい。 Thus, since the heat insulation panel 1 which concerns on this embodiment has high intensity | strength, it is preferable to be comprised as a floor panel. In this case, the heat insulation performance of the floor panel is ensured, and the strength reduction of the floor panel due to the heat insulating material 4 is suppressed. Of course, the heat insulation panel 1 may be comprised as a wall panel, a ceiling panel, etc.
 断熱パネル1は補強材7を備えなくてもよい。この場合でも、断熱パネル1の強度が高いため、断熱パネル1の高い強度が確保される。更に、補強材7を通じた熱伝導が生じないため、断熱パネル1の断熱性能が更に向上する。 The heat insulation panel 1 may not include the reinforcing material 7. Even in this case, since the strength of the heat insulation panel 1 is high, the high strength of the heat insulation panel 1 is ensured. Furthermore, since heat conduction through the reinforcing material 7 does not occur, the heat insulating performance of the heat insulating panel 1 is further improved.
 断熱パネル1が本実施形態のように補強材7を備える場合でも、断熱材4の強度が高いため、補強に要する補強材7の量を削減することが可能である。そのため、断熱パネル1における補強材7を通じた熱伝導を低減することで、断熱パネル1の高い断熱性能を維持することができる。 Even when the heat insulating panel 1 includes the reinforcing material 7 as in the present embodiment, the strength of the heat insulating material 4 is high, so that the amount of the reinforcing material 7 required for reinforcement can be reduced. Therefore, the high heat insulation performance of the heat insulation panel 1 can be maintained by reducing the heat conduction through the reinforcing material 7 in the heat insulation panel 1.
 各嵌合部81~84の形状は、本実施形態に制限されない。例えば各嵌合部81~84が、合決により嵌合する形状を有してもよい。枠材6が、嵌合部81~84を備えなくてもよいし、第一の嵌合部81及び第二の嵌合部82のみを備えてもよい。 The shape of each fitting part 81 to 84 is not limited to this embodiment. For example, each of the fitting portions 81 to 84 may have a shape to be fitted by a decision. The frame member 6 may not include the fitting portions 81 to 84, or may include only the first fitting portion 81 and the second fitting portion 82.
 本実施形態では、第一の基材2、枠材6及び補強材7は、別部材であるが、図3に示す変形例のように、第一の基材2、枠材6及び補強材7の各々が、一つの部材の一部であってもよい。すなわち、断熱パネル1が、第一の基材2、枠材6及び補強材7が一体となった部材を備えていてもよい。 In the present embodiment, the first base material 2, the frame material 6 and the reinforcing material 7 are separate members. However, as in the modification shown in FIG. 3, the first base material 2, the frame material 6 and the reinforcing material are used. Each of 7 may be a part of one member. That is, the heat insulating panel 1 may include a member in which the first base material 2, the frame material 6, and the reinforcing material 7 are integrated.
 本実施形態に係る断熱パネル1は、例えば次の方法で製造される(図1A~図1D参照)。 The heat insulation panel 1 according to the present embodiment is manufactured, for example, by the following method (see FIGS. 1A to 1D).
 本方法は、第一の基材2上に、複数のエアロゲル粒子とバインダとを含有する混合材料5を配置する工程;第二の基材3を第一の基材2と対向させて配置すると共に第二の基材3を混合材料5と重ねる工程;及び混合材料5を加熱して複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士をバインダで接着することで、断熱材4を形成する工程を、含む。 In this method, a step of disposing a mixed material 5 containing a plurality of airgel particles and a binder on the first substrate 2; disposing the second substrate 3 so as to face the first substrate 2. And a step of superposing the second base material 3 on the mixed material 5; and a step of forming the heat insulating material 4 by heating the mixed material 5 and adhering adjacent airgel particles among the plurality of airgel particles with a binder. Including.
 本方法では、まず第一の基材2を用意する。この第一の基材2上に、図1Aに示すように、枠材6及び補強材7を固定する。枠材6及び補強材7は、例えば適宜の接着剤、両面テープ等で固定される。枠材6及び補強材7が、釘等の固定具で固定されてもよい。 In this method, first, the first substrate 2 is prepared. As shown in FIG. 1A, the frame material 6 and the reinforcing material 7 are fixed on the first base material 2. The frame member 6 and the reinforcing member 7 are fixed with, for example, an appropriate adhesive, double-sided tape, or the like. The frame member 6 and the reinforcing member 7 may be fixed with a fixing tool such as a nail.
 尚、断熱パネル1が、第一の基材2、枠材6及び補強材7が一体となった部材を備える場合には、枠材6及び補強材7を固定する工程は不要である。このような部材は、例えば部材に切削加工により凹所を形成する工程を含む方法で、作製される。 In addition, when the heat insulation panel 1 is provided with the member by which the 1st base material 2, the frame material 6, and the reinforcement material 7 were united, the process of fixing the frame material 6 and the reinforcement material 7 is unnecessary. Such a member is manufactured by a method including a step of forming a recess in the member by cutting, for example.
 複数のエアロゲル粒子とバインダとを含有する混合材料5を調製する。混合材料5には、更に適宜の添加剤を配合してもよい。バインダは、粉末状であることが好ましいが、液状であってもよい。混合材料5が水を含有し、この水にバインダが溶解又は分散していてもよい。 A mixed material 5 containing a plurality of airgel particles and a binder is prepared. The mixed material 5 may further contain appropriate additives. The binder is preferably in the form of powder, but may be liquid. The mixed material 5 may contain water, and the binder may be dissolved or dispersed in this water.
 混合材料中では、エアロゲル粒子にバインダが付着していることが好ましい。特に、エアロゲル粒子に粉末状のバインダが付着していることが好ましい。この場合、バインダは常温で粉末状であることが好ましい。これにより、断熱材4中で、バインダがエアロゲル粒子の表面に点状に形成されやすくなる。混合材料中でエアロゲル粒子にバインダを付着させる方法としては、例えば、混合材料を粉体混合機で撹拌する方法が採用される。この場合、バインダは、バインダのみで凝集しにくいと共にエアロゲル粒子に付着しやすいように、適度の粘着性を有することが好ましい。尚、バインダの粘着性を高めるために、混合材料中に水などの液体を少量加えると共に乾燥しながら、混合材料を混合してもよい。また、バインダが付着しているエアロゲル粒子と、バインダが付着していないエアロゲル粒子を併用してもよい。 In the mixed material, it is preferable that a binder adheres to the airgel particles. In particular, it is preferable that a powdery binder adheres to the airgel particles. In this case, the binder is preferably in a powder form at normal temperature. Thereby, in the heat insulating material 4, a binder becomes easy to be formed in the shape of a dot on the surface of an airgel particle. As a method of attaching the binder to the airgel particles in the mixed material, for example, a method of stirring the mixed material with a powder mixer is employed. In this case, it is preferable that the binder has appropriate tackiness so that it is difficult to aggregate only with the binder and easily adheres to the airgel particles. In order to increase the adhesiveness of the binder, the mixed material may be mixed while adding a small amount of liquid such as water to the mixed material and drying. Moreover, you may use together the airgel particle to which the binder has adhered, and the airgel particle to which the binder has not adhered.
 混合材料中の粉末状のバインダの平均粒径は、混合材料中のエアロゲル粒子の平均粒径よりも小さいことが好ましい。この場合、エアロゲル粒子にバインダを付着させやすくなる。特に、粉末のバインダの平均粒径の、エアロゲル粒子の平均粒径に対する比の値が、1/200~1/10の範囲内であることが好ましい。尚、混合材料中の粉末状のバインダ及びエアロゲル粒子の各々の平均粒径は、レーザ回折・散乱法で測定される。 The average particle size of the powdery binder in the mixed material is preferably smaller than the average particle size of the airgel particles in the mixed material. In this case, it becomes easy to adhere the binder to the airgel particles. In particular, the ratio of the average particle diameter of the powder binder to the average particle diameter of the airgel particles is preferably in the range of 1/200 to 1/10. The average particle size of each of the powdery binder and the airgel particles in the mixed material is measured by a laser diffraction / scattering method.
 複数のエアロゲル粒子とバインダとを含有する混合材料5を、図1Bに示すように、第一の基材2上の、枠材6で囲まれた領域に配置する。第一の基材2上に配置されている混合材料5の高さは、枠材6と同じ或いはそれよりもやや高いことが好ましい。混合材料5を配置するにあたっては、例えば第一の基材2をコンベアで搬送しながら、この第一の基材2上に混合材料5を、定量供給装置から供給することができる。 The mixed material 5 containing a plurality of airgel particles and a binder is disposed in a region surrounded by the frame material 6 on the first base material 2 as shown in FIG. 1B. The height of the mixed material 5 disposed on the first substrate 2 is preferably the same as or slightly higher than that of the frame member 6. In arranging the mixed material 5, for example, the mixed material 5 can be supplied onto the first base material 2 from the quantitative supply device while the first base material 2 is conveyed by a conveyor.
 次に、図1Cに示すように、第二の基材3を、第一の基材2における混合材料5側の面と対向して配置し、この第二の基材3を、混合材料5、枠材6及び補強材7に重ねる。枠材6及び補強材7と第二の基材3との間には、例えば適宜の接着剤、両面テープ等を介在させることで、枠材6及び補強材7と第二の基材3とを接着することが好ましい。 Next, as shown to FIG. 1C, the 2nd base material 3 is arrange | positioned facing the surface at the side of the mixed material 5 in the 1st base material 2, and this 2nd base material 3 is mixed material 5 And the frame material 6 and the reinforcing material 7. Between the frame material 6 and the reinforcing material 7 and the second base material 3, for example, an appropriate adhesive, a double-sided tape or the like is interposed, so that the frame material 6 and the reinforcing material 7 and the second base material 3 Is preferably adhered.
 この状態で、混合材料5を加熱する。そうすると、バインダが熱可塑性樹脂を含有する場合には、バインダが軟化又は溶融する。続いて、混合材料5が冷却されると、バインダが固化することで、複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士が、バインダで接着される。一方、バインダが熱硬化性樹脂を含有する場合には、バインダが熱硬化することで、複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士が、バインダで接着される。これにより、複数のエアロゲル粒子とバインダとを含有する断熱材4が形成される。 In this state, the mixed material 5 is heated. Then, when the binder contains a thermoplastic resin, the binder is softened or melted. Subsequently, when the mixed material 5 is cooled, the binder is solidified so that adjacent airgel particles among the plurality of airgel particles are bonded together with the binder. On the other hand, when the binder contains a thermosetting resin, the airgel particles adjacent to each other among the plurality of airgel particles are bonded with the binder by thermosetting the binder. Thereby, the heat insulating material 4 containing several airgel particle and a binder is formed.
 混合材料5の加熱条件は、バインダの組成等に応じて適宜設定される。加熱温度は、例えば80~200℃の範囲内であってよく、好ましくは100~190℃の範囲内であってよい。加熱時間は、例えば1~60分の範囲内であってよく、好ましくは、5~30分の範囲内であってよい。特にバインダが熱硬化性樹脂を含有する場合、加熱温度は175~185℃の範囲内、加熱時間は30~60分の範囲内であることが、好ましい。また、バインダが熱可塑性樹脂を含有する場合、加熱温度は85~95℃の範囲内、加熱時間は30~60分の範囲内であることが、好ましい。 The heating conditions of the mixed material 5 are appropriately set according to the binder composition and the like. The heating temperature may be, for example, in the range of 80 to 200 ° C, and preferably in the range of 100 to 190 ° C. The heating time may be, for example, in the range of 1 to 60 minutes, and preferably in the range of 5 to 30 minutes. In particular, when the binder contains a thermosetting resin, the heating temperature is preferably in the range of 175 to 185 ° C., and the heating time is preferably in the range of 30 to 60 minutes. When the binder contains a thermoplastic resin, the heating temperature is preferably in the range of 85 to 95 ° C., and the heating time is preferably in the range of 30 to 60 minutes.
 混合材料5を加熱する際は、加熱プレスにより第一の基材2及び第二の基材3を混合材料5へ向けてプレスしながら加熱することが好ましい。この場合、断熱材4中のエアロゲル粒子の充填密度、すなわち体積当たりの充填量が高くなることで、断熱材4の断熱性能が向上する。加熱プレス時のプレス圧は、例えば0.1~10MPaの範囲内であってよく、好ましくは0.5~5MPaの範囲内であってよい。 When heating the mixed material 5, it is preferable to heat the mixed material 5 while pressing the first base material 2 and the second base material 3 toward the mixed material 5 by a heating press. In this case, the heat insulation performance of the heat insulating material 4 is improved by increasing the packing density of the airgel particles in the heat insulating material 4, that is, the filling amount per volume. The press pressure at the time of hot pressing may be, for example, in the range of 0.1 to 10 MPa, and preferably in the range of 0.5 to 5 MPa.
 また、このように加熱プレスにより断熱材4を形成することで、第一の基材2及び第二の基材3の各々と、断熱材4とを、断熱材4中のバインダで接着することが好ましい。この場合、断熱パネル1の強度が更に高くなる。 Moreover, bonding each of the first base material 2 and the second base material 3 to the heat insulating material 4 with a binder in the heat insulating material 4 by forming the heat insulating material 4 by the heating press in this way. Is preferred. In this case, the strength of the heat insulating panel 1 is further increased.
 続いて、必要に応じて、第一の基材2の外面(断熱材4とは反対側の表面)上に、断熱層10及び化粧層11を順次積層する。これにより、図1Dに示すように、断熱パネル1が得られる。 Subsequently, if necessary, the heat insulating layer 10 and the decorative layer 11 are sequentially laminated on the outer surface of the first base material 2 (the surface opposite to the heat insulating material 4). Thereby, as shown to FIG. 1D, the heat insulation panel 1 is obtained.
 1  断熱パネル
 2  第一の基材
 3  第二の基材
 4  断熱材
DESCRIPTION OF SYMBOLS 1 Heat insulation panel 2 1st base material 3 2nd base material 4 Heat insulation material

Claims (5)

  1. 第一の基材と、前記第一の基材と間隔をあけて対向する第二の基材と、前記第一の基材と前記第二の基材との間に介在する断熱材とを備え、
    前記断熱材が、複数のエアロゲル粒子と、前記複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を接着しているバインダとを含有する断熱パネル。
    A first substrate, a second substrate facing the first substrate with a gap, and a heat insulating material interposed between the first substrate and the second substrate. Prepared,
    The heat insulation panel in which the said heat insulating material contains several airgel particle and the binder which adhere | attached the airgel particle which adjoins among these airgel particles.
  2. 前記バインダが、熱可塑性樹脂を含有する請求項1に記載の断熱パネル。 The heat insulation panel according to claim 1, wherein the binder contains a thermoplastic resin.
  3. 前記バインダが、熱硬化性樹脂を含有する請求項1に記載の断熱パネル。 The heat insulation panel according to claim 1, wherein the binder contains a thermosetting resin.
  4. 床パネルとして構成されている請求項1乃至3のいずれか一項に記載の断熱パネル。 The heat insulation panel as described in any one of Claims 1 thru | or 3 comprised as a floor panel.
  5. 第一の基材上に、複数のエアロゲル粒子と前記複数のエアロゲル粒子の各々に付着しているバインダとを含有する混合材料を配置する工程、
    第二の基材を前記第一の基材と対向させて配置すると共に前記第二の基材を前記混合材料と重ねる工程、及び
    前記混合材料を加熱して前記複数のエアロゲル粒子のうち隣合うエアロゲル粒子同士を前記バインダで接着することで、断熱材を形成する工程を含む断熱パネルの製造方法。
    Disposing a mixed material containing a plurality of airgel particles and a binder attached to each of the plurality of airgel particles on the first substrate,
    A step of arranging a second base material facing the first base material and superimposing the second base material on the mixed material, and heating the mixed material to be adjacent to each other among the plurality of airgel particles The manufacturing method of the heat insulation panel including the process of forming a heat insulating material by adhere | attaching airgel particles with the said binder.
PCT/JP2014/004476 2013-09-05 2014-09-01 Thermal insulation panel and method for producing same WO2015033547A1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019038120A1 (en) * 2017-08-21 2019-02-28 Universität Duisburg-Essen Wood-concrete composite floor

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10147664A (en) * 1996-11-20 1998-06-02 C I Kasei Co Ltd Aerogel heat-insulating panel and its production
JPH11513349A (en) * 1995-09-11 1999-11-16 ヘキスト、リサーチ、アンド、テクノロジー、ドイッチェラント、ゲゼルシャフト、ミット、ベシュレンクテル、ハフツング、ウント、コンパニー、コマンディート、ゲゼルシャフト Airgel composites containing fibers
JP2000246822A (en) * 1999-02-26 2000-09-12 Mitsubishi Electric Corp Panel structure and production thereof
WO2012168617A1 (en) * 2011-05-26 2012-12-13 Electricite De France Aerogel-based material that is super-insulating at atmospheric pressure

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11513349A (en) * 1995-09-11 1999-11-16 ヘキスト、リサーチ、アンド、テクノロジー、ドイッチェラント、ゲゼルシャフト、ミット、ベシュレンクテル、ハフツング、ウント、コンパニー、コマンディート、ゲゼルシャフト Airgel composites containing fibers
JPH10147664A (en) * 1996-11-20 1998-06-02 C I Kasei Co Ltd Aerogel heat-insulating panel and its production
JP2000246822A (en) * 1999-02-26 2000-09-12 Mitsubishi Electric Corp Panel structure and production thereof
WO2012168617A1 (en) * 2011-05-26 2012-12-13 Electricite De France Aerogel-based material that is super-insulating at atmospheric pressure

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019038120A1 (en) * 2017-08-21 2019-02-28 Universität Duisburg-Essen Wood-concrete composite floor

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