WO2016084763A1 - Vacuum thermal insulating material and manufacturing method therefor - Google Patents

Abstract

Provided are: a vacuum thermal insulating material with which machining such as drilling and recess machining can be stably performed, for which the ease of work during manufacturing is favorable, and surface flatness has been maintained; and a manufacturing method therefor. A vacuum thermal insulating material is provided with: an outer covering material obtained by disposing a gas-tight film with a thermal welding layer on one surface so that the thermal welding layers face each other; a sheet-shaped core material with a lacuna that penetrates in the sheet thickness direction; and a replacement material, which is disposed in the lacuna so as to occlude the lacuna and has a gas-tight resin member with a pair of surfaces that are roughly parallel to the main surface of the core material. In the vacuum thermal insulating material in which the interior of the outer covering material is in a reduced pressure state, the core material in which said replacement material has been disposed is held within the outer covering material, and the region that is located outside the perimeter of the core material and entirely surrounds the core material is bonded tightly by thermal welding of the thermal welding layers to each other. The resin member is bonded with the outer covering material so as to maintain gas-tightness.

Description

Vacuum insulation material and manufacturing method thereof

The present invention relates to a vacuum heat insulating material and a manufacturing method thereof, and more particularly to a vacuum heat insulating material suitable for processing such as hole processing and concave processing and a manufacturing method thereof.

Normally, vacuum insulation is loaded with a porous core material made of glass fiber, silica, or other powder solidified in an airtight film having a heat-welded layer on the inner surface, and the core material of the airtight film exists under reduced pressure. It is produced by heat-sealing etc. by heat-welding the heat-welding layers of the outer part of the outer periphery of the core material. Therefore, once the vacuum heat insulating material is constructed, the film cannot be scratched or perforated, and thus the vacuum heat insulating material cannot be processed later.

To solve such a problem, for example, as shown in FIGS. 10A and 10B, a through-hole 4 is formed in the plate-like core material 5, and the airtight film 2 is thermally welded to the outer portion of the outer periphery of the core material 5. The layers 1 are thermally welded together to form a seal portion Y, and the heat-bonding layers 1 of the airtight film 2 are also heat-sealed in the same manner as described above for the through-hole portion without the core material 5. A technique for manufacturing a vacuum heat insulating material 10F having a welded portion X is known (see, for example, Patent Document 1). In such a vacuum heat insulating material 10F, the heat-welded portion X corresponding to the through hole 4 can be used for drilling or the like.

However, the heat-welded portion X that can be used for drilling or the like in the vacuum heat insulating material 10F obtained by the above method is smaller in thickness than the portion in which the core material 5 of the vacuum heat insulating material 10F is accommodated, and the entire vacuum heat insulating material 10F. As a result, not only the surface flatness is impaired but also the mechanical strength of the portion is not sufficient. Moreover, since it has a level | step difference, the workability | operativity in heat welding is bad and it is easy to produce wrinkles. As a result, heat welding is not performed sufficiently, and there is a fear that the sealing performance is impaired by making a hole.

JP 2011-153715 A

The present invention has been made from the above viewpoint, and is a vacuum heat insulating material that can stably perform processing such as hole processing and concave processing, and has good workability at the time of fabrication and ensures surface flatness. It is an object of the present invention to provide a vacuum heat insulating material and a manufacturing method thereof.

The present invention has the following configuration.
[1] A jacket material formed by disposing an airtight film having a heat-welded layer on one side so that the heat-welded layers face each other;
A plate-like core material having a missing portion penetrating in the thickness direction;
A replacement material having an airtight resin member having a pair of surfaces substantially parallel to the main surface of the core material, which is disposed in the missing portion so as to close the missing portion,
A core material in which the replacement material is disposed is housed in the outer jacket material, and an area extending outside the outer periphery of the core material and covering the entire periphery of the core material is between the heat-welded layers. A vacuum heat insulating material that is in close contact by heat welding and in which the inside of the outer cover material is in a reduced pressure state, wherein the resin member is bonded to the outer cover material so that airtightness is maintained.

[2] At least the vicinity of the pair of surfaces of the resin member is made of a heat-weldable resin with a constituent material of the heat-welding layer, and the resin member has the heat-welding layer of the jacket material on the pair of surfaces. [1] Vacuum heat insulating material heat-welded.
[3] The vacuum heat insulating material according to [1] or [2], wherein the ratio of the thickness of the replacement material to the thickness of the core material is 0.8 to 1.2.
[4] The vacuum heat insulating material according to any one of [1] to [3], wherein the resin member is a closed cell resin member having a porosity of 10 to 98%.
[5] The vacuum heat insulating material according to any one of [1] to [4], wherein the replacement material includes only the resin member.
[6] The resin member has a through-hole penetrating in a direction perpendicular to the surface, and the replacement member is a resin of the resin member disposed so as to be fitted into the through-hole of the resin member. The vacuum heat insulating material according to any one of [1] to [4], further including a dissimilar material member made of a material different from the above.

[7] The vacuum heat insulating material according to [6], wherein the material constituting the dissimilar material member is a resin, rubber, wood, paper, fiber accumulation material, or ceramics different from the resin of the resin member.
[8] The vacuum heat insulating material according to any one of [1] to [7], wherein a hole is formed in a region excluding a peripheral edge portion of the replacement material.
[9] The hole-processed hole is used for wiring and / or piping, a fixing member for fixing the vacuum heat insulating material to the heat insulating material is disposed, and the vacuum heat insulating material is hung on the protrusion of the heat insulating material. [8] The vacuum heat insulating material used for the use selected from.

[10] Form a missing portion penetrating in the plate thickness direction in the plate-shaped core material,
A replacement material having a gas-tight resin member having a pair of surfaces substantially parallel to the main surface of the core material is disposed in the missing portion so as to close the missing portion,
A core material in which the replacement material is disposed is housed in an outer cover material in which an airtight film having a heat-welded layer on one side is disposed so that the heat-welded layers face each other. The inside of the material is in a reduced pressure state, the region located outside the outer periphery of the core material and covering the entire periphery of the core material is adhered by heat welding of the heat welding layers, and the resin member is attached to the pair The manufacturing method of the vacuum heat insulating material joined to the said heat welding layer of the said jacket | cover material in the surface.
[11] The bonding between the resin member and the heat-welded layer of the jacket material is performed by heat-pressing a region of the jacket material corresponding to the pair of surfaces of the resin member from the outside of the jacket material. [10] The method for producing a vacuum heat insulating material according to [10], which is performed by heat welding.

According to the present invention, it is a vacuum heat insulating material in which surface flatness is ensured, the workability at the time of manufacturing is good, and the vacuum heat insulating material which can stably perform processing such as hole processing and concave processing, and its manufacture Can provide a method.

It is a top view which shows an example of embodiment of the vacuum heat insulating material of this invention. It is sectional drawing in the AA line of the vacuum heat insulating material shown to FIG. 1A. It is an expanded view which shows the core material by which the substitution material in the vacuum heat insulating material shown to FIG. 1A and B was arrange | positioned. It is a top view which shows the core material by which the substitution material in the vacuum heat insulating material shown to FIG. 1A and B was arrange | positioned. It is sectional drawing which shows the core material by which the substitution material in the vacuum heat insulating material shown to FIG. 1A and B was arrange | positioned. It is a figure which shows the modification of the core material by which the substitution material in the vacuum heat insulating material of this invention was arrange | positioned. It is a figure which shows the modification of the core material by which the substitution material in the vacuum heat insulating material of this invention was arrange | positioned. It is a figure which shows the modification of the core material by which the substitution material in the vacuum heat insulating material of this invention was arrange | positioned. It is a top view which shows the modification of embodiment of the vacuum heat insulating material of this invention. It is sectional drawing in the BB line of the vacuum heat insulating material shown to FIG. 4A. 4A and 4B are development views showing a replacement material in the vacuum heat insulating material shown in FIGS. 4A and 4B and a core material provided with the replacement material. It is a top view which shows the core material by which the substitution material and substitution material in the vacuum heat insulating material shown to FIG. 4A and B were arrange | positioned. It is sectional drawing which shows the core material by which the substitution material and substitution material in the vacuum heat insulating material shown to FIG. 4A and B were arrange | positioned. It is a top view which shows another modification of embodiment of the vacuum heat insulating material of this invention. FIG. 6B is a cross-sectional view taken along line CC of the vacuum heat insulating material shown in FIG. 6A. It is a top view which shows another modification of embodiment of the vacuum heat insulating material of this invention. FIG. 7B is a cross-sectional view (b) taken along line DD of the vacuum heat insulating material shown in FIG. 7A. It is a top view which shows another modification of embodiment of the vacuum heat insulating material of this invention. It is sectional drawing in the EE line of the vacuum heat insulating material shown to FIG. 8A. It is a figure which shows typically an example of the manufacturing method of the vacuum heat insulating material of this invention. It is a top view which shows an example of the conventional vacuum heat insulating material. It is sectional drawing in the FF line of the vacuum heat insulating material shown to FIG. 10A.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to this. In the following description, an abbreviation such as “substantially the same size” means a range that can be seen by visual observation. In this specification, that a certain member has a “missing portion” refers to a state in which a part of the shape is missing so that the member is mainly used in a predetermined shape. In the vacuum heat insulating material of the present invention, the core material mainly constitutes the filling portion of the vacuum heat insulating material, and the replacement material compensates for the missing portion of the core material.

[Vacuum insulation]
1A, B, 4A, and B are a plan view (FIGS. 1A and 4A) and a cross-sectional view (FIGS. 1B and 4B), respectively, illustrating an example and a modification of the vacuum heat insulating material of the present invention. FIGS. 2A to 2C and FIGS. 5A to 5C are diagrams showing core materials in which replacement materials are respectively disposed in the vacuum heat insulating materials shown in FIGS. 1A and 1B and FIGS. 4A and 4B. In the core material shown in FIGS. 2A to 2C and FIGS. 5A to 5C, the missing portion is a through hole. 3A to 3C are plan views of the core material in which the replacement material is disposed in the missing portions having various shapes. FIGS. 6A, B, 7A, B, 8A, and B are a plan view (FIGS. 6A, 7A, and 8A) and a cross-sectional view, respectively, showing another modification example and still another modification example of the embodiment of the present invention. 6B, 7B, and 8B). The vacuum heat insulating material shown in FIGS. 6A, B, 7A, B and 8A, B is an example of the vacuum heat insulating material according to the embodiment in which the hole is processed.

A vacuum heat insulating material 10A shown in FIGS. 1A and 1B has an airtight film 2 having a heat-welding layer 1 on one side, and a covering material 3 formed by arranging the film 2 so that the heat-welding layers 1 face each other. 2A-C, a plate-like core material 5 having a through-hole 4 penetrating in the thickness direction shown in detail in FIG. 2A-C, and a core material 5 disposed in the through-hole 4 so as to be fitted to the through-hole 4 And a replacement material 7 made of an airtight resin member 6 having a pair of surfaces 6a, 6b parallel to both the outer peripheral surface 6c and the both surfaces 5a, 5b of the core material 5. In FIGS. 1A and 1B, the replacement material 7 and the resin member 6 are the same member, and the reference numeral is 6 (7). The same applies to FIGS. 2A-C.

In the vacuum heat insulating material 10 </ b> A, the core material 5 in which the replacement material 7 is disposed is accommodated in the outer cover material 3 in which the heat-welding layers 1 face each other, and is positioned outside the outer periphery of the core material 5. A region Y extending over the entire periphery of the material 5 is brought into close contact by heat welding between the heat welding layers 1, and the inside of the jacket material 3 is in a reduced pressure state. Hereinafter, the heat-welded area Y is also referred to as a seal area Y.

Further, in the vacuum heat insulating material 10A, the resin member 6 is made of a resin that can be bonded to the material constituting the heat-welding layer 1, and the resin member 6 is bonded so that airtightness is maintained on the pair of surfaces 6a and 6b. Has been. Here, the joined interface corresponds to a pair of surfaces 6 a and 6 b included in the resin member 6.

In addition, the resin member 6 and the heat welding layer 1 do not necessarily have to be joined to the entire surface 6a, 6b of the resin member 6. If necessary, a part of the end portions of the surfaces 6a and 6b may not be joined. In other words, the vacuum heat insulating material 10A is usually subjected to processing such as drilling and nailing at a portion corresponding to the resin member 6 (substitution material 7), in particular, at a substantially central portion in use. In addition, as long as it joins so that airtightness may be hold | maintained, holes, nailing, etc. may be processed in addition to a substantially center part. As long as the surfaces 6a and 6b of the resin member 6 at a position surrounding at least the periphery of the portion to be processed and the heat-welded layer 1 are joined so as to maintain airtightness, the vacuum heat insulating material 10A is processed even after processing. It is possible to stably maintain a reduced pressure inside. Specifically, it is preferable that a range of 5 mm or more is joined from the outer periphery of the portion where the hole or the like is processed.

However, from the viewpoint of increasing the degree of freedom of processing such as drilling and nailing, and more stably maintaining the inside of the vacuum heat insulating material 10A in a reduced pressure state, the resin member 6 is preferably formed on the entire surface 6a, 6b. And the heat welding layer 1 are joined. Further, the surfaces 6a and 6b of the resin member 6 are provided with a slight inclination with respect to both surfaces 5a and 5b of the core material 5 or with minute unevenness to such an extent that the surfaces 6a and 6b can be bonded to the heat-welding layer 1 on the surface. May be.

The heat-welding layer 1 and the surfaces 6a and 6b of the resin member 6 can be joined by a known method. Specifically, joining by an adhesive and joining by heat welding are mentioned. In the case of using an adhesive for bonding, an adhesive layer is interposed between the heat-welded layer and the surface of the resin member, and both are bonded by the adhesive force of the adhesive. Therefore, in this case, the surface of the resin member does not necessarily need to be made of a material that can be thermally welded to the heat-welded layer. Further, the type of the adhesive is not particularly limited as long as the heat-welded layer and the surface of the resin member are bonded with airtightness.

The surfaces 6a and 6b of the heat welding layer 1 and the resin member 6 are preferably joined by heat welding from the viewpoint of workability. When performing thermal welding, it is preferable that at least the resin member surfaces 6 a and 6 b are made of a material that can be thermally welded to the thermal welding layer 1. When joining is performed by thermal welding, the heating method is not particularly limited. Known heating methods such as ultrasonic welding, high frequency welding, and thermal welding by contact with a heat medium can be mentioned.

In the vacuum heat insulating material 10A shown in FIGS. 1A and 1B, specifically, the resin member 6 is made of a material capable of being thermally welded to the material constituting the heat-welding layer 1, and the resin member 6 is formed on a pair of surfaces 6a and 6b. The outer cover material 3 is thermally welded to the heat-welded layer 1. Note that the interface between the resin member 6 and the heat-welded layer 1 does not actually exist clearly due to heat-welding. In FIG. 1B, the interface between the resin member 6 and the heat welding layer 1 is indicated by a broken line as the interface before the heat welding.

The relationship between the core material 5 having the through hole 4 in the vacuum heat insulating material 10A and the replacement material 7 made of the resin member 6 is shown in FIGS. 2A to 2C. 2A is a developed view, FIG. 2B is a plan view, and FIG. 2C is a cross-sectional view taken along the line A′-A ′ of FIG. 2B. In the vacuum heat insulating material 10A, the core member 5 has a pair of main surfaces 5a and 5b having a square plate shape, and a through hole 4 having a square opening at a substantially center. The replacement member 7 made of the resin member 6 is disposed so as to fit into the through hole 4 of the core member 5. That is, the outer peripheral surface 6 c of the resin member 6 is disposed so as to contact the inner surface 4 a of the through hole 4.

Resin member 6 has approximately the same size and shape as the portion cut out by the through hole. That is, the resin member 6 has a pair of surfaces 6 a and 6 b parallel to the main surfaces 5 a and 5 b of the core material 5, and the thickness is substantially the same as the thickness of the core material 5. Therefore, the main surface of the member in which the resin member 6 is fitted in the through hole 4 of the core member 5 is a flat surface as a whole. The thickness of the core material 5 is not particularly limited, but the thickness of the core material in a normal vacuum heat insulating material is about 3 to 40 mm.

Here, in the vacuum heat insulating material 10A, the inner surface 4a of the through hole 4 of the core material 5 is formed so as to be perpendicular to the main surfaces 5a and 5b, but the vacuum heat insulating material of the embodiment of the present invention. However, it is not necessarily vertical, and may be tapered, stepped, or the like as necessary. From the viewpoint of workability, the through hole in the core material is preferably formed so that the inner surface thereof is perpendicular to the main surface of the core material.

The shape of the opening of the through-hole 4, that is, the shape of the surface of the replacement material 7 can be an arbitrary shape including a triangle, a quadrangle, a polygon, a substantially circular shape, a substantially elliptical shape, an L shape, and a combination thereof. In addition, the shape of the surface of the replacement material 7 is preferably a shape that does not hinder drilling, nailing, or the like applied to a portion corresponding to the replacement material 7 as described later. At the same time, the area of the surface of the replacement material 7 is set to an area where there is no problem in drilling or nailing. The shape and area of the surface of the replacement material 7 are appropriately adjusted according to the use of the vacuum heat insulating material.

Further, the thicknesses of the core material 5 and the resin member 6 are not necessarily the same. As long as the bonding with the heat welding layer 1 of the jacket material 3 is sufficiently performed on the pair of surfaces 6a and 6b of the resin member 6, the thickness of the resin member is thin even if it is thicker than the thickness of the core material. Also good. The thickness of the resin member 6 is appropriately selected in consideration of the flatness required for the vacuum heat insulating material in addition to the above-described viewpoint of the heat weldability. Specifically, the thickness of the resin member 6, that is, the replacement material 7 is preferably 0.8 to 1.2 times the thickness of the core material 5. When the thickness of the resin member 6 is more than 1.0 and 1.2 times the thickness of the core material 5, the position of the resin member 6 is not changed even after the core material 5 is sealed in the envelope material 3 under reduced pressure. Since it is easy to confirm from the outside of the material 3, it is preferable.

In the vacuum heat insulating material 10A, the number of the through holes 4 included in the core material 5 is one. In the vacuum heat insulating material according to the embodiment of the present invention, the core material may have a plurality of through holes as necessary, and the replacement material may be fitted into all of the through holes. The replacement material includes a resin member having a small heat insulating property. Therefore, in consideration of the heat insulating property as the vacuum heat insulating material, the total area of the openings of the through holes is preferably up to 20% of the area of the main surface of the core material (not including the through hole openings). When there are a plurality of through-holes, the distance between the through-holes and the outer periphery of the through-hole is not particularly limited, but it is at least 5 mm or more in order to prevent the core material from cracking or unnecessary missing between the through-holes. preferable.

If the material of the resin member which comprises a substitution material in the vacuum heat insulating material of this invention is resin which has airtightness, it will not restrict | limit in particular. Further, from the viewpoint of maintaining high heat insulating properties of the vacuum heat insulating material, the resin member constituting the replacement material is preferably an air-tight closed cell resin. Note that airtightness specifically means that the air flow rate is 0 cm ³ / cm ² sec by the air permeability evaluation method defined by JIS K 6400-7. When the replacement material is an airtight closed cell resin, an increase in thermal conductivity can be suppressed to a small level. It is also lightweight and strong.

The resin member may have a configuration in which a plurality of resin layers are laminated in a direction parallel to the surface or in a direction orthogonal to the surface, or may be configured as a single member. In the case of a plurality of resin layers, each resin layer may be made of the same resin or different resins. When the resin member is made of closed cell resin, if the resin member has a structure in which a plurality of resin layers are laminated in a direction perpendicular to the surface, all the resin layers may be made of closed cell resin. Only the resin layer may be made of closed cell resin. For example, when a hole is formed by punching a central layer or a predetermined layer, these layers may not be formed of closed cell resin.

When joining the heat-welded layer and the resin member by heat-welding, even if the resin member is made of a single resin or a case of being made of a plurality of resins, at least the resin member is near the pair of surfaces, It is comprised with the constituent material of the heat welding layer which a jacket material has, and the resin which can be heat-welded. From the viewpoint of productivity, the entire resin member is preferably composed of a heat-weldable constituent material of the outer cover material and a resin that can be heat-welded. In the case where the resin member has a structure in which a plurality of layers are laminated in a direction parallel to the surface, it is essential that the layers are in close contact so as to maintain airtightness.

When joining the heat-welding layer and the resin member by heat-welding, the specific resin depends on the material constituting the heat-welding layer of the jacket material. Examples of the material constituting the heat-welded layer of the jacket material include low density polyethylene, chain low density polyethylene, high density polyethylene, polypropylene, polyacrylonitrile, unstretched polyethylene terephthalate, and ethylene-vinyl alcohol copolymer. . Therefore, when the heat-welded layer and the resin member are joined by heat-welding, the resin constituting the resin member is preferably a resin material that can be heat-welded with these resins. Specifically, the same resin as these resins is used. be able to. Preferably, the material constituting the heat-welded layer of the outer cover material and the resin constituting the resin member are the same resin.

Further, for example, when drilling a resin member as described later, it is required to keep gas and moisture from entering through the wall surface of the formed hole and diffusing into the core material. From such a viewpoint, the resin constituting the resin member is preferably a high-density resin with low gas diffusibility, and particularly preferably high-density polyethylene and polypropylene.
The resin member is preferably dried in advance to reduce outgas.

When the resin constituting the resin member is a closed-cell resin, the porosity is 10 to 98% from the viewpoint that light weight and strength can be maintained while suppressing an increase in thermal conductivity by the resin member. Preferably, 20 to 90% is more preferable, and 30 to 80% is particularly preferable. If the porosity is too high, the strength of the resin member is low, so that it may be destroyed by atmospheric pressure after vacuum sealing. If the porosity is too low, the heat insulating property of the resin member is smaller than that of the core material, so that a thermal bridge is formed and the heat insulating property of the vacuum heat insulating material may be lowered. The porosity of the closed cell resin is determined as a ratio of the volume of bubbles in the resin when the total volume of the closed cell resin is 100%.

The closed cell resin is not particularly limited as long as it is a closed cell resin capable of ensuring airtightness, and preferably ensuring the above-mentioned cell ratio. For example, a foamed resin having no communication hole or a compound resin using a hollow particle as a filler can be used. From the viewpoint of workability and suppressing the inflow of gas from the inside of the hollow bubbles into the vacuum heat insulating material, a compound resin having hollow particles as fillers is preferable.

In the case of a compound resin, the porosity depends on the porosity of the hollow particles themselves used as the filler and the content ratio of the hollow particles in the compound resin. In order to make the porosity of the closed cell resin within the above range, the porosity of the hollow particles used is preferably about 60 to 98%, and the particle diameter is preferably about 50 to 300 μm in D50. The material constituting the shell of the hollow particles is preferably a material having low thermal conductivity, for example, a resin, from the viewpoint of suppressing an increase in thermal conductivity due to the resin member. On the other hand, an inorganic material is preferable from the viewpoint of airtightness. Further, from the viewpoint of reducing the thermal conductivity, it is preferable that the inside of the hollow particles is in a reduced pressure state.

Specific examples of the hollow particles used as the filler of the compound resin include glass balloons, silica balloons, shirasu balloons, ceramic balloons, and resin balloons. Among these, a resin balloon is preferable from the viewpoint of suppressing the increase in the thermal conductivity, and a glass balloon and a silica balloon having high shell airtightness are preferable from the viewpoint of airtightness. Shirasu balloons, ceramic balloons and the like are preferable in that the inside of the hollow particles can be in a reduced pressure state.

The resin constituting the closed cell resin, for example, a foam resin or a compound resin having no communication hole is not particularly limited, but a resin having a good bondability with the heat-welded layer of the jacket material is preferable. . Furthermore, when the heat-welded layer and the resin member are joined by heat-welding, as described above, the resin constituting the resin member is preferably a resin material that can be heat-welded with these resins, and specifically, the same as these resins. These resins can be used.

In the vacuum heat insulating material 10 </ b> A, the outer cover material 3 is formed, for example, by having two identical and identical airtight films 2 having the heat welding layer 1 on one side, and the heat welding layers 1 of the respective films 2 facing each other. And can be superposed.

The size and shape of the jacket material 3 is such that the core material 5 in which the resin member 6 is fitted in the through hole 4 is accommodated between the two airtight films 2 and is outside the outer periphery of the core material 5. If it is the magnitude | size and shape in which the seal | sticker area | region Y is provided in, it will not specifically limit. It can be appropriately selected according to the size and shape of the core material 5. Moreover, the width | variety of the seal | sticker area | region Y shown by Yw in FIG. 1A and B will not be restrict | limited especially if it is the width | variety which can seal the inside of the jacket material 3 in a pressure-reduced state. Specifically, the width Yw of the seal region Y is preferably about 5 to 20 mm.

In the vacuum heat insulating material 10A, the degree of vacuum inside the cover material 3 inside the seal region Y of the cover material 3 is 1 × 10 from the viewpoint that excellent heat insulating performance can be obtained and the life of the vacuum heat insulating material becomes long. ³ Pa or less is preferable, and 1 × 10 ² Pa or less is more preferable.

As the material of the jacket material 3, a known material used for a vacuum heat insulating material can be used without limitation. Examples of the airtight film 2 having the heat-welding layer 1 used as the material of the covering material 3 include a laminate film having a gas barrier layer and a surface protective layer. As the laminate film, for example, a laminate film having a metal foil or a metal vapor deposition layer as a gas barrier layer on one surface of the surface protective layer can be applied. In this case, the outer cover material has a heat welding layer on the innermost side, a metal foil or a metal vapor deposition layer as an intermediate layer, and a surface protective layer as an outermost layer. In addition, the laminate film may be applied by combining two types of laminate films, ie, a laminate film having a metal foil and a laminate film having a metal vapor-deposited layer.

The heat-welded layer may be composed of a film made of the material constituting the heat-welded layer described above or a composite obtained by combining these films. As the surface protective layer, known materials such as nylon film, polyethylene terephthalate film, and stretched polypropylene film can be used.

As the core material, a known core material used for a vacuum heat insulating material can be used. Specifically, a core material obtained by processing a porous body having a gas phase ratio of about 90% into a plate shape is used. Examples of the porous body that can be industrially used include foams, powders, and fiber bodies having air permeability. These can use a well-known material according to the use use and required characteristic.

Among these, as the foam, open-cell bodies such as urethane foam, styrene foam, and phenol foam can be used. In view of facilitating evacuation at the time of vacuum encapsulation, the air flow rate of the open cell body used as the core material is preferably 1 cm ³ / cm ² sec or more. In addition, inorganic, organic, and mixtures thereof can be used as the powder, but industrially, powders mainly composed of dry silica, wet silica, pearlite, and the like can be used.

In addition, inorganic, organic, and mixtures thereof can be used as the fibrous body, but inorganic fibers are advantageous from the viewpoint of cost and heat insulation performance. As an example of the inorganic fiber, a known material such as glass wool, glass fiber, alumina fiber, silica alumina fiber, silica fiber, rock wool, or the like can be used.

Furthermore, mixtures and composites of these foams, powders, and fiber bodies can also be applied to the core material. Specific examples of such a core material include a composite of a porous powder and a fibrous body, for example, an airgel blanket.

Among these, the core material in which the heat insulating material containing powder is formed into a plate shape will be described below. As the heat insulating material of the core material containing powder, it is preferable that either or both of fibers and binders are contained in addition to the powder from the viewpoint of easily obtaining a high-strength core material.

<< Powder >>
The case of a core material containing powder will be described below as an example.
As powder, the well-known powder normally used for a core material can be used. Specific examples include fumed silica, porous silica, and a radiation suppressing material. The powder preferably contains fumed silica from the viewpoint of easily obtaining a core material having sufficient strength.
Only one type of powder may be used, or two or more types may be used in combination.

Since fumed silica is an extremely fine powder, a specific surface area is usually used as an index representing the particle size.

The specific surface area of the fumed silica is preferably 50 ~ 400m ² / g, more preferably 100 ~ 350m ² / g, particularly preferably 200 ~ 300m ² / g. If the specific surface area of fumed silica is not less than the lower limit of the above range, excellent heat insulating performance can be easily obtained. If the specific surface area of fumed silica is not more than the upper limit of the above range, it is easy to attach a binder to the surface of the particles.
The specific surface area is measured by a nitrogen adsorption method (BET method).

Specific examples of fumed silica include Aerosil 200 (specific surface area 200 m ² / g, manufactured by Nippon Aerosil Co., Ltd.), Aerosil 300 (specific surface area 300 m ² / g, manufactured by Nippon Aerosil Co., Ltd.), CAB-O-SIL. M-5 (specific surface area 200 m ² / g, manufactured by Cabot Japan KK), CAB-O-SIL H-300 (specific surface area 300 m ² / g, manufactured by Cabot Japan KK), Leoroseal QS30 (specific surface area 300 m ² / g) , Manufactured by Tokuyama Corporation).
Fumed silica may use only 1 type and may use 2 or more types together.

When used in combination porous silica, the specific surface area of porous silica is preferably 100 ~ 800m ² / g, more preferably 200 ~ 750m ² / g, particularly preferably 300 ~ 700m ² / g. If the specific surface area of the porous silica is not less than the lower limit of the above range, excellent heat insulating performance can be easily obtained. When the specific surface area of the porous silica is not more than the upper limit of the above range, the amount of the binder absorbed by the porous silica can be reduced when the binder is used. Therefore, the core material can be molded with a lower pressure even if the amount of the binder to be added is small. As a result, the density of the core material can be lowered, and excellent heat insulation performance can be easily obtained.

The porosity of the porous silica is preferably 60 to 90%, more preferably 65 to 85%, and particularly preferably 70 to 80%. If the porosity of the porous silica is equal to or higher than the lower limit of the above range, the heat conduction of the solid can be reduced, so that excellent heat insulation performance is easily obtained. When the porosity of the porous silica is not more than the upper limit of the above range, the porous silica particles are hardly crushed at the time of molding, and excellent heat insulating performance is easily obtained because the porosity is maintained.
The porosity of the porous silica is measured by a nitrogen adsorption method (BJH method).

The average particle diameter of the porous silica is preferably 1 to 300 μm, more preferably 2 to 150 μm, and particularly preferably 3 to 100 μm, when measured on a volume basis by the Coulter counter method. If the average particle diameter of the porous silica is not less than the lower limit of the above range, porous silica having a high porosity can be easily obtained, and excellent heat insulation performance can be easily obtained. If the average particle diameter of the porous silica is not more than the upper limit of the above range, the density of the core material does not become too high, and excellent heat insulation performance is easily obtained.

Specific examples of porous silica include M.I. S. GEL and sunsphere (both manufactured by AGC S-Tech Co., Ltd.) are included.

Examples of the radiation suppressing material include metal particles (aluminum particles, silver particles, gold particles, etc.), inorganic particles (graphite, carbon black, silicon carbide, titanium oxide, tin oxide, iron oxide, potassium titanate, etc.). It is done.

≪Binder≫
The heat insulating material can contain a binder in order to maintain the shape of the core material from the viewpoint that sufficient strength can be easily obtained even if the core material has a low density. For example, fumed silica can be used as powder, and a fumed silica with a binder can be obtained by previously applying a binder to the surface of the fumed silica. Binder applied to the surface of fumed silica allows fumed silica with binder or fumed silica with binder and other materials (porous silica, fibers, etc.) to adhere to each other even when the pressure during molding is low. The
Even if the binder is applied to the porous silica, the binder is absorbed by the porous silica, so that it is difficult to obtain the effect of the binder.

The binder may be an organic binder or an inorganic binder. Especially, as a binder, an inorganic binder is preferable from the point that heat conductivity is low and the outstanding heat insulation performance is easy to be obtained.
Examples of the inorganic binder include sodium silicate, aluminum phosphate, magnesium sulfate, magnesium chloride and the like. Among these, sodium silicate is particularly preferable because it is easy to obtain excellent heat insulation performance.

The binder is preferably dissolved in a solvent and used as a binder liquid, and more preferably an aqueous solution.

≪Fiber≫
When fibers are included in the heat insulating material, a high-strength core material is easily obtained.
As a fiber, the fiber normally used for a vacuum heat insulating material can be used, For example, a resin fiber and an inorganic fiber are mentioned. Of these, inorganic fibers are preferred because they have less outgas in a vacuum, can easily suppress a decrease in heat insulation performance due to a decrease in the degree of vacuum, and are excellent in heat resistance.

Examples of the inorganic fiber include alumina fiber, mullite fiber, silica fiber, glass wool, glass fiber, rock wool, slag wool, silicon carbide fiber, carbon fiber, silica alumina fiber, silica alumina magnesia fiber, silica alumina zirconia fiber, silica magnesia. Examples include calcia fiber.

The fiber length D30 of the fibers used is preferably 100 μm or more, and more preferably 200 μm or more. If fiber length D30 is more than the said lower limit, it will be easy to suppress that a core material will generate a crack.
The fiber length D90 of the fiber used is preferably 20 mm or less, and more preferably 10 mm or less. If the fiber length D90 is equal to or less than the above upper limit value, the fibers are not easily entangled with each other, so that they are easily mixed with the powder and the effect of the fibers is easily obtained.
The thickness (diameter) of the fiber is preferably 15 μm or less from the viewpoint of suppressing an increase in solid heat transfer due to the fiber. Moreover, the thickness (diameter) of the fiber is preferably 1 μm or more from the viewpoint of easily preventing the core material from cracking.

In this specification, “fiber length D30” means the fiber length at 30% in the cumulative number distribution curve where the total number of fiber length distributions obtained on the basis of the number is 100%. “Fiber length D90” means a fiber length at a point of 90% in a cumulative number distribution curve where the total number of fiber length distributions obtained on the basis of the number is 100%. The fiber length distribution is obtained from a frequency distribution and a cumulative number distribution curve obtained by randomly measuring the length of 50 or more fibers in a photograph observed with an optical microscope.

≪Powder, binder, fiber ratio≫
The proportion of fumed silica in the powder (100% by mass) is preferably 50 to 100% by mass, more preferably 70 to 100% by mass, and particularly preferably 80 to 100% by mass. If the ratio of fumed silica is not less than the lower limit of the above range, a core material with high strength can be easily obtained.

The proportion of porous silica in the powder (100% by mass) is preferably 0 to 50% by mass, more preferably 0 to 30% by mass, and particularly preferably 0 to 20% by mass. The larger the proportion of porous silica, the easier it is to obtain a vacuum heat insulating material with excellent heat insulating performance. If the ratio of the porous silica is not more than the upper limit of the above range, a core material with high strength can be easily obtained.

If the powder contains a pre-binder with fumed silica was applied a binder on the surface and the porous silica, the ratio M _{A /} M _B of the mass M _B of the mass M _A and the porous silica fumed silica before the binder imparting Is preferably 50/50 or more, more preferably 70/30 or more, and particularly preferably 80/20 or more. If the ratio M _{A /} M _B is more than the lower limit, it has excellent thermal insulation performance at lower density, and tends core material is obtained having a sufficient strength.

When the powder contains a radiation suppressing material, the proportion of the radiation suppressing material in the powder (100% by mass) is preferably 3 to 30% by mass, more preferably 5 to 25% by mass, and particularly 10 to 20% by mass. preferable. If the ratio of the radiation suppressing material is equal to or higher than the lower limit of the above range, the effect of the radiation suppressing material is easily obtained. If the ratio of a radiation suppression material is below the upper limit of the said range, since the increase in the solid heat transfer by a radiation suppression material can be suppressed, the outstanding heat insulation performance is easy to be obtained.

When using a fumed silica with a binder having a binder provided on the surface in advance, the binder ratio is preferably 0.1 to 15 parts by mass with respect to 100 parts by mass of the fumed silica before applying the binder, 10 parts by mass is more preferable, and 1 to 4 parts by mass is particularly preferable. When the ratio of the binder is equal to or higher than the lower limit of the above range, a core material having a lower density and sufficient strength can be easily obtained, and excellent heat insulation performance can be easily obtained. If the ratio of the said binder is below the upper limit of the said range, since the increase in the solid heat transfer by a binder can be suppressed, it is easy to suppress the fall of heat insulation performance.

In addition, if the shape maintenance property of the core material can be secured, it is preferable that the binder content in the heat insulating material is small in order to obtain better heat insulating performance. As long as the shape maintaining property of the core material can be ensured, the binder need not be applied to the fumed silica surface.

In addition, when fumed silica with a binder that has been previously provided with a binder is not used, such as when fumed silica, a binder and other components (porous silica, fibers, etc.) are mixed at the same time, The amount is preferably 0.1 to 15 parts by mass, more preferably 0.5 to 10 parts by mass, and particularly preferably 1 to 4 parts by mass with respect to 100 parts by mass of the body. If the binder ratio is at least the lower limit of the above range, a core material having a lower density and sufficient strength can be easily obtained, and excellent heat insulation performance can be easily obtained. If the ratio of a binder is below the upper limit of the said range, since the increase in the solid heat transfer by a binder can be suppressed, it is easy to suppress the fall of heat insulation performance.

When the powder is used as the core material, the preferred composition of the powder is a mass ratio, and fumed silica: porous silica: radiation suppression material is preferably 70 to 90: 0 to 20:10 to 20.

The fiber ratio is preferably 1 to 30 parts by mass, more preferably 2 to 20 parts by mass, and particularly preferably 4 to 10 parts by mass with respect to 100 parts by mass of the powder. When the fiber ratio is equal to or higher than the lower limit of the above range, a high-strength core material is easily obtained. If the ratio of the fiber is equal to or less than the upper limit of the above range, an increase in solid heat transfer due to the fiber can be suppressed, so that it is easy to suppress a decrease in heat insulation performance.

The configuration of the vacuum heat insulating material 10 </ b> A when the replacement material 7 shown in FIGS. 1A and 1B is made of the resin member 6 has been described above. In the vacuum heat insulating material 10A having the above-described configuration, an airtight resin member 6 is disposed in place of the core material 5 at a substantially central portion of the vacuum heat insulating material 10A, and the resin member 6 has an outer cover material 3 on both surfaces 6a and 6b. The heat-welded layer 1 is heat-welded. Accordingly, a portion of the vacuum heat insulating material 10A corresponding to the resin member 6 is penetrated from one surface layer to the other surface layer of the covering material 3 so as to leave a predetermined region from the outer peripheral surface of the resin member 6 to the inside. Even when processing such as making a hole or hitting a nail or the like is performed, the inside of the vacuum heat insulating material 10A can be stably maintained in a reduced pressure state. The vacuum heat insulating material 10A is useful as a vacuum heat insulating material capable of nailing and punching.

In the vacuum heat insulating material 10A, the core material is configured to have a through hole as a missing portion in a substantially central portion as shown in FIGS. 2A to 2C. However, the missing portion of the core material according to the present invention is not limited to the through hole. FIGS. 3A to 3C show an example in which the vacuum heat insulating material 10A has a substantially square plate-like core material whose outer shape is substantially the same, but the missing portion of the core material is not a through hole. Note that in this specification, the term “square” includes a quadrangle that is not a square.

FIG. 3A shows that the square core material 5 has a notch part that is cut out so as to penetrate a substantially central part of one side in a square shape smaller than the core material in the plate thickness direction, and close the missing part. An example is shown in which a replacement material 7 made of an airtight resin member 6 having substantially the same shape as the missing portion is disposed.

FIG. 3B shows that the square core material 5 has four missing portions cut out so as to penetrate in the plate thickness direction in a triangular shape having apexes at the four corners, and closes the missing portions. 4 shows an example in which four replacement members 7 made of an airtight resin member 6 having substantially the same shape as the missing portion are arranged.

FIG. 3C shows that the square core member 5 has a predetermined distance inside one side, is parallel to the side, has the same length as the side, has a predetermined width, and penetrates in the plate thickness direction. An example is shown in which a replacement material 7 having an airtight resin member 6 having substantially the same shape as the missing portion is provided so as to have the missing portion provided and close the missing portion.

Thus, the shape of the vacuum heat insulating material of the present invention is not particularly limited even when the missing portion of the core material is not a through hole as shown in FIGS. 2A to 2C. Further, the core material may have a missing portion obtained by combining a through hole as shown in FIGS. 2A to 2C and a notch as shown in FIGS. 3A to 3C. In consideration of heat insulation as a vacuum heat insulating material, the total area of the main surface of the missing portion (surface orthogonal to the thickness direction) is 20% of the area of the main surface of the core material (not including the missing portion). It is preferable that

The replacement material 7 shown in FIGS. 3A to 3C, which is disposed so as to close the missing portion of the core material and is made of the airtight resin member 6 having substantially the same shape as the missing portion, is shown in FIGS. 2A to 2C. The replacement material 7 made of the resin member 6 fitted in the through hole can be made in the same manner as the material, thickness, and the like. Further, with respect to processing such as drilling and nailing that may be performed on the replacement material 7 made of the resin member 6, the replacement material 7 made of the resin member 6 fitted in the through hole shown in FIGS. 2A to 2C is used. And you can do all the same.

Next, a vacuum heat insulating material 10B in which the replacement material 7 shown in FIGS. 4A and 4B is composed of the resin member 6 and the dissimilar material member 8 will be described. The vacuum heat insulating material 10B, as shown in detail in FIGS. 5A to 5C, is different from the vacuum heat insulating material 10A in the shape of the opening of the through hole 4 of the core material 5, and the replacement material 7 is different from the resin member 6. Except for the material member 8, it is the same as the vacuum heat insulating material 10A.

The relationship between the core material 5 having the through holes 4 in the vacuum heat insulating material 10B and the replacement material 7 made of the resin member 6 and the dissimilar material member 8 is shown in FIGS. 5A to 5C. 5A is a developed view, FIG. 5B is a plan view, and FIG. 5C is a cross-sectional view taken along line B′-B ′ in FIG. 5B. In the vacuum heat insulating material 10B, the core member 5 has a pair of main surfaces 5a, 5b having a square plate shape, and a through hole 4 having a circular opening at a substantially central portion. A replacement material 7 composed of a resin member 6 and a dissimilar material member 8 is disposed so as to fit in the through hole 4 of the core material 5.

The replacement material 7 has substantially the same size and shape as the portion cut out by the through hole 4. That is, the replacement material 7 has a cylindrical shape whose height is substantially equal to the thickness of the core material 5 and whose diameter is substantially equal to the diameter of the opening of the through hole 4, and is parallel to both surfaces 5 a and 5 b of the core material 5. A member having a pair of surfaces. Therefore, the main surface of the member in which the replacement material 7 is fitted in the through hole 4 of the core material 5 is a flat surface as a whole. In addition, about the thickness of the core material 5, it can do similarly to the thickness of the core material 5 in 10 A of vacuum heat insulating materials. Further, the surface of the replacement material 7 may be provided with a slight inclination with respect to both surfaces 5a and 5b of the core material 5 or with minute unevenness so that the surface can be bonded to the heat welding layer 1 on the surface. .

The replacement material 7 has a column-shaped dissimilar material member 8 that is substantially the same height as the replacement material 7 but has a diameter smaller than that of the replacement material 7 in a substantially central portion, and is a ring-shaped airtight resin member surrounding the periphery thereof. 6 is provided. That is, the resin member 6 has a pair of surfaces 6 a and 6 b parallel to both surfaces 5 a and 5 b of the core material 5, an outer peripheral surface 6 c in contact with the through hole inner surface 4 a of the core material 5, and the surfaces 6 a and 6 b. The dissimilar material member 8 is disposed so as to fit in the through hole, and the replacement material 7 is configured. The replacement member 7 is fitted into the through hole 4 of the core member 5 so that the outer peripheral surface 6 c of the resin member 6 is in contact with the inner surface 4 a of the through hole 4.

The dissimilar material member 8 is made of a material different from the resin of the resin member 6. In the replacement material 7, the resin member 6 is a member provided so that the reduced pressure state of the vacuum heat insulating material 10 </ b> B can be maintained even after processing. The dissimilar material member 8 is mainly provided in the vacuum heat insulating material 10 </ b> B, for example, with holes or nails. It is a layer provided for processing such as striking. Therefore, the material constituting the dissimilar material member 8 is preferably a material that can be easily processed. Specifically, a resin different from the resin of the resin member 6, rubber, wood, paper, fiber integrated material, ceramics, and the like can be given. Examples of the resin different from the resin of the resin member 6 include urethane resin, styrene resin, and silicone resin. The dissimilar material member 8 may have air permeability or airtightness.

The dissimilar material member 8 may have a structure in which a plurality of layers are laminated in a direction parallel to the surface or in a direction orthogonal to the surface, or may be composed of a single member. In the case of a plurality of layers, each layer may be made of the same material or different materials. For example, the upper surface and the bottom surface of the cylindrical shape, which are both surfaces of the dissimilar material member 8, are formed of a layer made of a resin that can be heat welded to the constituent material of the heat welding layer 1, 8 may be heat-welded to the heat-welding layer 1 of the jacket material 3 on the top and bottom surfaces. When the dissimilar material member 8 is heat-welded to the heat-welding layer 1 of the outer cover material 3 on the upper surface and the bottom surface in this way, for example, the dissimilar material member 8 as a whole is heat-welded different from the resin constituting the resin member 6. You may comprise with the constituent material of the layer 1, and resin which can be heat-welded.

5A-C, the dissimilar material member 8, the resin member 6, and the core material 5 have substantially the same thickness. However, the dissimilar material member 8 and the resin member are necessary as long as the effects of the present invention are not impaired. The thickness of the core material 5 of 6 may be increased or decreased. Specifically, the thickness of the dissimilar material member 8 and the resin member 6 with respect to the core material 5 can be made similar to the relationship between the thickness of the core material 5 and the thickness of the resin member 6 in the vacuum heat insulating material 10A. In addition, if it is in this range, the thickness of the dissimilar material member 8 and the thickness of the resin member 6 may be the same or different.

The resin member 6 can be the same as the resin member 6 in the vacuum heat insulating material 10A except that the shape is different. In the vacuum heat insulating material 10B, the resin member 6 is made of a resin that can be bonded to the material constituting the heat-welding layer 1, and the resin member 6 is air-tight with the heat-welding layer 1 of the jacket material 3 on a pair of surfaces 6a and 6b. It is joined so as to maintain the sex. In addition, when joining is performed by heat welding, the interface of the resin member 6 and the heat welding layer 1 does not exist clearly. In FIG. 4B, the interface when the resin member 6 and the heat-welding layer 1 are heat-welded is indicated by a broken line as the interface before heat-welding. Here, the interface corresponds to a pair of surfaces 6 a and 6 b included in the resin member 6.

Here, the resin member 6 and the heat welding layer 1 do not necessarily have to be joined to the entire surface 6a, 6b of the resin member 6. If necessary, a part of the end portions of the surfaces 6a and 6b may not be joined. Preferably, the resin member 6 and the heat-welding layer 1 are bonded on the entire surface 6a, 6b.

In the resin member 6, the wall thickness w <b> 1, which is the distance between the inner periphery and the outer periphery of the ring shape in the resin member 6, is preferably 5 mm or more in order to sufficiently exhibit the effect of the bonding with the heat welding layer 1.

In the vacuum heat insulating material 10B, a replacement material 7 having an airtight resin member 6 on the outer side and a dissimilar material member 8 on the inner side is disposed in place of the core material 5 at a substantially central portion of the vacuum heat insulating material 10B. Are bonded to the heat-welded layer 1 of the jacket material 3 on both surfaces so as to maintain airtightness. Therefore, by removing the covering material 3 corresponding to the different material member 8 from both sides of the vacuum heat insulating material 10B together with the different material member 8 from the vacuum heat insulating material 10B, the vacuum heat insulating material 10B corresponds to the different material member 8 It is possible to make a hole of the size to be. In that case, since the airtight resin member 6 of the replacement material 7 is not removed and remains as a part of the vacuum heat insulating material 10B, the interior of the vacuum heat insulating material 10B is stabilized even after the dissimilar material member 8 equivalent part is removed. It is possible to maintain a reduced pressure state.

When the vacuum heat insulating material 10B is used as described above, the hole can be drilled only by cutting only the outer covering material 3 corresponding to the dissimilar material member 8, so that the work efficiency is improved. Is advantageous.

Similarly, a part corresponding to the dissimilar material member 8 of the vacuum heat insulating material 10B is penetrated from one surface layer of the jacket material 3 to the other surface layer, and a process such as making a hole or hitting a nail or the like is performed. In this case, the presence of the resin member 6 can stably maintain the inside of the vacuum heat insulating material 10B in a reduced pressure state. In this case, by making the material of the dissimilar material member 8 a material advantageous for processing, the workability is improved as compared with the case where the entire replacement material 7 is constituted by the resin member 6.

Further, if necessary, in addition to the portion corresponding to the dissimilar material member 8 of the vacuum heat insulating material 10B, the resin member 6 is also subjected to vacuum processing to leave a predetermined region from the outer peripheral surface to the inside, and to cut off other portions. You may give to the heat insulating material 10B. Even when such processing is performed, the inside of the vacuum heat insulating material 10B can be stably maintained in a reduced pressure state after processing. Thus, the vacuum heat insulating material 10B is useful as a vacuum heat insulating material capable of nailing and punching.

Next, an example of the vacuum heat insulating material according to the embodiment in which the hole machining shown in FIGS. 6A and 6B, FIGS. 7A and 7B and FIGS. 8A and 8B is performed will be described. In addition, in the vacuum heat insulating material of this invention, when a substitution material has the hole shown to FIG. 6A, B, FIG. 7A, B, FIG. 8A, B, this hole is provided in the area | region except the peripheral part of a substitution material. If there is a hole in the peripheral region of the replacement material, there is a possibility that the adhesiveness at the joint between the resin member constituting the replacement material, the jacket material, and the heat welding layer cannot be secured. From such a viewpoint, the width of the peripheral edge portion is preferably 5 mm or more. Further, the interval between holes in the case where a plurality of holes are processed in the replacement material as in the vacuum heat insulating material of the embodiment shown in FIGS. 8A and 8B is also set to 5 mm or more for the same reason as the width of the peripheral portion. It is preferable.

The vacuum heat insulating material 10C shown in FIGS. 6A and 6B has an outer periphery in which the core material 5 has the through holes 4 at two locations, and each of the two through holes 4 is in contact with the inner surface 4a of the through hole of the core material 5. A replacement material 7 made of an airtight resin member 6 having a pair of surfaces 6a and 6b parallel to the surface 6c and both surfaces 5a and 5b of the core material 5 is fitted, and each replacement material 7 (= resin member 6) is abbreviated. Except for the point that the hole 9 is formed at a position corresponding to the central portion, it is the same as the vacuum heat insulating material 10A shown in FIGS. 1A and 1B.

In the vacuum heat insulating material 10C, the hole 9 formed at a position corresponding to the substantially central portion of the resin member 6 has a circular shape in one place in FIG. 6A, which is a plan view, and a square in the other place. It is. 6B is a cross-sectional view taken along the line CC of the vacuum heat insulating material 10C shown in FIG. 6A and passing through the center of the resin member 6 having the square holes 9. As shown in FIG.

The resin member 6 having the square hole 9 in the plan view in the vacuum heat insulating material 10C is, for example, a predetermined region extending from the outer peripheral surface of the resin member 6 to the inside in a portion corresponding to the resin member 6 included in the vacuum heat insulating material 10A. That is, it is the same as the structure which penetrated from one surface layer of the coating | covering material 3 to the other surface layer, and opened the hole 9, leaving the peripheral region. In the vacuum heat insulating material 10C, as shown in FIGS. 6A and 6B, the remaining predetermined region is a rectangular tube-shaped resin member 6 having a wall thickness w2 as a distance between the outer peripheral surface 6c and the inner peripheral surface. is there. The thickness w2 of the resin member 6 is preferably 5 mm or more from the viewpoint of stably maintaining a reduced pressure state in the vacuum heat insulating material 10C.

As shown in FIG. 6B, the resin member 6 is joined to both the surfaces 6a and 6b so as to maintain airtightness with the heat-welded layer 1 of the outer jacket material 3. According to the vacuum heat insulating material 10C having such a structure, although the hole 9 is provided, the inside thereof is stably maintained in a reduced pressure state to the same extent as the vacuum heat insulating material 10A.

The shape of the hole 9 shown in the vacuum heat insulating material 10C is circular or square in the plan view, but the shape is not particularly limited. For example, it may be an arbitrary shape made of a triangle, a quadrangle, a polygon, a substantially circular shape, a substantially elliptical shape, an L shape, and a combination thereof. Further, the inner surface of the vacuum heat insulating material 10C forming the hole 9 is formed to be perpendicular to the main surface of the resin member 6, but is not necessarily vertical in the vacuum heat insulating material of the embodiment of the present invention. There is no need, and a taper shape, a staircase shape, etc. may be sufficient as needed. From the viewpoint of workability, the inner surface forming the hole is preferably formed to be perpendicular to the main surface of the resin member 6.

A vacuum heat insulating material 10D shown in FIGS. 7A and 7B is obtained by removing the outer covering material 3 corresponding to the different material member 8 together with the different material member 8 from the vacuum heat insulating material 10B shown in FIGS. 4A and B. This is a hole-insulated vacuum heat insulating material obtained by opening a hole 9 having a size corresponding to.

The vacuum heat insulating material 10D having such a configuration has the above characteristics and also has good workability when a relatively large hole 9 is formed.

6A, B, 7A, and B, each replacement material has one hole, but the number of holes that the replacement material has in the vacuum heat insulating material of the present invention is not limited to one. 8A and 8B are a plan view (FIG. 8A) of a vacuum heat insulating material 10E having a plurality of holes drilled replacement materials, and a cross-sectional view taken along line EE of the vacuum heat insulating material 10E shown in FIG. 8A (FIG. 8B). Indicates.

The vacuum heat insulating material 10E shown in FIGS. 8A and 8B is provided with five smaller holes 9 instead of the single hole 9 that the resin member 6 has in the center in the vacuum heat insulating material 10D shown in FIGS. 7A and 7B. It is the vacuum heat insulating material of the structure comprised. The vacuum heat insulating material 10E is provided with one cylindrical hole 9 in the substantially central portion of the resin member 6 and four cylindrical holes 9 that are equally smaller around it.

In the vacuum heat insulating material 10E, in FIG. 8A and B, for example, the interval between the holes 9 indicated by w12, w13, etc. is preferably 5 mm or more. 8A and 8B, for example, the distance between the outer periphery of the resin member 6 in the hole 9 closest to the outer periphery of the resin member 6 indicated by w11, w14 and the like and the outer periphery of the resin member 6 is preferably 5 mm or more. By setting the intervals and distances to 5 mm or more, sufficient adhesion at the joint between the resin member 6 and the thermal welding layer 1 of the jacket material 3 can be secured. 8A and 8B, the intervals between the holes 9 are represented by w12 and w13, but the same applies to the intervals between the other holes 9. The distance between the hole 9 and the outer periphery of the resin member 6 is also representative of w11 and w14, but the same applies to the distance between the other hole 9 and the outer periphery of the resin member 6.

Note that the vacuum heat insulating material 10E corresponds to, for example, the five holes 9 shown in FIGS. 8A and 8B instead of the single dissimilar material member 8 provided in the center in the vacuum heat insulating material 10B shown in FIGS. 4A and 4B. Five dissimilar material members 8 are provided at positions where the outer material 3 corresponding to the dissimilar material member 8 is removed together with the dissimilar material member 8, and a hole 9 having a size corresponding to the dissimilar material member 8 is formed. Can be produced.

In the vacuum heat insulating material of the embodiment of the present invention, when there are substitution materials at a plurality of locations in the vacuum heat insulating material, the number and arrangement thereof are appropriately adjusted according to the application. In a vacuum heat insulating material having a replacement material at a plurality of locations, a part of a portion corresponding to the replacement material or a portion corresponding to all of the replacement material may be subjected to the above hole processing. Moreover, in the vacuum heat insulating material which has a substitute material in multiple places, the hole process does not need to be given to the part corresponded to all the substitute materials. Furthermore, when a hole is drilled in the replacement material, a plurality of holes may be drilled in one replacement material. Further, when a plurality of replacement materials are used, all of them may be replaced with a replacement material made of only a resin member, a replacement material made of a resin member and a different material member, or a combination thereof.

In the vacuum heat insulating material according to the embodiment of the present invention, the hole provided in the replacement material as described above is, for example, a fixing member when fixing the vacuum heat insulating material to the heat insulating material, for example, an application of wiring and / or piping. For example, it is used for applications such as disposing screws and nails, and applications where a vacuum heat insulating material is hung on a protrusion of a heat insulating material. In applications where the vacuum heat insulating material is hung on the protrusion of the heat insulating material, the heat insulating material itself may protrude to form a protrusion, and a hook or other hook provided on the heat insulating material may be used as the protrusion. Also good. When fixing the vacuum heat insulating material to the heat insulating material, another member may be provided between the vacuum heat insulating material and the heat insulating material.

Here, even when the hole is not drilled in the vacuum heat insulating material of the embodiment of the present invention, the vacuum heat insulating material is fixed to the heat insulating material by nailing the portion where the replacement member or the dissimilar material member is provided. can do. Similarly to the above, when fixing the vacuum heat insulating material to the heat insulating material, another member may be provided between the vacuum heat insulating material and the heat insulating material.

[Method of manufacturing vacuum insulation]
The method for manufacturing a vacuum heat insulating material of the present invention includes the following steps (1) to (5).
(1) A step of forming a through-hole penetrating in the plate thickness direction in a plate-shaped core material (2) An outer peripheral surface in contact with an inner surface of the through-hole of the core material and a pair of surfaces parallel to both surfaces of the core material A step of disposing a replacement material having an airtight resin member in the through hole so as to be fitted to the through hole. (3) An airtight film having a heat welding layer on one side is opposed to the heat welding layers. The step of storing the core material in which the replacement material is disposed inside the outer cover material that is arranged in such a manner (4) The inside of the outer cover material is brought into a reduced pressure state, and the outer periphery of the core material (5) Bonding the resin member to the heat-welded layer of the jacket material on the pair of surfaces, the step of closely adhering the entire region around the core material by heat-welding the heat-welded layers Process

Hereinafter, an example of an embodiment of the method for manufacturing a vacuum heat insulating material according to the present invention will be described with reference to FIG. 9, taking the method for manufacturing the vacuum heat insulating material 10A shown in FIGS. 1A and 1B as an example. The vacuum heat insulating material 10A is an example in which the resin member and the jacket material are joined by heat welding. In FIG. 9, reference numerals (1) to (5) correspond to the steps (1) to (5), respectively.

9 (1) shows a process of forming the through hole 4 in the plate-like core material 5. FIG. The means and method for forming the through hole 4 are not particularly limited. When a core material is processed into a plate shape and cut into a predetermined size, means and methods that are usually used can be applied as they are.

9 (2) shows a process of fitting a replacement material 7 made of an airtight resin member 6 having substantially the same shape and the same size as the through hole 4 into the through hole 4 of the core material 5. FIG. In this example, the resin member 6 and the replacement member 7 are the same member, and the reference numeral 6 (7) is used in FIG. The outer peripheral surface of the resin member 6 is formed so as to be in contact with the inner surface of the through hole, and the thickness of the core member 5 and the thickness of the resin member 6 are substantially the same. Here, the resin constituting the resin member 6 is composed of a heat-weldable layer and a heat-weldable layer on the inner surface of the jacket material 3 described in the next step.

In FIG. 9, (3) includes a core material 5 into which the resin member 6 obtained in the above step (2) is fitted, an airtight film having a heat-welded layer, and the film is bonded to the heat-welded layers. The process of accommodating in the inside of the jacket material 3 arrange | positioned so that may oppose is shown.

In (3), the outer cover material 3 has a structure in which two air-tight films having the same size and having a square shape having a heat-welded layer on one side are overlapped with the heat-welded layers of the respective films facing each other. This is a bag-shaped outer cover material in which three sides are heat-welded in advance with a predetermined width. That is, in the step (3), the jacket material 3 in which a part of the seal region Y finally composed of four sides is already formed is used. The core material 5 into which the resin member 6 is fitted is inserted into the inside of the cover material 3 formed into a bag shape. In addition, it is a method usually performed to use the jacket material formed into a bag shape in this way.

Thus, in the manufacturing method of the present invention, between the heat-welded layers facing the region (sealing region Y) located outside the outer periphery of the core material of the outer cover material in the step (4) and covering the entire periphery of the core material (sealing region Y). The step of closely adhering by thermal welding is a step of obtaining a state in which all of the seal regions Y are closely adhered by thermal welding in step (4). If a state where all the seal regions Y are in close contact is obtained in the step (4), a part of the seal region Y is already formed before the storing step (3) as described above, and the remaining seals in the step (4). A mode of performing an operation of bringing the region Y into close contact is also included in the manufacturing method of the present invention.

In FIG. 9, in (4) and (5), the bag-shaped outer covering material 3 in which the core material 5 in which the resin member 6 is fitted is housed in (3) is placed under reduced pressure, The opening part of the to-be-processed material 3 is closely_contact | adhered by the heat welding of the heat welding layers which oppose (process of said (4)). Thereafter, the outside of the jacket material 3 is returned to the atmospheric pressure condition, heat and pressure are applied to the region corresponding to the resin member 6 from the outside of the jacket material 3, and the resin member 6 is bonded to the heat welding layer through the surface. 10A of vacuum heat insulating materials are obtained by carrying out heat welding (process of (5)).

Here, in the above description, the step (5) is performed after the step (4). However, the step (5) may be performed before the step (4) or may be performed simultaneously. Usually, the steps (4) and (5) are performed in this order.

As a device for executing the step (4), a normally used device is used without particular limitation in a vacuum heat insulating material manufactured by inserting a plate-shaped core material into a bag-shaped jacket material. it can. In addition, the same conditions as in the case of producing the vacuum heat insulating material as described above using such an apparatus can be applied to the decompression conditions and the heat welding conditions during the production.

Note that, in the vacuum heat insulating material 10A, the degree of vacuum inside the jacket material 3 inside the seal region Y of the jacket material 3 is such that excellent heat insulating performance is obtained, and the life of the vacuum heat insulating material is increased. As described above, 1 × 10 ³ Pa or less is preferable, and 1 × 10 ² Pa or less is more preferable.

The manufacturing conditions are preferably set to conditions that can achieve the above degree of vacuum. Moreover, the material which comprises the heat welding layer which the jacket material 3 has is as above, In the case of the said heat welding, suitable welding temperature is set according to this material. Further, heat welding is usually performed under a pressurized condition of about 1 to 5 kg / cm ² .

The jacket material 3 has a temperature condition when heat and pressure are applied to the region corresponding to the resin member 6 from the outside of the jacket material 3 and the resin member 6 is thermally welded to the heat-welded layer through the surface. A suitable welding temperature is set according to the material constituting the thermal welding layer and the type of resin constituting the resin member 6. Moreover, as a pressure condition, the pressurization condition similar to the pressurization condition at the time of carrying out the heat welding of the said heat welding layers can be applied. The heating time is preferably about 1 to 15 seconds. Moreover, it is preferable to provide the cooling time which hold | maintains pressurization after a heating from a viewpoint of stabilizing heat welding. The cooling time is preferably about 1 to 15 seconds.

The vacuum heat insulating material according to the embodiment of the present invention has been described above by taking the vacuum heat insulating materials 10A to 10E shown in FIGS. 1A, B to 8A and B as examples. The design of the shape, material, and the like of each component can be changed as appropriate without departing from the spirit. Moreover, you may provide structural members other than having demonstrated above as needed. For example, the vacuum heat insulating material of the present invention can be a composite member that is combined with other heat insulating materials such as foamed or fiber-based materials and elastic members such as flexible polyurethane foam.

Moreover, although the manufacturing method of the vacuum heat insulating material of embodiment of this invention was demonstrated to the example of vacuum heat insulating material 10A with the schematic diagram shown in FIG. 9, in the manufacturing method of this invention, the limit which is not contrary to the meaning of this invention The conditions in each step, the order of steps, etc. can be changed as appropriate. Further, steps other than those described above may be provided as necessary.

Examples of the present invention will be described below, but the present invention is not limited to these examples.
[Example 1]
A vacuum heat insulating material A1 having the same configuration as the vacuum heat insulating material 10A shown in FIGS. 1A and 1B was manufactured by the manufacturing method shown in FIG.

(1) Production of plate-like core material 5 Fumed silica (trade name “Aerosil 300”, specific surface area 300 m ² / g, manufactured by Nippon Aerosil Co., Ltd., the same shall apply hereinafter) 40 parts by mass of sodium silicate A binder solution obtained by diluting 3.4 parts by mass (1.3 parts by mass in terms of solid content) of No. 3 (manufactured by AGC S-Tech Co., Ltd.) with 22.9 parts by mass of ion-exchanged water was mixed with a blender. Next, 40 parts by mass of fumed silica and M. as porous silica. S. 10 parts by weight of GEL (manufactured by AGC S-Tech Co., Ltd., average particle size 70 μm), 10 parts by weight of graphite (trade name “CP.B”, manufactured by Nippon Graphite Industry Co., Ltd.) as a radiation suppressing material, and further as inorganic fibers 10 parts by mass of silica magnesia calcia fiber (trade name “Super Wool”, D30: 227 μm, D90: 902 μm, manufactured by Shin Nippon Thermal Ceramics Co., Ltd.) was added and mixed with a blender to obtain a heat insulating material.

The obtained heat insulating material was put into a mold, pressed to form a flat plate of 150 mm long × 150 mm wide × 5 mm thick, and then heated at 200 ° C. for 1 hour to produce a core material.

(2) Formation of the through-hole 4 The through-hole 4 of 50 mm x 50 mm was formed in the center part of the core material 5 obtained by said (1) using the cutter.

(3) Insertion of replacement material 7 (resin member 6) Glass balloon as a filler (trade name “Glass Bubbles iM16K”, particle size D50; 20 μm, manufactured by 3M Japan Ltd.) 34 g and low density polyethylene (melting point 120 ° C.) A resin sheet obtained by processing 100 g of a compound resin (a closed cell resin having a porosity of 32% and a gas permeability of 0 cm ³ / cm ² sec) into a sheet of 50 mm × 50 mm × thickness 5 mm is used as the replacement material 7 (resin member 6). Prepared and fitted into the through hole 4 of the core member 5 having the through hole 4 obtained in (2) above.

(4) Depressurization sealing Two commercially available gas barrier films (ADY-134, manufactured by ADWY Co., Ltd., three-layer structure of heat welding layer / metal layer / surface protective layer) are superposed so that the heat welding layers face each other, The core material 5 in which the resin member 6 obtained in the above (3) was fitted was placed in the bag-shaped outer cover material 3 in which only three sides were heat-sealed, and placed in a vacuum chamber with a heat-sealing function. Thereafter, the pressure in the chamber was reduced to 3 Pa, and in this state, the opening of the bag-shaped outer covering material 3 was adhered and sealed by thermal welding between the thermal welding layers. Thereafter, the outside of the jacket material 3 was returned to atmospheric pressure conditions to obtain a vacuum heat insulating material precursor in which the portion corresponding to the core material 5 was 150 mm long, 150 mm wide, and 5 mm thick.

(5) Thermal welding by heating and pressurizing the corresponding portion of the replacement material 7 (resin member 6) Add the corresponding portion of the replacement material 7 (resin member 6) of the vacuum heat insulating material precursor obtained above from both sides of the jacket material 3. Heating was performed at 150 ° C. for 10 seconds under pressure (2 kg / cm ² ). Thereby, the vacuum heat insulating material A1 by which the substitute material 7 (resin member 6) was heat-welded with the heat welding layer of the jacket material 3 via the both surfaces was obtained.

[Example 2]
The vacuum insulation similar to Example 1 except that instead of the closed cell resin resin sheet, a low density polyethylene resin sheet processed to 50 mm × 50 mm × thickness 5 mm was used as the replacement material 7 (resin member 6). Material A2 was obtained.

[Example 3]
Except that the airgel blanket (trade name “PyrogelXT”, manufactured by Aspen Aerogels, Inc.) was cut as a core material 5 with a cutter into a length of 150 mm × width of 150 mm × thickness of 5 mm and then heated at 200 ° C. for 1 hour. A vacuum heat insulating material B1 similar to Example 1 was obtained.

[Example 4]
Except that the airgel blanket (trade name “PyrogelXT”, manufactured by Aspen Aerogels, Inc.) was cut as a core material 5 with a cutter into a length of 150 mm × width of 150 mm × thickness of 5 mm and then heated at 200 ° C. for 1 hour. A vacuum heat insulating material B2 similar to Example 2 was obtained.

(Drilling test)
In the center of the portion corresponding to the replacement material 7 (resin member 6) of the vacuum heat insulating materials A1, A2, B1 and B2 obtained as described above, from one surface layer surface to the other surface layer surface of the jacket material, respectively. A nail was driven so as to penetrate the hole, and a hole was made, but there was no change in the reduced-pressure sealed state of the portion corresponding to the core material 5 of the vacuum heat insulating materials A1, A2, B1, and B2.

(Thermal conductivity measurement)
When the thermal conductivity of the vacuum heat insulating materials A1 and A2 obtained as described above was measured, the thermal conductivity of A2 was higher than that of A1. It can be seen that although the vacuum heat insulating materials A1 and A2 have no difference in drilling workability, the vacuum heat insulating material A1 is superior in terms of heat insulating properties.

Further, when the thermal conductivity of the vacuum heat insulating materials B1 and B2 obtained as described above was measured, the thermal conductivity of B2 was higher than that of B1. It can be seen that although the vacuum heat insulating materials B1 and B2 have no difference in drilling workability, the vacuum heat insulating material B1 is superior in heat insulating properties.

The vacuum heat insulating material of the present invention can be applied to places where energy saving is required and where heat insulation, cold insulation and heat insulation are required. Specifically, for example, residential and building walls / roofs / floors / piping, solar / heat facilities, etc .; constant temperature baths, water heaters, hot water tanks, rice cookers, refrigerators, freezers, cold storage / cold storage tanks, Refrigerated gas tanks, vending machines, cooler boxes, cold covers, heat insulation and other cold insulation fields; notebook and liquid crystal projectors, photocopiers, batteries, fuel cells and other electrical and electronic equipment, and industrial equipment fields such as semiconductor manufacturing equipment Mobile fields such as automobiles, buses, trucks, cold trucks, trains, freight cars, ships, etc .; can be applied to plant piping, etc.

Moreover, since the outer periphery of the vacuum heat insulating material is mounted without being fixed when the vacuum heat insulating material of the present invention (FIG. 1A, FIG. 3C, etc.) is provided with a hole, the vacuum heat insulating material is changed even if the dimension of the surface to be insulated changes. Deformation stress is difficult to be transmitted. Further, it is particularly useful in applications where dimensional changes are large. Furthermore, if an elastic member such as flexible polyurethane foam is installed between the member to be insulated and the vacuum heat insulating material of the present invention, a higher heat insulating effect can be obtained.

10A, 10B, 10C, 10D, 10E, 10F ... Vacuum heat insulating material 1 ... Thermal welding layer, 2 ... Film, 3 ... Jacket material, 4 ... Through hole, 5 ... Core material, 6 ... Resin member, 7 ... Replacement material 8, dissimilar material member, 9 ... hole, Y ... seal region.

Claims (11)

1. A jacket material formed by arranging an airtight film having a heat-welded layer on one side so that the heat-welded layers face each other;
   A plate-like core material having a missing portion penetrating in the thickness direction;
   A replacement material having an airtight resin member having a pair of surfaces substantially parallel to the main surface of the core material, which is disposed in the missing portion so as to close the missing portion,
   A core material in which the replacement material is disposed is housed in the outer jacket material, and an area extending outside the outer periphery of the core material and covering the entire periphery of the core material is between the heat-welded layers. A vacuum heat insulating material that is in close contact by heat welding and in which the inside of the outer cover material is in a reduced pressure state, wherein the resin member is bonded to the outer cover material so that airtightness is maintained.
2. At least the vicinity of the pair of surfaces of the resin member is made of a heat-weldable resin with a constituent material of the heat-welding layer, and the resin member is heat-welded with the heat-welding layer of the jacket material on the pair of surfaces. The vacuum heat insulating material according to claim 1.
3. The vacuum heat insulating material according to claim 1 or 2, wherein the ratio of the thickness of the replacement material to the thickness of the core material is 0.8 to 1.2.
4. 4. The vacuum heat insulating material according to claim 1, wherein the resin member is a closed cell resin member having a porosity of 10 to 98%.
5. The vacuum heat insulating material according to any one of claims 1 to 4, wherein the replacement material is composed of only the resin member.
6. The resin member has a through-hole penetrating in a direction orthogonal to the surface, and the replacement material is different from the resin of the resin member disposed so as to be fitted into the through-hole of the resin member. The vacuum heat insulating material according to any one of claims 1 to 4, further comprising a dissimilar material member made of a material.
7. The vacuum heat insulating material according to claim 6, wherein the material constituting the dissimilar material member is a resin, rubber, wood, paper, fiber integrated material, or ceramics different from the resin of the resin member.
8. The vacuum heat insulating material according to any one of claims 1 to 7, wherein a hole is formed in a region excluding a peripheral edge portion of the replacement material.
9. The hole processed hole is selected from passing wiring and / or piping, arranging a fixing member for fixing the vacuum heat insulating material to the heat insulating material, and hanging the vacuum heat insulating material on the protrusion of the heat insulating material. The vacuum heat insulating material of Claim 8 used for the use used.
10. Form a missing part that penetrates in the plate thickness direction in the plate-shaped core material,
    A replacement material having a gas-tight resin member having a pair of surfaces substantially parallel to the main surface of the core material is disposed in the missing portion so as to close the missing portion,
    A core material in which the replacement material is disposed is housed in an outer cover material in which an airtight film having a heat-welded layer on one side is disposed so that the heat-welded layers face each other. The inside of the material is in a reduced pressure state, the region located outside the outer periphery of the core material and covering the entire periphery of the core material is adhered by heat welding of the heat welding layers, and the resin member is attached to the pair The manufacturing method of the vacuum heat insulating material joined to the said heat welding layer of the said jacket | cover material in the surface.
11. The bonding between the resin member and the thermal welding layer of the jacket material is performed by heat-bonding the outer jacket material region corresponding to the pair of surfaces of the resin member from outside the jacket material. The manufacturing method of the vacuum heat insulating material of Claim 10 performed by this.

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