JP5239345B2 - Manufacturing method of thermal insulation panel for building - Google Patents
Manufacturing method of thermal insulation panel for building Download PDFInfo
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- JP5239345B2 JP5239345B2 JP2008004754A JP2008004754A JP5239345B2 JP 5239345 B2 JP5239345 B2 JP 5239345B2 JP 2008004754 A JP2008004754 A JP 2008004754A JP 2008004754 A JP2008004754 A JP 2008004754A JP 5239345 B2 JP5239345 B2 JP 5239345B2
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Images
Classifications
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/24—Structural elements or technologies for improving thermal insulation
- Y02A30/242—Slab shaped vacuum insulation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
- Y02B80/10—Insulation, e.g. vacuum or aerogel insulation
Landscapes
- Building Environments (AREA)
Description
本発明は、建築用断熱パネルの製造方法に関するものであり、詳しくは、建物の壁、または天井に使用される高断熱性の建築用断熱パネルであって、真空断熱板と発泡樹脂製の断熱材とを積層した構造の建築用断熱パネルの製造方法に関するものである。 The present invention relates to a method of manufacturing a building insulation panels, and more particularly, a building wall or used on the ceiling a high heat insulating property of the building insulation panels, vacuum insulation panels with a foam insulation, the wood to a method for manufacturing a building thermal insulation panels having a structure laminated.
木造または鉄骨木造の建物においては、施工性に優れ且つ十分な耐力を発揮し得ることから、方形に組まれた木枠などの枠組に断熱材が予め収められた規格寸法の断熱パネルを柱の間や根太の間に配置して壁や床を構成する工法が普及している。そして、上記の様な断熱パネルにおいては、断熱性能を一層高めるため、ガスバリア性フィルムから成る扁平な袋にシリカ等の芯材（充填材）を収容し且つ袋内部を真空引きした薄板状のいわゆる真空断熱板の利用が種々検討されており、斯かる真空断熱板は、その表面フィルムの損傷によるリークを防止し且つ断熱性能を更に高める観点から、発泡樹脂の断熱材と併用されている。 In a wooden or steel-framed building, because it is excellent in workability and can exhibit sufficient proof stress, a heat insulating panel with a standard size in which heat insulating material is preliminarily stored in a rectangular frame such as a wooden frame is used as a pillar. The construction method which arrange | positions between a wall and a joist and comprises a wall and a floor has prevailed. In the heat insulation panel as described above, in order to further improve the heat insulation performance, a so-called thin plate-like material in which a core material (filler) such as silica is accommodated in a flat bag made of a gas barrier film and the inside of the bag is evacuated. Various uses of a vacuum heat insulating plate have been studied, and such a vacuum heat insulating plate is used in combination with a foamed resin heat insulating material from the viewpoint of preventing leakage due to damage of the surface film and further improving the heat insulating performance.
真空断熱板と発泡樹脂断熱材を併用した断熱パネルとしては、例えば、真空断熱板の全面（前後面および厚さ部分）をポリスチレン系発泡樹脂の断熱材で覆った断熱パネルが挙げられる。斯かる断熱パネルの製造においては、発泡樹脂成形体から成り且つ凹溝が設けられたブロック状の支持体を成形金型のキャビティ内の外周部に複数配置し、これら支持体の凹溝に真空断熱板の外周部を挟むことにより、当該真空断熱板をキャビティ内で浮かせた状態で支持し、真空断熱板の両面側に原料の粒状樹脂（ビーズ）を充填して発泡させることにより、支持体と一体化させた発泡樹脂の断熱材を形成している。
また、上記の構造の断熱パネルとしては、枠体の一面に石膏ボードを貼り付け、これを底面として枠体内に発泡樹脂成形体から成る板状断熱材を収容し、その上に当該発泡樹脂成形体よりも小面積の真空断熱板を積層収容し、更に、上面側からウレタン樹脂を注入し且つ炭酸ガス発泡させて断熱材を形成した断熱パネルが提案されている。斯かる断熱パネルは、真空断熱板の周縁部を露出させない構造とすることにより、真空断熱板の損傷防止を企図したものである。
ところで、上記の様な断熱パネルは、予め成形された発泡樹脂断熱材と真空断熱板を積層したものに比べ、断熱材を発泡成形して真空断熱板に対する密着性を高めるため、優れた断熱性能が得られる。しかしながら、断熱材を成形する際に支持体により真空断熱板の周縁を支持したり、断熱材よりも小面積の真空断熱板を使用するため、平面視した場合の真空断熱板の外周側における熱橋が大きくなり、真空断熱板の熱に対する遮蔽効果が十分に発揮されないと言う実情がある。更に、真空断熱板の両面で断熱材を発泡成形した場合には、発泡圧力の不均衡により、真空断熱板が湾曲することがある。 By the way, the heat insulation panel as described above is superior in heat insulation performance because the heat insulation material is foam-molded to improve the adhesion to the vacuum heat insulation plate, compared with the one obtained by laminating the pre-formed foam resin heat insulation material and the vacuum heat insulation plate. Is obtained. However, when forming the heat insulating material, the peripheral edge of the vacuum heat insulating plate is supported by the support, or a vacuum heat insulating plate having a smaller area than the heat insulating material is used. There is a situation that the bridge becomes large and the heat shielding effect of the vacuum heat insulating plate is not sufficiently exhibited. Further, when the heat insulating material is foam-molded on both surfaces of the vacuum heat insulating plate, the vacuum heat insulating plate may be bent due to an imbalance of foaming pressure.
本発明は、上記の実情に鑑みてなされたものであり、その目的は、真空断熱板と発泡樹脂の断熱材とが積層された構造の断熱パネルであって、より一層断熱性能に優れた建築用断熱パネルの製造方法を提供することにある。 The present invention has been made in view of the above circumstances, and an object of the present invention is a heat insulating panel having a structure in which a vacuum heat insulating plate and a heat insulating material of foamed resin are laminated, and has a further excellent heat insulating performance. and to provide a manufacturing method of use insulation panels.
上記の課題を解決するため、本発明においては、建物の躯体の一部を構成する木枠を使用し、当該木枠に真空断熱板を収容し且つ木枠を成型機のプレス板に挟み付け、木枠内に原料樹脂を充填、発泡させて真空断熱板の両面に断熱材を形成する。その際、本発明では、木枠の内縁長さに相当する平面寸法の真空断熱板を使用することにより、木枠に対して真空断熱板を隙間なく収め、しかも、木枠内の所定位置に支持した真空断熱板の両面側で同時に原料樹脂を発泡させることにより、木枠内における真空断熱板の変形や偏りを防止する様にした。 In order to solve the above problems, in the present invention, a wooden frame constituting a part of a building frame is used, a vacuum heat insulating plate is accommodated in the wooden frame, and the wooden frame is sandwiched between press plates of a molding machine. The raw material resin is filled in the wooden frame and foamed to form a heat insulating material on both sides of the vacuum heat insulating plate. At that time, in the present invention, by using a vacuum heat insulating plate having a plane size corresponding to the inner edge length of the wooden frame, the vacuum heat insulating plate is accommodated in the wooden frame without any gap, and at a predetermined position in the wooden frame. By simultaneously foaming the raw material resin on both sides of the supported vacuum heat insulating plate, deformation and bias of the vacuum heat insulating plate in the wooden frame were prevented.
すなわち、本発明の要旨は、縦枠および横枠によって方形に組まれた木枠と、当該木枠に収められた真空断熱板と、前記木枠に収められて前記真空断熱板の両面を被服する発泡樹脂製の断熱材とから主として構成された建築用断熱パネルの製造方法であって、前記真空断熱板は、前記木枠に対して隙間なく収められ、前記断熱材は、前記真空断熱板の両面側に原料樹脂を充填し且つこれを発泡させて形成されており、そして、当該建築用断熱パネルを製造するに当たり、平面寸法が前記木枠の内縁長さに相当する前記真空断熱板を前記木枠に収容し且つ発泡樹脂成形体から成る角材状の支持材を前記内縁に沿わせて前記真空断熱板の両面側に配置すると共に、成型機の２つのプレス板で前記木枠をその厚さ方向から挟み付け、次いで、前記真空断熱板の両面側に各形成された空間部に対し、前記支持材と同質の原料樹脂を充填して同時に発泡させることにより、前記断熱材を形成することを特徴とする建築用断熱パネルの製造方法に存する。 That is, the gist of the present invention is that a wooden frame formed into a rectangular shape by a vertical frame and a horizontal frame, a vacuum heat insulating plate housed in the wooden frame, and a clothing on both sides of the vacuum heat insulating plate housed in the wooden frame. A heat insulating panel for building mainly composed of a heat insulating material made of foamed resin, wherein the vacuum heat insulating plate is stored in the wooden frame without a gap, and the heat insulating material is the vacuum heat insulating plate. of which the raw material resin is formed by foaming it and filled on both sides, and that when manufacturing the building thermal insulation panels, said vacuum insulation plate plane dimension corresponds to the inner edge length of the crate A square-shaped support material made of a foamed resin molding and housed in the wooden frame is arranged on both sides of the vacuum heat insulating plate along the inner edge, and the wooden frame is moved by two press plates of a molding machine. Sandwiched from the thickness direction, then the true To space portion each formed on both sides of the insulating plate, manufacturing of the supporting material and the same quality of the raw material resin is filled by foaming simultaneously, building insulation panels, which comprises forming the heat-insulating material Lies in the way.
本発明に係る建築用断熱パネルによれば、木枠に対して真空断熱板が隙間なく収められ、真空断熱板の両面側に原料樹脂を充填し且つこれを発泡させて均一な厚さの断熱材が形成されているため、熱に対するより高い遮蔽効果が得られ、より一層優れた断熱性能が得られる。また、本発明に係る建築用断熱パネルの製造方法によれば、木枠に真空断熱板を隙間なく収め且つその両面側から角材状の支持材によって支持した状態において、真空断熱板の両面側に充填した原料樹脂を同時に発泡させることにより、支持材と一体化された均一な厚さの断熱材を形成するため、熱に対する遮蔽効果が高く、より一層断熱性能に優れた断熱パネルを製造することが出来る。 According to the heat insulating panel for building according to the present invention, the vacuum heat insulating plate is accommodated without gaps with respect to the wooden frame, and the both sides of the vacuum heat insulating plate are filled with the raw material resin and foamed so as to insulate the uniform thickness. Since the material is formed, a higher shielding effect against heat is obtained, and a further excellent heat insulating performance is obtained. Moreover, according to the manufacturing method of the heat insulating panel for building according to the present invention, the vacuum heat insulating plate is housed in the wooden frame without gaps, and is supported on the both surface sides of the vacuum heat insulating plate from the both surface sides by the square-shaped support material. By simultaneously foaming the filled raw material resin, a heat insulation panel with a uniform thickness integrated with the support material is formed, so that a heat insulation panel with a high heat shielding effect and further excellent heat insulation performance is manufactured. I can do it.
本発明の建築用断熱パネル（以下、「断熱パネル」と略記する。）並びに断熱パネルの製造方法の実施形態を図面に基づいて説明する。図１〜図６は、本発明の第１の態様に係る建築用断熱パネル及びその製造方法を示す図であり、図７は、本発明の第２の態様に係る建築用断熱パネルの内部構造示す図であり、図８〜図１０は、本発明の第３の態様に係る建築用断熱パネル及びその製造方法を示す図である。 DESCRIPTION OF EMBODIMENTS An embodiment of a heat insulating panel for building (hereinafter abbreviated as “heat insulating panel”) and a method for manufacturing a heat insulating panel according to the present invention will be described with reference to the drawings. FIGS. 1-6 is a figure which shows the heat insulation panel for buildings which concerns on the 1st aspect of this invention, and its manufacturing method, FIG. 7 is the internal structure of the heat insulation panel for buildings which concerns on the 2nd aspect of this invention. FIGS. 8-10 is a figure which shows the building thermal insulation panel which concerns on the 3rd aspect of this invention, and its manufacturing method.
本発明の断熱パネルは、木造または鉄骨木造の建物において、壁、床または天井を構成する構造部材として使用されるパネルであり、図３、図７及び図９に示す様に、縦枠（１０）及び横枠（１１）によって平面形状を方形、通常は長方形に組まれた木枠（１）と、当該木枠に収められた真空断熱板（３）と、木枠（１）に収められて真空断熱板（３）の両面を被服する発泡樹脂製の断熱材（７）（図６（ｂ）、図７（ｂ）及び図１０（ｂ）参照）とから主として構成される。 The heat insulation panel of the present invention is a panel used as a structural member constituting a wall, a floor, or a ceiling in a wooden or steel-framed building. As shown in FIGS. 3, 7, and 9, a vertical frame (10 ) And the horizontal frame (11), the plane shape is rectangular, usually rectangular, the wooden frame (1), the vacuum heat insulating plate (3) stored in the wooden frame, and the wooden frame (1). The heat insulating material (7) made of foamed resin (see FIGS. 6 (b), 7 (b) and 10 (b)) for covering both surfaces of the vacuum heat insulating plate (3).
本発明の断熱パネルの形態としては、種々の場所に適用可能な基本的な構成の第１の形態（図１〜図６参照）、間柱として機能する中間縦枠（１２）（図７参照）を配置して施
工性を高めた幅広構造の第２の形態、および、小面積の複数の真空断熱板（３）を使用して製造コストを低減した第３の形態（図８〜図１０参照）が挙げられる。
As a form of the heat insulation panel of this invention, the 1st form (refer FIGS. 1-6) of the basic composition applicable to various places, the intermediate | middle vertical frame (12) which functions as a stud (refer FIG. 7) The second form of the wide structure in which the workability is improved by arranging the structure, and the third form in which the manufacturing cost is reduced by using a plurality of vacuum heat insulating plates (3) having a small area (see FIGS. 8 to 10) ).
先ず、本発明の第１の態様に係る断熱パネルの製造方法および当該製造方法によって得られる断熱パネルについて説明する。 First, the manufacturing method of the heat insulation panel which concerns on the 1st aspect of this invention, and the heat insulation panel obtained by the said manufacturing method are demonstrated.
第１の態様に係る断熱パネルの製造においては、最初に、図１に示す様な木枠（１）を作製する。木枠（１）の材料としては、一般的な建築用パネルと同様に、構造用に適した各種木材や集成材から成る角材が使用される。木枠（１）の組立においては、通常、螺子または釘と接着剤とを使用し、平面形状が長方形となる様に、長辺部を構成する一組の縦枠（１０）と、短辺部を構成する一組の横枠（１１）と連結する。 In manufacturing the heat insulating panel according to the first aspect, first, a wooden frame (1) as shown in FIG. 1 is produced. As a material of the wooden frame (1), a square bar made of various kinds of wood and laminated wood suitable for a structure is used as in a general building panel. In assembling the wooden frame (1), usually a screw or nail and an adhesive are used, and a pair of vertical frames (10) constituting the long side portion and a short side so that the planar shape is rectangular. It connects with a set of horizontal frames (11) which comprise a part.
通常、木枠（１）を構成する角材の幅（縦枠（１０）及び横枠（１１）においてこれらの長さ方向に直交し且つ断熱パネルを形成した場合にその面方向に沿った角材の断面長さ）は３０〜１５０ｍｍに設計され、角材の厚さ（断熱パネルを形成した場合にその厚さに相当する角材の断面長さ）は８８〜１４０ｍｍに設計される。そして、木枠（１）の長辺部の外形長さは５００〜３０００ｍｍ、短辺部の外形長さは２００〜５００ｍｍに設計される。 Usually, the width of the square bars constituting the wooden frame (1) (the vertical frame (10) and the horizontal frame (11) are perpendicular to these length directions and when the heat insulation panel is formed, The cross-sectional length) is designed to be 30 to 150 mm, and the thickness of the square (the cross-sectional length of the square corresponding to the thickness when a heat insulating panel is formed) is designed to be 88 to 140 mm. And the external length of the long side part of a wooden frame (1) is 500-3000 mm, and the external length of a short side part is designed to 200-500 mm.
更に、図１に示す様に、木枠（１）の一辺部、通常、短辺部を構成する横枠（１１）には、後述する様に断熱材（７）の原料樹脂を充填するための一対の樹脂充填穴（１ｃ）が予め設けられる。これら樹脂充填穴（１ｃ）は、通常、横枠（１１）の長さの中央に相当する位置の真空断熱板（３）の配置位置から外れた部位（断熱パネルを形成した場合に表側および裏側の各面に近い部位）に当該横枠の厚さ方向に沿って設けられる。一対の樹脂充填穴（１ｃ）は、平行な両方の横枠（１１）にそれぞれ設けられる。一方の横枠（１１）の樹脂充填穴（１ｃ）は、原料樹脂を充填する際に使用され、他方の横枠（１１）の樹脂充填穴（１ｃ）は、脱気穴として使用される。 Further, as shown in FIG. 1, the horizontal frame (11) constituting one side of the wooden frame (1), usually the short side, is filled with the raw material resin of the heat insulating material (7) as will be described later. A pair of resin filling holes (1c) is provided in advance. These resin-filled holes (1c) are usually located at positions corresponding to the center of the length of the horizontal frame (11), which are out of the arrangement position of the vacuum heat insulating plate (3) (front side and back side when a heat insulating panel is formed). Are provided along the thickness direction of the horizontal frame. A pair of resin filling holes (1c) are respectively provided in both parallel horizontal frames (11). The resin filling hole (1c) of one horizontal frame (11) is used when filling the raw material resin, and the resin filling hole (1c) of the other horizontal frame (11) is used as a deaeration hole.
木枠（１）を準備した後は、図５（ｂ）に示す様に、真空断熱板（３）を木枠（１）に収容し且つ発泡樹脂成形体から成る角材状の支持材（２）を木枠（１）の内縁に沿わせて真空断熱板（３）の両面側に配置する。そして、成型機（本体の図示は省略）の２つのプレス板（５）で木枠（１）をその厚さ方向から挟み付ける。 After preparing the wooden frame (1), as shown in FIG. 5 (b), a square-shaped support material (2) containing a vacuum heat insulating plate (3) in the wooden frame (1) and made of a foamed resin molded body. ) Are arranged on both sides of the vacuum heat insulating plate (3) along the inner edge of the wooden frame (1). And a wooden frame (1) is clamped from the thickness direction with two press plates (5) of a molding machine (illustration of a main body is abbreviate | omitted).
具体的には、図２に示す様に、先ず、木枠（１）の内縁に沿わせて支持材（２）を配置する。その場合、支持材（２）は、木枠（１）の一面側が下になる状態において、すなわち、木枠（１）を平面視した状態において、木枠（１）の底面側に偏らせた状態で配置する。支持材（２）としては、後述する断熱材（７）と同様の材料で予め発泡成形されたものを使用する。支持材（２）の幅（支持材（２）の長さ方向に直交し且つ縦枠（１０）及び横枠（１１）に沿わせた状態における断熱パネルの面方向に沿った断面長さ）は１０〜５０ｍｍに設計され、支持材（２）の厚さ（断熱パネルを形成した場合その厚さに沿った支持材（２）の断面長さ）３０〜１３０ｍｍに設計される。 Specifically, as shown in FIG. 2, first, the support member (2) is arranged along the inner edge of the wooden frame (1). In that case, the support material (2) is biased toward the bottom surface side of the wooden frame (1) in a state where the one surface side of the wooden frame (1) is down, that is, in a state in which the wooden frame (1) is viewed in plan. Arrange in a state. As the support material (2), a material previously foamed with the same material as the heat insulating material (7) described later is used. Width of support material (2) (cross-sectional length along the surface direction of the heat insulation panel in a state orthogonal to the length direction of support material (2) and along the vertical frame (10) and the horizontal frame (11)) Is designed to be 10 to 50 mm, and is designed to have a thickness of the support member (2) (a cross-sectional length of the support member (2) along the thickness when a heat insulating panel is formed) of 30 to 130 mm.
また、例えば横枠（１１）に沿わせて配置される支持材（２）には、上記の樹脂充填穴（１ｃ）に重畳する樹脂充填穴（２ｃ）が当該支持材の長さの中央に相当する部位に設けられる。樹脂充填穴（２ｃ）は、木枠（１）の樹脂充填穴（１ｃ）と同様に、各横枠（１１）に沿わせる支持材（２）に設けられる。上記の支持材（２）は、木枠（１）の内縁に対して接着剤や粘着剤で固定しておく。 Further, for example, in the support material (2) arranged along the horizontal frame (11), the resin filling hole (2c) overlapping the resin filling hole (1c) is formed at the center of the length of the support material. It is provided in the corresponding part. Similarly to the resin filling hole (1c) of the wooden frame (1), the resin filling hole (2c) is provided in the support member (2) along each horizontal frame (11). The support material (2) is fixed to the inner edge of the wooden frame (1) with an adhesive or an adhesive.
木枠（１）に支持材（２）を収めた後は、図３に示す様に、支持材（２）の上に真空断熱板（３）を配置する。真空断熱板（３）は、ガスバリア性フィルムで芯材（充填材）を
封入し且つ内部を真空引きして板状に形成されたものである。上記の様な真空断熱板の構造は、周知であり、特表２０００−５０７３４０号、特開２００５−１０６０９０号、特開２００７−０５６５４７号などの各公報に開示されている。
After the support material (2) is stored in the wooden frame (1), the vacuum heat insulating plate (3) is disposed on the support material (2) as shown in FIG. The vacuum heat insulating plate (3) is formed in a plate shape by enclosing a core material (filler) with a gas barrier film and evacuating the inside. The structure of the vacuum heat insulating plate as described above is well known and is disclosed in Japanese Patent Publication Nos. 2000-507340, 2005-106090, 2007-056547, and the like.
真空断熱板において、ガスバリア性フィルムとしては、厚さ１０〜１５μｍ程度のアルミニウム層を有する多層フィルムが使用される。斯かる多層フィルムの層構成は、例えば、高密度ポリエチレン（熱融着層）／アルミニウム（ガスバリア層）／ポリエチレンテレフタレート（補強層）／高密度ポリエチレン（熱融着層）、或いは、ポリエチレン／アルミニウム／ポリエステルポリエチレン／アルミニウム／ポリエチレン／ポリエステルポリプロピレン／アルミニウム／ポリエステルとされる。また、芯材としては、珪酸、シリカゲル、フライアッシュ等の無機粉末、ガラスウール等の無機繊維、ウレタン、スチレン、エチレン等の樹脂発泡体やポリウレタン硬質フォーム粉末などが挙げられ、これらは、補形性を高めるために予備圧縮されてもよい。 In the vacuum heat insulating plate, a multilayer film having an aluminum layer having a thickness of about 10 to 15 μm is used as the gas barrier film. The layer structure of such a multilayer film is, for example, high-density polyethylene (heat-bonding layer) / aluminum (gas barrier layer) / polyethylene terephthalate (reinforcing layer) / high-density polyethylene (heat-bonding layer), or polyethylene / aluminum / Polyester polyethylene / aluminum / polyethylene / polyester polypropylene / aluminum / polyester. In addition, examples of the core material include inorganic powders such as silicic acid, silica gel and fly ash, inorganic fibers such as glass wool, resin foams such as urethane, styrene and ethylene, and polyurethane rigid foam powder. It may be pre-compressed to enhance the properties.
上記の真空断熱板（３）としては、その平面寸法が木枠（１）の内縁の縦横の長さに相当する寸法のもが使用される。すなわち、木枠（１）には、平面視して当該木枠に隙間なく収まる大きさの真空断熱板（３）を配置する。本発明において、木枠（１）に配置された真空断熱板（３）と当該木枠との間に隙間のない状態とは、木枠（１）の一面側の断熱材（７）と他面側の断熱材（７）とを発泡成形した際（図６（ｂ）参照）、原料樹脂が真空断熱板（３）の縁部と木枠（１）との間に浸透して前記の２つの断熱材（７）が繋がった状態にならない限りにおいて、僅かな隙間があってもよく、斯かる隙間の大きさは５ｍｍ以下が好ましい。なお、真空断熱板（３）の厚さは、建材として要求される断熱性能と軽量化とを考慮し、１５ｍｍ以下、好ましくは５〜１０ｍｍに設計される。 As said vacuum heat insulation board (3), the dimension of the plane dimension corresponds to the length and width of the inner edge of a wooden frame (1) is used. That is, on the wooden frame (1), a vacuum heat insulating plate (3) having a size that fits in the wooden frame without a gap in a plan view is disposed. In the present invention, the state where there is no gap between the vacuum heat insulating plate (3) disposed on the wooden frame (1) and the wooden frame refers to the heat insulating material (7) on one side of the wooden frame (1) and the like. When foam-molding the surface-side heat insulating material (7) (see FIG. 6 (b)), the raw material resin penetrates between the edge of the vacuum heat insulating plate (3) and the wooden frame (1), and the above-mentioned As long as the two heat insulating materials (7) are not connected, a slight gap may be present, and the size of the gap is preferably 5 mm or less. The thickness of the vacuum heat insulating plate (3) is designed to be 15 mm or less, preferably 5 to 10 mm in consideration of heat insulating performance and weight reduction required as a building material.
真空断熱板（３）を配置した後は、図４に示す様に、前述の支持材（図２に示す支持材）と同様の支持材（２）を木枠（１）の内縁に沿わせて真空断熱板（３）の上面側から配置する。すなわち、上記の支持材（２）は、木枠（１）を平面視した状態において、木枠（１）の上面側に偏らせた状態で配置する。また、図４に示す支持材（２）のうち、例えば各横枠（１１）に沿わせる支持材（２）としては、図２に示す支持材と同様に、樹脂充填穴（２ｃ）が設けられたものを使用する。なお、図４に示す支持材（２）も、前述の支持材と同様に、木枠（１）の内縁に対して接着剤や粘着剤で固定しておく。 After the vacuum heat insulating plate (3) is arranged, as shown in FIG. 4, the same support material (2) as the above-mentioned support material (support material shown in FIG. 2) is placed along the inner edge of the wooden frame (1). And arrange from the upper surface side of the vacuum heat insulating plate (3). That is, said support material (2) is arrange | positioned in the state biased to the upper surface side of the wooden frame (1) in the state which planarly viewed the wooden frame (1). Also, among the support material (2) shown in FIG. 4, for example, as the support material (2) along each horizontal frame (11), a resin filling hole (2c) is provided as in the support material shown in FIG. Use what is provided. In addition, the support material (2) shown in FIG. 4 is also fixed to the inner edge of the wooden frame (1) with an adhesive or a pressure-sensitive adhesive, similarly to the support material described above.
なお、真空断熱板（３）の下面側および上面側の各支持材（２）は、後述する断熱材（７）の原料樹脂を発泡させる際に、木枠（１）内の所定位置に真空断熱板（３）を保持するために配置される。従って、木枠（１）の厚さの中央に相当する位置に真空断熱板（３）を配置する通常の場合は、真空断熱板（３）の下面側および上面側の各支持材（２）とも同等の厚さに設計されたものを使用し、また、木枠（１）の厚さの中央からずれた位置に真空断熱板（３）を配置する場合は、上記の各支持材（２）としてそれぞれに異なる厚さに設計されたものを使用する。 In addition, each support material (2) on the lower surface side and the upper surface side of the vacuum heat insulating plate (3) is vacuumed at a predetermined position in the wooden frame (1) when foaming raw material resin of the heat insulating material (7) described later. Arranged to hold the thermal insulation plate (3). Therefore, in the normal case where the vacuum heat insulating plate (3) is arranged at a position corresponding to the center of the thickness of the wooden frame (1), each support material (2) on the lower surface side and the upper surface side of the vacuum heat insulating plate (3). In the case where both of them are designed to have the same thickness and the vacuum heat insulating plate (3) is arranged at a position deviated from the center of the thickness of the wooden frame (1), each of the support materials (2 ) Are used with different thicknesses.
上記の様に真空断熱板（３）及びその支持材（２）を収めた木枠（１）は、図５に示す様に、成型機に装填してそのプレス板（５）で挟み付ける。斯かる操作においては、木枠（１）を破損することなく且つ原料樹脂の発泡圧力に耐え得る程度にプレス板（５）の加圧力を調節する。上記の操作により、木枠（１）の両面側（断熱パネルを形成した場合の表側および裏側）を２つのプレス板（５）で覆い、木枠（１）内の真空断熱板（３）の両面側に断熱材（７）の原料樹脂を充填するための空間部をそれぞれ形成する。 The wooden frame (1) containing the vacuum heat insulating plate (3) and the supporting material (2) as described above is loaded into a molding machine and sandwiched between the press plates (5) as shown in FIG. In such an operation, the pressing force of the press plate (5) is adjusted to such an extent that the wooden frame (1) is not damaged and can withstand the foaming pressure of the raw material resin. By the above operation, both sides of the wooden frame (1) (the front side and the back side when the heat insulating panel is formed) are covered with the two press plates (5), and the vacuum heat insulating plate (3) in the wooden frame (1) is covered. Space portions for filling the raw material resin of the heat insulating material (7) are formed on both sides.
上記の成型機としては、例えば、複数の被処理物を同時にプレス板で鉛直方向に加圧する多段式プレス方式の成型機を使用できる。図示を省略するが、斯かる成型機は、上面に平板状の第１のプレス板が水平に配置された基台と、当該基台の上方に配置され且つ鉛直
方向に進退可能な複数の油圧シリンダーを含む加圧装置と、基台の上方に第１のプレス板と平行に配列され且つ第１のプレス板から順次にリンクを介して連結された第２〜第６のプレス板とを備え、かつ、各油圧シリンダーのロッド先端が最上段の第６のプレス板に接続されており、油圧シリンダーの後退によって第２〜第６のプレス板が各上昇することにより、第１〜第６のプレス板の間に５つの加圧処理空間を構成し、油圧シリンダーの前進によって第２〜第６のプレス板が各下降することにより、各圧処理空間に装填された被処理物を一定圧力で且つ同時に加圧保持する様に構成される。
As the molding machine, for example, a multi-stage press molding machine that simultaneously pressurizes a plurality of objects to be processed with a press plate in the vertical direction can be used. Although not shown in the drawings, such a molding machine includes a base on which a flat plate-like first press plate is horizontally disposed, and a plurality of hydraulic pressures that are disposed above the base and can be advanced and retracted in the vertical direction. A pressurizing device including a cylinder, and second to sixth press plates arranged in parallel with the first press plate above the base and connected sequentially from the first press plate via a link. In addition, the rod tip of each hydraulic cylinder is connected to the uppermost sixth press plate, and the second to sixth press plates are raised by the retreat of the hydraulic cylinder, whereby the first to sixth Five pressurizing process spaces are formed between the press plates, and the second to sixth press plates are lowered by the advancement of the hydraulic cylinder, so that the workpieces loaded in the pressurizing process spaces can be simultaneously treated at a constant pressure. It is configured to hold under pressure.
また、図５に示す様に、上記の成型機に木枠（１）を装填する場合には、上下のプレス板（５）と木枠（１）との間に原料樹脂付着防止用の保護シート（４）を介在させるのが好ましい。保護シート（４）としては、アルミニウム、クラフト紙、各種合成樹脂などから成るフィルム又はシートが使用される。保護シート（４）の大きさは、木枠（１）の外形寸法よりも僅かに狭い大きさとされる。保護シート（４）は、通常、接着剤や粘着剤によって木枠（１）の両面に貼り付ける。保護シート（４）を介在させた場合には、後述する断熱材（７）の原料樹脂がプレス板（５）に付着するのを防止でき且つ製造された断熱パネルにおける断熱材（７）を保護することが出来、しかも、熱に対する遮蔽効果が得られる。 In addition, as shown in FIG. 5, when the wooden frame (1) is loaded into the molding machine, protection for preventing adhesion of the raw material resin between the upper and lower press plates (5) and the wooden frame (1). It is preferable to interpose a sheet (4). As the protective sheet (4), a film or sheet made of aluminum, kraft paper, various synthetic resins or the like is used. The size of the protective sheet (4) is slightly narrower than the external dimensions of the wooden frame (1). The protective sheet (4) is usually attached to both sides of the wooden frame (1) with an adhesive or an adhesive. When the protective sheet (4) is interposed, it is possible to prevent the material resin of the heat insulating material (7) described later from adhering to the press plate (5) and to protect the heat insulating material (7) in the manufactured heat insulating panel. In addition, a heat shielding effect can be obtained.
次いで、図６に示す様に、木枠（１）の例えば横枠（１１）に設けられた一対の樹脂充填穴（１ｃ）の一方に対し、原料樹脂充填ノズル（６）（図６中に実線で示したノズル）を装着する。原料樹脂充填ノズル（６）としては、例えば、先端に２流体混合ノズルが取り付けられ、１組の可撓性配管から供給された後述するイソシアネートとポリオール等、２つの原料組成物を混合しながら上記の空間部に射出可能に構成されたものが使用される。そして、本発明においては、真空断熱板（３）の両面側に各形成された上記の空間部に対し、支持材（２）と同質の発泡樹脂を構成する原料樹脂を充填して同時に発泡させることにより、断熱材（７）を形成する。 Next, as shown in FIG. 6, the raw material resin filling nozzle (6) (in FIG. 6) is inserted into one of the pair of resin filling holes (1c) provided in the horizontal frame (11) of the wooden frame (1). Install the nozzle shown by the solid line. As the raw material resin filling nozzle (6), for example, a two-fluid mixing nozzle is attached to the tip, and the two raw material compositions such as isocyanate and polyol described later supplied from one set of flexible pipes are mixed with each other as described above. What is constituted so that injection | emission is possible is used for the space part. And in this invention, with respect to said space part formed in the both surfaces side of a vacuum heat insulating board (3), it fills with the raw material resin which comprises the same quality foam resin as a support material (2), and it is made to foam simultaneously. Thereby, a heat insulating material (7) is formed.
断熱材（７）を構成する発泡樹脂としては、ウレタン樹脂、フェノール樹脂、ポリエチレン樹脂などが挙げられる。通常、断熱性および強度を高め、軽量化を図るため、ポリウレタン樹脂が使用される。周知の通り、ポリウレタンの発泡においては、アミン化合物などの触媒、水やフルオロカーボン等の発泡剤、シリコンオイル等の整泡剤などと共にポリイソシアネートとポリオールを混合することにより、気泡化反応と樹脂化反応を同時に進行させてポリウレタンフォームを得る。原料樹脂の充填においては、圧送ポンプを含む発泡装置から供給したポリイソシアネートとポリオール等の発泡原料とを上記の原料樹脂充填ノズル（６）で混合しながら上記の空間部に充填する。 Examples of the foamed resin constituting the heat insulating material (7) include urethane resin, phenol resin, and polyethylene resin. Usually, a polyurethane resin is used in order to increase heat insulation and strength and to reduce weight. As is well known, in polyurethane foaming, polyisocyanate and polyol are mixed with a catalyst such as an amine compound, a foaming agent such as water or fluorocarbon, a foam stabilizer such as silicon oil, and the like, thereby forming a bubble and a resin. Are simultaneously advanced to obtain polyurethane foam. In filling the raw material resin, the space portion is filled while mixing the polyisocyanate supplied from a foaming device including a pressure pump and a foaming raw material such as polyol by the raw material resin filling nozzle (6).
本発明においては、成型機のプレス板（５）で木枠（１）を保持した状態で真空断熱板（３）の両面側に形成される空間部に対し、充填された原料樹脂を同時に発泡させることが重要であり、これにより、木枠（１）内の所定位置に真空断熱板（３）を偏りなく配置でき且つ真空断熱板（３）の湾曲などの変形を防止できる。 In the present invention, the filled raw resin is simultaneously foamed into the spaces formed on both sides of the vacuum heat insulating plate (3) while holding the wooden frame (1) with the press plate (5) of the molding machine. Therefore, it is possible to arrange the vacuum heat insulating plate (3) at a predetermined position in the wooden frame (1) without deviation and to prevent deformation of the vacuum heat insulating plate (3) such as bending.
本発明において、原料樹脂の同時発泡とは、次の様な時間差を含む概念である。すなわち、上記の時間差は、真空断熱板（３）の一面側の空間部に充填された原料樹脂の発泡開始と、真空断熱板（３）の他面側の空間部に充填された原料樹脂の発泡開始との時間的差異であって、一方の原料樹脂の発泡による膨張力と他方の原料樹脂の発泡による膨張力とが真空断熱板（３）を介して適度に相殺され、真空断熱板（３）の変形や偏りが生じない限りおいて許容される時間差である。具体的には、原料組成、環境温度、射出流量などによっても異なるが、各空間部への原料樹脂の充填開始の時間差で通常は５秒以下、好ましくは３秒以下である。 In the present invention, the simultaneous foaming of the raw material resin is a concept including the following time difference. That is, the time difference is the start of foaming of the raw material resin filled in the space portion on the one surface side of the vacuum heat insulating plate (3), and the raw material resin filled in the space portion on the other surface side of the vacuum heat insulating plate (3). It is a time difference from the start of foaming, and the expansion force due to foaming of one raw material resin and the expansion force due to foaming of the other raw material resin are appropriately offset via the vacuum heat insulating plate (3), and the vacuum heat insulating plate ( This is an allowable time difference as long as the deformation or bias of 3) does not occur. Specifically, although it varies depending on the raw material composition, the environmental temperature, the injection flow rate, etc., it is usually 5 seconds or less, preferably 3 seconds or less, due to the time difference of starting filling of the raw material resin into each space.
従って、原料樹脂の充填操作では、上記の時間差の範囲内で行う限りにおいて、１つの原料樹脂充填ノズル（６）を使用して真空断熱板（３）の両面の各空間部に原料樹脂を充填することも出来る。すなわち、図６（ａ）に実線で示す様に横枠（１１）の一方の樹脂充填穴（１ｃ）から一方の空間部に原料樹脂を充填した後、上記の時間差の範囲において、図６（ａ）に仮想線で示す様に他方の樹脂充填穴（１ｃ）に原料樹脂充填ノズル（６）を装着し直して他方の空間部に原料樹脂を充填してもよい。 Therefore, in the raw material resin filling operation, as long as it is performed within the above time difference range, the raw material resin is filled in the space portions on both sides of the vacuum heat insulating plate (3) using one raw material resin filling nozzle (6). You can also That is, as shown by a solid line in FIG. 6A, after filling the raw resin into one space from one resin filling hole (1c) of the horizontal frame (11), within the above time difference range, FIG. As indicated by a virtual line in a), the other resin filling hole (1c) may be reattached with the raw material resin filling nozzle (6) to fill the other space with the raw material resin.
上記の様に、木枠（１）に原料樹脂を充填して発泡させることにより、図６（ｂ）に示す様に、発泡後の樹脂がこれと同一組成の支持材（２）と一体化する。そして、発泡させた樹脂を一定時間放置して完全に硬化させることにより、支持材（２）と一体化された発泡樹脂の断熱材（７）を真空断熱板（３）の両面側に形成し、断熱パネルを構成することが出来る。なお、製造された断熱パネルは、成型機のプレス板（５）を開放して取り出される。また、原料樹脂の充填発泡においては、前述の様な例えば５段式の成型機を使用することにより、５枚の断熱パネルを同時に製造することが出来る。 By filling the wooden frame (1) with the raw material resin and foaming as described above, the foamed resin is integrated with the support material (2) having the same composition as shown in FIG. 6 (b). To do. Then, the foamed resin is allowed to stand for a certain time to be completely cured, thereby forming a foamed resin heat insulating material (7) integrated with the support material (2) on both sides of the vacuum heat insulating plate (3). A heat insulation panel can be constructed. The manufactured heat insulation panel is taken out by opening the press plate (5) of the molding machine. In addition, in the filling and foaming of the raw material resin, five heat insulating panels can be manufactured simultaneously by using, for example, a five-stage molding machine as described above.
なお、上記の製造例では、真空断熱板（３）及び各支持材（２）を予め木枠（１）に収め、斯かる木枠（１）を成型機に装填したが、本発明においては、開放状態の成型機のプレス板（５）に木枠（１）を載せ、当該木枠に一方の支持材（２）、真空断熱板（３）及び他方の支持材（２）を順次に収めた後、プレス板（５）で木枠（１）を挟み付け、原料樹脂を充填、発泡させてもよい。 In the above manufacturing example, the vacuum heat insulating plate (3) and each support material (2) are previously stored in the wooden frame (1), and the wooden frame (1) is loaded in the molding machine. The wooden frame (1) is placed on the press plate (5) of the molding machine in an open state, and one supporting member (2), the vacuum heat insulating plate (3) and the other supporting member (2) are sequentially placed on the wooden frame. After storage, the wooden frame (1) may be sandwiched between press plates (5), filled with raw material resin, and foamed.
上記の様に、本発明の製造方法では、木枠（１）に真空断熱板（３）を隙間なく収め且つ当該真空断熱板の両面側から発泡樹脂成形体である角材状の支持材（２）によって支持した状態において、真空断熱板（３）の両面側に充填した原料樹脂を同時に発泡させることにより、支持材（２）と一体化された均一な厚さの断熱材（７）を形成する。従って、本発明の製造方法によれば、熱に対する遮蔽効果が高く、より一層断熱性能に優れた断熱パネルを製造することが出来る。そして、上記の製造方法によって得られる断熱パネルは、木枠（１）に対して真空断熱板（３）が隙間なく収められ、真空断熱板（３）の両面側に原料樹脂を充填し且つこれを発泡させて均一な厚さの断熱材（７）が形成されている。従って、本発明の断熱パネルによれば、熱に対するより高い遮蔽効果が得られ、より一層優れた断熱性能が得られる。また、断熱材（７）に埋め込まれた真空断熱板（３）の周縁部は、木枠（１）によって保護されており、施工時、施工後に損傷を受けることがない。 As described above, in the production method of the present invention, the vacuum heat insulating plate (3) is stored in the wooden frame (1) without any gap, and the square-shaped support material (2) which is a foamed resin molded body from both sides of the vacuum heat insulating plate. ), The material resin filled on both sides of the vacuum heat insulating plate (3) is simultaneously foamed to form a heat insulating material (7) of uniform thickness integrated with the support material (2). To do. Therefore, according to the manufacturing method of the present invention, it is possible to manufacture a heat insulating panel that has a high heat shielding effect and is further excellent in heat insulating performance. And the heat insulation panel obtained by said manufacturing method has a vacuum heat insulating board (3) stored without gap with respect to a wooden frame (1), fills both surfaces of a vacuum heat insulating board (3) with raw material resin, and this Is formed to form a heat insulating material (7) having a uniform thickness. Therefore, according to the heat insulation panel of this invention, the higher shielding effect with respect to a heat | fever is acquired, and the further more heat insulation performance is obtained. Moreover, the peripheral part of the vacuum heat insulating board (3) embedded in the heat insulating material (7) is protected by the wooden frame (1), and is not damaged after construction during construction.
次に、本発明の第２の態様に係る断熱パネルの製造方法および当該製造方法によって得られる断熱パネルについて説明する。第２の態様は、主に壁材として断熱パネルを使用するため、間柱に相当する中間縦枠を配置して木枠内を２つの枠組に構成した点が第１の態様と相違する。 Next, the manufacturing method of the heat insulation panel which concerns on the 2nd aspect of this invention, and the heat insulation panel obtained by the said manufacturing method are demonstrated. The second mode is different from the first mode in that a heat insulation panel is mainly used as a wall material, and therefore, an intermediate vertical frame corresponding to a stud is arranged and the inside of the wooden frame is configured into two frames.
第２の態様に係る断熱パネルの製造においては、図７に示す様に、木枠として、各横枠（１１）の中央に渡って架設された中間縦枠（１２）により左右２つの枠組に分割された木枠（１）を使用する。すなわち、木枠（１）は、一方の縦枠（１０）、中間縦枠（１２）及び平行な２つの横枠（１１）により１つの枠組を構成し、他方の縦枠（１０）、中間縦枠（１２）及び平行な２つの横枠（１１）により他の１つの枠組を構成している。縦枠（１０）、横枠（１１）及び中間縦枠（１２）の構成材料ならびに組立方法は第１の態様におけるのと同様である。通常、木枠（１）の長辺部の外形長さは５００〜３０００ｍｍ、短辺部の外形長さは４００〜１０００ｍｍに設計される。 In manufacture of the heat insulation panel which concerns on a 2nd aspect, as shown in FIG. 7, as a wooden frame, it is divided into two right and left frames by the intermediate | middle vertical frame (12) constructed over the center of each horizontal frame (11). Use the divided wooden frame (1). That is, the wooden frame (1) forms one frame by one vertical frame (10), an intermediate vertical frame (12), and two parallel horizontal frames (11), and the other vertical frame (10), intermediate The vertical frame (12) and two parallel horizontal frames (11) constitute another frame. The constituent materials and the assembly method of the vertical frame (10), the horizontal frame (11) and the intermediate vertical frame (12) are the same as those in the first embodiment. Usually, the outer length of the long side portion of the wooden frame (1) is designed to be 500 to 3000 mm, and the outer length of the short side portion is designed to be 400 to 1000 mm.
木枠（１）の一辺部、通常、短辺部を構成する横枠（１１）には、断熱材（７）の原料樹脂を充填するための一対の樹脂充填穴（１ｃ）が各枠組に対応して２組設けられる。各組の樹脂充填穴（１ｃ）は、各横枠（１１）において、一方の縦枠（１０）と中間縦枠（
１２）の中間に相当する位置、および、他方の縦枠（１０）と中間縦枠（１２）の中間に相当する位置に設けられる。そして、第１の態様におけるのと同様に、一方の横枠（１１）の各樹脂充填穴（１ｃ）は、原料樹脂を充填する際に使用され、他方の横枠（１１）の各樹脂充填穴（１ｃ）は、脱気穴として使用される。
A pair of resin filling holes (1c) for filling the raw material resin of the heat insulating material (7) is formed in each frame on the horizontal frame (11) constituting one side of the wooden frame (1), usually the short side. Two sets are provided correspondingly. In each horizontal frame (11), each set of resin filling holes (1c) has one vertical frame (10) and an intermediate vertical frame (
12) and at a position corresponding to the middle between the other vertical frame (10) and the middle vertical frame (12). As in the first aspect, each resin filling hole (1c) of one horizontal frame (11) is used when filling the raw material resin, and each resin filling of the other horizontal frame (11). The hole (1c) is used as a deaeration hole.
図示を省略するが、断熱材（７）の発泡成形においては、平面寸法が木枠（１）の各枠組の内縁長さに相当する真空断熱板（３）を上記の各枠組にそれぞれ収容し且つ発泡樹脂成形体から成る角材状の支持材（２）を各枠組の内縁に沿わせて各真空断熱板（３）の両面側に配置すると共に、成型機の２つのプレス板で支持材（２）をその厚さ方向から挟み付ける。そして、木枠（１）内の各枠組の真空断熱板（３）の両面側に断熱材（７）の原料樹脂充填用の空間部をそれぞれ形成する。 Although illustration is omitted, in the foam molding of the heat insulating material (7), the vacuum heat insulating plate (3) whose plane dimension corresponds to the inner edge length of each frame of the wooden frame (1) is accommodated in each frame. In addition, a square-shaped support material (2) made of a foamed resin molded body is disposed on both sides of each vacuum heat insulating plate (3) along the inner edge of each frame, and the support material ( 2) is sandwiched from the thickness direction. And the space part for raw material resin filling of a heat insulating material (7) is each formed in the both surface side of the vacuum heat insulating board (3) of each frame in a wooden frame (1).
なお、各真空断熱板（３）の両面側に配置する支持材（２）の構成は、第１の態様におけるのと同様である。また、成型機に木枠（１）を装填する際、上下のプレス板と木枠（１）との間に第１の態様におけるのと同様の原料樹脂付着防止用の保護シート（４）を介在させるのが好ましい。その場合、保護シート（４）としては、２つの枠組を個別に覆う面積のものを木枠（１）の両面に各２枚使用してもよいし、製造効率を高める観点から、各枠組を一括して覆う面積のものを木枠（１）の両面に各１枚使用してもよい。 In addition, the structure of the support material (2) arrange | positioned on both surfaces side of each vacuum heat insulating board (3) is the same as that in the 1st aspect. Further, when loading the wooden frame (1) into the molding machine, the same protective sheet (4) for preventing the adhesion of the raw material resin as that in the first aspect is placed between the upper and lower press plates and the wooden frame (1). It is preferable to intervene. In that case, as a protection sheet (4), you may use the thing of the area which covers two frames individually on both surfaces of a wooden frame (1), respectively, and from a viewpoint of improving manufacturing efficiency, each frame is used. You may use the thing of the area which covers collectively, one each on both surfaces of a wooden frame (1).
次いで、第１の態様と同様に、木枠（１）に設けられた各一対の樹脂充填穴（１ｃ）に原料樹脂充填ノズルを装着し、各真空断熱板（３）の両面側に各形成された空間部に対し、支持材（２）と同質の原料樹脂を充填して同時に発泡させることにより、各真空断熱板（３）の両面側に断熱材（７）を形成する。その他の操作は、第１の態様におけるのと同様である。上記の製造方法により、各横枠（１１）の中央に渡って架設された中間縦枠（１２）により２つの枠組に木枠（１）が分割され、各枠組に対して真空断熱板（３）及び断熱材（７）がそれぞれ配置された図７に示す構造の断熱パネルを製造できる。 Next, in the same manner as in the first aspect, the raw material resin filling nozzles are mounted in the respective pairs of resin filling holes (1c) provided in the wooden frame (1), and each is formed on both sides of each vacuum heat insulating plate (3). A heat insulating material (7) is formed on both side surfaces of each vacuum heat insulating plate (3) by filling the space portion thus filled with the same raw material resin as the support material (2) and simultaneously foaming. Other operations are the same as in the first embodiment. By the above manufacturing method, the wooden frame (1) is divided into two frames by the intermediate vertical frame (12) installed over the center of each horizontal frame (11), and the vacuum heat insulating plate (3) is divided into each frame. ) And the heat insulating material (7), respectively, can be manufactured.
上記の第２の態様に係る製造方法においても、第１の態様と同様に、木枠（１）の各枠組内に隙間なく配置された各真空断熱板（３）の両面側に支持材（２）と一体化された均一な厚さの断熱材（７）を形成するため、熱に対する遮蔽効果が高く、より一層断熱性能に優れた断熱パネルを製造することが出来る。また、上記の製造方法によって得られる断熱パネルにおいては、第１の態様と同様に、木枠（１）に対して各真空断熱板（３）が隙間なく収められ、これら真空断熱板（３）の両面側に均一な厚さの断熱材（７）が形成されているため、熱に対するより高い遮蔽効果が得られ、より一層優れた断熱性能が得られる。そして、第２の態様に係る断熱パネルは、間柱として利用可能な中間縦枠（１２）が木枠（１）に設けられているため、当該断熱パネルを配置するだけで建物の構造壁を簡単に構築できる。 Also in the manufacturing method according to the second aspect, as in the first aspect, support materials (3) are provided on both sides of each vacuum heat insulating plate (3) arranged without gaps in each frame of the wooden frame (1). Since the heat insulating material (7) having a uniform thickness integrated with 2) is formed, a heat insulating panel having a high shielding effect against heat and further excellent in heat insulating performance can be manufactured. Moreover, in the heat insulation panel obtained by said manufacturing method, similarly to the 1st aspect, each vacuum heat insulation board (3) is stored without gap with respect to a wooden frame (1), These vacuum heat insulation boards (3) Since the heat insulating material (7) having a uniform thickness is formed on both sides of the film, a higher shielding effect against heat can be obtained, and a further excellent heat insulating performance can be obtained. And since the heat insulation panel which concerns on a 2nd aspect is provided in the wooden frame (1) with the intermediate | middle vertical frame (12) which can be used as a stud, the structural wall of a building is easy only by arrange | positioning the said heat insulation panel. Can be built.
次に、本発明の第３の態様に係る断熱パネルの製造方法および当該製造方法によって得られる断熱パネルについて説明する。第３の態様は、製造コストを低減するため、小面積の複数の真空断熱板を使用した点が第１の態様と相違する。 Next, the manufacturing method of the heat insulation panel which concerns on the 3rd aspect of this invention, and the heat insulation panel obtained by the said manufacturing method are demonstrated. The third aspect is different from the first aspect in that a plurality of vacuum heat insulating plates having a small area are used in order to reduce manufacturing costs.
第３の態様に係る断熱パネルの製造においては、図８に示す様に、例えば第１の態様におけるのと同様の木枠（１）を使用する。そして、図９及び図１０（ａ）に示す様に、配列状態における全体の平面寸法が木枠（１）の内縁長さに相当する複数の真空断熱板（３）を木枠（１）に収容し且つ発泡樹脂成形体から成る角材状の支持材（２）を木枠（１）の内縁および隣接する真空断熱板（３）の境界部分に沿わせてこれら真空断熱板の両面側に配置すると共に、図１０（ｂ）に示す様に、成型機の２つのプレス板（５）で木枠（１）をその厚さ方向から挟み付ける。 In manufacture of the heat insulation panel which concerns on a 3rd aspect, as shown in FIG. 8, the wooden frame (1) similar to the thing in a 1st aspect is used, for example. Then, as shown in FIG. 9 and FIG. 10 (a), a plurality of vacuum heat insulating plates (3) whose overall planar dimensions in the arrangement state correspond to the inner edge length of the wooden frame (1) are provided on the wooden frame (1). A square-shaped support material (2) that is housed and made of a foamed resin molded body is arranged on both sides of the vacuum heat insulating plate along the inner edge of the wooden frame (1) and the boundary portion of the adjacent vacuum heat insulating plate (3). At the same time, as shown in FIG. 10 (b), the wooden frame (1) is sandwiched between the two press plates (5) of the molding machine from its thickness direction.
具体的には、図８に示す様に、先ず、一面側が下になる状態で置かれた木枠（１）に対し、底面側に偏らせた状態で当該木枠の内縁に沿わせて支持材（２）を配置し、更に、複数収められる真空断熱板（３）の境界部分に相当する部分に横枠（１１）と平行に支持材（２１）（図８中の横枠（１１）と平行な３つの支持材）を配置する。 Specifically, as shown in FIG. 8, first, a wooden frame (1) placed with one side facing down is supported along the inner edge of the wooden frame while being biased toward the bottom side. A material (2) is arranged, and further, a support material (21) (a horizontal frame (11) in FIG. 8) parallel to the horizontal frame (11) at a portion corresponding to the boundary portion of the vacuum heat insulating plates (3) accommodated in plural. 3 support members in parallel with each other).
支持材（２）の基本な構成は、第１の形態におけるのと同様であるが、上記の境界部分に使用する支持材（２１）としては、隣接する上記の空間部同士を繋ぐ構造もの、例えば、当該支持材の幅方向（長さに直交する方向）に溝や穴が設けられたもの、あるいは、図示する様な複数に分断されたものを使用する。これにより、支持材（２１）によって真空断熱板（３）の一面側に形成される原料樹脂充填用の複数の空間部に対して順次に原料樹脂を充填できる。上記の支持材（２）は、木枠（１）の内縁に対して接着剤や粘着剤で固定し、また、境界部分に使用する支持材（２１）は、縦枠（１０）及び横枠（１１）に沿わせた支持材（２）に対して同様に接着剤や粘着剤で固定しておく。 The basic structure of the support material (2) is the same as in the first embodiment, but as the support material (21) used for the boundary portion, a structure that connects the adjacent space portions, For example, a material in which a groove or a hole is provided in the width direction (direction perpendicular to the length) of the support material or a material that is divided into a plurality of pieces as shown in the drawing is used. Thereby, raw material resin can be sequentially filled with respect to the several space part for raw material resin filling formed in the one surface side of a vacuum heat insulating board (3) with a support material (21). The support material (2) is fixed to the inner edge of the wooden frame (1) with an adhesive or an adhesive, and the support material (21) used for the boundary portion is the vertical frame (10) and the horizontal frame. Similarly, it is fixed to the support material (2) along (11) with an adhesive or a pressure-sensitive adhesive.
木枠（１）に支持材（２）を収めた後は、図９に示す様に、支持材（２）の上に例えば４枚の真空断熱板（３）を配置する。各真空断熱板（３）は、外形寸法（縦枠（１０）に沿わせる一辺の長さ）が異なる点を除き、第１の形態におけるのと同様の構造を備えている。木枠（１）に収める際に縦枠（１０）に沿わせる各真空断熱板（３）の一辺の長さは、使用枚数に応じて、５００〜２０００ｍｍに設計される。図９には、上記の一辺の長さが６００ｍｍの真空断熱板（３）を４枚配置した例を示している。 After the support material (2) is placed in the wooden frame (1), for example, four vacuum heat insulating plates (3) are arranged on the support material (2) as shown in FIG. Each vacuum heat insulating plate (3) has the same structure as in the first embodiment except that the external dimensions (length of one side along the vertical frame (10)) are different. The length of one side of each vacuum heat insulating plate (3) along the vertical frame (10) when stored in the wooden frame (1) is designed to be 500 to 2000 mm according to the number of sheets used. FIG. 9 shows an example in which four vacuum heat insulating plates (3) each having a side length of 600 mm are arranged.
真空断熱板（３）を配置した後は、図９及び図１０（ａ）に示す様に、前述の支持材（図８に示す支持材）と同様の各支持材（２）を木枠（１）の内縁および隣接する真空断熱板（３）の境界部分に沿わせてこれら真空断熱板の上面側から配置する。すなわち、上記の各支持材（２）は、木枠（１）を平面視した状態において、木枠（１）の上面側に偏らせた状態で配置する。なお、前述の下面側の支持材（２）と同様に、上面側の支持材（２）も、木枠（１）の内縁に対して接着剤や粘着剤で固定し、また、境界部分に使用する支持材（２１）は、縦枠（１０）及び横枠（１１）に沿わせた支持材（２）に対して同様に接着剤や粘着剤で固定しておく。 After placing the vacuum heat insulating plate (3), as shown in FIGS. 9 and 10 (a), each support material (2) similar to the above-described support material (support material shown in FIG. 8) is attached to a wooden frame ( It arrange | positions from the upper surface side of these vacuum heat insulating boards along the inner edge of 1) and the boundary part of an adjacent vacuum heat insulating board (3). That is, each said support material (2) is arrange | positioned in the state biased to the upper surface side of the wooden frame (1) in the state which planarly viewed the wooden frame (1). In addition, like the support material (2) on the lower surface side, the support material (2) on the upper surface side is also fixed to the inner edge of the wooden frame (1) with an adhesive or a pressure sensitive adhesive. The support material (21) to be used is similarly fixed to the support material (2) along the vertical frame (10) and the horizontal frame (11) with an adhesive or an adhesive.
上記の様に複数の真空断熱板（３）及びその支持材（２）を収めた木枠（１）は、図１０（ｂ）に示す様に、成型機に装填してそのプレス板（５）で挟み付ける。斯かる操作により、木枠（１）の両面側（断熱パネルを形成した場合の表側および裏側）を２つのプレス板（５）で覆い、木枠（１）内の各真空断熱板（３）の両面側に断熱材（７）の原料樹脂を充填するための空間部をそれぞれ形成する。また、成型機に木枠（１）を装填する場合には、上下のプレス板（５）と木枠（１）との間に第１の態様におけるのと同様の原料樹脂付着防止用の保護シート（４）を介在させるのが好ましい。 The wooden frame (1) containing the plurality of vacuum heat insulating plates (3) and the supporting materials (2) as described above is loaded into a molding machine and the press plate (5) as shown in FIG. ). By such an operation, both sides of the wooden frame (1) (the front side and the back side when the heat insulating panel is formed) are covered with two press plates (5), and each vacuum heat insulating plate (3) in the wooden frame (1) is covered. The space portions for filling the raw material resin of the heat insulating material (7) are respectively formed on the both sides. In addition, when the wooden frame (1) is loaded into the molding machine, the same protection for raw material resin adhesion as in the first aspect is provided between the upper and lower press plates (5) and the wooden frame (1). It is preferable to interpose a sheet (4).
次いで、第１の態様と同様に、例えば横枠（１１）に設けられた樹脂充填穴（１ｃ）に原料樹脂充填ノズルを装着し、上記の樹脂充填穴（１ｃ）、支持材（２）の樹脂充填穴（２ｃ）及び支持材（２１）の溝、穴または分断部分を通じて、各真空断熱板（３）の両面側に各形成された上記の複数の空間部に対し、支持材（２）と同質の発泡樹脂の原料樹脂を充填して同時に発泡させることにより、断熱材（７）を形成する。その他の操作は、第１の態様におけるのと同様である。そして、上記の製造方法により、縦枠（１０）に沿って配列された状態で木枠（１）に真空断熱板（３）が複数枚収められた図１０（ｂ）に示す構造の断熱パネルを製造できる。なお、上記の製造方法においては、縦枠（１０）の各空間部に対応する位置にそれぞれ樹脂充填穴を設けて原料樹脂を充填することも出来る。 Next, in the same manner as in the first aspect, for example, the resin filling hole (1c) provided in the horizontal frame (11) is mounted with the raw material resin filling nozzle, and the resin filling hole (1c) and the support material (2) The support material (2) with respect to the plurality of space portions formed on both sides of each vacuum heat insulating plate (3) through the resin-filled hole (2c) and the groove, hole or divided portion of the support material (21). A heat insulating material (7) is formed by filling a foamed resin raw material resin of the same quality and foaming simultaneously. Other operations are the same as in the first embodiment. And by the said manufacturing method, the heat insulation panel of the structure shown in FIG.10 (b) with which the vacuum insulation board (3) was accommodated in the wooden frame (1) in the state arranged along the vertical frame (10). Can be manufactured. In the above manufacturing method, the resin filling holes can be provided at positions corresponding to the spaces of the vertical frame (10) to fill the raw material resin.
上記の第３の態様に係る製造方法においても、第１の態様と同様に、木枠（１）内に隙間なく配置された各真空断熱板（３）の両面側に支持材（２）と一体化された均一な厚さ
の断熱材（７）を形成するため、熱に対する遮蔽効果が高く、より一層断熱性能に優れた断熱パネルを製造することが出来る。また、上記の製造方法によって得られる断熱パネルにおいては、第１の態様と同様に、複数の真空断熱板（３）が木枠（１）に対して配列状態で隙間なく収められ、これら真空断熱板（３）の両面側に均一な厚さの断熱材（７）が形成されているため、熱に対するより高い遮蔽効果が得られ、より一層優れた断熱性能が得られる。そして、第３の態様に係る断熱パネルは、平面視して一層小面積の真空断熱板（３）を使用して製造できるため、その製造コストを更に低減できる。なお、上記の第３の形態に係る断熱パネルの構造およびその製造方法は、前述の第２の形態に係る断熱パネル及びその製造方法に対しても適用できる。
In the manufacturing method according to the third aspect, as in the first aspect, the support material (2) and the support material (2) are provided on both sides of each vacuum heat insulating plate (3) arranged without a gap in the wooden frame (1). Since the heat insulating material (7) having an integrated uniform thickness is formed, a heat insulating panel having a high heat shielding effect and further excellent heat insulating performance can be manufactured. Moreover, in the heat insulation panel obtained by said manufacturing method, similarly to the 1st aspect, a several vacuum heat insulation board (3) is stored without a clearance gap with the arrangement | sequence state with respect to the wooden frame (1), These vacuum heat insulation Since the heat insulating material (7) having a uniform thickness is formed on both sides of the plate (3), a higher shielding effect against heat can be obtained, and a further excellent heat insulating performance can be obtained. And since the heat insulation panel which concerns on a 3rd aspect can be manufactured using a vacuum insulation board (3) of a smaller area in planar view, the manufacturing cost can further be reduced. The structure of the heat insulation panel according to the third embodiment and the method for manufacturing the same can also be applied to the heat insulation panel according to the second embodiment and the method for manufacturing the same.
１ ：木枠
１０：縦枠
１１：横枠
１２：中間縦枠
１ｃ：樹脂充填穴（脱気穴）
２ ：支持材
２１：支持材
２ｃ：樹脂充填穴（脱気穴）
３ ：真空断熱板
４ ：保護シート
５ ：プレス板
６ ：原料樹脂充填ノズル
７ ：断熱材
1: Wooden frame 10: Vertical frame 11: Horizontal frame 12: Intermediate vertical frame 1c: Resin filling hole (deaeration hole)
2: Support material 21: Support material 2c: Resin filling hole (deaeration hole)
3: Vacuum heat insulating plate 4: Protection sheet 5: Press plate 6: Raw material resin filling nozzle 7: Heat insulating material
Claims (4)
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| KR101865674B1 (en) * | 2017-10-31 | 2018-06-08 | 정태영 | Cargo of liquefied petroleum gas carrier, manufacture method of the cargo, and high-performance insulation and structural components thereof |
| KR101865672B1 (en) * | 2017-09-12 | 2018-06-08 | 정태영 | Cargo of liquefied petroleum gas carrier, manufacture method of the cargo, and high-performance insulation and structural components thereof |
| FR3139879A1 (en) * | 2022-09-19 | 2024-03-22 | Gaztransport Et Technigaz | Process for manufacturing an insulating block |
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| KR101277058B1 (en) * | 2010-03-23 | 2013-06-20 | 한국건설기술연구원 | The adiabatic structure of high airtightness adiabatic door frame |
| JP5852358B2 (en) * | 2011-08-09 | 2016-02-03 | 太陽工業株式会社 | Method for producing foamed resin block |
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| KR101865672B1 (en) * | 2017-09-12 | 2018-06-08 | 정태영 | Cargo of liquefied petroleum gas carrier, manufacture method of the cargo, and high-performance insulation and structural components thereof |
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| FR3139879A1 (en) * | 2022-09-19 | 2024-03-22 | Gaztransport Et Technigaz | Process for manufacturing an insulating block |
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