JP7466389B2 - Liquid heat retaining structure and manufacturing method thereof - Google Patents
Liquid heat retaining structure and manufacturing method thereof Download PDFInfo
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- JP7466389B2 JP7466389B2 JP2020111443A JP2020111443A JP7466389B2 JP 7466389 B2 JP7466389 B2 JP 7466389B2 JP 2020111443 A JP2020111443 A JP 2020111443A JP 2020111443 A JP2020111443 A JP 2020111443A JP 7466389 B2 JP7466389 B2 JP 7466389B2
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- 239000007788 liquid Substances 0.000 title claims description 71
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 239000010410 layer Substances 0.000 claims description 65
- 239000011247 coating layer Substances 0.000 claims description 45
- 229920005749 polyurethane resin Polymers 0.000 claims description 45
- 239000000463 material Substances 0.000 claims description 43
- 238000009413 insulation Methods 0.000 claims description 39
- 230000003014 reinforcing effect Effects 0.000 claims description 36
- 239000006261 foam material Substances 0.000 claims description 31
- 229910052751 metal Inorganic materials 0.000 claims description 13
- 239000002184 metal Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 8
- 239000011248 coating agent Substances 0.000 claims description 6
- 238000000034 method Methods 0.000 claims description 6
- 238000000926 separation method Methods 0.000 claims 3
- 229910052782 aluminium Inorganic materials 0.000 description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 229920002396 Polyurea Polymers 0.000 description 8
- 238000005187 foaming Methods 0.000 description 8
- 229920005989 resin Polymers 0.000 description 8
- 239000011347 resin Substances 0.000 description 8
- 229920006327 polystyrene foam Polymers 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000004793 Polystyrene Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 230000017525 heat dissipation Effects 0.000 description 3
- 230000014759 maintenance of location Effects 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- 230000005855 radiation Effects 0.000 description 3
- 238000004134 energy conservation Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000002918 waste heat Substances 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Description
本発明は、液槽の内部に保持される高温の液体を保温する液体保温構造、及びその製造方法に関する。 The present invention relates to a liquid insulation structure that keeps high-temperature liquid held inside a liquid tank warm, and a method for manufacturing the same.
従来、保温対象物を外囲して保温する恒温保温容器を、ポリスチレンを発泡させ硬化させた材料としての発泡材料（所謂、発泡スチロール）を用いて作成したものが知られている（特許文献１を参照）。当該恒温保温容器は、発泡材料に含まれる気体による断熱効果により、容器の内部と外部との断熱を行う形態で、容器の内部を保温するものである。
他の保温機能を発揮するものとして、袋状容器を構成する基材の内面又は外面にアルミニウム等の金属膜を形成したものが知られている（特許文献２を参照）。当該特許文献２に開示の技術では、アルミニウムによる輻射熱の反射により、袋状容器の内部を保温するものである。
Conventionally, a constant temperature insulation container that surrounds an object to be kept warm and is made from a foam material (so-called expanded polystyrene) obtained by foaming and hardening polystyrene is known (see Patent Document 1). The constant temperature insulation container keeps the inside of the container warm by insulating the inside and outside of the container through the insulating effect of the gas contained in the foam material.
Another known example of a material that exhibits a heat-retaining function is a bag-shaped container having a metal film of aluminum or the like formed on the inner or outer surface of the base material that constitutes the bag-shaped container (see Patent Document 2). The technology disclosed in Patent Document 2 retains heat inside the bag-shaped container by reflecting radiant heat by the aluminum.
昨今、工場等で工業製品を製造する製造業では、省エネルギー性の観点から、排熱を用いた発電や、製造過程での排熱の再利用等が積極的に行われている。
このような省エネ性を向上する流れの中で、製造過程で用いる液体のうち、比較的高温の液体を、工場の休止時等において保温する技術が求められている。例えば、液体保温槽に高温の液体を保持する場合、当該液体保温槽に対して、特許文献１に開示の技術のような発泡材料を用いて作成された蓋部を載置して、大気への放熱を抑制することが考えられる。しかしながら、液体が高温の場合、発泡材料としての発泡スチロールは、硬化後に熱が加えられることで変形する場合があり、蓋部の変形により液体保温槽と蓋部との間に隙間が生じるときには、放熱ロスを十分に抑制できないという問題があった。
一方、特許文献２に開示の如く、輻射熱を反射する材料としてのアルミニウムを用いて蓋部を作成する場合、アルミニウム自体が蒸発した液体との接触により昇温し、当該アルミニウムから大気へ放熱するという問題があった。また、アルミニウム自体が昇温して高温となるため、例えば蓋部を素手などで人為的に移動させる場合に、把持がし難くなるという問題があった。
2. Description of the Related Art Recently, in the manufacturing industry where industrial products are produced in factories and the like, from the viewpoint of energy conservation, power generation using waste heat and reuse of waste heat from the manufacturing process have been actively carried out.
In the trend of improving energy conservation, there is a demand for a technology that can keep relatively high-temperature liquids used in the manufacturing process warm during factory downtime, etc. For example, when a high-temperature liquid is kept in a liquid insulation tank, it is possible to place a lid made of a foaming material such as the technology disclosed in Patent Document 1 on the liquid insulation tank to suppress heat radiation to the atmosphere. However, when the liquid is hot, polystyrene foam as the foaming material may deform when heat is applied after hardening, and when a gap occurs between the liquid insulation tank and the lid due to deformation of the lid, there is a problem that heat radiation loss cannot be sufficiently suppressed.
On the other hand, as disclosed in Patent Document 2, when the lid is made of aluminum, which is a material that reflects radiant heat, there is a problem that the aluminum itself heats up due to contact with the evaporated liquid and dissipates heat into the atmosphere. In addition, since the aluminum itself heats up and becomes very hot, there is a problem that it becomes difficult to hold the lid when it is moved manually with bare hands, for example.
本発明は、上述の課題に鑑みてなされたものであり、その目的は、比較的高い断熱性能を維持しながらも、高い形状維持機能をも有する液体保温構造、及びその製造方法を提供することにある。 The present invention was made in consideration of the above-mentioned problems, and its purpose is to provide a liquid insulation structure that has a high shape retention function while maintaining a relatively high insulation performance, and a manufacturing method thereof.
上記目的を達成するための液体保温構造は、高温の液体を保持して保温する液体保温構造であって、その特徴構成は、
気泡を含む板状の発泡材料の表面にポリウレア樹脂が塗布されて成るポリウレア樹脂層を有する成型断熱部材にて、少なくとも液槽の蓋部が構成され、
板状の前記発泡材料の厚み方向に沿って形成される板側面には、硬化後の前記発泡材料よりも強度が高い金属から成る補強枠体が固設されており、
前記ポリウレア樹脂層は、前記板側面に前記補強枠体が固設された状態の前記発泡材料の外側に形成され、
前記ポリウレア樹脂層は、前記発泡材料及び前記補強枠体の表面に所定の厚みで塗布される第１塗布層と、当該第１塗布層の外表面に形成され且つ層が厚い厚層部位と当該厚層部位より薄い薄層部位とが存在する第２塗布層とから構成されている点にある。
The liquid insulation structure for achieving the above object is a liquid insulation structure that holds and keeps a high-temperature liquid warm, and its characteristic configuration is as follows:
At least the lid of the liquid tank is formed of a molded insulation member having a polyurethane resin layer formed by applying a polyurethane resin to the surface of a plate-shaped foam material containing bubbles ,
A reinforcing frame made of a metal having a strength higher than that of the foamed material after hardening is fixed to a plate side surface formed along a thickness direction of the plate-shaped foamed material,
The polyurethane resin layer is formed on the outside of the foam material in a state in which the reinforcing frame is fixed to the side surface of the plate,
The polyurethane resin layer is characterized in that it is composed of a first coating layer applied to the surfaces of the foam material and the reinforcing frame body at a predetermined thickness, and a second coating layer formed on the outer surface of the first coating layer and having a thick layer portion and a thin layer portion which is thinner than the thick layer portion .
上記特徴構成によれば、高温の液体の液体保温構造を構成する蓋部を、気泡を含む板状の発泡材料の表面にポリウレア樹脂が塗布されて成るポリウレア樹脂層を有する成型断熱部材にて構成することで、発泡材料の表面が、硬化後に高い強度を示すポリウレア樹脂により被覆されるから、昇温による発泡材料の変形を抑制できる。結果、成型断熱部材の初期の形状を維持することができ、形状変形による液槽と蓋部との間における隙間の発生を抑制でき、放熱ロスを低減できる。
更に、当該ポリウレア樹脂は、従来技術に示したアルミニウム等に比べ熱伝導度が小さいため、当該ポリウレア樹脂を伝達媒体として、高温の液体から大気等への放熱を十分に抑制することができる。また、成型断熱部材の基材としての発泡材料が、内部に気泡を含む断熱構造を有しているから、比較的高い断熱性も期待できる。
更に、上記特徴構成によれば、板状の発泡材料の板側面には、硬化後の発泡材料よりも強度が高い金属から成る補強枠体が固設されているから、発泡材料の熱による変形をより一層良好に抑制できる。
一般的に、金属は熱伝導度が高く、それ自体を通して熱が外部へ放熱する虞があるが、上記特徴構成によれば、比較的熱伝導度の低いポリウレア樹脂により、金属としての補強枠体の外部を被覆するから、当該金属を介する大気への放熱が効果的に抑制できる。
更に、上記特徴構成によれば、発泡材料の表面には、層が厚い厚層部位と当該厚層部位よりも薄い薄層部位とが存在する第２塗布層が形成されているから、例えば、厚層部位と薄層部位とを斑（エンボス状）に形成することにより、発泡材料の表面にポリウレア樹脂が塗布された蓋部を移動させる際に、その表面を把持する場合の表面摩擦力を向上させて、把持する際の力を低減できる。
更に、ポリウレア樹脂層として、例えば、厚層部位と薄層部位とが斑に存在する第２塗布層のみを形成する場合、発泡材料の表面がポリウレア樹脂に覆われていない部位が生じる可能性があるが、上記特徴構成によれば、第２塗布層の内側（発泡材料と第２塗布層との間、又は補強枠体と第２塗布層との間）に所定の厚みで塗布される第１塗布層が形成されているから、発泡材料の表面の全体を確実にポリウレア樹脂で覆うことができ、発泡材料の全体の強度を良好に補強できる。
以上より、比較的高い断熱性能を維持しながらも、高い形状維持機能をも有する液体保温構造を実現できる。
According to the above characteristic configuration, the lid part constituting the liquid insulation structure for high-temperature liquid is made of a molded insulation member having a polyurethane resin layer formed by applying a polyurethane resin to the surface of a plate-shaped foam material containing bubbles, so that the surface of the foam material is covered with the polyurethane resin that exhibits high strength after curing, thereby suppressing deformation of the foam material due to temperature rise. As a result, the initial shape of the molded insulation member can be maintained, and the occurrence of gaps between the liquid vat and the lid part due to shape deformation can be suppressed, thereby reducing heat radiation loss.
Furthermore, since the polyurea resin has a smaller thermal conductivity than aluminum and the like shown in the prior art, the polyurea resin can be used as a transfer medium to sufficiently suppress heat dissipation from high-temperature liquid to the atmosphere, etc. In addition, since the foam material used as the base material of the molded insulation member has an insulating structure containing air bubbles inside, relatively high thermal insulation can be expected.
Furthermore, according to the above-mentioned characteristic configuration, a reinforcing frame made of a metal having strength greater than that of the hardened foamed material is fixed to the plate side of the plate-shaped foamed material, thereby even more effectively suppressing deformation of the foamed material due to heat.
Generally, metals have high thermal conductivity and there is a risk that heat will be dissipated to the outside through the metal itself. However, according to the above-described characteristic configuration, the outside of the metallic reinforcing frame is covered with polyurea resin, which has relatively low thermal conductivity, so that heat dissipation to the atmosphere through the metal can be effectively suppressed.
Furthermore, according to the above-mentioned characteristic configuration, a second coating layer is formed on the surface of the foamed material, in which there are thick layer portions and thin layer portions that are thinner than the thick layer portions. Therefore, for example, by forming the thick layer portions and the thin layer portions in a mottled (embossed) pattern, when moving a lid portion on which a polyurethane resin is applied to the surface of the foamed material, the surface friction force when gripping the surface can be improved, thereby reducing the force required for gripping.
Furthermore, if, for example, only a second coating layer having unevenly distributed thick and thin areas is formed as the polyurethane resin layer, there is a possibility that areas of the surface of the foamed material will not be covered with polyurethane resin. However, according to the above-mentioned characteristic configuration, a first coating layer is formed that is applied to a predetermined thickness inside the second coating layer (between the foamed material and the second coating layer, or between the reinforcing frame and the second coating layer), so that the entire surface of the foamed material can be reliably covered with polyurethane resin, and the overall strength of the foamed material can be effectively reinforced.
As a result, it is possible to realize a liquid heat-retaining structure that has a high shape-retaining function while maintaining a relatively high insulating performance.
液体保温構造の更なる特徴構成は、
前記蓋部は、平面視で長手方向に沿って延びる長方形状であり、
当該長手方向に沿って延びる分割部位に沿って分離可能な第１蓋部と第２蓋部とから構成され、
前記第１蓋部の前記分割部位に沿う前記板側面と、前記第２蓋部の前記分割部位に沿う前記板側面とには、前記補強枠体としての分割部位補強枠体が固設される点にある。
Further characteristic configurations of the liquid heat retaining structure are:
The cover portion has a rectangular shape extending along a longitudinal direction in a plan view,
The container is made up of a first lid portion and a second lid portion that can be separated along a dividing portion extending in the longitudinal direction,
The reinforcing frame is a divided portion reinforcing frame that is fixed to the plate side surface along the divided portion of the first lid portion and the plate side surface along the divided portion of the second lid portion.
発泡材料は、熱が加えられた場合に熱変形（反り）が発生するのであるが、当該熱変形は、長手方向に沿う熱変形が、短手方向に沿う熱変形よりも大きい。
上記特徴構成によれば、蓋部が、長手方向に沿って延びる分割部位に沿って分離可能な第１蓋部と第２蓋部とから構成され、第１蓋部の分割部位に沿う板側面と第２蓋部の分割部位に沿う板側面とには分割部位補強枠体が固設されるから、当該分割部位補強枠体により長手方向に沿う強度が補強され、長手方向に沿う熱変形（反り）を、より一層良好に抑制できる。
また、金属から成る補強枠体及びポリウレア樹脂を含んで成る蓋部は、比較的重量が大きくなるが、上記特徴構成によれば、蓋部を第１蓋部と第２蓋部とに分割可能に構成されているから、蓋部を移動させる場合に、第１蓋部と第２蓋部とを個別に移動でき、移動の際の人的負荷を低減できる。
When heat is applied to a foam material, thermal deformation (warping) occurs, and the thermal deformation along the longitudinal direction is greater than the thermal deformation along the lateral direction.
According to the above characteristic configuration, the lid portion is composed of a first lid portion and a second lid portion that can be separated along a division portion extending along the longitudinal direction, and a division portion reinforcing frame is fixed to the plate side surface along the division portion of the first lid portion and the plate side surface along the division portion of the second lid portion, so that the strength along the longitudinal direction is reinforced by the division portion reinforcing frame, and thermal deformation (warping) along the longitudinal direction can be even more effectively suppressed.
In addition, the lid portion comprising a reinforcing frame made of metal and polyurea resin is relatively heavy; however, according to the above-mentioned characteristic configuration, the lid portion is configured to be separable into a first lid portion and a second lid portion. Therefore, when moving the lid portion, the first lid portion and the second lid portion can be moved separately, thereby reducing the human load when moving the lid portion.
上記特徴構成によれば、発泡材料の表面には、層が厚い厚層部位と当該厚層部位よりも薄い薄層部位とが存在する第２塗布層が形成されているから、例えば、厚層部位と薄層部位とを斑（エンボス状）に形成することにより、発泡材料の表面にポリウレア樹脂が塗布された蓋部を移動させる際に、その表面を把持する場合の表面摩擦力を向上させて、把持する際の力を低減できる。
更に、ポリウレア樹脂層として、例えば、厚層部位と薄層部位とが斑に存在する第２塗布層のみを形成する場合、発泡材料の表面がポリウレア樹脂に覆われていない部位が生じる可能性があるが、上記特徴構成によれば、第２塗布層の内側（発泡材料と第２塗布層との間）に所定の厚みで塗布される第１塗布層が形成されているから、発泡材料の表面の全体を確実にポリウレア樹脂で覆うことができ、発泡材料の全体の強度を良好に補強できる。
According to the above-described characteristic configuration, a second coating layer is formed on the surface of the foamed material, in which there are thick layer portions and thin layer portions that are thinner than the thick layer portions. Therefore, for example, by forming the thick layer portions and the thin layer portions in a mottled (embossed) pattern, when moving a lid portion on which a polyurethane resin is applied to the surface of the foamed material, the surface friction force when gripping the surface can be improved, thereby reducing the force required for gripping.
Furthermore, if, for example, only the second coating layer having uneven thick and thin areas is formed as the polyurethane resin layer, there is a possibility that areas of the surface of the foamed material will not be covered with polyurethane resin. However, according to the above-mentioned characteristic configuration, a first coating layer is formed that is applied at a predetermined thickness inside the second coating layer (between the foamed material and the second coating layer), so that the entire surface of the foamed material can be reliably covered with polyurethane resin, and the overall strength of the foamed material can be effectively reinforced.
上記目的を達成するための液体保温構造の製造方法は、高温の液体を保持して保温するべく、気泡を含む板状の発泡材料の表面にポリウレア樹脂が塗布されて成るポリウレア樹脂層を有する成型断熱部材にて、少なくとも液槽の蓋部が構成され、板状の前記発泡材料の厚み方向に沿って形成される板側面には、硬化後の前記発泡材料よりも強度が高い金属から成る補強枠体が固設されており、前記ポリウレア樹脂層は、前記板側面に前記補強枠体が固設された状態の前記発泡材料の外側に形成される液体保温構造の製造方法であって、その特徴構成は、
前記発泡材料及び前記補強枠体の表面に対し、前記ポリウレア樹脂を所定の厚みで塗布する第１塗布層を塗布する第１塗布工程と、当該第１塗布層の外表面に対し層が厚い厚層部位と当該厚層部位より薄い薄層部位とが存在する第２塗布層を塗布する第２塗布工程とを、記載の順に実行する点にある。
A method for manufacturing a liquid insulation structure for achieving the above object is a method for manufacturing a liquid insulation structure in which at least a lid portion of a liquid tank is formed of a molded insulation member having a polyurethane resin layer formed by applying a polyurethane resin to the surface of a plate-shaped foam material containing bubbles in order to hold and keep a high temperature liquid warm, and a reinforcing frame made of a metal having a strength higher than that of the foam material after hardening is fixed to a plate side surface formed along the thickness direction of the plate-shaped foam material, and the polyurethane resin layer is formed on the outside of the foam material in a state in which the reinforcing frame is fixed to the plate side surface, and the method is characterized by the following configuration:
The feature of this method is that a first coating step is performed in the order described above, in which a first coating layer is applied to the surfaces of the foam material and the reinforcing frame body by applying the polyurethane resin to a predetermined thickness, and a second coating step is performed in which a second coating layer is applied to the outer surface of the first coating layer, the second coating layer having a thick layer portion where the layer is thick and a thin layer portion where the layer is thinner than the thick layer portion.
上記特徴構成によれば、高温の液槽の液体保護構造を構成する蓋部を、気泡を含む発泡材料を板状に加工した表面に、ポリウレア樹脂を塗布して蓋部を構成することで、発泡材料の表面が、硬化後に高い強度を示すポリウレア樹脂により被覆されるから、昇温による発泡材料の変形を抑制することができる。結果、成型断熱部材の初期の形状を維持することができ、形状変形により液槽と蓋部との間に隙間ができることを防止でき、放熱ロスを低減できる。
更に、当該ポリウレア樹脂は、従来技術に示したアルミニウム等に比べ熱伝導度が小さいため、当該ポリウレア樹脂を伝達媒体として、高温の液体から大気等への放熱を十分に抑制することができる。
また、上記特徴構成によれば、発泡材料の表面には、層が厚い厚層部位と当該厚層部位より薄い薄層部位とが存在する第２塗布層が形成されているから、例えば、厚層部位と薄層部位とを斑（エンボス状）に形成することにより、発泡材料の表面にポリウレア樹脂が塗布された蓋部を移動させる際に、その表面を把持する場合の表面摩擦力を向上させて、把持する際の力を低減できる。
尚、ポリウレア樹脂による層として、例えば、厚層部位と薄層部位とが斑に存在する第２塗布層のみを形成する場合、発泡材料の表面がポリウレア樹脂に覆われていない部位が生じる可能性があるが、上記特徴構成によれば、第２塗布層の内側（発泡材料と第２塗布層との間、又は補強枠体と第２塗布層との間）に所定の厚みで塗布される第１塗布層が形成されているから、発泡材料の表面の全体を確実にポリウレア樹脂で覆うことができ、発泡材料の全体の強度を良好に補強できる。
According to the above characteristic configuration, the lid constituting the liquid protection structure for the high-temperature liquid vat is made by coating the surface of a foamed material containing bubbles into a plate shape with a polyurethane resin, so that the surface of the foamed material is covered with the polyurethane resin, which exhibits high strength after curing, and deformation of the foamed material due to temperature rise can be suppressed. As a result, the initial shape of the molded insulation member can be maintained, and gaps caused by deformation of the shape between the liquid vat and the lid can be prevented, thereby reducing heat loss.
Furthermore, since the polyurea resin has a lower thermal conductivity than aluminum or the like shown in the prior art, the polyurea resin can be used as a transmission medium to sufficiently suppress heat dissipation from the high-temperature liquid to the atmosphere, etc.
Furthermore, according to the above-mentioned characteristic configuration, a second coating layer is formed on the surface of the foamed material, in which there are thick layer portions and thin layer portions that are thinner than the thick layer portions. Therefore, for example, by forming the thick layer portions and the thin layer portions in a mottled (embossed) pattern, when moving a lid portion on which a polyurethane resin is applied to the surface of the foamed material, the surface friction force when gripping the surface can be improved, thereby reducing the force required for gripping.
Furthermore, when, for example, only a second coating layer having uneven thick and thin areas is formed as a layer of polyurethane resin, there is a possibility that areas of the surface of the foamed material will be produced that are not covered with polyurethane resin. However, according to the above-mentioned characteristic configuration, a first coating layer is formed that is applied to a predetermined thickness inside the second coating layer (between the foamed material and the second coating layer , or between the reinforcing frame and the second coating layer ), so that the entire surface of the foamed material can be reliably covered with polyurethane resin, and the overall strength of the foamed material can be effectively reinforced.
本発明の実施形態に係る液体保温構造１００及びその製造方法では、比較的高い断熱性能を維持しながらも、高い形状維持機能をも有するものである。
以下、図１～４を用いて、当該液体保温構造１００及びその製造方法について説明する。
The
The
当該実施形態に係る高温の液体５１を保持して保温する液体保温構造１００は、図１、２に示すように、平面視で長方形状であり且つ有底箱状の液槽５０と、当該液槽５０の上部を閉止する蓋部Ｆとから構成さており、液槽５０には、平面視で角部の近傍に、保温対象としての液体５１を流入する流入管Ｌ１と液体を外部へ送出する流出管Ｌ２とが配設されている。
ここで、保温対象としている液体５１は、リン酸塩液等の種々の液体が考えられ、温度域としては、４０℃以上８０℃以下程度の温度域のものを対象としている。
As shown in Figures 1 and 2, the
The
蓋部Ｆは、所定の厚みを有するものであり、気泡を含む板状の発泡材料Ｈ（例えば、ポリスチレンを発泡させ硬化させた材料としての発泡スチロール、ウレタン結合を有する重合体中にガスを細かく分散させ発泡状又は多孔質形状に成形された発泡ポリウレタン）の表面に、ポリウレア樹脂が塗布されて成るポリウレア樹脂層Ｐを有する成型断熱部材にて構成されている。このように、ポリウレア樹脂を塗布することにより成型断熱部材の強度及び防水性能を高くすることができる。
更に、蓋部Ｆは、強度の更なる向上を図るべく、板状の前記発泡材料Ｈの厚み方向に沿って形成される板側面には、硬化後の前記発泡材料Ｈよりも強度が高いＳＵＳ（金属の一例）から成る補強枠体Ｗが接着剤により接着される形態で固設されており、ポリウレア樹脂層Ｐは、板側面に補強枠体Ｗが固設された状態の発泡材料Ｈの外側に形成される。
The lid F has a predetermined thickness and is made of a molded insulation member having a polyurethane resin layer P formed by applying a polyurethane resin to the surface of a plate-shaped foam material H containing bubbles (for example, polystyrene foam, which is a material made by foaming and hardening polystyrene, or polyurethane foam, which is made by finely dispersing gas in a polymer having urethane bonds and forming it into a foamed or porous shape). In this way, applying the polyurethane resin can increase the strength and waterproof performance of the molded insulation member.
Furthermore, in order to further improve the strength of the lid portion F, a reinforcing frame W made of SUS (an example of a metal) which is stronger than the foam material H after hardening is fixed to the plate side formed along the thickness direction of the plate-shaped foam material H by adhesive, and a polyurethane resin layer P is formed on the outside of the foam material H with the reinforcing frame W fixed to the plate side.
より詳細には、蓋部Ｆは、平面視で長手方向に沿って延びる長方形状であり、当該長手方向に沿って延びる分割部位に沿って分離可能な第１蓋部Ｆ１と第２蓋部Ｆ２とから構成され、第１蓋部Ｆ１の分割部位に沿う板側面には、第１蓋部Ｆ１の補強枠体Ｗ１としての分割部位補強枠体Ｗ１ａが固設されており、第２蓋部Ｆ２の分割部位に沿う板側面には、第２蓋部Ｆ２の補強枠体Ｗ２としての分割部位補強枠体Ｗ２ａが固設されている。
因みに、第１蓋部Ｆ１及び第２蓋部Ｆ２には、平面視において、その角部が切り欠かれたた切欠部Ｋ１、Ｋ２が設けられており、液槽５０に蓋部Ｆが載置されている状態で、第１蓋部Ｆ１の第１切欠部Ｋ１には流入管Ｌ１が位置し、第２蓋部Ｆ２の第２切欠部Ｋ２には流出管Ｌ２が位置する形態で、配設される。
More specifically, the lid part F has a rectangular shape extending along the longitudinal direction in a plan view, and is composed of a first lid part F1 and a second lid part F2 that can be separated along a division part extending along the longitudinal direction, and a division part reinforcing frame W1a is fixed to the plate side along the division part of the first lid part F1 as the reinforcing frame W1 of the first lid part F1, and a division part reinforcing frame W2a is fixed to the plate side along the division part of the second lid part F2 as the reinforcing frame W2 of the second lid part F2.
Incidentally, the first lid portion F1 and the second lid portion F2 have cutout portions K1 and K2 in which the corners are cut out when viewed in a plane, and are arranged such that when the lid portion F is placed on the
ポリウレア樹脂層Ｐは、図２に示すように、発泡材料Ｈの表面に対し、所定の厚みで塗布する第１塗布層Ｐ１を塗布（当該実施形態ではスプレー）する第１塗布工程と、当該第１塗布層Ｐ１の外表面に対し層が厚い厚層部位ＥＢ１と当該厚層部位ＥＢ１より薄い薄層部位ＥＢ２とが斑に存在する第２塗布層Ｐ２を塗布（当該実施形態ではスプレー）する第２塗布工程とを記載の順に実行することで形成される。
当該構成により、発泡材料Ｈとしての発泡スチロールの板表面（表面と裏面とを含む）と板側面の補強枠体Ｗの外面、即ち、その外側の全面を所定の厚みで塗布される第１塗布層Ｐ１にてコーティングされるから、その外周面の全体が、強度の高いポリウレア樹脂層Ｐにて一定以上の強度が担保される。
更に、第１塗布層Ｐ１の外側には、厚層部位ＥＢ１と薄層部位ＥＢ２とから成るエンボス状の第２塗布層Ｐ２が形成されている、即ち、厚層部位ＥＢ１と薄層部位ＥＢ２とが斑に形成され厚さが不均一となっているから、当該蓋部Ｆを把持して移動させる際に、蓋部Ｆの表面での摩擦抵抗を大きくでき、滑り難くできる。
As shown in FIG. 2, the polyurea resin layer P is formed by carrying out a first coating process in which a first coating layer P1 is applied (sprayed in this embodiment) to a predetermined thickness onto the surface of the foam material H, and a second coating process in which a second coating layer P2 is applied (sprayed in this embodiment) to the outer surface of the first coating layer P1, the second coating layer P2 having a thick layer portion EB1 that is thicker than the outer surface of the first coating layer P1 and a thin layer portion EB2 that is thinner than the thick layer portion EB1, in the order described below.
With this configuration, the surface (including the front and back) of the polystyrene foam plate as the foaming material H and the outer surface of the reinforcing frame W on the side of the plate, i.e., the entire outer surface, are coated with a first coating layer P1 applied to a predetermined thickness, so that the entire outer peripheral surface is guaranteed to have a certain level of strength by the high-strength polyurethane resin layer P.
Furthermore, an embossed second coating layer P2 consisting of a thick layer portion EB1 and a thin layer portion EB2 is formed on the outside of the first coating layer P1. In other words, the thick layer portion EB1 and the thin layer portion EB2 are formed in a spotted pattern and have an uneven thickness. Therefore, when the lid portion F is gripped and moved, the frictional resistance on the surface of the lid portion F can be increased, making it less likely to slip.
図２に示すように、発泡材料Ｈは、蓋部Ｆの重さを抑えつつ所定の保温性能を発揮する観点から、その厚みＬαを３０ｍｍ以上５０ｍｍ以下程度に設定されており、ポリウレア樹脂層Ｐとしての第１塗布層Ｐ１は、蓋部Ｆの重さを抑えつつ所定の強度を維持する観点から、１ｍｍ以上２ｍｍ以下程度に設定されており、ポリウレア樹脂層Ｐとしての第２塗布層Ｐ２は、蓋部Ｆの重さを抑えつつ表面の摩擦抵抗を一定以上にする観点から、０．５ｍｍ以上１ｍｍ以下程度に設定されている。 As shown in FIG. 2, the foam material H has a thickness Lα set to about 30 mm or more and 50 mm or less in order to provide a predetermined heat retention performance while reducing the weight of the lid portion F, the first coating layer P1 as the polyurethane resin layer P is set to about 1 mm or more and 2 mm or less in order to maintain a predetermined strength while reducing the weight of the lid portion F, and the second coating layer P2 as the polyurethane resin layer P is set to about 0.5 mm or more and 1 mm or less in order to maintain a certain level of surface friction resistance while reducing the weight of the lid portion F.
尚、当該実施形態では、液槽５０は、蓋部Ｆと同様に、気泡を含む発泡材料Ｈ（例えば、ポリスチレンを発泡させ硬化させた材料としての発泡スチロール）を有底箱状に加工した表面にポリウレア樹脂を塗布して成るポリウレア樹脂層Ｐを有する成型断熱部材から構成している。ただし、金属から成る補強枠体Ｗは設けないものとする。
In this embodiment, the
次に、当該実施形態に係る液体保温構造１００の保温性能を示す試験結果を、図３、４のグラフ図に基づいて説明する。
図３は、本発明に係る液体保温構造１００を用いた場合の試験結果であり、図４は、従来技術に係るアルミニウムを主材料とする蓋部を用いた場合の試験結果である。
両者は、共通の液槽５０に対して共通の液体（水）が貯留されている状態で試験を行った結果を示している。本発明に係る液体保温構造１００に係る試験では、発泡材料Ｈの厚みＬαを５０ｍｍとし、ポリウレア樹脂層Ｐの第１塗布層Ｐ１の厚みＬβを１ｍｍとし、第２塗布層Ｐ２の厚み（厚層部位（Ｌγ）：１ｍｍ、薄層部位：０．５ｍｍ）とした。従来技術に係るアルミニウムを主材料とする蓋部は、アルミニウムの厚みを５ｍｍとした。
夫々のグラフ図は、液体が８０℃（図３、４で（ａ））、６０℃（図３、４で（ｂ））、５０℃（図３、４で（ｃ））で貯留されている状態における液体温度の経時変化を示している。
Next, test results showing the heat retention performance of the liquid
FIG. 3 shows the test results when the
Both show the results of tests conducted with a common liquid (water) stored in a
The graphs show the change in liquid temperature over time when the liquid is stored at 80° C. (FIGS. 3 and 4 (a)), 60° C. (FIGS. 3 and 4 (b)), and 50° C. (FIGS. 3 and 4 (c)).
試験結果から、液体の温度が、８０℃、６０℃、５０℃の何れの場合においても、当該実施形態に係る液体保温構造１００を用いた場合のほうが、従来技術に係るアルミニウムを主材料とする蓋部を用いた場合に比べて、高い保温性能を発揮できていることがわかる。
The test results show that regardless of whether the liquid temperature is 80°C, 60°C, or 50°C, the
〔別実施形態〕
（１）上記実施形態において、液槽５０は、蓋部Ｆと同様に、ポリスチレンを発泡させ硬化させた材料としての発泡材料（例えば、発泡スチロール）を液槽形状に加工した表面に、ポリウレア樹脂層Ｐを塗布して成る成型断熱部材から構成する例を示した。
しかしながら、当該液槽５０は、液体を保持する強度を有すると共に保温効果を有する材料であれば、どのようなものから構成しても構わない。
例えば、ＳＵＳ３０４のような材料を好適に用いることができる。
[Another embodiment]
(1) In the above embodiment, the
However, the
For example, a material such as SUS304 can be suitably used.
（２）上記実施形態において、補強枠体ＷはＳＵＳから構成される例を示したが、経済性の観点から、鉄等の他の金属を採用しても構わない。
上記実施形態に係る成型断熱部材では、補強枠体Ｗの材料として鉄を採用する場合であっても、その外部に防水性能のあるポリウレア樹脂層Ｐが形成されるため、錆等の発生を効果的に防止できる。
(2) In the above embodiment, an example was shown in which the reinforcing frame W was made of SUS. However, from an economical standpoint, other metals such as iron may be used.
In the molded insulation member of the above embodiment, even if iron is used as the material for the reinforcing frame W, a waterproof polyurethane resin layer P is formed on the outside, thereby effectively preventing the occurrence of rust, etc.
（３）蓋部Ｆは、２つである必要はなく、３つ以上の複数であっても構わない。蓋部Ｆが３つ以上の複数であっても、夫々の蓋部Ｆが、補強枠体Ｗを有する構成としても構わない。 (3 ) The number of lid portions F does not need to be two, and may be three or more. Even if the number of lid portions F is three or more, each of the lid portions F may have a reinforcing frame W.
尚、上記実施形態（別実施形態を含む、以下同じ）で開示される構成は、矛盾が生じない限り、他の実施形態で開示される構成と組み合わせて適用することが可能であり、また、本明細書において開示された実施形態は例示であって、本発明の実施形態はこれに限定されず、本発明の目的を逸脱しない範囲内で適宜改変することが可能である。 The configurations disclosed in the above embodiment (including other embodiments, the same applies below) can be applied in combination with configurations disclosed in other embodiments, provided no contradictions arise. Furthermore, the embodiments disclosed in this specification are merely examples, and the present invention is not limited to these embodiments. Appropriate modifications can be made without departing from the scope of the present invention.
本発明の比較的高い断熱性能を維持しながらも、高い形状維持機能をも有する液体保温構造、及びその製造方法として、有効に利用可能である。 The present invention can be effectively used as a liquid heat-retaining structure and manufacturing method that maintains the relatively high insulating performance while also having a high shape retention function.
５０ ：液槽
５１ ：液体
１００ ：液体保温構造
ＥＢ１ ：厚層部位
ＥＢ２ ：薄層部位
Ｆ ：蓋部
Ｆ１ ：第１蓋部
Ｆ２ ：第２蓋部
Ｈ ：発泡材料
Ｐ ：ポリウレア樹脂層
Ｐ１ ：第１塗布層
Ｐ２ ：第２塗布層
Ｗ ：補強枠体
Ｗ１ ：分割部位補強枠体
50: Liquid tank 51: Liquid 100: Liquid insulation structure EB1: Thick layer portion EB2: Thin layer portion F: Lid portion F1: First lid portion F2: Second lid portion H: Foaming material P: Polyurea resin layer P1: First coating layer P2: Second coating layer W: Reinforcing frame W1: Split portion reinforcing frame
Claims (3)
気泡を含む板状の発泡材料の表面にポリウレア樹脂が塗布されて成るポリウレア樹脂層を有する成型断熱部材にて、少なくとも液槽の蓋部が構成され、
板状の前記発泡材料の厚み方向に沿って形成される板側面には、硬化後の前記発泡材料よりも強度が高い金属から成る補強枠体が固設されており、
前記ポリウレア樹脂層は、前記板側面に前記補強枠体が固設された状態の前記発泡材料の外側に形成され、
前記ポリウレア樹脂層は、前記発泡材料及び前記補強枠体の表面に所定の厚みで塗布される第１塗布層と、当該第１塗布層の外表面に形成され且つ層が厚い厚層部位と当該厚層部位より薄い薄層部位とが存在する第２塗布層とから構成されている液体保温構造。 A liquid insulation structure that holds and keeps a high-temperature liquid warm,
At least the lid of the liquid tank is formed of a molded insulation member having a polyurethane resin layer formed by applying a polyurethane resin to the surface of a plate-shaped foam material containing bubbles ,
A reinforcing frame made of a metal having a strength higher than that of the foamed material after hardening is fixed to a plate side surface formed along a thickness direction of the plate-shaped foamed material,
The polyurethane resin layer is formed on the outside of the foam material in a state in which the reinforcing frame is fixed to the side surface of the plate,
The polyurethane resin layer is a liquid insulation structure composed of a first coating layer applied to the surfaces of the foam material and the reinforcing frame body at a predetermined thickness, and a second coating layer formed on the outer surface of the first coating layer and having a thick layer portion and a thin layer portion that is thinner than the thick layer portion .
当該長手方向に沿って延びる分割部位に沿って分離可能な第１蓋部と第２蓋部とから構成され、
前記第１蓋部の前記分割部位に沿う前記板側面と、前記第２蓋部の前記分割部位に沿う前記板側面とには、前記補強枠体としての分割部位補強枠体が固設される請求項１に記載の液体保温構造。 The cover portion has a rectangular shape extending along a longitudinal direction in a plan view,
The container is made up of a first lid portion and a second lid portion that can be separated along a dividing portion extending in the longitudinal direction,
The liquid insulation structure according to claim 1, wherein a separation portion reinforcing frame as the reinforcing frame is fixed to the plate side along the separation portion of the first lid portion and the plate side along the separation portion of the second lid portion.
前記発泡材料及び前記補強枠体の表面に対し、前記ポリウレア樹脂を所定の厚みで塗布する第１塗布層を塗布する第１塗布工程と、当該第１塗布層の外表面に対し層が厚い厚層部位と当該厚層部位より薄い薄層部位とが存在する第２塗布層を塗布する第２塗布工程とを、記載の順に実行する製造方法。 A method for manufacturing a liquid insulation structure, comprising: at least a lid portion of a liquid tank being formed of a molded insulation member having a polyurethane resin layer formed by applying a polyurethane resin to a surface of a plate-shaped foam material containing bubbles in order to hold and keep a high-temperature liquid warm; a reinforcing frame made of a metal having a strength higher than that of the foam material after hardening is fixed to a plate side surface formed along a thickness direction of the plate-shaped foam material; and the polyurethane resin layer being formed on the outside of the foam material in a state in which the reinforcing frame is fixed to the plate side surface ,
The manufacturing method includes a first coating step of coating a first coating layer by applying the polyurethane resin to a predetermined thickness onto the surfaces of the foam material and the reinforcing frame , and a second coating step of applying a second coating layer to the outer surface of the first coating layer, the second coating layer having a thick layer portion and a thin layer portion that is thinner than the thick layer portion, in the order described above.
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3203263U (en) | 2015-11-25 | 2016-03-24 | 邦彦 上原 | Bath lid |
| JP2018015977A (en) | 2016-07-27 | 2018-02-01 | 竹本 直文 | Resin molding and method for producing resin molding |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JPH0771694A (en) * | 1993-06-25 | 1995-03-17 | Kawatetsu Container Kk | High pressure gas cylinder |
| JPH08282743A (en) * | 1995-04-08 | 1996-10-29 | Inoac Corp | Heat-insulating case |
| JP2729783B2 (en) * | 1995-11-27 | 1998-03-18 | 純二 水摩 | Bathtub lid |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3203263U (en) | 2015-11-25 | 2016-03-24 | 邦彦 上原 | Bath lid |
| JP2018015977A (en) | 2016-07-27 | 2018-02-01 | 竹本 直文 | Resin molding and method for producing resin molding |
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