JP3295804B2 - Adiabatic daylighting plate and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insulated lighting plate having heat insulation and daylighting properties, and more particularly to an insulated lighting plate having low surface gloss.

[0002]

2. Description of the Related Art Conventionally, as a heat-insulating daylighting plate having heat-insulating and daylighting properties, which is used, for example, for Japanese-style rooms such as shoji screens and interior doors, the surface of a light-transmitting polystyrene foam plate is bonded to a heat-sealing material layer and bonded. There has been known one coated with a polymethyl methacrylate (hereinafter, referred to as “PMMA”) film containing an ultraviolet absorber via an agent layer. Such a heat-insulating daylighting plate is a polystyrene-based foam plate having excellent heat-insulating properties and light-transmitting properties but low weather (light) resistance, and a PMMA containing an ultraviolet absorber.
By protecting with a system film, heat insulation and daylighting properties are ensured and weather resistance (light) is imparted.

[0003]

However, in the above-mentioned conventional heat-insulating daylighting plate, when light is applied to the surface thereof, the surface is glossy and glossy due to reflection, so that it is uncomfortable for applications such as shoji. Was. That is, the surface glossiness of Japanese paper (JIS Z) generally used for shoji paper
8741 (based on the specular gloss measurement method) is several percent, whereas that of the conventional heat insulating daylighting plate is about 20%.

[0004] As a method for reducing the surface gloss and performing matting, for example, an embossing method in which an embossing roll is directly pressed against a surface material, a sand blasting method in which fine powder is sprayed on the surface material to roughen the surface are known. However, these methods are not suitable for the production of the above-mentioned conventional heat-insulating daylighting plate.
That is, by giving an uneven shape to a surface material obtained by laminating a PMMA-based film and a heat-sealing material using an embossing method or a sand blasting method, the surface glossiness of such a surface material alone can be reduced. When the material is thermally bonded to a polystyrene foam plate or the like, heat is returned by thermal softening (plasticization) of the surface material, and as a result, the unevenness is flattened and the surface gloss is increased.

SUMMARY OF THE INVENTION In view of the above circumstances, an object of the present invention is to provide a heat-insulating daylighting plate having a low-gloss Japanese paper texture by lowering the surface glossiness of the heat-insulating daylighting plate having heat insulation and daylighting properties. Things.

[0006]

The structure of the present invention to achieve the above object is as follows.

That is, a first aspect of the present invention is that a surface material including a plastic film provided with a thin layer containing a mat material on a surface is laminated on at least one surface of a diffused light transmitting hard plastic foam plate. It is a feature of the heat insulation lighting plate.

[0008] A second aspect of the present invention is that a surface material obtained by laminating a polyester film or a polycarbonate film provided with a mat layer containing inorganic fine particles on the surface thereof and a polystyrene film is used with the polystyrene film inside. A method for manufacturing a heat-insulating daylighting plate, comprising a step of thermally bonding a diffused light-transmitting rigid polystyrene-based synthetic resin foam.

In the above description, the mat material is a material (agent) for imparting a matte tone, and the matte layer is a mat layer.

In the present invention, a surface material including a plastic film provided with a thin layer containing a granular or powdery mat material is used. The thin layer containing such a mat material has low surface glossiness due to irregular reflection of light, and can further reduce surface glossiness by forming fine irregularities by an embossing method or the like. Then, the heat-insulating daylighting plate of the present invention in which this surface material is thermally bonded to a hard plastic foam plate such as a polystyrene foam having diffused light transmittance can maintain the surface glossiness of the surface material alone,
The reason is not clear, but in many cases the surface gloss is further reduced, resulting in a dull product.

[0011]

Next, the present invention will be described in detail with reference to preferred embodiments.

FIG. 1 is a sectional view showing an example of a heat insulating daylighting plate according to the present invention, wherein 1 is a thin layer containing a mat material (hereinafter referred to as "mat layer"), 2 is a plastic film, and 3 is an adhesive. Reference numeral 4 denotes a heat-sealing material layer, 5 denotes a diffused light-transmitting hard plastic foam plate, and 6 denotes a surface material comprising a mat material layer 1, a plastic film 2, an adhesive layer 3, and a heat-sealing material layer 4. is there. Reference numeral 7 denotes minute irregularities provided on the surface of the mat layer 1.

The mat layer 1 is a layer formed by mixing a granular or powdery mat material with a binder resin to form a thin film.

As the material of the matting material, high hardness inorganic fine particles such as silica powder, aluminum powder and glass beads, and organic fine particles such as polyethylene particles and Teflon powder can be used. Strange) is difficult to do,
Alternatively, the above-mentioned inorganic fine particles are preferable in that they are not easily deformed by heat in the manufacturing process, particularly in the heat bonding process.

Examples of the binder resin include polyester resins, polyether resins, acrylic resins, epoxy resins, urethane resins, melamine resins, acrylic-melamine mixed resins, and acrylic-urethane mixed resins. It is possible to use various curable resins,
In particular, a mixed resin of an acrylic resin and a urethane resin is preferably used from the viewpoint of weather resistance.

The mat layer 1 has an ultraviolet absorber to improve the weather resistance of the mat layer 1 and to prevent light deterioration of a hard plastic foam plate such as a polystyrene foam having a diffused light transmittance described later. Is also preferred. Such ultraviolet absorbers include, for example, nickel salts,
Various compounds such as nickel complex salt, benzophenone, benzotriazole, phenyl salicylate, and triazine can be used.

The above-mentioned matting material and ultraviolet absorber are mixed with the above-mentioned binder resin at an appropriate mixing ratio, and formed thinly by coating (coating) or spraying on the plastic film 2.

As the plastic film 2, various plastic films can be used, for example, polyester film, polyethylene film, polypropylene film, polyvinyl chloride film, polyvinylidene chloride film, polycarbonate film, polyamide film, polystyrene film, ethylene-acetic acid film. A vinyl copolymer film or the like can be used. Among these, a polyester film and a polycarbonate film, which are excellent in transparency and are also excellent in physical properties such as heat resistance and small heat deformation under a heating environment when the mat layer 1 is dried and fixed, are particularly preferable.

When the thickness of the plastic film 2 is a polyester film or a polycarbonate film,
It is preferably 15 μm or less, particularly preferably 1 μm or less.
It is around 2 μm. The thickness of the plastic film 2 is 1
If it exceeds 5 μm, the strength of the film is too strong, so that thermal deformation (twisting) is liable to occur at the time of thermal bonding to the diffused light transmitting hard plastic foam plate 5 described later, and the appearance may be impaired. On the other hand, if the thickness of the plastic film 2 is too thin, a problem is likely to occur in terms of handling in the process. The diffused light-transmitting hard plastic foam plate 5 is a hard plastic foam plate made of a material having a relatively high light transmittance. For example, a polystyrene synthetic resin foam plate, a polymethyl methacrylate synthetic resin foam plate, or the like can be used. In particular, a polystyrene foam plate or a polymethyl methacrylate (PMMA) foam plate, which is excellent in daylighting properties, heat insulation properties, strength and the like, can be preferably used.

The average cell size of the foam plate 5 is 0.2 mm or more.
5.0 mm is preferable, and particularly preferably 0.3 mm to
2.0 mm. The average cell size is the average value of the cell diameter measured in the horizontal, vertical and thickness directions of the plate, and if the cell diameter varies, the average cell size of each cell in the thickness direction (Typically "A
STM D3576 "). In addition, it is preferable that the cells (bubbles) in the foam plate are substantially uniformly distributed.

The thickness of the foam plate 5 varies depending on the material and the average cell size, but is preferably 1 mm to 15 mm.

When the average cell size of the foam plate 5 is too small or the thickness is too large, the light-receiving property (light transmittance) is deteriorated although the heat insulating property is excellent. On the other hand, when the average cell size of the foam plate 5 is too large or the thickness is too small,
Although the light transmittance increases, the shape of the cell is easily visually perceived, and natural lighting cannot be obtained.

The heat-sealing material layer 4 is a layer made of a material having a thermal adhesive property to the foam board 5. For example, when a particularly preferable polystyrene foam board is used as the foam board 5,
A polystyrene film, an ethylene-vinyl acetate resin film, or the like can be used. When a PMMA foam board is used as the foam board 5, an acrylic film is preferable.

The surface material 6 is formed by bonding a heat sealing material layer 4 via an adhesive layer 3 to a surface of the plastic film 2 opposite to the surface on which the mat layer 1 is provided. Then, the heat insulating daylighting plate A is formed by thermally bonding the surface material 6 and the foam plate 5. Note that a polystyrene film was used as the plastic film 2 and the foam plate 5 was used.
When a polystyrene-based resin foam plate is used, the heat-sealing material layer 4 and the adhesive layer 3 are omitted, and the plastic film 2 provided with the mat layer 1 is directly heat-bonded to the foam plate 5 to form a heat-insulating daylighting plate. It can also be formed.

When the surface material 6 is thermally bonded to the foam plate 5, the thickness of the heat-sealing material layer 4 must be set so that the surface material 6 can be bonded well without being affected by the unevenness of the surface of the foam plate 5. Is 15μ
m or more. On the other hand, if the thickness of the heat-sealing material layer 4 is too large, the heat-sealing becomes difficult.
Is preferably 100 μm or less.

It is also preferred that the heat-insulating daylighting plate of the present invention is provided with an anti-static induction agent. This antistatic agent can be provided on the surface of the plastic film 2 opposite to the surface on which the mat material layer 1 is provided, thereby preventing the heat insulating daylight plate from being charged and preventing dust and the like from adhering. can do. As the anti-static induction agent, a polymer having both an anti-static induction function and an adhesion function to a film is preferable. Specifically, for example, "BONDEIP" (trade name) is gravure printed Can be applied to the film surface.

In the heat-insulating lighting plate A shown in FIG. 1, the surface material 6 is laminated on both sides of the foam plate 5, but the heat-insulating lighting plate of the present invention is not limited to this. Also includes those in which the surface material 6 is laminated.

Next, a method of manufacturing the heat-insulating daylighting plate of the present invention will be described.

The mat layer 1 containing the mat material is formed on the surface of the plastic film 2.

As a method for forming the mat layer 1, for example,
Any coating method such as a blade coating method, a gravure coating method, and a spray coating method can be used, but a gravure coating method or the like which is particularly excellent in the accuracy of the coating thickness and the like is preferable. The gravure roll includes a trapezoidal plate, a tortoiseshell plate, a hatched plate, and the like. When the coating thickness is relatively large in terms of improving the weather resistance, the hatched plate is preferable.

In forming the mat layer 1, the surface glossiness can be designed to some extent by appropriately setting the amount of the mat material added to the binder resin, the particle size of the mat material, the thickness of the layer, and the like. The surface glossiness can also be kept low.

By forming fine irregularities on the mat layer 1 by an embossing method or the like, the surface glossiness can be further reduced. As the embossing method, a conventionally known method such as a continuous film embossing method using an embossing roll and a high-frequency embossing method can be used.

On the plastic film 2 on which the mat layer 1 has been formed, the heat-sealing material layer 4
To form the surface material 6. As the adhesive layer 3, an acrylic resin type, a urethane resin type, or the like can be used.

Next, the surface material 6 is applied to the diffused light-transmitting hard plastic foam plate 5 with the plastic film 2 (or the heat-sealing material layer 4 when the heat-sealing material layer 4 is bonded) inside. By bonding, a heat insulating daylighting plate is obtained.

In the heat-insulating daylighting plate of the present invention thus manufactured, even when the fine unevenness 7 is formed on the mat layer 1 by the embossing method or the like, the surface glossiness of the surface material 6 itself is maintained. In many cases, the surface glossiness is further reduced, resulting in a matte panel.

[0036]

Next, examples and comparative examples of the present invention will be described.

(Examples 1 to 4) A heat-insulating daylighting plate of the present invention as shown in FIG. 1 was manufactured as follows.

First, an acrylic-urethane-based mixed resin (binder resin) / silica powder (mat material) / oxalic acid anilide derivative hindered amine-based light stabilizer (ultraviolet absorber) = 100/24 / 7.2. This was applied to a 12 μm-thick biaxially stretched polyester film 2 with a gravure roll, and the temperature was 190 ° C. and the linear velocity was 25 m.
/ Min. In a drying oven, rolled and cured at room temperature
Cured for days and established.

In this example, silica powder having an average particle diameter of 4 μm was used, and a gravure roll was formed by using a diagonal plate, and the coating thickness of the matting agent was set to 6 μm.

Next, an acrylic resin-based adhesive 3 is applied to the back surface of the polyester film 2 coated with the matting agent to a thickness of 3 μm by a roll coater, dried, and dried at the same time.
A μm stretched polystyrene resin film 4 was dry-laminated and cured at room temperature for 3 days to obtain a surface material 6.

The surface gloss was measured to determine the degree of gloss of the surface material 6. Specifically, JIS Z 8
741 specular gloss measurement method (method name: 60 degree specular gloss)
Was measured by As a result, the surface glossiness of the surface material 6 was 1
2%.

Next, the surface material 6 and the polystyrene-based resin foam plate 5 are superimposed and passed between a pressurized heating roll at 170 ° C. and a backup roll at a linear velocity of 5 m / min.
Panel 7 was obtained by heat bonding.

The polystyrene resin foam plate 5 used here
Are thickness 2 mm, average cell size 0.6 mm (Example 1), thickness 4 mm, average cell size 0.6 mm (Example 2), thickness 6 mm, average cell size 0.6 mm (Example 3), There are four types with a thickness of 10 mm and an average cell size of 0.7 mm (Example 4).

The surface glossiness of the four types of panels 7 manufactured as described above was measured in the same manner as described above.
When the surface roughness was measured, the average peak height was 3.5.
There were 96 μm particles almost uniformly per 0.1 mm ² . The surface roughness of the polyester film 2 before the application of the matting agent was measured. As a result, there were approximately 24 particles having an average peak height of 0.9 μm per 0.1 mm ² .

Further, the light transmittance was measured according to JIS K 6717, and the yellowness after irradiation with a sunshine weather meter for 300 hours was measured to evaluate the weather resistance.

Table 1 shows the above results. As shown in Table 1, all of the panels of Examples 1 to 4 have appropriate light transmittance (light-collecting property) and heat insulation, and have a surface gloss lower than that of the surface material alone. It was an insulated lighting plate with the texture of Japanese paper.

(Comparative Examples 1 and 2) As shown in Table 1, a panel was formed using a surface material having a structure in which a PMMA-based film was adhered to the surface of a polystyrene-based film with an adhesive, and a polystyrene-based resin foam plate. Produced.

In Comparative Example 1, irregularities were formed on the surface material by an embossing method, and in Comparative Example 2, irregularities were formed by a sandblasting method.

Each of the above surface materials and panels was evaluated in the same manner as in the above-described embodiment. As a result, Table 1
As shown in, although the surface gloss of the surface material alone is also high,
In the panel in which the surface material was thermally bonded to the foamed board, the surface glossiness was further increased due to the heat return of the surface material, and the surface was glossy and plastic-like due to the reflection of the interior light.

[0050]

[Table 1]

[0051]

As described above, according to the present invention, the following effects can be obtained. (1) A heat-insulating daylighting plate having moderate heat-insulating properties and daylighting properties, low surface glossiness, and a matte Japanese paper texture (so-called matte tone) is realized. (2) In particular, by using a heat or ultraviolet curable resin, for example, a mixed resin of an acrylic resin and a urethane resin as a binder resin of the mat layer, it is firmly fixed to the surface of the plastic film and has excellent weather resistance (light) and discoloration. A difficult adiabatic daylighting plate is realized. (3) In particular, by using a polyester film or a polycarbonate film as the plastic film constituting the surface material, an insulated light-collecting plate having excellent impact strength (no scattering) and excellent light-collecting properties, durability and water resistance is realized. . (4) In particular, by using a polystyrene-based synthetic resin foam or a polymethyl methacrylate-based synthetic resin foam having a specific average cell size and thickness as a diffused light-transmitting rigid plastic foam board, extremely heat insulating and daylighting properties are obtained. A heat-insulating daylighting plate having excellent heat resistance is realized.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a heat insulating daylighting plate of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Matt material layer 2 Plastic film 3 Adhesive layer 4 Thermal fusion | melting material layer 5 Diffusion light transmission hard plastic foam board 6 Surface material 7 Micro unevenness A Thermal insulation lighting board

Claims (10)

(57) [Claims] 1. A heat insulating daylighting plate characterized in that a surface material including a plastic film having a thin layer containing a mat material provided on a surface thereof is laminated on at least one surface of a diffused light transmitting hard plastic foam plate. 2. The heat-insulating daylighting plate according to claim 1, wherein the mat member is an inorganic fine particle material. 3. The heat insulating daylighting plate according to claim 1, wherein the thin layer containing the mat member is a cured resin layer. 4. The heat-insulating daylighting plate according to claim 1, wherein the thin layer containing the mat member has fine irregularities on the surface. 5. The heat-insulating daylighting plate according to claim 1, wherein the plastic film is a polyester film or a polycarbonate film. 6. The plastic film has a thickness of 15 μm.
The heat-insulating daylighting plate according to claim 5, wherein: 7. A polystyrene-based synthetic resin foam or a polymethyl methacrylate-based synthetic resin foam having an average cell size of 0.3 mm to 2.0 mm and a thickness of 1 mm to 15 mm as a diffused light transmitting hard plastic foam plate. The heat-insulating daylighting plate according to any one of claims 1 to 5, wherein 8. The method according to claim 1, wherein an anti-static induction agent is provided on the surface of the plastic film opposite to the surface on which the thin layer containing the mat material is provided. Insulated lighting plate. 9. A diffused light-transmitting hard polystyrene-based material in which a polyester film or a polycarbonate film having a mat layer containing inorganic fine particles provided on the surface thereof and a polystyrene-based film are laminated with the polystyrene-based film inside. A method for producing a heat-insulating daylighting plate, comprising a step of thermally bonding to a synthetic resin foam. 10. The method according to claim 1, further comprising, before the step of heat-bonding the surface material to the diffused light-transmitting hard polystyrene-based synthetic resin foam, a step of providing fine irregularities on the surface of the mat layer of the surface material. A method for manufacturing a heat-insulating daylighting plate according to claim 9.