JP6240004B2 - Resin product including sealed hollow part and production method of resin product including sealed hollow part - Google Patents

Description

  The present invention relates to a resin product including a sealed hollow portion having heat insulation performance by a hollow portion and a method for producing a resin product including a sealed hollow portion.

Glass wool, rock wool, and the like are often used as members having heat insulation performance. However, when these members are used, there is a problem that the thickness of the members increases.
Various research and development have been conducted to overcome these drawbacks.

For example, Patent Document 1 (Japanese Patent Application Laid-Open No. 2008-49981) discloses a hollow shape material that provides high soundproofing and heat insulation properties without causing an increase in cost.
The hollow shape material described in Patent Document 1 (Japanese Patent Application Laid-Open No. 2008-49981) is a hollow shape material in which the front and back plates are connected to each other with a plurality of hollow portions, and the decompressed space or the vacuum space by the hollow portions. Is provided.

Patent Document 2 (Japanese Patent Laid-Open No. 2003-42651) supplies a vacuum panel for building materials with a stable quality by molding an integrated vacuum panel made of synthetic resin and a large amount of waste plastic that is industrial waste. A vacuum panel unit that contributes to processing is disclosed.
The vacuum panel unit described in Patent Document 2 (Japanese Patent Application Laid-Open No. 2003-42651) is obtained by providing a closing member on the end face of a cylindrical unit formed of a synthetic resin and keeping the inside in a vacuum state.

Furthermore, Patent Document 3 (Japanese Patent Laid-Open No. 2004-9493) is designed to prevent reuse of resources, environmental pollution, and environmental destruction, has excellent mechanical strength, has buffering properties and heat insulation properties, water resistance, soundproofing, etc. In addition, a plate-like hollow structure formed of a non-chlorine synthetic resin material and a method for producing the same are disclosed.
The provision of the plate-like hollow structure described in Patent Document 3 (Japanese Patent Application Laid-Open No. 2004-9493) and its manufacturing method is a surface made of a non-chlorine-based synthetic resin material arranged in parallel at a predetermined interval in the thickness direction. A sheet layer, a back sheet layer, and an intermediate layer made of a non-chlorine synthetic resin material interposed between the sheet layers, the intermediate layer being formed in an uneven shape in the lateral width direction, And the concavo-convex portions are fused and integrally connected to each other, and a plurality of longitudinal groove-shaped hollow portions S are formed between the front and back sheet layers.

JP 2008-49981 A JP 2003-42651 A Japanese Patent Laid-Open No. 2004-9493

  However, the vacuum panel has a drawback that the production process is complicated and the production efficiency is poor. As a result, there is a problem that the manufacturing cost of the vacuum panel increases.

Moreover, the hollow shape material described in Patent Document 1 has a suction port, and the vacuum panel described in Patent Document 2 has a blocking plug. Therefore, there is a problem that outside air enters from these suction ports or plugs, the hollow portion communicates with the outside air, the vacuum degree of the hollow portion is lowered, and the heat insulation efficiency is lowered.
Furthermore, since the plate-like hollow structure described in Patent Document 3 is produced by extruding a panel having a hollow portion, the end portion in the extrusion direction is in an open state, the outside air passes through the hollow portion, and the heat generated by the flow of the outside air An exchange occurs. As a result, there is a problem that the heat insulation efficiency is lowered.

  The objective of this invention is providing the production method of the resin product containing the sealed hollow part which can maintain heat insulation efficiency, and the sealed hollow part.

(1)
The resin product including the sealed hollow portion according to one aspect includes a sealed hollow portion formed by being closed inside the resin.

  In this case, since a resin product having a completely sealed hollow portion can be formed, it is possible to prevent a decrease in heat insulation efficiency. That is, since there is no seal part or plug part, there is no possibility that outside air may invade, heat exchange due to the flow of outside air can be prevented, and a fitting dimension with the plug part is not necessary, so that the thickness can be reduced. .

(2)
The resin product including the sealed hollow portion according to the second invention is a resin product including the sealed hollow portion according to one aspect. The sealed hollow portion may be formed by closing a space formed inside the resin.

  In this case, since the space formed inside the resin is closed, the resin product having a completely sealed hollow portion can be formed. Therefore, a decrease in heat insulation efficiency can be prevented.

(3)
The resin product including the sealed hollow portion according to the third invention is a resin product according to one aspect or including the sealed hollow portion according to the second invention. The sealed hollow portion is continuously formed inside the resin by extrusion molding. The space may be closed at a predetermined interval.

In this case, since a resin product having a completely sealed hollow portion can be formed, it is possible to prevent a decrease in heat insulation efficiency. That is, since there is no seal part or plug part, there is no possibility that outside air may invade, heat exchange due to the flow of outside air can be prevented, and a fitting dimension with the plug part is not necessary, so that the thickness can be reduced. . Moreover, since it can be manufactured basically by extrusion molding, cost increase can be suppressed, and continuous mass production is also possible.
Moreover, it is not limited to extrusion molding, You may use other arbitrary shaping | molding methods, for example, blow molding, vacuum forming, etc.
Specifically, in blow molding, after the parison is sandwiched between molds, a press process for closing the space may be performed in an arbitrary process. In vacuum molding, after heat molding, before cooling, the space You may perform the press process which obstruct | occludes.

(4)
The resin product including the sealed hollow portion according to the fourth invention is in accordance with one aspect or in the resin product including the second and third sealed hollow portions, and the resin may use a gas barrier resin at least in part.

In this case, since the gas barrier resin is used, the gas barrier property can be improved. That is, gas exchange between the sealed hollow portion and the outside air can be blocked for a long period of time.
The gas barrier resin here is placed under conditions of a temperature of 20 ° C. and a humidity of 50% or less,
A resin having a permeability coefficient for nitrogen and oxygen of 100 (cc · 20 μm / m 2 · day · atm) or less is desirable.

(5)
According to another aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion, wherein an extrusion step of extruding a resin including a continuously formed space from a mold, and at least a continuously formed space of the resin extruded by the extrusion step. And a closing step of closing one or more spaces every predetermined time to form a sealed hollow portion.

  In this case, since the resin product having a completely sealed hollow portion can be formed by the extrusion step and the closing step, it is possible to prevent the heat insulation efficiency from being lowered. In particular, since it can be basically manufactured by extrusion molding, an increase in cost can be suppressed and mass production is also possible.

(6)
A method for producing a resin product including a sealed hollow portion according to a sixth aspect of the invention is a method for producing a resin product including a sealed hollow portion according to another aspect, and a cooling step of cooling the extruded resin to a predetermined temperature. Including, at least one of the extrusion step, the closing step, and the cooling step is performed in a reduced pressure space.

In this case, since any one of the extrusion process, the closing process, and the cooling process is performed in the reduced pressure space, even when the continuously formed space is in a vacuum state, the resin is not exposed to the atmospheric pressure. Crushing at atmospheric pressure can be prevented. Moreover, since the resin product which has a perfect sealed hollow part can be formed, the fall of heat insulation efficiency can be prevented. In particular, since it can be basically manufactured by extrusion molding, an increase in cost can be suppressed and mass production is also possible.
The predetermined temperature is preferably in the range of 0 ° C. or higher and 50 ° C. or lower, and more preferably 18 ° C. or higher and 30 ° C. or lower.

(7)
According to a seventh aspect of the present invention, there is provided a resin product production method including a sealed hollow portion according to another aspect of the invention, wherein the mold includes a continuously formed space and an outside air around the mold. You may have a hole which communicates.

In this case, it is possible to prevent outside air from flowing into the space through the communicating hole and crushing the space due to a pressure difference. Further, since no special process such as gas injection is required, the cost can be reduced.
For example, when there are a plurality of spaces, the holes to be communicated may be not only when all the holes are in communication, but also when only some of the holes are in communication. .

(8)
According to an eighth aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion, wherein the fluid is injected into a continuously formed space from a hole in the method for producing a resin product including the sealed hollow portion according to the seventh aspect. An injection step may be further included.

  In this case, by injecting a gas having a low thermal conductivity typified by argon gas or carbon dioxide gas, a resin product in which the gas having a low thermal conductivity is filled in the sealed hollow portion can be continuously produced. Accordingly, it is possible to continuously produce a resin product having a higher heat insulation performance than when the gas in the continuously formed space is air.

(9)
The method for producing a resin product including a sealed hollow portion according to the ninth invention is the method for producing a resin product including the sealed hollow portion according to the eighth invention, wherein the first injection step uses a predetermined gas as a fluid, The resin is at least partially made of a resin having a permeability coefficient with respect to a predetermined gas at a temperature of 20 ° C. and a humidity of 50% or less of 50 times or more of a permeability coefficient with respect to nitrogen at a temperature of 20 ° C. and a humidity of 50% or less. Also good.

  In this case, by using a resin whose permeability coefficient for a given gas is 50 times or more than the permeability coefficient for nitrogen, the prescribed gas in the sealed hollow portion is quickly released out of the resin product, but the entry of outside air is delayed. . As a result, the sealed hollow portion is quickly brought into a low vacuum state and is maintained for a long time.

(10)
According to a tenth aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion, wherein the predetermined gas may be composed of helium gas.

  In this case, since helium gas is used, the resin permeation performance is high, and the helium gas in the sealed hollow portion is quickly released out of the resin product, but there is an advantage that the intrusion of outside air is delayed. As a result, the sealed hollow portion quickly enters a low vacuum state and is maintained for a long period of time, so that it is possible to continuously produce a resin product having higher heat insulation performance than when air and other gases are sealed.

(11)
According to an eleventh aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion according to the eighth invention. In the method for producing a resin product including the sealed hollow portion according to the eighth invention, the first injection step includes at least water and water vapor as fluids. Either of them may be used.

In this case, the degree of vacuum in the sealed hollow portion can be obtained by using at least one of water and water vapor as the fluid in the first injection step.
For example, when 100 ° C. saturated water vapor is injected under an atmosphere of 1 atm, the temperature decreases after molding, and the saturated water vapor pressure at 20 ° C. is 0.03 atm or less. A degree of vacuum of 97% or more can be obtained. Moreover, since the boiling point of water is 100 ° C., there is an advantage that it is not affected by atmospheric pressure until it becomes 100 ° C. or lower. Therefore, it is preferable to use a resin having a solidification temperature of around 100 ° C. In addition, there is an advantage that water is inexpensive and can be used safely.
It should be noted that the present invention is not limited to water, and various substances such as ethanol, methanol, gasoline, and the like may be used as long as problems related to fire can be removed.
Further, the first injection process may be a process in a pretreatment stage before production or may be a process in production.

(12)
According to a twelfth aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion. In the method for producing a resin product according to the seventh aspect of the present invention, a state change (phase change) from a hole to a continuously formed space is performed. The method may further include a second injection step of injecting a substance with

In this case, as the temperature decreases during molding, a state change (phase change) of the injected substance occurs in the sealed hollow part, and the inside of the sealed hollow part is reduced to the saturated vapor pressure of the injected substance. By using a substance having a small saturated vapor pressure at 20 ° C., the sealed hollow portion can be brought into a high vacuum state when the molding is completed.
Further, since the decompression starts below the boiling point of the substance, the resin is not exposed to the atmospheric pressure at a temperature higher than the boiling point of the substance, and the continuously formed space can be prevented from being crushed by the atmospheric pressure. Therefore, as a substance to be used, the effect can be enhanced by using a substance having a small saturated vapor pressure of 20 ° C., a boiling point not lower than room temperature and not higher than the solidification temperature of the resin.

(13)
According to a thirteenth aspect of the present invention, there is provided a method for producing a resin product including a sealed hollow portion according to the twelfth aspect of the invention, wherein the second injection step includes water, ice and water vapor as substances. At least one of the above may be used.

In this case, the degree of vacuum in the sealed hollow portion can be obtained by using at least one of water, ice, and water vapor as the substance for the second injection step.
For example, when 100 ° C. saturated water vapor is injected under an atmosphere of 1 atm, the temperature decreases after molding, and the saturated water vapor pressure at 20 ° C. is 0.03 atm or less. A degree of vacuum of 97% or more can be obtained. Moreover, since the boiling point of water is 100 ° C., there is an advantage that it is not affected by atmospheric pressure until it becomes 100 ° C. or lower. Therefore, it is preferable to use a resin having a solidification temperature of around 100 ° C. In addition, there is an advantage that water is inexpensive and can be used safely.
It should be noted that the present invention is not limited to water, and various substances such as ethanol, methanol, gasoline, and the like may be used as long as problems related to fire can be removed.
Further, the second injection process may be a pre-processing stage before production, or may be a process during production.

It is a typical perspective view which shows an example of the flat panel containing a hollow part. It is typical sectional drawing which shows the AA sectional view taken on the plane panel of FIG. It is typical sectional drawing which shows the BB sectional drawing of the flat panel of FIG. It is a typical perspective view which shows an example of the cylindrical pipe containing a sealed hollow part. It is typical sectional drawing which shows CC line sectional drawing of the cylindrical pipe of FIG. It is typical sectional drawing which shows the DD sectional view taken on the line of the cylindrical pipe of FIG. It is typical sectional drawing for demonstrating the outline of a sealed hollow part. It is typical sectional drawing for demonstrating the other example of the outline of a sealed hollow part. It is typical sectional drawing for demonstrating an example of the flat panel in which the sealed hollow part was formed in multiple steps. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows an example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows the other example of the manufacturing process of the flat panel containing a sealed hollow part. It is a schematic diagram which shows the further another example of the manufacturing process of the flat panel containing a sealed hollow part.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the same parts are denoted by the same reference numerals. Moreover, in the case of the same code | symbol, those names and functions are also the same. Therefore, detailed description thereof will not be repeated.

(Flat panel including sealed hollow part)
FIG. 1 is a schematic perspective view showing an example of a flat panel 100 including a sealed hollow portion according to the present embodiment, and FIG. 2 is a schematic cross-sectional view taken along line AA of the flat panel 100 of FIG. FIG. 3 is a cross-sectional view, and FIG. 3 is a schematic cross-sectional view showing a cross-sectional view taken along line BB of the flat panel 100 of FIG.

  As shown in FIG. 1, the flat panel 100 including the sealed hollow portion according to the present embodiment is made of a thick plate member. Further, as shown in FIG. 2, the sealed hollow portion 200 is not formed in the cross section along the line AA, and as shown in FIG. They are formed in parallel.

  That is, the flat panel 100 shown in FIG. 1 is formed in a state in which the sealed hollow portions 200 extending in the x direction are arranged in parallel in a plurality of y directions, and the sealed hollow portions 200 are sealed at the ends of the flat panel 100. Has been.

The flat panel 100 according to the present embodiment has, for example, a thickness in the z direction of 15 mm, a length in the x direction of 1820 mm, and a length in the y direction of 910 mm.
Moreover, the sealed hollow part 200 has a height in the z direction of 13 mm and a length in the y direction of 20 mm, for example. Details of the sealed hollow portion 200 will be described later.

(Cylindrical pipe including sealed hollow part)
FIG. 4 is a schematic perspective view showing an example of the cylindrical pipe 400 including the sealed hollow portion according to the present embodiment, and FIG. 5 is a cross-sectional view taken along the line C-C of the cylindrical pipe 400 of FIG. FIG. 6 is a schematic cross-sectional view, and FIG. 6 is a schematic cross-sectional view showing a cross-sectional view taken along the line D-D of the cylindrical pipe 400 of FIG.

  As shown in FIGS. 4 and 5, the cylindrical pipe 400 including the sealed hollow portion according to the present embodiment includes a double cylindrical body of an inner cylinder 410 and an outer cylinder 420. In the present embodiment, for the sake of explanation, the inner cylinder 410 and the outer cylinder 420 are provided. However, the present invention is not limited to this, and the inner cylinder 410 and the outer cylinder 420 are formed from the same material, and will be described later. The portion 200 may be formed.

  Further, as shown in FIG. 5, in the cross section taken along the line CC, the sealed hollow portion 200 is not formed in either the inner cylinder 410 or the outer cylinder 420, and as shown in FIG. , The inner cylinder 410 is not formed with the sealed hollow part 200, and the outer cylinder 420 is formed with a plurality of sealed hollow parts 200 in parallel.

That is, in the cylindrical pipe 400 shown in FIG. 4, the sealed hollow portion 200 extending in the x direction is circumferentially arranged in parallel in the outer cylinder 420, and the sealed hollow portion 200 is sealed at the end of the cylindrical pipe 400. It is formed in the state.
In the case of the cylindrical pipe 400 according to the present embodiment, the portion through which the fluid passes is not closed on the inner peripheral side of the inner cylinder 410, but is used for heat insulation provided on the outer peripheral side of the inner cylinder 410 of the cylindrical pipe 400. The sealed hollow portion 200 is closed.

(Detailed description of sealed hollow part)
FIG. 7 is a schematic cross-sectional view for explaining the outline of the sealed hollow part 200, and FIG. 8 is a schematic cross-sectional view for explaining another example of the outline of the sealed hollow part 200.

7 and 8 is formed of at least one or more of a general-purpose resin 210, a general-purpose foamed resin 220, and a gas barrier resin 230.
For example, as shown in the cross section of FIG. 7, a general-purpose resin 210 is formed in the y direction, and a rectangular shape is formed of the general-purpose foamed resin 220 in the z direction. Covering. A sealed hollow portion 200 is formed inside the gas barrier resin 230.

  Further, for example, as shown in the cross section of FIG. 8, a general-purpose resin 210 is formed in the y direction, and a rectangular shape is formed by the general-purpose foamed resin 220 in the z direction. Covered with. The sealed hollow portion 200 may be formed in a rectangular shape formed by the general-purpose resin 210 and the general-purpose foamed resin 220.

  Here, the general-purpose resin 210 in the present embodiment is made of PVC (polyvinyl chloride). The general-purpose foamed resin 220 is made of foamed PVC (foamed polyvinyl chloride). The gas barrier resin 230 is made of an ethylene-vinyl alcohol copolymer resin.

Note that the general-purpose resin 210 is a part that receives atmospheric pressure, and thus is preferably a resin that is low in cost and has a large elastic modulus and strength.
Moreover, since the general-purpose foamed resin 220 is a part corresponding to a thermal bridge, a resin having low thermal conductivity is desirable. Further, the gas barrier resin 230 is desirably a resin having high gas barrier performance.

Instead of using the general-purpose foamed resin 220, the general-purpose resin 210 may be used for the portion, and the general-purpose resin 210 may be made of high-density polyethylene (HDPE).
Furthermore, when the general-purpose resin 210 is made of high-density polyethylene (HDPE) and the gas barrier resin 230 is made of an ethylene-vinyl alcohol copolymer resin, the barrier performance against main gases such as water vapor, nitrogen, and oxygen can be improved.

  Further, instead of using the general-purpose resin 210 and the general-purpose foamed resin 220, the gas barrier resin 230 may be used for the portion, and the gas barrier resin 230 may be an ethylene-vinyl alcohol copolymer resin, and other resins having high gas barrier performance. It may be.

In addition, it is not limited to said resin, As general-purpose resin 210, general-purpose foamed resin 220, and gas barrier resin 230, all the resin which can be extrusion-molded is applicable, and multiple types of resin may be used together, gas barrier performance Is high, water vapor barrier performance is high, the thermal conductivity of the thermal bridge is low,
A combination of resins having a large elastic modulus or strength and a low overall cost is considered optimal.
Moreover, if a transparent resin is used, a transparent panel can be produced and can also be used inside a window.

As the transparent resin, acrylic, polycarbonate, PET, vinyl chloride and the like can be used. As the general-purpose resin 210, vinyl chloride, polyethylene (PE), polypropylene (PP), polycarbonate (PC), ABS resin (acrylonitrile, butadiene) Styrene copolymer synthetic resin), polyethylene terephthalate (PET), and the like can be used.
As the gas barrier resin 230, ethylene-vinyl alcohol copolymer resin, acrylonitrile copolymer, vinylidene chloride copolymer, nylon, polyethylene terephthalate (PET), polyester, polyarylate, polychlorotrifluoroethylene, polyvinylidene fluoride, and the like can be used. .

  In the present embodiment, the planar panel 100 including the sealed hollow portion 200 or the cylindrical pipe 400 including the sealed hollow portion 200 has been described. However, the present invention is not limited thereto, and a curved panel, a modified cross-section pipe, or the like is extruded. You may apply to all the resin products which can shape | mold and can form the sealed hollow part 200. FIG.

(Multiple stack type)
Next, FIG. 9 is a schematic cross-sectional view for explaining an example of a flat panel 100a in which a plurality of sealed hollow portions 200 are formed.

The flat panel 100a shown in FIG. 9 may overlap the sealed hollow portion 200 in the z direction while shifting the position of the thermal bridge. As a result, the length of the thermal bridge can be extended, and the heat insulation efficiency can be further increased.
In addition, instead of the two-stage type illustrated in FIG. 9, a three-stage, four-stage, or any number of types may be stacked, or the positions may be stacked without shifting the position of the thermal bridge.

In the present embodiment, the cross-section of the sealed hollow portion 200 is formed in a rectangular shape, but is not limited thereto, and is formed in an arbitrary shape such as a polygon, a circle, a triangle, a honeycomb, or an ellipse. Also good.
Moreover, by setting the hollow thickness to around 6 mm, convection when gas is present in the sealed hollow portion can be suppressed, and heat insulation performance can be improved.

(Manufacturing method of the flat panel 100 including the sealed hollow part 200)
10 to 15 are schematic views showing an example of the manufacturing process of the flat panel 100 including the sealed hollow portion 200. FIG. As shown in FIGS. 10 to 15, the manufacturing apparatus 500 includes an extrusion molding machine 510, a mold 520, and a press compressor 530.

  As shown in FIG. 10, a resin product having a simple space is extruded from an extruder 510 through a mold 520. That is, it is a state before the flat panel 100 including the sealed hollow portion 200 is formed.

Next, as shown in FIG. 11, the resin extruded by the press compressor 530 is subjected to a press compression process in a short time in the vertical direction (the direction of the arrow Z).
As a result, one end portion of the flat panel 100 having the sealed hollow portion 200 starts to be crushed and formed.

Next, as shown in FIG. 12, the press compressor 530 is moved in the vertical direction (the direction of the arrow -Z). Subsequently, as shown in FIG. 13, the product of the flat panel 100 including the sealed hollow portion 200 is extruded from the extruder 510 through the mold 520. For example, the flat panel 100 is extruded 1820 mm from the mold. Thereby, the dimension of the flat panel 100 of FIG. 1 is formed. During this time, the press compressor 530 does not operate.
Of course, the interval may be set to an arbitrary length instead of 1820 mm. As a result, the product length of the flat panel 100 can be freely adjusted, and many dimensional variations of the flat panel 100 can be easily provided.

Finally, as shown in FIG. 14, after being pushed out by 1820 mm, a press compressor 530 performs a press compression process in a short time in the vertical direction (in the direction of arrow Z). As a result, the other end of the flat panel 100 having the sealed hollow portion 200 is crushed and the sealed hollow portion 200 is completely closed. Finally, as shown in FIG. 15, the press compressor 530 is moved in the vertical direction (the direction of the arrow −Z).
By repeating the steps of FIGS. 10 to 15, the flat panel 100 including the sealed hollow portion 200 can be continuously produced by extrusion.

  In the present embodiment, the press compressor 530 is used. However, the present invention is not limited to this, and any unit that can close the space and form the sealed hollow portion 200 may be used.

  Also, in the case of the cylindrical pipe 400 shown in FIGS. 4 to 6, the portion of the ordinary cylindrical pipe that extends only from the outlet of the mold is used as the inner mold for the press, and the outer mold for the press is provided. This can be achieved by performing a compression operation from the circumferential direction to the axial direction.

(Manufacturing process in decompression space)
FIG. 16 is a schematic diagram illustrating another example of the manufacturing process of the flat panel 100 including the sealed hollow portion 200. Hereinafter, differences in the manufacturing process of the flat panel 100 including the sealed hollow part 200 of FIG. 16 from the manufacturing process of the flat panel 100 including the sealed hollow part 200 of FIGS. 10 to 15 will be described.

As shown in FIG. 16, the step of forming the flat panel 100 including the sealed hollow portion 200 may be performed in a reduced pressure space.
That is, you may implement the arbitrary processes from the obstruction | occlusion process by the press compressor 530 of the flat panel 100 containing the airtight hollow part 200 to a cooling process and a taking-off process in the pressure reduction space made into the vacuum state with the vacuum pump. In addition, the broken line in FIG. 16 means the closed space closed, and the inside of the closed space is decompressed.

  Thereby, even if the flat panel 100 is in a molten state, it can be prevented from being deformed by the atmospheric pressure, that is, the sealed hollow portion 200 can be prevented from being crushed by the atmospheric pressure.

(Hole formation process or gas injection process)
FIG. 17 is a schematic diagram showing still another example of the manufacturing process of the flat panel 100 including the sealed hollow portion 200.

  The manufacturing process of the flat panel 100 including the sealed hollow portion 200 illustrated in FIG. 17 will be described mainly with respect to the differences from the manufacturing process of the flat panel 100 including the sealed hollow portion 200 illustrated in FIGS. 10 to 16.

  As shown in FIG. 17, a hole 540 is formed from the outer surface of the mold 520 through a bridge that connects the outer die and the inner core, so that a space is formed between the outer surface of the mold and the inside of the resin. May be communicated by the hole 540. In the present embodiment, since 24 cores are used, the 24 spaces communicate with the outer surface of the mold. In addition, you may make it connect only arbitrary spaces, without making all the spaces communicate.

  That is, after the press compressor 530 is operated, the sealed hollow portion 200 is in a vacuum state. Therefore, an internal / external pressure difference is generated between the outside air and the sealed hollow portion 200. Therefore, in the manufacturing process, by forming the hole 540 communicating with the outside air, the outside air naturally flows in from the hole 540, and the pressure can be balanced. Thereby, even if the resin of the flat panel 100 is in a molten state, the sealed hollow portion 200 can be prevented from being crushed by atmospheric pressure. Furthermore, you may add the drying process which dries the external air which flows in. As a result, it is possible to prevent water droplets from being generated inside the sealed hollow portion 200 after air sealing.

In addition, as shown in FIG. 17, a fluid infuser 550 may be provided on the side opposite to the core surface side of the hole 540, that is, on a portion for sucking outside air.
Specifically, the fluid injector 550 includes a gas cylinder having a low thermal conductivity such as argon gas or carbon dioxide gas. By using the fluid injector 550, the internal pressure of the sealed hollow portion 200 can be increased from the atmospheric pressure. Accordingly, deformation due to external force can be suppressed, so that the thickness in the Z direction of the general-purpose resin 210 in FIG. 7 can be reduced.

  The fluid injector 550 may include a gas cylinder of helium gas that is a highly resin permeable gas. In the case of helium gas, since the resin permeability is extremely high, it is released from the sealed hollow portion 200 in a short time. As a result, the sealed hollow portion 200 can be in a low vacuum state.

  Further, instead of helium gas, a gas such as hydrogen, which is light and has a small molecular size, and consequently has high resin permeability may be used. Further, the injection step of injecting the fluid may include a fluid temperature raising step. In the case of a high-temperature fluid, the number of molecules is smaller than injecting at a room temperature of about 20 ° C., so that it is effective in the case where it is desired to remove it quickly like helium gas.

Further, the fluid injector 550 may include a water vapor generator. The steam generator may include a step of promoting a phase change from water to steam, for example, a step of boiling water by heating.
For example, when 100 ° C. saturated water vapor is injected at 1 atm, the temperature drops during molding, and when the temperature becomes 100 ° C. or lower, the water vapor in the sealed hollow portion 200 partially becomes water, and the sealed hollow portion 200 The pressure is reduced to the saturated water vapor pressure of the temperature.

As a result, the water vapor is decompressed to 0.03 atm or less in a 20 ° C. environment, and a vacuum degree of 97% or more can be obtained.
Moreover, since it is not influenced by atmospheric pressure until it becomes 100 degrees C or less, when resin with a solidification temperature of 100 degreeC or more is used, it will receive atmospheric pressure only after solidification. Furthermore, the substance to be injected is not limited to water, and any other substance that changes state during molding may be used.
For example, various substances such as ethanol, methanol, gasoline, etc., which are gases at a molding temperature (around 200 ° C.) and liquid at room temperature (around 20 ° C.) under an atmosphere of 1 atmosphere, may be used. However, there are many substances that are problematic in terms of safety to fire and the human body, and water is optimal. As a combination of the substance to be injected and the resin, a resin having a solidification temperature equal to or higher than the boiling point of the substance to be injected is desirable.

As described above, since the flat panel 100 including the sealed hollow portion 200 according to the present invention does not have a seal portion or a plug portion, there is no possibility of communicating with the outside air from the portion. However, even if the seal portion or the plug portion is not provided, there is a considerable amount of gas exchange due to permeation.
In addition, when the sealed hollow portion 200 is vacuum, it is necessary to block the intrusion of outside air into the sealed hollow portion 200 in order to maintain high heat insulation performance.
Furthermore, when a low thermal conductivity gas typified by argon gas or carbon dioxide gas is sealed in the sealed hollow part 200, it is necessary to block gas diffusion to the outside in order to maintain high heat insulation performance.
Finally, when a high resin-permeable gas typified by helium gas is sealed in the sealed hollow portion 200, it is necessary to promote gas diffusion to the outside in order to quickly bring the sealed hollow portion 200 into a low vacuum state. is there.
In order to satisfy the above requirements, it is possible to use a gas barrier resin 230 having a high gas barrier performance such as an ethylene-vinyl alcohol copolymer resin. That is, the ethylene-vinyl alcohol copolymer resin is characterized by high barrier performance against nitrogen or oxygen, which is the main component of air, but low barrier performance against helium gas.

From the above, as shown in FIG. 7, the provision of the gas barrier resin 230 prevents the entry of outside air from the outside into the sealed hollow portion 200, prevents the diffusion of argon gas or carbon dioxide gas from the inside to the outside, External diffusion is not prevented, and invasion of gas from the outside can be prevented in order to maintain a low vacuum state generated after diffusion.
In order to quickly release helium to the outside, it is desirable to store the resin product in a high-temperature tank for an arbitrary period after extrusion. Further, by reducing the pressure in the high-temperature tank, the difference in internal and external partial pressure of helium can be increased, so that it can be released more quickly.

Further, a getter agent may be introduced from the hole 540. Here, the getter agent absorbs a predetermined fluid. The getter agent desirably absorbs nitrogen or oxygen, which is the main component of air, or water or water vapor, but is not limited thereto. Specific examples include silica gel and the like.
When the getter agent is introduced into the hole 540, an equal amount of getter agent can be introduced for each product by synchronizing the operation interval of the press compressor 530 and the introduction interval into the hole 540.
Further, a resin having a getter function may be used. Specifically, it is a resin mixed with silica and / or zeolite.

  In this embodiment, it is made of the general-purpose resin 210, the general-purpose foamed resin 220, and the gas barrier resin 230. However, the present invention is not limited to this, and it may be combined with a material having high gas barrier performance. An aluminum foil, an aluminum film, or an aluminum plate may be bonded.

  Furthermore, iron or glass may be combined. As a compounding method, any method such as adhesion, vapor deposition, and fusion may be used. The compounding may be performed during extrusion molding or may be performed by post-processing.

  As described above, since the flat panel 100 having the complete sealed hollow portion 200 can be formed, it is possible to prevent the heat insulation efficiency from being lowered. That is, since there is no seal part or plug part, there is no possibility that outside air may invade, heat exchange due to the flow of outside air can be prevented, and a fitting dimension with the plug part is not necessary, so that the thickness can be reduced. . Moreover, since it can be manufactured basically by extrusion molding, cost increase can be suppressed, and continuous mass production is also possible.

  In the present invention, the sealed hollow portion 200 corresponds to a “sealed hollow portion”, the flat panels 100 and 100a, and the cylindrical pipe 400 correspond to “resin product”, and at least the process of FIG. The mold 520 corresponds to the “extrusion step”, at least FIGS. 11, 12, 14, 15 and the press compressor 530 correspond to the “closure step”, and FIGS. 10 to 17 show “resin including a sealed hollow portion”. 16 corresponds to “Production Method”, the inside of the broken line in FIG. 16 corresponds to “inside the decompression space”, the hole 540 corresponds to “hole”, the gas barrier resin 230 corresponds to “gas barrier resin”, and the fluid injector 550 Corresponds to “first injection step or second injection step”.

  Moreover, although one preferable embodiment of this invention is as above-mentioned, this invention is not restrict | limited only to it. It will be understood that various other embodiments may be made without departing from the spirit and scope of the invention. Furthermore, in this embodiment, although the effect | action and effect by the structure of this invention are described, these effect | actions and effects are examples and do not limit this invention.

DESCRIPTION OF SYMBOLS 100,100a Flat panel 200 Sealing hollow part 210 General-purpose resin 220 General-purpose foamed resin 230 Gas barrier resin 400 Cylindrical pipe 500 Manufacturing apparatus 510 Extrusion machine 520 Mold 530 Press compressor 540 Hole 550 Fluid injection machine

Claims (2)

A method for producing a resin product including a sealed hollow part,
An extrusion process of extruding a resin including a continuously formed space from a mold;
Including a closing step of closing at least one space among the continuously formed spaces of the resin extruded by the extrusion step at predetermined time intervals to form a sealed hollow portion,
The mold has a hole for communicating the continuously formed space and the outside air around the mold,
A first injection step of injecting a fluid from the holes into the continuously formed space;
The first injection step uses a predetermined gas as the fluid,
The resin is at least partly a resin having a permeability coefficient with respect to the predetermined gas at a temperature of 20 ° C. and a humidity of 50% or less of 50 times or more of a permeability coefficient with respect to nitrogen at a temperature of 20 ° C. and a humidity of 50% or less. A method for producing a resin product including a sealed hollow portion. Wherein the predetermined gas is composed of helium gas, a method of producing a resin product containing a sealed hollow portion of claim 1.

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