JP7629953B2 - Heat insulating sheet and its manufacturing method - Google Patents
Heat insulating sheet and its manufacturing method Download PDFInfo
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- JP7629953B2 JP7629953B2 JP2023055241A JP2023055241A JP7629953B2 JP 7629953 B2 JP7629953 B2 JP 7629953B2 JP 2023055241 A JP2023055241 A JP 2023055241A JP 2023055241 A JP2023055241 A JP 2023055241A JP 7629953 B2 JP7629953 B2 JP 7629953B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 239000010419 fine particle Substances 0.000 claims description 35
- 239000011347 resin Substances 0.000 claims description 32
- 229920005989 resin Polymers 0.000 claims description 32
- 239000000463 material Substances 0.000 claims description 30
- 238000007906 compression Methods 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 8
- 230000006835 compression Effects 0.000 claims description 7
- 238000005452 bending Methods 0.000 claims description 6
- 229910044991 metal oxide Inorganic materials 0.000 claims description 6
- 150000004706 metal oxides Chemical class 0.000 claims description 6
- 230000004927 fusion Effects 0.000 claims description 2
- 229920006395 saturated elastomer Polymers 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- 239000000835 fiber Substances 0.000 description 50
- 239000002245 particle Substances 0.000 description 35
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 21
- 239000011810 insulating material Substances 0.000 description 17
- 238000002156 mixing Methods 0.000 description 16
- -1 calcia aluminate Chemical class 0.000 description 10
- 238000000748 compression moulding Methods 0.000 description 10
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 239000004698 Polyethylene Substances 0.000 description 9
- 229920000573 polyethylene Polymers 0.000 description 9
- 239000000377 silicon dioxide Substances 0.000 description 9
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 8
- 238000009413 insulation Methods 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 230000009970 fire resistant effect Effects 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 239000004743 Polypropylene Substances 0.000 description 6
- 229920001155 polypropylene Polymers 0.000 description 6
- 239000003365 glass fiber Substances 0.000 description 5
- 239000012774 insulation material Substances 0.000 description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 3
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 3
- 229910052863 mullite Inorganic materials 0.000 description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- 235000012255 calcium oxide Nutrition 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910021485 fumed silica Inorganic materials 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000002105 nanoparticle Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052809 inorganic oxide Inorganic materials 0.000 description 1
- 239000010954 inorganic particle Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000011146 organic particle Substances 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000002310 reflectometry Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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Description
本発明は、断熱シート及び該断熱シートの製造方法に関し、特に曲面への施工が可能な可撓性の断熱シート及び該断熱シートの製造方法に関する。 The present invention relates to a heat insulating sheet and a method for manufacturing the heat insulating sheet, and in particular to a flexible heat insulating sheet that can be applied to curved surfaces and a method for manufacturing the heat insulating sheet.
溶融金属を一時的に保持する有底円筒形状の溶湯容器の鉄皮の内張りや小型加熱炉の炉体の断熱、高温の流体が内部を流れる大口径配管の保温等の様々な用途に断熱材が用いられている。例えば断熱材を加熱炉の炉体に施工する場合は、炉体からの放熱の大幅な抑制及び炉体を構成する鉄皮への熱負荷軽減の目的で、シリカ等の無機微粒子を主材とした低熱伝導率材料からなる断熱材が使用されている。低熱伝導率材料は一般的に熱伝導率が８００℃で０.０８Ｗ／(ｍ・Ｋ)以下であり、最高使用温度が約１０００℃であり、最高使用温度１２００℃程度の高温用の断熱材製品もある。また、低熱伝導率材料からなる断熱材は、厚さ３～５ｍｍで用いられることが多い。 Insulating materials are used for various purposes, such as lining the steel shell of bottomed cylindrical molten metal containers that temporarily hold molten metal, insulating the furnace body of small heating furnaces, and keeping large-diameter pipes through which high-temperature fluids flow warm. For example, when insulating materials are applied to the furnace body of a heating furnace, insulating materials made of low thermal conductivity materials, mainly inorganic fine particles such as silica, are used to significantly reduce heat radiation from the furnace body and reduce the thermal load on the steel shell that makes up the furnace body. Low thermal conductivity materials generally have a thermal conductivity of 0.08 W/(m・K) or less at 800°C, a maximum operating temperature of approximately 1000°C, and there are also insulating materials for high temperatures with a maximum operating temperature of approximately 1200°C. Insulating materials made of low thermal conductivity materials are often used in thicknesses of 3 to 5 mm.
しかしながら、低熱伝導率材料は非常に脆弱であるため、上記の溶湯容器や大口径配管等のように曲面を有する機器や配管等に断熱材を施工する際、厚さ３～５ｍｍの断熱材をかかる曲面に沿って曲げたときに破損することがあった。このため、例えば有底円筒状の溶湯容器１の内壁面に低熱伝導率材料からなる断熱材２を施工するときは、図１に示すように、短冊状の複数の断熱材を溶湯容器１の曲面に合わせて多角形状に組み合わせて施工する必要があった。特に、混鉄車や小径容器等のように曲面の曲率半径が小さい部分を含むものの場合は、面積の小さな短冊状の断熱材を多数用いる必要があるため、施工に時間と手間が掛かるうえ、目地が増えるので断熱性が低下するおそれがあった。なお、溶湯容器の内面側に断熱材を施工するときは、必要に応じて該断熱材の内側に更に耐火材を施工することがある。
However, since low thermal conductivity materials are very fragile, when insulating materials are applied to equipment and piping having curved surfaces such as the above-mentioned molten metal container and large-diameter piping, insulating materials with a thickness of 3 to 5 mm may break when bent along such curved surfaces. For this reason, when applying insulating
そこで、曲面に沿わせて施工できるように工夫された断熱材が各種提案されている。例えば非特許文献１や非特許文献２には、ナノサイズのシリカ粒子（ヒュームドシリカ）からなる低熱伝導率材料を袋に収納した後に縫製することで、断熱材を布団状、キルト状、分節状等の様々な形態に製造する技術が開示されている。また、特許文献１には、低熱伝導率材料からなる成形体の少なくとも片面に無機繊維又は有機繊維からなる抗張力６０Ｎ／２５ｃｍ以上の強化材を接着した複合断熱材が提案されており、特許文献２には、テキスタイル生地層にヒュームドシリカ粉末を含有させた断熱生地が提案されている。
Various types of insulation materials have been proposed that are designed to be applied along curved surfaces. For example, Non-Patent
上記の非特許文献１や非特許文献２の断熱材を用いることで曲面に沿った施工は可能になるものの、断熱材を袋に入れて縫製した断熱材は、施工時の継ぎ目部分に加えて、縫製部分において低熱伝導率材料が途切れるか厚みが薄くなるので、局所的に断熱性が不十分になるいわゆる熱漏れが発生するのを避けることができなかった。また、ナノサイズの粒子を主材とする低熱伝導率材料は強度が比較的弱いため、取扱い中に袋内で損壊したり、施工後に静鉄圧や耐火物の熱膨張による圧縮応力で損壊したりする問題が生ずることもあった。
Although the insulating materials described in
特許文献１の複合断熱材は、熱膨張による圧縮応力で損壊しない圧縮強さと優れた断熱性とを兼ね備えることが可能になると考えられるが、最大曲率半径が１５００ｍｍまでの制限があった。特許文献２の断熱生地は、実施例１～４の全てにおいてガラス繊維がテキスタイル生地の主材に用いられているため、耐熱温度にはガラス転移温度を考慮する必要があると考えられる。本発明は上記事情に鑑みてなされたものであり、熱膨張による圧縮応力で損壊しない圧縮強さと優れた断熱性とを兼ね備えていることに加えて、施工に際して機器の曲面に沿って曲げても破損しにくい施工性に優れた断熱シートを提供することを目的とする。
The composite insulation material of
上記目的を達成するため、本発明者らは鋭意研究を重ねたところ、主材としてのシリカ等の無機微粒子に有機樹脂を配合することで得た低熱伝導率材料の成形体を加熱圧縮したところ、有機樹脂が溶融して無機微粒子に熱融着することでバインダーとして機能し、これにより断熱シートを曲げたときの撓み量が増加することを見出し、本発明を完成するに至った。 In order to achieve the above object, the inventors conducted extensive research and discovered that when a molded body of a low thermal conductivity material obtained by blending inorganic fine particles such as silica as the main material with an organic resin was heated and compressed, the organic resin melted and thermally fused to the inorganic fine particles, functioning as a binder, thereby increasing the amount of deflection when the heat insulating sheet was bent, and thus completing the present invention.
すなわち、本発明に係る断熱シートは、主材としての金属酸化物からなる無機微粒子に有機樹脂が含有率３～４０質量％の範囲内で混在した成形体からなり、前記有機樹脂が熱融着により前記無機微粒子に接着しており、厚さ５ｍｍのものをスパン１００ｍｍで曲げ強さ測定したときの破断時の撓み量が３.０ｍｍ以上１０ｍｍ以下であり、６００℃での熱伝導率が０.０３Ｗ／(ｍ・Ｋ)以上０.０５Ｗ／(ｍ・Ｋ)以下であり、圧縮強さが０.５５ＭＰａ以上で１.５６ＭＰａ以下であり、かさ密度が２００～５００ｋｇ／ｍ ３ であることを特徴としている。 That is, the heat insulating sheet of the present invention is composed of a molded body in which inorganic fine particles made of a metal oxide as a main material are mixed with an organic resin at a content in the range of 3 to 40 mass%, the organic resin is adhered to the inorganic fine particles by thermal fusion, and when a 5 mm thick sheet is measured for bending strength with a span of 100 mm, the deflection at break is 3.0 mm or more and 10 mm or less , the thermal conductivity at 600°C is 0.03 W/(m·K) or more and 0.05 W/(m·K) or less , the compressive strength is 0.55 MPa or more and 1.56 MPa or less, and the bulk density is 200 to 500 kg/ m3 .
また、本発明に係る断熱シートの製造方法は、主材としての金属酸化物からなる無機微粒子に有機樹脂を混合して圧縮成形した後、得られた成形体を加熱圧縮成形する（加圧された水蒸気飽和雰囲気で養生する場合を除く）ことで前記有機樹脂を前記無機微粒子に熱融着させることを特徴としている。 In addition, the manufacturing method of the insulation sheet of the present invention is characterized in that an organic resin is mixed with inorganic fine particles consisting of a metal oxide as a main material, and compression molded, and then the resulting molded body is heat-compression molded (except when curing is performed in a pressurized water vapor saturated atmosphere) to thermally fuse the organic resin to the inorganic fine particles.
本発明によれば、熱膨張による圧縮応力で損壊しない圧縮強さと優れた断熱性とを兼ね備えているうえ、施工に際して機器の曲面に沿って曲げても破損しにくいので極めて効率よく施工することが可能な断熱シートを提供することができる。 The present invention provides an insulating sheet that combines compressive strength that does not break due to compressive stress caused by thermal expansion with excellent insulating properties, and is also resistant to damage even when bent along the curved surface of equipment during installation, making it possible to provide an insulating sheet that can be installed extremely efficiently.
以下、本発明に係る断熱シートの実施形態について説明する。本発明の実施形態の断熱シートは、主材としての無機酸化物の無機微粒子に有機樹脂が混在した成形体の形態を有しており、この成形体には必要に応じて更に耐火繊維や赤外線散乱材が含まれている。また、本発明の実施形態の断熱シートは、小型容器等の断熱材として施工する際に要求される厚さ３～５ｍｍ程度まで薄く成形することが可能であり、厚さ５ｍｍのものをスパン１００ｍｍで曲げ強さ測定したときの破断時の撓み量が３.０ｍｍ以上である。従って、本発明の実施形態の断熱シートであれば、厚さ５ｍｍのものを曲率半径５００ｍｍの曲面に沿わせて曲げても破損させることなく施工することができる。なお、配合する有機樹脂の種類や形態、配合量、加熱圧縮成形時の加熱温度や保持時間を調整することによって、曲げ撓み量を変えることができる。また、上記の撓み量の上限は約１０ｍｍであり、この場合は厚さ５ｍｍの断熱シートを曲率半径１２５ｍｍの曲面に沿わせて曲げても破損させることなく施工することができる。 The following describes an embodiment of the heat insulating sheet according to the present invention. The heat insulating sheet according to the embodiment of the present invention has the form of a molded body in which inorganic fine particles of inorganic oxide as the main material are mixed with organic resin, and this molded body further contains fire-resistant fibers and infrared scattering materials as necessary. In addition, the heat insulating sheet according to the embodiment of the present invention can be molded to a thickness of about 3 to 5 mm, which is required when used as a heat insulating material for small containers, and when a 5 mm thick sheet is measured for bending strength at a span of 100 mm, the deflection at break is 3.0 mm or more. Therefore, with the heat insulating sheet according to the embodiment of the present invention, a 5 mm thick sheet can be bent along a curved surface with a curvature radius of 500 mm without breaking. The bending deflection can be changed by adjusting the type, form, and amount of the organic resin to be mixed, and the heating temperature and holding time during heat compression molding. The upper limit of the above deflection is about 10 mm, and in this case, a 5 mm thick heat insulating sheet can be bent along a curved surface with a curvature radius of 125 mm without breaking.
本発明の実施形態の断熱シートは、その製造方法によるものの、一般的に幅６００ｍｍ以上のシート形状に製造することが可能であるので、図２に示すように、有底円筒の溶湯容器１１の内壁面に本発明の実施形態の断熱シート１２を丸めた状態で施工できるので、作業性を高めることができるうえ、施工時の継ぎ目箇所を最小限に抑えることができるので、熱漏れの問題を防ぐことができる。
Depending on the manufacturing method, the insulating sheet of the embodiment of the present invention can be manufactured into a sheet shape with a width of generally 600 mm or more. As shown in FIG. 2, the
加えて、本発明の実施形態の断熱シートにおいては無機微粒子にシリカに代えて、あるいはシリカに加えてアルミナを用いることで、耐熱温度を１２００℃程度まで高めることができるので、常用の使用温度１０００℃において長期間使用することができる。また、本発明の実施形態の断熱シートは、６００℃での熱伝導率を０.０５Ｗ／(ｍ・Ｋ)以下にできるので、放熱量を低く抑えることができ、よって熱エネルギー消費量の削減効果が得られる。 In addition, by using alumina instead of silica or in addition to silica as inorganic fine particles in the heat insulating sheet of the embodiment of the present invention, the heat resistance temperature can be increased to about 1200°C, so it can be used for a long period of time at the normal operating temperature of 1000°C. Also, the heat insulating sheet of the embodiment of the present invention can achieve a thermal conductivity of 0.05 W/(m·K) or less at 600°C, so the amount of heat dissipation can be kept low, thereby achieving the effect of reducing thermal energy consumption.
次に、上記の断熱シートに含まれる各材料について具体的に説明する。無機微粒子は、１０００～１２００℃程度の高温での耐熱温度を有する金属酸化物からなる。この金属酸化物には、シリカ、アルミナ、マグネシア、ムライト、及びジルコニアからなる群より選択される１種以上を使用するのが好ましい。また、上記無機微粒子は平均粒径０.５μｍ以下のものを用いるのが好ましい。これにより、断熱シート内の空隙サイズ小さくすることができ、特に断熱シートに耐火繊維や赤外線散乱材が含まれる場合は、これらと無機微粒子との粒子間の空隙サイズを小さくできるので、高温での気体の対流伝熱を抑制することができる。なお、本明細書内において平均粒径とは、レーザー回折式粒度分布測定装置によって測定した体積基準の５０％径（Ｄ５０）である。 Next, each material contained in the heat insulating sheet will be specifically described. The inorganic fine particles are made of metal oxides that have a heat resistance at high temperatures of about 1000 to 1200°C. It is preferable to use one or more metal oxides selected from the group consisting of silica, alumina, magnesia, mullite, and zirconia. It is also preferable to use inorganic fine particles with an average particle size of 0.5 μm or less. This makes it possible to reduce the size of voids in the heat insulating sheet, and in particular, when the heat insulating sheet contains fire-resistant fibers or infrared scattering materials, it is possible to reduce the size of voids between these particles and the inorganic fine particles, thereby suppressing convective heat transfer of gas at high temperatures. In addition, the average particle size in this specification is the 50% diameter (D50) based on volume measured by a laser diffraction type particle size distribution measuring device.
耐火繊維は、６００～１６００℃程度の耐熱温度を有する無機組成物からなる繊維であり、代表的な耐火繊維としては、限定するものではないが、例えばガラス繊維、アルミナ質繊維、ムライト質繊維、ＣａＯ・６Ａｌ２Ｏ３（カルシアアルミネート）繊維、ジルコニア繊維、生体溶解性繊維、及びＡＥＳ（アルカリアースシリケート）繊維を挙げることができ、これら繊維からなる群より選択される１種以上を使用するのが好ましい。この耐火繊維は平均繊維径が１μｍ以上１３μｍ以下であるのが好ましく、２μｍ以上１０μｍ以下であるのがより好ましい。なお、本明細書内において平均繊維径とは、測定対象の繊維群を電子顕微鏡で撮影し、得られた画像の中から任意に選択した２００本以上の繊維の幅方向の距離を計測し、これらを算術平均したものである。 The refractory fiber is a fiber made of an inorganic composition having a heat resistance temperature of about 600 to 1600°C. Representative refractory fibers include, but are not limited to, glass fibers, alumina fibers, mullite fibers, CaO.6Al 2 O 3 (calcia aluminate) fibers, zirconia fibers, biosoluble fibers, and AES (alkaline earth silicate) fibers. It is preferable to use one or more fibers selected from the group consisting of these fibers. The average fiber diameter of this refractory fiber is preferably 1 μm to 13 μm, more preferably 2 μm to 10 μm. In this specification, the average fiber diameter is obtained by photographing the fiber group to be measured with an electron microscope, measuring the distance in the width direction of 200 or more fibers arbitrarily selected from the obtained image, and calculating the arithmetic average of these.
上記の耐火繊維には同じ材質の非繊維粒子が含まれていてもよい。この場合の非繊維粒子の含有量は、耐火繊維１００質量部に対して６０質量部以下が好ましく、５０質量部以下がより好ましい。特に平均粒径４２５μｍ以上の非繊維粒子は３質量部以下であるのが好ましく、１質量部以下であるのがより好ましい。 The fire-resistant fibers may contain non-fiber particles of the same material. In this case, the content of the non-fiber particles is preferably 60 parts by mass or less, and more preferably 50 parts by mass or less, per 100 parts by mass of the fire-resistant fibers. In particular, the content of non-fiber particles with an average particle size of 425 μm or more is preferably 3 parts by mass or less, and more preferably 1 part by mass or less.
赤外線散乱材は、８００℃以上の耐熱温度を有し、ふく射による伝熱を低減可能な組成物からなるものであれば特に限定はないが、赤外線反射性のあるものが好ましい。このような組成物としては、例えば炭化ケイ素、二酸化チタン、鉄、珪酸ジルコニウム、ジルコニア等を挙げることができ、これら組成物からなる群より選択される１種以上を使用するのが好ましい。また、上記の赤外線散乱材は、平均粒径が０.１μｍ以上３.０μｍ以下であるのが好ましく、特に上限値は、ふく射伝熱をもたらす赤外線の１２００℃のピーク波長と同程度の平均粒径である２.０μｍ以下であるのがより好ましい。 The infrared scattering material is not particularly limited as long as it has a heat resistance of 800°C or more and is made of a composition that can reduce heat transfer by radiation, but infrared reflectivity is preferable. Examples of such compositions include silicon carbide, titanium dioxide, iron, zirconium silicate, zirconia, etc., and it is preferable to use one or more types selected from the group consisting of these compositions. In addition, the above infrared scattering material preferably has an average particle size of 0.1 μm to 3.0 μm, and in particular, the upper limit is more preferably 2.0 μm or less, which is the average particle size equivalent to the peak wavelength at 1200°C of infrared rays that cause radiative heat transfer.
有機樹脂は、１５０℃以下で溶融するものが好ましく、このような有機樹脂としては、特に限定するものではないが、例えばポリエステル、ポリビニルアルコール、ポリエチレン、ポリプロピレン又はそれらの２種以上の複合体を挙げることができ、複合体の場合はポリエチレン（ＰＥ）／ポリプロピレン（ＰＰ）の芯鞘構造繊維が好ましい。有機樹脂の形態は粒子状でも構わないし、繊維状でも構わない。特にＰＥ／ＰＰ等の芯鞘構造繊維の場合は、溶融後でも芯部分が残るので、優れた曲げ性能を維持できる点においてより好ましい。なお、上記の芯鞘構造繊維とは、ポリプロピレンからなる芯部と、これを略同芯軸状に囲むポリエチレンからなる鞘部との二重構造を有する繊維のことである。粒子状の場合は、良好な分散性を確保する点から平均粒径０.５ｍｍ以下が好ましい。一方、繊維状の場合は、測定した長さＬ（ｍ）及び重量Ｗ（ｇ）をＴ＝（１００００×Ｗ）／Ｌに代入することよって求まる繊維太さの尺度Ｔ（ｄｔｅｘ）が１.０～２０の範囲内にあるのが好ましく、電子顕微鏡により測定した繊維長が３～２０ｍｍの範囲内にあるのが好ましい。 The organic resin is preferably one that melts at 150°C or less. Examples of such organic resins include, but are not limited to, polyester, polyvinyl alcohol, polyethylene, polypropylene, or a composite of two or more of these. In the case of a composite, a polyethylene (PE)/polypropylene (PP) core-sheath structure fiber is preferred. The organic resin may be in the form of particles or fibers. In particular, in the case of a core-sheath structure fiber such as PE/PP, the core portion remains even after melting, so it is more preferred in terms of maintaining excellent bending performance. The above-mentioned core-sheath structure fiber refers to a fiber having a double structure of a core made of polypropylene and a sheath made of polyethylene that surrounds it in a roughly concentric axial shape. In the case of a particulate form, an average particle size of 0.5 mm or less is preferred in order to ensure good dispersibility. On the other hand, in the case of fibers, the fiber thickness scale T (dtex), calculated by substituting the measured length L (m) and weight W (g) into T = (10,000 x W)/L, is preferably within the range of 1.0 to 20, and the fiber length measured by electron microscope is preferably within the range of 3 to 20 mm.
上記の有機樹脂の形態が粒子状の場合は、その平均粒径や粒度分布、加熱圧縮成形時の加熱温度や保持時間を調整することで、断熱シートを曲げたときの撓み量を変えることができる。一方、上記の有機樹脂が繊維状の場合は、その繊維径や繊維長、加熱圧縮成形時の加熱温度や保持時間を調整することで、断熱シートを曲げたときの撓み量を変えることができる。断熱シートにおける上記有機樹脂の含有率は、３～４０質量％が好ましく、５～２０質量％がより好ましい。この含有率が３質量％より少ないと、加熱圧縮成形時に該有機樹脂が溶融することで生じるバインダー力が小さくなりすぎ、断熱シートにおいて十分な曲げ応力が得られない。逆にこの含有率が４０質量％より多いと、施工後の加熱で分解したときに大きな空隙が生じるので、圧縮強さが著しく低下し、圧縮強さ０.５５ＭＰａ以上を確保するのが困難になる。更に、大きな空隙が生じると、断熱性も著しく低下する。すなわち、本発明の実施形態の断熱シートは、気体分子の自由行程を阻害する程度に小さな空隙(マイクロポーラス)を無数に含むことで静止空気よりも断熱性が優れているため、気体分子の自由行程が可能になる程度に大きな空隙ができると断熱性が著しく低下する。 When the organic resin is in the form of particles, the amount of deflection when the heat insulating sheet is bent can be changed by adjusting the average particle size and particle size distribution, the heating temperature and holding time during heat compression molding. On the other hand, when the organic resin is in the form of fibers, the amount of deflection when the heat insulating sheet is bent can be changed by adjusting the fiber diameter and fiber length, the heating temperature and holding time during heat compression molding. The content of the organic resin in the heat insulating sheet is preferably 3 to 40 mass%, more preferably 5 to 20 mass%. If this content is less than 3 mass%, the binder force generated by the melting of the organic resin during heat compression molding becomes too small, and sufficient bending stress cannot be obtained in the heat insulating sheet. On the other hand, if this content is more than 40 mass%, large voids will be generated when decomposed by heating after construction, so the compressive strength will be significantly reduced, and it will be difficult to ensure a compressive strength of 0.55 MPa or more. Furthermore, if large voids are generated, the insulation properties will also be significantly reduced. In other words, the insulating sheet of the present invention has better insulating properties than still air because it contains countless small voids (microporous) that are small enough to inhibit the free movement of gas molecules, so if voids large enough to allow the free movement of gas molecules are created, the insulating properties will decrease significantly.
本発明の実施形態の断熱シートに含まれる上記の構成要素は、上記した各構成要素の作用・効果を考慮したうえで断熱シートとして所望の特性が得られるように配合割合（含有率）の調整が適宜行なわれる。具体的には、本発明の実施形態の断熱シートを構成する上記の各構成要素の含有率は、無機微粒子では好ましくは３５～７５質量％、より好ましくは４０～６０質量％であり、耐火繊維では好ましくは１０～３０質量％であり、赤外線散乱材では好ましくは８～２０質量％であり、有機樹脂では好ましくは３～４０質量％である。これらが合計９８質量％以上含まれているのが好ましく、不可避不純物や成形助剤が含まれていてもよい。 The above components contained in the heat insulating sheet of the embodiment of the present invention are appropriately adjusted in their mixing ratio (content) so as to obtain the desired characteristics of the heat insulating sheet, taking into consideration the action and effect of each component. Specifically, the content of each of the above components constituting the heat insulating sheet of the embodiment of the present invention is preferably 35 to 75 mass %, more preferably 40 to 60 mass %, for inorganic fine particles, preferably 10 to 30 mass %, for refractory fibers, preferably 8 to 20 mass %, for infrared scattering materials, preferably 3 to 40 mass %, for organic resins. It is preferable that these are contained in a total of 98 mass % or more, and inevitable impurities and molding aids may be included.
本発明の実施形態の断熱シートは、かさ密度が２００～５００ｋｇ／ｍ３であるのが好ましく、２５０～３００ｋｇ／ｍ３であるのがより好ましい。これにより、熱膨張による圧縮応力で容易に損壊することのない圧縮強さと優れた断熱性とを兼ね備えた断熱シートを提供することが可能になる。このかさ密度が２００ｋｇ／ｍ３未満では、十分な圧縮強度が得られず、ハンドリング性も不十分になるおそれがある。逆にこのかさ密度が５００ｋｇ／ｍ３を超えると、強度が大きすぎて良好な撓み性が得られない。 The heat insulating sheet according to the embodiment of the present invention preferably has a bulk density of 200 to 500 kg/m 3 , more preferably 250 to 300 kg/m 3. This makes it possible to provide a heat insulating sheet that has both compressive strength that is not easily damaged by compressive stress due to thermal expansion and excellent heat insulating properties. If the bulk density is less than 200 kg/m 3 , sufficient compressive strength cannot be obtained and handling properties may be insufficient. Conversely, if the bulk density exceeds 500 kg/m 3 , the strength is too large and good flexibility cannot be obtained.
次に、上記した本発明の実施形態の断熱シートの製造方法について説明する。この断熱シートの製造方法は、先ず、上記した含有率となるように、無機微粒子、耐火繊維、赤外線散乱材、及び有機樹脂を配合して混合機で混合し、得られた混合物を圧縮成形機に装入して上記のかさ密度となるように圧縮成形することで成形体を形成する。次に、得られた成形体を加熱プレス機に装入し、１３０～１５０℃程度に加熱処理しながら圧力をかけて加熱圧縮成形する。これにより、繊維状又は粒子状の有機樹脂の一部又は全体が溶融することで、無機微粒子、耐火繊維、及び赤外線散乱材が有機樹脂を介して互いに熱溶着するので、断熱シートの撓み量を向上させることができる。 Next, a method for manufacturing the heat insulating sheet according to the embodiment of the present invention will be described. In this method for manufacturing the heat insulating sheet, first, inorganic fine particles, fireproof fiber, infrared scattering material, and organic resin are blended and mixed in a mixer so as to obtain the above-mentioned content, and the resulting mixture is loaded into a compression molding machine and compression molded to obtain the above-mentioned bulk density to form a molded body. Next, the resulting molded body is loaded into a heating press machine and heated to about 130 to 150°C while applying pressure to perform heat compression molding. As a result, part or all of the fibrous or particulate organic resin melts, and the inorganic fine particles, fireproof fiber, and infrared scattering material are thermally welded to each other via the organic resin, thereby improving the amount of deflection of the heat insulating sheet.
本発明の実施例及び比較例の断熱シートを作製し、それらの各々を下記の方法で求めたかさ密度、撓み性、曲率半径、圧縮強さ、断熱性、及び耐熱性の点から評価した。すなわち、かさ密度は、質量を体積で除算することで求めた。撓み性は、強度試験機を用いた３点曲げ試験において、距離（スパン）１００ｍｍで互いに離間する２つの支点の上に載置した厚さ５ｍｍの試験片に対して、その中央部を押し下げて破断させた時の最大撓み量を測定して求めた。曲率半径は、厚さ５ｍｍの試験片を撓ませていったときに破断が生じたときの曲率半径として求めた。圧縮強さは、「圧縮強さ［Ｎ／ｍｍ２］＝(試験片を１０％圧縮させたときの最大荷重(Ｎ))／面積(ｍｍ２)」で定義し、強度試験機を用いて圧縮させて歪１０％となったときの最大荷重から求めた。断熱性は、平板比較法（ＪＩＳ Ａ１４１２－２ 付属書Ａ）に準拠して６００℃での熱伝導率を測定することで求めた。耐熱性は、試験片を２４時間加熱したときの加熱線収縮率が３％以下となる最高温度として求めた。 The heat insulating sheets of the examples and the comparative examples of the present invention were prepared, and each of them was evaluated in terms of bulk density, flexibility, radius of curvature, compressive strength, heat insulation, and heat resistance, which were determined by the following methods. That is, the bulk density was determined by dividing the mass by the volume. The flexibility was determined by measuring the maximum deflection amount when a 5 mm thick test piece placed on two supports separated by a distance (span) of 100 mm was broken by pushing down the center of the test piece in a three-point bending test using a strength tester. The radius of curvature was determined as the radius of curvature at which a break occurred when a 5 mm thick test piece was deflected. The compressive strength was defined as "compressive strength [N/mm 2 ] = (maximum load (N) when the test piece is compressed by 10%)/area (mm 2 )" and was determined from the maximum load when the test piece was compressed to a strain of 10% using a strength tester. The thermal insulation property was determined by measuring the thermal conductivity at 600° C. according to the flat plate comparison method (JIS A1412-2 Appendix A). The heat resistance was determined as the maximum temperature at which the linear heat shrinkage rate was 3% or less when the test piece was heated for 24 hours.
［実施例１］
無機微粒子としてのシリカ質微粒子（平均粒径０.２μｍ）を６５質量％、耐火繊維としてのガラス繊維（Ｅガラス 平均繊維径１３μｍ）を１０質量％、赤外線散乱材としての炭化ケイ素粒子（平均粒径２μｍ）を１５質量％、及び有機樹脂としてのポリエチレン粒子（平均粒径０.５ｍｍ）を１０質量％の配合割合で混合機に装入して混合した。得られた混合物を金型に装入して圧縮成形することで薄片シート状の成形体を成形した後、この成形体を１５０℃で加熱圧縮成形して厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、かさ密度３００ｋｇ／ｍ３、撓み量４.９ｍｍ、曲率半径２５８ｍｍ、圧縮強さ０.７８ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 1]
The mixture was mixed in a mixer at a blending ratio of 65% by mass of siliceous particles (average particle size 0.2 μm) as inorganic particles, 10% by mass of glass fibers (E glass, average fiber diameter 13 μm) as fire-resistant fibers, 15% by mass of silicon carbide particles (
［実施例２］
かさ密度が実施例１と比べて２／３倍となるように圧縮成形した以外は実施例１と同様にして、かさ密度２００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量３.１ｍｍ、曲率半径４０５ｍｍ、圧縮強さ０.６４ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 2]
A heat insulating sheet having a bulk density of 200 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the bulk density was 2/3 times that of Example 1. The obtained heat insulating sheet had a deflection of 3.1 mm, a radius of curvature of 405 mm, a compressive strength of 0.64 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例３］
かさ密度が実施例１と比べて５／３倍となるように圧縮成形した以外は実施例１と同様にして、かさ密度５００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量３.０ｍｍ、曲率半径４１８ｍｍ、圧縮強さ１.５６ＭＰａ、熱伝導率０.０４Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 3]
A heat insulating sheet having a bulk density of 500 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the bulk density was compressed to be 5/3 times that of Example 1. The obtained heat insulating sheet had a deflection of 3.0 mm, a radius of curvature of 418 mm, a compressive strength of 1.56 MPa, a thermal conductivity of 0.04 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例４］
有機樹脂の配合割合を３質量％とし、シリカ質微粒子の配合割合を７２質量％としたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量３.５ｍｍ、曲率半径３５９ｍｍ、圧縮強さ０.８５ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 4]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the blending ratio of the organic resin was 3 mass% and the blending ratio of the siliceous fine particles was 72 mass%. The obtained heat insulating sheet had a deflection of 3.5 mm, a radius of curvature of 359 mm, a compressive strength of 0.85 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例５］
有機樹脂の配合割合を４０質量％とし、シリカ質微粒子の配合割合を３５質量％としたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量５.３ｍｍ、曲率半径２３８ｍｍ、圧縮強さ０.６２ＭＰａ、熱伝導率０.０４Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 5]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the blending ratio of the organic resin was 40 mass% and the blending ratio of the siliceous fine particles was 35 mass%. The obtained heat insulating sheet had a deflection of 5.3 mm, a radius of curvature of 238 mm, a compressive strength of 0.62 MPa, a thermal conductivity of 0.04 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例６］
有機樹脂に粒子状のものに変えて同材質の繊維状（繊維径１.７ｄｔｅｘ、繊維長５ｍｍ）を用いたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量９.１ｍｍ曲率半径１４２ｍｍ、圧縮強さ０.７８ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度は１０００℃であった。
[Example 6]
A heat insulating sheet with a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the organic resin was replaced by a fibrous form (fiber diameter 1.7 dtex, fiber length 5 mm) of the same material instead of a particulate form. The obtained heat insulating sheet had a deflection of 9.1 mm, a radius of curvature of 142 mm, a compressive strength of 0.78 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例７］
有機樹脂にポリエチレン粒子に代えてポリエチレン／ポリプロピレンの芯鞘構造繊維（繊維径１.７ｄｔｅｘ、繊維長５ｍｍ）を用いたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量９.８ｍｍ、曲率半径１３２ｍｍ、圧縮強さ０.７８ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 7]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that a polyethylene/polypropylene core-sheath structure fiber (fiber diameter 1.7 dtex, fiber length 5 mm) was used in place of the polyethylene particles in the organic resin. The obtained heat insulating sheet had a deflection of 9.8 mm, a radius of curvature of 132 mm, a compressive strength of 0.78 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例８］
無機微粒子にシリカ質微粒子に代えてアルミナ質微粒子（平均粒径０.２μｍ）を用いたこと以外は実施例６と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量４.４ｍｍ、曲率半径２８６ｍｍ、圧縮強さ０.７７ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１２００℃であった。
[Example 8]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 6, except that alumina fine particles (average particle size 0.2 μm) were used instead of silica fine particles as the inorganic fine particles. The obtained heat insulating sheet had a deflection of 4.4 mm, a radius of curvature of 286 mm, a compressive strength of 0.77 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1200°C.
［実施例９］
無機微粒子にシリカ質微粒子に代えてマグネシア質微粒子（平均粒径０.２μｍ）を用いると共にかさ密度が実施例１に比べて４／３倍となるように圧縮成形したこと以外は実施例１と同様にしてかさ密度４００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量４.８ｍｍ、曲率半径２６０ｍｍ、圧縮強さ０.５８ＭＰａ、熱伝導率０.０５Ｗ／(ｍ・Ｋ)、耐熱温度１１００℃であった。
[Example 9]
A heat insulating sheet having a bulk density of 400 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that magnesia fine particles (average particle size 0.2 μm ) were used instead of silica fine particles as the inorganic fine particles and compression molding was performed so that the bulk density was 4/3 times that of Example 1. The obtained heat insulating sheet had a deflection of 4.8 mm, a radius of curvature of 260 mm, a compressive strength of 0.58 MPa, a thermal conductivity of 0.05 W/(m·K), and a heat resistance temperature of 1100°C.
［実施例１０］
無機微粒子にシリカ質微粒子に代えてムライト質微粒子（平均粒径０.２μｍ）を用いると共にかさ密度が実施例１に比べて４／３倍となるように圧縮成形したこと以外は実施例１と同様にしてかさ密度４００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量４.８ｍｍ、曲率半径２６２ｍｍ、圧縮強さ０.６５ＭＰａ、熱伝導率０.０５Ｗ／(ｍ・Ｋ)、耐熱温度１１００℃であった。
[Example 10]
A heat insulating sheet having a bulk density of 400 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that mullite fine particles (average particle size 0.2 μm) were used as the inorganic fine particles instead of the silica fine particles and compression molding was performed so that the bulk density was 4/3 times that of Example 1. The obtained heat insulating sheet had a deflection of 4.8 mm, a radius of curvature of 262 mm, a compressive strength of 0.65 MPa, a thermal conductivity of 0.05 W/(m·K), and a heat resistance temperature of 1100°C.
［実施例１１］
無機微粒子にシリカ質微粒子に代えてジルコニア質微粒子（平均粒径０.２μｍ）を用いると共にかさ密度が実施例１に比べて４／３倍となるように圧縮成形したこと以外は実施例１と同様にしてかさ密度４００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量５.０ｍｍ、曲率半径２４２ｍｍ、圧縮強さ０.６２ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１１００℃であった。
[Example 11]
A heat insulating sheet having a bulk density of 400 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that zirconia-based fine particles (average particle size 0.2 μm) were used instead of silica-based fine particles as the inorganic fine particles and compression molding was performed so that the bulk density was 4/3 times that of Example 1. The obtained heat insulating sheet had a deflection of 5.0 mm, a radius of curvature of 242 mm, a compressive strength of 0.62 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1100°C.
［実施例１２］
炭化ケイ素の含有率をゼロとし、代わりに有機粒子の配合割合を３質量％に代えて８質量％にすると共に同材質の繊維状の有機樹脂（１.７ｄｔｅｘ、繊維長５ｍｍ）の配合割合を１０質量％としたこと以外は実施例４と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量５.０ｍｍ、曲率半径２３０ｍｍ、圧縮強さ０.６０ＭＰａ、熱伝導率０.０５Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 12]
A heat insulating sheet having a bulk density of 300 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 4, except that the content of silicon carbide was set to zero, the blending ratio of organic particles was changed from 3 % by mass to 8% by mass, and the blending ratio of fibrous organic resin (1.7 dtex, fiber length 5 mm) of the same material was changed to 10% by mass. The obtained heat insulating sheet had a deflection of 5.0 mm, a radius of curvature of 230 mm, a compressive strength of 0.60 MPa, a thermal conductivity of 0.05 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例１３］
ガラス繊維の含有率をゼロとし、代わりに有機樹脂としてポリエチレン粒子（粒子粒径０.５ｍｍ）の配合割合を１０質量％としたこと以外は実施例６と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量３.０ｍｍ、曲率半径４００ｍｍ、圧縮強さ０.６０ＭＰａ、熱伝導率０.０４Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Example 13]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 6, except that the glass fiber content was set to zero and the blending ratio of polyethylene particles (particle diameter 0.5 mm) as an organic resin was set to 10 mass% instead. The obtained heat insulating sheet had a deflection of 3.0 mm, a radius of curvature of 400 mm, a compressive strength of 0.60 MPa, a thermal conductivity of 0.04 W/(m·K), and a heat resistance temperature of 1000°C.
［実施例１４］
ガラス繊維の代わりにＡＥＳ（アルカリアースシリケート）繊維（非繊維粒子の含有量は、耐火繊維１００質量部に対して５０質量部、平均粒径４２５μｍ以上の非繊維粒子は１質量部）の配合割合を１０質量％としたこと以外は実施例６と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量４.４ｍｍ、曲率半径２８８ｍｍ、圧縮強さ０.７７ＭＰａ、熱伝導率０.０５Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。上記の実施例１～１４の断熱シートの配合割合、製法、及び物性をまとめたものを下記表１に示す。
[Example 14]
A heat insulating sheet having a bulk density of 300 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 6, except that the blending ratio of AES (alkaline earth silicate) fiber (the content of non-fibrous particles was 50 parts by mass per 100 parts by mass of fire-resistant fiber, and non-fibrous particles having an average particle size of 425 μm or more was 1 part by mass) was changed to 10 mass% instead of glass fiber. The obtained heat insulating sheet had a deflection of 4.4 mm, a radius of curvature of 288 mm, a compressive strength of 0.77 MPa, a thermal conductivity of 0.05 W/(m·K), and a heat resistance temperature of 1000°C. The blending ratios, manufacturing methods, and physical properties of the heat insulating sheets of Examples 1 to 14 above are summarized in Table 1 below.
［比較例１］
かさ密度が１８０ｋｇ／ｍ３となるように圧縮成形することで得た成形体を加熱圧縮することなくそのまま断熱シートとしたこと以外は実施例１と同様にしてかさ密度１８０ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量１.８ｍｍ、曲率半径６９５ｍｍ、圧縮強さ０.５８ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Comparative Example 1]
An insulating sheet having a bulk density of 180 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the molded body obtained by compression molding to a bulk density of 180 kg/ m3 was used as an insulating sheet without being heated and compressed. The obtained insulating sheet had a deflection of 1.8 mm, a radius of curvature of 695 mm, a compressive strength of 0.58 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［比較例２］
かさ密度が５１０ｋｇ／ｍ３となるように圧縮成形した以外は実施例１と同様にしてかさ密度５１０ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量２.１ｍｍ、曲率半径５９６ｍｍ、圧縮強さ１.６５ＭＰａ、熱伝導率０.０４Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Comparative Example 2]
A heat insulating sheet having a bulk density of 510 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the material was compression molded to have a bulk density of 510 kg/ m3 . The obtained heat insulating sheet had a deflection of 2.1 mm, a radius of curvature of 596 mm, a compressive strength of 1.65 MPa, a thermal conductivity of 0.04 W/(m·K), and a heat resistance temperature of 1000°C.
［比較例３］
有機樹脂の配合割合を２質量％とし、シリカ質微粒子の配合割合を７３質量％としたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量２.４ｍｍ、曲率半径５４５ｍｍ、圧縮強さ０.８７ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Comparative Example 3]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the blending ratio of the organic resin was 2 mass% and the blending ratio of the siliceous fine particles was 73 mass%. The obtained heat insulating sheet had a deflection of 2.4 mm, a radius of curvature of 545 mm, a compressive strength of 0.87 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat resistance temperature of 1000°C.
［比較例４］
有機樹脂の配合割合を４１質量％とし、シリカ質微粒子の配合割合を３４質量％としたこと以外は実施例１と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量５.５ｍｍ、曲率半径２３０ｍｍ、圧縮強さ０.５０ＭＰａ、熱伝導率０.０６Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。
[Comparative Example 4]
A heat insulating sheet having a bulk density of 300 kg/ m3 and a thickness of 5 mm was produced in the same manner as in Example 1, except that the blending ratio of the organic resin was 41 mass% and the blending ratio of the siliceous fine particles was 34 mass%. The obtained heat insulating sheet had a deflection of 5.5 mm, a radius of curvature of 230 mm, a compressive strength of 0.50 MPa, a thermal conductivity of 0.06 W/(m·K), and a heat resistance temperature of 1000°C.
［比較例５］
ＡＥＳ（アルカリアースシリケート）繊維において、非繊維粒子の含有量は、耐火繊維１００質量部に対して６５質量部、平均粒径４２５μｍ以上の非繊維粒子は３質量部の繊維としたこと以外は実施例１４と同様にしてかさ密度３００ｋｇ／ｍ３、厚さ５ｍｍの断熱シートを作製した。得られた断熱シートは、撓み量３.５ｍｍ、曲率半径３５５ｍｍ、圧縮強さ０.８５ＭＰａ、熱伝導率０.０３Ｗ／(ｍ・Ｋ)、耐熱温度１０００℃であった。上記の比較例１～５の断熱シートの配合割合、製法、及び物性をまとめたものを下記表２に示す。
[Comparative Example 5]
A heat insulating sheet having a bulk density of 300 kg/m3 and a thickness of 5 mm was produced in the same manner as in Example 14, except that the content of non-fibrous particles in the AES (alkaline earth silicate) fiber was 65 parts by mass per 100 parts by mass of the fire-resistant fiber, and non-fibrous particles having an average particle size of 425 μm or more were 3 parts by mass. The obtained heat insulating sheet had a deflection of 3.5 mm, a radius of curvature of 355 mm, a compressive strength of 0.85 MPa, a thermal conductivity of 0.03 W/(m·K), and a heat-resistant temperature of 1000°C. The compounding ratios, manufacturing methods, and physical properties of the heat insulating sheets of Comparative Examples 1 to 5 are summarized in Table 2 below.
１、１１ 溶湯容器
２ 従来の断熱材
１２ 本発明の実施形態の断熱シート
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| JP2008194974A (en) | 2007-02-14 | 2008-08-28 | Nichias Corp | Insulating material and manufacturing method thereof |
| JP2011073959A (en) | 2009-09-02 | 2011-04-14 | Nichias Corp | Thermal insulation material |
| JP2012145217A (en) | 2010-12-22 | 2012-08-02 | Nichias Corp | Heat insulating material and method for manufacturing the same |
| JP2013028501A (en) | 2011-07-28 | 2013-02-07 | Asahi Kasei Chemicals Corp | Powder, molded body, encapsulated body, and method for producing the powder |
| JP2021048069A (en) | 2019-09-19 | 2021-03-25 | イビデン株式会社 | Heat insulation sheet for battery pack and battery pack |
| JP2023029174A (en) | 2021-08-20 | 2023-03-03 | イビデン株式会社 | Heat transfer suppression sheet, manufacturing method therefor, and assembly battery |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2008194974A (en) | 2007-02-14 | 2008-08-28 | Nichias Corp | Insulating material and manufacturing method thereof |
| JP2011073959A (en) | 2009-09-02 | 2011-04-14 | Nichias Corp | Thermal insulation material |
| JP2012145217A (en) | 2010-12-22 | 2012-08-02 | Nichias Corp | Heat insulating material and method for manufacturing the same |
| JP2013028501A (en) | 2011-07-28 | 2013-02-07 | Asahi Kasei Chemicals Corp | Powder, molded body, encapsulated body, and method for producing the powder |
| JP2021048069A (en) | 2019-09-19 | 2021-03-25 | イビデン株式会社 | Heat insulation sheet for battery pack and battery pack |
| JP2023029174A (en) | 2021-08-20 | 2023-03-03 | イビデン株式会社 | Heat transfer suppression sheet, manufacturing method therefor, and assembly battery |
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