JPH0780270B2 - Composite heat insulating panel and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite heat insulating panel suitable as a heat insulating material for buildings such as wooden houses, which is particularly lightweight and has a low manufacturing cost, is excellent in construction characteristics on site, and is also excellent as a structural member. In addition to exhibiting strength characteristics,
The present invention relates to a composite heat insulating panel having a high airtight and high heat insulating property, a high energy saving effect and a high living environment improving effect, and a manufacturing method thereof.

[0002]

2. Description of the Related Art As a heat insulating material for walls, roofs, floors and ceilings of wooden houses conventionally constructed by a frame construction method or a two-by-four construction method, fibrous glass wool or a composite heat insulation panel in which glass wool is filled in a hollow flat plate. Is widely used.

However, in the case of a fibrous heat insulating material such as glass wool, there is a fatal defect that the characteristics of the heat insulating material deteriorate over time due to moisture absorption and the like. In particular, under a hot and humid climate condition like Japan, the decrease in heat insulation is remarkable.
Further, since it is difficult to maintain airtightness only with glass wool, it was not possible to expect an effective sound insulation effect by the heat insulating material.

Further, since glass wool itself does not serve as a member for strengthening the structural strength at all, in order to secure the required structural strength, studs, braces, etc. are provided in the structure separately from the heat insulating material. Arranged appropriately. In other words, because the heat insulating material and the strength member were designed and constructed individually,
There is a problem in that the design man-hours and the on-site construction man-hours increase significantly.

On the other hand, a heat insulating panel having a hollow flat plate filled with glass wool is mass-produced in advance at a factory at low cost, and is formed so that the hollow flat plate itself retains a certain degree of structural strength. It has both functions and can reduce the number of construction man-hours on site.

However, in recent years, the construction standards for building heat insulating materials have been revised from the viewpoint of energy saving, and there is a tendency to increase the thickness of the heat insulating material in order to improve the heat insulating properties. However, since the required thickness of the conventional fibrous heat insulating material such as glass wool exceeds the thickness of the stud to be attached, there is a problem that it cannot be actually installed.

As a heat insulating material panel for solving the above problems, for example, a composite heat insulating panel 1 as shown in FIG. 4 has been proposed. In this composite heat insulation panel 1, wood plywood 3 and 3 are pasted on both sides of an enclosure 2 having a predetermined size formed by joining wood in a square shape, and a panel body 4 having a closed space is formed. By injecting urethane resin or the like into the closed space and allowing it to foam, the closed space is filled with the foam 5 having excellent heat insulating properties. Further, at the edge of the panel body 4, a connecting metal fitting mounting hole 6 for joining the composite heat insulating panel 1 and the stud or the adjacent composite heat insulating panel is provided.

According to the composite heat insulating panel 1 described above, since it is formed by filling the inside thereof with a foam which is more excellent in heat insulating properties than glass wool and has high rigidity and structural strength, it can be used as a heat insulating material and a structural material. It has excellent features,
The effect that the construction man-hours at the site could be reduced was expected.

On the other hand, as a means for solving the above problems, for example, there is a heat insulating panel described in Japanese Utility Model Laid-Open No. 3-8211. As shown in FIG. 6, this heat insulating panel forms a rectangular frame body 100, and one side of the frame body 100 has a rectangular structural plywood board 101 that is slightly larger than the frame body 100.
The peripheral portion 102 is overhanged and fixed, the reinforcing bar 103 is installed in the frame body 100, and the heat insulating material 104 is embedded in each section in the frame body 100.

[0010]

However, according to the conventional composite heat insulating panel 1 as shown in FIG.
Since it has a structure in which a wooden or metal enclosure 2 and two wood plywood 3 and 3 are arranged around the panel, a large amount of wood is used in the panel body 4, and there are also embedded mounting brackets and the like. You also need accessories. Therefore, the material cost and the processing cost increase, and the weight becomes extremely large. By the way, it is a panel that uses wood plywood with a thickness of 12 mm and has a width of 9
A composite heat insulation panel of 0 cm, 295 cm in length, and 7 cm in total thickness weighs about 54 kg. Therefore, the manufacturing cost increases, and at least two workers are required to transport and assemble the composite heat insulation panel, and it takes time to align the panel surface at a predetermined position. There is a drawback that requires a lot of labor.

There is also a problem that it is extremely difficult to appropriately adjust and correct the dimensions of the composite heat insulating panel according to the magnitude of the assembly error of the frame body to be mounted. In other words, if the finished size of the panel installation location (frame body) is narrower than the design value, it cannot be installed. On the contrary, if the finished size is large, labor is required to repair the gap created, which greatly affects the finished accuracy of the structure. There was a problem that it was easily received.

Further, as shown in FIG. 5, in order to bond and fix the composite heat insulation panel 1 to the stud 7, a dedicated fixing metal fitting 8 is used.
Is required, and a special connecting fitting 9 is required for joining with the adjacent composite heat insulating panel 1, so that there is a problem that the manufacturing cost of the panel and the number of on-site installation steps increase, and the workability becomes low. It was

On the other hand, in the heat insulating panel shown in FIG. 6, a frame 100 made of wood or metal is provided on the outer peripheral portion of the heat insulating material 104.
Since the heat insulating panel is provided, the weight of the entire heat insulating panel is still large, the manufacturing cost is high, and there is a problem in transportation and handling. Further, since the frame body 100 is provided, it is difficult to correct the shape of the panel by sawing or the like, and there is a problem that the construction characteristics and workability on site are still low. That is, there is a problem that it becomes difficult to insert and fix the panel itself due to a variation in width between adjacent studs in the wooden frame and a slight dimensional error due to warping or twisting of the wooden frame itself.

The present invention has been made in order to solve the above-mentioned various problems, and in addition to exhibiting excellent strength characteristics as a structural member as well as being lightweight, having a low manufacturing cost, being excellent in construction characteristics on site. It is an object of the present invention to provide a composite heat insulating panel having a high airtight and high heat insulating property, a high energy saving effect and a high living environment improving effect, and a manufacturing method thereof.

[0015]

[Means and Actions for Solving the Problems] The inventors of the present invention have earnestly studied to develop a lightweight composite heat insulating panel having excellent characteristics such as workability on site, workability, and structural strength. It was confirmed that the lightweight composite material integrally formed with the hard organic foam on one surface of the working plywood by spray foaming or injection foaming met the above-mentioned object, and the present invention was completed.

That is, the composite heat insulation panel according to the present invention is
A rigid organic foam is integrally joined to the central portion of one side of the structural plywood to form a panel body, and a fixing edge portion for fixing the panel body to a frame of a predetermined shape is provided on the outer periphery of the structural plywood. At the same time, at least one reinforcing material is integrally joined to the structural plywood so as to be exposed from the surface of the rigid organic foam, while the outer peripheral side surface of the rigid organic foam is formed so as to be inclined inward. Characterize.

Further, the rigid organic foam may be formed of a plate-like foam formed by foaming a polyurethane resin at a foaming ratio of 10 to 25 times and having a large number of cells dispersed therein.

As the plywood used in the composite heat insulation panel of the present invention, a structural plywood having a thickness of about 7.5 to 28 mm is used in order to exert a function as a structural reinforcing material of a building. The size of the structural plywood varies depending on the size of the mounting place (frame body), but the width is approximately 450 to 120.
A standard product with 0 mm and a height in the range of 400 to 3000 mm is used.

As the hard organic foam, for example, a polymer of urethane, styrene, vinyl chloride, styrene, ethylene or the like, or a copolymer with vinyl acetate, etc. is used, and the thickness thereof is about 30 to 100 mm. It In particular, a plate-shaped foam body formed by foaming a polyurethane resin at a foaming ratio of about 10 to 25 times and having a large number of air bubbles dispersed therein has excellent heat insulating properties and structural strength, and is integrally bonded to the structural plywood. By doing so, it becomes possible to significantly increase the rigidity of the panel body.

Further, the fixing edge portion is provided on the outer periphery of the structural plywood with a width of about 50 to 100 mm for attaching the panel body to the frame body. By fitting the composite heat insulating panel into the frame body made of the pillar material and fixing the fixing edge portion by nailing or the like, the whole composite heat insulating panel is quickly fixed at a predetermined position.

This composite heat insulating panel is manufactured by the following procedure. First, at least one reinforcing material is integrally joined to one surface central part of the structural plywood prepared according to the size of the frame body to which the panel is mounted, and a frame-shaped foam forming jig is attached. To do. The foam forming jig is disposed inside the fixing edge portion so that the fixing edge portion is secured on the outer peripheral portion of the structural plywood. The foam forming jig is arranged so that its side surface is inclined inward.

On the other hand, if necessary, a liquid foaming agent containing a cross-linking agent and a liquid resin raw material are continuously supplied to the mixing chamber under pressure to mix both raw materials. It is necessary to maintain the temperature of both raw materials at about 30 to 60 ° C.
Simultaneously with the mixing, the pressurized resin material mixture is sprayed from the injection nozzle of the automatic spraying machine to the space inside the frame of the foam forming jig to have a predetermined thickness and the outer peripheral side surface is the inner side. A rigid organic foam body inclined to one side is integrally formed with a structural plywood. When the curing of the organic foam is completed, the foam forming jig is removed.

When forming an organic foam by injection foaming, a flat working plate is placed on the upper surface of the foam forming jig to form a closed space, and then the temperature 2 is applied.
Resin material mixture kept at 0 ~ 22 ℃, pressure 6 ~ 7kg
Inject and fill the above-mentioned closed space with an air pressure of about / cm ² .

The thickness of the rigid organic foam depends on the characteristics such as heat insulating property and structural strength required for heat insulating panel products.
It is selected to be 0 to 100 mm.

Further, the foaming ratio of the resin material has a great influence on the heat insulating property, structural strength, sound insulating property, water resistance and heat retaining property of the heat insulating panel, but in order to satisfy both the heat insulating property and the structural strength, the foaming ratio is 8 to 25. Double range is good.

As the foaming agent, azodicarbonamide or the like is used, while as the cross-linking agent, an organic peroxide such as dicumyl peroxide is optionally used.

The hard organic foam (plate-like foam) thus formed has a structure in which a large number of cells are dispersed in the matrix resin. There are two types of bubbles, that is, open bubbles that communicate with both sides of the foam and closed bubbles that form a closed space in the foam. Since open cells have the property of easily burning after ignition and have a slightly inferior heat insulating property and sound insulating property due to ventilation, it is preferable to use a closed cell foam.

According to the composite heat insulating panel and the method for producing the same of the present invention, unlike the conventional wood thin plate and veneer, the structural plywood is used, and the hard organic foam excellent in heat insulating property and structural strength is used for the structure. Since it is integrally bonded to the plywood, the rigidity is synergistically increased compared to the case where the structural plywood and the rigid organic foam are used independently, and not only the heat insulating material but also the structural member. Also exhibits excellent characteristics.

Further, since the composite heat insulating panel of the present invention does not have a surrounding frame or the like on the outer periphery of the foam and has a simple structure in which the structural plywood is attached to only one surface of the foam, the amount of wood used is small. The material cost and the processing cost can be significantly reduced. Furthermore, since the weight of the composite insulation panel itself can be reduced to about half that of conventional products, the transportation and handling of products in the factory and on-site is extremely simple. Especially, in the field, one worker installs the panel. Since it can be fixed, it is possible to reduce the work man-hours on the site.

In particular, according to the composite heat insulating panel of the present invention, the outer peripheral side surface of the hard organic foam is formed so as to be inclined inward, so that the panel can be easily fitted into the frame body to be mounted. This makes it possible to perform on-site construction extremely easily. Particularly, since the inclined foam body and the frame body are in good contact with each other, the airtightness between the frame body and the foam body can be maintained almost completely, and the heat insulating property and the sound insulating property can be significantly improved. it can.

Further, according to the composite heat insulating panel of the present invention, unlike the conventional composite heat insulating panel in which structural plywoods are arranged on both sides of the foam, the panel is mounted at a predetermined position only by nailing the fixing edge portion. It becomes possible to fix it. Also, since no surrounding frame etc. is provided on the outer circumference of the foam, it is easy to saw and cut with a blade, so the panel dimensions can be appropriately modified and used according to the finished dimensions of the frame at the site. Yes, installation workability on site is extremely excellent.

Further, since at least one reinforcing material is integrally bonded to the structural plywood so as to be exposed from the surface of the hard organic foam, it is possible to use this reinforcing material as a furring strip or a stud of a building. Therefore, it is possible to more securely and firmly fix the partitioning material, the interior decorative board, and the like. Further, the reinforcing material is also effective for firmly holding the hard organic foam, and it is possible to effectively prevent the foam from peeling or falling off from the structural plywood. It goes without saying that the positions, intervals, dimensions, etc. of the above-mentioned reinforcing materials comply with the construction standards of buildings.

[0033]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described more specifically with reference to the accompanying drawings. FIG. 1 is a perspective view showing an embodiment of the composite heat insulation panel according to the present invention.

That is, the composite heat insulation panel 1b shown in FIG.
Is a panel body 12b formed by integrally joining a rigid organic foam 11b to the central portion of one side of a structural plywood 10b having a thickness of 12 mm, a width of 905 mm, and a length of 2930 mm, and forming the panel body into a frame body of a predetermined shape. A fixing edge portion 13b for fixing is provided on the outer periphery of the structural plywood 10b. The rigid organic foam 11b was formed by foaming polyurethane resin at a foaming ratio of 25 times, and was formed of a plate-like foam having a large number of closed cells inside. Further, as shown in FIG. 3, the outer peripheral side surface of the plate-shaped foam is formed so as to be inclined inward by a predetermined angle θ.

Further, one reinforcing member 14 is integrally joined to the structural plywood 10b along the longitudinal direction so as to be exposed and projected from the surface of the hard organic foam 11b.

In the composite heat insulating panel 1b, a fixing edge portion 13b is formed on the outer peripheral edge of a structural plywood board 10b having a predetermined size joined with a reinforcing material 14, and inside the fixing edge portion 13b,
A foam forming jig (not shown) was arranged so that the inner peripheral surface thereof was inclined inward, and a polyurethane resin material containing a foaming agent was sprayed into the space inside the jig to manufacture.

As the foam forming jig, a square rectangular or rectangular stainless steel rectangular copper tube assembled into a rectangular frame shape was used. The foam forming jig may be formed of an aluminum square pipe or a mild steel square pipe material.
Prior to spray foaming, a silicone liquid or mineral oil was applied as a release agent to the inner surface of the foam forming jig.

In blowing foam molding, a heater is wound around 2
The liquid polyurethane resin raw material adjusted to a temperature of 40 ° C. and the liquid foaming agent also adjusted to a temperature of 40 ° C. are introduced into a mixer under a pressurized state of about 6 to 7 kg / cm ² through a supply hose, and uniformly mixed. At the same time, the obtained mixture is sprayed from the spray nozzle of the automatic spraying machine to the inside area of the frame-shaped foam forming jig, and further cured to give a thickness of 50.
mm rigid organic foam 11b was formed. After the sprayed resin material is cured, the foam forming jig is attached to the panel body 12b.
The composite heat insulation panel 1b shown in FIG.

The composite heat insulating panel having a relatively narrow width is fitted into a frame body formed of rafters 15 as a roof material of a building, as shown in FIG. 2, and nails 16 are attached to the fixing edges thereof. Or fixed by hammering in. Further, the wide composite heat insulation panel 1b is fitted into the frame body for the large wall formed by the girder material 17 and the pillar 18, and is similarly fixed.

That is, as shown in FIG. 3, the composite heat-insulating panel 1b is fitted between the pillars 18 and 18, and the nail 16 is driven into the fixing edge portion 13b of the structural plywood 10b which is crimped to the pillar 18, thereby driving the panel. 1b is effectively fixed. The reinforcing material 14 is integrally joined to the structural plywood 10b with nails 16 or the like in advance when the panel is manufactured. By projecting the reinforcing material 14 to the same position as the indoor surface of the pillar 18,
It can be used as a furring strip and a stud, and can more firmly fix the interior decorative plate 20 on the indoor side. On the other hand, short composite heat insulating panels 1c and 1d prepared by cutting a long composite heat insulating panel 1b as shown in FIG. 1 into a required size are fitted and fixed to the frame bodies located at the upper and lower portions of the window frame 19, respectively. .

In FIG. 2, the composite heat insulation panel 1 is shown.
Although b is shown as an example of being used as a heat insulating material for roofs and side walls of wooden buildings, it goes without saying that it can also be used as a heat insulating material for floors and ceilings.

Further, as shown in FIG. 3, foaming is performed so that the angle θ formed by the side surface of the rigid organic foam 11b in contact with the pillar 18 and the side surface of the opposed pillar 18 is about 0.5 to 5 degrees. Since the side surface of the body 11b is formed so as to be inclined, it is extremely easy to fit the composite heat insulating panel 1b into the frame body, and further the airtightness between the column 18 and the foam body 11b is almost completely maintained. Is possible and is extremely effective in improving heat insulation and sound insulation.

The composite heat insulating panel 1b according to this embodiment has a simple structure in which no surrounding frame is provided on the outer periphery of the foam 11b, and the structural plywood 10b is attached to only one side of the foam 11b. Since the amount of wood used is small, material costs and processing costs can be significantly reduced. Furthermore, since the weight of the composite heat insulation panel 1b itself can be reduced to about half as compared with the conventional product, the transportation and handling of the product in the factory and the site are extremely simplified, and particularly in the field, one worker can operate the panel 1b. Can be attached and fixed, and the work man-hours at the site can be reduced.

Next, the effect of the composite heat insulation panel of this embodiment based on an actual construction example will be described in comparison with a conventional example. That is, for a wooden house having a heat insulating construction area of 150 m ² on the roof, floor, ceiling, side walls, etc., a composite heat insulating panel having substantially the same dimensions as shown in FIGS. , Comparative Example 1 and Comparative Example 2 were manufactured in large numbers, the weight of each panel was compared, and the number of work steps required for assembling and fixing the panel in the wooden house (artificial ×
When the number of days) was compared, the results shown in Table 1 below were obtained.

[0045]

[Table 1] As is clear from the results shown in Table 1, the composite heat insulating panel according to the present example has an average weight much smaller than that of the conventional product, resulting in low manufacturing cost, easy handling in the field, and modification of the shape. Is also easy. In particular, the hard urethane part can be easily scraped off with a small blade or a cutter, etc., and it is extremely easy to perform dimensional matching on site, so it is possible to greatly reduce the number of man-hours on site and save labor and It was proved that it greatly contributes to the reduction of construction cost.

Further, according to the composite heat insulating panel of the present embodiment, since the adhesion to the frame is excellent, the rain is almost completely removed after the panel is fitted and fixed to the frame of the frame. Guaranteed. Therefore, it is possible to carry out the groundwork and interior work on the indoor side even in rainy weather, and the period for carrying out the indoor and outdoor work in parallel becomes longer, and it is possible to shorten the overall construction period. Become.

[0047]

As described above, according to the composite heat insulating panel and the method of manufacturing the same according to the present invention, unlike the conventional wood thin plate and veneer, the structural plywood is used, and further, the heat insulating property and the structural strength are excellent. Since the organic foam is integrally joined to the structural plywood, the rigidity is significantly increased compared to the case where the structural plywood or the rigid organic foam are used individually, and only the heat insulating material is used. It also exhibits excellent properties as a structural member. In particular, since it has a high airtightness and a high heat insulation property, the energy saving effect and the sound insulation effect are extremely high, and it is extremely effective for improving the living economy and maintaining and improving a good living environment.

Further, since the composite heat insulating panel of the present invention has a simple structure in which the surrounding frame is not provided and the structural plywood is attached to only one side of the foam, the amount of the surrounding wood and the plywood used is limited. The material cost and the processing cost can be significantly reduced. Furthermore, since the weight of the composite insulation panel itself can be reduced to about half that of conventional products, the transportation and handling of products in the factory and on-site is extremely simple. Especially, in the field, one worker installs the panel. Since it can be fixed, it is possible to reduce the work man-hours on the site.

In particular, according to the composite heat insulating panel of the present invention, since the outer peripheral side surface of the hard organic foam is formed so as to be inclined inward, the panel can be easily fitted into the frame body to be mounted. This makes it possible to perform on-site construction extremely easily. Particularly, since the inclined foam body and the frame body are in good contact with each other, the airtightness between the frame body and the foam body can be maintained almost completely, and the heat insulating property and the sound insulating property can be significantly improved. it can.

In recent years, demands and regulations for workability and safety, especially at construction sites, have become stricter, and measures to reduce labor load on site workers and save labor are desired. From this point of view, it is difficult to force a single worker to repeatedly handle a heat insulating panel having a weight exceeding 40 kg as in the conventional case. However, according to the composite heat insulating panel of the present invention, the weight can be reduced to half, and it is extremely effective in improving the working conditions of the worker.

Further, according to the composite heat insulating panel of the present invention, unlike the conventional heat insulating panel in which structural plywood is arranged on both sides of the foam, the panel is mounted and fixed at a predetermined position only by nailing the fixing edge portion. It becomes possible to do. In addition, since the surrounding frame of the foam is not provided with the surrounding frame, the hard organic foam can be easily cut with a saw or a blade, and since there are few cut parts of wood, the panel can be made according to the finished dimensions of the frame at the site. It is possible to modify and use the dimensions as appropriate in the field, and the workability of mounting in the field is extremely excellent.

Further, since at least one reinforcing material is integrally bonded to the structural plywood so as to be exposed from the surface of the hard organic foam, it is possible to use this reinforcing material as a furring strip or a stud of a building. Therefore, it is possible to more securely and firmly fix the partitioning material, the interior decorative board, and the like.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a composite heat insulation panel according to the present invention.

FIG. 2 is a perspective view showing a state in which the composite heat insulation panel shown in FIG. 1 is attached to a building.

FIG. 3 is a plan sectional view showing a state in which the composite heat insulating panel shown in FIG. 1 is mounted between columns.

FIG. 4 is a perspective sectional view showing a structural example of a conventional composite heat insulating panel.

FIG. 5 is a partial cross-sectional view showing a conventional connection fixing structure for a composite heat insulating panel.

FIG. 6 is a perspective view showing another configuration example of a conventional composite heat insulation panel.

[Explanation of symbols]

 1, 1b, 1c, 1d Composite heat insulating panel 2 Enclosure 3 Wood plywood 4 Panel body 5 Foam 6 Connection metal fitting mounting hole 7 Connecting pillar 8 Fixing metal fitting 9 Connection metal fitting 10b Structural plywood 11b Hard organic foam 12b Panel body 13b For fixing Edge portion 14 Reinforcement material 15 Rafters 16 Nails 17 Girder material 18 Columns 19 Window frame 20 Interior decorative board 100 Frame body 101 Structural plywood 102 Peripheral portion 103 Reinforcing bar 104 Thermal insulation material

Claims (4)

[Claims] 1. A rigid organic foam is integrally joined to a central portion of one surface of a structural plywood to form a panel main body, and a fixing edge portion for fixing the panel main body to a frame of a predetermined shape is structural. While being provided on the outer periphery of the plywood, at least one reinforcing material is integrally joined to the structural plywood so as to be exposed from the surface of the hard organic foam, while the outer peripheral side surface of the hard organic foam is inclined inward. Composite insulation panel characterized by being formed into. 2. The rigid organic foam comprises polyurethane resin 1
The composite heat insulation panel according to claim 1, wherein the composite heat insulation panel is a plate-like foam body formed by foaming at a foaming ratio of 0 to 25 times and having a large number of bubbles dispersed therein. 3. The composite heat insulation panel according to claim 2, wherein the cells of the plate-shaped foam are closed cells. 4. A fixing edge portion is formed on the outer periphery of a structural plywood having a predetermined size, and at least one reinforcing material is integrally joined to the central portion of the structural plywood, and a frame is provided inside the fixing edge portion. After arranging the foam-shaped jigs in the shape of a pipe inward, spray a resin material containing a foaming agent onto the inner space of the foam-formed jigs in the shape of a frame to obtain a predetermined thickness. A method for manufacturing a composite heat insulating panel, comprising integrally forming a rigid organic foam body having an outer peripheral side surface inclined inward with a structural plywood.