JPH10196880A - Manufacturing method of vacuum insulation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase flatness by holding an ear around the core of a gas barrier container with upper and lower jigs and welding this by heat for manufacture of a vacuum insulating material made by evacuating a space formed by a core material provided between two upper and lower sheet glass barrier materials and its periphery is welded by heat. SOLUTION: For manufacturing a vacuum insulating material, three sides of two upper and lower sheet glass barrier materials having a heat welded layer in an innermost layer are welded by heat except one side thereof, and a bag-like gas barrier container 5 having a specified width ear 3 is formed. Then, a core material 7 wedge-shaped in section is inserted from one non-sealed opening part into the gas barrier container 5. Then, a vacuum chamber 15 having this gas barrier container 5 set inside is evacuated by a vacuum pump and a flat ear 3 is formed around the core material 7. Then, after evacuation of the inside of the vacuum chamber 15 is completed, one opening part of the gas barrier container 5 is sealed and, then, the inside of the vacuum chamber 15 is returned to an atmospheric pressure while the ear 3 is supported from upper and lower sides by supporting jigs 23.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a vacuum heat insulating material suitable for a refrigerator or the like.

[0002]

2. Description of the Related Art Generally, as a vacuum heat insulating material used as a heat insulating material for a refrigerator, for example, as shown in FIG. Seal the sides to form ears 103,
A bag-shaped gas barrier container 105 having an ear 103 on the outer periphery is formed, a dried core material 109 is put through one unsealed opening 107, and then evacuated in a vacuum chamber 111 to reach a predetermined degree of vacuum. At this point, the opening 107 is sealed by the heat sealing device 113. After sealing,
By returning the inside of the vacuum chamber 111 to the atmospheric pressure, a vacuum heat insulating material is produced.

[0003]

SUMMARY OF THE INVENTION Gas barrier container 105
When the inside of the vacuum chamber is returned to the atmospheric pressure, the gas barrier material 101 rapidly adheres along the upper, lower, left, right, front and rear six faces of the square core material 109 due to the differential pressure. At this time, the ear 103 having a predetermined width is
9 rapidly, but due to the influence of the excessively close contact shape of the corner portion and the free end, for example,
As shown in FIGS. 25A and 25B, deformation such as bending and waving occurs.

[0004] For this reason, when transporting or assembling in a refrigerator or the like, it is liable to be hit or damaged, such as being easily caught. In some cases, it can lead to damage.
In particular, at the time of assembling into the heat insulating space between the outer box and the inner box of a refrigerator or the like, urethane foam is filled together with the gas barrier container 105.
The flow is obstructed by the
It causes defects such as voids.

[0005] In addition, the occurrence of a bent region at the ear portion of the gas barrier container 103 causes undesirable disadvantages in terms of instantaneous stability and reliability, such as cracks are easily generated in the corners of the gas barrier container 105 and gas leaks. is there.

Accordingly, the present invention provides a gas barrier container 10
It is an object of the present invention to provide a method of manufacturing a vacuum heat insulating material that can provide a vacuum heat insulating material having excellent flatness without causing bending, waving, or the like in the portion of the ear 103 of No. 5.

[0007]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention evacuates a space formed by interposing a core material between two upper and lower sheet-like gas barrier materials to heat the surroundings. A vacuum heat insulating material that forms a flat ear around the core material by fusing to form a gas barrier container that is vacuum-sealed, wherein the vacuum heat insulating material after sealingly forming the core material into the gas barrier material in a vacuum chamber. Regulates the movement of the flat part of the ear formed on the gas barrier container in a direction perpendicular to the plane, and after holding the flat part by a supporting jig movable in the plane horizontal to the plane. Then, the vacuum in the vacuum chamber is released.

In a preferred embodiment, the outer periphery of the core member has a wedge-shaped cross section inclined from the core member body toward the flat ear.

Alternatively, the entire region of the ear of the gas barrier container has a double laminated structure.

According to the method for manufacturing a vacuum heat insulating material, when the inside of the vacuum chamber is evacuated and returned to the atmospheric pressure, the gas barrier material is manufactured by abruptly adhering along the shape of the core material. At this time, the outer peripheral ears are supported in a state in which movement perpendicular to the sealing surface is restricted, and are movably supported in the horizontal direction. can get.

In this case, by forming the entire area of the ear in a double laminated structure, the stiffness of the seal area is increased, and an ear with less deformation can be obtained.

The wedge-shaped cross section of the outer periphery of the core material eliminates any excessively close contact portions, and the gas barrier material is securely and correctly adhered along the shape of the core material to obtain an ear with reduced deformation.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. In FIG. 7, reference numeral 1 denotes a vacuum heat insulating material. The vacuum heat insulating material 1 includes a gas barrier container 5 having an ear 3 serving as a sealing surface having a predetermined width on an outer periphery, and a core material 7 filled in the gas barrier container 5. It is composed of

FIGS. 1 to 4 show a method for manufacturing the vacuum heat insulating material 1. FIG.

That is, as shown in FIG. 4, the upper and lower two sheet-like gas barrier members 9 and 9 composed of a metal foil and a plastic laminate filter having a heat-sealing layer as the innermost layer are heat-sealed on three sides except one side. Then, a bag-shaped gas barrier container 5 having ears 3 of a predetermined width is formed.

Next, one opening 1 which is not sealed
The core material 7 dried from 1 is inserted into the gas barrier container 5. In this case, as the core material 7, a molded product formed of inorganic powder, glass fiber, organic foam having an open-cell structure, or the like,
Alternatively, any material put in a bag such as a nonwoven fabric may be used.
Further, a gas adsorbent of zeolite and activated carbon may be added together with the core material 7. As shown in FIGS. 4 and 5, the outer periphery of the core member 7 is a tapered surface 13 having a wedge-shaped cross section inclined outward from the main body 7 a of the core member 7. The shape is such that damage such as does not occur.

Next, as shown in FIG. 1, the gas barrier container 5 into which the core material 7 is inserted is placed on the stage 1 in the vacuum chamber 15.
Set to 7.

The vacuum chamber 15 communicates with a vacuum pump (not shown) through a connection port 19, and is evacuated to obtain a predetermined degree of vacuum. A pair of vertically movable support jigs 23 having a support surface 21 having a fixed area for supporting the ears 3 of the gas barrier container 5 from above and below and preventing deformation is provided in the vacuum chamber 15.
And a pair of upper and lower sealing devices 27 provided with a heat-sealed portion 25 for sealing the opening 11. The heat-sealed portion 25 seals by closely contacting each other, and releases the sealing operation by separating. When the seal of the heat-sealed portion 25 is released, the ear 3 is set to be supported by the support jig 23 so as to be movable in the horizontal (left and right directions in the drawing) direction with respect to the seal surface.

Next, as shown in FIG.
After the evacuation of the inside of the gas barrier container 5 is completed,
1 is heat-sealed and sealed by a sealing device 27.

Next, as shown in FIG. 3, after the sealing is completed, the inside of the vacuum chamber 15 is returned to the atmospheric pressure while the ears 3 are supported by the support jig 23 from above and below.

At this time, the gas barrier material 9 is tightly and correctly adhered along the core material 7 by the differential pressure, and the ears 3 are supported from above and below by the support jig 23, so that no bending or waving occurs. . Thereby, as shown in FIG. 6, the ear 3 excellent in flatness without deformation can be obtained.

FIGS. 7 to 9 show a pair of upper and lower U-shaped support jigs 23 in the vacuum chamber 15 and a heat-sealed portion 25 of a sealing device for sealing the ear 3 on one side of the gas barrier container 5. 9 shows a second embodiment of the manufacturing method using the sealed sealer support jig 24.

That is, one opening 1 of the gas barrier container 5
On the support surface 21 side of the pair of upper and lower sealer support jigs 24 arranged on one side, a heat fusion part 25 for heat fusion is provided.
Seal 1 is performed.

The heat-sealing portion 25 seals when the vacuum chamber 15 is evacuated while the vacuum chamber 1
When the inside of the container 5 is returned to the atmospheric pressure, the sealing operation is released, and the sealer supporting jig 24 supports the ear 3 of the gas barrier container 5 so as to be movable horizontally with respect to the sealing surface, like the supporting jig 23. ing.

Since the gas barrier container 5 and the core member 7 are the same as those in the above-described embodiment, the same reference numerals are given and the detailed description is omitted.

Therefore, according to this embodiment, FIG.
The gas barrier container 5 with the core material 7 inserted therein is set on the stage 17 in the vacuum chamber 15 as shown in FIG.

Next, as shown in FIG.
After the evacuation of the inside, the ear 3 of the gas barrier container 5 is supported by the support surfaces 21 of the upper and lower support jigs 23, and one opening 11 is sealed by the heat-sealed portion 25 of the sealer support jig 24.

Next, after the sealing is completed, the inside of the vacuum chamber 15 is returned to the atmospheric pressure as shown in FIG. Is supported by the support surface 21 of the support jig 23 so as to be freely movable in the horizontal direction, so that the ear 3 is not deformed without bending or waving.

FIGS. 10 to 12 show the vacuum chamber 15.
The gas barrier container 5 is set with the upper and lower support jigs 23 inside. FIG. 13 shows a third embodiment of a manufacturing method in which the stage and the sealing device are integrally formed to serve as both.

That is, of the upper and lower support jigs 23, the lower side is constituted by the fixed side support jig 23 and the upper side is constituted by the movable side support jig 23. And a gas barrier material 9 on the ear support surface 31 side.
Is provided, while the upper movable jig 23 is provided with the ear support surface 33 and the heat-sealed portion 25 for sealing the entire circumference.

The heat-sealing portion 25 seals when the inside of the vacuum chamber 15 is evacuated, and releases the seal when returning the inside of the vacuum chamber 15 to atmospheric pressure during close contact. It is set so as to be movable in the horizontal direction.

Since the gas barrier container 5 and the core member 7 are the same as those of the above-described embodiment, the same reference numerals are given and the detailed description is omitted.

Therefore, according to this embodiment, FIG.
As shown at 0, the lower gas barrier material 9 and the core material 7 are set on the stage 29, and the upper gas barrier material 9 is placed thereon.

Next, as shown in FIG. 11, after the evacuation of the vacuum chamber 15 is completed, the upper movable support jig 23 is lowered to seal the entire periphery of the gas barrier material 9 with the heat-sealed portion 25.

Next, after the sealing is completed, the inside of the vacuum chamber 15 is returned to the atmospheric pressure as shown in FIG. 12, so that the gas barrier material 9 is tightly and correctly adhered along the core material 7 by the differential pressure, and the ear 3 is , Ear support surface 3 of upper and lower support jigs 23
The ears 3 and 3 are movably supported in the horizontal direction, so that the ears 3 do not bend or undulate without deformation.
Is obtained.

FIGS. 13 to 14 show a fourth embodiment of a method for manufacturing a vacuum heat insulating material operated in a flow operation.

That is, as shown in FIG. 13, the first chamber chamber is made independent by an entrance gate 34, a first movable gate section 35, a second movable gate section 37, and an exit gate 38 which can open and close the vacuum chamber 15. 39, a second chamber 41, and a third chamber 43 are formed.

The first chamber 39 has an entrance gate 34.
Is opened, the gas barrier container 5 is set, the entrance gate 34 and the first moving gate 35 are closed, and a room for preliminary exhaust is provided. The second chamber 41 is the gas barrier container 5
It has a pair of upper and lower sealing devices 27 provided with a heat-sealing portion 25 for heat-sealing one of the openings 11, and a room where a predetermined degree of vacuum can be obtained by main exhaust. Third chamber room 4
Reference numeral 3 denotes a room which has a fixed support jig 47 and a movable support jig 49 provided with support surfaces 45, 45 for supporting the gas barrier container 5 and the ears 3 from above and below, and returns to atmospheric pressure.

Since the gas barrier container 5 and the core member 7 are the same as those of the above-described embodiment, the same reference numerals are given and the detailed description is omitted.

Therefore, according to this embodiment, FIG.
As shown in FIG. 3, first, the second and third chambers 41, 4
With the inside of the chamber 3 evacuated, the gas barrier container 5 in which the core material 7 is inserted into the first chamber 39 is set on the stage 17, and the inside of the first chamber 39 is evacuated.

Next, after a lapse of a predetermined time, the first gate unit 35
Is opened, the gas barrier container 5 is moved into the second chamber 41, and the first moving gate 35 is closed.

Next, when the inside of the second chamber 41 reaches a predetermined degree of vacuum, one opening 11 of the gas barrier container 5 is sealed by sealing devices 23, 23 as shown in FIG. Then, as shown in FIG. 15, the sealed gas barrier container 5 is moved to the evacuated third chamber 43, and is set on the fixed support jig 49. After the setting is completed, the second moving gate section 37 is closed, and the third chamber 43 is returned to the atmospheric pressure.
And after taking out the vacuum insulation material from the exit gate 38,
The third chamber 43 is evacuated again. Thereafter, this operation is sequentially repeated.

As a result, the gas barrier material 9 can easily and correctly adhere along the core material 7 by the differential pressure.
Since the ear 3 is supported by the fixed support jig 49 and the movable support jig 47, the ear 3 does not bend or undulate, and the ear 3 without deformation is obtained. In addition, workability is improved.

FIGS. 16 to 18 show a fifth embodiment of the method for manufacturing a vacuum heat insulating material.

That is, as shown in FIG. 16, the gas barrier container 5 into which the core material 7 has been inserted is set on the stage 17 in the vacuum chamber 15 and the three-sided ears 3 already sealed.
Is sandwiched by a support 51 made of synthetic resin (only one position in the drawing) so as not to cause deformation.

Next, as shown in FIG. 17, the inside of the vacuum chamber 15 is evacuated, and when a predetermined degree of vacuum is reached, one opening 11 is sealed by the sealing device 27. next,
As shown in FIG. 18, after the sealing is completed, the sealing device 27 releases the sealing operation, the sealing device 27 also holds the ear 3 movably in the horizontal direction, and returns the inside of the vacuum chamber 15 to the atmospheric pressure.

As a result, the gas barrier member 9 can be easily and correctly adhered along the core member 7 due to the differential pressure, and the ear 3 free from bending and waving can be obtained.

FIG. 19 shows a modified example of the vacuum heat insulating material 1.

That is, the manufacturing method is the same as that of the first embodiment, except that a gas barrier material 53 is newly provided in the entire region of the ears 3 of the gas barrier container 5 to form a double laminated structure.

Thus, the stiffness of the ear 3 is increased by the double laminated structure, and the ear 3 with less deformation can be obtained. In these series of embodiments, FIG. 20 shows the thermal conductivity and the breakage rate of each embodiment.

FIG. 20 shows the results obtained by applying vibration to the upper and lower sides and the left and right sides for 10 hours in a shaking test apparatus, and evaluating the ratio of breakage. It is to be noted that, assuming that the puncture is completely punctured, the internal pressure of the vacuum heat insulating material 1 is measured.
Anything greater than 2 torr was considered broken.

As is apparent from this figure, it has been proved that it is less susceptible to breakage and has less change in heat insulation performance over a long period of time, as compared with the conventional example.

FIGS. 21 and 22 show the results of power consumption obtained by providing the vacuum heat insulating material 1 in the refrigerator.

According to the present invention, the variation was smaller than that of the conventional one, and the average value was 66.8 kwh / month, compared with 68.9 kwh / month of the conventional example.

[0055]

As described above, according to the vacuum heat insulating material of the present invention, an ear without deformation can be obtained, and it is hard to break, and stable heat insulating performance can be obtained for a long period of time. Also, when incorporated in a refrigerator or the like, stable power consumption with little variation can be obtained.

[Brief description of the drawings]

FIG. 1 is an operation explanatory view in which a gas barrier container into which a core material is inserted is set in a vacuum chamber.

FIG. 2 is an operation explanatory view in which one opening of a gas barrier container set in a vacuum chamber is sealed.

FIG. 3 is an operation explanatory view in a state in which the inside of the vacuum chamber is returned to the atmospheric pressure with the ears of the gas barrier container supported by a support jig.

FIG. 4 is an explanatory view of inserting a core material from one opening of the gas barrier container.

FIG. 5 is a plan view of a core material.

FIG. 6 is a cutaway view of the vacuum heat insulating material obtained according to FIG. 3;

FIG. 7 is an operation explanatory view similar to FIG. 1, in which a support jig and a heat-sealing portion of a sealing device are integrated.

FIG. 8 is an operation explanatory view in which one opening of the gas barrier container is sealed by the support jig of FIG. 8;

FIG. 9 is an operation explanatory diagram in which the inside of the vacuum chamber in which sealing is completed in FIG. 9 is set to the atmospheric pressure.

FIG. 10 is an operation explanatory view similar to FIG. 1 in which a stage and a sealing device are integrated with a support jig.

FIG. 11 is an operation explanatory view for sealing the entire periphery of the gas barrier container by the support jig of FIG. 11;

FIG. 12 is an operation explanatory diagram in which sealing is completed and the inside of the vacuum chamber is set to atmospheric pressure according to FIG. 12;

FIG. 13 is an operation explanatory view similar to FIG. 1 for manufacturing a vacuum heat insulating material while moving the vacuum insulating material to the first, second, and third chambers.

FIG. 14 is an explanatory diagram of the operation of moving to the second chamber.

FIG. 15 is an explanatory diagram of the operation of moving to a third chamber.

FIG. 16 is an operation explanatory view similar to FIG. 1, in which three ears of the gas barrier container are set in a vacuum chamber so as not to be deformed by the support tool.

FIG. 17 is an operation explanatory view in which one opening of the gas barrier container is sealed.

FIG. 18 is an operation explanatory view in which the inside of the vacuum chamber is returned to the atmospheric pressure after the sealing is completed.

FIG. 19 is an explanatory view showing the gas barrier container having a double-layered ear.

FIG. 20 is an explanatory diagram comparing thermal conductivity and breakage rate with a conventional example.

FIG. 21 is an explanatory diagram comparing the amount of power consumption of a refrigerator according to the present invention with a conventional example.

FIG. 22 is an explanatory diagram showing a monthly average value of power consumption compared with a conventional example.

FIG. 23 is an explanatory view of a conventional method for manufacturing a vacuum heat insulating material.

FIG. 24 is an explanatory view showing a conventional completed ear.

[Explanation of symbols]

 3 Ears 5 Gas barrier container 7 Core material 15 Vacuum chamber

Claims (3)

[Claims] 1. A space formed by interposing a core material between two upper and lower sheet-shaped gas barrier materials is evacuated and the periphery is thermally fused to form a flat ear around the core material. In a vacuum heat insulating material forming and forming a gas barrier container to be vacuum-sealed, the vacuum heat insulating material after the core material is hermetically molded in the gas barrier material in the vacuum chamber has a flat surface portion of the ear formed in the gas barrier container in its surface. A vacuum characterized in that the movement in a direction perpendicular to the surface is restricted, and after holding by a support jig movable in a direction parallel to the surface, the vacuum in the vacuum chamber is released. Manufacturing method of thermal insulation. 2. The method for manufacturing a vacuum heat insulating material according to claim 1, wherein the outer periphery of the core material has a wedge-shaped cross section inclined from the core material body to the flat ear. 3. The method according to claim 1, wherein the entire area of the ear of the gas barrier container has a double-layered structure.