Vacuum heat insulation panel

Abstract

The invention provides a vacuum heat insulation panel with improved manufacturability. A vacuum insulation panel (100) in which a pair of plates (1, 2) face each other so as to form an internal space (Q) therebetween, the vacuum insulation panel (100) being characterized by comprising a first metal plate, a second metal plate that forms an internal space between the first plate and the second plate, and a spacer (S) that supports the first plate and the second plate from the internal space side, the first plate has a first outer edge plate portion (13), a standing plate portion (12) standing from the first outer edge plate portion and formed by a curved surface, and a main plate portion (11) continuous from the standing plate portion and supported by the spacer, and a first resin material (3) having gas barrier properties is interposed between the first outer edge plate portion on the outer edge side of the first plate and a second outer edge plate portion (22) on the outer edge side of the second plate. The spacer is made of a resin material and is separated from the first outer edge plate part and the second outer edge plate part.

Description

Technical Field

[0001] The invention relates to a vacuum insulation panel for use in buildings. Background Art

[0002] When installing an insulation wall in a building such as a residence, a building, a factory, or a warehouse, the insulation wall is constructed by installing an insulation panel. In addition to laminating an insulation material in an internal space formed by a pair of face materials, or foaming on site, a vacuum insulation panel in which the internal space is evacuated is known as a structure with better insulation. On the other hand, depending on the material or structure, the vacuum insulation panel has the following risks: the face material is deformed due to the pressure difference between the internal space and the atmospheric pressure, and the insulation is greatly reduced due to the contact between the face materials.

[0003] Patent document 1 discloses a vacuum insulation panel in which protrusions are brought into contact with each other, and the protrusions are obtained by protruding the surfaces of a pair of opposing titanium thin plates in a substantially hemispherical shape. In addition, patent document 2 discloses a vacuum insulation panel, which is composed of a core material having heat insulation properties and an outer metal plate covering the periphery thereof, and the interior is placed in a vacuum state and sealed by the peripheral edge of the outer metal plate.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2004-211376

[0007] Patent Document 2: Japanese Patent Application Publication No. 2013-170652 Summary of the invention

[0008] Technical problem to be solved by the invention

[0009] According to the vacuum insulation panel disclosed in Patent Document 1, since the protrusions abut against each other, the deformation of the titanium thin plate can be suppressed. However, the vacuum insulation panel disclosed in Patent Document 1 has the following problem: because the hemispherical protrusions are abutted against each other except for the outer edge portion required for joining, the thermal insulation will be reduced when the abutting portion is offset over time or due to external pressure. In addition, according to the vacuum insulation panel disclosed in Patent Document 2, the interior is filled with core material, and the formation of a vacuum layer is not envisioned. Therefore, there is a problem that the improvement of thermal insulation based on the vacuum layer cannot be achieved. In addition, according to Patent Documents 1-2, a structure obtained by joining relative metal plates to each other by welding is disclosed. Here, for example, when the welding tool is brought into a vacuum chamber for welding, there is the following problem: the manufacturing cost of the vacuum insulation panel is very high and the manufacturability is low.

[0010] Therefore, the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a vacuum insulation panel with improved manufacturability.

[0011] Technical means for solving technical problems

[0012] The vacuum insulation panel in the first invention is a vacuum insulation panel in which a pair of plates are opposite to each other in a manner that an internal space is formed between them, and is characterized in that it includes: a first plate made of metal; a second plate made of metal, which forms an internal space between the first plate; and a spacer, which supports the first plate and the second plate from the internal space side, and the first plate has: a first outer edge plate portion on the outer edge side; a vertical plate portion, which is upright from the first outer edge plate portion and is formed by a curved surface; and a main board portion, which is continuous from the vertical plate portion and is supported by the spacer, and a first resin material with gas barrier properties is sandwiched between the first outer edge plate portion and the second outer edge plate portion on the outer edge side of the second plate.

[0013] The vacuum heat insulation panel according to the second invention is characterized in that, in the first invention, the spacer is made of a resin material and is separated from the first outer edge plate portion and the second outer edge plate portion.

[0014] The vacuum insulation panel according to the third invention is characterized in that, in the first invention or the second invention, a second resin material having a higher melting point than the first resin material is interposed between the first outer edge plate portion and the second outer edge plate portion.

[0015] The vacuum insulation panel in the fourth invention is characterized in that, in the first invention or the second invention, the spacer has: a plate-shaped first support portion, which extends along the first plate material and supports the first plate material; a plate-shaped second support portion, which extends along the second plate material in a manner of forming a hollow space between the first support portion and the second plate material, and supports the second plate material; and a plurality of third support portions, which support the first support portion and the second support portion from the hollow space side, and the plurality of third support portions extend in one direction and are integrally formed with the first support portion and the second support portion.

[0016] The vacuum heat insulation panel according to a fifth aspect of the present invention is characterized in that, in the first aspect of the present invention or the second aspect of the present invention, the first resin material is interposed only between the first outer edge plate portion and the second outer edge plate portion.

[0017] The vacuum heat insulating panel according to a sixth aspect of the present invention is characterized in that, in the first aspect or the second aspect, the second plate member has a curved portion that is curved between the first outer edge plate portion and the spacer.

[0018] Effects of the Invention

[0019] According to the first to sixth inventions, a first resin material having gas barrier properties is sandwiched between the first outer edge plate portion of the first metal plate and the second outer edge plate portion of the second metal plate. That is, the metal plates can be joined to each other at a temperature lower than the welding temperature. Therefore, the metal plates can be joined to each other in a vacuum chamber at a lower cost and in a shorter time than when a welding tool is used in a vacuum chamber. Thus, it is possible to seek to improve the manufacturability of the vacuum insulation panel. In addition, the upright plate portion of the first plate is formed by a curved surface. Therefore, it is easy to release the external pressure applied to the first plate through the shell structure. Thus, it is possible to seek to improve the durability of the vacuum insulation panel. In addition, the first plate 1 and the second plate 2 can be joined more strongly by welding the outer edge side outside the vacuum chamber in a state where the first plate 1 and the second plate 2 are joined by the first resin material 3.

[0020] In particular, according to the second invention, the spacer is made of a resin material and is separated from the first outer edge plate portion and the second outer edge plate portion. Therefore, since each plate is supported by a spacer made of a resin material having a lower thermal conductivity than metal, and heat is difficult to be transferred from the outer edge side to the spacer when each plate is joined, the spacer is difficult to deform or evaporate in the internal space. As a result, the thermal insulation of the vacuum insulation panel can be improved, and the manufacturability can be improved.

[0021] In particular, according to the third invention, the second resin material is sandwiched between the first outer edge plate portion and the second outer edge plate portion. Therefore, it is easy to ensure the thickness of the resin material, and heat is more difficult to conduct between the plates. As a result, the heat insulation of the vacuum insulation panel can be improved.

[0022] In particular, according to the fourth invention, the spacer has: a plate-shaped second support portion, which extends along the second plate material in a manner of forming a hollow space between the first support portion and the second plate material, and supports the second plate material; and a third support portion, which extends in one direction and is formed integrally with the first support portion and the second support portion. Therefore, a vacuum layer can be formed in the hollow space. Thus, the thermal insulation of the vacuum insulation panel can be improved. In addition, the first support portion, the second support portion and the third support portion can be easily manufactured by extrusion molding or the like. Thus, the manufacturability of the vacuum insulation panel can be further improved.

[0023] In particular, according to the fifth invention, the first resin material is only sandwiched between the first outer edge plate portion and the second outer edge plate portion. Therefore, it is easy to suppress the influence of the first resin material being heated and evaporated on the vacuum state of the internal space. Thus, it is possible to suppress the reduction of the heat insulation property of the vacuum insulation panel.

[0024] In particular, according to the sixth invention, the second plate has a curved portion between the first outer edge plate portion and the spacer. Therefore, the second plate can deform following the deformation caused by heating of the first plate, and wrinkles or cracks are unlikely to occur. This can suppress the reduction in the thermal insulation of the vacuum insulation panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 (a)~ Figure 1 (d) is a schematic diagram showing an example of a vacuum insulation panel in this embodiment, Figure 1 (a) is a top view, Figure 1 (b) is Figure 1 (a) A-A section view, Figure 1 (c) is Figure 1 (b) is a partially enlarged cross-sectional view, Figure 1 (d) is Figure 1 BB section view of (a).

[0026] Figure 2 (a)~ Figure 2 (d) is a schematic diagram showing a first modified example of the vacuum insulation panel in this embodiment. Figure 2 (a) is a top view, Figure 2 (b) is a partially enlarged cross-sectional view. Figure 1 (d) is Figure 2 (a) C-C section view.

[0027] Figure 3 (a)~ Figure 3 (d) is a schematic diagram showing second to fifth modifications of the vacuum insulation panel in the present embodiment.

[0028] Figure 4 (a)~ Figure 4 (c) is a schematic diagram showing the sixth to eighth modified examples of the vacuum insulation panel in this embodiment, Figure 4 (d)~ Figure 4 (e) is a schematic diagram showing a ninth modified example of the vacuum insulation panel in the present embodiment.

[0029] Figure 5 (a)~ Figure 5 (b) is a schematic diagram showing an example of a method for manufacturing a vacuum insulation panel in this embodiment, Figure 5 (a) is a cross-sectional view, Figure 5 (b) is Figure 5 (a) is a partially enlarged cross-sectional view. DETAILED DESCRIPTION

[0030] Hereinafter, an example of a vacuum insulation panel 100 as an embodiment of the present invention will be described in detail with reference to the accompanying drawings. In addition, in each figure, a first direction is set as X, a direction intersecting with the first direction X, for example, orthogonal to the first direction X is set as a second direction Y, and a direction intersecting with the first direction X and the second direction Y, for example, orthogonal to each other, is set as a thickness direction Z. The configurations in each figure are schematically described for the convenience of description, and for example, the size of each configuration or the comparison of the size in each configuration may be different from the drawings.

[0031] (Vacuum insulation panel 100)

[0032] An example of the vacuum insulation panel 100 in the present embodiment will be described with reference to the drawings.

[0033] The vacuum insulation panel 100 is used for, for example, insulation walls of buildings such as houses, buildings, factories, warehouses, etc. The vacuum insulation panel 100 is fixed and used on, for example, the exterior side of a structural plywood.

[0034] The vacuum insulation panel 100 is configured such that a pair of plates face each other. Figure 1 (a)~ Figure 1 As shown in (d), the vacuum insulation panel 100 includes a first plate 1, a second plate 2, a first resin material 3, and a spacer S. The vacuum insulation panel 100 is configured, for example, such that the first plate 1 and the second plate 2 are opposite to each other. The vacuum insulation panel 100 exists in the following manner: extending in a plane direction including the first direction X and the second direction Y.

[0035] The vacuum insulation panel 100 is provided with a spacer S in the internal space Q, for example, and the internal space Q is formed between the first plate 1 and the second plate 2. In the vacuum insulation panel 100, the first plate 1 and the second plate 2 are joined by the first resin material 3 in the outer edge region, and a vacuum layer maintained as a vacuum is formed in the internal space Q.

[0036] Here, the so-called vacuum in the present invention means a state where the pressure is reduced more than the atmospheric pressure, that is, negative pressure. Specifically, it means, for example, the vacuum described in ISO3529-1 or JISZ8161-2, including low vacuum, medium vacuum, high vacuum, and ultra-high vacuum. By forming a vacuum layer, the heat conduction caused by air convection in the internal space Q becomes very small. As a result, it is possible to seek to improve the thermal insulation compared to the area where the plates 1 and 2 are in contact. In addition, with the formation of the vacuum layer, an external force is applied to the first plate 1 to deform toward the second plate 2 side due to the negative pressure in the internal space Q, but because it is supported by the spacer S, it is possible to obtain sufficient strength against the external force.

[0037] The dimensions of the vacuum insulation panel 100 are, for example, about 1.5 to 3 m in length in the first direction X, about 450 mm in length in the second direction Y, and about 8 to 20 mm in thickness in the thickness direction Z.

[0038] <1st plate 1>

[0039] The first plate member 1 is supported by a spacer S on its inner surface facing the inner space Q.

[0040] As a material of the first plate member 1 , for example, metal such as aluminum or stainless steel (SUS304 or the like) is used.

[0041] The first plate 1 is, for example, Figure 1 As shown in (a), the first plate 1 is rectangular in plan view. Figure 1 As shown in (b), it is joined to the second plate material 2 in the outer edge region and separated from the second plate material 2 in the central region.

[0042] The first plate 1 is, for example, Figure 1 As shown in (c), it is composed of a first main plate portion 11, a first outer edge plate portion 12, and a vertical plate portion 13, and is joined to the second plate 2 in the first outer edge plate portion 12, and is separated from the second plate 2 in the first main plate portion 11 and the vertical plate portion 13. The first main plate portion 11 is supported by the first outer edge plate portion 12 via the vertical plate portion 13. The first main plate portion 11 is formed, for example, in a flat plate shape without bumps. The vertical plate portion 13 stands upright from the first outer edge plate portion 12 and is formed by a curved surface. The first main plate portion 11 is continuous with the vertical plate portion 13 and is supported by a spacer S.

[0043] Regarding the first plate 1, for example, the vertical plate portion 13 is formed by a curved surface. In this case, it is easy to release the external pressure applied to the first plate 1 through the shell structure. As a result, the durability of the vacuum insulation panel 100 can be improved. In addition, the vertical plate portion 13 is a smooth curved surface shape without folds, so Figure 1 In (a), the area of ​​the curved surface shape is indicated by shading.

[0044] Here, the surface of the first outer edge plate portion 12 that is the short side of the rectangle and exposed to the outside is set as the first main surface f1, and the surface that is the long side of the rectangle and exposed to the outside is set as the second main surface f2. In addition, the surface of the first outer edge plate portion 12 that is the opposite surface of the first main surface f1 and in contact with the second plate material 2 is set as the third main surface f3, and the surface that is the opposite surface of the second main surface f2 and in contact with the second plate material 2 is set as the fourth main surface f4. In this case, with respect to the first plate material 1, in a state where the resin material (including the first resin material 3 described later) is sandwiched between the main surfaces f3 and f4 in contact with the second plate material 2 and the second plate material 2, by heating the exposed main surfaces f1 and f2, the resin material is melted by the heat conducted through the main surfaces f3 and f4. Then, by cooling the vacuum heat insulation panel 100 , the melted resin material solidifies, and the main surfaces f3 , f4 and the second plate material 2 can be joined by welding.

[0045] The width w1 of the first main surface f1 in the first direction X is, for example, approximately 20 mm. The width w2 of the second main surface f2 in the second direction Y is, for example, approximately 20 mm.

[0046] The thickness of the first plate 1 in the thickness direction Z is, for example, about 0.1 mm to 2.0 mm, and preferably about 0.2 mm. The standing width of the first main plate portion 11 in the thickness direction Z based on the first outer edge plate portion 12 of the first plate 1 is, for example, about 1.0 mm to 20.0 mm, and preferably about 7.5 mm.

[0047] <2nd plate 2>

[0048] The inner surface of the second plate member 2 facing the internal space Q is supported by the spacer S. As the material of the second plate member 2 , for example, the same material as that of the first plate member 1 can be used.

[0049] The second plate 2 is, for example, rectangular in plan view. Figure 1 As shown in (b), it is in contact with the outer edge of the first plate 1 in the outer edge region and is separated from the first plate 1 in the central region.

[0050] The second plate 2 is, for example, Figure 1 As shown in (c), it is composed of a second main plate portion 21 and a second outer edge plate portion 22. In the second outer edge plate portion 22, it is joined to the first outer edge plate portion 12 via the first resin material 3, and in the second main plate portion 21, it is separated from the first main plate portion 11 and the vertical plate portion 13. The second main plate portion 21 and the second outer edge plate portion 22 are formed into a flat plate shape without concave-convex and flat.

[0051] The second plate 2 may also have, for example, a vertical plate portion corresponding to the vertical plate portion 13. In this case, the second main plate portion 21 is supported by the second outer edge plate portion 22 via the vertical plate portion. In addition, the second plate 2 is joined to the first plate 1 by heating the first resin material 3 on the surface of the second outer edge plate portion 22 and joining the outer edge plate portion to the first outer edge plate portion 12.

[0052] The thickness of the second plate material 2 in the thickness direction Z is, for example, approximately 0.1 mm to 2.0 mm, and particularly preferably approximately 0.3 mm.

[0053] <First resin material 3>

[0054] The first resin material 3 is composed of a thermoplastic resin or a thermosetting resin and has gas barrier properties. Here, the so-called resin having gas barrier properties refers to a resin having a gas barrier property in ISO 15105-1:

[0055] In the gas permeability test described in Plastics-Film and sheeting-Determination of gas-transmission rate-Part 1: Differential-pressure method, the oxygen permeability under the conditions of 23°C temperature and 0% humidity (0% RH) is 5 L / (m 3 ·24h·atm) or less, and the water vapor permeability is 50g / (m 3 · 24h) or less. As the first resin material 3, for example, EVOH (ethylene-vinyl alcohol copolymer) or PVDC (polyvinylidene chloride) or the like is used as the first resin material 3. In addition, it may be a synthetic rubber-based hot melt adhesive having equivalent gas permeability. The synthetic rubber-based hot melt adhesive is an adhesive obtained by kneading synthetic rubber with a tackifier resin, a plasticizer, and the like.

[0056] The first plate 1 and the second plate 2 are joined by heating the outer edge side (for example, the first outer edge plate portion 12 or the second outer edge plate portion 22) in a state where the first resin material 3 is sandwiched between the first outer edge plate portion 12 and the second outer edge plate portion 22. That is, the metal plates 1 and 2 can be joined to each other at a temperature lower than the welding temperature. In this case, the metal plates can be joined to each other at a lower cost and in a shorter time than when a welding tool is used in a vacuum chamber. Thus, the manufacturability of the vacuum insulation panel 100 can be improved. In addition, the first plate 1 and the second plate 2 can be joined more strongly by welding the outer edge side outside the vacuum chamber in a state where the first plate 1 and the second plate 2 are joined by the first resin material 3.

[0057] The first resin material 3 may, for example, be provided only on the second outer edge plate portion 22 in the surface of the second plate 2 opposite to the first plate 1. That is, the first resin material 3 is sandwiched only between the first outer edge plate portion 12 and the second outer edge plate portion 22. In this case, it is easy to suppress the influence on the vacuum state of the internal space Q due to the heating and evaporation of the first resin material 3. Thus, it is possible to suppress the reduction in the thermal insulation of the vacuum insulation panel 100. In this case, the first resin material 3 may also be provided on the third main surface f3 of the first outer edge plate portion 12.

[0058] <Spacer S>

[0059] The spacer S is, for example, Figure 1 (c)~ Figure 1 As shown in (d), it has: a first support portion S1 that supports the first plate 1; a second support portion S2 that supports the second plate 2; and a plurality of third support portions S3 that support the respective support portions S1 and S2.

[0060] The first support portion S1 is, for example, in a plate shape, and extends along the first plate member 1. The first support portion S1 is in contact with the first plate member 1 at a surface, for example, and supports the first plate member 1 with the contact surface.

[0061] The second support portion S2 is, for example, plate-shaped and extends along the second plate 2. The second support portion S2 is separated from the first support portion S1 in a manner that a hollow space R is formed between the second support portion S2 and the first support portion S1. The second support portion S2 is, for example, in surface contact with the second plate 2 or the first resin material 3 on the surface of the second plate 2, and supports the second plate 2 with the contact surface. The second support portion S2 is, for example, Figure 1 As shown in (c), the second plate material 2 may be supported via the first resin material 3 or directly supported. Here, the hollow space R represents a region of the internal space Q excluding the region occupied by the spacer S.

[0062] The plurality of third support parts S3 support the first support part S1 and the second support part S2 from the hollow space R side. The plurality of third support parts S3 are, for example, Figure 1 As shown in (d) of FIG. 8 , the hollow space R is maintained by supporting the load applied to the hollow space R side along the thickness direction Z from the first support portion S1 and the second support portion S2 .

[0063] By configuring the support portions S1 to S3, the spacer S can form a hollow space R between the first plate 1 and the second plate 2. In this case, a vacuum layer can be formed in the hollow space R. Thus, the heat insulation of the vacuum insulation panel 100 can be improved. In addition, since the support portions S1 and S2 support the first plate 1 and the second plate 2, the hollow space R can be maintained even if the support portion of one of the plates 1 and 2 is deviated. Thus, the reduction in the heat insulation of the vacuum insulation panel 100 can be suppressed.

[0064] In addition, it is also possible that a plurality of third support parts S3 are provided. Figure 1 As shown in (c), it is plate-shaped and has a Figure 1 In (d), the first support portion S1 and the second support portion S2 are formed integrally with each other. In this case, the first support portion S1, the second support portion S2 and the third support portion S3 can be easily manufactured by extrusion molding or the like. Thus, the manufacturability of the vacuum insulation panel 100 can be further improved.

[0065] As the material of the spacer S, for example, plastic (synthetic resin) described in ISO1043-1 or JISK6899-1 is used. The vacuum insulation panel 100 supports each plate 1, 2 with the spacer S made of resin having a lower thermal conductivity than metal. Therefore, when a metal having a higher strength than resin is used for each plate 1, 2, the area where the metal plates contact each other can be reduced compared to the case where the spacer S is not used. As a result, the durability of the vacuum insulation panel 100 can be improved and the thermal insulation can be improved.

[0066] The spacer S is separated from the first outer edge plate portion 12, for example. In this case, since the plates 1 and 2 are supported by the spacer S made of a resin material having a lower thermal conductivity than metal, and heat is difficult to be conducted from the outer edge side to the spacer S when the plates 1 and 2 are joined, the spacer S is difficult to deform or evaporate in the internal space Q. Thus, the heat insulation of the vacuum insulation panel 100 can be improved, and the manufacturability can be improved.

[0067] The separation distance between the spacer S and the first outer edge plate portion 12 is, for example, about 10 to 20 mm in width w3 from the third main surface f3 along the first direction X and about 10 to 20 mm in width w4 from the fourth main surface f4 along the second direction Y.

[0068] As the size of the spacer S, for example, the long side direction ( Figure 1 The length of the first direction X) is about 1460 mm, and the short side direction ( Figure 1The length in the second direction Y) is about 372.5 mm, and the thickness is 0.5 mm. The size of the second support portion S2 is preferably the same as that of the first support portion S1.

[0069] Regarding the dimensions of the third support portion S3, for example, the longitudinal direction ( Figure 1 The length in the first direction X) is the same as that of the first support portion S1, the thickness in the second direction Y is about 0.5 mm, and the short side direction ( Figure 1 The width w5 of the third support portion S3 in the thickness direction Z) is about 10 mm. Here, the width w5 of the third support portion S3 is the same as the separation width of the first support portion S1 and the second support portion S2. In addition, the width w6 of the adjacent plurality of third support portions S3 is, for example, about 12 mm.

[0070] (First Modification of Vacuum Insulation Panel 100)

[0071] <2nd plate 2>

[0072] The second plate 2 is, for example, Figure 2 (a)~ Figure 2 As shown in (c), the protruding curved portion T is provided, and the protruding curved portion T is bent toward the upright plate portion 13 in the region between the first outer edge plate portion 12 and the spacer S and opposite to the upright plate portion 13. Figure 2 (a) shows that the area of ​​the bent portion T represented by the dashed line overlaps the area of ​​the curved surface shape of the vertical plate portion 13 represented by the shaded line when viewed from above. The bent portion T is elastically deformed or plastically deformed, for example, by external pressure in the first direction X and the second direction Y. The bent portion T can also be arranged in an area between the first outer edge plate portion 12 and the spacer S, and opposite to the first main plate portion 11. The bent portion T can also be arranged between the first resin material 3 and the spacer S. In addition, although not shown in the figure, the bent portion T can also be a groove-shaped portion that bends toward the opposite side of the vertical plate portion 13.

[0073] Here, when the first resin material 3 is heated to manufacture the vacuum insulation panel 100 and the plates 1 and 2 are joined, if the temperature around the first outer edge plate portion 13 is about 200°C and the temperature around the first main plate portion 11 is about 20°C, a large temperature difference will occur, the difference in thermal expansion will increase, and strain will easily occur in the first plate 1. If the strain is not taken care of, internal stress will continue to act, and the strain will increase over time due to creep, and there is a risk that the first resin material 3 will eventually peel off from the plates 1 and 2.

[0074] According to this modification, by providing the bent portion T in the second plate 2, the second plate 2 can deform to follow the deformation caused by the heating of the first plate 1, and wrinkles or cracks are less likely to occur on the surface of the second plate 2. Thus, it is possible to suppress the reduction in the insulation performance of the vacuum insulation panel 100.

[0075] In addition, the bent portion T is separated from the upright plate portion 13, for example. In this case, heat conduction caused by contact with the upright plate portion 13 (the first plate 1) does not occur, and deformation of the bent portion T itself, such as thermal expansion, that does not follow the deformation of the upright plate portion 13 can be reduced. As a result, the reduction in the thermal insulation performance of the vacuum insulation panel 100 can be further suppressed.

[0076] As the size of the curved portion T, for example, the width of the curved protrusion or groove is about 1 mm, and the height of the curved protrusion or groove is about 2 mm to 3 mm.

[0077] (Second Modification of Vacuum Insulation Panel 100)

[0078] <First resin material 3>

[0079] The first resin material 3 is, for example, Figure 3 As shown in (a), the entire surface (the second main plate portion 21 and the second outer edge plate portion 22) of the second plate 2 opposite to the first plate 1 is provided, thereby improving the coating workability on the surface of the second plate 2 and suppressing the manufacturing cost. In addition, the flexibility of the configuration of the first plate 1 is improved. Thus, the manufacturability of the vacuum insulation panel 100 can be improved.

[0080] (Third Modification of Vacuum Insulation Panel 100)

[0081] <Vacuum insulation panel 100> The vacuum insulation panel 100 may be, for example, Figure 3 As shown in (b), a second resin material 4 is also included.

[0082] <Second resin material 4>

[0083] The second resin material 4 is made of, for example, a plastic (synthetic resin) described in ISO 1043-1 or JIS K 6899-1 and having a lower thermal conductivity than the first resin material 3. As the second resin material 4, for example, a silicone resin or the like is used.

[0084] The second resin material 4 is, for example, sandwiched between the first resin material 3 and the second plate 2. In this case, it is easy to ensure the thickness of the resin material, and it is more difficult for heat to be conducted between the plates 1 and 2, compared with the case where only the first resin material 3 is sandwiched. As a result, it is possible to seek to improve the thermal insulation of the vacuum insulation panel 100. In addition, the melting point of the second resin material 4 may be higher than that of the first resin material 3. In this case, the second resin material 4 will be more difficult to melt than the first resin material 3, and it will be difficult to evaporate when the first resin material 3 is heated, and it is easy to suppress the influence on the vacuum state of the internal space Q. As a result, it is possible to seek to suppress the reduction in the thermal insulation of the vacuum insulation panel 100.

[0085] (Fourth Modification of Vacuum Insulation Panel 100)

[0086] <Vacuum insulation panel 100>

[0087] The vacuum insulation panel 100 may also be Figure 3 As shown in (c), the outer edge curved portion 22a is formed by plastically deforming and riveting the first outer edge plate portion 12 and the second outer edge plate portion 22. In this case, the plates 1 and 2 can be more firmly joined than when joined only with the first resin material 3. Thus, the durability of the vacuum insulation panel 100 can be improved.

[0088] In addition, the resin bent portion 3a may be formed by deforming the first resin material 3 in the same manner as the second outer edge plate portion 22 when forming the outer edge bent portion 22a. In this case, the first resin material 3 is contained inside the outer edge bent portion 22a, and the plates 1 and 2 can be more firmly joined. Thus, the durability of the vacuum insulation panel 100 can be further improved.

[0089] (Fifth Modification of Vacuum Insulation Panel 100)

[0090] <Vacuum insulation panel 100>

[0091] The vacuum insulation panel 100 is, for example, Figure 3 As shown in (d), a protective material 5 may also be installed to protect the first outer edge plate portion 12, the second outer edge plate portion 22 and the first resin material 3. In this case, the joint portion of each plate 1, 2 is less likely to be affected by the external environment. Thus, the durability of the vacuum insulation panel 100 can be improved.

[0092] As the material of the protective material 5, for example, a known molded product is used, and a molded product using a resin material may be used. The protective material 5 is formed, for example, in a U-shaped cross section, and the first outer edge plate portion 12 and the second outer edge plate portion 22 are sandwiched and held by both sides of the U-shaped. In addition, the protective material 5 may be formed by curing a film impregnated with an adhesive material such as wax or latex.

[0093] (Sixth Modification of Vacuum Insulation Panel 100)

[0094] <Spacer S>

[0095] The spacer S is, for example, Figure 4 As shown in (a), it has: a first support portion S1 that supports the first plate 1; a second support portion S2 that supports the second plate 2; and a connecting portion S4 that connects the supporting portions S1 and S2 to each other.

[0096] The spacer S has, for example, a grid-shaped connecting portion S4 as a base material, and has, at each intersection of the grid: a first support portion S1 that protrudes toward the first plate 1; and a second support portion S2 that protrudes toward the second plate 2. That is, with respect to the spacer S, with respect to one first support portion S1, a plurality of first support portions S1 are connected via the connecting portion S4, and with respect to one second support portion S2, a plurality of second support portions S2 are connected via the connecting portion S4. In this case, the stress acting on each plate 1, 2 can be dispersed by the plurality of support portions S1, S2. Thus, the durability of the vacuum insulation panel 100 can be improved.

[0097] Moreover, compared with the case of using the flat plate-shaped connection part S4, it is possible to reduce the material cost and prevent the support parts S1 and S2 from being concentrated in one part. Thus, it is possible to improve the manufacturability of the vacuum insulation panel 100.

[0098] The spacer S forms a hollow space R by forming a hollow space R1 between the plurality of first support portions S1 , the first plate 1 , and the connecting portion S4 , and forming a hollow space R2 between the plurality of second support portions S2 , the second plate 2 , and the connecting portion S4 , for example.

[0099] At this time, the first support portion S1 supports the inner surface of the first plate 1 with, for example, a convex curved surface. In addition, the second support portion S2 supports the inner surface of the second plate 2 with, for example, a convex curved surface. That is, each support portion S1 and S2 point supports the first plate 1 and the second plate 2. In this case, a vacuum layer can be formed with a larger volume in the hollow space R. As a result, the heat insulation property of the vacuum insulation panel 100 can be further improved.

[0100] As the size of the spacer S, for example, the width X1 of adjacent first support portions S1 and adjacent second support portions S2 along the first direction X is about 20 mm to 30 mm, and the width of adjacent first support portions S1 and adjacent second support portions S2 along the second direction Y is about 20 mm to 30 mm.

[0101] As an example of the spacer S, for example, a known knotted net in a lattice shape with vertical and horizontal lines intersecting each other may be used. In this case, each support portion S1, S2 is composed of knots of the knotted net. In this case, the effort of adjusting the configuration of the spacer S can be reduced. Thus, the manufacturability of the vacuum insulation panel 100 can be improved.

[0102] (Seventh Modification of Vacuum Insulation Panel 100)

[0103] <Spacer S>

[0104] The spacer S is, for example, Figure 4As shown in (b), a mesh shape in which the meshes of a plurality of nets intersect can also be formed. The spacer S is, for example, a lattice-shaped net in which the first support portion S1 of the horizontal line and the second support portion S2 of the vertical line intersect, the first support portion S1 of the horizontal line extending along the first direction X, and the second support portion S2 of the vertical line extending along the second direction Y. The connecting portion S4 connects the support portions S1 and S2 at the intersection of the vertical line and the horizontal line. In this case, the first support portion S1 and the second support portion S2 support each other along the thickness direction Z. Here, the so-called lattice shape includes, in addition to a rectangular lattice, a triangular lattice, a hexagonal lattice, a honeycomb structure, etc. In addition, it can also be that the spacer S is alternately woven with the horizontal line and the vertical line, so that the horizontal line and the vertical line alternately form the first support portion S1 and the second support portion S2.

[0105] That is, regarding the spacer S, a plurality of second support parts S2 are connected via the connection part S4 to one first support part S1, and a plurality of first support parts S1 are connected via the connection part S4 to one second support part S2. In this case, the stress acting on each plate 1, 2 can be dispersed by the plurality of support parts S1, S2. Thus, the durability of the vacuum insulation panel 100 can be improved.

[0106] The spacer S forms the hollow space R by forming, for example, the hollow space R1 between the plurality of first support portions S1 and the plates 1 and 2 and by forming the hollow space R2 between the plurality of second support portions S2 and the plates 1 and 2 .

[0107] As the size of the spacer S, for example, the width X2 of the adjacent second support portions S2 along the first direction X is about 20 mm to 30 mm, and the width of the adjacent first support portions S1 along the second direction Y is about 20 mm to 30 mm.

[0108] Examples of the type of mesh used for the spacer S include a plain mesh, a leno mesh, a raschel mesh, a text mesh, and a tin wire mesh. The spacer S may be a knotless mesh.

[0109] In addition, the spacer S may be a plastic net formed by integrally forming the first support portion S1, the second support portion S2, and the connecting portion S4 by extrusion molding, cutting processing, stamping processing, etc. of a resin (polyethylene, polypropylene, polyvinyl chloride, etc.). In this case, the mesh of the spacer S is difficult to collapse, and it is easy to disperse the stress acting on each plate 1, 2. Thus, the durability of the vacuum insulation panel 100 can be improved. In addition, the effort of adjusting the configuration of the spacer S can be reduced. Thus, the manufacturability of the vacuum insulation panel 100 can be improved.

[0110] Examples of the spacer S include “nakusa (registered trademark)”, “nitron (registered trademark) sheet”, and “tricalnet (registered trademark)”.

[0111] The spacer S may be formed in a lattice shape by first supporting portions S1 of a plate or rod shape extending in the first direction X and second supporting portions S2 of a plate or rod shape extending in the second direction Y intersecting with each other.

[0112] (Eighth Modification of Vacuum Insulation Panel 100)

[0113] <Spacer S>

[0114] The spacer S is, for example, Figure 4 As shown in (c), a flat connecting portion S4 is used as a base material, and in the flat surface, there are: a first support portion S1, which protrudes toward the first plate 1; and a second support portion S2, which protrudes toward the second plate 2. In this case, compared with the case of using a lattice-shaped connecting portion S4, the supporting portions of each support portion S1, S2 will be less likely to deviate, and it is easier to disperse the stress acting on each plate 1, 2. Thus, the durability of the vacuum insulation panel 100 can be improved. In addition, the effort of adjusting the configuration of the spacer S can be reduced. Thus, the manufacturability of the vacuum insulation panel 100 can be improved.

[0115] The spacer S forms a hollow space R by forming a hollow space R1 between the plurality of first support portions S1 , the first plate 1 , and the connecting portion S4 , and forming a hollow space R2 between the plurality of second support portions S2 , the second plate 2 , and the connecting portion S4 , for example.

[0116] As the size of the spacer S, for example, the width X3 of the adjacent first support portions S1 and the adjacent second support portions S2 along the first direction X is about 20 mm to 30 mm, and the width of the adjacent first support portions S1 and the adjacent second support portions S2 along the second direction Y is about 20 mm to 30 mm.

[0117] The spacer S may be formed with the support portions S1 and S2 on both surfaces of the flat plate by, for example, performing press molding or die molding on a flat plate-shaped thermoplastic resin.

[0118] Examples of the spacer S include "Rakuraku Road" manufactured by Katsuron Corporation.

[0119] (Ninth Modification of Vacuum Insulation Panel 100)

[0120] <Spacer S> The spacer S may be, for example, Figure 4 (d)~ Figure 4 As shown in (e), a plurality of first support portions S1 and second support portions S2 are arranged along a plane direction including the first direction X and the second direction Y, and are arranged alternately in a cross-sectional view and connected to each other via a connecting portion S4, that is, the surface of the spacer S has a convex and concave shape like a wave. The spacer S has: a first support portion S1, which protrudes toward the first plate 1; a second support portion S2, which protrudes toward the second plate 2; and a connecting portion S4, which connects the first support portion S1 and the second support portion S2. Each support portion S1, S2 is composed of a convex surface, and can point-support the first plate 1 and the second plate 2 at the vertex of the convex surface.

[0121] As the size of the spacer S, Figure 4 As shown in (d), for example, the width X4 of the adjacent first support portions S1 along the first direction X is about 20 mm to 30 mm, and the width Y4 of the adjacent first support portions S1 along the second direction Y is about 20 mm to 30 mm. In addition, the width X4' of the adjacent second support portions S2 along the first direction X is about 20 mm to 30 mm, and the width Y4' of the adjacent second support portions S2 along the second direction Y is about 20 mm to 30 mm.

[0122] The spacer S is, for example, Figure 4 As shown in (e), a hollow space R1 is formed between the multiple first support parts S1, the first plate 1, the opposite surface of the second support part S2 (the surface opposite to the first plate 1), and the connecting part S4, and a hollow space R2 is formed between the multiple second support parts S2, the second plate 2, the opposite surface of the first support part S1 (the surface opposite to the second plate 2), and the connecting part S4, thereby forming a hollow space R.

[0123] (Method of Manufacturing Vacuum Insulation Panel 100)

[0124] Next, refer to Figure 5 (a)~ Figure 5 (b) , an example of a method for manufacturing the above-mentioned vacuum insulation panel 100 is described.

[0125] First, if Figure 5 (a)~ Figure 5As shown in (b), the first plate 1 is arranged on the hollow conductive tray 61 in the following manner: the sides of the first main surface f1 of the first outer edge plate portion 12 are all in contact, and the vertical plate portion 13 is oriented to stand up toward the inside of the conductive tray 61. In addition, after the spacer S is arranged on the inner surface side of the first main plate portion 11, the second plate 2 coated with the first resin material 3 is arranged above the first plate 1 in such a manner that the third main surface f3 of the first outer edge plate portion 12 is opposite to the first resin material 3. At this time, in order to evacuate the internal space Q, for example, an operable electric wedge clamp not shown is installed between the first outer edge plate portion 12 and the second outer edge plate portion 22, and a gap is formed between the first outer edge plate portion 12 and the second outer edge plate portion 22 to connect the internal space Q with the external environment. Thus, the setting of the vacuum front panel 101 is completed.

[0126] Here, depending on the thickness of the spacer S in the thickness direction Z, there may be a case where the first outer edge plate portion 12 and the second outer edge plate portion 22 of the second plate 2 do not contact well, so a conductive tray 62 having the same material and shape as the conductive tray 61 may be arranged above the second plate 2. In this case, the first outer edge plate portion 12 and the second outer edge plate portion 22 are in good contact with each other because they are sandwiched by the conductive trays 61 and 62, and the airtightness of the internal space Q is easily improved.

[0127] Furthermore, the vacuumized front panel 101 in a state where a gap is formed between the first outer edge plate portion 12 and the second outer edge plate portion 22 is accommodated in the vacuum chamber C together with the conductive trays 61 and 62, and then the vacuum chamber C is evacuated. At this time, the internal space Q is communicated with the inside of the vacuum chamber C, and the inside of the vacuum chamber C is evacuated, thereby the internal space Q is also evacuated. After the internal space Q is evacuated, the above-mentioned electric wedge (not shown) is operated from the outside of the vacuum chamber C while the inside of the vacuum chamber C is kept as a vacuum, and the wedge is removed from between the first outer edge plate portion 12 and the second outer edge plate portion 22. At this time, the second plate 2 loses the support from the electric wedge and falls onto the first plate 1. Thus, the first outer edge plate portion 12 and the second outer edge plate portion 22 can be brought into contact without a gap while the internal space Q is kept as a vacuum.

[0128] Then, an external power source not shown is electrically connected to the conductive trays 61 and 62 to supply power to the conductive trays 61 and 62. As a result, the first resin material 3 is heated via the first outer edge plate portion 12 and the second outer edge plate portion 22 of the first sheet 1, and the first outer edge plate portion 12 and the second outer edge plate portion 22 are electrically fused. Thus, after the first sheet 1 and the second sheet 2 are taken out of the vacuum chamber C, the internal space Q is also maintained as a vacuum. Alternatively, after the first sheet 1 and the second sheet 2 are taken out of the vacuum chamber C, the first outer edge plate portion 12 and the second outer edge plate portion 22 are welded. The welding method may also include laser welding, resistance welding, and arc welding, but is not limited thereto. Electric fusion is used here, but it is not limited to electric fusion as long as the first resin can be heated.

[0129] The vacuum insulation panel 100 is manufactured by the above procedure. The vacuum insulation panel 100 can be manufactured more efficiently by further stacking the conductive trays 61 and 62 and the vacuum front panel 101 in the vertical direction and then simultaneously performing electric welding.

[0130] In addition, a jack not shown in the figure may be further arranged above the second plate 2 to press each conductive tray 61, 62 from above during electric welding. In this case, the first outer edge plate portion 12 and the second outer edge plate portion 22 are firmly clamped by each conductive tray 61, 62, and thus are in further good contact, and it is easy to further improve the airtightness of the internal space Q. In addition, when the conductive trays 61, 62 and the vacuum front panel 101 are further stacked in the up and down direction, each panel can be reliably clamped. Furthermore, after the first plate 1 and the second plate 2 are taken out of the vacuum chamber C, the first outer edge plate portion 12 and the second outer edge plate portion 22 are welded. In this way, it is possible to seek to improve the manufacturing efficiency and quality of the vacuum insulation panel 100.

[0131] According to the present embodiment, a first resin material 3 having gas barrier properties is sandwiched between the first outer edge plate portion 12 of the first metal plate 1 and the second outer edge plate portion 22 of the second metal plate 2. That is, the metal plates can be joined to each other at a temperature lower than the welding temperature. Therefore, the metal plates 1 and 2 can be joined to each other at a lower cost and in a shorter time than when a welding tool is used in a vacuum chamber. Thus, the manufacturability of the vacuum insulation panel 100 can be improved. In addition, the vertical plate portion 13 of the first plate 1 is formed by a curved surface. Therefore, it is easy to release the external pressure applied to the first plate 1 through the shell structure. Thus, the durability of the vacuum insulation panel 100 can be improved. Furthermore, the first outer edge plate portion 12 and the second outer edge plate portion 22 can be welded after the first plate 1 and the second plate 2 are joined and taken out from the vacuum chamber C, so that the first outer edge plate portion 12 and the second outer edge plate portion 22 are more strongly joined.

[0132] Furthermore, according to the present embodiment, the spacer S is made of a resin material and is separated from the first outer edge plate portion 12 and the second outer edge plate portion 22. Therefore, since the plates 1 and 2 are supported by the spacer S made of a resin material having a lower thermal conductivity than metal, and heat is difficult to be conducted from the outer edge side to the spacer S when the plates 1 and 2 are joined, the spacer S is difficult to deform or evaporate in the internal space Q. Thus, the heat insulation of the vacuum insulation panel 100 can be improved, and the manufacturability can be improved.

[0133] Furthermore, according to the present embodiment, a second resin material 4 having a lower thermal conductivity than the first resin material 3 is sandwiched between the first outer edge plate portion 12 and the second outer edge plate portion 22. Therefore, it is easy to ensure the thickness of the resin material, and it is more difficult for heat to be conducted between the plates 1 and 2. Thus, it is possible to seek to improve the thermal insulation of the vacuum insulation panel 100. Furthermore, in the case where the melting point of the second resin material 4 is higher than the melting point of the first resin material 3, the second resin material 4 is more difficult to melt than the first resin material 3, and it is difficult to evaporate when the first resin material 3 is heated, and it is easy to suppress the influence on the vacuum state of the internal space Q. Thus, it is possible to seek to suppress the reduction in the thermal insulation of the vacuum insulation panel 100.

[0134] In addition, according to the present embodiment, the spacer S has: a plate-shaped second support portion S2, which extends along the second plate material 2 in a manner of forming a hollow space R between the first support portion S1 and the second plate material 2, and supports the second plate material 2; and a third support portion S3, which extends in one direction and is integrally formed with the first support portion S1 and the second support portion S2. Therefore, a vacuum layer can be formed in the hollow space R. Thus, the thermal insulation of the vacuum insulation panel 100 can be improved. In addition, the first support portion S1, the second support portion S2, and the third support portion S3 can be easily manufactured by extrusion molding or the like. Thus, the manufacturability of the vacuum insulation panel 100 can be further improved.

[0135] Furthermore, according to the present embodiment, the first resin material 3 is sandwiched only between the first outer edge plate portion 12 and the second outer edge plate portion 22. Therefore, it is easy to suppress the influence of the first resin material 3 being heated and evaporated on the vacuum state of the internal space Q. Thus, it is possible to suppress the reduction in the heat insulation property of the vacuum insulation panel 100.

[0136] In addition, according to the present embodiment, the second plate 2 has a curved portion T between the first outer edge plate portion 12 and the spacer S. Therefore, the second plate 2 can deform following the deformation accompanying the heating of the first plate 1, and wrinkles or cracks are unlikely to occur. Thus, it is possible to suppress the reduction in the thermal insulation of the vacuum insulation panel 100.

[0137] Although several embodiments of the present invention have been described, these embodiments are only provided as examples and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other ways, and can be omitted, replaced, and changed in various ways without departing from the scope of the invention. These embodiments and their variations are included in the scope and purpose of the invention, and are included in the technical solutions recorded in the scope of protection and their equivalents.

[0138] Description of Reference Numerals

[0139] 100 Vacuum insulation panel

[0140] 101 Vacuum front panel

[0141] 11th Plate

[0142] 1111st Main Board

[0143] 12 1st outer edge plate

[0144] 13 vertical plate

[0145] 2nd Plate

[0146] 21Second Main Board

[0147] 22 2nd outer edge plate

[0148] 3.1st resin material

[0149] 4. Second resin material

[0150] 5. Protective Materials

[0151] 61, 62 Conductive tray

[0152] C Vacuum Chamber

[0153] Q Internal Space

[0154] R Hollow Space

[0155] S Spacer

[0156] T-bend

[0157] S1 1st support part

[0158] S2 Second support part

[0159] S3 3rd support part

[0160] S4 connection

[0161] X 1st direction

[0162] Y 2nd direction

[0163] Z thickness direction

Claims

1. A vacuum insulation panel, comprising a pair of plates facing each other so as to form an internal space therebetween, The vacuum insulation panel is characterized by comprising: A first plate made of metal; a second plate made of metal, which forms an internal space between the second plate and the first plate; as well as a spacer that supports the first plate and the second plate from the inner space side, The first plate has: a first outer edge plate portion on the outer edge side; a vertical plate portion, which is vertical from the first outer edge plate portion and is formed by a curved surface; and a main plate portion, which is continuous from the vertical plate portion and is supported by the spacer. A first resin material having a gas barrier property is interposed between the first outer edge plate portion and a second outer edge plate portion on the outer edge side of the second plate member.

2. The vacuum insulation panel according to claim 1, characterized in that: The spacer is made of a resin material and is separated from the first outer edge plate portion and the second outer edge plate portion.

3. The vacuum insulation panel according to claim 1 or 2, characterized in that: A second resin material having a lower thermal conductivity than the first resin material is interposed between the first outer edge plate portion and the second outer edge plate portion.

4. The vacuum insulation panel according to claim 1 or 2, characterized in that: The spacer has: a plate-shaped first support portion extending along the first plate and supporting the first plate; a plate-shaped second support portion extending along the second plate member so as to form a hollow space between the second support portion and the first support portion, and supporting the second plate member; and a plurality of third support parts that support the first support part and the second support part from the hollow space side, The plurality of third support portions extend in one direction and are formed integrally with the first support portion and the second support portion.

5. The vacuum insulation panel according to claim 1 or 2, characterized in that: The first resin material is interposed only between the first outer edge plate portion and the second outer edge plate portion.

6. The vacuum insulation panel according to claim 1 or 2, characterized in that: The second plate member has a curved portion between the first outer edge plate portion and the spacer.

7. The vacuum insulation panel according to claim 1, characterized in that: The first outer edge plate portion and the second outer edge plate portion are welded together by a first resin material.

8. The vacuum insulation panel according to claim 7, characterized in that: The first outer edge plate portion and the second outer edge plate portion are welded.

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