External capsule material for vacuum heat insulating material, vacuum heat insulating material and building material

Abstract

To provide an external capsule material for a vacuum heat insulating material capable of forming a vacuum heat insulating material with excellent flame resistance.SOLUTION: An external capsule material for a vacuum heat insulating material has a heat-sealable layer 1, one or more gas barrier layers 2, a protective layer 3, and a flame-resistant layer 4 containing a flame retardant, in this order. The gas barrier layer has a resin substrate, and an inorganic vapor deposition film arranged on one surface of the resin substrate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a vacuum insulation material outer packaging material capable of forming a vacuum insulation material, a vacuum insulation material, and a building material. [Background technology]

[0002] Conventionally, thermal insulation materials have been used in buildings to improve their thermal insulation. However, conventional thermal insulation materials cannot fully meet the thermal insulation and energy-saving performance required for recent buildings. Therefore, the use of vacuum insulation materials, which have excellent thermal insulation performance, as thermal insulation materials for buildings has been considered.

[0003] Fire prevention and fire resistance are also required for buildings. Therefore, the vacuum insulation material needs to be flame retardant. For example, Patent Document 1 discloses a vacuum insulation panel in which a heat-resistant protective layer made of mica particles is arranged on the outside of the vacuum insulation panel. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6920452 Summary of the Invention [Problem to be solved by the invention]

[0005] It is known that the flame retardancy of building materials is evaluated by flammability tests. Flame retardancy includes, for example, ignition ability (ease of catching fire) and the ease of spreading fire after ignition. However, conventional vacuum insulation materials have insufficient flame retardancy.

[0006] The present disclosure is an invention made in consideration of the above circumstances, and has a main object to provide an outer packaging material for a vacuum insulation material that can form a vacuum insulation material having excellent flame retardancy. [Means for solving the problem]

[0007] One embodiment of the present disclosure provides an outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, wherein the gas barrier layer has a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate.

[0008] Another embodiment of the present disclosure provides an outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, wherein the thickness of the flame-retardant layer is greater than 10 μm, the flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, and when the phosphorus, nitrogen, or metal element is a specific element, the content of the specific element in the flame-retardant layer is 30 mass% or more relative to the total content of carbon, oxygen, and the specific element in the flame-retardant layer.

[0009] Another embodiment of the present disclosure provides an outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, wherein the flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, and satisfies the following formula (1): (T1×A1) / T2≧0.030 (1) (In the above formula (1), T1 is the thickness (μm) of the flame-retardant layer, T2 is the thickness (μm) of the outer packaging material for vacuum insulation materials, and A1 is the content (mass%) of the specific element in the flame-retardant layer relative to the total content of the carbon element, the oxygen element, and the specific element in the flame-retardant layer, where the specific element is the phosphorus element, the nitrogen element, or the metal element.)

[0010] Another embodiment of the present disclosure provides a vacuum insulation material having a core material and an outer packaging material in which the core material is encapsulated, the outer packaging material being the vacuum insulation outer packaging material described above.

[0011] Another embodiment of the present disclosure provides a building material comprising the above-mentioned vacuum insulation material. Effect of the Invention

[0012] According to the present disclosure, it is possible to provide an outer packaging material for a vacuum insulation material that can form a vacuum insulation material having excellent flame retardancy. [Brief description of the drawings]

[0013] [Figure 1] 1 is a schematic cross-sectional view illustrating an example of an outer packaging material for a vacuum insulation material according to the present disclosure. [Diagram 2] 1 is a schematic cross-sectional view illustrating an example of an outer packaging material for a vacuum insulation material according to the present disclosure. [Diagram 3] 1 is a schematic cross-sectional view illustrating an example of an outer packaging material for a vacuum insulation material according to the present disclosure. [Figure 4] 1 is a schematic cross-sectional view illustrating an example of an outer packaging material for a vacuum insulation material according to the present disclosure. [Diagram 5] 1 is a schematic cross-sectional view illustrating an example of an outer packaging material for a vacuum insulation material according to the present disclosure. [Figure 6] 1A and 1B are schematic perspective and cross-sectional views illustrating a vacuum insulation material according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The present disclosure includes an outer packaging material for vacuum insulation materials, a vacuum insulation material, and a building material. Hereinafter, the embodiments of the present disclosure will be described with reference to the drawings. However, the present disclosure can be implemented in many different embodiments, and is not to be interpreted as being limited to the description of the embodiments exemplified below. In addition, in order to make the explanation clearer, the drawings may be schematic in terms of the width, thickness, shape, etc. of each part compared to the embodiments, but these are merely examples and do not limit the interpretation of the present disclosure. In addition, in this specification and each figure, elements similar to those described above with respect to the previously mentioned figures may be given the same reference numerals, and detailed explanations may be omitted as appropriate. In addition, for convenience of explanation, the terms "upper" and "lower" may be used in the explanation, but the up-down direction may be reversed.

[0015] Furthermore, in this specification, when a certain component or region is described as being "on (or under)" another component or region, unless otherwise specified, this not only includes the case where it is directly on (or directly under) the other component, but also the case where it is above (or below) the other component, i.e., the case where another component is included between the other component and the component above (or below) the other component.

[0016] The vacuum insulation packaging material, the vacuum insulation material, and the building material according to the present disclosure will be described below.

[0017] A. Vacuum insulation packaging material The packaging material for a vacuum insulation material according to the present disclosure has three embodiments, each of which will be described below.

[0018] A-1. First embodiment of packaging material for vacuum insulation material The vacuum insulation packaging material of this embodiment has, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame retardant layer containing a flame retardant, and the flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, and satisfies the following formula (1). (T1×A1) / T2≧0.030 (1) In the above formula (1), T1 is the thickness (μm) of the flame-retardant layer, T2 is the thickness (μm) of the outer packaging material for vacuum insulation material, and A1 represents the content (mass%) of the specific element in the flame-retardant layer relative to the total content of the carbon element, the oxygen element, and the specific element in the flame-retardant layer, where the specific element is the phosphorus element, the nitrogen element, or the metal element.

[0019] 1 is a schematic cross-sectional view showing an example of an outer packaging material for a vacuum insulation material according to this embodiment. The outer packaging material for a vacuum insulation material 10 has, in this order, a heat-sealable layer 1, one gas barrier layer 2, a protective layer 3, and a flame-retardant layer 4 containing a flame retardant. The outer packaging material for a vacuum insulation material 10 satisfies the above formula (1).

[0020] There are national and international standards for flammability tests for building materials. In some countries, vacuum insulation materials are required to meet the German standard DIN4102-1 Class B2 ignition test. DIN4102-1 evaluates the flame propagation distance and whether the material continues to burn after the flame has separated. Therefore, DIN4102-1 can be said to evaluate flame retardancy in terms of ignition ability (ease of catching fire), how easily the flame spreads after ignition, and self-extinguishing ability. However, conventional vacuum insulation materials are insufficiently flame retardant. This is because the outer packaging material for vacuum insulation materials contains a large amount of resin components.

[0021] Therefore, the inventor of the present disclosure focused on the relationship between the thickness of the vacuum insulation material outer packaging material and the flame retardancy. If the thickness of the vacuum insulation material outer packaging material is thick, the resin component is increased, and if the thickness of the vacuum insulation material outer packaging material is thin, the resin component is decreased. Therefore, even if a flame retardant layer is arranged on the outermost layer of the vacuum insulation material outer packaging material, sufficient flame retardancy may not be obtained depending on the thickness of the vacuum insulation material outer packaging material. Then, the above formula (1) was derived using the thickness of the vacuum insulation material outer packaging material, the thickness of the flame retardant layer, and the content of the flame retardant in the flame retardant layer. Note that the content of the flame retardant in the flame retardant layer was the content of a specific element contained in the flame retardant.

[0022] In this embodiment, the vacuum insulation packaging material satisfies the above formula (1), so that excellent flame retardancy can be obtained regardless of the thickness of the vacuum insulation packaging material, and therefore it is possible to achieve DIN4102-1 Class B2.

[0023] Hereinafter, each component of the packaging material for a vacuum insulation material of this embodiment will be described.

[0024] 1.Equation (1) The packaging material for a vacuum insulation material of this embodiment satisfies the following formula (1). (T1×A1) / T2≧0.030 (1) In the above formula (1), T1 is the thickness of the flame-retardant layer (μm), T2 is the thickness of the outer packaging material for vacuum insulation material (μm), and A1 represents the content (mass%) of a specific element in the flame-retardant layer relative to the total content of carbon, oxygen, and the specific element in the flame-retardant layer, where phosphorus, nitrogen, or a metal element is the specific element.

[0025] By the vacuum insulation material outer packaging material of this embodiment satisfying the above formula (1), excellent flame retardancy can be obtained regardless of the thickness of the vacuum insulation material outer packaging material. The value of (T1×A1) / T2 is 0.030 or more, preferably 0.040 or more, and more preferably 0.050 or more. On the other hand, the value of (T1×A1) / T2 is, for example, 0.200 or less, may be 0.175 or less, or may be 0.150 or less. That is, the value of (T1×A1) / T2 is preferably 0.030 or more and 0.200 or less, more preferably 0.040 or more and 0.175 or less, and even more preferably 0.050 or more and 0.150 or less.

[0026] 2.Flame-retardant layer The flame-retardant layer in this embodiment is a member disposed in the outermost layer opposite the heat-sealable layer side of the vacuum insulation packaging material in this embodiment.

[0027] The flame-retardant layer contains at least a flame retardant, and usually contains a flame retardant and a resin component.

[0028] The flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements. The flame retardant is not particularly limited as long as it contains these elements, but it is preferably one or more selected from the group consisting of phosphorus compounds, nitrogen compounds, metal hydroxides, and antimony compounds. These are non-halogen flame retardants, and there is no risk of generating harmful gases when decomposed at high temperatures. Among them, the flame retardant is preferably at least one of phosphorus compounds and metal hydroxides. That is, it is preferable that the flame retardant contains at least one of phosphorus and metal elements.

[0029] As the phosphorus compound, a general phosphorus-based flame retardant can be used, for example, phosphoric acid ester, polyphosphate, phosphinate such as aluminum phosphinate, phosphite such as aluminum phosphite, and red phosphorus. As the nitrogen compound, a general nitrogen-based flame retardant can be used, for example, melamine compound, triazine compound, guanidine compound, amide compound, amine compound, and ammonium carbonate. As the metal hydroxide, a general metal hydroxide-based flame retardant can be used, for example, aluminum hydroxide and magnesium hydroxide. As the antimony compound, a general antimony-based flame retardant can be used, for example, antimony trioxide and antimony pentoxide.

[0030] When phosphorus, nitrogen or metal elements are the specific elements, the content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and specific elements in the flame retardant layer is not particularly limited as long as it satisfies the above formula (1). The content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and specific elements in the flame retardant layer is, for example, preferably 15% by mass or more, more preferably 30% by mass or more, and even more preferably 40% by mass or more. In addition, the content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and specific elements in the flame retardant layer is, for example, preferably 90% by mass or less, more preferably 80% by mass or less, and even more preferably 75% by mass or less. That is, the content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and specific elements in the flame retardant layer is, for example, preferably 15% by mass or more and 90% by mass or less, more preferably 30% by mass or more and 80% by mass or less, and even more preferably 40% by mass or more and 75% by mass or less. If the content of the specific element is within the above range, it is easy to satisfy the above formula (1). If the content of the specific element is too small, the content of the flame retardant will be small, so there is a possibility that sufficient flame retardancy cannot be obtained. On the other hand, if the content of the specific element is too large, the content of the flame retardant will be large, so there is a possibility that it may be difficult to form a flame retardant layer or that the adhesion between the flame retardant layer and the protective layer may be reduced.

[0031] In the case of phosphorus compounds, the phosphorus element is the specific element. In addition, when the phosphorus compound is a polyphosphate, a phosphinate, a phosphite, or the like, it may contain not only the phosphorus element but also a metal element or a nitrogen element, and in such cases, the phosphorus element is also the specific element. In addition, in the case of nitrogen compounds, the nitrogen element is the specific element. In addition, the nitrogen compound may contain not only the nitrogen element but also a phosphorus element, and in such cases, the nitrogen element is also the specific element. In addition, in the case of metal hydroxides, the metal element is the specific element.

[0032] The content of a specific element in the flame retardant layer relative to the total content of carbon, oxygen and specific elements in the flame retardant layer is measured by X-ray fluorescence analysis (XRF). When measuring the content of each element in the flame retardant layer, only the flame retardant layer is scraped off from the vacuum insulation packaging material. A wavelength dispersive X-ray fluorescence analyzer is used as the X-ray fluorescence analyzer.

[0033] The resin component is not particularly limited as long as it can form a flame-retardant layer containing a flame retardant and a resin component, but it is preferable that the resin component has heat resistance that can withstand the process of joining the ends of opposing vacuum insulation packaging materials by heat welding when manufacturing a vacuum insulation material using the vacuum insulation packaging material of this embodiment.Specific examples of the resin component include polyester resin, acrylic urethane resin, polycarbonate resin, acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylic resin, and polyamide resin.The resin component may be used alone or in combination of two or more types.

[0034] The flame-retardant layer may contain weather resistance agents such as ultraviolet absorbers, light stabilizers, and antioxidants, if necessary.

[0035] The thickness of the flame retardant layer is not particularly limited as long as it satisfies the above formula (1). The thickness of the flame retardant layer is, for example, preferably 5 μm or more, more preferably more than 10 μm, and even more preferably 12.5 μm or more. The thickness of the flame retardant layer is, for example, preferably 50 μm or less, more preferably 30 μm or less, and even more preferably 20 μm or less. That is, the thickness of the flame retardant layer is, for example, preferably 5 μm or more and 50 μm or less, more preferably more than 10 μm and 30 μm or less, and even more preferably 12.5 μm or more and 20 μm or less. If the thickness of the flame retardant layer is within the above range, it is easy to satisfy the above formula (1). Also, if the thickness of the flame retardant layer is too thin, it may be difficult to form the flame retardant layer, or the adhesion between the flame retardant layer and the protective layer may be reduced. On the other hand, the thicker the flame retardant layer, the higher the flame retardancy, but if the thickness of the flame retardant layer is too thick, the flexibility of the outer packaging material for vacuum insulation material may decrease, defects may occur when forming the vacuum insulation material, and the flame retardancy and gas barrier properties may be reduced.

[0036] The flame-retardant layer can be formed by a coating method.

[0037] 3.Gas barrier layer The gas barrier layer in this embodiment is not particularly limited as long as it has gas barrier properties, and examples thereof include a gas barrier resin substrate and a gas barrier film having a resin substrate and a barrier film disposed on one side of the resin substrate.

[0038] (1) Gas barrier resin substrate Examples of materials for the gas barrier resin substrate include ethylene-vinyl alcohol copolymer and polyvinyl alcohol. Commercially available products such as EVAL film manufactured by Kuraray Co., Ltd. may also be used as the gas barrier resin substrate. The thickness of the gas barrier resin substrate is not particularly limited as long as the desired gas barrier properties are obtained.

[0039] (2) Gas barrier film Examples of the barrier film that constitutes the gas barrier film include inorganic films, gas barrier resin films, and organic-inorganic hybrid films.

[0040] The inorganic substance used in the inorganic film is not particularly limited, and examples thereof include metals and inorganic compounds. Examples of metals include metals such as aluminum, stainless steel, titanium, nickel, iron, and copper, or alloys containing these metals. Examples of inorganic compounds include inorganic oxides, inorganic oxynitrides, inorganic nitrides, inorganic oxycarbides, and inorganic oxycarbonitrides. Specific examples of inorganic compounds include inorganic compounds containing one or more selected from the group consisting of silicon, aluminum, magnesium, calcium, potassium, tin, sodium, titanium, boron, yttrium, zirconium, cerium, and zinc. More specific examples of inorganic compounds include silicon oxide, aluminum oxide, magnesium oxide, titanium oxide, tin oxide, silicon-zinc alloy oxide, indium alloy oxide, silicon nitride, aluminum nitride, titanium nitride, and silicon oxynitride. The inorganic compounds may be used alone or in combination of two or more. Among these, the inorganic substance used in the inorganic film is preferably aluminum, aluminum oxide, or silicon oxide.

[0041] Examples of materials for the gas barrier resin film include ethylene-vinyl alcohol copolymer, polyvinylidene chloride, polyvinyl alcohol, and polyamide resin obtained from metaxylylenediamine and adipic acid.

[0042] The barrier film may or may not have transparency.

[0043] The thickness of the barrier film is not particularly limited as long as the desired gas barrier properties are obtained, and is appropriately set according to the type of the barrier film. When the barrier film is an inorganic film, the thickness of the inorganic film is, for example, 10 nm or more and 300 nm or less.

[0044] The method for forming the barrier film is appropriately selected depending on the material, and examples thereof include a vapor deposition method and a coating method. That is, the barrier film may be a vapor deposition film formed by a vapor deposition method, or a coating film formed by a coating method. In addition, when the barrier film is a gas barrier resin film, a gas barrier film in which a resin substrate and a gas barrier resin film are laminated by a co-extrusion method can also be obtained.

[0045] The resin used for the resin substrate constituting the gas barrier film is not particularly limited, and examples thereof include polyolefin resin, polyester resin, cyclic polyolefin resin, polystyrene resin, acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), poly(meth)acrylic resin, polycarbonate resin, ethylene-vinyl ester copolymer and its saponification product, polyamide resin, polyimide resin, polyurethane resin, acetal resin, and cellulose resin. Examples of polyolefin resin include polyethylene and polypropylene. Examples of polyester resin include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), and the like. Examples of polyamide resin include nylon and the like. The above resin may be a gas barrier resin. Examples of gas barrier resin include the material of the above gas barrier resin substrate. The thickness of the resin substrate is not particularly limited and is appropriately set. In order to improve adhesion with the barrier film, the resin substrate may be subjected to a surface treatment. The thickness of the resin substrate is preferably a thickness that can support the inorganic film and exhibit puncture resistance.

[0046] The gas barrier film may further have an overcoat film on the side of the barrier film opposite to the resin substrate. This can further improve the gas barrier properties. As the material for the overcoat film, materials generally used as barrier coating agents or overcoat agents can be used.

[0047] The gas barrier layer is preferably a gas barrier film having the above-mentioned resin substrate and barrier film. The gas barrier film can exhibit high gas barrier properties even if it is thin. In addition, the gas barrier film has a lower thermal conductivity than metal foil, so heat bridges are less likely to occur, and the heat insulation performance can be improved. Furthermore, the gas barrier film has a lower thermal conductivity than metal foil, so heat is less likely to be transmitted in the thickness direction and surface direction, and it is considered that the vacuum insulation material outer packaging material is less likely to spread fire. In addition, the gas barrier film has better flexibility than metal foil, so defects are less likely to occur when forming the vacuum insulation material, and the gas barrier property is less likely to decrease due to defects.

[0048] In the gas barrier film, the barrier film is preferably an inorganic film among the above. The inorganic film is more preferably a vapor deposition film, that is, an inorganic vapor deposition film, because the gas barrier properties can be improved.

[0049] The arrangement of the resin substrate and the barrier film in the gas barrier film is not particularly limited, and can be appropriately set depending on the configuration of each layer other than the gas barrier layer, the number of gas barrier layers described later, etc. When the outer packaging material for vacuum insulation material of this embodiment has one gas barrier layer, as exemplified in Figure 2(a), the gas barrier layer 2 may have, in order from the heat-sealable layer 1 side, a resin substrate 11 and a barrier film 12, or as exemplified in Figure 2(b), the gas barrier layer 2 may have, in order from the heat-sealable layer 1 side, a barrier film 12 and a resin substrate 11. Furthermore, when the vacuum insulation packaging material of this embodiment has two gas barrier layers, the two gas barrier layers 2a, 2b may be arranged so that their respective barrier films 12 face each other, as illustrated in Figure 3(a), or the two gas barrier layers 2a, 2b may each have, in order from the heat-sealable layer 1 side, a resin substrate 11 and a barrier film 12, as illustrated in Figure 3(b), or the two gas barrier layers 2a, 2b may each have, in order from the heat-sealable layer 1 side, a barrier film 12 and a resin substrate 11, as illustrated in Figure 3(c).

[0050] As described later, the vacuum insulation packaging material of this embodiment preferably has two or more gas barrier layers. When the vacuum insulation packaging material of this embodiment has two gas barrier layers, as shown in FIG. 3(a), the two gas barrier layers 2a and 2b are preferably arranged so that their barrier films 12 face each other. As for the gas barrier layer 2a, the barrier film 12 is protected by being located on the surface opposite to the heat-sealable layer 1, so that the gas barrier properties can be improved. As for the gas barrier layer 2b, the barrier film 12 is protected by being located on the surface opposite to the protective layer 3, so that the gas barrier properties can be improved.

[0051] (4) Other aspects of the gas barrier layer The vacuum insulation packaging material of this embodiment may have at least one gas barrier layer, but preferably has two or more, which can further improve the gas barrier properties.

[0052] When the vacuum insulation packaging material of this embodiment has two or more gas barrier layers, the two or more gas barrier layers may be the same or different from each other.

[0053] When the vacuum insulation packaging material of this embodiment has two or more gas barrier layers, as described above, it is preferable that all of the two or more gas barrier layers are gas barrier films having the above-mentioned resin substrate and barrier film.

[0054] Moreover, from the viewpoints of heat insulating performance, gas barrier properties, and flame retardancy, it is preferable that the vacuum insulation material outer packaging material of this embodiment does not contain a metal foil as a gas barrier layer.

[0055] 4.Protective layer The protective layer in this embodiment is a member disposed on the opposite side of the heat-sealable layer with respect to the gas barrier layer in the vacuum insulation material using the vacuum insulation material packaging material of this embodiment. The protective layer preferably has sufficient mechanical strength to protect the inside of the vacuum insulation material and is excellent in heat resistance, moisture resistance, pinhole resistance, puncture resistance, etc. in the vacuum insulation material using the vacuum insulation material packaging material of this embodiment.

[0056] The material of the protective layer is preferably a resin having a higher melting point than the heat-weldable layer. Examples of such resins include polyamide resins, polyester resins, polyolefin resins, acrylic resins, cellulose resins, and ethylene-vinyl alcohol copolymers. Examples of polyamide resins include nylon, etc. Examples of polyester resins include polyethylene terephthalate and polyethylene naphthalate, etc. Examples of polyolefin resins include polypropylene, etc.

[0057] The protective layer may be a resin sheet or a uniaxially or biaxially oriented resin film. The protective layer may be a single layer or a multilayer. In the case of a multilayer, the materials of the layers may be the same or different from each other.

[0058] The protective layer may have, in order from the flame retardant layer side, a resin substrate and a barrier film. The protective layer can also be imparted with gas barrier properties. The resin substrate and the barrier film are the same as those in the gas barrier layer.

[0059] In the case where the protective layer has a resin substrate and a barrier film in this order from the flame retardant layer side, and the vacuum insulation material outer packaging material of this embodiment has two gas barrier layers as described above, it is preferable that the two gas barrier layers 2a and 2b are arranged so that the barrier films 12 face each other as shown in FIG. 3(a). As for the gas barrier layer 2a, the barrier film 12 is protected by being located on the side opposite to the heat-sealable layer 1, so that the gas barrier property can be improved. As for the gas barrier layer 2b, the barrier film 12 is protected by being located on the side opposite to the protective layer 3, so that the gas barrier property can be improved. As for the protective layer 3, although not shown, the barrier film is protected by being located on the side opposite to the flame retardant layer 4, so that the gas barrier property can be improved. As the barrier film is protected in each layer, the gas barrier property can be maintained for a long time, and the vacuum insulation material can maintain high heat insulation performance for a long time.

[0060] The protective layer may be subjected to a surface treatment to improve adhesion, such as a corona discharge treatment.

[0061] The thickness of the protective layer is not particularly limited as long as it is a thickness that can protect the heat-sealable layer and the gas barrier layer, and is, for example, from 5 μm to 80 μm.

[0062] 5. Heat-sealable layers The heat-sealable layer in this embodiment is a component that comes into contact with the core material when the vacuum insulation material is produced using the vacuum insulation material packaging material of this embodiment, and that joins the ends of opposing vacuum insulation material packaging materials when sealing the core material.

[0063] The material of the heat-sealable layer is preferably a thermoplastic resin, since it can be melted and fused by heating. Examples of such thermoplastic resins include polyolefin resins, polyester resins, polyvinyl acetate resins, polyvinyl chloride resins, poly(meth)acrylic resins, urethane resins, polyvinyl alcohol resins, ethylene-vinyl alcohol copolymers (EVOH), polyphenylene sulfide (PPS), tetrafluoroethylene (C 2 F 4 )·Ethylene (C 2 H 4 ) copolymer (ETFE). Examples of polyolefin resins include polyethylene such as linear short-chain branched polyethylene (LLDPE) and high-density polyethylene (HDPE), and unoriented polypropylene (CPP). Examples of polyester resins include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and polybutylene terephthalate (PBT).

[0064] The heat-sealable layer may contain additives such as antiblocking agents, lubricants, flame retardants, fillers, etc.

[0065] The thickness of the heat-sealable layer is, for example, 20 μm or more and 100 μm or less, and may be 25 μm or more and 90 μm or less, or 30 μm or more and 80 μm or less. If the thickness of the heat-sealable layer is too thick, the gas barrier performance of the vacuum insulation packaging material may be reduced. On the other hand, if the thickness of the heat-sealable layer is too thin, the desired adhesive strength may not be obtained.

[0066] 6. Vacuum insulation packaging material The thickness of the vacuum insulation packaging material in this embodiment is not particularly limited as long as it satisfies the above formula (1) and the desired gas barrier performance and strength are obtained, and may be, for example, 30 μm or more and 200 μm or less, or 50 μm or more and 150 μm or less.

[0067] In the vacuum insulation packaging material of this embodiment, the layers constituting the vacuum insulation packaging material may be laminated in direct contact with each other, or may be laminated via an interlayer adhesive. As the interlayer adhesive, an adhesive generally used for vacuum insulation packaging materials may be used.

[0068] The method for producing the vacuum insulation packaging material of this embodiment is not particularly limited as long as it is a method that can produce the vacuum insulation packaging material having the above-mentioned configuration, and any known method can be used. For example, there is a dry lamination method in which each layer that has been previously formed is bonded together using the above-mentioned interlayer adhesive, and a method in which the material of each layer that has been heat-melted is extruded using a T-die or the like and bonded together.

[0069] The vacuum insulation material packaging material of this embodiment may or may not have transparency. The transparency of the vacuum insulation material packaging material of this embodiment is appropriately set according to the application of the vacuum insulation material using the vacuum insulation material packaging material. The transparency of the vacuum insulation material packaging material is not specified by a strict transmittance, and can be appropriately determined according to the application, etc.

[0070] When the vacuum insulation packaging material of this embodiment has transparency, the inside of the vacuum insulation material using the vacuum insulation packaging material can be visually confirmed. Therefore, by putting a detecting agent together with a core material inside the vacuum insulation material, it becomes possible to visually confirm the vacuum state inside from the change in the detecting agent.

[0071] The vacuum insulation material packaging material of this embodiment can be used for a vacuum insulation material. In the vacuum insulation material, the vacuum insulation material packaging material of this embodiment can be used by arranging the heat-sealable layer on the core material side and facing the core material therebetween.

[0072] A-2. Second embodiment of packaging material for vacuum insulation material The vacuum insulation packaging material of this embodiment has, in that order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, the flame-retardant layer having a thickness greater than 10 μm, the flame retardant containing one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, and when the phosphorus, nitrogen, or metal element is defined as a specific element, the content of the specific element in the flame-retardant layer is 30 mass% or more relative to the total content of carbon, oxygen, and the specific element in the flame-retardant layer.

[0073] 1 is a schematic cross-sectional view showing an example of an outer packaging material for vacuum insulation materials according to this embodiment. The outer packaging material for vacuum insulation materials 10 has, in this order, a heat-sealable layer 1, one gas barrier layer 2, a protective layer 3, and a flame-retardant layer 4 containing a flame retardant. The thickness T1 of the flame-retardant layer 4 is greater than 10 μm. The flame retardant contained in the flame-retardant layer 4 contains a specific element, and the content of the specific element in the flame-retardant layer 4 is within a predetermined range.

[0074] As explained in the first embodiment, there are national and international standards for the flammability test of building materials. In some countries, vacuum insulation materials are required to meet the German standard DIN4102-1 Class B2 ignition test. DIN4102-1 evaluates the flame propagation distance and the ability to not continue burning after the flame has separated. Therefore, DIN4102-1 can be said to evaluate the ignition ability (ease of ignition), the ease of flame spread after ignition, and self-extinguishing as flame retardancy. However, conventional vacuum insulation materials have insufficient flame retardancy. This is because a large amount of resin components are used in the outer packaging material for vacuum insulation materials.

[0075] Therefore, the inventor of the present disclosure has focused on the relationship between the thickness of the vacuum insulation material outer packaging material and the flame retardancy. If the thickness of the vacuum insulation material outer packaging material is thick, the resin component is increased, and if the thickness of the vacuum insulation material outer packaging material is thin, the resin component is decreased. Therefore, even if a flame retardant layer is arranged on the outermost layer of the vacuum insulation material outer packaging material, sufficient flame retardancy may not be obtained depending on the thickness of the vacuum insulation material outer packaging material.

[0076] In this embodiment, since the thickness of the flame-retardant layer is greater than a predetermined value and the content of the specific element in the flame-retardant layer is equal to or greater than a predetermined value, excellent flame retardancy can be obtained even when the thickness of the vacuum insulation packaging material is thick. Therefore, it is possible to achieve DIN4102-1 Class B2.

[0077] Hereinafter, each component of the packaging material for a vacuum insulation material of this embodiment will be described.

[0078] 1.Flame-retardant layer The flame-retardant layer in this embodiment is a member disposed in the outermost layer opposite the heat-sealable layer side of the vacuum insulation packaging material in this embodiment.

[0079] The material of the flame retardant layer is the same as that of the flame retardant layer in the first embodiment.

[0080] When phosphorus, nitrogen or metal elements are the specific elements, the content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and the specific elements in the flame retardant layer is 30% by mass or more, preferably 40% by mass or more. The content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and the specific elements in the flame retardant layer is, for example, preferably 90% by mass or less, more preferably 80% by mass or less, and even more preferably 75% by mass or less. That is, the content of the specific elements in the flame retardant layer relative to the total content of carbon, oxygen and the specific elements in the flame retardant layer is, for example, preferably 30% by mass or more and 90% by mass or less, more preferably 30% by mass or more and 80% by mass or less, and even more preferably 40% by mass or more and 75% by mass or less. If the content of the specific elements is within the above range, excellent flame retardancy can be obtained even when the thickness of the outer packaging material for vacuum insulation material is thick. If the content of the specific elements is too low, the content of the flame retardant is low, so there is a possibility that sufficient flame retardancy cannot be obtained. On the other hand, if the content of the specific element is too high, the content of the flame retardant will be high, which may make it difficult to form a flame-retardant layer or may reduce adhesion between the flame-retardant layer and the protective layer.

[0081] The thickness of the flame retardant layer is preferably more than 10 μm and more than 12.5 μm. The thickness of the flame retardant layer is preferably, for example, 50 μm or less, more preferably 30 μm or less, and even more preferably 20 μm or less. That is, the thickness of the flame retardant layer is preferably, for example, more than 10 μm and less than 50 μm, more preferably more than 10 μm and less than 30 μm, and even more preferably 12.5 μm or more and less than 20 μm. If the thickness of the flame retardant layer is within the above range, excellent flame retardancy can be obtained even if the thickness of the outer packaging material for vacuum insulation material is thick. If the thickness of the flame retardant layer is too thin, it may be difficult to form the flame retardant layer, or the adhesion between the flame retardant layer and the protective layer may be reduced. On the other hand, the thicker the flame retardant layer, the higher the flame retardancy, but if the thickness of the flame retardant layer is too thick, the flexibility of the outer packaging material for vacuum insulation material may decrease, defects may occur when forming the vacuum insulation material, and the flame retardancy and gas barrier properties may be reduced.

[0082] 2.Gas barrier layer The gas barrier layer in this embodiment is the same as the gas barrier layer in the first embodiment.

[0083] 3.Protective layer The protective layer in this embodiment is the same as the protective layer in the first embodiment.

[0084] 4. Heat-sealable layers The heat-sealable layer in this embodiment is the same as the heat-sealable layer in the first embodiment.

[0085] 5. Vacuum insulation packaging material Other points of the packaging material for a vacuum insulation material of this embodiment are the same as those of the packaging material for a vacuum insulation material of the above-mentioned first embodiment.

[0086] A-3. Third embodiment of packaging material for vacuum insulation material The vacuum insulation packaging material of this embodiment has, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, and the gas barrier layer has a resin substrate and an inorganic vapor deposition film disposed on one side of the resin substrate.

[0087] 4(a) and 4(b) are schematic cross-sectional views showing an example of the vacuum insulation packaging material of this embodiment. The vacuum insulation packaging material 10 has, in this order, a heat-sealable layer 1, one gas barrier layer 2, a protective layer 3, and a flame retardant layer 4 containing a flame retardant. The gas barrier layer 2 has a resin substrate 11 and an inorganic vapor deposition film 13 disposed on one surface of the resin substrate 11.

[0088] As explained in the first embodiment, there are national and international standards for flammability tests of building materials. In some countries, vacuum insulation materials are required to meet the German standard DIN4102-1 Class B2 ignition test. DIN4102-1 evaluates the flame propagation distance and the ability to not continue burning after the flame has separated. Therefore, DIN4102-1 can be said to evaluate ignition ability (ease of ignition), ease of flame spread after ignition, and self-extinguishing ability as flame retardancy. However, conventional vacuum insulation materials sometimes had insufficient flame retardancy.

[0089] In vacuum insulation packaging materials, metal foil is sometimes used as a gas barrier layer because of its excellent gas barrier properties. However, metal foil has high thermal conductivity, so heat is easily transmitted in the thickness direction and surface direction. Therefore, there is a risk of fire spreading if heat is transmitted from the metal foil to a layer containing a resin component adjacent to the metal foil.

[0090] In contrast, in this embodiment, the gas barrier layer has a resin substrate and an inorganic vapor deposition film. The gas barrier layer having a resin substrate and an inorganic vapor deposition film has a lower thermal conductivity than metal foil, so heat is less likely to be transmitted in the thickness direction and surface direction, and it is considered that the vacuum insulation material outer packaging material is less likely to spread fire. Therefore, it is possible to suppress the tendency of fire to spread and improve the flame retardancy. In addition, the gas barrier layer having a resin substrate and an inorganic vapor deposition film has a lower thermal conductivity than metal foil, so heat bridges are less likely to occur, and the insulation performance can be improved. Furthermore, the gas barrier layer having a resin substrate and an inorganic vapor deposition film has better flexibility than metal foil, so defects are less likely to occur when forming the vacuum insulation material, and the gas barrier property is less likely to deteriorate due to defects.

[0091] Hereinafter, each component of the packaging material for a vacuum insulation material of this embodiment will be described.

[0092] 1.Flame-retardant layer The flame-retardant layer in this embodiment is a member disposed in the outermost layer opposite the heat-sealable layer side of the vacuum insulation packaging material in this embodiment.

[0093] The material and thickness of the flame-retardant layer are similar to those of the flame-retardant layer in the first embodiment.

[0094] 2.Gas barrier layer The gas barrier layer of this embodiment has a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate.

[0095] The material and thickness of the resin substrate are the same as those of the resin substrate constituting the gas barrier film in the first embodiment.

[0096] The material and thickness of the inorganic vapor deposition film are the same as those of the inorganic film constituting the gas barrier film in the first embodiment. The inorganic vapor deposition film may or may not have transparency. The inorganic vapor deposition film is formed by a vapor deposition method.

[0097] The gas barrier layer may further have an overcoat film on the side of the inorganic vapor deposition film opposite to the resin substrate. This can further improve the gas barrier properties. As the material for the overcoat film, materials generally used as barrier coating agents or overcoat agents can be used.

[0098] The arrangement of the resin substrate and the inorganic vapor deposition film in the gas barrier layer is not particularly limited, and can be appropriately set depending on the configuration of each layer other than the gas barrier layer, the number of gas barrier layers described later, etc. When the outer packaging material for vacuum insulation material of this embodiment has one gas barrier layer, the gas barrier layer 2 may have, in order from the heat-sealable layer 1 side, a resin substrate 11 and an inorganic vapor deposition film 13, as exemplified in Fig. 4(a), or the gas barrier layer 2 may have, in order from the heat-sealable layer 1 side, an inorganic vapor deposition film 13 and a resin substrate 11, as exemplified in Fig. 4(b). Furthermore, when the vacuum insulation packaging material of this embodiment has two gas barrier layers, as illustrated in Figure 5(a), the two gas barrier layers 2a, 2b may be arranged so that their respective inorganic vapor deposition films 13 face each other, as illustrated in Figure 5(b), the two gas barrier layers 2a, 2b may each have, in order from the heat-sealable layer 1 side, a resin substrate 11 and an inorganic vapor deposition film 13, or as illustrated in Figure 5(c), the two gas barrier layers 2a, 2b may each have, in order from the heat-sealable layer 1 side, an inorganic vapor deposition film 13 and a resin substrate 11.

[0099] As described later, the vacuum insulation packaging material of this embodiment preferably has two or more gas barrier layers. When the vacuum insulation packaging material of this embodiment has two gas barrier layers, as shown in FIG. 5(a), the two gas barrier layers 2a and 2b are preferably arranged so that their inorganic vapor deposition films 13 face each other. For the gas barrier layer 2a, the inorganic vapor deposition film 13 is protected by being located on the surface opposite to the thermally fusible layer 1, so that the gas barrier properties can be improved. For the gas barrier layer 2b, the inorganic vapor deposition film 13 is protected by being located on the surface opposite to the protective layer 3, so that the gas barrier properties can be improved.

[0100] The vacuum insulation packaging material of this embodiment may have at least one gas barrier layer, but preferably has two or more, which can further improve the gas barrier properties.

[0101] When the vacuum insulation packaging material of this embodiment has two or more gas barrier layers, the two or more gas barrier layers may be the same or different from each other.

[0102] When the vacuum insulation packaging material of this embodiment has two or more gas barrier layers, at least one of the gas barrier layers may have the above-mentioned resin substrate and inorganic vapor deposition film. In particular, it is preferable that each of the two or more gas barrier layers has the above-mentioned resin substrate and inorganic vapor deposition film.

[0103] Moreover, from the viewpoints of heat insulating performance, gas barrier properties, and flame retardancy, it is preferable that the vacuum insulation material outer packaging material of this embodiment does not contain a metal foil as a gas barrier layer.

[0104] 3.Protective layer The protective layer in this embodiment is the same as the protective layer in the first embodiment.

[0105] In the case where the protective layer has a resin substrate and a barrier film in this order from the flame retardant layer side, and the vacuum insulation material outer packaging material of this embodiment has two gas barrier layers as described above, it is preferable that the two gas barrier layers 2a and 2b are arranged so that the inorganic vapor deposition films 13 face each other as shown in FIG. 5(a). For the gas barrier layer 2a, the inorganic vapor deposition film 13 is protected by being located on the side opposite the thermally fusible layer 1, so that the gas barrier property can be improved. For the gas barrier layer 2b, the inorganic vapor deposition film 13 is protected by being located on the side opposite the protective layer 3, so that the gas barrier property can be improved. For the protective layer 3, although not shown, the barrier film is protected by being located on the side opposite the flame retardant layer 4, so that the gas barrier property can be improved. The inorganic vapor deposition film is protected in the gas barrier layer, and the barrier film is protected in the protective layer, so that the gas barrier property can be maintained for a long time, and the vacuum insulation material can maintain high heat insulation performance for a long time.

[0106] 4. Heat-sealable layers The heat-sealable layer in this embodiment is the same as the heat-sealable layer in the first embodiment.

[0107] 5. Vacuum insulation packaging material Other points of the packaging material for a vacuum insulation material of this embodiment are the same as those of the packaging material for a vacuum insulation material of the above-mentioned first embodiment.

[0108] B. Vacuum insulation material The vacuum insulation material in the present disclosure has a core material and an outer packaging material that encapsulates the core material, and the outer packaging material is the aforementioned outer packaging material for a vacuum insulation material.

[0109] Fig. 6(a) is a schematic perspective view showing an example of a vacuum insulation material in the present disclosure, and Fig. 6(b) is a cross-sectional view taken along line XX in Fig. 6(a). The vacuum insulation material 20 shown in Fig. 6 has a core material 21 and an outer packaging material 10 that encloses the core material 21, and the outer packaging material 10 is the outer packaging material for the vacuum insulation material described above. The vacuum insulation material 20 is a bag body in which two outer packaging materials 10 are opposed to each other so that their heat-sealable layers face each other and end portions 22 are joined by heat welding, the core material 21 is enclosed in the bag body, and the inside of the bag body is depressurized.

[0110] According to the present disclosure, the outer packaging material that encapsulates the core material is the above-mentioned outer packaging material for a vacuum insulation material, thereby resulting in a vacuum insulation material with excellent flame retardancy.

[0111] Below, the vacuum insulation material in this disclosure will be described in detail for each component.

[0112] 1.Outer packaging material The outer packaging material in this disclosure is a member that encloses the core material, and is the outer packaging material for vacuum insulation material described above. The outer packaging material for vacuum insulation material was explained in detail in the section "A. Outer packaging material for vacuum insulation material", so the explanation here is omitted.

[0113] 2. Core material The core material in the present disclosure is a member that is enclosed by the outer packaging material. Enclosed means that the core material is sealed inside the bag formed by using the outer packaging material.

[0114] The core material preferably has low thermal conductivity and is a porous material with a porosity of 50% or more, particularly 90% or more.

[0115] Materials constituting the core material can include powder, foam, fiber, etc. The powder can be either inorganic or organic, and can include, for example, dry silica, wet silica, agglomerated silica powder, conductive powder, calcium carbonate powder, perlite, clay, talc, etc. Among them, a mixture of dry silica and conductive powder is advantageous when used in a temperature range where the internal pressure increases, since the decrease in the insulation performance due to the increase in the internal pressure of the vacuum insulation material is small. Furthermore, by adding a substance with low infrared absorption rate, such as titanium oxide, aluminum oxide, or indium-doped tin oxide, to the above-mentioned material as a radiation suppressing material, the infrared absorption rate of the core material can be reduced.

[0116] The foam may be urethane foam, styrene foam, phenol foam, etc. Among them, foams that form open cells are preferred.

[0117] The fibrous body may be either inorganic or organic fiber, but it is preferable to use inorganic fiber from the viewpoint of heat insulating performance. Examples of such inorganic fibers include glass fibers such as glass wool and glass fiber, alumina fibers, silica alumina fibers, silica fibers, ceramic fibers, rock wool, etc. These inorganic fibers are preferable because they have low thermal conductivity and are easier to handle than powders.

[0118] The core material may be any of the above-mentioned materials, or may be a composite material made by mixing two or more of these materials.

[0119] 3.Other The vacuum insulation material of the present disclosure has a core material enclosed in an outer packaging material, and the inside is decompressed to a vacuum state. The degree of vacuum inside the vacuum insulation material is preferably, for example, 5 Pa or less. This is because it is possible to reduce heat conduction due to convection of air remaining inside, and it is possible to exhibit excellent heat insulation properties.

[0120] The lower the thermal conductivity of the vacuum insulation material, the more preferable. For example, the thermal conductivity (initial thermal conductivity) is preferably 5 mW / (mK) or less. This is because the vacuum insulation material is less likely to conduct heat to the outside, and can provide a high thermal insulation effect. In particular, the initial thermal conductivity is more preferably 4 mW / (mK) or less. The thermal conductivity is a value measured in accordance with JIS A1412-2:1999 under conditions of a high temperature side of 30°C, a low temperature side of 10°C, and an average temperature of 20°C.

[0121] The vacuum insulation material of the present disclosure can be manufactured by a general method. For example, two sheets of the above-mentioned vacuum insulation material outer packaging material are prepared, and the heat-sealable films of each sheet are stacked facing each other, and the outer edges of the three sides are heat-sealed to obtain a bag with one side open. After the core material is placed in the bag through the opening, air is sucked through the opening, and the opening is sealed in a state where the inside of the bag is decompressed, thereby obtaining the vacuum insulation material.

[0122] The vacuum insulation material of the present disclosure is suitable for use in building materials, which will be described later.

[0123] C. Building materials The building material in the present disclosure comprises the above-mentioned vacuum insulation material.

[0124] According to the present disclosure, since the vacuum insulation material uses the above-mentioned outer packaging material for a vacuum insulation material, it is possible to achieve excellent heat insulation performance and energy saving performance. In addition, since the vacuum insulation material uses the above-mentioned outer packaging material for a vacuum insulation material, it is possible to achieve excellent flame retardancy.

[0125] The vacuum insulation material in this disclosure has been described in detail above in the sections "B. Vacuum insulation material" and "A. Outer packaging material for vacuum insulation material," so a detailed description thereof will be omitted here.

[0126] The building material in the present disclosure may be an insulating panel. The insulating panel may have a vacuum insulating material. The insulating panel may be a vacuum insulating material itself, or may have a vacuum insulating material and a surface material arranged on at least one side of the vacuum insulating material. The surface material may be a base material or a finishing material. The surface material may be an exterior material or an interior material. Examples of the surface material include wooden boards such as plywood and veneer boards, metal boards such as iron boards and steel boards, gypsum boards, and cement boards such as calcium silicate boards and wood wool cement boards.

[0127] Furthermore, when a panel construction method is used as the construction method, the building material in the present disclosure may be a panel in which the vacuum insulation material and the building frame are integrated.

[0128] Applications of the building materials in the present disclosure include wall materials, floor materials, ceiling materials, roof materials, door materials, and the like.

[0129] In the case of reinforced concrete construction, the building material may be used for external insulation or internal insulation. In the case of wood or steel frame construction, the building material may be used for external insulation or filling insulation.

[0130] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and any embodiment that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits similar effects is included in the technical scope of the present disclosure. EXAMPLES

[0131] [Production Example 1] A polyethylene terephthalate film having a thickness of 12 μm and having an aluminum film (Al film) deposited on one side was used as the protective layer. A base material mainly composed of acrylic polyol ("FW (NT) Clear" manufactured by Showa Ink Co., Ltd.), a curing agent mainly composed of isocyanate ("FW (NT) Curing Agent" manufactured by Showa Ink Co., Ltd.), and aluminum phosphinate as a flame retardant were mixed so that the content of the flame retardant was a predetermined value to prepare a composition for a flame retardant layer. The composition for a flame retardant layer was applied to the surface of the protective layer opposite to the Al film to form a flame retardant layer.

[0132] As the gas barrier layer, a polyethylene terephthalate film (PET film) with a thickness of 12 μm and an aluminum film (Al film) vapor-deposited on one side was used. Two gas barrier layers were used. In addition, a linear low-density polyethylene film ("TUX HC-E" manufactured by Mitsui Chemicals Tohcello, Inc., thickness 50 μm) was used as the heat-sealable layer. As the adhesive for forming the interlayer adhesive layer, a two-liquid curing adhesive was used in which a base agent mainly composed of polyester polyol ("RU-77T" manufactured by Rock Paint Co., Ltd.), a curing agent containing aliphatic polyisocyanate ("H-7" manufactured by Rock Paint Co., Ltd.), and a solvent of ethyl acetate were mixed in a weight ratio of base agent:curing agent:solvent = 10:1:14. The protective layer with the flame retardant layer formed thereon, the two gas barrier layers, and the heat-sealable layer were laminated by the dry lamination method via the interlayer adhesive layer, respectively, to obtain an outer packaging material for vacuum insulation material. At this time, of the two layers bonded by the interlayer adhesive layer, the adhesive was applied to the surface of the layer located outside the interlayer adhesive layer in an amount (solid content) of 3.5 g / m 2 In addition, the two gas barrier layers were arranged so that the Al films faced each other.

[0133] Two sheets of the vacuum insulation packaging material were prepared. The two sheets of the vacuum insulation packaging material were stacked so that the heat-sealable layers faced each other, and the three sides of the quadrilateral were heat-sealed to produce a bag with only one side open. Glass wool was used as the core material, and after drying treatment, the core material and calcium oxide as a desiccant were placed in the bag, and the inside of the bag was evacuated. Thereafter, the opening of the bag was sealed by heat sealing to obtain a vacuum insulation material. The ultimate pressure was 0.05 Pa.

[0134] [Manufacturing Examples 2-5, 7] An outer packaging material for a vacuum insulation material and a vacuum insulation material were produced in the same manner as in Production Example 1, except that the content of the specific elements in the flame-retardant layer and the thickness of the flame-retardant layer were changed as shown in Table 1 below.

[0135] [Production Example 6] An outer packaging material for a vacuum insulation material and a vacuum insulation material were produced in the same manner as in Production Example 1, except that no flame retardant was added to the flame retardant layer and the thickness of the flame retardant layer was changed as shown in Table 1 below.

[0136] [Manufacturing Examples 8-9] An outer packaging material for vacuum insulation material and a vacuum insulation material were prepared in the same manner as in Production Example 1, except that aluminum hydroxide was used as the flame retardant and the content of specific elements in the flame retardant layer and the thickness of the flame retardant layer were changed as shown in Table 1 below.

[0137] [Reference example 1] A flame-retardant layer was formed by applying a composition for flame-retardant layer to the surface of the protective layer opposite to the Al film in the same manner as in Production Examples 8 to 9. Next, the protective layer on which the flame-retardant layer was formed and a heat-sealable layer were laminated via an interlayer adhesive layer by dry lamination in the same manner as in Production Examples 8 to 9 to obtain an outer packaging material for vacuum insulation material.

[0138] [Reference example 2] Except for changing the content of the specific element in the flame-retardant layer and the thickness of the flame-retardant layer as shown in Table 2 below, outer packaging materials for vacuum insulation materials were produced in the same manner as in Production Examples 8 and 9.

[0139] [evaluation] (1) The content of specific elements in the flame-retardant layer relative to the total content of carbon, oxygen and specific elements in the flame-retardant layer First, only the flame-retardant layer was scraped off from the vacuum insulation packaging material. Next, the content of each element in the flame-retardant layer was measured by X-ray fluorescence analysis (XRF) using a wavelength-dispersive X-ray fluorescence analyzer (Rigaku's "RIX-3100"). When aluminum phosphinate was used as the flame retardant, phosphorus was the specific element, and the content of phosphorus in the flame-retardant layer relative to the total content of carbon, oxygen, and phosphorus in the flame-retardant layer was determined. When aluminum hydroxide was used as the flame retardant, aluminum was the specific element, and the content of aluminum in the flame-retardant layer relative to the total content of carbon, oxygen, and aluminum in the flame-retardant layer was determined.

[0140] (2) Flame retardancy The vacuum insulation packaging material and the vacuum insulation material were subjected to a DIN4102-1 Class B2 ignition test. The vacuum insulation materials of Production Examples 1 to 9 were subjected to a flammability test by edge contact. On the other hand, the vacuum insulation packaging materials of Reference Examples 1 to 2 were subjected to a flammability test by surface contact. In the flammability test by edge contact, the sample size was 90 mm x 190 mm, and the number of samples was 5. In the flammability test by surface contact, the sample size was 90 mm x 230 mm, and the number of samples was 5. In both the flammability test by edge contact and the flammability test by surface contact, the flaming time was 15 seconds, and the flame propagation distance within 20 seconds from the start of flaming was confirmed. In addition, it was confirmed whether the sample continued to burn after the flame was removed. Flame retardancy was evaluated as follows. Additionally, DIN4102-1 Class B2 requires that the flame spread distance for all samples must be within 150 mm and that the sample must not continue to burn after the flame has separated. Therefore, the number of samples that meet this criterion is also shown in Table 1. As mentioned above, DIN4102-1 Class B2 requires that the flame spread distance must be within 150 mm, but taking into account the safety factor, it is preferable that the flame spread distance be within 75 mm. A: For all samples, the flame propagation distance is within 75 mm and the sample does not continue to burn after the flame leaves. B: For all samples, the flame propagation distance is within 150 mm, and the sample does not continue to burn after the flame leaves. C: For one or more samples, the flame spread distance is more than 150 mm, or the sample continues to burn after the flame has left.

[0141] Since the DIN4102-1 Class B2 ignition test is a flammability test for building materials, the ignition test for the outer packaging material for vacuum insulation materials was used as a reference example.

[0142] [Table 1]

[0143] [Table 2]

[0144] As shown in Table 1, when the vacuum insulation packaging material satisfies the above (1) and when the content of specific elements in the flame-retardant layer and the thickness of the flame-retardant layer in the vacuum insulation packaging material are within the specified ranges, the material has excellent flame retardancy.

[0145] Furthermore, Table 2 shows that as the thickness of the vacuum insulation packaging material increases, the flame retardancy decreases.

[0146] [Comparative Example] A nylon film (Unitika Ltd. "Emblem ON", thickness 25μm), a polyethylene terephthalate film (Unitika Ltd. "Emblett PTMB", thickness 12μm), an aluminum alloy foil (UACJ Corporation "Aluminum Foil (8079 general use)", thickness 6μm), and a linear low-density polyethylene film (Mitsui Chemicals Tohcello Inc. "TUX HC-E", thickness 50μm) were laminated with an adhesive to obtain an outer packaging material for vacuum insulation materials. The nylon film and polyethylene terephthalate film are protective layers, the aluminum alloy foil is a gas barrier layer, and the polyethylene film is a layer that can be heat-sealed.

[0147] The thermal conductivity in the surface direction was evaluated for the vacuum insulation packaging materials of Production Examples 1 to 9 and Comparative Example. In Production Examples 1 to 9, a PET film with an Al film deposited thereon was used as the gas barrier layer, whereas in Comparative Example, an aluminum alloy foil was used as the gas barrier layer, so that the Comparative Example had higher thermal conductivity in the surface direction. This suggests that the Comparative Example has inferior thermal insulation performance.

[0148] In the present disclosure, for example, the following inventions are provided. [1] An outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, The gas barrier layer comprises a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate. [2] An outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, The thickness of the flame-retardant layer is greater than 10 μm, The flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, When the phosphorus element, the nitrogen element or the metal element is defined as a specific element, the content of the specific element in the flame-retardant layer is 30 mass% or more relative to the total content of the carbon element, the oxygen element and the specific element in the flame-retardant layer. [3] An outer packaging material for a vacuum insulation material having, in this order, a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, The flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements, An outer packaging material for vacuum insulation material, which satisfies the following formula (1). (T1×A1) / T2≧0.030 (1) (In the above formula (1), T1 is the thickness (μm) of the flame-retardant layer, T2 is the thickness (μm) of the outer packaging material for vacuum insulation materials, and A1 is the content (mass%) of the specific element in the flame-retardant layer relative to the total content of the carbon element, the oxygen element, and the specific element in the flame-retardant layer, where the specific element is the phosphorus element, the nitrogen element, or the metal element.) [4] An outer packaging material for vacuum insulation materials according to [1], having two or more of the above gas barrier layers. [5] The packaging material for a vacuum insulation material according to [2] or [3], wherein the gas barrier layer has a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate. [6] An outer packaging material for vacuum insulation material according to any one of [1] to [5], wherein the flame retardant is one or more selected from the group consisting of phosphorus compounds, nitrogen compounds, metal hydroxides, and antimony compounds. [7] A vacuum insulation material having a core material and an outer packaging material in which the core material is encapsulated, wherein the outer packaging material is a vacuum insulation outer packaging material described in any one of [1] to [6]. [8] [7] A building material comprising the vacuum insulation material described in [7]. [Explanation of symbols]

[0149] 1 … Heat-sealable layer 2 … Gas barrier layer 3…protective layer 4...Flame-retardant layer 10...Outer packaging material for vacuum insulation materials 11 ... Resin substrate 12... Barrier film 13 ... Inorganic vapor deposition film 20... Vacuum insulation material 21 ... Core material

Claims

1. An outer packaging material for a vacuum insulation material, comprising a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, in this order, The gas barrier layer comprises a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate.

2. An outer packaging material for a vacuum insulation material, comprising a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, in this order, The thickness of the flame-retardant layer is greater than 10 μm, The flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements; When the phosphorus element, the nitrogen element or the metal element is defined as a specific element, the content of the specific element in the flame-retardant layer is 30 mass% or more relative to the total content of the carbon element, the oxygen element and the specific element in the flame-retardant layer.

3. An outer packaging material for a vacuum insulation material, comprising a heat-sealable layer, one or more gas barrier layers, a protective layer, and a flame-retardant layer containing a flame retardant, in this order, The flame retardant contains one or more elements selected from the group consisting of phosphorus, nitrogen, and metal elements; An outer packaging material for vacuum insulation material, which satisfies the following formula (1). (T1×A1) / T2≧0.030 (1) (In the formula (1), T1 represents the thickness (μm) of the flame-retardant layer, T2 represents the thickness (μm) of the outer packaging material for vacuum insulation materials, and A1 represents the content (mass%) of the specific element in the flame-retardant layer relative to the total content of the carbon element, the oxygen element, and the specific element in the flame-retardant layer, when the phosphorus element, the nitrogen element, or the metal element is a specific element.)

4. The vacuum insulation packaging material according to claim 1 , comprising two or more gas barrier layers.

5. 4. The packaging material for a vacuum insulation material according to claim 2, wherein the gas barrier layer has a resin substrate and an inorganic vapor deposition film disposed on one surface of the resin substrate.

6. The packaging material for vacuum insulation material according to any one of claims 1 to 3, wherein the flame retardant is one or more selected from the group consisting of phosphorus compounds, nitrogen compounds, metal hydroxides and antimony compounds.

7. A vacuum insulation material having a core material and an outer packaging material in which the core material is enclosed, A vacuum insulation material, wherein the outer packaging material is the vacuum insulation outer packaging material according to any one of claims 1 to 3.

8. A building material comprising the vacuum insulation material according to claim 7.

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