Thermal control material, thermal control sheet installation kit, and method for manufacturing thermal control material

Abstract

To provide a thermal control material that solves at least one of the problems of conventional technology. [Solution] A thermal control material comprising a sealed pouch made of film containing a metal layer, a core material housed in the bag of the sealed pouch and having external dimensions that conform to the internal dimensions of the sealed pouch, with recesses arranged on its surface, and a fluid held in the core material.

Description

Technical Field

[0001] The present disclosure relates to a heat control material, a heat control sheet construction kit, and a method for manufacturing a heat control material.

Background Art

[0002] There is known a heat absorption pack used for covering the entire surface or a part of the surface of a steel material and constructing it so as to surround and cover the periphery with a refractory heat insulating material or the like (Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 discloses a method for forming a steel structure fireproof coating by fixing, with welding pins or the like, to a steel material or the like, "a heat absorption pack formed by sandwiching an aluminum foil between two films formed by sandwiching a heat absorption material such as a liquid or a gel-like substance such as water or a polymer impregnated with water between a nylon film and a polyethylene film and heat-sealing the periphery".

[0005] FIG. 16 is a cross-sectional view showing a state in which the above-described conventionally known heat absorption pack is constructed on a steel material (column). Further, FIG. 17 is a cross-sectional view showing a state in which the above-described conventionally known heat absorption pack is constructed on the back surface of a corrugated steel sheet roofing material. The heat absorption pack 400 includes a bag body formed by two films 402A and 402B and a heat absorption material 404 made of a liquid or a gel-like substance accommodated inside the bag body. Further, the heat absorption pack 400 is fixed to the back surface of the corrugated iron sheet half roof 84 supported by the column 42 or the columns 80 and the beam 82 by welding pins 406.

[0006] As shown in Figures 16-17, conventionally known heat-absorbing packs 400 have a structure in which a liquid or gel-like heat-absorbing material 404 is directly sealed inside the bag, which can lead to the following problems depending on the installation conditions. Firstly, there is the uneven distribution of the heat-absorbing material 404. When installed vertically, such as on a column 42 as shown in Figure 16, or on a curved surface on the underside of a folded roof 84 as shown in Figure 17, the heat-absorbing material 404 inside the bag may shift due to gravity and become unevenly distributed. This uneven distribution can result in uneven heat absorption performance, leading to localized overheating or poor insulation. Secondly, there is the difficulty of installation. Because the heat-absorbing material 404 is "liquid or gel-like," it is difficult to maintain the shape of the heat-absorbing pack 400 during installation, which can lead to a decrease in installation accuracy. In particular, when installed on curved surfaces or vertically, the heat-absorbing pack 400 may not be able to maintain the intended shape, affecting its heat absorption performance. Thirdly, there is the issue of durability. If the heat-absorbing material 404 remains unevenly distributed, excessive stress is applied to a portion of the heat-absorbing pack 400, increasing the risk of damage or leakage during long-term use. This disclosure solves at least one of the problems of the prior art described above. [Means for solving the problem]

[0007] The thermal control material of this disclosure comprises a sealed pouch made of film including a metal layer, a core material housed in the bag of the sealed pouch and having external dimensions that conform to the internal dimensions of the sealed pouch, with recesses arranged on its surface, and a fluid held in the core material.

[0008] The present disclosure is a method for manufacturing a heat control material, comprising: separating a swollen polymer absorbent from a used absorbent sanitary product; and sealing the separated swollen polymer absorbent together with a core material having recesses on its surface in a film pouch containing a metal layer, wherein the core material has external dimensions that conform to the internal dimensions of the sealed pouch. [Effects of the Invention]

[0009] The thermal control material of this disclosure can solve at least one of the problems of the prior art. [Brief explanation of the drawing]

[0010] [Figure 1] This is a partial cross-sectional view showing a first embodiment of the thermal control material. [Figure 2] This is a cross-sectional view in the width direction of the first embodiment of the thermal control material. [Figure 3] This is a perspective view showing an example of how thermal control materials are used in wooden houses. [Figure 4] This is a perspective view showing an example of how a heat control material is used as a fire-resistant coating material in a steel frame structure. [Figure 5] This is a schematic cross-sectional view of a thermal control material attached to a column. [Figure 6] This is a perspective view showing another application example of thermal control materials in steel frame structures. [Figure 7] This is a perspective view showing another application example of thermal control materials in steel frame structures. [Figure 8] This is a front view showing an example of application of a heat control material to piping and valves. [Figure 9] This is a cross-sectional view showing the thermal control material installed on the underside of a corrugated sheet metal roof. [Figure 10] This is a partial cross-sectional view showing a second embodiment of the thermal control material. [Figure 11] This is a cross-sectional view of a modified thermal control material. [Figure 12] This is a plan view showing an example of a thermal control sheet. [Figure 13] This is a cross-sectional view of the thermal control sheet along line AA. [Figure 14] This is an explanatory diagram (cross-sectional view) of a thermal control sheet installation kit, including additional components and a thermal control sheet. [Figure 15] This is a flowchart of the manufacturing method for thermal control materials. [Figure 16] This is a cross-sectional view showing a conventionally known heat-absorbing pack installed on a steel column. [Figure 17] This is a cross-sectional view showing a conventionally known heat-absorbing pack installed on the underside of a corrugated sheet metal roof.

Best Mode for Carrying Out the Invention

[0011] The first heat control material of the present disclosure includes a sealed pouch made of a film containing a metal layer, a core material having an outer dimension that fits the inner dimension of the sealed pouch and having recesses arranged on its surface, and a fluid held by the core material.

[0012] Since the first heat control material adopts a configuration including a sealed pouch made of a film containing a metal layer, a core material having an outer dimension that fits the inner dimension of the sealed pouch and having recesses arranged on its surface, and a fluid held by the core material, it can appropriately protect the core material and the fluid while suppressing the intrusion of humidity, oxygen, etc. from the outside, and has an excellent effect of being able to stably and effectively perform heat storage and heat dissipation inside the core material. Also, since the core material has an outer dimension that fits the inner dimension of the sealed pouch, the movement of the core material inside the sealed pouch is suppressed. Furthermore, since the core material has recesses arranged on its surface, it is easier to hold the fluid in the above-mentioned recesses. As a result, even when constructed vertically or at a bent portion, the bias of the fluid inside the sealed pouch is suppressed. According to the first heat control material, the heat absorption performance by the fluid can be uniformly exhibited regardless of the construction location and construction form.

[0013] The second heat control material of the present disclosure is a heat control material in which, in the first heat control material, the fluid includes a polymer absorbent that swells by containing water.

[0014] The second heat control material includes a polymer absorbent that swells by containing water as the fluid. When the polymer absorbent absorbs moisture and swells, it exhibits excellent heat insulation, heat absorption, and heat shielding properties, and can effectively suppress heat conduction. Also, by combining the swollen polymer absorbent with a core material having recesses, the fluid retention is improved, the handling at the construction site becomes easier, and the heat absorption performance can be more uniformly exhibited.

[0015] The third thermal control material of this disclosure is a thermal control material in which, in the second thermal control material, the core material is a nonwoven sheet composed of laminated fibers, and the polymer absorbent is dispersed and held in the nonwoven sheet.

[0016] The third thermal control material has a nonwoven sheet constructed of laminated fibers as a core material, and a polymer absorbent is dispersed and held within the nonwoven sheet. This configuration allows the porous structure of the nonwoven sheet to uniformly hold the polymer absorbent, stabilizing the distribution of the swollen polymer absorbent. Furthermore, the flexibility of the nonwoven sheet makes the thermal control material easily adaptable to various installation locations.

[0017] The fourth thermal control material of this disclosure is a thermal control material in which, in the third thermal control material, the fibers are glass fibers and the nonwoven sheet is a needle-punched fiber sheet.

[0018] The fourth thermal control material comprises a nonwoven sheet (glass fiber mat) formed by laminating glass fibers and integrating them through needle punching. This configuration provides the core material with high rigidity and durability, while the glass fiber mat effectively holds the swollen polymer absorbent material stably. Furthermore, because the glass fiber mat has high heat resistance, the fire resistance performance of the thermal control material is improved. In addition, since the glass fiber mat itself has low water absorption and almost all moisture is held by the polymer absorbent material, the distribution of moisture within the core material is more uniformly maintained, and the heat absorption performance by the fluid can be exhibited more uniformly regardless of the installation location and method.

[0019] A fifth thermal control material of this disclosure is a thermal control material in which, in the first thermal control material, the core material comprises the fluid which is independently sealed.

[0020] The fifth thermal control material features a core material with an independently sealed fluid. This configuration prevents the entire fluid from leaking even if a part of the core material is damaged, as each core material independently holds the fluid. Furthermore, it facilitates maintaining a uniform fluid distribution within the core material, thus improving the reliability of the thermal control material. It also has the effect of making handling and placement at the construction site easier.

[0021] The sixth thermal control material of this disclosure is a thermal control material in which a plurality of types of the fluid are held in the first thermal control material.

[0022] The sixth thermal control material has a configuration that holds multiple types of fluids. This makes it possible to exhibit thermal insulation and heat shielding properties according to the characteristics of each fluid, and it has the flexibility to adapt to different environmental conditions and applications. For example, by combining a polymer absorbent (gel) swollen with water with a fluid having different physical properties, such as air, the effect of suppressing heat conduction can be optimized.

[0023] The first thermal control sheet installation kit of this disclosure comprises a thermal control sheet formed by continuously arranging thermal control materials described in any one of the first to sixth descriptions in a tile-like manner, and a cap mold shaped to fit the connecting portion of the thermal control material, wherein the cap mold comprises a support material made of a long film including the metal layer, a second core material fixed on the support material and having recesses on its surface, and a polymer absorbent dispersed in the second core material, and is configured such that when the support material is attached to the surface of the sealing pouch with the core material side facing the connecting portion, the connecting portion is covered and the surface of the thermal control material becomes substantially flat.

[0024] The first thermal control sheet installation kit improves the thermal insulation and fire resistance of the joints between the thermal control materials, which are arranged in a continuous tile-like pattern, by covering the joints with cap molds. Because the cap molds have a core material, the surface of the joints is finished almost flat, improving the appearance and safety after installation.

[0025] The second thermal control sheet installation kit of the present disclosure comprises a thermal control sheet formed by continuously arranging thermal control materials described in any one of the first to sixth descriptions in a tile-like manner, and an edge cap that covers the peripheral edge of the thermal control material, wherein the edge cap comprises a long film including the metal layer having a U-shaped cross-section, a third core material fixed inside the U-shape and having a recess on its surface, and a polymer absorbent dispersed in the third core material, wherein the third core material is configured to hold the peripheral edge of the sealing pouch in its center when viewed in cross-section.

[0026] The second thermal control sheet installation kit features an edge cap configuration, which protects the periphery of the thermal control material, allowing for installation without compromising its insulation or heat shielding properties. The edge cap has a U-shaped cross-section, which securely clamps the periphery, resulting in a high level of airtightness that is less susceptible to external influences.

[0027] The first method for manufacturing a thermal control material according to this disclosure comprises separating a swollen polymer absorbent from a used absorbent sanitary product, and sealing the separated swollen polymer absorbent together with a core material having recesses on its surface in a film pouch containing a metal layer, wherein the core material has external dimensions that conform to the internal dimensions of the sealed pouch.

[0028] The first method for manufacturing the heat control material involves separating the swollen polymer absorbent from used absorbent sanitary products and using it directly as the heat control material. This configuration eliminates the drying process required in conventional polymer absorbent recycling methods, thereby reducing manufacturing costs and environmental impact. Furthermore, using the swollen polymer absorbent directly as the heat control material can provide high thermal insulation and heat shielding properties.

[0029] Embodiments will be described in detail below with reference to the attached drawings. The following examples illustrate apparatuses and methods for realizing the technical concept of the disclosure, and the technical concept of this disclosure is not limited to those described below. The technical concept of this disclosure can be modified in various ways within the scope of the claims. In particular, it should be noted that the drawings are schematic and may differ from actual ones.

[0030] (Example 1) Figure 1 is a partial cross-sectional view showing a first embodiment of the thermal control material of this disclosure, and Figure 2 is a cross-sectional view in the width direction.

[0031] The heat control material 10 comprises a sealed pouch 12C formed by heat-sealing the peripheral edges 20 of two laminated films 12A and 12B, which include a metal layer, and a core material 14 housed inside the sealed pouch 12C, with external dimensions that conform to the internal dimensions of the sealed pouch 12C. Furthermore, an adhesive layer 18 is placed on one side of the surface of the laminated film 12A. The core material 14 is a binderless porous body formed by integrating multiple laminated nonwoven sheets of glass fiber by needle punching. A polymer absorbent 16 is dispersed in the core material 14. The polymer absorbent 16 is held in the voids within the core material 14, which is made of glass fiber. Furthermore, water (not shown) is sealed inside the bag along with these materials, and the polymer absorbent 16 absorbs the water, swelling and becoming gel-like.

[0032] The laminated films 12A and 12B are the main components that form the sealed pouch 12C. The two laminated films 12A and 12B are heat-sealed on all four sides of their peripheral edges 20 to form the sealed pouch 12C. The size of the sealed pouch 12C is not particularly limited and can be appropriately selected depending on the size and area of ​​the installation site. As will be described in detail later, one basic form of using the heat control material 10 is to attach it to the area where heat needs to be blocked. In this case, one sheet of heat control material 10 can be used to cover the entire installation site, or multiple sheets of heat control material 10 can be used to install it in a tile-like manner. In this case, some or all of the heat control material 10 may be overlapped during installation. The size of the heat control material 10, that is, the size and thickness of the sealed pouch 12C, varies depending on the installation method as described above, but in light of ease of transport and handling, it is preferable that the size is 10 cm to 500 cm and the thickness is 0.3 to 3 cm.

[0033] The laminated films 12A and 12B constituting the sealed pouch 12C are preferably multilayer structures including at least a metal layer and a resin layer. This provides high heat shielding, light shielding, and airtightness. On the other hand, it is not necessary for them to be laminated films 12A and 12B; they may also be in a form that only includes a metal layer, i.e., a metal foil. The layer configuration and materials can be appropriately selected depending on the application and environmental conditions.

[0034] The metal layer effectively blocks the effects of heat and light from the external environment and also serves to suppress the dissipation of the fluid sealed inside. The material of the metal layer is not particularly limited, but an aluminum layer is preferred. Aluminum has excellent heat shielding, light shielding, and gas barrier properties, while maintaining the overall lightness of the film. On the other hand, if higher thermal conductivity is required than heat shielding, copper can be used. This provides the property of efficiently dispersing heat. The metal layer may be a metal foil or a vapor-deposited layer. The thickness of the metal layer is not particularly limited and may be, for example, 5 μm to 100 μm. When using a film consisting only of a metal layer (metal foil), its thickness may be, for example, 10 μm to 200 μm.

[0035] The resin layer is a component that ensures the overall mechanical strength of the laminated film, improves its durability, and provides a heat-seal function. This resin layer may also play a role in enabling efficient sealing during the formation of a sealed pouch and maintaining the flexibility of the film. The resin layer may consist of one layer or multiple layers. Furthermore, the film may have multiple resin layers. For example, it may have a multilayer structure in which a metal layer is sandwiched between two resin layers.

[0036] For the resin layer, for example, polyolefin resins can be used. Among polyolefin resins, polyethylene (PE) offers excellent flexibility, chemical resistance, and heat sealability in low-temperature environments. Polypropylene (PP) has excellent heat resistance and strength, making it suitable for use in high-temperature environments. Linear low-density polyethylene (LLDPE) is particularly useful in multilayer structures because it provides higher tensile strength and flexibility than standard polyethylene. By creating a multilayer film structure and placing a layer made of polyolefin resin on the inside, heat sealing becomes easier.

[0037] Polyester resins can also be used as the material for the resin layer. Polyester resins (e.g., polyethylene terephthalate) have excellent mechanical strength and heat resistance. Ethylene-vinyl alcohol copolymer (EVOH) has very high gas barrier properties, so it can effectively suppress the dissipation of fluids sealed inside. Polyamide resins (nylon) also have excellent mechanical strength and high abrasion resistance. These resins may be used alone, but in many cases they function as part of a laminated structure.

[0038] The resin layer may consist of a single layer or multiple layers. For example, it is preferable to combine a polyester layer as the outer layer to enhance durability and printability, and a polyethylene layer as the inner layer to provide heat-sealability. Such a multilayer structure allows for the optimization of the properties of each layer, resulting in high overall performance.

[0039] Furthermore, additives may be incorporated into the resin layer. For example, a lubricant can be added to the resin layer to improve the surface slipperiness of the film, or a UV absorber can be added to prevent degradation due to ultraviolet rays. The thickness of the resin layer is preferably, for example, 10 μm to 200 μm. The overall thickness of the film, including the metal side, is preferably, for example, 50 μm to 400 μm.

[0040] The core material 14 is housed within the bag of a sealed pouch 12C formed from laminated films 12A and 12B. The core material 14 has external dimensions that conform to the internal dimensions of the sealed pouch 12C. In this specification, "external dimensions that conform to the internal dimensions of the sealed pouch" refers to a state in which the core material 14 is substantially fixed within the sealed pouch 12C without moving freely. Specifically, this means that the external dimensions of the core material 14 are approximately the same as the internal dimensions of the sealed pouch 12C, and that the core material is positioned so as not to shift position or tilt within the sealed pouch 12C.

[0041] This dimensional fit ensures that the core material 14 is held integrally within the sealed pouch 12C, allowing the main functions of the heat control material 10 (insulation, fire resistance, and heat shielding) to be efficiently performed. Furthermore, because the core material 14 is in substantial contact with the inner wall of the sealed pouch 12C, the overall shape stability of the sealed pouch 12C is improved, preventing performance degradation due to external pressure and vibration.

[0042] On the other hand, the external dimensions of the core material 14 do not need to perfectly match the internal dimensions of the sealed pouch 12C, and a reasonable amount of play is allowed to account for errors in the manufacturing and assembly processes. Specifically, even if the core material 14 can move slightly within the sealed pouch 12C, this is acceptable as long as it does not impair its substantial function. This design ensures efficiency in the manufacturing process and facilitates the insertion and assembly of the core material 14.

[0043] In the thermal control material 10 of this example, the core material 14 is a binder-less porous body formed by integrating multiple laminated nonwoven sheets of glass fibers by needle punching. The size and thickness can be appropriately selected according to the size and thickness of the thermal control material, and for example, a thickness of 200 μm to 2.8 mm is preferable. The porous body that is the core material is conventionally a laminate of glass cotton molded into a felt-like form, sometimes called a "glass fiber mat," etc.

[0044] Glass fiber mats have traditionally been used for insulation work on flat and curved surfaces, but in this example, they are newly used as a core material 14 in the thermal control material 10. Because glass fiber mats are molded without a binder, they have a structure in which the fibers intertwine without the use of adhesives, forming numerous interconnected pores inside. These interconnected pores function as spaces for dispersing and holding the polymer absorbent material 16 inside the core material 14, and play a role in stably supporting the swollen polymer absorbent material 16.

[0045] Furthermore, the glass fiber mat exhibits excellent thermal and mechanical stability, allowing it to maintain the shape of the core material 14 even in high-temperature environments or against external impacts. This characteristic enables the overall performance of the heat control material 10 to be maintained over a long period. In addition, the glass fiber mat has fine irregularities on its surface, which improves the retention of the polymer absorbent material 16 and assists in uniform dispersion during water absorption and swelling.

[0046] The core material 14 in this example possesses a combination of appropriate flexibility and rigidity. The core material can be used in applications that do not require a self-supporting structure, and even when bent by external force, the bent portion does not become extremely thin, and is less prone to breakage or damage. Specifically, due to the entanglement of the glass fibers that make up the core material 14, the internal structure does not deform significantly even when bent, and it has the characteristic of maintaining uniformity. This characteristic makes it less likely for abrupt thickness reduction or uneven rigidity to occur at the bent portion, and the performance as a heat control material 10 is more easily maintained. In addition, because the core material 14 has a porous structure, it exhibits appropriate flexibility while also having the ability to return to its original shape after bending, showing high adaptability in construction and usage environments.

[0047] Furthermore, the core material 14 can maintain its structural strength through the entanglement of its fibers even when subjected to extreme pressure or stress. Therefore, the physical properties of the core material 14 are not significantly impaired even in construction sites where bending and deformation are required. This ensures the overall performance and durability of the heat control material 10.

[0048] Furthermore, since the core material 14 in this example is binder-less, it has a structure that is less susceptible to degradation by chemical substances such as adhesives. As a result, long-term stability of water absorption and heat absorption performance is ensured. In addition, by using a glass fiber mat as the core material 14, it is possible to realize a lightweight and high-strength heat control material 10 while efficiently utilizing the internal space of the sealed pouch 12C. Moreover, since the glass fiber mat itself has almost no water absorption, the polymer absorbent material 16 can absorb almost all of the enclosed water. Therefore, even after long-term use, uneven distribution of moisture inside the bag is easily suppressed. This effect is particularly noticeable when used vertically or in curved sections.

[0049] The core material 14 is not limited to the glass fiber mat in this example, but may be made of other materials or have a different structure. As will be described later, a fluid that swells the polymer absorbent 16 is sealed inside the sealed pouch 12C. In particular, if this fluid contains liquid water, the temperature inside the sealed pouch 12C will not rise easily even if the outside of the heat control material 10 becomes hot. Therefore, even when the heat control material 10 is used as a fire-resistant coating material, there are no restrictions on the material of the core material 14, especially its fire resistance and heat resistance. For example, the core material 14 may be made of pulp nonwoven fabric or the like.

[0050] On the other hand, the core material 14 needs to have recesses on its surface to ensure uniform dispersion and retention of the fluid sealed inside the bag. The state of "having recesses on the surface" can be described as a porous body, such as the glass fiber mat described above. In the case of a porous body, the holes may be connecting holes that lead from one surface to the other, non-connecting holes, or a structure having both. Examples of such porous bodies include nonwoven sheets, foams, sintered bodies, natural porous bodies, and 3D printed porous bodies.

[0051] Nonwoven sheets are porous materials composed of laminated fibers. Glass fiber mats, which are needle-punched fiber sheets, are also included in nonwoven sheets. Examples of nonwoven sheets other than those mentioned above include spunbond nonwovens, meltblown nonwovens, carbon fiber nonwovens, cellulose nonwovens, and ceramic nonwovens. Spunbond nonwovens are nonwovens manufactured from thermoplastic polymers such as polypropylene (PP) and polyester (PET), and the fibers are bonded together by heat. Spunbond nonwovens are lightweight and highly flexible. Meltblown nonwovens are formed by extruding resin as fine fibers, creating a high-density nonwoven. Meltblown nonwovens have fine pores, allowing for more efficient control of fluid diffusion. Carbon fiber nonwovens are nonwovens composed of heat-resistant and conductive carbon fibers, making them suitable for high-temperature environments and special applications. Cellulose nonwovens are nonwovens manufactured using cellulose fibers, a natural material. Ceramic nonwoven fabrics are nonwoven fabrics made using ceramic fibers, and they have excellent fire resistance and heat resistance.

[0052] Foamed materials are materials such as polyurethane foam and polystyrene foam that have countless closed or open cells inside. These are lightweight, easy to process, and suitable for fluid retention and dispersion. Closed cells may hold gaseous fluids, while open cells may hold liquid fluids. Sintered bodies are porous bodies formed by sintering ceramic or metal powders. They are suitable for high-temperature environments and applications requiring high mechanical strength. On the other hand, glass fiber mats offer superior flexibility. Natural porous materials are sponge-like plant materials or porous bodies derived from animals. 3D-printed porous bodies allow for the design of highly precise pore structures. The material is often resin.

[0053] Furthermore, the core material having recesses on its surface may also have an uneven surface structure other than those described above. That is, it may be a core material having multiple protrusions instead of holes. In this case, the fluid can be held in the spaces (recesses) partitioned between the protrusions and by the laminated film. Alternatively, there may be hollow spaces within the protrusions, and the fluid may be sealed in these hollow spaces. In this case, the fluid will be held within the protrusions, but such a configuration is also acceptable. Examples of core materials having an uneven surface structure include corrugated plates, pyramidal structures, and sheets with hollow protrusions, etc.

[0054] A corrugated plate is a rigid or flexible plate-like material having a regular corrugated pattern on its surface, preferably made of resin. The valleys in the corrugations function as recesses, forming spaces that hold fluid. A pyramid structure is a structure in which multiple small protrusions are arranged across the entire surface, and fluid can be held in the spaces between the protrusions. While not particularly limited, it is preferably made of resin. A hollow protrusion is a form in which the inside of the protrusion is hollow, and fluid can be sealed in the hollow portion (for example, a structure used as an air packing). This makes it possible to achieve both fluid holding performance and overall weight reduction of the core material at the same time.

[0055] Incidentally, in conventionally known "heat-absorbing packs" such as those described in Patent Document 1, the use of a core material has not been considered. One reason for this lies in the installation method. As described in Patent Document 1, conventionally known "heat-absorbing packs" used so-called "welding pins" to fix them to steel materials, etc. The "welding pins" employ a structure that is fixed by being directly welded to the steel material, and the heat-absorbing pack is installed via these welding pins. However, if the "welding pins" are inserted from outside the "heat-absorbing pack" and a core material (especially a core material made of resin or glass) adheres to them, electrical conductivity during welding may be hindered, and a problem may arise in which the welding pins are not properly connected to the steel material. Due to this problem, heat-absorbing packs with built-in core materials have been difficult to implement using conventional installation methods. Conversely, because this installation method was assumed in the past, the use of core materials was not considered, and the problems caused by the absence of a core material were not fully recognized. On the other hand, the heat control material 10 of Example 1 does not necessarily require fixing with welding pins, and employs a structure that adheres to the object using an adhesive layer 18. This configuration was possible because the heat control material 10 has a core material 14, making it highly morphological and easy to apply with the adhesive layer 18. Conventional "heat-absorbing packs" do not have a core material, resulting in poor morphological properties and difficulty in stable application with an adhesive layer, so their adoption has not been considered. Consequently, fixing with welding pins was the only option, which further hindered the adoption of core materials.

[0056] A fluid is held in the core material 14 in order to improve the main function of the thermal control material 10. The fluid held is not particularly limited, but examples include gases such as air and nitrogen gas, and liquids such as water and organic solvents. Furthermore, other components may be added to the fluid. Examples of other components include polymer absorbents with swelling properties, antifreezes, preservatives, and disinfectants. Among these, water is particularly suitable as a fluid for thermal control materials because it has a large specific heat capacity and its temperature does not rise rapidly even when absorbing a lot of thermal energy. In addition, water has an excellent shielding effect against radiation (neutron rays, gamma rays, etc.), so when the thermal control material is used as an insulating material in nuclear reactors and related equipment, a radiation shielding effect can also be expected.

[0057] For example, a solution of water to which a polymer absorbent 16 has been added, in other words, a polymer absorbent 16 that has swollen with water, is treated as a form of fluid in this specification. The polymer absorbent 16 absorbs moisture and swells into a gel-like state, exhibiting fluidity. Examples of polymer absorbent 16 that can be used include acrylic acid polymers, cellulose polymers, and polyacrylamide polymers. Natural polymers such as chitosan and alginates can also be used.

[0058] The form of the polymer absorbent 16 is not particularly limited, but it is preferable if it is in the form of a powder, granules, or fibers, as this allows for more uniform dispersion on or within the core material 14, or makes it easier to hold the polymer absorbent 16 in place. For example, if the core material 14 is a glass fiber mat, and the polymer absorbent 16 is in the form of a powder or granules (as in this example), the polymer absorbent 16 can be dispersed in the voids of the glass fiber mat. If the polymer absorbent 16 is in the form of fibers, it can be molded simultaneously with the molding of the glass fiber mat.

[0059] The amount of superabsorbent polymer 16 in the core material 14 is not particularly limited. In one embodiment, since the superabsorbent polymer 16 can absorb 50 to 300 mL of water per gram, it can be appropriately selected according to the capacity of the sealed pouch 12C and the water absorption capacity of the core material 14 itself. The hardness of the heat control material 10 can also be adjusted by changing the amount of superabsorbent polymer 16 used.

[0060] The heat control material 10 further includes an adhesive layer 18 on at least one main surface of the sealed pouch 12C. The heat control material 10 is adhered to and fixed to the object via the adhesive layer 18. There are no particular limitations on the material and thickness of the adhesive layer 18, but they can be appropriately selected depending on the application and the object. Examples of materials for the adhesive layer 18 include acrylic adhesives, silicone adhesives, or rubber adhesives. Acrylic adhesives have excellent heat resistance and weather resistance, making them suitable for use in a wide range of environments. On the other hand, silicone adhesives are suitable for bonding in high-temperature environments, and rubber adhesives are suitable when flexibility is required. The material of the adhesive layer 18 can be appropriately selected depending on the installation location and environment of the heat control material 10.

[0061] The thickness of the adhesive layer 18 is not particularly limited, but 10 to 2000 μm is preferred as one form. When the thickness of the adhesive layer 18 is within this range, a higher level of balance between adhesive performance and flexibility can be achieved. Furthermore, if the surface shape of the object is not smooth, a thicker adhesive layer 18 can be used to fill in the irregularities and ensure secure fixation. On the other hand, for smooth surfaces, a thinner adhesive layer 18 can be used to reduce weight and cost.

[0062] Furthermore, the adhesive layer 18 does not need to be provided over the entire sealed pouch 12C; it may be provided only in a portion of the main surface of the sealed pouch 12C. For example, if the adhesive surface of the object is only partial, the adhesive layer 18 can be placed only in the necessary area, enabling efficient use of the material. Moreover, by making the adhesive layer 18 removable, it can also be used for temporary fixing purposes. In this case, it is preferable to use a material with weak adhesion or a structure that allows for re-adhesion.

[0063] The heat control material 10 may further include a release sheet (not shown) to protect the adhesive layer 18. The release sheet serves to prevent external contamination and damage to the adhesive layer 18 until it is used. This ensures that the adhesive performance of the adhesive layer 18 is maximized during installation.

[0064] The release sheet material is preferably a flexible film material such as polyester (e.g., PET), polypropylene (PP), or polyethylene (PE). Release sheets made of paper are also applicable, and release paper coated with silicone is particularly good at peeling from the adhesive layer 18.

[0065] The release sheet may be provided over the entire surface of the adhesive layer 18, or it may be provided only in part. For example, by leaving a portion of the adhesive layer 18 exposed, it is possible to facilitate positioning during installation. The release sheet may also be provided with an easily removable tab portion as needed. Such a tab portion improves workability at the construction site.

[0066] The thickness and rigidity of the release liner are set appropriately according to ease of handling and installation. For example, a thickness in the range of 20 to 200 μm ensures sufficient protection while allowing for easy removal. Selecting a release liner with heat resistance and waterproofing properties can further improve protection.

[0067] The thermal control material 10 can be used in a variety of applications in buildings and facilities. For example, it can be attached to the surface of steel frames (beams and columns) of buildings as a fire-resistant coating, or attached to the inside of roofs as insulation or heat shielding material. It can also be attached to the inside of walls in wooden houses to improve insulation performance, or wrapped around pipes and ducts as insulation and / or heat shielding material. In this way, the thermal control material contributes to improving the heat retention and fire resistance performance of buildings and facilities.

[0068] Furthermore, the size of the heat control material 10 can be adjusted as needed according to the installation location. Specifically, by customizing the shape and dimensions of the product in advance, it is possible to perfectly fit the shape and size of the installation location. In addition, it can be further adapted by cutting and processing as needed at the installation site. Since the heat control material has an adhesive layer 18, it can be easily fixed by simply attaching it to the installation location. Even if the adhesive layer 18 is not used, methods of fixing using bands or clips can be applied.

[0069] Furthermore, because the heat control material 10 is flexible, it can be applied to curved surfaces as well as flat surfaces. For example, by wrapping it around cylindrical objects such as pipes and ducts, the object can be completely covered, providing heat insulation and heat shielding performance. In this case, possible methods include removing the release sheet to expose the adhesive layer 18 and directly applying it to the object, or reinforcing the entire material with tape after application.

[0070] Figure 3 is a perspective view showing an example of how the thermal control material 10 is used in a wooden house 30. In this example, the thermal control material 10 is applied as insulation within the wall structure of the wooden house 30.

[0071] The wall structure of the wooden house 30 using the post-and-beam construction method comprises a floor surface 31 formed on a foundation 36, a base plate 32 placed on the foundation 36, and a framework structure consisting of multiple columns 33 extending upward from the base plate 32, and is covered with exterior wall material 34. The thermal control material 10 is placed between the columns 33 within this wall structure and, together with the exterior wall material 34, plays a role in improving the overall thermal insulation performance of the house.

[0072] The thermal control material 10 used in this example has a structure comprising a sealed pouch 12C and a core material 14, and the fluid held in the core material 14 exhibits thermal insulation and heat absorption effects. Unlike conventional on-site construction type insulation materials such as urethane foam, the thermal control material 10 in this example is provided as a ready-made product and has the advantage that construction can be completed simply by attaching it between the columns 33.

[0073] The thermal control material 10 is cut or adjusted as appropriate according to the width and height between the columns 33, and processed to the optimal shape and size for the installation location. Furthermore, since an adhesive layer 18 is provided, there is no need to use additional adhesive during installation, and it can be easily fixed between the columns 33. For example, by placing thermal control material 10 cut or adjusted to the appropriate size around the opening for the window frame 35, uniform thermal insulation performance can be ensured.

[0074] Furthermore, due to its flexibility, the thermal control material 10 in this example can be installed not only between columns 33 but also in close contact with areas of specific shapes. For example, along columns 33 or foundation 32, the thermal control material 10 can be bent or partially processed as needed to meet the diverse needs of the construction site. Since the thermal control material 10 has a core material 14, even if the thermal control material 10 is cut, the gel inside will not immediately leak out completely, and it can be reused after resealing.

[0075] The application of the thermal control material 10 as shown in this example significantly simplifies the construction process and reduces the risk of construction defects. Furthermore, after construction, the fluid held within the core material 14 effectively controls heat and prevents heat intrusion from the external environment. In addition, when the thermal control material 10 has a release sheet on the adhesive layer 18, handling during construction becomes easier, improving on-site work efficiency.

[0076] Figure 4 is a perspective view showing an example of how the thermal control material 10 is used as a fire-resistant coating material in a steel frame structure. In this example, the thermal control material 10 is attached to the surfaces of beams 43 and columns 42 in the steel frame structure 40 of the building.

[0077] The steel frame structure 40 is the main structural member of the building and consists of H-shaped steel columns 41 on the upper floors, columns 42 on the lower floors, and beams 43. The floor members 44 are supported by the H-shaped steel, and these structural members are integrated to form the frame of the building.

[0078] In this example, the heat control material 10 is attached as a fire-resistant coating to the outer periphery of the H-shaped steel beam 43, the upper floor column 41, and the lower floor column 42. Figure 5 is a schematic cross-sectional view of the heat control material 10 attached to the lower floor column 42. The heat control material 10 has a structure in which a core material 14 is housed in a sealed pouch 12C, and the fluid held inside is uniformly distributed and held throughout without becoming uneven, so that the entire heat control material 10 can exhibit uniform fire resistance performance.

[0079] The thermal control material 10 is attached along the flange and web portions of the H-shaped steel, thereby blocking thermal bridges in the steel frame structure 40 and suppressing heat exchange with the external environment. In addition to its function as a fireproofing, it improves the insulation performance inside the building and reduces the heating and cooling load. Furthermore, because the thermal control material 10 is flexible, it can be installed in close contact with the complex shapes of the H-shaped steel and columns.

[0080] Furthermore, the thermal control material 10 in this example can be cut and processed as needed depending on the installation location, and can be adjusted to the required size before installation. For example, when attaching it to the outer perimeter of columns 41 and 42 (upper and lower floor columns), the thermal control material 10 can be installed while adhering tightly to the curved surface, allowing for efficient coverage of the entire structure. It can also be accurately attached to the joint between the web and flange portions of the H-shaped steel of beam 43.

[0081] Thus, the thermal control material 10 in this example, when applied to the steel frame structure 40 of a building, can improve thermal insulation and heat shielding performance, as well as provide fire resistance. Furthermore, since it can be directly attached to the steel frame structure 40 via the adhesive layer 18 during construction, it offers good workability. Moreover, in the case of a form equipped with a release sheet, handling at the construction site is simple, enabling efficient construction.

[0082] Figures 6 and 7 are perspective views showing another application example of the thermal control material 10 in a steel frame structure 50. Figure 6 shows the thermal control material 10 applied to an H-shaped steel beam 52 and a duct 55, and Figure 7 shows a pre-cut thermal control material 100 for application to the duct 55. In this example as well, the thermal control material 10 and the pre-cut thermal control material 100 are installed as fire-resistant covering material for the steel frame structure 50.

[0083] The steel frame structure 50 is composed of H-shaped steel beams 52 and square steel pipes 51, and furthermore, the H-shaped steel beams 52 have a structure through which multiple ducts pass through the steel frame structure. Note that the ratio of the web and flange lengths of the H-shaped steel beams 52 in this example has been adjusted for the sake of explanation and differs from the actual values. In this example, the pre-cut thermal control material 100 is provided, processed to fit the shape of the through-holes 54 provided in the web 53 of the H-shaped steel beam, ensuring thermal insulation as the ducts 55 pass through the holes.

[0084] The web of the H-shaped steel beam 52 is provided with a through-hole 54 for the passage of a duct 55, and a pre-cut thermal control material 100 with a pre-drilled hole 56 corresponding to this opening is applied. The pre-cut thermal control material 100 has a hole 56 formed in the center of the thermal control material 10 already described, and the area around the hole 56 is heat-sealed, so that the duct 55 passes through this hole 56. Normally, the diameter of the through-hole 54 provided in the H-shaped steel beam 52, i.e., the diameter of the duct 55, is predetermined, so it is possible to prepare the pre-cut thermal control material 100 in advance. This makes it possible to install the thermal control material quickly and accurately at the construction site without additional processing. In addition, an adhesive layer 18 (not shown) is provided on the back side (the side of the H-shaped steel beam 52) of the laminated film 12B of the pre-cut thermal control material 100, and the pre-cut thermal control material 100 is fixed to the H-shaped steel beam 52 by the adhesive layer 18.

[0085] Furthermore, the heat control material 10 is wrapped around the duct 55 itself, creating a structure that suppresses heat exchange between the inside and outside of the duct 55. The heat control material 10 wrapped around the duct 55 has an adhesive layer 18, making it easy to fix in place during installation. As a result, the entire duct 55 is efficiently covered, improving its heat insulation and heat shielding performance.

[0086] In this example, the thermal control material 10 is installed to completely cover the contact area between the web of the H-shaped steel 52 and the duct 55, effectively preventing thermal bridging. Furthermore, because the thermal control material 10 is flexible, it can be made to conform to the shape of the duct 55 to improve adhesion, thereby improving the heat insulation and heat absorption performance at the connection point.

[0087] Figure 8 is a front view showing an example of application of the thermal control material to the piping 64 and valve 60. In this example, the thermal control material 10 is wrapped around the piping 64 and valve 60 for the purpose of heat insulation / heat shielding.

[0088] In Figure 8, pipe 64 is a tubular member for transporting fluid, and thermal control material 10 is wrapped around its outer circumference. Furthermore, thermal control material 61 and thermal control material 200, which have been specially adjusted to their respective shapes, are applied to the valve bonnet 62 and valve body 63 installed in the middle of pipe 64. In this example, thermal control materials 10, 61, and 200 are installed so as to cover all of these members, serving to prevent heat loss and reduce the thermal influence from the external environment.

[0089] A heat-control material 10, specifically designed for pipe 64, is wrapped around pipe 64 and secured using an adhesive layer 18. Because the heat-control material 10 is flexible, it can be easily wrapped around pipe 64 to conform to its cylindrical shape. Furthermore, once wrapped, it is stably secured by the adhesive layer 18, making it less susceptible to shifting due to vibration or temperature changes.

[0090] A heat-regulating material 200, which conforms to the shape of the valve body 63, is applied to the valve body 63. The heat-regulating material 200 is designed to match the shape of the valve body 63 and can be easily overlapped. Furthermore, a portion of the heat-regulating material 200 is cut at an angle, and by intersecting them at the overlapping portion, gaps are minimized and the thermal insulation performance is improved.

[0091] A special heat control material 61 is also applied to the valve bonnet 62 located at the top. This heat control material 61 can be tightly fitted to conform to the shape of the valve bonnet 62, and by being positioned to cover the entire structure, it effectively suppresses heat loss.

[0092] The application of the thermal control material in this example significantly improves the thermal insulation and heat shielding performance of the piping 64 and valve 60. Furthermore, using pre-cut thermal control material simplifies on-site work and improves construction accuracy.

[0093] Figure 9 is a cross-sectional view showing an example of the use of a thermal control material in a corrugated sheet metal roof structure. In this example, the thermal control material 10 is applied to the curved sections (valleys) of the folded sheet metal roof, and functions primarily as a fire-resistant coating material while also exhibiting thermal insulation performance.

[0094] The corrugated metal roof 84 has a structure in which corrugated iron sheets are continuously formed, and ideally, a heat control material would be applied to the entire structure. However, in Figure 9, for illustrative purposes, the heat control material 10 is shown to be placed only in the bent sections (valley sections). The heat control material 10 can be installed in close contact with the bent sections of the corrugated metal roof 84 by the adhesive layer 18. Furthermore, due to the internal structure of the heat control material 10, even when bending or deformation occurs, the contents do not become unevenly distributed, and uniform performance is maintained.

[0095] By applying the thermal control material 10 in this example, the corrugated sheet metal roof 84 not only improves the fire resistance performance in the event of a fire, but also improves the thermal insulation performance by suppressing heat exchange between the inside and outside of the building. Furthermore, this thermal control material is easy to install and has the advantage of being easily added to existing corrugated sheet metal roofs.

[0096] In addition to the above, thermal control materials can also be used for insulating motors and engines. In this case, they can be applied to automobiles, trains, and airplanes. They can also be used for insulating, shielding, retaining heat, and keeping cold equipment and piping in the energy sector. Furthermore, thermal control materials can be fixed not only by being attached to an object, but also by being sandwiched between objects.

[0097] (Demonstration test) Next, we will explain the results of the demonstration test to evaluate the performance of the thermal control material as a fire-resistant coating material for steel frame buildings. The thermal control material used was a glass fiber mat (approximately 5 mm thick) with a polymer absorbent (Chemical Technos Co., Ltd. "CP-1") dispersed inside a bag formed by heat-sealing a laminated film (PET 12 μm / LDPE 15 μm / aluminum 9 μm / LDPE 40 μm), and tap water was sealed inside.

[0098] With the above-mentioned heat control material sandwiched between insulating materials, one side was heated in a small electric furnace at 750°C, and the temperature of the other side was measured for 3 hours. As a result, even after heating one side at 750°C for 3 hours, the temperature of the other side remained almost constant at less than 100°C, and when the heat control material was opened after the test, gel (moisture) remained inside.

[0099] On the other hand, when a similar test was conducted using an alkali earth silicate (AES) blanket of the same thickness (a common fire-resistant coating material) as a control, the temperature on the reverse side began to rise about 30 minutes after the start of the test, reaching a maximum of approximately 300°C.

[0100] The results above clearly demonstrate that the thermal control material in this example exhibits excellent heat insulation and heat absorption performance, and has an effect equivalent to or better than conventional fire-resistant coating materials. Because the thermal control material in this example has a core material, even when used in various parts of buildings, the contents are less likely to become unevenly distributed, and the thermal insulation and heat absorption performance can be stably exhibited over a long period of time.

[0101] (Example 2) Figure 10 is a partial cross-sectional view showing a second embodiment of the thermal control material. The thermal control material 101 of this embodiment has a different structure from the first embodiment in that it employs a core material 102 with an uneven surface structure. The structure of the sealing pouch and the structure of the adhesive layer 18 are the same as in the first embodiment, so a detailed explanation thereof is omitted.

[0102] In the heat control material 101 of this embodiment, the core material 102 has a base portion 104 and a plurality of independent hollow protrusions 106 provided on one side surface of the base portion 104. The base portion 104 and the hollow protrusions 106 are each made of resin, and the material is not particularly limited, but examples include polyolefin resin, polyester resin, acrylic resin, and polystyrene resin. As a result, the core material 102 has a lightweight and flexible structure and can be applied to a wide range of applications.

[0103] The hollow protrusions 106 are filled with air or a gas (a form of fluid) such as nitrogen and sealed. This structure allows the hollow protrusions 106 to exhibit thermal insulation properties that suppress heat conduction. Specifically, the core material 102 may be configured as "air packing" (so-called bubble wrap). In this case, the regular arrangement of the hollow protrusions 106 provides uniform thermal insulation performance to the core material 102 as a whole.

[0104] The heat control material 101 configured in this way can be easily attached to an object via an adhesive layer 18 (not shown) provided on the surface of the sealed pouch. Since the adhesive layer 18 supports the entire sealed pouch, the heat control material 101 is stably fixed to the application surface and will not shift due to vibration or impact. Furthermore, because the heat control material 101 of this embodiment is lightweight, installation work is easy, and it is suitable for use as insulation material for buildings and equipment.

[0105] Furthermore, the core material 102 having hollow protrusions 106 can flexibly adapt to curved surfaces and objects with complex shapes. For example, it can be installed in close contact with cylindrical shapes such as pipes and ducts, or with bent sections such as corrugated iron plates. This ensures uniform thermal insulation performance and effectively suppresses heat exchange with the external environment.

[0106] Furthermore, the thermal control material 101 in this example may also contain water or a polymer absorbent swollen with water as another fluid. Since the core material 102 has recesses on its surface (between the hollow protrusions 106), the above fluid can be uniformly dispersed and retained in those portions.

[0107] Figure 11 is a cross-sectional view of a modified thermal control material of Example 2. In the thermal control material 110, air or a gas such as nitrogen is filled into the hollow protrusions 106, and a polymer absorbent material 108 that has swollen with moisture is held in the region partitioned by the hollow protrusions 106 and the inner surface of the sealed pouch. In other words, the core material 102 of the thermal control material 110 holds two types of fluids. The thermal control material 110 of this modified example has better heat insulation and heat absorption effects due to the two types of fluids (gas and gel). Note that the adhesive layer is not shown in Figure 11.

[0108] (Thermal control sheet) Figure 12 is a plan view showing an example of the thermal control sheet of this disclosure. In this example, the thermal control sheet 120 is constructed as a long unit in which multiple thermal control materials 10 described above are arranged in a continuous tile-like manner. The thermal control sheet 120 can be cut to the required size and shape at the construction site and has the convenience of being able to accommodate a wide range of applications.

[0109] The thermal control sheet 120 has a structure in which multiple thermal control materials 10 are arranged continuously in the width direction and length direction, and each thermal control material 10 is independently sealed. Connecting parts 122 are provided between the thermal control materials 10, and only laminated films 12A and 12B are placed in these connecting parts 122, and there are no contents (core material, fluid). Therefore, even if the connecting parts 122 are cut, the contents of the thermal control material 10 will not leak out, and it is possible to cut it to the required size at the construction site and use it.

[0110] The size of each heat control material 10 is not particularly limited, but it is preferable for ease of handling if each side is within the range of approximately 30 cm to 2 m square. This size is designed to accommodate various installation locations in buildings and facilities, and is easy to handle per unit area. The heat control sheet 120 is formed by continuously forming multiple sealed pouches in the width and length directions, and the whole is constructed as a long body. Since this long body is supplied wound in a roll, it is easy to transport and store, and is also efficient to handle at the construction site.

[0111] Furthermore, one side of the heat control sheet 120 is provided with an adhesive layer 18 (not shown), which is protected by a release sheet. By peeling off the release sheet during installation, the heat control sheet 120 can be easily fixed to the surface of the object. This adhesive layer 18 allows for secure fixation to the installation site without the use of additional adhesives.

[0112] The configuration of this thermal control sheet allows for flexible application depending on the size and shape of the installation location. For example, multiple thermal control materials 10 can be used continuously on large walls and ceilings, while smaller components and narrow spaces can be fitted with pieces cut to the required size. The thermal control sheet 120 in this example is provided as a long unit by continuously arranging multiple thermal control materials 10 arranged in a tile-like manner, improving transportability, ease of installation, and flexibility. The thermal control sheet 120 can be used as a fire-resistant coating, thermal insulation, and heat shielding material applied to buildings and equipment.

[0113] The size of the thermal control sheet can be adjusted as appropriate depending on the installation location, but one example is a roll-shaped sheet with a width of approximately 100 to 500 cm, in which thermal control material of about 50 to 100 cm is arranged in a continuous tile-like pattern.

[0114] (Thermal control sheet installation kit) Figure 13 is a cross-sectional view of the thermal control sheet 120 along line AA. The thermal control sheet 120 has a structure in which multiple thermal control materials 10 are continuously arranged in a tile-like manner. The thermal control materials 10 are sealed by laminated films 12A and 12B containing a metal layer, and a core material 14 is housed inside that holds a polymer absorbent material 16 that has swollen by absorbing water. As a result, the thermal control materials 10 exhibit fire resistance, heat absorption, heat insulation, and heat shielding properties.

[0115] Here, connecting portions 122 are provided between the heat control materials 10, and these connecting portions 122 have no internal contents and are composed only of laminated films 12A and 12B. Therefore, they can be easily cut to any size at this portion. Also, due to the structure, the edges of the heat control sheet 120 also have a peripheral portion 124 structure that does not contain a core material 14 or the like. Therefore, when it is attached to an object using an adhesive layer (not shown) placed on one main surface, groove-like indentations may occur in the peripheral portion 124 or connecting portion 122 on the surface opposite to the attachment surface. Although emphasized in the drawing, this area is actually only a few millimeters, so in terms of practicality it does not affect fire resistance, heat absorption, heat insulation, and heat shielding performance. However, because the peripheral portion 124 and connecting portion 122 do not contain a core material 14 or the like, partial non-uniformity in fire resistance, heat absorption, heat insulation, and heat shielding performance may occur.

[0116] The thermal control sheet installation kit in this example includes additional members for finishing the connecting portions 122 and peripheral portions 124. Figure 14 is a cross-sectional view showing these additional members. One is a cap mold 130 for covering the connecting portion 122. The cap mold 130 comprises a support material 132 and a second core material 134 fixed on the support material 132. The support material 132 is made of a long laminated film including a metal layer and has a width and length that covers the entire connecting portion 122. The structure of the laminated film is not particularly limited, but may be the same as the laminated films 12A and 12B that constitute the sealing pouch of the thermal control material 10.

[0117] The second core material 134 is fixed to the surface of the support material 132 and is configured to have a cross-sectional shape that fits the connecting portion 122. That is, it has a convex portion (with a trapezoidal cross-section) that fits snugly into a groove-shaped recess formed in the connecting portion 122. The second core material 134 may be made of the same material and structure as the core material 14 of the heat control material 10, but its thickness is preferably smaller than that of the core material 14 of the heat control material 10. Specifically, it is preferably about 10 to 60% of the thickness of the core material 14 of the heat control material 10. A thickness within the above range is preferable because, when applied to the connecting portion 122, the surface of the heat control material 10 after installation tends to be nearly flat. It is also preferable that the second core material 134 contains the same polymer absorbent as the heat control material.

[0118] It is preferable that the surface of the second core material 134 is exposed to the outside. In other words, it is preferable that the second core material 134 is not sealed. The support material 132 of the cap mold 130 is configured to be larger than the width of the second core material 134, and it is preferable that adhesion to the heat control sheet 120 is performed between the support material 132 that protrudes from the second core material 134 ("ear portion") and the surface of the heat control sheet 120. In this case, since the surface of the second core material 134 is exposed to the outside, at the construction site, water can be sprayed onto the second core material 134 to swell the polymer absorbent material 136, and in that state, the second core material 134 can be facing the surface of the connecting part and bonded and fixed. This improves handling at the construction site. The connecting part 122 is completely covered by the cap mold 130, and the entire heat control sheet 120 is configured to form a flat surface. By making this flat surface the opposite side from the surface that is attached to the object, a better aesthetic appearance (appearing flat) can be obtained, and the heat insulation performance and other properties can be more uniformly exhibited.

[0119] Another additional component is the edge cap 140. The edge cap 140 is used to cover the peripheral edge 124 of the heat control material 10, which is positioned on the outer periphery of the heat control sheet 120. The edge cap 140 comprises a support material 142 and a third core material 144 fixed on the support material 142. The support material 142 is made of a long film containing a metal layer, and has a so-called "channel" shape with a U-shaped cross-section, and has a width and length that covers the peripheral edge 124. The structure and material of the support material 142 are not particularly limited, but may be the same as the laminated films 12A and 12B that constitute the heat control material 10.

[0120] The third core material 144 is fixed inside the U-shaped support material 142 and is configured to hold the peripheral edge 124 of the heat control sheet 120 by sandwiching it. Specifically, it has a slit into which the peripheral edge 124 can be inserted and a taper into which the peripheral edge 124 can be fitted. The third core material 144 may have the same material and structure as the core material 14 of the heat control material 10. In addition, the third core material 144 is equipped with a polymer absorbent material 146, and its material and other properties may be the same as the polymer absorbent material 16 of the heat control material 10.

[0121] It is preferable that at least a portion of the surface of the third core material 144 is exposed to the outside. In other words, it is preferable that the third core material 144 is not completely sealed. The support material 142 of the edge cap 140 is made larger than the third core material 144, and it is preferable that adhesion to the heat control sheet 120 is performed between the support material 142 that protrudes from the third core material 144 ("ear portion") and the surface of the heat control sheet 120. In this case, because the surface of the third core material 144 is exposed to the outside, at the construction site, water can be sprayed onto the third core material 144 to swell the polymer absorbent material 146, and in that state, the third core material 144 can be facing the surface of the peripheral edge 124 and bonded and fixed. This improves handling at the construction site. The peripheral edge 124 is covered by the edge cap 140, and the entire heat control sheet 120 is configured to form a flat surface. This provides an excellent aesthetic appearance (appears flat) and makes it easier for the heat insulation performance to be exhibited more uniformly.

[0122] In addition to the above, the thermal control sheet installation kit may also include individual thermal control materials for repair purposes. While there are no particular limitations on their size, they may be rectangular with sides of 50 to 100 cm.

[0123] (Method for manufacturing heat-resistant material 1) The method for manufacturing thermal control materials and thermal control sheets is not particularly limited and can be carried out by appropriately combining known manufacturing technologies. An example is shown below, but is not limited thereto.

[0124] First, as the initial step, a core material is prepared in which the polymer absorbent is dispersed and retained. There are no particular limitations on the method of preparing the core material, but one method is to introduce powdered or granular polymer absorbent into the pores of the core material. In this case, the powder or granules are uniformly scattered on the surface and inside the core material and physically retained within the pores. Spray devices and dispensing devices can be used for dispersion. Furthermore, the core material may be vibrated or pressurized after dispersion to ensure a more uniform dispersion of the polymer absorbent within the core material.

[0125] Another method involves simultaneously introducing fibrous polymer absorbent material during the molding of the core material. In this case, the polymer absorbent material is mixed in during the molding process of the core material itself. For example, when manufacturing nonwoven sheets, the polymer absorbent material is mixed with the raw fibers of the core material and integrated with the core material on the production line. This method has the advantage of uniformly dispersing the absorbent material inside the core material and preventing physical shedding.

[0126] Another method involves dispersing the polymer absorbent in a liquid medium such as water to form a gel or slurry, which is then impregnated into the core material. In this method, the core material is immersed in the gel or slurry, the polymer absorbent is introduced into it, and then the absorbent is fixed within the core material after drying. It can also be used without drying. In this case, water supply to the core material in subsequent stages is unnecessary.

[0127] Next, in the second step, core materials holding the polymer absorbent are continuously placed on a film containing a metal layer that has been unfolded from the roll onto the production line. The core materials are placed on the film at regular intervals. This interval determines the width of the connecting section formed in the third step (compression step) described later. The placement position of the core materials is adjusted as appropriate, taking into consideration the uniformity of the entire product and ease of installation. By using mechanical handling devices or suction-type conveying devices, it is possible to streamline the manufacturing process and place the core materials with high precision.

[0128] The placed core material contains a polymer absorbent and may be in a swollen state or in an unswollen state. If it is unswollen, a liquid medium such as water may be added after the core material is placed. The film unfolding speed and core material placement speed in this process can be adjusted according to the specifications of the manufacturing line and the size of the product. Furthermore, it is preferable to combine a position detection sensor and an automatic control device to improve the accuracy of core material placement. The core material placed in this manner is then wrapped and sealed with film in the next process to form individual heat control materials.

[0129] Next, in the third step, another film containing a metal layer is placed over the core material positioned in the second step from above to enclose it. This film, like the film unfolded in the first step, has a laminated structure that provides heat resistance, airtightness, and durability. Preferably, at least one of the films unfolded in the third or second step has an adhesive layer and a release sheet on its back side.

[0130] Pressurization and heating are applied to the areas corresponding to the joints and periphery of the film. This heat-welds the joints and periphery, forming individual sealed pouches that enclose the core material, and creating a continuous series of heat-controlled materials connected via the joints. A heat sealing device and a roll press device may be used for the bonding. If the film does not have heat-sealing properties, adhesive strips may be placed at the joints and other areas before bonding.

[0131] After the crimping is complete, the formed connecting section integrates the heat control materials together, serving as a heat control sheet, and also allowing for cutting as needed at the construction site. This makes it possible to flexibly adapt the heat control sheet, which is provided in long lengths, to the size and shape required for the application. In this way, individual heat control materials with sealed cores are continuously formed, and a heat control sheet is obtained in which the entire material is integrated via the connecting section. The resulting heat control sheet may be wound around a roll core and made into a roll.

[0132] (Method for manufacturing thermal control material 2) Next, another form of the manufacturing method for the heat control material will be described. Figure 15 is a flowchart of the manufacturing method for the heat control material. First, in step S101, the swollen superabsorbent polymer is separated from the used absorbent sanitary product. The absorbent sanitary product is not particularly limited, but examples include diapers, incontinence pads, and sanitary napkins. The used absorbent sanitary product contains the swollen superabsorbent polymer, and recovering this material is the first step of this manufacturing method.

[0133] There are no particular limitations on the method for separating swollen superabsorbent polymers from used absorbent sanitary products, and known methods can be applied. In one specific form, a combination of mechanical and chemical treatment is preferred. After crushing the used absorbent sanitary products into small pieces using a pulverizer or cutter, the superabsorbent polymer can be separated from the fibers and other components by adding water or other solvents.

[0134] Traditionally, in the material recycling of superabsorbent polymers (SAPs), it was necessary to remove the water contained within the polymer while it was swollen. This water removal process has been a major challenge in the recycling process because it consumes a lot of energy and carries the risk of damaging the properties of the polymer.

[0135] On the other hand, the manufacturing method in this example is characterized by the direct use of the swollen polymer absorbent. This eliminates the moisture removal process that was previously required, resulting in process simplification and a significant reduction in energy costs. Furthermore, by directly incorporating the swollen polymer absorbent into the thermal control material, its heat insulation and heat shielding properties are enhanced. Therefore, this manufacturing method is more efficient and superior to conventional technologies in terms of reducing environmental impact.

[0136] The separated, swollen polymer absorbent is dispersed into the core material in the next process and used as a material to exhibit its performance as a thermal control material. In this way, by reusing used absorbent sanitary products, it is possible to simultaneously achieve efficient resource utilization and waste reduction.

[0137] Next, in step S102, the separated swollen polymer absorbent material is sealed in a film pouch containing a metal layer, together with a core material having recesses on its surface.

[0138] The swollen polymer absorbent obtained in step S101 becomes gel-like when it absorbs moisture, and in this step, it is impregnated into the core material in this state. By immersing the core material in the gel of the swollen polymer absorbent, the polymer absorbent is uniformly dispersed within the pores and physically held in place.

[0139] The impregnated core material is sandwiched from above and below by a film containing a metal layer on the production line and sealed. The subsequent steps are the same as those of the manufacturing method in the first embodiment. According to the manufacturing method of the second embodiment, by directly impregnating the core material with a gel-like polymer absorbent, the dewatering process of conventional polymer absorbents can be omitted, and it becomes possible to achieve effective resource utilization and increased efficiency in the manufacturing process. [Explanation of Symbols]

[0140] 10 Thermal control material, 12A, 12B Laminated film, 12C Sealed pouch, 14 Core material, 16 Superabsorbent polymer, 18 Adhesive layer, 20 Peripheral part, 61 Thermal control material, 100 Pre-cut thermal control material, 101 Thermal control material, 102 Core material, 104 Base, 106 Hollow protrusion, 108 Superabsorbent polymer, 110 Thermal control material, 120 Thermal control sheet, 122 Connecting part, 124 Peripheral part, 130 Cap mold, 132 Support material, 134 Second core material, 136 Superabsorbent polymer, 140 Edge cap, 142 Support material, 144 Third core material, 146 Superabsorbent polymer, 200 Thermal control material

Claims

1. A sealed pouch made of film containing a metal layer, A thermal control material comprising a core material housed in the bag of the sealed pouch, having external dimensions that conform to the internal dimensions of the sealed pouch, and having recesses on its surface, and a fluid held in the core material.

2. The thermal control material according to claim 1, wherein the fluid comprises a polymer absorbent that has swollen with water.

3. The thermal control material according to claim 2, wherein the core material is a nonwoven sheet composed of laminated fibers, and the polymer absorbent is dispersed and held in the nonwoven sheet.

4. The heat control material according to claim 3, wherein the fiber is a glass fiber and the nonwoven sheet is a needle-punched fiber sheet.

5. The thermal control material according to claim 1, wherein the core material comprises the fluid, which is independently sealed.

6. The thermal control material according to claim 1, which holds multiple types of the aforementioned fluids.

7. A heat control sheet formed by continuously arranging the heat control material according to any one of claims 1 to 6 in a tile-like manner, The system comprises a cap mold shaped to fit the connecting portion of the heat control material, The cap mold comprises a support material consisting of a long film including the metal layer, a second core material fixed on the support material and having recesses on its surface, and a polymer absorbent dispersed in the second core material. A heat control sheet installation kit is configured such that when the support material is attached to the surface of the sealed pouch with the core material side facing the connecting portion, the connecting portion is covered and the surface of the heat control material becomes nearly flat.

8. A heat control sheet formed by continuously arranging the heat control material according to any one of claims 1 to 6 in a tile-like manner, The heat control material comprises an edge cap that covers the peripheral edge, The edge cap comprises a long film including the metal layer having a U-shaped cross-section, a third core material fixed inside the U-shape and having a recess on its surface, and a polymer absorbent dispersed in the third core material. The third core material is configured to hold the peripheral edge of the sealed pouch in its center when viewed in cross-section, in a heat-controlled sheet installation kit.

9. The process involves separating swollen superabsorbent polymers from used absorbent sanitary products, The separated swollen polymer absorbent material is sealed together with a core material having recesses on its surface in a sealed pouch made of film containing a metal layer, A method for manufacturing a heat control material, wherein the core material has external dimensions that conform to the internal dimensions of the sealed pouch.

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