Surface material for foam insulation board and foam insulation board

Abstract

To suppress the expansion of a foaming heat insulation board caused by the stagnation of a gas generated from a foaming heat insulation material at combustion between the board and the foaming heat insulation material, and to suppress the occurrence of poor appearance at integral processing with the foaming heat insulation material.SOLUTION: In a surface material for foaming heat insulation board 1 having aluminum foil 2 and a resin film 3 formed at one face side of the aluminum foil, a thickness of the surface material for foaming heat insulation board is equal to or thicker than 25 μm and equal to or thinner than 80 μm, and stick rigidity from the aluminum foil side with the foaming heat insulation material integrated with a surface at a side opposite to the aluminum foil of the resin film as a foaming heat insulation material side is equal to or higher than 6.1 N / Φ1 mm. The surface at the side opposite to the aluminum foil of the resin film constitutes an outermost surface of the surface material for foaming heat insulation board, and a push-in elasticity modulus of the resin film is equal to or higher than 1000 MPa.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a surface material for a foam insulation board and a foam insulation board using the same. [Background technology]

[0002] Insulation boards are used as heat insulating materials in buildings, etc. Due to factors such as the stability of power supply and demand, rising energy prices, and environmental considerations, the use of insulation boards in buildings is expected to increase more than ever before. Therefore, many technologies related to foam insulation boards, including foam insulation materials, have been proposed (Patent Document 1 and Patent Document 2).

[0003] Conventionally, a metal foil such as aluminum foil has been attached to the surface of foam insulation material in some cases. The purpose of using the metal foil is to suppress combustion of the foam insulation material by the heat-shielding effect of the metal foil, and to suppress leakage of insulating gas such as fluorine gas enclosed in the foam insulation material to the outside by the barrier effect of the metal foil. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6823394 [Patent Document 2] Japanese Patent Application Publication No. 2018-171885 Summary of the Invention [Problem to be solved by the invention]

[0005] In the case of foam insulation boards in which metal foil is attached to the front and back surfaces of foam insulation as a surface material, the insulating gas contained in the foam insulation may become trapped between the surface material and the foam insulation during combustion, causing the foam insulation board to expand. In this case, the insulating gas trapped between the surface material and the foam insulation expands, causing the metal foil to peel off, losing its heat-reflecting properties. The foam insulation may then be exposed to high temperatures and burn. Furthermore, if the surface material has low strength, it may not be able to withstand the stress imposed on the surface material by the expansion of the foam insulation board, causing cracks in the surface material, which may lead to combustion of the foam insulation through the cracks. Furthermore, expansion of the foam insulation board results in poor appearance and requires replacement. In particular, in recent years, increasing the thickness of foam insulation boards has been considered to further improve insulation performance. In this case, as the volume of the foam insulation increases, the amount of gas generated from the foam insulation during combustion also increases, which may further exacerbate the expansion of the foam insulation board.

[0006] Furthermore, the surface material for foam insulation boards is also required to suppress poor appearance when integrated with the foam insulation material.

[0007] The present disclosure has been made in consideration of the above circumstances, and its main object is to provide a surface material for a foam insulation board that can suppress the expansion of the foam insulation board due to gas generated from the foam insulation material remaining between the foam insulation board and the board during combustion, and can suppress poor appearance when integrated with the foam insulation material. [Means for solving the problem]

[0008] One embodiment of the present disclosure is a surface material for a foam insulation board having an aluminum foil and a resin film arranged on one side of the aluminum foil, the surface material for a foam insulation board having a thickness of 25 μm or more and 80 μm or less, and when the surface of the resin film opposite the aluminum foil is integrated with the foam insulation material so that the surface of the resin film opposite the aluminum foil is the foam insulation material side, the puncture strength from the aluminum foil side is 6.1 N / Φ1 mm or more, the surface of the resin film opposite the aluminum foil forms the outermost surface of the surface material for a foam insulation board, and the indentation elastic modulus of the resin film is 1000 MPa or more.

[0009] One embodiment of the present disclosure is a foam insulation board comprising a foam insulation material and the above-mentioned foam insulation board surface material arranged on at least one side of the foam insulation material, wherein the foam insulation board surface material is arranged so that the resin film faces the foam insulation material. [Effects of the Invention]

[0010] The present disclosure has the advantage of being able to provide a surface material for a foam insulation board that can suppress the expansion of the foam insulation board due to gas generated from the foam insulation material during combustion remaining between the foam insulation material and the board, and that can suppress poor appearance when integrated with the foam insulation material. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic cross-sectional view illustrating a surface material for a foam insulation board according to the present disclosure. [Figure 2] 1 is a schematic cross-sectional view illustrating a foam insulation board of the present disclosure. [Figure 3] 1 is a schematic cross-sectional view illustrating a surface material for a foam insulation board according to the present disclosure. [Figure 4] 1 is a schematic cross-sectional view illustrating an example of an insulation board using a conventional foam insulation board surface material. DETAILED DESCRIPTION OF THE INVENTION

[0012] Embodiments of the present disclosure will be described below with reference to the drawings and the like. However, the present disclosure can be implemented in many different forms, and should not be construed as being limited to the description of the embodiments exemplified below. Furthermore, to clarify the explanation, the drawings may schematically depict the width, thickness, shape, etc. of each part compared to the actual form, but these are merely examples and are not intended to limit the interpretation of the present disclosure. Furthermore, in this specification and each drawing, elements similar to those previously described with reference to the preceding drawings will be designated by the same reference numerals, and detailed descriptions may be omitted as appropriate.

[0013] In this specification, when describing a mode in which another component is placed on a certain component, the terms "above" or "below" are used, unless otherwise specified, to include both a case in which another component is placed directly above or below a certain component so as to be in contact with the component, and a case in which another component is placed above or below a certain component with another component interposed therebetween. Also, in this specification, when describing a mode in which another component is placed on the surface of a certain component, the terms "on the surface side" or "on the surface" are used, unless otherwise specified, to include both a case in which another component is placed directly above or below a certain component so as to be in contact with the component, and a case in which another component is placed above or below a certain component with another component interposed therebetween.

[0014] Figure 4 is a schematic cross-sectional view of a foam insulation board using a conventional foam insulation board facing material. Foam insulation board facing material 51 in foam insulation board 100 shown in Figure 4 includes aluminum foil 52 and PE resin film 53, and PE resin film 53 is arranged so that it is in contact with foam insulation material 61. When such insulation board 100 burns, there is a concern that insulating gas generated from foam insulation material 61 will accumulate between facing material 51 and foam insulation material 61, causing it to swell and peel off. Furthermore, if the surface material has low strength, it cannot withstand the stress applied to it by the expansion of the foam insulation board, causing cracks in the surface material, which can lead to the foam insulation burning through the cracks. Furthermore, conventional surface materials for foam insulation boards can sometimes cause poor appearances such as streaks and wrinkles when they are integrated with the foam insulation.

[0015] The inventors, faced with such problems, have conducted extensive research and have found the following surface material for foam insulation boards, thereby solving the above problems. The foam insulation board surface material and foam insulation board according to the present disclosure will be described in detail below.

[0016] A. Surface material for foam insulation board Fig. 1 is a schematic cross-sectional view showing an example of a foam insulation board facing material according to the present disclosure. As shown in Fig. 1, the foam insulation board facing material 1 according to the present disclosure includes an aluminum foil 2 and a resin film 3 disposed on one side of the aluminum foil 2. Furthermore, the foam insulation board facing material 1 has a thickness of 25 µm to 80 µm. When the surface of the resin film 3 opposite the aluminum foil 2 is integrated with the foam insulation material, the puncture strength from the aluminum foil 2 side (i.e., the puncture strength measured by the method described in the Examples) is 6.1 N / Φ1 mm or more. The surface of the resin film 3 opposite the aluminum foil 2 constitutes the outermost surface 1A of the foam insulation board facing material 1, and the resin film 3 has an indentation modulus of 1000 MPa or more.

[0017] Figure 2 is a schematic cross-sectional view showing an example of a foam insulation board comprising a foam insulation board facing material according to the present disclosure. As shown in Figure 2, foam insulation board 10 comprises foam insulation material 11 and the foam insulation board facing material 1 described above disposed on at least one side of foam insulation material 11, with foam insulation board facing material 1 disposed so that resin film 3 faces foam insulation board 11. It is preferred that outermost surface 1A of foam insulation board facing material 1 on the resin film 3 side be in direct contact with foam insulation board 11.

[0018] In the present disclosure, the resin film constituting the outermost surface of the foam insulation board facing has a predetermined indentation elasticity modulus, which provides excellent adhesion to the foam insulation during combustion (at high temperatures). This allows the facing to withstand the stress imposed on the facing by the expansion of the insulating gas during combustion, preventing the insulating gas from accumulating between the facing and the foam insulation, and suppressing expansion of the foam insulation board. Furthermore, the surface material for foam insulation boards disclosed herein has a resin film and a predetermined thickness and the above-mentioned puncture strength, which helps to prevent poor appearance such as streaks and wrinkles when integrated with the foam insulation.In addition, during combustion (high temperatures), the surface material has the strength to withstand the stress exerted on it by the expansion of the insulating gas within the foam insulation and the thermal expansion of the foam insulation itself, making it less likely to crack.

[0019] In particular, if the thickness of the foam insulation material is increased to further improve its insulating properties, there is a risk that the amount of insulating gas generated from the foam insulation material during combustion will increase, but even in such cases, the expansion of the foam insulation board can be suppressed.

[0020] Additionally, insulation boards are required to meet the requirements for obtaining non-combustible certification in heat generation tests using a cone calorimeter in accordance with ISO5660-1:2002. A cone calorimeter is a device that heats a sample with a cone-shaped heater, ignites it with a spark igniter, and burns it, measuring the oxygen concentration in the generated gas. Cone calorimeters can be used to evaluate flammability by measuring gross heat release, maximum heat release rate, combustion time from ignition to extinction, and weight retention (weight percentage after the test compared to the weight before the test). Even when conducting such heat release tests using foam insulation boards, gases generated during combustion of the foam insulation may be generated between the foam insulation and the surface material, causing the foam insulation board to expand. If the insulation board expands and deforms during the heat release test, the surface material may peel off, exposing the foam insulation to high temperatures and causing it to burn. Furthermore, the board may come into contact with a spark igniter, making measurement impossible. Therefore, even if the insulation board is flame-retardant or non-combustible, its expansion during the heat release test makes it impossible to measure, preventing it from meeting the requirements for non-combustible certification.

[0021] In contrast, the present disclosure provides excellent adhesion between the foam insulation board facing and the foam insulation. This prevents gases generated from the foam insulation from accumulating between the foam insulation board facing and the foam insulation during heat generation tests, thereby suppressing expansion of the foam insulation board. This prevents peeling of the facing and contact with a spark igniter during heat generation tests, allowing for a foam insulation board that meets the requirements for non-combustibility certification and is certified as non-combustible in the event of a fire.

[0022] The surface material for a foam insulation board of the present disclosure has an aluminum foil 2 and a resin film 3 arranged on one side of the aluminum foil 2.

[0023] 1. Thickness The thickness of the facing material for foam insulation boards of the present disclosure is 25 μm or more, preferably 30 μm or more, and particularly preferably 35 μm or more. If the thickness is too thin, poor appearance is likely to occur when integrated with the foam insulation material. Furthermore, at high temperatures, cracks are likely to occur when stress is applied to the facing material due to the expansion of the insulating gas within the foam insulation material or the thermal expansion of the foam insulation material itself. On the other hand, the thickness of the facing material for foam insulation boards is 80 μm or less, preferably 70 μm or less, and particularly preferably 60 μm or less. If the thickness is too thick, it is disadvantageous in terms of cost. In this disclosure, the "thickness of the facing material for foam insulation boards" refers to the total thickness of the layers that make up the facing material for foam insulation boards.

[0024] 2.Puncture strength When the surface material for foam insulation boards of the present disclosure is integrated with a foam insulation board, with the surface of the resin film opposite the aluminum foil serving as the foam insulation board side, the puncture strength from the aluminum foil side (i.e., puncture strength measured using the method described in the Examples) is 6.1 N / Φ1mm or more, preferably 7.0 N / Φ1mm or more, and particularly preferably 8.0 N / Φ1mm or more. If the puncture strength is too low, poor appearance is likely to occur during integration with the foam insulation board. Furthermore, cracks are likely to occur when stress is applied to the surface material at high temperatures. On the other hand, the puncture strength may be, for example, 30 N / Φ1mm or less, or 20 N / Φ1mm or less.

[0025] In the present disclosure, the method for measuring puncture strength can be the method described in the Examples. Regardless of the type of foam insulation, the stress required for a needle to penetrate the foam insulation is much smaller than the stress required for a needle to penetrate the surface material. Therefore, the puncture strength of the surface material and the foam insulation integrated together does not depend on the type of foam insulation. Therefore, the puncture strength of the surface material and the foam insulation integrated together can be used as an indicator of the puncture strength of the surface material.

[0026] 3. Indentation modulus In the foam insulation board surfacing material of the present disclosure, the resin film constituting the outermost surface has an indentation modulus of 1000 MPa or more at room temperature (25°C). The outermost surface of this foam insulation board surfacing material (hereinafter also referred to as the outermost surface on the resin film side) is the surface that comes into contact with the foam insulation when the foam insulation board is made. If the indentation modulus is too low, the resin will be more likely to flow during combustion (at high temperatures), resulting in poor adhesion to the foam insulation. This can lead to gas accumulation between the foam insulation and the surfacing material, causing swelling and peeling of the surfacing material, which can expose the foam insulation to high temperatures and cause it to burn.

[0027] The indentation elastic modulus is preferably 2000 MPa or more, while the indentation elastic modulus is, for example, 100000 MPa or less, preferably 10000 MPa or less.

[0028] The indentation modulus can be measured by, for example, the method described in the Examples.

[0029] 4. Configuration Below, each configuration of the surface material for foam insulation board of the present disclosure will be described.

[0030] (1) Resin film The foam insulation board facing material of the present disclosure includes a resin film. By including the resin film, it is possible to prevent wrinkles and the like from occurring in the aluminum foil when it is integrated with the foam insulation material, etc. In the present disclosure, the resin film constitutes one of the outermost surfaces of the foam insulation board facing material.

[0031] In the present disclosure, the resin contained in the resin film constituting the outermost surface (the resin film in contact with the foam insulation) preferably has a glass transition temperature of 60° C. or higher, and particularly preferably 70° C. or higher. A glass transition temperature of this value or higher provides sufficient heat resistance, resulting in little change in state even at high temperatures and less deterioration in adhesion between the resin film and the foam insulation. The glass transition temperature (Tg) can be determined, for example, by a measurement method in accordance with JIS K7121 using a differential calorimeter (DSC, manufactured by Shimadzu Corporation, model number: DSC-60) or the like.

[0032] In the present disclosure, the resin contained in the resin film constituting the outermost surface (the resin film in contact with the foam insulation material) is not particularly limited as long as the indentation modulus satisfies the above range, but examples thereof include polyethylene terephthalate (PET), nylon, polybutylene terephthalate (PBT), etc. In the present disclosure, PET is more preferably used among the above resins. Biaxially stretched PET film is particularly preferred.

[0033] The resin film may be one that has been subjected to a corona treatment on one or both sides of the outermost surface of the surface material, so that the indentation modulus of the resin film can be within the above range. The resin film may be unstretched, or may be uniaxially or biaxially stretched.

[0034] The thickness of the resin film is not particularly limited as long as it is a thickness that allows the thickness of the surface material for the foam insulation board to be in the above range, but is, for example, 6 μm or more and 50 μm or less, preferably 9 μm or more and 38 μm or less.

[0035] (2) Aluminum foil In the present disclosure, the aluminum foil is disposed on one side of the resin film. The thickness of the aluminum foil is not particularly limited as long as the thickness of the surface material for the foam insulation board falls within the above range, but is, for example, 6 μm or more, preferably 20 μm or more. If it is greater than the above value, the strength of the surface material is increased, which is preferable. On the other hand, the thickness is, for example, 50 μm or less, and if it is 35 μm or less, it is preferable from the viewpoint of cost.

[0036] Furthermore, the ratio of the thickness of the aluminum foil to the total thickness of the foam insulation board facing material of the present disclosure (thickness of the aluminum foil / total thickness of the foam insulation board facing material) is, for example, 0.075 or more, and may be 0.25 or more. If it is above this value, it is preferable because the strength of the facing material is high. On the other hand, it may be, for example, 0.70 or less, and may be 0.54 or less.

[0037] (3) Other configurations The foam insulation board surface material of the present disclosure may include layers other than the aluminum foil and the resin film. Figure 3 is a schematic cross-sectional view showing another example of the foam insulation board surface material of the present disclosure. The foam insulation board surface material 1 shown in Figure 3 has a reinforcing layer 4 disposed between the aluminum foil 2 and the resin film 3.

[0038] (a) Reinforcement layer The surface material for foam insulation boards of the present disclosure may have a reinforcing layer between the aluminum foil and the resin film to achieve a thickness equal to or greater than the above-mentioned value or to achieve a puncture strength equal to or greater than the above-mentioned value. The reinforcing layer may be made of a material that can improve rigidity by increasing its thickness, or a material that has relatively high rigidity, such as a resin. Examples of resins include polyethylene terephthalate (PET), nylon, polybutylene terephthalate (PBT), polypropylene (PP), and polyethylene (PE). Nylon is preferred because it has high puncture strength.

[0039] (b) Adhesive layer The surface material for foam insulation boards of the present disclosure may have an adhesive layer disposed between the aluminum foil and the resin film, between the resin film and the reinforcing layer, between the aluminum foil and the reinforcing layer, or the like.

[0040] As the material for such an adhesive layer, conventionally known adhesives (for example, pressure-sensitive adhesives, thermoplastic adhesives, and curable adhesives) can be used.

[0041] 5.Other The foam insulation board facing material of the present disclosure is preferably flexible. The foam insulation board facing material of the present disclosure is placed on at least one side of the foam insulation material and is used to produce the foam insulation board.

[0042] B. Foam insulation board The foam insulation board of the present disclosure comprises a foam insulation material and the above-mentioned foam insulation board surface material arranged on at least one side of the foam insulation material, and the foam insulation board surface material is arranged so that the resin film faces the foam insulation material.

[0043] Figure 2 is a schematic cross-sectional view showing an example of a foam insulation board according to the present disclosure. Note that Figure 2 has already been explained in the section "A. Surface material for foam insulation board" above, so further explanation will be omitted here.

[0044] The foam insulation board of the present disclosure includes the foam insulation board facing material described above, which prevents the accumulation of insulating gas between the foam insulation material and the foam insulation board facing material during combustion, thereby suppressing expansion. Therefore, the foam insulation board can meet the requirements for obtaining non-combustible certification in heat release tests. Furthermore, the foam insulation board of the present disclosure can suppress appearance defects during manufacturing. Each component of the foam insulation board of the present disclosure is described below.

[0045] 1. Surface material for foam insulation board The surface material for the foam insulation board in the present disclosure may be arranged on at least one side of the foam insulation board, for example, it may be arranged on one side of the foam insulation board or on both sides of the foam insulation board.

[0046] The surface material for foam insulation boards has been explained in detail in the above section "A. Surface material for foam insulation boards," so a detailed explanation will be omitted here.

[0047] 2.Foam insulation The foam insulation material in this disclosure is composed of a rigid material with thermal insulating properties. Examples of foam insulation materials that can be used include those commonly used in insulation boards, such as rigid urethane foam and phenolic foam. Examples of insulating gases enclosed within the internal bubbles include fluorocarbon gases such as CFCs (chlorofluorocarbons), HCFCs (hydrochlorofluorocarbons), and HFCs (hydrofluorocarbons).

[0048] Rigid urethane foams are primarily formed by the reaction of hydroxyl groups (OH groups) with isocyanate groups, and generally include isocyanurate foams, which are included in the definition of rigid urethane foam. Rigid urethane foams can be formed, for example, using a polyol compound having a hydroxyl group (OH group), an isocyanate compound having an isocyanate group, and a blowing agent. The polyol compound is not particularly limited, and examples thereof include polyether polyols, polyester polyols, and polyether ester polyols. The polyol compounds may be used alone or in combination of two or more. Examples of isocyanate compounds that can be used include aliphatic or aromatic polyisocyanates having two or more isocyanate groups, mixtures thereof, and modified polyisocyanates obtained by modifying them.

[0049] The phenolic foam can be formed using, for example, a phenolic resin, a foaming agent, a hardener, and the like.

[0050] The foaming agent may be, for example, a fluorine-based foaming agent. Specifically, a fluorocarbon material with low thermal conductivity, particularly a hydrofluorocarbon (HFC) material, may be used. The raw materials for the foam insulation may contain, for example, a catalyst, an additive, a flame retardant, etc.

[0051] The planar shape of the foam insulation is not particularly limited, and may be, for example, a rectangular shape, a polygonal shape, a circular shape, or the like. It can be cut into any shape, such as a square or rectangular shape, and used.

[0052] 3.Foam insulation board In the foam insulation board of the present disclosure, the foam insulation board facing material may be disposed on at least one side of the foam insulation material. For example, (i) the foam insulation board facing material may be disposed on both sides of the foam insulation material, (ii) the foam insulation board facing material may be disposed on one side of the foam insulation material with the other side exposed, or (iii) the foam insulation board facing material may be disposed on one side of the foam insulation material with another facing material disposed on the other side of the foam insulation material.

[0053] As the other surface materials, surface materials generally used for insulating boards can be used, such as glass paper, plastic sheets, moisture-proof paper, calcium carbonate paper, resin-impregnated paper, coated paper, nonwoven fabric, etc.

[0054] (1) Thickness The thickness of the foam insulation board of the present disclosure is, for example, 10 mm or more, and preferably 50 mm or more. If the thickness is above this value, the volume of the foam insulation increases, and the gas generated from the foam insulation during the heat generation test also increases, so the effects of the present invention can be more significantly obtained. On the other hand, the thickness of the foam insulation board of the present disclosure is generally 200 mm or less, and preferably 100 mm or less.

[0055] (2) Ash content The foam insulation board of the present disclosure has an ash content of, for example, 10% by mass or more and 90% by mass or less when heated to 600°C. The ash content can be measured, for example, using the method described in the Examples. If the ash content is above this value, the proportion of aluminum foil in the foam insulation board is sufficient, which is preferable because it increases the strength of the surface material. On the other hand, if the ash content is below this value, it is preferable from the standpoint of cost.

[0056] 4.Other The foam insulation board can be manufactured using a conventional method for manufacturing an insulation board. For example, a mold (foam molding mold) consisting of a lower mold and an upper mold and having a cavity for a foam insulation material of the desired thickness is used. A foam insulation board facing material of the present disclosure is placed on the bottom of the cavity in the lower mold, with the resin film facing upward, and a foam insulation composition is injected into the cavity with the temperature adjusted to, for example, 120°C. Then, the upper mold, in which another foam insulation board facing material of the present disclosure is set with the resin film facing downward, is placed over the lower mold and closed. The foam insulation composition is foamed in the cavity, and the molded product is then demolded. The closed cell ratio is preferably 10 to 40%. The closed cell ratio in the present invention is a value measured in accordance with ASTM D 2856. The rigid urethane foam used in the foam insulation has self-adhesive properties and is bonded to the facing material by the integrated foaming method described above. To improve adhesion, a general adhesive may be used on the surface of the facing material that comes into contact with the foam insulation material.

[0057] The foam insulation board of the present disclosure can be used, for example, as an insulating material for use in buildings and the like.

[0058] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and any configuration that is substantially identical to the technical idea described in the claims of the present disclosure and that provides similar effects is included within the technical scope of the present disclosure. [Example]

[0059] The present disclosure will be described in more detail below with reference to examples and comparative examples.

[0060] [Example 1] (Manufacturing surface materials for foam insulation boards) A 9 μm thick aluminum foil was prepared. A 12 μm thick PET film was prepared as a resin film. A 12 μm thick PET film was prepared as a reinforcing layer. These were bonded together via an adhesive layer to produce a 39 μm thick foam insulation board surface material with a layer structure of PET (12 μm) / PET (12 μm) / aluminum foil (9 μm).

[0061] (Manufacture of foam insulation board) A mold (foam molding mold) consisting of a lower mold and an upper mold and having a cavity for a foam insulation material of the desired thickness was used, and the resulting foam insulation board facing material was placed on the bottom of the cavity in the lower mold with the resin film facing up as the back facing material, and a foam insulation composition (polyol compound, isocyanate compound, and fluorine-based blowing agent) for forming a rigid urethane foam was injected into the cavity with the temperature adjusted to 120° C. Then, another foam insulation board facing material was prepared, and the upper mold of the mold was set so that the resin film faced down, and the mold was closed to cover the lower mold, and the foam insulation material composition was foamed in the cavity, and the molded product was then demolded to obtain a foam insulation board with a thickness of 50 mm.

[0062] [Example 2] A 52 μm-thick surface material for a foam insulation board having a layer structure of PET (12 μm) / nylon (25 μm) / aluminum foil (9 μm) was produced in the same manner as in Example 1, except that a 25 μm-thick nylon was used as the reinforcing layer. A foam insulation board was also obtained in the same manner as in Example 1, except that the obtained surface material for a foam insulation board was used.

[0063] [Example 3] An aluminum foil having a thickness of 12 μm was prepared. A PET film having a thickness of 12 μm was also prepared as a resin film. These were bonded together via an adhesive layer to produce a surface material for a foam insulation board having a thickness of 27 μm and a layer structure of PET (12 μm) / aluminum foil (12 μm). A foam insulation board was also obtained in the same manner as in Example 1, except that the resulting surface material for a foam insulation board was used.

[0064] [Example 4] A 42 μm thick foam insulation board surface material having a layer structure of PET (12 μm) / PET (12 μm) / aluminum foil (12 μm) was produced in the same manner as in Example 1, except that a 12 μm thick aluminum foil was used. A foam insulation board was also obtained in the same manner as in Example 1, except that the obtained foam insulation board surface material was used.

[0065] [Example 5] A 55 μm thick foam insulation board surface material having a layer structure of PET (12 μm) / nylon (25 μm) / aluminum foil (12 μm) was produced in the same manner as in Example 1, except that a 12 μm thick aluminum foil was used and a 25 μm thick nylon was used as the reinforcing layer. Further, a foam insulation board was obtained in the same manner as in Example 1, except that the obtained foam insulation board surface material was used.

[0066] [Example 6] An aluminum foil having a thickness of 35 μm was prepared. A PET substrate having a thickness of 12 μm was also prepared as a resin film. These were bonded via an adhesive layer to produce a 50 μm thick foam insulation board surface material having a layer structure of PET (12 μm) / aluminum foil (35 μm). A foam insulation board was also obtained in the same manner as in Example 1, except that the foam insulation board surface material obtained was used.

[0067] [Example 7] Except for using 35 μm thick aluminum foil instead of 9 μm thick aluminum foil, a 65 μm thick foam insulation board surface material having a layer structure of PET (12 μm) / PET (12 μm) / aluminum foil (35 μm) was produced in the same manner as in Example 1. Further, a foam insulation board was obtained in the same manner as in Example 1 except for using the foam insulation board surface material obtained.

[0068] [Example 8] Except for using 35 μm thick aluminum foil instead of 9 μm thick aluminum foil, a 78 μm thick foam insulation board surface material having a layer structure of PET (12 μm) / nylon (25 μm) / aluminum foil (35 μm) was produced in the same manner as in Example 2. Further, a foam insulation board was obtained in the same manner as in Example 1, except for using the foam insulation board surface material obtained.

[0069] (Comparative Example 1) A foam insulation board was prepared, having a layer structure of PE film (35 μm) / PE film (15 μm) / aluminum foil (20 μm), with a 70 μm thick foam insulation board surface material attached to both sides of a foam insulation material made of rigid urethane foam.

[0070] (Comparative Example 2) A foam insulation board was prepared in which aluminum foil (30 μm) was attached to both sides of a foam insulation material made of rigid urethane foam via a coating agent.

[0071] (Comparative Example 3) A foam insulation board was prepared, having a layer structure of PE film (40 μm) / kraft paper (170 μm) / PE film (20 μm) / aluminum foil (7 μm) / primer layer, with a 240 μm thick foam insulation board surface material attached to both sides of a foam insulation material made of rigid urethane foam.

[0072] Comparative Example 4 A 21 μm thick surface material for a foam insulation board having a layer structure of PET (12 μm) / aluminum foil (6 μm) was produced in the same manner as in Example 3, except that a 6 μm thick aluminum foil was used instead of the 12 μm thick aluminum foil. A foam insulation board was also obtained in the same manner as in Example 1, except that the obtained surface material for a foam insulation board was used.

[0073] (Comparative Example 5) A 24 μm thick surface material for a foam insulation board having a layer structure of PET (12 μm) / aluminum foil (9 μm) was produced in the same manner as in Example 3, except that a 9 μm thick aluminum foil was used instead of the 12 μm thick aluminum foil. A foam insulation board was also obtained in the same manner as in Example 1, except that the obtained surface material for a foam insulation board was used.

[0074] <Puncture strength> The puncture strength of the foam insulation boards (i.e., the integrated surface material for foam insulation boards and the foam insulation material) in Examples 1 to 8 and Comparative Examples 1 to 5 from the aluminum foil side was measured using the following method. The results are shown in Tables 1 and 2. Test pieces were cut out of the integrated surface material and foam insulation material (rigid urethane foam) measuring 50 mm x 50 mm. The test pieces were fixed in place, and a semicircular needle with a diameter of 1.0 mm and a tip radius of 0.5 mm was pierced into the center at a rate of 50 ± 5 mm per minute. The maximum stress until the needle penetrated was measured, and the puncture strength was obtained.

[0075] <Indentation elastic modulus> The indentation elastic modulus of the resin film was measured as follows for the surface materials for foam insulation boards in Examples 1 to 8 and Comparative Examples 1 to 5. The results are shown in Tables 1 and 2. The indentation elastic modulus was measured by the following measurement method. (Measurement method) In accordance with ISO 14577:2015, the indentation modulus was measured on the cross-section of the sample using an ultra-microload hardness tester equipped with a Vickers indenter (a diamond indenter with a square pyramidal indenter with a 136° facing angle) at approximately 23°C and 60% RH. Measurements were performed at an indentation speed of 0.1 μm / s, an indentation depth of 2 μm, a hold time of 5 seconds, and a withdrawal speed of 0.1 μm / s. The ultra-microload hardness tester used was a Picodentor HM500 (Fisher Instruments). At least five samples were measured for each condition, and the average of these measurements was used as the indentation modulus value for that condition. The cross-section of the sample was obtained by cutting the outer periphery of the sample from the surface material, fixing it with a curing resin adhesive, and then cutting the fixed sample in the thickness direction with a diamond knife, revealing the exposed cross-section. The thickness of each film used to calculate the indentation modulus was measured by optical microscopy of the cut cross-section.

[0076] The following evaluations were carried out on the heat insulating boards obtained in Examples 1 to 8 and Comparative Examples 1 to 5. The results are shown in Tables 1 and 2. <Cone calorimeter test evaluation> The heat generation evaluation test was carried out on the obtained heat insulating board using a cone calorimeter test in accordance with ISO5660-1:2002. The amount of radiant heat was 50 kW / m 2 Products that met all of the requirements for obtaining non-combustible certification (the following requirements (i) to (iii)) were evaluated as ◯, and products that did not meet even one of them were evaluated as ×. The equipment used was a cone calorimeter C-3 manufactured by Toyo Seiki Seisakusho. (1) The total heat output for 20 minutes after the start of heating is 8MJ / m 2 Is less than or equal to (2) For 20 minutes after the start of heating, there are no cracks or holes that penetrate to the back surface that are harmful to fire prevention. (3) For 20 minutes after the start of heating, the heat generation rate is 200 kW / m for 10 seconds or more. 2 Don't exceed That

[0077] <Appearance evaluation> The appearance of the resulting heat insulating board was visually observed and evaluated according to the following criteria. Evaluation criteria ◎: No wrinkles or streaks 〇: There are some wrinkles. No streaks. △: There are some wrinkles and some lines where the aluminum does not fold into the foam insulation. ×: Wavy wrinkles are present on the entire surface, and there are also creases where the aluminum has folded into the foam insulation.

[0078] <Ash residue evaluation> Measurement samples were taken from the resulting foam insulation board, and the ash residue was measured using the following method when heated to 600°C. The results are shown in Tables 1 and 2. Measurement samples were taken by cutting from the insulation board integrated with the surface material. The mass of the measurement sample was measured using a simultaneous thermogravimetry / differential thermal analyzer (TG-DTA). After measuring the mass, the sample was heated from room temperature to 600°C at a rate of 10°C / min in an aluminum pan under air, and then heated at 600°C for 30 minutes to incinerate the measurement sample. The post-heating mass was expressed as a percentage of the pre-heating mass. The thermogravimetry / differential thermal analyzer used was a TG8120 manufactured by Rigaku Corporation.

[0079] [Table 1]

[0080] [Table 2]

[0081] As shown in Tables 1 and 2, the foam insulation board surfacing materials of Examples 1 to 8 produced foam insulation boards that met the requirements for non-combustibility certification in the cone calorimeter test and were able to suppress poor appearance when integrated with the foam insulation. On the other hand, the foam insulation board surfacing materials of Comparative Examples 1 and 3 had a PE resin film on the foam insulation side, resulting in a low indentation modulus. The foam insulation boards using these materials burned in the cone calorimeter test and did not meet the requirements for non-combustibility certification. This is thought to be due to gas accumulation between the surfacing material and the foam insulation, causing swelling and peeling. Furthermore, the foam insulation boards using the foam insulation board surfacing material of Comparative Example 2 had poor appearance because they did not have a resin film. The foam insulation board surfacing materials of Comparative Examples 4 and 5 had low strength, resulting in poor appearance when integrated with the foam insulation. [Explanation of symbols]

[0082] 1. Surface material for foam insulation board 2...aluminum foil 3... Resin film 4... Reinforcement layer 10...Insulation board

Claims

1. A surface material for a foam insulation board having an aluminum foil and a resin film arranged on one side of the aluminum foil, The surface material for the foam insulation board has a thickness of 25 μm or more and 80 μm or less, and when the surface of the resin film opposite the aluminum foil is integrated with the foam insulation material as the foam insulation material side, the puncture strength from the aluminum foil side is 6.1 N / Φ1 mm or more, The surface of the resin film opposite to the aluminum foil constitutes the surface of the foam insulation board surface material, The resin film has an indentation elastic modulus of 1000 MPa or more, The foam insulation board is a surface material for foam insulation boards that meets the following three requirements for obtaining non-combustible certification in a heat generation evaluation test using a cone calorimeter test in accordance with ISO 5660-1:2002. <Conditions> (1) The total heat generation amount for 20 minutes after the start of heating is 8 MJ / m 2 or less. (2) For 20 minutes after the start of heating, there are no cracks or holes that penetrate to the back surface and are harmful to fire prevention. (3) For 20 minutes after the start of heating, the heat generation rate must not exceed 200 kW / m 2 for 10 seconds or more.

2. 2. The surface material for foam insulation board according to claim 1, wherein the glass transition temperature of the resin contained in the resin film is 60°C or higher.

3. The surface material for a foam insulation board according to claim 1 or claim 2, wherein the resin film contains polyethylene terephthalate.

4. The ratio of the thickness of the aluminum foil to the thickness of the foam insulation board surface material (thickness of the aluminum foil / thickness of the foam insulation board surface material) is 0.075 or more and 0.70 or less, according to any one of claims 1 to 3. A foam insulation board surface material.

5. foam insulation; The foam insulation board surface material according to any one of claims 1 to 4 is disposed on at least one side of the foam insulation material, The foam insulation board surface material is arranged so that the resin film faces the foam insulation material.

6. 6. The foam insulation board according to claim 5, wherein the thickness of the foam insulation board is 10 mm or more.

7. 7. The foam insulation board according to claim 5, wherein the ash content when heated to 600°C is 10% by mass or more and 90% by mass or less.

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