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 the prior art. [Solution] A thermal control material comprising: a sealed pouch made of a film including a metal layer; a core material contained in the sealed pouch, having outer dimensions that fit the inner dimensions of the sealed pouch and having a recess on its surface; and a fluid held in the core material.

Description

[Technical Field]

[0001] The present disclosure relates to a thermal control material, a thermal control sheet application kit, and a method for manufacturing a thermal control material. [Background technology]

[0002] BACKGROUND ART A heat-absorbing pack is known which is used to cover the entire or part of the surface of a steel material and surround and cover the periphery with a fire-resistant insulating material or the like (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 7-133640 Summary of the Invention [Problem to be solved by the invention]

[0004] Patent Document 1 discloses a method of using "a heat-absorbing material such as a liquid or gel-like substance, such as water or a water-impregnated polymer, or other liquid, in cells formed between two sheets of film, sandwiching aluminum foil between nylon film and polyethylene film, and then heat-sealing the periphery" to fix to steel or the like with welding pins or the like to create a fire-resistant coating for steel frames.

[0005] Fig. 16 is a cross-sectional view showing the above-mentioned conventionally known heat-absorbing pack attached to a steel material (column). Fig. 17 is a cross-sectional view showing the above-mentioned conventionally known heat-absorbing pack attached to the back surface of a corrugated steel roofing material. Heat-absorbing pack 400 includes a pouch formed by two films 402A, 402B, and heat-absorbing material 404 made of a liquid or gel-like substance contained inside the pouch. Heat-absorbing pack 400 is fixed by welding pins 406 to the back surface of a corrugated steel half-roof 84 supported by columns 42 or columns 80 and beams 82.

[0006] As shown in Figures 16 and 17, conventionally known heat-absorbing packs 400 have a structure in which liquid or gel-like heat-absorbing material 404 is directly sealed within the bag. This can lead to the following problems depending on the installation conditions. First, the heat-absorbing material 404 may become unevenly distributed. When installed vertically on a pillar 42, as shown in Figure 16, or on the curved surface of the underside of a half-height roof 84, as shown in Figure 17, the heat-absorbing material 404 within the bag may shift due to gravity and become unevenly distributed. This uneven distribution can result in uneven heat absorption performance, resulting in localized overheating and poor insulation. Second, installation is difficult. 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 reduced installation accuracy. In particular, when installed on curved surfaces or vertically, the heat-absorbing pack 400 may not maintain its intended shape, which can affect its heat-absorbing performance. Third, durability is an issue. If the endothermic material 404 continues to be biased, excessive stress is applied to a portion of the endothermic pack 400, increasing the risk of breakage or leakage over long-term use. The present disclosure solves at least one of the problems associated with the prior art described above. [Means for solving the problem]

[0007] The thermal control material of the present disclosure is a thermal control material comprising: a sealed pouch made of a film including a metal layer; a core material contained in the sealed pouch bag, having outer dimensions that fit the inner dimensions of the sealed pouch and having a recess on its surface; and a fluid held in the core material.

[0008] The method for manufacturing a thermal control material disclosed herein includes separating a swollen polymer absorbent material from a used absorbent sanitary product, and sealing the separated swollen polymer absorbent material together with a core material having a recess on its surface in a pouch made of a film including a metal layer, wherein the core material has outer dimensions that fit the inner dimensions of the sealed pouch. [Effects of the Invention]

[0009] According to the thermal control material of the present disclosure, at least one of the problems of the conventional technology can be solved. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a partial cross-sectional view showing a first embodiment of a thermal control material. [Figure 2] 1 is a widthwise cross-sectional view of a first embodiment of a thermal control material. [Figure 3] FIG. 1 is a perspective view showing an example of how a thermal control material is used in a wooden house. [Figure 4] FIG. 1 is a perspective view showing an example of a usage form in which the thermal control material is applied to a steel frame structure as a fire-resistant covering material. [Figure 5] FIG. 2 is a cross-sectional schematic diagram of a thermal control material attached to a pillar. [Figure 6] FIG. 10 is a perspective view showing another example of application of a thermal control material in a steel frame structure. [Figure 7] FIG. 10 is a perspective view showing another example of application of a thermal control material in a steel frame structure. [Figure 8] FIG. 10 is a front view showing an example of application of a thermal control material to piping and a valve. [Figure 9] This is a cross-sectional view showing the state in which thermal control material has been applied to the back surface of a half-roof made of corrugated iron sheets. [Figure 10] FIG. 4 is a partial cross-sectional view showing a second embodiment of the thermal control material. [Figure 11] FIG. 10 is a cross-sectional end view of a thermal control material according to a modified example. [Figure 12] FIG. 2 is a plan view showing an example of a thermal control sheet. [Figure 13] FIG. 2 is a cross-sectional view of the thermal control sheet taken along line AA. [Figure 14] FIG. 10 is an explanatory diagram (cross-sectional view) of a thermal control sheet installation kit including an additional member and a thermal control sheet. [Figure 15] FIG. 2 is a flow diagram of a method for manufacturing a thermal control material. [Figure 16] FIG. 1 is a cross-sectional view showing a state in which a conventionally known heat absorption pack is installed on a steel material (pillar). [Figure 17] FIG. 1 is a cross-sectional view showing a state in which a conventionally known heat absorption pack is installed on the back surface of a half-fold roof made of corrugated iron sheets. DETAILED DESCRIPTION OF THE INVENTION

[0011] The first thermal control material of the present disclosure is a thermal control material comprising a sealed pouch made of a film including a metal layer, a core material contained in the sealed pouch bag, having outer dimensions that fit the inner dimensions of the sealed pouch and having a recess on its surface, and a fluid held in the core material.

[0012] The first thermal control material comprises a sealed pouch made of a film including a metal layer, a core material having outer dimensions that fit the inner dimensions of the sealed pouch and a recessed portion on its surface, and a fluid held within the core material. This configuration provides the excellent advantages of adequately protecting the core material and fluid while preventing the intrusion of humidity, oxygen, and other external elements, and stably and effectively storing and releasing heat within the core material. Furthermore, because the core material has outer dimensions that fit the inner dimensions of the sealed pouch, movement of the core material within the sealed pouch is suppressed. Furthermore, because the core material has a recessed portion on its surface, the fluid is easily held within the recessed portion. This prevents uneven distribution of the fluid within the sealed pouch, even when the material is installed vertically or in a curved section. The first thermal control material allows the fluid to exhibit uniform heat absorption performance regardless of the installation location or installation form.

[0013] A second thermal control material of the present disclosure is the first thermal control material, wherein the fluid includes a polymer absorbent material that is swollen with water.

[0014] The second thermal control material includes a polymer absorbent that is swollen with water as a fluid. The polymer absorbent absorbs water and swells, exhibiting excellent heat insulating, heat absorbing, and heat shielding properties, and can effectively suppress heat conduction. Furthermore, by combining the swollen polymer absorbent with a core material having recesses, fluid retention is improved, making it easier to handle at the construction site and allowing for more uniform heat absorbing performance.

[0015] The third thermal control material of the present disclosure is a thermal control material in which, in the second thermal control material, the core material is a nonwoven sheet formed by laminating fibers, and the polymer absorbent material is dispersed and held in the nonwoven sheet.

[0016] The third thermal control material has a nonwoven sheet made of laminated fibers as a core material, and the polymer absorbent material is dispersed and held in the nonwoven sheet. With this configuration, the porous structure of the nonwoven sheet uniformly holds the polymer absorbent material, stabilizing the distribution of the swollen polymer absorbent material. In addition, the flexibility of the nonwoven sheet makes the thermal control material more adaptable to a variety of installation locations.

[0017] A fourth thermal control material of the present disclosure is the third thermal control material, wherein 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 with high rigidity and durability, while the glass fiber mat stably holds the swollen polymer absorbent material. Furthermore, the glass fiber mat's high heat resistance improves the fire resistance of the thermal control material. Furthermore, the glass fiber mat itself has low water absorption, and almost all of the moisture is held by the polymer absorbent material, which makes it easier to maintain a more uniform distribution of moisture within the core material, allowing for more uniform heat absorption performance by fluids regardless of the installation location or installation form.

[0019] A fifth thermal control material of the present disclosure is the first thermal control material, wherein the core material includes the fluid that is independently sealed.

[0020] The fifth thermal control material has a core material with a fluid sealed independently. This configuration allows each core material to hold the fluid independently, preventing all of the fluid from leaking even if one core material is damaged. Furthermore, the fluid distribution within the core material is easily maintained uniformly, further improving the reliability of the thermal control material. This also has the effect of making it easier to handle and install at the construction site.

[0021] A sixth thermal control material of the present disclosure is a thermal control material in which a plurality of types of the fluids are retained in the first thermal control material.

[0022] The sixth thermal control material is configured to hold multiple types of fluids. This allows it to exhibit heat insulating and heat blocking properties according to the characteristics of each fluid, giving it the flexibility to adapt to different environmental conditions and applications. For example, by combining a water-swollen polymer absorbent (gel) with a fluid with different physical properties, such as air, it is possible to optimize the heat conduction suppression effect.

[0023] The first thermal control sheet installation kit of the present disclosure comprises a thermal control sheet formed by continuously arranging the thermal control material described in any one of items 1 to 6 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 a recess on its surface, and a polymer absorbent material dispersed in the second core material, and is configured so 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 thermal control material becomes approximately flat.

[0024] The first thermal control sheet installation kit is configured to cover the connecting parts of the thermal control material, which is arranged in a continuous tile-like pattern, with a cap mold, thereby improving the thermal insulation and fire resistance of the connecting parts. Because the cap mold has a structure that includes a core material, the surface of the connecting parts is finished almost flat, improving the appearance and safety after installation.

[0025] The second thermal control sheet installation kit of the present disclosure is a thermal control sheet installation kit comprising: a thermal control sheet formed by continuously arranging the thermal control material described in any one of items 1 to 6 in a tile-like shape; and an edge cap that covers the peripheral portion of the thermal control material, wherein the edge cap comprises a long film including the metal layer formed with 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 material dispersed in the third core material, wherein the three core materials are configured to be able to hold the peripheral portion of the sealed pouch by clamping it in the center when viewed in cross section.

[0026] The second thermal control sheet installation kit is equipped with edge caps that protect the peripheral edges of the thermal control material, enabling installation without compromising its thermal insulation or heat-shielding properties. The edge caps have a U-shaped cross section, and by securely clamping the peripheral edges, they have the effect of achieving a high level of sealing that is resistant to external influences.

[0027] The first method for manufacturing a thermal control material of the present disclosure includes separating a swollen polymer absorbent material from a used absorbent sanitary product, and sealing the separated swollen polymer absorbent material together with a core material having a recess on its surface in a pouch made of a film including a metal layer, wherein the core material has outer dimensions that fit the inner dimensions of the sealed pouch.

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

[0029] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. The following examples illustrate devices and methods for embodying the technical ideas of the disclosure, but the technical ideas of the disclosure are not limited to those described below. Various modifications can be made to the technical ideas of the disclosure within the scope of the claims. It should be noted that the drawings are schematic and may differ from the actual product.

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

[0031] The thermal control material 10 includes a sealed pouch 12C formed by heat-sealing the peripheral edges 20 of two laminated films 12A and 12B, each including a metal layer, and a core material 14 housed within the sealed pouch 12C and having outer dimensions that match the inner dimensions of the sealed pouch 12C. An adhesive layer 18 is disposed on one surface of the laminated film 12A. The core material 14 is a binderless porous material formed by integrating multiple laminated glass fiber nonwoven sheets using a needle punch process. A polymer absorbent material 16 is dispersed within the core material 14. The polymer absorbent material 16 is held in voids within the core material 14, which is made of glass fiber. Water (not shown) is also enclosed within the pouch, and the polymer absorbent material 16 absorbs the water, swells, and becomes gel-like.

[0032] The laminated films 12A and 12B are the main components forming the sealed pouch 12C. The two laminated films 12A and 12B are heat-sealed at the four sides of their peripheral edge 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 area and size of the application area. As will be described in detail later, one basic use of the thermal control material 10 is to apply it to an area where heat insulation is desired. In this case, a single thermal control material 10 can be used to cover the entire application area, or multiple thermal control materials 10 can be applied in a tile-like pattern. In this case, the thermal control materials 10 may be applied in part or in whole, overlapping each other. The appropriate size of the thermal control material 10, i.e., the size and thickness of the sealed pouch 12C, varies depending on the application method as described above. However, in consideration of ease of transportation and handling, one embodiment preferably has a size of 10 cm to 500 cm and a thickness of 0.3 cm to 3 cm.

[0033] The laminated films 12A and 12B constituting the sealed pouch 12C preferably have a multilayer structure including at least a metal layer and a resin layer. This provides high heat-shielding, light-shielding, and airtight properties. However, the laminated films 12A and 12B do not necessarily have to be laminated films, and may be in a form including only a metal layer, i.e., a metal foil. The layer structure and materials can be selected appropriately 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 prevents 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 light weight of the entire film. On the other hand, when higher thermal conductivity is required rather than heat-shielding properties, 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 a film consisting of only a metal layer (metal foil) is used, its thickness may be, for example, 10 μm to 200 μm.

[0035] The resin layer is a component that ensures the mechanical strength of the entire laminated film, improves durability, and provides heat sealing functionality. This resin layer may enable efficient sealing processing and maintain the flexibility of the film when forming a sealed pouch. The resin layer may be composed of one layer or multiple layers. The film may also have multiple resin layers. For example, the film may have a multilayer structure in which a metal layer is sandwiched between two resin layers.

[0036] For example, polyolefin resins can be used as the material for the resin layer. Among polyolefin resins, polyethylene (PE) has excellent flexibility, chemical resistance, and heat sealing properties 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) offers higher tensile strength and flexibility than standard polyethylene, making it particularly useful in multilayer structures. By using a multilayer film with a polyolefin resin layer on the inside, heat sealing becomes easier.

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

[0038] The resin layer may be composed of a single layer or multiple layers, and preferably, for example, a polyester layer as an outer layer for improving durability and printability and a polyethylene layer as an inner layer for imparting heat sealability are combined. Such a multilayer structure allows the properties of each layer to be optimized, enabling the overall performance to be high.

[0039] The resin layer may also contain additives. For example, a lubricant may be added to the resin layer to improve the surface smoothness of the film, or a UV absorber may be added to prevent deterioration due to ultraviolet rays. The thickness of the resin layer is preferably, for example, 10 μm to 200 μm. The thickness of the entire film, including the metal side, is preferably, for example, 50 μm to 400 μm.

[0040] The core material 14 is housed within a sealed pouch 12C formed by the laminate films 12A and 12B. The core material 14 has outer dimensions that match the inner dimensions of the sealed pouch 12C. In this specification, "outer dimensions that match the inner 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 outer dimensions of the core material 14 approximately match the inner dimensions of the sealed pouch 12C, and the core material is positioned within the sealed pouch 12C without shifting or tilting.

[0041] Such dimensional compatibility holds the core material 14 integrally within the sealed pouch 12C, and efficiently performs the main functions (thermal insulation, fire resistance, and heat shielding) of the thermal control material 10. Furthermore, since the core material 14 is structured to be in substantial contact with the inner wall of the sealed pouch 12C, the shape stability of the entire sealed pouch 12C is improved, and performance degradation due to external pressure or vibration is prevented.

[0042] On the other hand, the outer dimensions of the core 14 do not need to match the inner dimensions of the sealed pouch 12C perfectly, and a moderate amount of play is allowed to account for errors in the manufacturing and assembly processes. Specifically, even if the core 14 can move slightly within the sealed pouch 12C, this is allowed as long as it does not impair its essential functionality. This design ensures efficiency in the manufacturing process and makes it easy to insert and assemble the core 14.

[0043] In the thermal control material 10 of this example, the core material 14 is a binderless porous body formed by integrating multiple laminated glass fiber nonwoven sheets using needle punching. The size and thickness can be selected appropriately depending on the size and thickness of the thermal control material, and a thickness of 200 μm to 2.8 mm is preferable, for example. The porous body that is the core material is a laminate of glass wool molded into a felt-like shape, which is generally sometimes called a "glass fiber mat" or the like.

[0044] Glass fiber mats have traditionally been used for insulating flat and curved surfaces, but in the thermal control material 10 of this example, they are newly utilized as the core material 14. Because the glass fiber mat is formed binderless, it has a structure in which the fibers intertwine without the use of adhesive, and many interconnected pores are formed inside. These interconnected pores function as spaces for dispersing and retaining the polymer absorbent material 16 inside the core material 14, and serve to stably support the swollen polymer absorbent material 16.

[0045] Furthermore, the glass fiber mat has excellent thermal and mechanical stability, allowing it to maintain the shape of the core material 14 even in high-temperature environments and against external impacts. This characteristic makes it possible to maintain the performance of the entire thermal control material 10 for a long period of time. In addition, the surface of the glass fiber mat is formed with fine irregularities, which improve the retention of the polymer absorbent material 16 and help it to be uniformly dispersed when it absorbs water and swells.

[0046] The core material 14 of this example has physical properties that combine 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 is unlikely to become extremely thin or to break or be damaged. Specifically, the entanglement of the glass fibers that make up the core material 14 prevents significant deformation of the internal structure even when bent, maintaining uniformity. This characteristic makes it less likely that a sudden decrease in thickness or imbalance in rigidity will occur at the bent portion, making it easier to maintain the performance of the thermal control material 10. Furthermore, because the core material 14 has a porous structure, it has appropriate flexibility while also exhibiting the ability to return to its original shape after bending, demonstrating high adaptability in construction and usage environments.

[0047] Furthermore, the core material 14 can maintain its structural strength due to the intertwining 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 at construction sites where work involving bending and deformation is required. This ensures the performance and durability of the entire thermal control material 10.

[0048] Furthermore, because the core material 14 in this example is binderless, it has a structure that is less susceptible to degradation by chemical substances such as adhesives. As a result, long-term stability of the water absorption and heat absorption properties is ensured. Furthermore, by using a glass fiber mat as the core material 14, it is possible to realize a lightweight, high-strength thermal control material 10 while efficiently utilizing the internal space of the sealed pouch 12C. Furthermore, because 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 with long-term use, uneven distribution of moisture within the bag is easily suppressed. This effect is particularly noticeable when the bag is used vertically or in a bent section.

[0049] The core material 14 is not limited to the glass fiber mat of this example, and may be made of other materials and have other structures. As will be described later, a fluid that swells the polymer absorbent material 16 is sealed inside the sealed pouch 12C. In particular, if this fluid contains liquid water, the temperature inside the sealed pouch 12C is less likely to rise even if the temperature outside the thermal control material 10 becomes high. Therefore, even when the thermal control material 10 is used as a fire-resistant covering material, there are no limitations on the material of the core material 14, particularly on its fire resistance and heat resistance. For example, the core material 14 may be a 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. An example of a state in which "recesses are arranged on the surface" is a porous body, such as the glass fiber mat described above. In the case of a porous body, the pores may be interconnected pores that connect from one surface to the other, or may be non-interconnected pores, or may have a structure that includes 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 bodies formed by laminating fibers. Glass fiber mats, which are needle-punched fiber sheets, are also included in the category of nonwoven sheets. Other examples of nonwoven sheets include spunbond nonwoven fabrics, meltblown nonwoven fabrics, carbon fiber nonwoven fabrics, cellulosic nonwoven fabrics, and ceramic nonwoven fabrics. Spunbond nonwoven fabrics are made from thermoplastic polymers such as polypropylene (PP) and polyester (PET), and are integrated by thermally bonding the fibers. Spunbond nonwoven fabrics are lightweight and highly flexible. Meltblown nonwoven fabrics are formed by extruding resin into fine fibers to form high-density nonwoven fabrics. Meltblown nonwoven fabrics have fine pores, which allow for more efficient control of fluid diffusion. Carbon fiber nonwoven fabrics are made from heat-resistant and electrically conductive carbon fibers, and are suitable for high-temperature environments and special applications. Cellulosic nonwoven fabrics are made from natural cellulose fibers. Ceramic nonwoven fabrics are nonwoven fabrics made from ceramic fibers and have excellent fire resistance and heat resistance.

[0052] Foam materials, such as polyurethane foam and polystyrene foam, are materials with numerous closed or open cells inside. They are lightweight, easy to process, and suitable for retaining and dispersing fluids. The closed cells may hold gaseous fluids, while the open cells may hold liquid fluids. Sintered bodies are porous bodies formed by sintering ceramic or metal powder. They are suitable for high-temperature environments or when high mechanical strength is required. On the other hand, glass fiber mats are superior in terms of flexibility. Natural porous materials are sponge-like plant materials or porous bodies derived from animals. 3D-printed porous bodies can be appropriately designed with high-precision pore structures. They are often made from resin.

[0053] In addition to the above, the core material having recesses on its surface may also have an uneven surface structure. That is, it may have a plurality of protrusions instead of holes. In this case, the fluid can be held in the spaces (recesses) defined between the protrusions and by the laminated film. Alternatively, the protrusions may have hollow spaces within them, and the fluid may be sealed in these hollow spaces. In this case, the fluid is held within the protrusions, and such a configuration is also acceptable. Examples of core materials having an uneven surface structure include corrugated plates, pyramidal structures, and sheets having hollow protrusions, etc.

[0054] The corrugated plate is a hard or flexible plate-like material with a regular corrugation on its surface, and is preferably made of resin. The valleys of the corrugations function as recesses, forming spaces for retaining fluid. The pyramidal structure has multiple small protrusions arranged over the entire surface, and can retain fluid in the spaces between the protrusions. Although not particularly limited, it is preferably made of resin. The hollow protrusions have a hollow structure inside, allowing fluid to be sealed in the hollow space (for example, a structure used as air packing, etc.). This allows for both fluid retention performance and weight reduction of the entire core material.

[0055] Incidentally, the use of a core material has not been considered in conventionally known "endothermic packs" such as those described in Patent Document 1. One reason for this is their installation method. As described in Patent Document 1, conventionally known "endothermic packs" use so-called "welding pins" to secure the pack to steel or other materials. The "welding pins" are fixed by being directly welded to the steel, and the endothermic pack is installed via these welding pins. However, if the "welding pin" is inserted from the outside of the "endothermic pack" and a core material (especially a resin or glass core material) adheres to the welding pin, electrical conduction during welding can be hindered, resulting in problems such as the welding pin not being properly connected to the steel. Due to these problems, it has been difficult to use conventional installation methods for endothermic packs with built-in core materials. Conversely, because this installation method was previously assumed, the use of a core material was not considered, and the issues caused by the lack of a core material were not fully recognized. On the other hand, the thermal control material 10 of Example 1 does not necessarily require fixation with a welding pin, and employs a structure in which it is attached to an object with an adhesive layer 18. This structure was adopted because the thermal control material 10 has a core material 14, which makes it highly configurable, and application with the adhesive layer 18 is easy. Conventional "heat-absorbing packs" do not have a core material, so they are less configurable and stable application with the adhesive layer is difficult, and therefore their adoption has not been encouraged. Therefore, fixation with a welding pin has been the only option, which further hinders the use of a core material.

[0056] The core material 14 retains a fluid to improve the primary function of the thermal control material 10. The retained fluid is not particularly limited, but examples thereof 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 the other components include polymeric absorbents with swelling properties, antifreeze agents, preservatives, and disinfectants. Among these, water has a large specific heat capacity and is less likely to experience a rapid rise in temperature even when absorbing a large amount of thermal energy, making it more suitable as a fluid for the thermal control material. Furthermore, water has an excellent shielding effect against radiation (neutron rays, gamma rays, etc.), and therefore, when the thermal control material is used as a thermal insulating material in a nuclear reactor or related equipment, it can also be expected to provide a radiation shielding effect.

[0057] For example, a polymer absorbent material 16 added to water, in other words, a polymer absorbent material 16 that has absorbed water and swollen, is treated as a form of fluid in this specification. The polymer absorbent material 16 absorbs water and swells to become a gel, which is fluid. For example, acrylic acid-based polymers, cellulose-based polymers, and polyacrylamide-based polymers can be used as such polymer absorbents 16. Furthermore, chitosan, alginate, and the like can also be used as natural polymers.

[0058] The form of the polymer absorbent material 16 is not particularly limited, but powder, granules, fiber, or the like are preferred in that they can be dispersed more uniformly on or within the core material 14, or can be more easily held by the core material 14. For example, when the core material 14 is a glass fiber mat, if the polymer absorbent material 16 is powder or granules (this example), the polymer absorbent material 16 can be dispersed in the voids of the glass fiber mat, and if the polymer absorbent material 16 is fibrous, it can be molded simultaneously with the molding of the glass fiber mat.

[0059] There are no particular limitations on the amount of polymer absorbent material 16 contained in core material 14. In one embodiment, 1 g of polymer absorbent material 16 can absorb 50 to 300 mL of water, and therefore, the amount can be appropriately selected depending on the capacity of the sealed pouch 12C and the water absorption capacity of core material 14 itself. The hardness of thermal control material 10 can also be adjusted by the amount of polymer absorbent material 16 used.

[0060] The thermal control material 10 further includes an adhesive layer 18 on at least one main surface of the sealed pouch 12C. The thermal control material 10 is adhered and fixed to an object via the adhesive layer 18. The material and thickness of the adhesive layer 18 are not particularly limited and are selected appropriately depending on the application and the object. Examples of materials for the adhesive layer 18 include acrylic adhesives, silicone adhesives, and rubber adhesives. Acrylic adhesives have excellent heat resistance and weather resistance and can be used in a wide range of environments. On the other hand, silicone adhesives are suitable for adhesion in high-temperature environments, and rubber adhesives are suitable when flexibility is required. The material of the adhesive layer 18 can be selected appropriately depending on the application location and application environment of the thermal control material 10.

[0061] The thickness of the adhesive layer 18 is not particularly limited, but is preferably 10 to 2000 μm in one embodiment. When the thickness of the adhesive layer 18 is within this range, it is possible to achieve a higher degree of compatibility between adhesive performance and flexibility. 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 reliable fixation. On the other hand, for smooth surfaces, a thinner adhesive layer 18 can be used to achieve weight reduction and cost reduction.

[0062] Furthermore, the adhesive layer 18 does not need to be provided over the entire sealed pouch 12C, but may be provided in a partial area of ​​the main surface of the sealed pouch 12C. For example, if the adhesive surface of the object is partial, the adhesive layer 18 can be provided only in the necessary area, allowing for efficient use of materials. Furthermore, by making the adhesive layer 18 removable, it can also be used for temporary fixation. In this case, it is preferable to use a weakly adhesive material or a re-adhesive structure.

[0063] The thermal control material 10 may further include a release sheet (not shown) to protect the adhesive layer 18. The release sheet serves to prevent the adhesive layer 18 from being soiled or damaged from the outside until it is used. This allows the adhesive performance of the adhesive layer 18 to be maximized during application.

[0064] The material of the release sheet is preferably a flexible film material such as polyester (e.g., PET), polypropylene (PP), or polyethylene (PE). A release sheet made of paper is also applicable, and silicone-coated release paper in particular has excellent releasability from the adhesive layer 18.

[0065] The release sheet may be provided over the entire surface of the adhesive layer 18, or may be provided partially. For example, by providing a form in which a portion of the adhesive layer 18 is exposed, it is possible to facilitate alignment during construction. Furthermore, the release sheet may be provided with a tab portion that makes it easy to remove, if necessary. Such a tab portion improves workability at the construction site.

[0066] The thickness and rigidity of the release sheet are appropriately set depending on ease of handling and application. For example, a thickness in the range of 20 to 200 μm ensures sufficient protective performance while allowing easy peeling. Protective performance can be further improved by selecting a release sheet that is heat-resistant and waterproof.

[0067] The thermal control material 10 can be used for a variety of purposes in buildings and facilities. For example, it can be attached to the surface of the steel frame (beams and columns) of a building to be used as a fire-resistant covering material, or attached to the inside of a roof to be used as an insulating or heat-shielding material. It can also be attached to the inside of the walls of a wooden house to improve insulating performance, or wrapped around pipes and ducts to be used as an insulating and / or heat-shielding material. In this way, the thermal control material contributes to improving the heat retention and fire resistance of buildings and facilities.

[0068] Furthermore, the size of the thermal control material 10 can be adjusted appropriately depending on the application location. Specifically, by customizing the shape and dimensions of the product in advance, it can be made to fit perfectly to the shape and size of the application location. Furthermore, cutting and processing can be performed as needed at the application site, allowing for even greater flexibility. Because the thermal control material has an adhesive layer 18, it can be easily fixed by simply sticking it to the application location. Even if the adhesive layer 18 is not used, methods such as using bands or clips for fixing can be applied.

[0069] Furthermore, because the thermal control material 10 is flexible, it can be applied in close contact with not only flat surfaces but also curved surfaces. For example, by wrapping it around a cylindrical object such as a pipe or duct, it can completely cover the object and provide thermal insulation and heat shielding properties. In this case, the release sheet can be removed to expose the adhesive layer 18, and the material can be applied directly to the object, or the entire surface can be reinforced with tape after application.

[0070] 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 a heat insulating material within the wall structure of the wooden house 30.

[0071] The wall structure of a wooden house 30 constructed using a framework method comprises a floor 31 formed on a foundation 36, a base 32 placed on the base 36, and a framework structure consisting of a plurality of pillars 33 extending upward from the base 32, and is covered with an exterior wall material 34. The thermal control material 10 is placed between the pillars 33 within this wall structure, and plays a role in improving the thermal insulation performance of the entire house together with the exterior wall material 34.

[0072] The thermal control material 10 used in this example has a structure including a sealed pouch 12C and a core material 14, and the fluid held in the core material 14 exhibits heat insulating and heat absorbing effects. Unlike conventional on-site applied heat insulating materials such as urethane foam, the thermal control material 10 of this example is supplied as a ready-made product, and has the advantage that installation can be completed simply by attaching it between the pillars 33.

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

[0074] Furthermore, due to its flexibility, the thermal control material 10 of this example can be installed in close contact with areas with specific shapes, not just between pillars 33. For example, in areas along pillars 33 or foundations 32, the thermal control material 10 can be bent or partially processed as needed to meet the diverse needs of the installation site. Because the thermal control material 10 has a core material 14, even if the thermal control material 10 is cut, the gel inside does not immediately leak out, and it can be reused by resealing.

[0075] By applying the thermal control material 10 as shown in this example, the installation process is greatly simplified and the risk of installation defects is reduced. Furthermore, after installation, the fluid held within the core material 14 effectively controls heat and prevents heat from entering from the external environment. Furthermore, when the adhesive layer 18 of the thermal control material 10 is provided with a release sheet, handling during installation is easier, improving work efficiency on site.

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

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

[0078] In this example, the thermal control material 10 is attached as a fire-resistant covering material to the outer periphery of the H-shaped steel beam 43, the column 41 of the upper floor, and the column 42 of the lower floor. Fig. 5 is a cross-sectional schematic diagram of the thermal control material 10 attached to the column 42 of the lower floor. The thermal control material 10 has a structure in which the core material 14 is housed in a sealed pouch 12C, and the fluid held inside is dispersed and held uniformly throughout without uneven distribution, allowing the entire thermal control material 10 to exhibit uniform fire resistance.

[0079] By attaching the thermal control material 10 along the flange and web portions of the H-shaped steel, it blocks thermal bridges in the steel structure 40 and suppresses heat exchange with the external environment. In addition to functioning as a fire-resistant coating, it also improves the thermal 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 H-shaped steel and columns.

[0080] Furthermore, the thermal control material 10 of this example can be cut or processed as needed depending on the installation location, and is installed after being adjusted to the required size. For example, when attaching it to the outer periphery of columns 41, 42 (upper floor columns and lower floor columns), the thermal control material 10 can be installed while being in close contact with the curved surface, thereby efficiently covering the entire area. It can also be attached accurately to the joint between the web and flange of the H-shaped steel beam 43.

[0081] In this way, the thermal control material 10 of this example can be applied to the steel frame structure 40 of a building to improve the thermal insulation and heat shielding performance, as well as to impart fire resistance. Furthermore, since it can be directly attached to the steel frame structure 40 via the adhesive layer 18 during construction, it is easy to install. Furthermore, when the material is provided with a release sheet, it is easy to handle at the construction site, allowing for efficient installation.

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

[0083] The steel frame structure 50 is composed of an H-shaped steel 52 and a square steel pipe 51, and the H-shaped steel 52 has a structure in which a plurality of ducts pass through the steel frame structure. Note that the length ratio of the web and flange of the H-shaped steel 52 in this example has been adjusted for the convenience of explanation and differs from the actual length. In this example, the material is provided as a pre-cut thermal control material 100 processed into a shape that fits the through-hole 54 provided in the web 53 of the H-shaped steel, ensuring thermal insulation when the duct 55 passes through the hole.

[0084] A through hole 54 for passing a duct 55 is provided in the web of the H-shaped steel 52, and a pre-cut thermal control material 100 is applied, with a hole 56 pre-drilled to correspond to this opening. The pre-cut thermal control material 100 has a structure in which the hole 56 is formed in the center of the thermal control material 10 as described above, and the periphery of the hole 56 is heat-sealed, allowing the duct 55 to pass through this hole 56. Typically, the diameter of the through hole 54 provided in the H-shaped steel 52, i.e., the diameter of the duct 55, is predetermined, so the pre-cut thermal control material 100 can be prepared in advance. This allows the thermal control material to be installed quickly and accurately at the construction site without additional processing. An adhesive layer 18 (not shown) is provided on the back surface (the side facing the H-shaped steel 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 52 by the adhesive layer 18.

[0085] Furthermore, the thermal control material 10 is wrapped around the duct 55 itself, creating a structure that suppresses heat exchange inside and outside the duct 55. The thermal control material 10 wrapped around the duct 55 has an adhesive layer 18, so it can be easily fixed in place during installation. This effectively covers the entire duct 55, improving thermal insulation and heat blocking performance.

[0086] The thermal control material 10 in this example is installed in a way that completely covers the contact area between the web of the H-shaped steel 52 and the duct 55, effectively preventing the thermal bridge phenomenon. In addition, because the thermal control material 10 is flexible, it can be adjusted to fit the shape of the duct 55 and improve adhesion, thereby improving the heat insulation and heat absorption performance at the connection.

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

[0088] 8 is a tubular member for transporting a fluid, and has thermal control material 10 wrapped around its outer periphery. Thermal control materials 61 and 200, each adjusted to a special shape, are also applied to a valve bonnet 62 and a valve box 63, which are installed midway along the piping 64. In this example, thermal control materials 10, 61, and 200 are applied so as to cover the entirety of these components, thereby preventing heat loss and reducing the thermal effects from the external environment.

[0089] Thermal control material 10 designed for piping 64 is wrapped around piping 64 and fixed using an adhesive layer 18. This thermal control material 10 is flexible, so it can be easily wrapped around the cylindrical shape of piping 64. After wrapping, it is stably fixed by adhesive layer 18, so it is less likely to shift due to vibration or temperature changes.

[0090] A thermal control material 200 adapted to the shape of the valve body 63 is applied. The thermal control material 200 is designed to fit the shape of the valve body 63 and can be easily overlapped. Furthermore, a portion of the thermal control material 200 is cut diagonally, and by intersecting at the overlapping portion, gaps are minimized and heat insulation performance is improved.

[0091] A dedicated thermal control material 61 is also applied to the valve bonnet 62 installed on top. This thermal control material 61 can be fitted closely to the shape of the valve bonnet 62, and by being placed so as to cover the entire valve bonnet, it effectively suppresses heat loss.

[0092] The application of the thermal control material of this example significantly improves the heat insulating and heat blocking performance of the piping 64 and the valve 60. In addition, the use of pre-cut thermal control material has the advantage of simplifying work at the installation site and improving installation accuracy.

[0093] 9 is a cross-sectional view showing an example of the use of a thermal control material in a roof structure made of corrugated iron sheets. In this example, the thermal control material 10 is applied to the bent portions (valley portions) of a half-height roof, and functions primarily as a fire-resistant covering material while also exhibiting heat insulation performance.

[0094] The folded roof 84 has a structure in which corrugated iron plates are formed continuously, and although thermal control material is normally applied to the entire structure, for the sake of explanation, FIG. 9 shows a state in which thermal control material 10 is placed only in the bent portions (valley portions). Thermal control material 10 can be installed in close contact with the bent portions of the folded roof 84 using adhesive layer 18. Furthermore, due to the internal structure of the thermal control material 10, the contents do not become uneven even when bending or deformation occurs, and uniform performance is achieved.

[0095] By applying the thermal control material 10 of this example, the corrugated iron sheet half-roof 84 not only improves the fire resistance performance in the event of a fire, but also suppresses heat exchange between indoors and outdoors, improving the insulation performance. Furthermore, this thermal control material has the advantage of being easy to install and can be easily added to an existing corrugated iron sheet half-roof.

[0096] In addition to the above, the thermal control material can also be used for insulating motors, engines, etc. In this case, it can be applied to automobiles, trains, airplanes, etc. It can also be used for insulating, blocking heat, keeping warm, keeping cold, etc., equipment, piping, etc. in the energy field. In addition to being attached to an object, the thermal control material can also be sandwiched between objects to fix it.

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

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

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

[0100] The above results demonstrate that the thermal control material of this example has excellent heat insulating and heat absorbing properties, and is as effective as or better than conventional fire-resistant coating materials. Because the thermal control material of this example has a core material, it is less likely to experience imbalance in the contents even when used in various locations in buildings, etc., and can stably demonstrate its heat insulating and heat absorbing properties for a long period of time.

[0101] Example 2 10 is a partial cross-sectional view showing a thermal control material according to a second embodiment. The thermal control material 101 of this embodiment has a different structure from that of the first embodiment in that it employs a core material 102 having an uneven surface. The remaining structure of the sealed pouch and the adhesive layer 18 are the same as those of the first embodiment, and therefore detailed description thereof will be omitted.

[0102] In the thermal control material 101 of this embodiment, the core material 102 has a base 104 and a plurality of independent hollow protrusions 106 provided on one surface of the base 104. The base 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. This gives the core material 102 a lightweight and flexible structure, making it applicable to a wide range of uses.

[0103] The hollow protrusions 106 are filled with air or a gas such as nitrogen (a form of fluid) and sealed. With this structure, the hollow protrusions 106 can exhibit heat insulating properties that suppress heat conduction. As a specific example, the core material 102 may be configured as "air packing" (so-called bubble cushioning material). In this case, the hollow protrusions 106 are regularly arranged, so that the core material 102 as a whole has uniform heat insulating properties.

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

[0105] Furthermore, the core material 102 with the hollow protrusions 106 can flexibly accommodate curved or complex shaped objects. For example, it can be installed in close contact with cylindrical pipes and ducts, or curved parts of 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 of this example may contain water or a polymeric absorbent material swollen with water as another fluid. The core material 102 has recesses (between the hollow protrusions 106) on its surface, so that the fluid can be uniformly dispersed and retained in those areas.

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

[0108] (heat control seat) 12 is a plan view showing an example of a thermal control sheet according to the present disclosure. The thermal control sheet 120 of this example is configured as a long body in which a plurality of the thermal control materials 10 described above are continuously arranged in a tile-like manner. The thermal control sheet 120 can be cut to the required size and shape at the construction site, making it convenient for use in 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 sealed independently. Connecting portions 122 are provided between the thermal control materials 10, and only laminated films 12A and 12B are arranged in these connecting portions 122, with no contents (core material, fluid) present. Therefore, even if the connecting portions 122 are cut, the contents of the thermal control material 10 will not leak out, and the sheet can be accurately cut to the required size at the construction site for use.

[0110] The size of each thermal control material 10 is not particularly limited, but it is preferable for ease of handling that one side be within the range of approximately 30 cm to 2 m. This size is designed to be compatible with various installation locations in buildings and facilities, and allows for easy handling per unit area. The thermal control sheet 120 is formed by forming multiple sealed pouches continuously in the width and length directions, and is configured as a long body overall. This long body is provided rolled up, making it easy to transport and store, and also efficient to handle at the installation site.

[0111] Furthermore, an adhesive layer 18 (not shown) is provided on one side of the thermal control sheet 120, and this adhesive layer 18 is protected by a release sheet. By peeling off the release sheet at the time of application, the thermal control sheet 120 can be easily fixed to the surface of the object. This adhesive layer 18 allows for secure fixation to the application location without using any additional adhesive material.

[0112] The configuration of this thermal control sheet allows for flexible adaptation to the size and shape of the installation location. For example, multiple thermal control materials 10 can be used continuously on large wall or ceiling surfaces, while pieces cut to the required size can be applied to small components or narrow spaces. The thermal control sheet 120 of this example is made by continuously arranging multiple tile-shaped thermal control materials 10 and providing them as a long body, thereby improving transportability, workability, and flexibility. The thermal control sheet 120 can be used as a fire-resistant coating material, insulation material, and heat-shielding material applied to buildings and facilities.

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

[0114] (Thermal control sheet installation kit) 13 is a cross-sectional view of the thermal control sheet 120 taken along line AA. The thermal control sheet 120 has a structure in which a plurality of thermal control materials 10 are arranged continuously in a tile-like pattern. The thermal control material 10 is sealed by laminated films 12A and 12B including a metal layer, and contains a core material 14 inside that holds a polymer absorbent material 16 that has absorbed water and swelled. This allows the thermal control material 10 to exhibit fire resistance, heat absorption, heat insulation, and heat shielding properties.

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

[0116] The thermal control sheet installation kit of this example includes additional members for finishing these connecting portions 122 and peripheral portions 124. FIG. 14 is a cross-sectional view showing these additional members. One is a cap mold 130 for covering the connecting portions 122. The cap mold 130 includes a support material 132 and a second core material 134 fixed onto 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 sufficient to cover 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 make up the sealed 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 so that its cross-sectional shape fits in 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 thermal control material 10, but its thickness is preferably smaller than that of the core material 14 of the thermal control material 10. Specifically, it is preferably about 10 to 60% of the thickness of the core material 14 of the thermal control material 10. A thickness within the above range is preferable because, when applied to the connecting portion 122, the surface of the thermal control material 10 after application is likely to be in a substantially flat state. The second core material 134 preferably comprises a polymer absorbent material similar to that of the thermal control material.

[0118] The surface of the second core 134 is preferably exposed to the outside. In other words, the second core 134 is preferably not sealed. The support material 132 of the cap mold 130 is configured to be wider than the second core 134, and the thermal control sheet 120 is preferably bonded to the support material 132 at the portion ("edge portion") protruding from the second core 134 and the surface of the thermal control sheet 120. In this case, since the surface of the second core 134 is exposed to the outside, water can be sprayed onto the second core 134 at the construction site to swell the polymer absorbent 136, and in this state, the second core 134 can be bonded and fixed to the surface of the connecting portion with the second core 134 side facing it. This improves handling at the construction site. The connecting portion 122 is completely covered by the cap mold 130, and the entire thermal control sheet 120 is configured to form a flat surface. By placing this flat surface on the side opposite to the surface to be attached to the object, a better aesthetic appearance (appears flat) can be obtained, and the heat insulating performance and the like can be more uniformly exhibited.

[0119] Another additional member is an edge cap 140. The edge cap 140 is used to cover the peripheral edge 124 of the thermal control material 10 arranged around the periphery of the thermal control sheet 120. The edge cap 140 includes a support material 142 and a third core material 144 fixed onto the support material 142. The support material 142 is made of a long film including a metal layer, and has a U-shaped cross section, a so-called "channel" shape, with a width and length sufficient to cover the peripheral edge 124. The structure, material, etc. of the support material 142 are not particularly limited, but may be the same as the laminate films 12A and 12B that make up the thermal control material 10.

[0120] The third core material 144 is fixed inside the U-shape of the support material 142 and is configured to be able to hold the peripheral edge portion 124 of the thermal control sheet 120 by sandwiching it. Specifically, it has a slit into which the peripheral edge portion 124 can be inserted and a taper into which the peripheral edge portion 124 can be fitted. The third core material 144 may be made of the same material and have the same structure as the core material 14 of the thermal control material 10. The third core material 144 also has a polymer absorbent material 146, and the material etc. may be the same as the polymer absorbent material 16 of the thermal control material 10.

[0121] It is preferable that at least a portion of the surface of the third core 144 is exposed to the outside. In other words, it is preferable that the third core 144 is not completely sealed. The support material 142 of the edge cap 140 is configured larger than the third core 144, and the thermal control sheet 120 is preferably bonded to the support material 142 at the portion ("edge portion") protruding from the third core 144 and the surface of the thermal control sheet 120. In this case, since the surface of the third core 144 is exposed to the outside, water can be sprayed onto the third core 144 at the construction site to swell the polymer absorbent 146, and in this state, the third core 144 side can be bonded and fixed to the surface of the peripheral edge 124. This improves handling at the construction site. The peripheral edge 124 is covered by the edge cap 140, so that the entire thermal control sheet 120 forms a flat surface. This provides an excellent aesthetic appearance (appears flat) and makes it easier to achieve more uniform insulation performance.

[0122] In addition to the above, the thermal control sheet installation kit may further include a single thermal control material for repair purposes. There are no particular restrictions on the size, but it may be a rectangle with each side measuring 50 to 100 cm.

[0123] (Thermal Control Material Manufacturing Method 1) The manufacturing method of the thermal control material and the thermal control sheet is not particularly limited, and known manufacturing techniques can be appropriately combined. An example is shown below, but the present invention is not limited to this.

[0124] In the first step, a core material is prepared in which a polymer absorbent material is dispersed and retained. There are no particular limitations on the method for preparing the core material, but one method involves introducing a powdered or granular polymer absorbent material into the pores of the core material. In this case, the powder or granules are uniformly dispersed on the surface and inside of the core material and physically retained within the pores. A spray device, a scattering device, or the like 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 material within the core material.

[0125] Another method is to simultaneously incorporate a fibrous polymer absorbent material into the core material during its formation. In this case, the polymer absorbent material is mixed into the core material during its formation. For example, when manufacturing a nonwoven sheet, the polymer absorbent material is mixed into the raw fiber of the core material and then integrated with the core material on the manufacturing line. This method has the advantage of uniformly dispersing the absorbent material within the core material and preventing physical detachment.

[0126] Another method that can be used is to disperse a polymer absorbent in a liquid medium such as water to form a gel or slurry, which is then impregnated into a core material. In this method, the core material is immersed in the gel or slurry, the polymer absorbent material is introduced inside, and then the core material is dried to fix the absorbent material within the core material. It is also possible to use the core material as is without drying it. In this case, there is no need to supply water to the core material in the subsequent stage.

[0127] Next, in the second step, core materials holding polymer absorbent materials are continuously placed on a film containing a metal layer that is unrolled from a roll onto a production line. The core materials are placed on the film at regular intervals. This interval determines the width of the connecting portion formed in the third step (pressing step) described below. The placement position of the core materials is adjusted appropriately, taking into consideration the uniformity of the entire product and ease of installation. As a method for placing the core materials, mechanical handling devices or suction-type conveying devices can be used to streamline the production process and place the core materials with high precision.

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

[0129] Next, in the third step, another film including a metal layer is applied from above to encase the core material placed in the second step. This film has a laminated structure that is heat-resistant, airtight, and durable, similar to the film developed in the first step. It is preferable that at least one of the films developed in the third step or the second step has an adhesive layer and a release sheet on the back side.

[0130] Pressurization and heating are performed on the areas of the film corresponding to the connecting portions and peripheral portions. This heat-welds the connecting portions and peripheral portions, turning the film into individual sealed pouches that seal the core materials, and continuously forming multiple thermal control materials connected via the connecting portions. A heat-sealing device, a roll press device, or the like can be used for the pressure-bonding. Note that if the film does not have heat-sealing properties, adhesive strips may be placed at the connecting portions, etc., and pressure-bonded.

[0131] After the crimping is complete, the formed connecting portions serve to integrate the thermal control materials into a thermal control sheet, and the structure allows the thermal control sheet to be cut as needed at the construction site. This makes it possible to flexibly adapt the thermal control sheet, which is provided as a long body, to the size and shape required for the application. In this way, individual thermal control materials with sealed cores are continuously formed, and a thermal control sheet is obtained that is integrated as a whole via the connecting portions. The obtained thermal control sheet may be wound around a roll core to form a roll.

[0132] (Thermal control material manufacturing method 2) Next, another embodiment of the method for manufacturing a thermal control material will be described. Fig. 15 is a flow diagram of the method for manufacturing a thermal control material. First, in step S101, a swollen polymer absorbent material is separated from a used absorbent sanitary product. Examples of absorbent sanitary products include, but are not limited to, diapers, incontinence pads, and sanitary napkins. Used absorbent sanitary products contain a swollen polymer absorbent material, and recovering this material is the first step in this manufacturing method.

[0133] The method for separating the swollen polymeric absorbent material from used absorbent sanitary products is not particularly limited, and known methods can be applied. A specific example is a combination of mechanical and chemical treatments. After the used absorbent sanitary products are broken into small pieces using a grinder or shredder, the polymeric absorbent material can be separated from the fibers and other components by adding water or other solvents.

[0134] Conventionally, in the material recycling of super absorbent polymers (SAP), it has been necessary to remove the moisture contained within the swollen polymer. This moisture removal process has been a major challenge in the reuse process because it consumes a lot of energy and carries the risk of damaging the properties of the polymer absorbent.

[0135] On the other hand, the manufacturing method of this example is characterized by using the swollen polymer absorbent material as it is. This makes it possible to omit the moisture removal step that was previously required, simplifying the process and significantly reducing energy costs. Furthermore, by directly incorporating the swollen polymer absorbent material into the thermal control material, the effect of improving its thermal insulation and heat-shielding properties can be obtained. Therefore, this manufacturing method is more efficient than conventional techniques and is superior in terms of reducing environmental impact.

[0136] The separated swollen polymer absorbent material is dispersed in a core material in the next process and used as a material to exert its thermal control properties. In this way, by reusing used absorbent sanitary products, it is possible to simultaneously achieve effective use of resources and reduction of waste.

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

[0138] The swollen polymer absorbent material separated and obtained in step S101 has become gelatinous due to the incorporation of water, 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 material, the polymer absorbent material is uniformly dispersed within the pores and physically held therein.

[0139] The core material after completion of impregnation is sandwiched between films containing metal layers on the top and bottom and sealed on the production line. The subsequent processes are the same as those in the manufacturing method of the first embodiment. According to the manufacturing method of the second embodiment, by directly impregnating the core material with a gel-like polymer absorbent material, the dehydration process of the conventional polymer absorbent material can be omitted, and it is possible to effectively utilize resources and improve the efficiency of the manufacturing process. [Explanation of symbols]

[0140] 10 thermal control material, 12A, 12B laminated film, 12C sealed pouch, 14 core material, 16 polymer absorbent material, 18 adhesive layer, 20 peripheral portion, 61 thermal control material, 100 pre-cut thermal control material, 101 thermal control material, 102 core material, 104 base portion, 106 hollow protrusion, 108 polymer absorbent material, 110 thermal control material, 120 thermal control sheet, 122 connecting portion, 124 peripheral portion, 130 cap mold, 132 support material, 134 second core material, 136 polymer absorbent material, 140 edge cap, 142 support material, 144 third core material, 146 polymer absorbent material, 200 thermal control material

Claims

1. A thermal control material for fire-resistant coating that is attached to the steel frame of a building, a sealed pouch made of a film including a metal layer; A core material that is contained in the bag of the sealed pouch and has an outer dimension that matches the inner dimension of the sealed pouch and has a recess on its surface; and a fluid held in the core material. an adhesive layer laminated on at least one surface of the sealed pouch; A thermal control material wherein the core material is a solid structure distinct from the fluid.

2. A thermal control material for heat insulation or heat shielding that is attached to the inside of the roof or wall of a building, a sealed pouch made of a film including a metal layer; A core material that is contained in the bag of the sealed pouch and has an outer dimension that matches the inner dimension of the sealed pouch and has a recess on its surface; and a fluid held in the core material. an adhesive layer laminated on at least one surface of the sealed pouch; A thermal control material wherein the core material is a solid structure distinct from the fluid.

3. A thermal control material for heat insulation or heat shielding that is attached to a pipe or duct, a sealed pouch made of a film including a metal layer; A core material that is contained in the bag of the sealed pouch and has an outer dimension that matches the inner dimension of the sealed pouch and has a recess on its surface; and a fluid held in the core material. an adhesive layer laminated on at least one surface of the sealed pouch; A thermal control material wherein the core material is a solid structure distinct from the fluid.

4. A thermal control material described in any one of claims 1 to 3, wherein the core material does not contain a polymer absorbent material.

5. A thermal control material for fire-resistant coating to be attached to the steel frame of a building, a sealed pouch made of a film including a metal layer; A core material that is contained in the bag of the sealed pouch and has an outer dimension that matches the inner dimension of the sealed pouch and has a recess on its surface; and a fluid held in the core material. an adhesive layer laminated on at least one surface of the sealed pouch; A thermal control material that is a pre-cut thermal control material with through holes already provided for inserting ducts.

6. The bags of the thermal control material according to any one of claims 1 to 3 are connected via connecting parts to form a tile-like shape, The connecting portion is formed by the film that constitutes the sealed pouch, and does not contain the core material or the fluid.

7. A method for applying a fire-resistant covering material, comprising applying the adhesive layer of the thermal control material according to claim 1 to a steel frame of a building to provide fire-resistant covering.

8. A thermal control material for fire-resistant coating to be attached to the steel frame of a building, a sealed pouch made of a film including a metal layer; A core material that is contained in the bag of the sealed pouch and has an outer dimension that matches the inner dimension of the sealed pouch and has a recess on its surface; and a fluid held in the core material. an adhesive layer laminated on at least one surface of the sealed pouch, Separating the swollen polymeric absorbent material from the used absorbent sanitary product; and sealing the separated swollen polymer absorbent material in a water-containing state together with a core material having a recessed portion on its surface in a sealed pouch made of a film including a metal layer, The core material has an outer dimension that fits the inner dimension of the sealed pouch, The method for manufacturing a thermal control material according to any one of claims 1 to 3, wherein after sealing, the moisture contained in the polymer absorbent material functions as the fluid held in the core material.

9. a thermal control sheet formed by continuously arranging, in a tile-like manner, a thermal control material that is contained in the sealed pouch and has outer dimensions that fit the inner dimensions of the sealed pouch, a core material with a recessed portion on its surface, and a fluid held in the core material; and a cap mold having a shape that fits the connecting portion of the thermal control material; 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 a recessed portion disposed on a surface thereof, and a polymer absorbent material dispersed in the second core material; A thermal control sheet installation kit configured so 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 thermal control material becomes approximately flat.

10. a thermal control sheet formed by continuously arranging, in a tile-like manner, a thermal control material that is contained in the sealed pouch and has outer dimensions that fit the inner dimensions of the sealed pouch, a core material with a recessed portion on its surface, and a fluid held in the core material; and an edge cap for covering a peripheral edge of the thermal control material; The edge cap comprises an elongated film having a U-shaped cross section including the metal layer, a third core material fixed to the inside of the U-shape and having a recessed portion disposed on a surface thereof, and a polymer absorbent material dispersed in the third core material; A thermal control sheet installation kit, wherein the third core material is configured to hold the peripheral edge of the sealed pouch in its center when viewed in cross section.

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