Method for manufacturing vacuum insulation material and method for applying it

Abstract

To prevent defective application of a bonding member to a vacuum heat insulation material.SOLUTION: A manufacturing method for a vacuum heat insulation material comprises a main body creation step of creating a main body of the vacuum heat insulation material, a first application step of applying a bonding member to a bonding surface of the main body of the vacuum heat insulation material, an extrusion step of extruding a defective application portion to which the bonding member has not been applied in the first application step, out of the bonding surface from the side opposite to the bonding surface, and a second application step of applying the bonding member to the bonding surface again after the extrusion step.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a vacuum insulating material and a coating method.

Background Art

[0002] In order to improve heat insulation performance, it is known that a vacuum insulating material is disposed inside a housing of a refrigerating device such as a refrigerator or a freezer. In Patent Document 1, after drying a core material in a drying furnace, it is inserted into an outer wrapping material formed into a bag shape by heat-sealing three sides of a laminate film, the inside of the outer wrapping material is depressurized to 10 Pa or less in a decompression chamber, and the opening is hermetically sealed by heat-sealing. A vacuum insulating material produced by this method is described.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Due to variations in the density and shape of the core material during the manufacturing process of the vacuum insulating material, the surface may become uneven. When an adhesive member is applied to the surface of such a vacuum insulating material, there may occur an uncoated defective portion where the adhesive member is not applied, and there is a risk that the vacuum insulating material cannot be sufficiently adhered and fixed to the housing of the product. Even if it can be adhered and fixed, a gap may occur between the vacuum insulating material and the housing, and air, a filler, etc. may enter this gap, resulting in a reduction in the heat insulation effect, deformation of the product, etc.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a method for manufacturing a vacuum insulating material and a coating method that can prevent defective coating of an adhesive member on the vacuum insulating material.

Means for Solving the Problems

[0006] In the method for manufacturing vacuum insulation material described herein, first, the main body of the vacuum insulation material is created, and then an adhesive member is applied to the bonding surface of the main body. Subsequently, the adhesive member that was not applied to the bonding surface in the first application is... A recess that is deeper than the predetermined depth. Poorly coated area Area corresponding to the size of, Until the dent is resolved The adhesive is pushed out from the opposite side of the bonding surface. Then, after pushing it out, the adhesive material is applied again to the bonding surface. [Effects of the Invention]

[0007] According to this disclosure, since the poorly coated portion is pushed out from the opposite side of the bonding surface before applying the adhesive member, poor application of the adhesive member to the vacuum insulation material can be prevented. [Brief explanation of the drawing]

[0008] [Figure 1] External view of vacuum insulation material [Figure 2] Figure 1 shows a cross-sectional view of the vacuum insulation material along line II-II. [Figure 3] Cross-section of a refrigerator with vacuum insulation installed. [Figure 4] Diagram showing the manufacturing procedure for vacuum insulation material in Embodiment 1. [Figure 5] Diagram showing the structure of the laminating film. [Figure 6] Diagram illustrating the manufacturing process of vacuum insulation material. [Figure 7] Diagram (1) illustrating the application of adhesive material using a roller. [Figure 8] Diagram (2) illustrating the application of adhesive material using a roller. [Figure 9A] Diagram (1) illustrating the defective coating area and the extrusion jig. [Figure 9B] Diagram (2) illustrating the defective coating area and the extrusion jig. [Figure 9C] Diagram (3) illustrating the defective coating area and the extrusion jig. [Figure 10] A diagram showing the manufacturing procedure for vacuum insulation material in Embodiment 2. [Figure 11]Figure showing the manufacturing procedure of the vacuum insulation material in Embodiment 3 [Figure 12] Figure (Part 1) for explaining an example in which application of the adhesive member and extrusion of defective application portions are performed simultaneously [Figure 13] Figure (Part 2) for explaining an example in which application of the adhesive member and extrusion of defective application portions are performed simultaneously [Figure 14] Figure (Part 1) showing an extrusion jig according to a modification example [Figure 15] Figure (Part 2) showing an extrusion jig according to a modification example [Figure 16] Figure (Part 3) showing an extrusion jig according to a modification example [Figure 17] Figure (Part 4) showing an extrusion jig according to a modification example [Figure 18] Figure (Part 5) showing an extrusion jig according to a modification example

Mode for Carrying Out the Invention

[0009] Hereinafter, a method for manufacturing a vacuum insulation material according to the present disclosure will be described. Note that the present disclosure is not limited by each of the embodiments described below. Also, in the drawings shown below, the relationship of the sizes of each component may be different from the actual ones.

[0010] [Embodiment 1] A method for manufacturing a vacuum insulation material according to Embodiment 1 will be described.

[0011] (Structure of Vacuum Insulation Material) First, the vacuum insulation material 10 to which the adhesive member is applied will be described. FIG. 1 is a view of the main body of the vacuum insulation material 10 before the adhesive member is applied, as seen from above. FIG. 2 is a cross-sectional view of the main body of the vacuum insulation material 10 shown in FIG. 1 when cut along the line segment II-II.

[0012] The vacuum insulation material 10 is a flat insulation material. The vacuum insulation material 10 includes a core material 11 which is an aggregate of glass fibers containing an adsorbent 13, and an outer wrapping material 12 which is a laminate film having a gas barrier property and covering the core material 11. The inside of the outer wrapping material 12 is depressurized and sealed.

[0013] The core material 11 employs a fiber aggregate with a large proportion of internal space and sufficient strength to maintain that space even after the inside of the outer packaging material 12 is evacuated, in order to suppress heat leakage due to the heat conduction of the core material 11 itself. The core material 11 is formed, for example, by stacking multiple aggregates of glass fiber.

[0014] The core material 11 is covered by the outer packaging material 12. That is, the core material 11 is housed in the outer packaging material 12 and, in a vacuum state, is compressed by atmospheric pressure through the outer packaging material 12. The thickness of the core material 11 before being housed in the outer packaging material 12 is several to several tens of times the thickness of the core material in a vacuum state.

[0015] The outer packaging material 12 is formed by processing two gas barrier films 121a and 121b into a bag shape. Specifically, the edges of the overlapping films 121a and 121b are bonded together by heat welding to form the bag-shaped outer packaging material 12. The outer packaging material 12 contains the core material 11 and the adsorbent 13.

[0016] In the following description, films 121a and 121b will be collectively referred to as film 121. Film 121 is, for example, a laminate film having a multilayer structure. More specifically, film 121 has a resin film as a heat-sealable layer that is heat-sealed by heating, and a metal film as a gas barrier layer that prevents gas permeation.

[0017] The vacuum insulation material 10 is bonded to the sheet metal forming the inner surface of the outer casing 21 of the refrigerator 20 by an adhesive applied to the bonding surface of the main body using a coating method described later, as shown in Figure 3. The adhesive here is, for example, a hot melt that melts with heat and hardens when cooled. The space formed by the outer casing 21 and the inner casing 22, excluding the vacuum insulation material 10, is filled with raw materials for rigid polyurethane foam 23 and integral foaming is performed. As a result, the vacuum insulation material 10 is embedded in the rigid polyurethane foam 23 between the outer casing 21 and the inner casing 22.

[0018] Here, if there are irregularities on the bonding surface of the vacuum insulation material 10, there is a risk that when applying the adhesive, there will be areas where the adhesive is not sufficiently applied. If the vacuum insulation material 10 is bonded to the sheet metal and the casing of the refrigerator 20 is completed while these areas of poor adhesion exist, a gap will be created between the vacuum insulation material 10 and the sheet metal at the poorly bonded areas, which may lead to poor adhesion. Furthermore, even if the vacuum insulation material 10 is successfully bonded to the sheet metal, when the outer box 21 is formed from this sheet metal and the raw material for rigid polyurethane foam 23 is injected into the space between it and the inner box 22 for integral foaming, the raw material may flow into this space as well, causing the outer box 21 to deform during the foaming of the rigid polyurethane foam 23, which may result in a poor appearance of the refrigerator 20. In addition, there is a risk that air may enter the space in the damaged area, preventing the refrigerator 20 from achieving the desired insulation effect. The manufacturing method of the vacuum insulation material 10 according to the embodiment of the present disclosure described below makes it possible to prevent such poor adhesion.

[0019] (Method for manufacturing vacuum insulation material 10) Next, we will describe the manufacturing method of the vacuum insulation material 10 to which the adhesive material has been applied. Figure 4 is a diagram showing the manufacturing procedure of the vacuum insulation material 10.

[0020] First, the process of creating the main body of the vacuum insulation material 10 is carried out (step S11). The process in step S11 is an example of the main body creation process of this disclosure. Specifically, first, the worker prepares the core material 11, films 121a and 121b, and adsorbent 13 to be used in the manufacture of the vacuum insulation material 10. The core material 11 is formed from a laminate of glass wool layers. At this stage, a core material 5 to 50 times the size in the thickness direction of the completed vacuum insulation material 10 is prepared. The films 121a and 121b are formed by sequentially laminating a resin film 51, a gas barrier layer 52, and a heat-sealed layer 53, respectively, as shown in Figure 5. The adsorbent 13 is formed, for example, by housing calcium oxide in a breathable bag.

[0021] Next, the worker prepares the outer packaging material 12. Specifically, the worker first aligns and overlaps the rectangular films 121a and 121b with the heat-sealing layers 53 facing each other. Then, the worker heat-seals the edges of all four sides of the films 121a and 121b. As a result, all four sides are fixed, preventing the films 121a and 121b from shifting position. Alternatively, the core material 11 and the adsorbent 13 may be sandwiched between the films 121a and 121b before heat-sealing the edges of all four sides. Next, the worker uses a cutter or the like to create an opening near one of the four heat-sealed sides of the films 121a and 121b. The size of this opening is such that the core material 11 can be inserted. As a result, the films 121a and 121b become a bag-like shape with three sides sealed and one side open, thus preparing the outer packaging material 12.

[0022] Next, the worker uses a compressor to compress the core material 11 until it reaches a thickness of about two to several times the finished thickness of the vacuum insulation material that can pass through the opening of the outer packaging material 12, and inserts the core material 11 into the outer packaging material 12 through the opening.

[0023] Next, the worker places the outer packaging material 12 containing the core material 11 into a drying oven for 30 minutes to 5 hours to dry it. This allows moisture and other volatile components adsorbed on the films 121a, 121b, and the core material 11 to be released through the opening. The temperature inside the drying oven is set to a temperature approximately 10°C to 20°C lower than the melting point of the resins that make up the films 121a and 121b. This is to prevent the heat-sealed layer 53 from melting.

[0024] Next, the worker degassed the inside of the outer packaging material 12. Specifically, first, the worker removed the outer packaging material 12, which contained the core material, from the drying oven and placed it inside the vacuum container 30 as shown in Figure 6. Inside the vacuum container 30, there was a regulating plate 31 and a welding sealing machine 32. The worker then placed and secured the outer packaging material 12 containing the core material 11 between the two regulating plates 31. Next, if the worker had not included the adsorbent 13 inside the outer packaging material 12 when it was made, the worker inserted the adsorbent 13 into the outer packaging material 12 through the opening. Subsequently, the worker evacuated the vacuum container 30, reducing the pressure inside. As the pressure inside the vacuum container 30 decreased, the air inside the outer packaging material 12 and the core material 11 was exhausted to the outside of the vacuum container 30 through the opening.

[0025] After evacuating the vacuum container 30 until the internal pressure drops from 0 to 10 Pa, the operator uses a heat sealing machine 32 to heat-seal the opening of the outer packaging material 12. This seals the core material 11 inside the outer packaging material 12 under vacuum.

[0026] Next, the worker removes the vacuum insulation material 10 from the vacuum container 30. The vacuum insulation material 10 is compressed by the external air pressure, and a vacuum insulation material 10 of the designed size is obtained. This completes the main body of the vacuum insulation material 10. In addition, the ear portion of the vacuum insulation material 10, which is the part that protrudes from the surface of the core material 11 of the outer packaging material 12, may be folded to the opposite side of the adhesive surface to which the adhesive material is applied. Furthermore, the method for creating the main body of the vacuum insulation material 10 described above is just one example, and the main body of the vacuum insulation material 10 may be created by other methods.

[0027] Next, the adhesive material is applied to the bonding surface of the main body of the vacuum insulation material 10 in order to bond it to the sheet metal, using the application method described in steps S12 to S14 later.

[0028] First, the worker applies adhesive to the bonding surface of the vacuum insulation material 10 (step S12). Step S12 is an example of the first application process of this disclosure. Specifically, as shown in Figure 7, the worker places the vacuum insulation material 10 on the belt conveyor 41 with the bonding surface facing upwards. As a result, the vacuum insulation material 10 is transported by the belt conveyor 41 in a rightward direction toward the metal roller 42 to which the adhesive is applied. Here, the metal roller 42 is fixed by a spring (not shown) and can change its position vertically while receiving the elastic force of the spring. Also, in the initial state, the height from the belt conveyor 41 to the metal roller 42 is set to a height that is smaller by a clearance amount than the expected thickness of the vacuum insulation material. Here, the clearance is, for example, about 2 mm. Therefore, when the transported vacuum insulation material 10 passes under the metal roller 42, the metal roller 42 rides up on the vacuum insulation material 10 and passes while in contact with the bonding surface of the vacuum insulation material 10. As a result, as shown in Figure 8, the adhesive is applied to the bonding surface of the vacuum insulation material 10.

[0029] Here, due to variations in the core material 11, the adhesive surface of the vacuum insulation material 10 has an uneven shape, and there may be thin-walled sections that are less than the expected thickness by the clearance amount. In such cases, if the adhesive is applied using the method described above, the metal roller 42 cannot come into contact with the thin-walled sections, and therefore the adhesive will not be applied. In the following explanation, such thin-walled sections to which the adhesive is not applied will also be referred to as poorly coated sections.

[0030] Therefore, the worker checks the adhesive surface of the vacuum insulation material 10 after the adhesive member has been applied in step S12 to check for any such coating defects. For example, Figure 9A is a view from above of the main body of the vacuum insulation material 10 after the adhesive member has been applied in step S12. Figure 9B is a cross-sectional view of the vacuum insulation material 10 shown in Figure 9A when it is cut along the line segment III-III. As shown in Figure 9A, a coating defect has occurred on the adhesive surface of the vacuum insulation material 10. Therefore, as shown in Figure 9B, the worker pushes out the coating defect from the opposite side of the adhesive surface of the vacuum insulation material 10 by a certain thickness (step S13). Here, as shown in Figure 9B, the worker pushes out the coating defect by pressing an extrusion jig 60, which is a plate material having a rectangular surface corresponding to the size of the coating defect, from the opposite side of the adhesive surface. Alternatively, the coating defect may be pushed out from the opposite side of the adhesive surface by the worker's hand, a hammer, etc., instead of using such an extrusion jig 60. As a result, as shown in Figure 9C, the coating defect on the adhesive surface is eliminated. Step S13 is an example of the extrusion process of this disclosure.

[0031] Next, the worker applies the adhesive to the bonding surface of the vacuum insulation material 10 again using the same method as in step S12 (step S14). The process in step S14 is an example of the second coating process of this disclosure. By following the above procedure, the vacuum insulation material 10 with the adhesive applied is manufactured.

[0032] (Effect, Action) Thus, according to this embodiment, when the adhesive is applied to the bonding surface of the vacuum insulation material 10, any areas where the adhesive is not applied are pushed out from the opposite side, and the adhesive is applied again. Therefore, since the areas with poor coating are eliminated in the second application, the adhesive can be applied evenly to the entire bonding surface, making it possible to prevent poor application of the adhesive to the vacuum insulation material.

[0033] Furthermore, the vacuum insulation material 10, to which the adhesive has been applied, is then bonded to the sheet metal that makes up the inner surface of the outer casing 21 of the refrigerator 20, thereby forming the outer casing 21 of the refrigerator 20. Then, rigid polyurethane foam 23 is filled into the space between the outer casing 21 and the inner casing 22. As described above, since there are no areas with poorly applied adhesive on the bonding surface of the vacuum insulation material 10, the vacuum insulation material 10 and the sheet metal can be securely bonded and fixed. In addition, since no gaps are created between the vacuum insulation material 10 and the sheet metal, it is possible to prevent the insulation effect of the refrigerator 20 from being reduced, deformation, etc., due to the filler filling filling into the gaps.

[0034] [Embodiment 2] Next, a method for applying an adhesive member to a vacuum insulation material 10 according to Embodiment 2 of this disclosure will be described. Components common to Embodiment 1 will be denoted by the same reference numerals, and the differences will be the main focus of the description.

[0035] Figure 10 shows the manufacturing procedure for the vacuum insulation material 10 in this embodiment.

[0036] First, the main body of the vacuum insulation material 10 is produced in the same manner as in Embodiment 1 (step S21). Step S21 is an example of the main body production process of this disclosure. Next, the worker measures the thickness of the vacuum insulation material 10 over the entire adhesive surface of the vacuum insulation material 10 (step S22). For example, the thickness may be measured by laser scanning with a laser displacement meter, or the worker may manually measure the thickness with a caliper cage. If the tabs are folded into the vacuum insulation material, the thickness including the tabs should be measured. Step S22 is an example of the measurement process of this disclosure.

[0037] Next, based on the measurement results in step S22, the operator identifies areas of poor coating where the adhesive member is not applied when the adhesive member is applied to the bonding surface of the vacuum insulation material 10 (step S23). The process in step S23 is an example of the identification process of this disclosure. For example, if the application is performed using a metal roller 42, as in Embodiment 1, areas with a thickness less than or equal to the value obtained by subtracting the clearance of the metal roller 42 from the expected thickness of the vacuum insulation material 10 at the design stage should be identified as areas of poor coating.

[0038] Next, the worker extrudes the identified defective coating portion from the opposite side of the adhesive surface of the vacuum insulation material 10 by a certain thickness (step S24). Step S24 is an example of the extrusion process of this disclosure. This process is the same as step S13 of Embodiment 1.

[0039] Then, the worker applies the adhesive to the bonding surface of the vacuum insulation material 10 (step S25). Step S25 is an example of the application process of this disclosure. Here, unlike Embodiment 1, various methods can be used for applying the adhesive, such as applying with a metal roller 42, applying double-sided tape, or applying a bead-shaped adhesive using a handgun-type hot melt applicator. Since any poorly applied portions are pushed out in step S24, the poorly applied portions are eliminated in step S25, and the adhesive can be applied evenly to the entire bonding surface. By following the above procedure, a vacuum insulation material 10 with the adhesive applied is manufactured.

[0040] Thus, in this embodiment, by measuring the thickness of the vacuum insulation material 10, defective areas are identified without applying the adhesive, and the adhesive is only applied after the identified defective areas have been pushed out from the opposite side of the adhesive surface. Therefore, it is possible to reduce the number of times the adhesive is applied compared to Embodiment 1. In addition, since defective areas are known in advance before applying the adhesive, it is possible to employ various methods for applying the adhesive compared to Embodiment 1.

[0041] [Embodiment 3] Next, a method for applying an adhesive member to a vacuum insulation material 10 according to Embodiment 3 of this disclosure will be described. Components common to Embodiments 1 and 2 will be denoted by the same reference numerals, and the differences will be the main focus of the description.

[0042] Figure 11 shows the procedure for applying the adhesive member to the vacuum insulation material 10 in this embodiment.

[0043] First, the main body of the vacuum insulation material 10 is produced in the same manner as in Embodiments 1 and 2 (Step S31). Next, in the same manner as in Embodiment 2, the worker measures the thickness of the vacuum insulation material 10 over the entire adhesive surface (Step S32). Then, based on the measurement results, the worker identifies areas of poor coating where the adhesive member is not applied when the adhesive member is applied to the adhesive surface of the vacuum insulation material 10 (Step S33).

[0044] Next, the worker simultaneously performs the steps of extruding the identified defective coating area and applying adhesive to the adhesive surface of the vacuum insulation material after extrusion (step S34).

[0045] Specifically, as shown in Figure 12, the worker places the vacuum insulation material 10 on the belt conveyor 41 with the adhesive surface facing upwards. At this time, an extrusion jig 60 with a shape and size corresponding to the defective coating area is interposed between the belt conveyor 41 and the vacuum insulation material 10 at a position corresponding to the defective coating area. In this state, the vacuum insulation material 10 is then conveyed forward by the belt conveyor 41 toward the metal roller 42 to which the adhesive member is attached. As shown in Figure 13, when the metal roller 42 passes over the vacuum insulation material 10, the metal roller 42 presses against the adhesive surface as it passes, and the extrusion jig 60 interposed between the belt conveyor 41 and the metal roller pushes the defective coating area upwards. This makes it possible to push out the defective coating area and apply the adhesive member simultaneously, thereby shortening the time required for applying the adhesive member.

[0046] [Example 1] In the embodiments described above, a rectangular plate material with a constant thickness was used as the extrusion jig 60, but the shape of the extrusion jig is not limited to this. For example, as shown in Figure 14, a stepped plate-shaped extrusion jig 61 may be used to extrude the defective coating portion. This extrusion jig 61 is provided with a step corresponding to the height to be extruded in the extrusion process, and when extruding the defective coating portion, the step acts as a stopper, preventing extrusion up to the height of the step. Therefore, it is possible to prevent over-extrusion of the defective coating portion.

[0047] Furthermore, as shown in Figure 15, an extrusion jig 62 with various undulations may be used to extrude the defective areas. Since this extrusion jig 62 has various undulations, it is possible to press the part with the most suitable undulation for the shape of the defective area against it, thereby creating a smoother adhesive surface. Also, as shown in Figure 16, an extrusion jig 63 with a shape other than rectangular may be used to extrude the defective areas. In practice, it is desirable to prepare extrusion jigs of various shapes in advance and use the extrusion jig best suited to the identified defective area to extrude it.

[0048] [Differentiation 2] As shown in Figure 17, if the area of ​​the coating defect is large, multiple (two in Figure 17) extrusion jigs 64 and 65 may be combined to extrude the coating defect. This makes it possible to extrude coating defects of any size by combining multiple small extrusion jigs, even when large extrusion jigs cannot be prepared due to material cost, processing environment, etc.

[0049] [Difference 3] As shown in Figure 18, if the area of ​​the coating defect is large, multiple extrusions may be performed with a single extrusion jig 66 while changing the extrusion position. This makes it possible to extrude coating defects of any size using a small number of extrusion jigs, without requiring a large extrusion jig.

[0050] [Other variations] The embodiments 1 to 3 and modifications 1 to 3 described above are merely examples, and various modifications and applications are possible. For example, although an example of attaching the vacuum insulation material 10 to a refrigerator 20 was shown, it may also be attached to other refrigeration equipment such as freezers and air conditioners.

[0051] The various aspects of this disclosure are summarized below as an appendix.

[0052] (Note 1) The main body manufacturing process for creating the vacuum insulation material, A first coating step involves applying an adhesive member to the adhesive surface of the main body, An extrusion step is performed to push out any defective portions of the adhesive surface from the opposite side of the adhesive surface, where the adhesive member was not applied in the first coating step. A second coating step is performed after the extrusion step, in which the adhesive material is applied again to the adhesive surface. A method for manufacturing vacuum insulation material.

[0053] (Note 2) The main body manufacturing process for creating the vacuum insulation material, A measurement step of measuring the thickness of the vacuum insulation material over the entire adhesive surface of the main body, Based on the measurement results from the measurement step, a determination step is made to identify areas of poor coating where the adhesive member is not applied when the adhesive member is applied to the adhesive surface of the vacuum insulation material. An extrusion step in which the defective coating portion identified in the aforementioned specific step is pushed out from the opposite side of the adhesive surface, After the extrusion step, a coating step is performed in which an adhesive member is applied to the adhesive surface. A method for manufacturing vacuum insulation material.

[0054] (Note 3) With an extrusion jig corresponding to the defective coating portion located on the opposite side of the adhesive surface and facing the defective coating portion identified in the specific step, the roller to which the adhesive member is attached passes over the adhesive surface of the vacuum insulation material while pressing against it, thereby simultaneously executing the extrusion step and the coating step. The method for manufacturing vacuum insulation material as described in Appendix 2.

[0055] (Note 4) In the extrusion process, the defective coating portion is pushed out by pressing an extrusion jig, which has a shape corresponding to the defective coating portion, against the opposite side of the adhesive surface. A method for manufacturing vacuum insulation material as described in Appendix 1 or 2.

[0056] (Note 5) The extrusion jig is provided with steps corresponding to the height to be extruded in the extrusion process. The method for manufacturing vacuum insulation material as described in Appendix 4.

[0057] (Note 6) In the extrusion process, the defective coating portion is extruded using a plurality of extrusion jigs. A method for manufacturing vacuum insulation material as described in Appendix 4 or 5.

[0058] (Note 7) A first coating step involves applying an adhesive to the bonding surface of the vacuum insulation material, An extrusion step is performed to push out any defective portions of the adhesive surface from the opposite side of the adhesive surface, where the adhesive member was not applied in the first coating step. A second coating step is performed after the extrusion step, in which the adhesive material is applied again to the adhesive surface. A coating method having

[0059] (Note 8) A measurement process to measure the thickness of the vacuum insulation material across the entire bonding surface, Based on the measurement results from the measurement step, a determination step is made to identify areas of poor coating where the adhesive member is not applied when the adhesive member is applied to the adhesive surface of the vacuum insulation material. An extrusion step in which the defective coating portion identified in the aforementioned specific step is pushed out from the opposite side of the adhesive surface, After the extrusion step, a coating step is performed in which an adhesive member is applied to the adhesive surface. A coating method having [Explanation of symbols]

[0060] 10 Vacuum insulation material, 11 Core material, 12 Outer packaging material, 13 Adsorbent, 121, 121a, 12b Film, 20 Refrigerator, 21 Outer box, 22 Inner box, 23 Rigid polyurethane foam, 30 Vacuum container, 31 Regulating plate, 32 Welding sealing machine, 51 Resin film, 52 Gas barrier layer, 53 Heat welding layer, 60-66 Extrusion jig

Claims

1. The main body manufacturing process for creating the vacuum insulation material, A first coating step involves applying an adhesive member to the adhesive surface of the main body, An extrusion step is performed to push out a region of the adhesive surface corresponding to the size of a defective coating portion, which is a recess of a predetermined depth or greater, where the adhesive member was not applied in the first coating step, from the opposite side of the adhesive surface until the recess is eliminated. A second coating step is performed after the extrusion step, in which the adhesive material is applied again to the adhesive surface. A method for manufacturing vacuum insulation material.

2. The main body manufacturing process for creating the vacuum insulation material, A measurement step of measuring the thickness of the vacuum insulation material over the entire adhesive surface of the main body, Based on the measurement results from the measurement step, a determination step is made to identify a defective coating portion, which is a recess of a predetermined depth or greater in which the adhesive member is not applied when the adhesive member is applied to the adhesive surface of the vacuum insulation material. An extrusion step in which the region corresponding to the size of the defective coating portion identified in the aforementioned specific step is pushed out from the opposite side of the adhesive surface until the depression is eliminated, After the extrusion step, a coating step is performed in which an adhesive member is applied to the adhesive surface. A method for manufacturing vacuum insulation material.

3. With an extrusion jig corresponding to the defective coating portion located on the opposite side of the adhesive surface and facing the defective coating portion identified in the specific step, the roller to which the adhesive member is attached passes over the adhesive surface of the vacuum insulation material while pressing against it, thereby simultaneously executing the extrusion step and the coating step. A method for manufacturing a vacuum insulation material according to claim 2.

4. In the extrusion process, the defective coating portion is pushed out by pressing an extrusion jig, which has a shape corresponding to the defective coating portion, against the opposite side of the adhesive surface. A method for manufacturing a vacuum insulation material according to claim 1 or 2.

5. The extrusion jig is provided with steps corresponding to the height to be extruded in the extrusion process. A method for manufacturing a vacuum insulation material according to claim 4.

6. In the extrusion process, the defective coating portion is extruded using a plurality of extrusion jigs. A method for manufacturing a vacuum insulation material according to claim 4.

7. A first coating step involves applying an adhesive to the bonding surface of the vacuum insulation material, An extrusion step is performed to push out a region of the adhesive surface corresponding to the size of a defective coating portion, which is a recess of a predetermined depth or greater, where the adhesive member was not applied in the first coating step, from the opposite side of the adhesive surface until the recess is eliminated. A second coating step is performed after the extrusion step, in which the adhesive material is applied again to the adhesive surface. A coating method having

8. A measurement process to measure the thickness of the vacuum insulation material across the entire bonding surface, Based on the measurement results from the measurement step, a determination step is made to identify a defective coating portion, which is a recess of a predetermined depth or greater in which the adhesive member is not applied when the adhesive member is applied to the adhesive surface of the vacuum insulation material. An extrusion step in which the region corresponding to the size of the defective coating portion identified in the aforementioned specific step is pushed out from the opposite side of the adhesive surface until the depression is eliminated, After the extrusion step, a coating step is performed in which an adhesive member is applied to the adhesive surface. A coating method having

Images