Thermal insulation material

Abstract

The present invention improves the heat insulation property of a heat insulation material including a three-dimensional printed structure. A heat insulation material according to the present application includes a three-dimensional printed structure printed so as to have a predetermined solid structure, the predetermined solid structure having an aperture ratio equal to or less than a first threshold and a volume density equal to or less than a second threshold.

Description

insulation

[0001] The present invention relates to a thermal insulation material.

[0002] Conventionally, techniques related to three-dimensional structures having a plurality of structures are known. For example, a technique related to a three-dimensional structure having a plurality of structures with different rigidities is known (see Patent Document 1 below). Also, for example, a technique related to a three-dimensional structure in which a plurality of structures with different rigidities are stacked to alleviate discomfort caused by stress is known (see Patent Document 2 below).

[0003] JP 2022-513070 A JP 2020-179044 A

[0004] However, conventional techniques have not been able to improve the heat retention of insulating materials that include three-dimensionally printed structures.

[0005] The present application has been made in consideration of the above, and aims to improve the heat retention properties of an insulating material including a three-dimensional printed structure.

[0006] The insulating material of the present application is a three-dimensional printed structure printed to have a predetermined three-dimensional structure, and is characterized in that the predetermined three-dimensional structure includes a three-dimensional printed structure having an opening ratio equal to or less than a first threshold value and a volume density equal to or less than a second threshold value.

[0007] According to one aspect of the embodiment, it is possible to achieve an effect of improving the heat retention of an insulating material including a three-dimensional printed structure.

[0008] FIG. 1 is a diagram showing an example of simulation results using CAE for various structures. FIG. 2 is a diagram showing an example of a parameter comparison between the structure of a three-dimensional printed structure according to an embodiment and a conventional existing structure. FIG. 3A is an explanatory diagram (1) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3B is an explanatory diagram (2) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3C is an explanatory diagram (3) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3D is an explanatory diagram (4) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3E is an explanatory diagram (5) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3F is an explanatory diagram (6) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3G is an explanatory diagram (7) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3H is an explanatory diagram (8) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3I is an explanatory diagram (9) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3J is an explanatory diagram (10) for explaining a three-dimensional printed structure according to an embodiment. FIG. 3K is an explanatory diagram (11) for explaining a three-dimensional printed structure according to an embodiment. FIG. 4 is a diagram showing an example of a method for generating a three-dimensional printed structure according to an embodiment. FIG. 5A is a diagram showing an example of a structure (spiral type) of a three-dimensional printed structure according to an embodiment. FIG. 5B is a diagram showing an example of a structure (screw type) of a three-dimensional printed structure according to an embodiment. FIG. 6A is an explanatory diagram (1) for explaining parameters of the structure of a three-dimensional printed structure according to an embodiment. FIG. 6B is an explanatory diagram (2) for explaining parameters of the structure of a three-dimensional printed structure according to an embodiment. FIG. 6C is an explanatory diagram (3) for explaining parameters of the structure of a three-dimensional printed structure according to an embodiment. FIG. 6D is an explanatory diagram (4) for explaining parameters of the structure of a three-dimensional printed structure according to an embodiment. FIG. 7A is a diagram (1) showing an example of a six-sided view (spiral type: front view) of a three-dimensional printed structure according to an embodiment. FIG. 7B is a diagram (2) showing an example of a six-sided view (spiral type: back view) of a three-dimensional printed structure according to an embodiment. Figure 7C is a diagram (3) showing an example of a six-sided view (spiral type: plan view) of a three-dimensional printed structure according to an embodiment.FIG. 7D is a diagram (4) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (spiral type: bottom side). FIG. 7E is a diagram (5) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (spiral type: left side). FIG. 7F is a diagram (6) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (spiral type: right side). FIG. 8A is a diagram (1) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw type: front). FIG. 8B is a diagram (2) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw type: back). FIG. 8C is a diagram (3) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw type: top). FIG. 8D is a diagram (4) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw type: bottom side). FIG. 8E is a diagram (5) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw type: left side). FIG. 8F is a diagram (6) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (7-degree screw: right side). FIG. 9A is a diagram (1) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: front). FIG. 9B is a diagram (2) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: back). FIG. 9C is a diagram (3) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: top). FIG. 9D is a diagram (4) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: bottom). FIG. 9E is a diagram (5) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: left side). FIG. 9F is a diagram (6) showing an example of a six-sided view of a three-dimensional printed structure according to an embodiment (14-degree screw: right side).

[0009] Hereinafter, a mode for carrying out the thermal insulation material according to the present application (hereinafter referred to as "embodiment") will be described in detail with reference to the drawings. Note that the thermal insulation material according to the present application is not limited to this embodiment. Furthermore, the same components in the following embodiments will be given the same reference numerals, and duplicated explanations will be omitted.

[0010] (Embodiment) Conventionally, techniques for three-dimensionally printing structures directly onto fabrics have been known. Three-dimensional printing is a technique for creating shapes by layering and curing resin using several methods (e.g., FDM, SLA, SLS, inkjet, etc.). Unlike mold molding, which has traditionally been the main resin molding method, three-dimensional printing allows for free shaping with fewer molding restrictions. Applying this technology to three-dimensionally print structures on fabric surfaces, in which the physical properties of the material change depending on the structure, is believed to make it possible to create textiles with a variety of composite properties. For example, by imitating three-dimensional structures with resin to create air layers, it is possible to create textiles with high thermal insulation, or by changing the volume filling density (volume density) of the lattice structure, it is possible to create textiles with high mobility (flexibility, stretchability, etc.).

[0011] For example, existing products such as down jackets use feathers as the main insulating material, creating an air layer to enhance insulation, but this has become problematic in recent years from an animal welfare perspective. Furthermore, recent tightening of regulations has led to a decrease in supply, increasing costs and creating a barrier to securing materials and new entrants. Furthermore, when creating products tailored to consumers' body sizes and needs, fabrics are produced for each function and large quantities of inventory are required, often resulting in inventory risk and waste. Therefore, establishing a method for creating optimal materials from digital data could potentially enable the free design of fabrics with optimal performance at low cost. Furthermore, being able to freely design performance would enable greater freedom in clothing design than ever before, potentially leading to the creation of new product categories and the development of products that meet previously unmet consumer needs.

[0012] Furthermore, when a filling material such as feathers is used as a heat-retaining material, functions such as heat insulation and mobility are fixed, and it is not possible to, for example, locally customize the heat insulation performance for each part or control the stretchability, rigidity, etc. In addition, a sewing process is required to fill the material, which is troublesome.

[0013] As described above, conventional techniques have not been able to customize three-dimensional printed structures to have physical properties suited to specific purposes. The present application has been made in light of the above, and aims to improve the heat retention of insulating materials including three-dimensional printed structures by appropriately imparting physical properties suited to specific purposes to three-dimensional printed structures.

[0014] Through preliminary experiments, simulation analysis was performed using CAE on various structures, and those with excellent properties were selected. Samples were then made using actual equipment and their thermal conductivity was measured according to the JIS standard. As a result, although there was some error depending on the structure, the simulation values ​​were close to the actual measured values ​​(especially in the case of a lattice structure). Qualitatively, the trends were similar, and the values ​​were also quantitatively close. In the following embodiments, the simulation values ​​will be described as being close to the actual measured values.

[0015] Figure 1 shows an example of CAE simulation results for various structures. Here, the analysis results of thermal conductivity and the amount of heat contributing to thermal conductivity are shown. The analysis results for each structure are described below.

[0016] Structure "A016" was an air-only structure, with a thermal conductivity of 0.136 (W / mK), a total heat of 10.86 (mW), and a radiant heat of 8.81 (mW). Structure "A017" was a resin-only structure, with a thermal conductivity of 0.322 (W / mK), a total heat of 25.75 (mW), and a radiant heat of 0.00 (mW). Structure "A018" was a lattice structure with dimensions of 0.2 (mm), with a thermal conductivity of 0.090 (W / mK), a total heat of 7.18 (mW), and a radiant heat of 4.00 (mW). Structure "A019" was a lattice structure with dimensions of 0.6 (mm), with a thermal conductivity of 0.073 (W / mK), a total heat of 5.82 (mW), and a radiant heat of 1.96 (mW). Structure "A020" was a lattice structure with dimensions of 1.5 (mm), and had a thermal conductivity of 0.106 (W / mK), a total heat of 8.46 (mW), and a radiant heat of 0.65 (mW). Structure "A021" was a vertical structure with dimensions of 0.2 (mm), and had a thermal conductivity of 0.092 (W / mK), a total heat of 7.34 (mW), and a radiant heat of 2.57 (mW). Structure "A022" was a vertical structure with dimensions of 0.6 (mm), and had a thermal conductivity of 0.128 (W / mK), a total heat of 10.28 (mW), and a radiant heat of 1.87 (mW). Structure "A023" had a vertical structure with dimensions of 1.5 (mm), a thermal conductivity of 0.215 (W / mK), a total heat amount of 17.18 (mW), and a radiant heat of 0.65 (mW). Structure "A024" had a horizontal structure with dimensions of 0.2 (mm), a thermal conductivity of 0.058 (W / mK), a total heat amount of 4.60 (mW), and a radiant heat of 1.85 (mW). Structure "A025" had a horizontal structure with dimensions of 0.6 (mm), a thermal conductivity of 0.070 (W / mK), a total heat amount of 5.59 (mW), and a radiant heat of 1.75 (mW). Structure "A026" had a horizontal structure with dimensions of 1.5 (mm), a thermal conductivity of 0.099 (W / mK), a total heat of 7.91 (mW), and a radiant heat of 1.55 (mW). Structure "A027" had a horizontal structure with dimensions of 0.2 (mm), a thermal conductivity of 0.054 (W / mK), a total heat of 4.33 (mW), and a radiant heat of 2.13 (mW). Structure "A028" had a horizontal structure with dimensions of 0.6 (mm), a thermal conductivity of 0.055 (W / mK), a total heat of 4.43 (mW), and a radiant heat of 2.13 (mW).The structure "A029" had a horizontal structure with a dimension of 1.5 (mm), a thermal conductivity of 0.059 (W / mk), a total heat amount of 4.70 (mW), and a radiant heat amount of 2.14 (mW).

[0017] In FIG. 1, ART1 is a diagram of each structure viewed from the side. The blank areas represent air, and the shaded areas represent the structure of the structure. For example, since structure "A016" is made of only air, ART1 is entirely blank. Also, for example, since structure "A017" is made of only resin, ART1 is entirely shaded. Also, for example, since structures "A018" to "A020" have a lattice structure, ART1 is shaded in a lattice (or pattern) pattern. Also, for example, since structures "A021" to "A023" have a vertical structure, ART1 is shaded vertically. Also, for example, since structures "A024" to "A029" have a horizontal structure, ART1 is shaded horizontally. Also, ART2 is a diagram of each structure viewed from directly above. As with ART1, the blank areas represent air, and the shaded areas represent the structure of the structure. For example, since structure "A016" is made up of only air, all ART2s are diagonal lines indicating the base of the structure. Also, for example, since structure "A017" is made up of only resin, all ART2s are diagonal lines indicating the structure of the structure. Also, for example, since structures "A018" to "A020" are lattice structures, ART2s are lattice-like (or pattern-like) diagonal lines indicating the structure of the structure and diagonal lines indicating the base of the structure in the gaps. Also, for example, since structures "A021" to "A023" are vertical structures, ART2s are vertical diagonal lines indicating the structure of the structure and diagonal lines indicating the base of the structure in the gaps. Also, for example, since structures "A024" to "A029" are horizontal structures, all ART2s are diagonal lines indicating the structure of the structure.

[0018] Among the simulation results shown in Figure 1, the results for structures "A016" and "A017" indicate that increasing the air layer (reducing the volume density) reduces the thermal conductivity (i.e., improves the insulating effect). Furthermore, the results for structures "A018" and "A025" indicate that increasing the shielding factor (reducing the opening ratio when viewed from above) reduces the thermal conductivity (i.e., improves the insulating effect). Generally, increasing the air layer reduces the thermal conductivity, but radiant heat can sometimes increase the thermal conductivity. Since structure "A025" can block radiant heat by increasing the shielding factor, it is thought to have a lower thermal conductivity and a higher insulating effect than structure "A018." These simulation results indicate that a certain level of insulating performance can be achieved with a specific structure. This makes it possible, for example, to control the physical properties of a material in a region-specific manner by changing the structure for each region of the material.

[0019] FIG. 2 shows an example of a parameter comparison between the structure of a three-dimensional printed structure according to an embodiment and a conventional existing structure. Here, the parameters are aperture ratio and volume density. The aperture ratio ranges from 0% to 100%, and the volume density ranges from 0 to 50%. Furthermore, the regions are divided using thresholds of an aperture ratio of approximately 75% and a volume density of approximately 37.5%. Region R1, one of the divided regions, is the region covered by the conventional existing structure. From a lattice structure with dimensions of 0.6 mm, a density of 3.1%, and an aperture ratio of 77%, a lattice structure with dimensions of 1.0 mm, a density of 8.3%, and an aperture ratio of 64%, and a lattice structure with dimensions of 1.5 mm, a density of 17.3%, and an aperture ratio of 49%, it is believed that as the structure becomes more complex, the aperture ratio decreases but the fill ratio increases. Because the fill ratio remains high even when the aperture ratio decreases, the conventional existing structure has limited thermal insulation effect. Meanwhile, the other divided region, region R2, is the region covered by the structure of a three-dimensional printed structure according to an embodiment. The aperture ratio decreases and the fill ratio increases from a structure with dimensions of 0.3 mm, a density of 1.6%, and an aperture ratio of 53%, a structure with dimensions of 0.6 mm, a density of 6.0%, and an aperture ratio of 20%, and a structure with dimensions of 1.0 mm, a density of 15.8%, and an aperture ratio of 1.0%, but the fill ratio remains low even when the aperture ratio decreases. Therefore, the structure of the three-dimensional printed structure according to the embodiment can be expected to have a high thermal insulation effect. Note that in FIG. 2 , the lattice structure belonging to region R1 is represented by a dotted box, and the lattice structure belonging to region R2 is represented by a diagonal box. Therefore, the three types of lattice structures belonging to region R1 are represented by dotted boxes, and the three types of lattice structures belonging to region R2 are represented by diagonal boxes.

[0020] The following describes three-dimensional printed structures according to embodiments. The three-dimensional printed structures according to embodiments may be any composite material (composite material) that incorporates a thick structure (e.g., 5 to 30 mm) on the surface of a fabric. For example, the three-dimensional printed structure may be a composite material that is 3D printed directly onto one side of a fabric (particularly the lining) and then adhered to it, or may be a composite material that is 3D printed separately and then adhered to a fabric. Alternatively, the three-dimensional printed structure according to embodiments may be a fabric composite material in which such a thick structure is sandwiched between two layers of fabric, one on top and one on the lining. Furthermore, the three-dimensional printed structure according to embodiments may be a structure in which structures with different physical properties (e.g., elasticity, stretchability, thermal insulation, acoustics, soundproofing, optical properties, etc.) are arranged in different locations, taking into account factors such as the range of motion of the body. Furthermore, the three-dimensional printed structure according to the embodiment may be a structure in which the distribution of the pattern varies in the direction of the length and breadth axes (horizontal direction) when viewed from above and in the direction of the height axis (vertical direction) when viewed from the side, and physical changes are obtained by varying the volume density or shape density (thickness) in each direction. Furthermore, the three-dimensional printed structure according to the embodiment may be a composite material having a lattice structure in which pillars are arranged within basic cells of space-filling polyhedrons and are connected or intersecting with each other. Furthermore, the fabric may be, for example, a material used in clothing (especially for cold weather, etc.), with the back surface or other surface treated for radiation prevention.

[0021] The outer and inner linings according to the embodiments are, for example, textiles (animal fibers such as wool, polyester, cotton, silk, nylon, cupra, polylactic acid fibers, hemp, rayon, polyurethane, synthetic rubber, leather, etc.), knits (animal fibers such as wool, polyester, cotton, silk, nylon, cupra, polylactic acid fibers, hemp, rayon, polyurethane, synthetic rubber, leather, etc.), etc. The structural layer according to the embodiments is, for example, polypropylene, polyethylene, polymethyl methacrylate, polylactic acid carbon fiber, glass fiber, ABS resin, silicone elastomer, polyurethane, acrylic elastomer, polyurethane elastomer, melamine resin, polystyrene foam, wool, cellulose fiber, down material, padding material, materials used as filaments or heat insulating materials for various 3D printing, and foam materials that expand upon post-treatment with heat. The interfacial heat-shielding layer according to the embodiments is, for example, a heat-shielding sheet material or a metal (aluminum, copper, etc.). The space-filling material according to the embodiments is, for example, down, inner layer material, wool, polystyrene beads, and foam materials that expand upon heating.

[0022] Furthermore, the three-dimensional printed structure according to the embodiment may be a structure in which, within this thickness range, the opening rate to the bottom surface when viewed from the top surface of the textile is 50% or less, and the volume density is 35% or less (ideally, a structure in which the opening rate is 30% or less, and the volume density is 15% or less).

[0023] Furthermore, the three-dimensional printed structure according to the embodiment may incorporate a design for sewing. For example, the three-dimensional printed structure according to the embodiment may have a large volume near the sewing location of the pattern end face portion, and may be chamfered with a C-shape or an R-shape, thereby ensuring airtightness without interfering with the movement of the sewing machine to a minimum during sewing.

[0024] Furthermore, the three-dimensional printed structure according to the embodiment may be a composite material with fabric, designed to assemble into the shape of clothing without placing strain on the structure when assembled. For example, it may be a composite fabric material in which soft resin structures with properties such as heat retention, elasticity, and stretchability are arranged on the fabric. It may also be a composite material designed to create a three-dimensional structure when sewn. It may also be a composite material divided into sloped blocks of a specific size. It may also be a composite material divided into linear shapes. It may also be a composite material designed to maintain airtightness while avoiding the sewing machine presser foot at the sewing location.

[0025] FIG. 3A is an explanatory diagram (1) for describing a three-dimensionally printed structure according to an embodiment. As described above, the three-dimensionally printed structure according to the embodiment may be a composite material formed by directly 3D printing and adhering a thick structure to one side of a fabric, or by separately 3D printing and then adhering the structure to the fabric. That is, the three-dimensionally printed structure according to the embodiment may be a composite material integrally molded with one side of the fabric by printing on the fabric, or a composite material molded by printing and then adhering the structure to the fabric. In FIG. 3A, the three-dimensionally printed structure is molded so as to be in direct contact with the fabric. Note that FIG. 3B is an explanatory diagram (2) for describing a three-dimensionally printed structure according to an embodiment. In FIG. 3B, the three-dimensionally printed structure is molded so as to be adhered to the fabric via an adhesive layer.

[0026] 3C is an explanatory diagram (3) for explaining a three-dimensional printed structure according to an embodiment. As described above, the three-dimensional printed structure according to an embodiment may be a fabric composite material in which a thick structure is sandwiched between two layers of fabric, an outer fabric and a lining fabric. In other words, the three-dimensional printed structure according to an embodiment may be a composite material in which a predetermined three-dimensional structure is sandwiched between two layers of fabric, an outer fabric and a lining fabric. In FIG. 3C, the three-dimensional printed structure is sandwiched between the two layers of fabric, an outer fabric and a lining fabric, so that it is in direct contact with the two layers of fabric.

[0027] FIG. 3D is an explanatory diagram (4) for describing a three-dimensional printed structure according to an embodiment. As described above, the three-dimensional printed structure according to an embodiment may be a structure configured with structures having different physical properties arranged in different regions, taking into account factors such as the range of motion of the body. That is, the three-dimensional printed structure according to an embodiment may be a composite material having different three-dimensional structures depending on the location of the fabric. In FIG. 3D , region P1 is a region where a crushable structure (crushable structure) is arranged, region P2 is a region where a highly stretchable structure (stretchable structure) is arranged, region P3 is a region where a highly elastic structure (highly elastic structure) is arranged, and region P4 is a region where a highly heat-retaining structure (heat-retaining structure) is arranged.

[0028] FIG. 3E is an explanatory diagram (5) for explaining a three-dimensional printed structure according to an embodiment. As described above, the three-dimensional printed structure according to an embodiment may be formed by preparing two textiles each having a structure on one side, sandwiching them together, and sewing them together. In such a case, the three-dimensional printed structure according to an embodiment may be formed by sewing the two textiles together with the center fixed, or by sewing the two textiles together without the center fixed. Furthermore, the three-dimensional printed structure according to an embodiment may be formed by sandwiching an aluminum-deposited sheet between them, for example.

[0029] FIG. 3F is an explanatory diagram (6) for describing a three-dimensional printed structure according to an embodiment. As described above, the three-dimensional printed structure according to an embodiment may be a structure in which the distribution of the pattern varies in the vertical and horizontal axis directions when viewed from above and in the height axis direction when viewed from the side, and physical changes are obtained by varying the volume density, feature density, etc. in each direction. In FIG. 3F, the structure is molded so that the volume density varies in the height axis direction. Specifically, the structure is molded so that the volume density increases in a predetermined direction (top surface direction). FIG. 3G is an explanatory diagram (7) for describing a three-dimensional printed structure according to an embodiment, in which the structure is molded so that the volume density varies in the vertical and horizontal axis directions. Specifically, the structure is molded so that the volume density increases in a predetermined direction (width and depth directions). In addition, FIGS. 3H and 3I are explanatory diagrams (8) and (9) for describing a three-dimensional printed structure according to an embodiment, in which the structure is molded so that the feature density varies. For example, the feature density in FIG. 3I is higher than that in FIG. 3H. 3J and 3K are explanatory diagrams (10) and (11) for explaining the three-dimensional printed structure according to the embodiment, which are molded to have a varying structure. For example, the structure in Fig. 3K is more detailed and complex than that in Fig. 3J.

[0030] (Process leading up to sewing) The 2D drawn pattern is loaded into 3D design CAD. The pattern range is divided into arbitrary grids, and arbitrary structural elements are placed inside the voxels based on this. The design is modified so that there are no geometric intersections during assembly (taking into consideration thickness, edge faces, etc.). The design is output and the outer and lining fabrics are sewn.

[0031] The designer specifies a range in pattern data representing a garment template, and a three-dimensional structure is retrieved from a database based on the range specified on the pattern data and the physical property data specified by the designer, and the retrieved three-dimensional structure is placed in the specified range. The database, for example, converts the specified physical property data parameters into numerical values ​​for an algorithm for generating a structure. The physical property instruction data input to the database includes numerical values ​​related to thermal insulation, stretchability, elasticity, etc., and the database inputs the numerical values ​​into an algorithm that generates a three-dimensional shape based on a relational expression between the structure analyzed and evaluated up to that point and these numerical values. The database acquires at least one of the physical property data, selects a structure generation algorithm that is estimated to be suitable, and generates the three-dimensional structure.

[0032] (Use Mode) The following describes actual use modes. For example, by molding a resin structure to have a predetermined three-dimensional structure on fabric, it is possible to adjust the insulation properties, mobility, and other functions of a product (e.g., wearable items such as clothing, building walls, housing surface materials, furniture, etc.). For example, by creating a thick air layer for heat insulation on the surface of fabric using a flexible resin structure (e.g., a lattice structure, a rib structure, a pillar structure, an origami structure, a honeycomb structure, etc.), it is possible to provide a heat-retaining effect similar to that of down. For example, by using it in a jacket, it is possible to manufacture products with enhanced insulation and stretchability. Furthermore, it is possible to manufacture products with high stretchability around the elbows and high elasticity in the elbow area, depending on the designer's intention, taking into account the range of motion of the body, etc. Furthermore, by switching the structure according to the purpose depending on the part, it is possible to impart (or change) multiple properties to the fabric, such as stretchability and elasticity, depending on the structure.

[0033] (Embodiment 2) While the first embodiment is structured to block radiant heat from the top surface, the second embodiment is structured to block radiant heat from all directions. Blocking radiant heat from all directions results in a lattice structure that is more suitable as a thermal insulation structure. In the second embodiment, the shielding ratio is calculated by rotating the projection surface toward the structure by a predetermined angle at a predetermined incidence angle, thereby rotating the projection surface 360 ​​degrees. For example, the shielding ratio is calculated by positioning the projection surface toward the structure while rotating it by 2.5 degrees at an incidence angle of 80 degrees (for example, positioning it in a 3770° direction). In the second embodiment, the shielding ratio is calculated based on the transmittance of light projected from the projection surface toward the structure. For example, the shielding ratio is calculated by projecting light from the projection surface toward the structure, performing hit determination (for example, determination from 4800 points arranged within a 10 mm diameter circle for each projection surface), and calculating the ratio of transmitted light to non-transmitted light. In the second embodiment, the aperture ratio is the aperture ratio in the direction perpendicular to the sandwich direction when the structure is sandwiched between any shielding layers.

[0034] The three-dimensional printed structure according to the embodiment may be a three-dimensional printed structure using a body centroid lattice (BC lattice) with moderate elasticity as the basic shape for CAE analysis. Specifically, the three-dimensional printed structure according to the embodiment may be a lattice structure in which a shape formed by connecting the vertices of a cube at its center is arranged in the XYZ directions as a single smallest unit (cell). The three-dimensional printed structure according to the embodiment may also be generated by changing each parameter of the structure. As shown in FIG. 4 , the three-dimensional printed structure according to the embodiment may be generated by changing parameters related to each dimension of the BC lattice for each phase result. For example, the three-dimensional printed structure according to the embodiment may be generated based on the results of multiple phases by changing parameters based on the results of the "1st CAE" phase, the "2nd CAE" phase, and the "3rd CAE" phase. The three-dimensional printed structure according to the embodiment may also be generated by controlling the shape with parameters or algorithms and connecting nodes using a CAD software application such as Rhinocerous (e.g., Grasshopper).

[0035] The following describes the structure of a three-dimensional printed structure according to an embodiment. There are three types of three-dimensional printed structures according to an embodiment (one spiral type and two screw types). Each structure is created by modifying a BC lattice with the goal of "increasing the shielding rate of the structure as a countermeasure against radiant heat while taking elasticity into consideration." Specifically, because uniform shapes can significantly reduce the shielding rate at certain angles when arranged in a row, the structure creates a complex / disorderly internal shape by adding variables to the shape / direction of the beams to increase the shielding rate. Furthermore, to ensure thermal insulation, the structure is designed to block light from all directions on the top surface of the structure. One three-dimensional printed structure according to an embodiment has a spiral structure ( FIG. 5A ), in which cells are stacked in a DNA spiral pattern by rotating the stacking direction of the lattice cells. Another three-dimensional printed structure according to an embodiment has a screw structure ( FIG. 5B ), in which the extension direction of the lattice beams is adjusted to rotate by a specific angle (7 degrees or 14 degrees) each time a cell is stacked. Hereinafter, a structure adjusted to rotate in 7 degree increments will be referred to as a "7 degree screw type," and a structure adjusted to rotate in 14 degree increments will be referred to as a "14 degree screw type."

[0036] The structural parameters of the three-dimensional printed structure according to the embodiment are described below. Examples of basic parameters of the lattice structure ( FIG. 6A ) include the diameter of the beams and the size of the cube (length, width, and depth). Furthermore, examples of parameters related to the thickness of the thermal insulation layer ( FIG. 6B ) include the number of rows of cells stacked in the height direction. Note that the number of rows may be determined by setting the height (e.g., 20 mm). Furthermore, examples of structural parameters for increasing the shielding rate ( FIGS. 6C and 6D ) include the angle of the beams rotated for each lattice cell stacked, and the rotation angle when stacking the lattice cells. The shape of the structure is determined by manipulating these dimensional parameters.

[0037] Furthermore, for a structure with high thermal insulation (i.e., low thermal conductivity), three parameters are important: the volume ratio of the entire structure, the average shading ratio, and the aperture ratio of the largest open area. The volume ratio indicates the proportion of the space occupied by the structure. The average shading ratio indicates the average rate of blocking light at each angle from the celestial sphere. The aperture ratio of the largest open area indicates the aperture ratio of the most open area from the celestial sphere directly above the structure. For example, a high volume ratio tends to increase conductive heat and reduce thermal insulation performance (increase thermal conductivity), so a lower volume ratio is considered preferable. For example, a high average shading ratio of a structure tends to reduce radiant heat and increase thermal insulation performance (decrease thermal conductivity), so a higher volume ratio is considered preferable. Furthermore, even if a structure has a large opening, not only does heat transfer through the opening but also tends to increase the aperture ratio of the surrounding incident angle, which tends to reduce overall thermal insulation performance (increase thermal conductivity). Therefore, a lower aperture ratio of the largest open area is considered preferable. The three-dimensional printed structure according to the embodiment is designed to have a volume ratio of 7% or less (preferably 6% or less or 5% or less) (note that the reference space size is 10 mm wide, 10 mm deep, and 1 mm high), an average shielding ratio of 98% or more, and an opening ratio of the largest opening portion of 15% or less. The three-dimensional printed structure according to the embodiment may be designed to have an average shielding ratio in the range of 99.49% to 99.98%, a minimum shielding ratio in the range of 87.5% to 94.11%, and a volume ratio in the range of 4.3% to 5.2%. Furthermore, the three-dimensional printed structure according to the embodiment may be designed to have a number of projection surfaces with 80% or less shielding in the range of 0 / 3770 and a number of projection surfaces with 90% or less shielding in the range of 0 / 3770 to 52 / 3770.

[0038] Six-sided views of a three-dimensional printed structure according to an embodiment are described below. Figures 7A to 7F show an example of a six-sided view of a three-dimensional printed structure (spiral type) according to an embodiment. Figure 7A is a front view of the six-sided view, Figure 7B is a rear view of the six-sided view, Figure 7C is a plan view of the six-sided view, Figure 7D is a bottom view of the six-sided view, Figure 7E is a left side view of the six-sided view, and Figure 7F is a right side view of the six-sided view. Figures 8A to 8F show an example of a six-sided view of a three-dimensional printed structure (7-degree screw type) according to an embodiment. Figure 8A is a front view of the six-sided view, Figure 8B is a rear view of the six-sided view, Figure 8C is a plan view of the six-sided view, Figure 8D is a bottom view of the six-sided view, Figure 8E is a left side view of the six-sided view, and Figure 8F is a right side view of the six-sided view. Figures 9A to 9F show an example of a six-sided view of a three-dimensional printed structure (14-degree screw type) according to an embodiment. 9A is a front view of the six-sided view, FIG. 9B is a rear view of the six-sided view, FIG. 9C is a plan view of the six-sided view, FIG. 9D is a bottom view of the six-sided view, FIG. 9E is a left side view of the six-sided view, and FIG. 9F is a right side view of the six-sided view.

[0039] (Effect) As described above, the insulating material according to the embodiment is a three-dimensional printed structure printed to have a predetermined three-dimensional structure, and the predetermined three-dimensional structure is characterized by including a three-dimensional printed structure having an opening ratio equal to or less than a first threshold value and a volume density equal to or less than a second threshold value.

[0040] This makes it possible to give 3D printed structures the appropriate physical properties for a specific purpose. Furthermore, the high degree of freedom in 3D printing allows the mechanical properties of an object to be defined not only by the material but also by its structure. This makes it possible to improve the heat retention of insulating materials, including 3D printed structures.

[0041] The insulating material of the embodiment is characterized by including a three-dimensional printed structure whose opening ratio in a direction perpendicular to the sandwich direction when the three-dimensional printed structure is sandwiched between any shielding layers is equal to or less than a first threshold value.

[0042] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure has a certain opening ratio, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0043] The heat insulating material according to the embodiment is characterized in that it includes a three-dimensional printed structure whose shielding rate is within a predetermined range when the projection surface onto the three-dimensional printed structure is rotated by a predetermined angle at a predetermined incident angle and rotated 360 degrees.

[0044] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure meets a certain shielding rate, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0045] The insulating material according to the embodiment is characterized in that it includes a three-dimensional printed structure having a shielding rate within a predetermined range calculated based on the transmittance of light projected from a projection surface onto the three-dimensional printed structure.

[0046] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure meets a certain shielding rate, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0047] The heat insulating material according to the embodiment is characterized by including a three-dimensional printed structure that is created to block light from all directions of the celestial sphere.

[0048] This makes it possible to improve the physical properties of the three-dimensional printed structure, and therefore to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0049] The insulating material of the embodiment is characterized by including a three-dimensional printed structure generated by changing parameters related to a lattice structure in which the shape formed by connecting each vertex of a cube at its center is the smallest unit.

[0050] This makes it possible to improve the physical properties of the heat insulating material including the three-dimensional printed structure by adjusting the lattice structure so that the physical properties of the three-dimensional printed structure are improved.

[0051] The insulating material according to the embodiment is characterized by including a three-dimensional printed structure created by rotating the direction of extension of the beams of a lattice structure, with the smallest unit being a shape formed by connecting each vertex of a cube at its center, by a predetermined angle each time the lattice is stacked.

[0052] This makes it possible to improve the physical properties of the heat insulating material including the three-dimensional printed structure by adjusting the lattice structure so that the physical properties of the three-dimensional printed structure are improved.

[0053] The insulating material according to the embodiment is characterized by including a three-dimensional printed structure generated by changing at least one of the parameters: the diameter of the beams of a lattice structure, in which the shape formed by connecting each vertex of a cube at its center is used as a single smallest unit; the size of the cube; the height at which the lattices are stacked; the angle at which the beams are rotated each time the lattices are stacked; and the rotation angle when the lattices are stacked.

[0054] This makes it possible to adjust the parameters of the lattice structure, and by adjusting the parameters to improve the physical properties of the three-dimensional printed structure, it is possible to improve the physical properties of the insulation material including the three-dimensional printed structure.

[0055] The heat insulating material according to the embodiment is characterized by including a three-dimensional printed structure having a volume fraction of 7% or less.

[0056] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure satisfies certain parameters, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0057] The heat insulating material according to the embodiment is characterized by including a three-dimensional printed structure having an average shielding rate of 98% or more.

[0058] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure satisfies certain parameters, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0059] The heat insulating material according to the embodiment is characterized by including a three-dimensional printed structure having an opening ratio of 15% or less at the maximum opening portion.

[0060] This makes it possible to improve the physical properties of the three-dimensional printed structure by ensuring that the lattice structure satisfies certain parameters, thereby making it possible to improve the physical properties of the insulating material including the three-dimensional printed structure.

[0061] (Other) Furthermore, among the processes described in the above embodiments, all or part of the processes described as being performed automatically can be performed manually, or all or part of the processes described as being performed manually can be performed automatically using known methods. In addition, the information including the processing procedures, specific names, various data, and parameters shown in the above documents and drawings can be changed as desired unless otherwise specified. For example, the various information shown in each drawing is not limited to the information shown in the drawings.

[0062] Furthermore, the components of each device shown in the figure are conceptual functional components and do not necessarily have to be physically configured as shown in the figure. In other words, the specific form of distribution and integration of each device is not limited to that shown in the figure, and all or part of them can be functionally or physically distributed and integrated in any unit depending on various loads, usage conditions, etc.

[0063] Furthermore, the above-described embodiments can be combined as appropriate within the scope of not causing any contradiction in the processing content.

[0064] Although some of the embodiments of the present application have been described in detail above with reference to the drawings, these are merely examples, and the present invention can be implemented in other forms that include the embodiments described in the Disclosure of the Invention section and that have undergone various modifications and improvements based on the knowledge of those skilled in the art.

[0065] The following configurations also fall within the technical scope of the present disclosure. (1) A thermal insulation material including a three-dimensionally printed structure that constitutes at least a part of a product, the three-dimensionally printed structure being printed to have a predetermined three-dimensional structure according to the purpose of the product. (2) The thermal insulation material according to (1), including the three-dimensionally printed structure, in which the opening ratio in a direction perpendicular to the sandwiching direction when the three-dimensionally printed structure is sandwiched between any shielding layers is equal to or less than a first threshold. (3) The thermal insulation material according to (1), including the three-dimensionally printed structure, in which the shielding ratio when a projection surface onto the three-dimensionally printed structure is rotated by a predetermined angle at a predetermined incident angle and rotated 360 degrees is within a predetermined range. (4) The thermal insulation material according to (1), including the three-dimensionally printed structure, in which the shielding ratio calculated based on the transmittance of light projected from the projection surface onto the three-dimensionally printed structure is within a predetermined range. (5) The thermal insulation material according to (1), including the three-dimensionally printed structure generated so as to block light from all celestial sphere directions. (6) The heat insulating material according to (1), including the three-dimensional printed structure generated by changing parameters related to a lattice structure in which the shape formed by connecting the vertices of a cube at its center is one minimum unit. (7) The heat insulating material according to (1), including the three-dimensional printed structure generated by rotating the extension direction of beams of the lattice structure in which the shape formed by connecting the vertices of a cube at its center is one minimum unit by a predetermined angle each time the lattice is stacked. (8) The heat insulating material according to (1), including the three-dimensional printed structure generated by changing at least one parameter among the diameter of the beams of the lattice structure in which the shape formed by connecting the vertices of a cube at its center is one minimum unit, the size of the cube, the height at which the lattice is stacked, the angle at which the beams are rotated each time the lattice is stacked, and the rotation angle when the lattice is stacked. (9) The heat insulating material according to (1), including the three-dimensional printed structure having a volume fraction of 7% or less. (10) The heat insulating material according to (1), including the three-dimensional printed structure having an average shielding factor of 98% or more. (11) The heat insulating material according to (1), including the three-dimensional printed structure having an opening ratio of 15% or less at the largest opening portion.(12) A computer-implemented printing method, the printing method comprising printing a three-dimensional printed structure to form at least a part of a product so as to have a predetermined three-dimensional structure according to the purpose of the product. (13) A wearing article comprising a three-dimensional printed structure to form at least a part of a product, the three-dimensional printed structure being printed so as to have a predetermined three-dimensional structure according to the purpose of the product.

Claims

1. An insulating material comprising a three-dimensional printed structure printed to have a predetermined three-dimensional structure, the predetermined three-dimensional structure having an opening ratio equal to or less than a first threshold and a volume density equal to or less than a second threshold.

2. The insulating material described in claim 1, characterized in that it includes a three-dimensional printed structure, the opening ratio in a direction perpendicular to the sandwich direction when the three-dimensional printed structure is sandwiched between any shielding layer being equal to or less than the first threshold value.

3. The heat insulating material according to claim 1, characterized in that it includes a three-dimensional printed structure whose shielding rate is within a predetermined range when the projection surface onto the three-dimensional printed structure is rotated 360 degrees at a predetermined angle of incidence and in predetermined increments.

4. The insulation material described in claim 1, characterized in that it includes a three-dimensional printed structure whose shielding rate calculated based on the transmittance of light projected from a projection surface onto the three-dimensional printed structure is within a predetermined range.

5. The heat insulating material according to claim 1, characterized in that it includes the three-dimensional printed structure generated so as to block light from all celestial directions.

6. The heat insulating material according to claim 1, characterized in that it includes the three-dimensional printed structure generated by changing parameters related to a lattice structure in which the shape formed by connecting each vertex of a cube at its center is the smallest unit.

7. The heat insulating material according to claim 1, characterized in that it includes the three-dimensional printed structure produced by rotating the direction in which the beams of a lattice structure, in which the smallest unit is a shape formed by connecting each vertex of a cube at its center, extend by a predetermined angle each time the lattice is stacked.

8. The heat insulating material according to claim 1, characterized in that it includes the three-dimensional printed structure generated by changing at least one of the parameters of the diameter of the beams of a lattice structure in which the shape formed by connecting each vertex of a cube at its center is one smallest unit, the size of the cube, the height at which the lattice is stacked, the angle of the beams rotated each time the lattice is stacked, and the rotation angle when the lattice is stacked.

9. The insulation material according to claim 1, characterized in that it contains the three-dimensional printed structure having a volume fraction of 7% or less.

10. The insulation material according to claim 1, characterized in that it contains the three-dimensional printed structure having an average shielding rate of 98% or more.

11. The heat insulating material according to claim 1, characterized in that it includes the three-dimensional printed structure, the opening rate of the maximum opening portion being 15% or less.

Images