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CN108474511B - 制造隔离产品的方法和通过该方法获得的产品 - Google Patents

制造隔离产品的方法和通过该方法获得的产品 Download PDF

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Publication number
CN108474511B
CN108474511B CN201680074248.XA CN201680074248A CN108474511B CN 108474511 B CN108474511 B CN 108474511B CN 201680074248 A CN201680074248 A CN 201680074248A CN 108474511 B CN108474511 B CN 108474511B
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China
Prior art keywords
gas
foil
insulation
product
wrapping
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CN201680074248.XA
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CN108474511A (zh
Inventor
J·E·拉贝克
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Rockwell Co ltd
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Rockwool International AS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
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    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
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    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Thermal Insulation (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种生产隔离产品的方法，该隔离产品包括包裹在不透气的箔中的多孔隔离材料板，所述方法包括以下步骤：在第一输送设备上提供一系列的多孔隔离材料板并在第二输送设备上馈送所述板；提供包裹箔并包裹所述箔以在所述第二输送设备上的板周围形成管，用隔离气体冲洗板，并且在每个板的端部处横向于第二输送设备的行进方向密封包裹箔。

Description

制造隔离产品的方法和通过该方法获得的产品
技术领域
本发明涉及一种制造隔离产品的方法和通过该方法获得的产品，该隔离产品包括包裹在不透气的箔中并包含隔离气体的多孔隔离材料。
背景技术
在紧密密封的袋中的热隔离材料的产品在本领域中是公知的，例如所谓的真空隔离面板(VIP)。
目前的VIP技术通常包括例如由锻制的二氧化硅、矿物纤维或其他微孔材料芯形成的隔离材料。芯被包裹在柔性的、气密的封套中而在密封之前施加有真空。真空对面板的隔离性能至关重要。如果真空消失，则面板失去了很大一部分热性能，而热导率恢复到芯材料的热导率。这意味着，由一种或多种处理损害而造成的所有类型的封套刺穿对于面板而言都是非常成问题和关键的，所述处理损害例如是切割成尺寸，固定到建筑物基板，以及由于钻孔用于布线、固定架子等而造成的损坏。前面提到的是现在在建筑物构造中使用VIP技术还不是很普遍的原因之一。此外，特别是矿物纤维材料的使用具有一些额外的缺点，因此这些芯材料不会是第一选择。因此，会需要微孔材料，但是这种材料非常昂贵。
先前已经提出了另一种方法，在密封袋内提供密封多孔隔离材料并用气体取代所包含的空气。例如参考美国专利US 2,779,066，该专利涉及一种制冷设备，更具体地涉及一种用于使这种冰箱的壁隔离的改进的布置。提供的是一种改进的和实用的隔离体，其中具有低热导系数的气体与玻璃纤维或类似物结合使用。
在WO 2012/164310中公开了包含隔离层的复合材料面板，该隔离层包括实心开孔泡沫板，所述实心开孔泡沫板可在其中具有至少一个内部空隙，并且其中面板的一个或多个表面和/或空隙设置有气密的密封涂层。内部空隙空间可以被抽空或包含在大气压力附近的空气或惰性气体。
WO 96/03555公开了一种重量轻、部分抽空的负载支撑隔离面板，其包括不透气的外部封套和透气的内部封套。内部封套填充有粗的透气颗粒和细的透气微粒的混合物，形成在所述颗粒和微粒之内和之间的空隙空间包含有低热导性气体。
在CA 1290677中公开了隔离面板，所述隔离面板由充入有隔离气体的压缩颗粒材料形成，该组合保持在气密袋中。这些袋可以放置在要提供隔离的结构的隔离空间中，并且如果需要，可以将其包装在泡沫隔离材料中。可能的颗粒材料是沉淀二氧化硅，而各种氟里昂气体可以用作隔离气体。
尽管包括由不透气箔包裹并包括隔离气体的多孔隔离材料板的隔离产品本身是已知的，但是由于生产一直是主要挑战，所以没有这样的产品曾经被引入建筑领域；因此没有工业上合适的生产这种产品的方法。
发明内容
因此，本发明的目的是提供一种制造具有增强的热性能的这种产品的方法，其中生产成本可以保持合理低并且具有高生产能力。
该目的通过一种生产隔离产品的方法来实现，所述隔离产品包括包裹在不透气的箔中的多孔隔离材料板，所述方法包括以下步骤：
-在第一输送设备上提供一序列的多孔隔离材料板，并在第二输送设备上馈送所述板；
-提供包裹箔并包裹所述箔以在所述第二输送设备上在流动包裹设备上的所述板周围形成管，
-用隔离气体冲洗所述板，和
-横向于所述第二输送设备的行进方向在每个板的端部处密封所述包裹箔。
合适的多孔隔离材料具体来说是结合的(bound)纤维隔离材料，优选结合的矿物纤维产品，例如，石棉或玻璃棉产品，但也可以是结合的天然纤维产品，例如，木纤维、植物或动物纤维，此外还可以是合成或半合成纤维。此外，添加或不添加粘合剂的多孔矿物粗粒或颗粒材料，例如，珍珠岩、蛭石或其他材料也可能是合适的。
因此，提供了一种高效的生产工艺，其特别适用于大规模生产用于建筑元件或类似结构的热隔离的隔离板。
该制造方法的结果是一系列的隔离板，其中多孔隔离材料中的空气被隔离气体代替，在包装内仅留下少量空气。这降低了热隔离值，即热导率值，并且提供了所得产品的更好的热性能。
典型地，现在通常已知的矿物纤维板可以具有32mW/(m*K)的热导率(λ)。通过用不透气的箔包裹板并用CO2代替空气，热导率可以降低约10mW/(m*K)。这两者都是根据气体的热导率值计算出来的(λ空气＝26mW/(m*K)-λCO2＝16mW/(m*K)，因此导致约10mW/(m*K)的减少)，并基于对根据本发明的方法生产出的各个隔离产品的实际测量结果得到了验证。
下表给出了不同气体的热导率值，给出了作为温度函数的气体热导系数。
除非在图表中另有说明，否则这些数值指的是100kPa(1bar)的压力下的或者在低于100kPa时则是在饱和蒸汽压下的。注释P＝0表示给出了低压极限值。通常，P＝0和P＝100kPa的值相差小于1％。
单位：mW/mK(毫瓦每米开尔文)
Figure BDA0001698296600000031
Figure BDA0001698296600000041
来源：https://www.engineersedge.com/heat_transfer/thermal-conductivity-gases.htm
已经测量了根据本发明的产品的热导率值。下面提到的测量值是基于n＝9测量的平均值λ平均：
具有空气的石棉：λ平均＝32mW/(m*K)
具有氩气的石棉：λ平均＝24mW/(m*K)
具有CO2的石棉：λ平均＝22mW/(m*k)
测量根据欧洲标准EN12667完成，参考平均温度为10℃。
包裹工艺是流动包裹工艺。通过在包裹工艺完成之前冲洗多孔隔离材料，多孔隔离材料内的空气被隔离气体代替。与创建真空和从隔离材料内部排空空气相比这是有利的，因为这允许隔离产品的连续制造工艺，所述连续制造工艺更容易且更快速，而导致具有非常低的生产成本的更高效和可靠的生产工艺。
在优选实施例中，在第一输送设备上提供隔离材料的压缩。这确保了成品板内部的压力将略低于环境气压。这确保了当安装在建筑物结构或类似物中时使用隔离板期间由于热量或环境压力下降而导致的过压风险的降低。
优选地，保持预压缩直到执行板的端部的密封。当密封包装后释放压缩时，隔离材料的膨胀将导致包装内的压力较低。
作为预压缩的代替或补充，可以在第一输送设备上提供隔离材料的预热。这对于实现包装内部的压力低于环境压力也是有利的，因为当多孔隔离材料以及由此还有隔离气体在密封之后冷却时，包装内的压力将成比例地降低。
在一个实施例中，在冲洗管状的包裹箔的内部之前提供隔离气体的预热。这增加了预热效果，并且由此也增加了随后包装内部的较低压力的创建。
冲洗步骤优选地包括用隔离气体冲洗所述管状包裹箔的内部和其中的板。这确保了就在进行板的端部密封之前，在流动包裹工艺期间管状包裹箔内的空气由隔离气体的代替。因此，气体冲洗步骤优选将管状包裹箔内部的80-98％之间的空气替代为隔离气体，并由此也代替多孔隔离材料板中的空气。
有利地，用于气体冲洗的隔离气体是从由二氧化碳(CO2)、氩气或热导率低于空气的率的其他气体所组成的组中选择出的至少一种气体。
在本发明的优选实施例中，包裹箔是多层塑料箔，并且形成管状包裹箔包括形成和纵向焊接包裹箔。因此，端部密封可以是跨越管状包裹箔的热塑性焊接。
在本发明的第二方面中，提供了一种隔离产品，其包括包裹在不透气的箔中的多孔隔离材料的板，其中产品是通过执行根据本发明第一方面的方法获得的。优选地，多孔隔离材料是纤维状矿物棉，例如石棉或玻璃棉。
如上所述，有利的是，多孔隔离材料内的截留气体处于亚大气压力下，从而吸收了隔离产品在使用过程中的任何热膨胀。
优选地，产品中的截留气体至少80％为隔离气体，例如二氧化碳(CO2)、氩气或类似气体、或类似的热导系数低于空气热导系数的一种或多种气体。
包裹箔有利地是包括金属化塑料箔和外部热塑性层的多层塑料箔。与铝箔不同，金属化塑料箔不会在隔离中形成任何热桥。通过使用金属化箔、气密箔，在隔离体中不会引入热桥接。通过确保在多层箔上的热塑性内层，可以确保箔可以被热封，即焊接在一起。
附图说明
参考附图进一步详细地公开了本发明，其中：
图1是用于制造隔离产品的生产工艺的示意图，该隔离产品包括包裹在不透气的箔中的多孔隔离材料的板，和
图2是由生产工艺得到的隔离产品的示意性截面图。
具体实施方式
参照图1，根据本发明的优选实施例的隔离产品的生产始于将多孔隔离材料切割成构成隔离板1所期望的尺寸。板1以连续方式顺序地馈送到第一输送器10上。多孔隔离材料优选为具有密度范围为30-120kg/m3的石棉、密度范围为15-60kg/m3的玻璃棉、或其它多孔隔离材料。生产流向由图1中的箭头表示。
板1可优选通过第一上输送带11或类似物而被机械压缩，例如5-20％，更优选10-15％。所述压缩由在后续输送带12、13的上部和下部之间的输送带11的开口的最终高度与隔离材料的标称厚度相比较而确定。在第一输送设备10、11中，还可以有利地提供用于加热板1的装置，例如将板加热到30-120℃的温度。
板1被馈送入包括第二组输送器12、13和第三组输送器14和15的水平流动打包机构(流动打包机)20中。流动打包机20将包裹箔2馈送到第二下输送器12上的板1，同时第二上输送器13以及进一步的第三下输送器14和第三上输送器15保持板1的压缩。然后将箔折叠或弯曲成管状(未示出)并提供纵向密封件6，提供如图2所示的焊接密封2A。优选地，流动打包机将隔离体加热到30-80℃，并且还将气密箔2包裹在板1周围，用隔离气体通过气体冲洗管3冲洗隔离板1，并且在端部密封站7处密封端部。隔离气体从气体源4供应，并且优选地在通过气体管3被馈送并进入围绕流动打包机20中的板形成为管状构造的包裹箔中之前，被加热到30-120℃的温度。
该工艺的结果是隔离板1在包装1A中留下约2-15％的空气，其中多孔隔离材料中的空气被隔离气体取代。与没有气密包裹而隔离材料内部有空气的的隔离板相比，这增加了热隔离性能。通过根据本发明的工艺，这种产品的热导率值因此显著降低。
通过压缩芯材和/或通过加热材料和气体，成品板1A内的压力将低于环境空气压力。这降低了在使用隔离板1A期间由于热量或环境压力下降而导致的过压风险。
由于箔2紧密地围绕隔离材料1包装，所以隔离材料的预压缩确保了密封的成品产品1A中的较低压力。因此，隔离材料板1优选地在包装之前和期间被压缩，例如通过第一、第二和第三上输送器11、13、15。当在密封站7密封了包装1A之后释放压缩时，隔离材料的膨胀将导致包装内的压力较低。
确保包装内的压力始终低于环境压力的另一种方法是加热隔离材料板1和隔离气体。当隔离气体在密封后冷却时，成品产品内部的压力会下降。通过本发明可以认识到，除了单独地两个工艺步骤之外，可以使用预压缩和预加热以实现成品产品内的较低压力。
当在密封站7处密封之后，产品在此处还被彼此分离，成品产品被输送到进一步处理，如在第四输送器系统16上进行包装。还可以在该第四输送器系统16处提供质量控制步骤QC，如图1所示，其中可以测量热导率。
可以提供额外的工艺步骤9(参见图1)。该附加步骤9是可选的附加保护包裹或覆盖，其在成品板1A上实施。由此，实现了对板1A的保护以防止在说明书的背景技术中提到的损害。
成品板1A包括多孔隔离材料的芯1，其可以是矿棉或其他开放的多孔隔离材料，其被包裹在气密的箔2中。箔2优选为热塑性多层箔2，其具有金属化塑料箔层以确保箔2的不透气性。此外，多层箔2优选具有可焊接的外层，以便使用热密封工艺，用于在站6处进行纵向密封以及用于端部密封7。通过如图1所示的工艺，板1中的空气被隔离气体3代替。该气体可以是CO2、氩气或另外的隔离气体。通过用隔离气体代替空气，产品的热导率可以显著降低。
参考标记
1 多孔隔离板
1A 包装好的隔离板
2 气密箔
2A 底部密封/焊接密封
3 气体喷枪
4 隔离气体
5 隔离气体的可能的预热
6 底部密封机
7 端部密封机
8 气体喷枪出口
9 可选的附加保护包裹
10 第一下输送器，用于压缩且潜在地还用于预热
11 第一上输送器，用于压缩且潜在地还用于预热
12 第二下输送器
13 第二上输送器
14 第三下输送器
15 第三上输送器
16 第四输送器系统

Claims (18)

1.一种生产隔离产品的方法，所述隔离产品包括包裹在不透气的箔中的多孔隔离材料的板，所述方法包括以下步骤：
在第一输送设备上提供一系列的多孔隔离材料板，并在第二输送设备上馈送所述板；
提供包裹箔并包裹所述箔以在所述第二输送设备上在流动包裹设备上的所述板周围形成管状包裹箔，
用隔离气体冲洗所述管状包裹箔的内部和其中的所述板，然后横向于所述第二输送设备的行进方向在每个板的端部处密封所述包裹箔。
2.根据权利要求1所述的方法，其中在所述第一输送设备上提供对所述隔离材料的预压缩。
3.根据权利要求2所述的方法，其中所述预压缩在所述隔离材料的标称厚度的5-20％的范围内。
4.根据权利要求2或3所述的方法，其中保持所述预压缩直到执行完对所述板的所述端部的密封。
5.根据权利要求1至3中任一项所述的方法，其中在所述第一输送设备上提供对所述隔离材料的预加热。
6.根据权利要求1至3中任一项所述的方法，其中在冲洗所述管状包裹箔的内部之前提供对所述隔离气体的预加热。
7.根据权利要求1至3中任一项所述的方法，其中冲洗步骤包括用隔离气体冲洗所述管状包裹箔的内部和在其中的所述板。
8.根据权利要求1至3中任一项所述的方法，其中气体冲洗步骤用所述隔离气体代替所述管状包裹箔和所述板内部的80-98％的空气。
9.根据权利要求1至3中任一项所述的方法，其中所述隔离气体是从具有比空气低的热导率的气体所组成的组中选择出的至少一种气体，其中所述具有比空气低的热导率的气体包括二氧化碳（CO2）和氩气。
10.根据权利要求1至3中任一项所述的方法，其中所述包裹箔是多层塑料箔，并且所述管状包裹箔的形成包括所述包裹箔的形成和纵向焊接。
11.一种隔离产品，包括包裹在不透气的箔中的多孔隔离材料的板，所述产品通过执行根据前述权利要求中任一项所述的方法而获得。
12.根据权利要求11所述的隔离产品，其中所述产品具有根据EN12667测量得到的平均热导率λ平均，所述平均热导率λ平均等于或低于25 mW/(m*K)。
13.根据权利要求11或12所述的隔离产品，其中所述多孔隔离材料内的截留气体处于亚大气压力下。
14.根据权利要求11或12所述的隔离产品，其中所述产品中的截留气体至少80％为隔离气体。
15.根据权利要求14所述的隔离产品，其中所述隔离气体为二氧化碳（CO2）或氩气。
16.根据权利要求11或12所述的隔离产品，其中所述多孔隔离材料是纤维状矿物棉。
17.根据权利要求16所述的隔离产品，其中所述纤维状矿物棉为石棉或玻璃棉。
18.根据权利要求11或12所述的隔离产品，其中所述包裹箔为包括金属化塑料箔和外部热塑性层的多层塑料箔。
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US10632708B2 (en) * 2016-02-29 2020-04-28 Alienus Film Llc Insulating film
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