KR101257361B1 - Vacuum insulator and method for fabricating thereof - Google Patents

Abstract

The present invention relates to a vacuum insulator and a method of manufacturing the same.

The vacuum insulator according to the present invention is a vacuum insulator composed of a predetermined inner structure, a filler filling an empty space of the inner structure, and an outer shell material surrounding the inner structure, wherein the outer shell material is a polymer layer formed on the metal layer and the metal layer. Each of the upper and lower shells surrounding the upper and lower surfaces of the internal structure, and in a certain section along the edges of the upper and lower shells, LDPE (Lowdensity) between the metal layer of the upper shell and the metal layer of the lower shell Polyethylene) and LLDPE (Linear-Lowdensity Polyethylene) laminated films are sandwiched and heat-sealed, and in a section other than a certain section, the metal layer of the upper shell material and the metal layer of the lower shell material are bonded together by a polyurethane adhesive. At least one polymer film is laminated in the polymer layer.

Vacuum insulator, jacket, polymer layer, polyurethane material

Description

Vacuum insulator and its manufacturing method {VACUUM INSULATOR AND METHOD FOR FABRICATING THEREOF}

The present invention relates to a vacuum insulator that can be used as a heat insulator such as a building or a refrigerator, and a method of manufacturing the same.

Half of the total energy consumed by mankind is spent on heating and cooling of residential and commercial buildings, the same rate in Korea. Considering that supply and demand of alternative energy is only 1 to 2% of total energy consumption and the long-term plan has not exceeded 10%, the reduction of heating and cooling energy is the most effective way to overcome the current energy crisis. Can be. The reason why so much energy is consumed for heating and cooling is that the thermal conductivity coefficient of existing insulators has not developed at all at the limit of 30mW / m · K over the last century. With current insulation, one can consider controlling the thickness of the insulation as a way to reduce energy consumption by half. However, this is because the thickness of the insulation is so thick that economically feasible construction is impossible, and in the case of existing buildings, there is no alternative without breaking it down.

Therefore, super insulation must be developed that can be applied to existing and new buildings in the form of interior and exterior materials, and vacuum insulation can make it possible. Here, the vacuum insulator is composed of a porous filler and a barrier coating material surrounding the vacuum insulator, which means that the vacuum insulator has a very low thermal conductivity by removing the gas in the jacket and maintaining the vacuum state for several years. That is, the vacuum insulator has a heat insulation performance of 10 to 100 times compared to the existing heat insulator, and if applied to this, the utilization of the internal space will be increased by increasing the effect of heat insulation and reducing the thickness of the heat insulator. In addition, the interior of the vacuum insulator is maintained in a vacuum state to prevent convective heat transfer therein. Here, since a significant difference occurs in the performance depending on the degree of vacuum inside the vacuum insulator, maintaining the degree of vacuum inside the vacuum insulator is a significant matter. Factors affecting the maintenance of the degree of vacuum by increasing the internal pressure in the vacuum insulator include degassing from the internal structure, gas infiltration through the skin material surface, and gas infiltration through the skin material adhesive portion. Here, the biggest influence among them may be referred to as gas penetration through the adhesive part of the shell material.

Conventionally, in order to prevent gas permeation through the adhesive part of the outer cover material, an adhesive method by thermal fusion of a low density polyethylene (LDPE) film and a linear low density polyethylene (LLDPE) film having high permeability is used.

1A and 1B are a top view and a cross-sectional view showing the structure of a vacuum insulator according to the prior art.

As shown in FIGS. 1A and 1B, the vacuum insulator according to the prior art includes an outer shell 10, an inner structure 30, and an inner filler 40. Here, the outer cover material 10 is a structure in which the adhesive portion 20 of the four corners on which a low density polyethylene (LDPE) film, an aluminum film, and a linear low density polyethylene (LLDPE) film are deposited are bonded by a heat fusion method. This structure prevents air infiltration into the atmosphere.

2A and 2B are sectional views showing the structure of the shell material of the vacuum insulator according to the prior art. FIG. 2A is a cross-sectional view showing the structure of the outer cover material of the region cut out of the B-B portion of FIG. 1B, and FIG. 2B is a cross-sectional view showing the structure of the outer cover material of the region cut out of the region A-A of FIG. 2A is a cross-sectional view of the envelope 10 of FIG. 1A, and FIG. 2B is a cross-sectional view of the adhesive part 20 of FIG. 1A.

As shown in Figure 2a, the outer cover material of the single-layer film according to the prior art, a polyethylene terephthalate (PET) film 11, a low density polyethylene (LDPE) film 12, an aluminum film (13), low density polyethylene (LDPE) ) Film 14, LLDPE (Linear low density polyethylene) film (15). Here, since the aluminum film 13 located in the middle has a low permeability, it can prevent the penetration of the outside atmosphere through the surface of the shell material.

As shown in FIG. 2B, the adhesive site 20 to which two envelope materials of the single layer film are bonded is formed of a polyethylene terephthalate (PET) film 11a and a low density polyethylene (LDPE) film of the same single layer film of FIG. 2A. 12a, an aluminum film 13a, a low density polyethylene (LDPE) film (14a), and a linear low density polyethylene (LLDPE) film (15) are laminated, and under this structure is another shell material. A structure in which a low density polyethylene (LDPE) film 14b, an aluminum film 13b, a low density polyethylene (LDPE) film 12b, and a polyethylene terephthalate (PET) film 11b are stacked is attached.

Here, the outer cover material of the two single-layer films is bonded by a method of thermally fusion the low density polyethylene (LDPE) films 14a and 14b and the linear low density polyethylene (LLDPE) film 15. However, the low density polyethylene (LDPE) films 14a and 14b and the linear low density polyethylene (LLDPE) film 15 have a problem in that permeability to air is high, so that the penetration of the atmosphere through the adhesive portion can be facilitated.

In addition, due to these factors, the degree of vacuum inside the vacuum insulator may not be maintained, and the heat insulation performance may be significantly reduced, and thus there is a problem in that the vacuum insulator may not serve as a vacuum insulator.

Therefore, in order to solve the above problems, the present invention by adhering the metal layer of the upper shell material and the metal layer of the lower shell material by using a polyurethane adhesive, but is bonded to the shell material than the case of bonding the shell material by conventional thermal fusion It is an object of the present invention to provide a vacuum insulator and a method of manufacturing the same that can reduce air penetration through the vacuum and improve vacuum holding performance.

In addition, the present invention provides a vacuum insulator and a method for manufacturing the same, which can effectively prevent the invasion of the outside air through the surface of the outer shell material and can be easily bonded by a urethane adhesive since the outer shell material includes a metal layer. For that purpose.

In addition, according to the present invention, a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper envelope and the metal layer of the lower envelope is inserted only in a predetermined section along the edge of the upper envelope and the lower envelope. It is an object of the present invention to provide a vacuum insulator and a method for manufacturing the same, which can improve the holding performance of the vacuum state inside the vacuum insulator.

In addition, the present invention, since the metal layer made of aluminum on the bottom layer of the outer cover material serves as a radiation shielding film by high reflectance, there is no need to install a separate radiation shielding film, the vacuum insulation and its manufacturing method is simple and convenient Its purpose is to provide.

The vacuum insulator according to claim 1 is composed of a predetermined inner structure, a filler filling an empty space of the inner structure, and an outer shell covering the inner structure. The outer shell consists of a metal layer and a polymer layer formed on the metal layer, respectively. It includes a top shell and a bottom shell covering the upper and lower surfaces of the inner structure, and in a certain section along the edge of the upper shell and the lower shell material, LDPE (Lowdensity polyethylene) between the metal layer of the upper shell material and the metal layer of the lower shell material The film laminated with LLDPE (Linear-Lowdensity polyethylene) is sandwiched and heat-sealed. In a section excluding a certain section, the metal layer of the upper shell material and the metal layer of the lower shell material are bonded to each other by a polyurethane adhesive. At least one polymer film is laminated in the polymer layer.

Therefore, according to the vacuum insulator of the invention according to claim 1, by bonding the metal layer of the upper outer shell material and the metal layer of the lower outer shell material together with a polyurethane adhesive, the outer shell material is bonded through the outer shell material bonding portion than when the outer shell material is bonded by conventional thermal fusion. It can reduce air penetration and improve vacuum holding performance. In addition, since the envelope includes a metal layer, it is possible to effectively prevent the invasion of the outside air through the surface of the envelope and to facilitate adhesion by the urethane adhesive. In addition, a vacuum film is laminated by heat-sealing a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper shell material and a metal layer of the lower shell material only in a certain section along the edges of the upper and lower skin materials. The holding performance of the vacuum state inside a heat insulating body can be improved. In addition, since the polymer layer is formed of at least one or more polymer films, the lower metal layer can be protected from being broken, and air can be effectively prevented from penetrating into the outer cover material.

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The vacuum insulator manufacturing method of the invention according to claim 3 is composed of a predetermined internal structure, a filler filling an empty space of the internal structure, and an envelope covering the internal structure, wherein the envelope is a polymer layer formed on the metal layer and the metal layer. A method of manufacturing a vacuum insulator, each of which is made of a vacuum insulator including an upper shell and a lower shell covering the upper and lower surfaces of the internal structure, and a metal layer of the upper shell in a section except for a predetermined section along the edge of the upper shell and the lower shell. And bonding the metal layer of the lower envelope material to each other with a polyurethane adhesive, and in a certain section, a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are laminated between the metal layer of the upper envelope and the inner layer of the lower envelope. Heat-sealing.
Therefore, according to the vacuum insulator of the invention according to claim 3, by bonding the metal layer of the upper outer shell material and the metal layer of the lower outer shell material together with a polyurethane adhesive, the outer shell material is bonded to the outer shell material rather than the case of bonding the outer shell material by conventional thermal fusion. It can reduce air penetration and improve vacuum holding performance. In addition, since the envelope includes a metal layer, it is possible to effectively prevent the invasion of the outside air through the surface of the envelope and to facilitate adhesion by the urethane adhesive. In addition, a vacuum film is laminated by heat-sealing a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper shell material and a metal layer of the lower shell material only in a certain section along the edges of the upper and lower skin materials. The holding performance of the vacuum state inside a heat insulating body can be improved. In addition, since the polymer layer is formed of at least one or more polymer films, the lower metal layer can be protected from being broken, and air can be effectively prevented from penetrating into the outer cover material.

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As described above, according to the present invention, by adhering the metal layer of the upper outer shell material and the metal layer of the lower outer shell material together by a polyurethane adhesive, air penetration through the outer shell material bonding portion is more effective than when the outer shell material is bonded by conventional thermal fusion. Can be reduced, and the vacuum holding performance can be improved.

In addition, according to the present invention, since the envelope includes a metal layer, it is possible to effectively prevent invasion of the outside air through the surface of the envelope, and adhesion can be facilitated by a urethane adhesive.

In addition, according to the present invention, a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper envelope and the metal layer of the lower envelope only in a certain section along the edges of the upper envelope and the lower envelope. By heat-sealing, the holding | maintenance performance of the vacuum state inside a vacuum heat insulating body can be improved.

In addition, according to the present invention, since the metal layer made of aluminum acts as a radiation shielding film with a high reflectance on the bottom layer of the outer cover material, there is no need to provide a separate radiation shielding film, and the manufacture thereof is simple and convenient.

Specific matters other than the problem to be solved, the problem solving means, and the effects of the present invention as described above are included in the following embodiments and the drawings. Advantages and features of the present invention and methods for achieving them will be apparent with reference to the embodiments described below in detail with the accompanying drawings. Like reference numerals refer to like elements throughout.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. It is to be understood, however, that the appended drawings illustrate the present invention in order to more easily explain the present invention, and the scope of the present invention is not limited thereto. You will know.

3 is a phase diagram showing the structure of a vacuum insulator according to the present invention.

As shown in Figure 3, the vacuum insulator according to the present invention, the outer shell material 130, the joint portion 140, which is the edge of the outer shell material 130, the air in a predetermined section along the edge of the outer shell material (130) It is made of an opening 120 for discharging.

Here, the opening 120 has a high permeability between the metal layer of the upper shell material and the metal layer of the lower shell material along a border of the upper shell material and the lower shell material constituting the shell material 130, LDPE (Lowdensity polyethylene), LLDPE ( Linear-Lowdensity polyethylene) refers to a portion heat-sealed by inserting a film (see description regarding FIG. 6) laminated. In addition, the junction 140 of the section excluding the predetermined section is a portion where the upper outer cover material and the lower outer cover material formed of the polymer layer and the metal layer are bonded to each other, and the metal layer is bonded by a urethane adhesive having low permeability. The vacuum insulator is formed in a pouch form by adhering a metal layer in a section other than a predetermined section in which the opening 120 is disposed with a urethane adhesive. Then, after discharging the air inside the outer cover material 130 through the opening 120, the opening 120 is bonded by a thermal fusion method is completed. Here, the reason for thermally fusion only the opening 120 is, when bonding with a urethane adhesive takes a considerable time (about 24 hours) to dry the urethane adhesive, it is difficult to maintain a vacuum inside the vacuum insulator Because. Therefore, by quickly heat-sealing only the opening 120, the vacuum inside the vacuum insulator can be easily maintained.

4 is a cross-sectional view showing the internal structure of a vacuum insulator according to the present invention.

As shown in FIG. 4, the vacuum insulator according to the present invention includes a predetermined inner structure 200, a filler 300 filling an empty space of the inner structure 200, and an outer shell surrounding the inner structure 200. It is composed of ash (100).

The envelope material 100 is to prevent air infiltration in the external atmosphere, and a film made of a material having low gas permeability and capable of maintaining a vacuum degree for a long time is preferably used. The envelope material is a structure in which at least one polymer film is laminated with a polymer layer and a metal layer are laminated.

The internal structure 200 is designed to withstand atmospheric pressure and is designed to minimize heat transfer. In addition, the internal structure is preferably formed of a material having a high ratio of tensile strength and thermal conductivity coefficient. For example, a polymer is used in consideration of tensile strength, thermal conductivity, and manufacturability. More specifically, it is preferable that polycarbonate or polyimide, which is a material having a high ratio of tensile strength and thermal conductivity, is used in the polymer.

Filler 300 is to maintain the performance of the vacuum insulator even at low vacuum degree, the smaller the size shows a good performance. In addition, as a porous filler that serves to suppress conduction heat transfer by gas, a material such as silica powder, pearlite powder, glass fiber, wool, aerogel, or the like may be used.

FIG. 5 is a cross-sectional view showing the structure of the outer cover material for the vacuum insulator in the region cut along the B-B portion of FIG. 4, and FIG. 6 is a cross-sectional view showing the structure of the outer cover material for the vacuum insulator in the region cut in the region A-A in FIG. 4. 5 is a cross-sectional view of the envelope 130 of FIG. 3, and FIG. 6 is a cross-sectional view of the adhesive part 140 of FIG. 3. The outer cover material for the vacuum insulator according to the present invention covers the outside of the vacuum insulator and reduces the gas permeation from the outside into the vacuum insulator, and maintains the vacuum state therein. This will be described with reference to FIG. 6. Meanwhile, in FIGS. 5 and 6, a polyethylene terephthalate (PET) film and a low density polyethylene (LDPE) film may be used as at least one polymer film constituting a polymer layer constituting the outer cover material for the vacuum insulator and the vacuum insulator according to the present invention. An example will be described.

As shown in FIG. 5, the outer cover material for the vacuum insulator according to the present invention includes the polymer layers 131 and 132 and the metal layer 133.

The polymer layers 131 and 132 have a structure in which at least one polymer film is laminated. For example, a polyethylene terephthalate (PET) film 131 and a low density polyethylene (LDPE) film 132 are stacked. In the present invention, although the polymer layers 131 and 132 are composed of two layers, a polyethylene terephthalate (PET) film 131 and a low density polyethylene (LDPE) film 132, the polymer layer is polyethylene terephthalate (PET). The film 131 and the low density polyethylene (LDPE) film 132 may have a stacked structure of a polymer film such as a linear-low density polyethylene (LLDPE) film.

The metal layer 133 is formed of a metal having a high reflectance to serve as a radiation shielding film. For example, the metal having high reflectance may be aluminum, SUS, or the like. Therefore, the outer cover material for the vacuum insulator according to the present invention does not need to install a separate radiation shielding film, and is easy to manufacture.

As shown in Figure 6, the adhesive portion of the outer cover material for the vacuum insulator according to the present invention, the upper cover material (131a, 132a, 133a), the lower cover material (131b, 132b, 133b), the upper cover material (131a, 132a, And an adhesive layer 134 between the 133a and the lower envelope 131b, 132b, and 133b. That is, FIG. 6 is a structure in which the outer skin material formed from the single-layer film of FIG. 5 is bonded to each other up and down. In addition, the adhesive layer 134 means a layer on which a polyurethane adhesive is applied to bond the metal layer 133a of the upper envelope 131a, 132a, and 133a and the metal layer 133b of the lower envelope 131b, 132b, and 133b. It is.

The upper outer cover material 131a, 132a, and 133a consists of the metal layer 133a and the polymer layers 131a and 132a formed on the metal layer 133a. The metal layer 133a is made of aluminum. The polymer layers 131a and 132a have a structure in which at least one polymer film is laminated. For example, a polyethylene terephthalate (PET) film, a low density polyethylene (LDPE) film, and a linear-low density polyethylene (LLDPE) film may be used.

The lower envelope materials 131b, 132b, and 133b are made of the metal layer 133b and the polymer layers 131b and 132b formed on the metal layer 133b. The metal layer 133b is made of aluminum. The polymer layers 131b and 132b have a structure in which at least one polymer film is stacked. For example, a polyethylene terephthalate (PET) film, a low density polyethylene (LDPE) film, and a linear-low density polyethylene (LLDPE) film may be used.

The adhesive layer 134 includes a polyurethane material and bonds the metal layer 133a of the upper envelope 131a, 132a, and 133a to the metal layer 133b of the lower envelope 131b, 132b, and 133b. I'm making it. Here, the metal layer 133a of the upper shell members 131a, 132a, and 133a and the metal layer 133b of the lower shell members 131b, 132b, and 133b are bonded by the urethane adhesive layer 134. Since the method of bonding using the urethane adhesive layer 134 has a lower permeability to air than the method of thermal fusion of a low density polyethylene (LDPE) film and a linear low density polyethylene (LLDPE) film, which are conventionally used, In addition, it shows better vacuum holding performance than conventional outer jacket. For example, the permeability of polyurethane to nitrogen and oxygen gas is k _N2 = 0.00975 × 10 ¹³ cm ³ cm / cm ² sPa, k _O2 = 0.0645 × 10 ¹³ cm ³ cm / cm ² sPa to be. In addition, the permeability of low density polyethylene (LDPE) to nitrogen and oxygen gas was k _N2 = 0.13 x 10 ¹³ cm ³ cm / cm ² sPa, k _O2 = 2.2 x 10 ¹³ cm ³ cm / cm ² sPa. (Ref. J. Brandrup, EH Immergut and EA Grulke, Polymer Handbook-Permeability and Diffusion Data 4 ^th ed., Wiley, New York, 1999, pp. 545-560).

According to the vacuum insulating material and the vacuum insulating material according to the present invention as described above, by bonding the metal layer of the upper shell material and the metal layer of the lower shell material by a polyurethane adhesive, by bonding the shell material by conventional heat fusion. It is possible to reduce the air penetration through the outer skin adhesive portion, and improve the vacuum holding performance. In addition, since the envelope includes a metal layer, it is possible to effectively prevent the invasion of the outside air through the surface of the envelope and to facilitate adhesion by the urethane adhesive. In addition, a vacuum film is laminated by heat-sealing a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper shell material and a metal layer of the lower shell material only in a certain section along the edges of the upper and lower skin materials. The holding performance of the vacuum state inside a heat insulating body can be improved. In addition, since the metal layer made of aluminum serves as the radiation shielding film by the high reflectance on the bottom layer of the outer cover material, there is no need to install a separate radiation shielding film, which makes the manufacturing simple and convenient.

As described above, it is to be understood that the technical structure of the present invention can be embodied in other specific forms without departing from the spirit and essential characteristics of the present invention.

Therefore, the exemplary embodiments described above are to be understood as illustrative and not restrictive in all respects, and the scope of the present invention is indicated by the following claims rather than the detailed description, and the meaning and scope of the claims and their All changes or modifications derived from equivalent concepts should be construed as being included in the scope of the present invention.

1A and 1B are top and cross-sectional views showing the structure of a vacuum insulator according to the prior art.

FIG. 2A is a cross-sectional view showing the structure of the envelope material of the region B-B in FIG. 1B; FIG.

FIG. 2B is a cross-sectional view showing the structure of an outer cover material of a region obtained by cutting the A-A portion of FIG. 1B; FIG.

Figure 3 is a top view showing the structure of a vacuum insulator according to the present invention.

Figure 4 is a cross-sectional view showing the internal structure of the vacuum insulator according to the present invention.

Fig. 5 is a cross-sectional view showing the structure of the outer cover material for the vacuum insulator in the region obtained by cutting the portion B-B in Fig. 4.

6 is a cross-sectional view showing the structure of the outer cover material for the vacuum insulator in the region obtained by cutting the A-A portion of FIG. 4.

Claims (3)

A vacuum insulator composed of a predetermined inner structure, a filler filling an empty space of the inner structure, and an outer cover material surrounding the inner structure, The envelope material, Comprising a metal layer and a polymer layer formed on the metal layer, respectively, and comprises an upper shell and a lower shell surrounding the upper and lower surfaces of the internal structure, In certain sections along the edges of the upper and lower envelopes, a film in which LDPE (Lowdensity polyethylene) and LLDPE (Linear-Lowdensity polyethylene) are sandwiched between a metal layer of the upper envelope and the metal layer of the lower envelope is heat-sealed. In the section except for the predetermined section, the metal layer of the upper outer cover material and the metal layer of the lower outer cover material are bonded to each other by a polyurethane adhesive, The polymer layer, at least one polymer film is laminated, Vacuum insulator. delete It consists of a predetermined internal structure, a filler to fill the empty space of the internal structure, and an outer material surrounding the inner structure, the outer material consists of a metal layer and a polymer layer formed on the metal layer, respectively, the upper surface of the inner structure And a method of manufacturing a vacuum insulator including an upper outer cover material and a lower outer cover material surrounding the lower surface thereof. Bonding the metal layer of the upper envelope material and the metal layer of the lower envelope material to each other in a section except for a predetermined section along the edges of the upper envelope and the lower envelope material with a polyurethane adhesive; And Heat-sealing the film by laminating LDPE (Lowdensity Polyethylene) and LLDPE (Linear-Lowdensity Polyethylene) between the metal layer of the upper envelope and the inner layer of the lower envelope in the predetermined section; Including, Method of manufacturing a vacuum insulator.

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