CN109699187B - 吸音板 - Google Patents

吸音板 Download PDF

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Publication number
CN109699187B
CN109699187B CN201880002172.9A CN201880002172A CN109699187B CN 109699187 B CN109699187 B CN 109699187B CN 201880002172 A CN201880002172 A CN 201880002172A CN 109699187 B CN109699187 B CN 109699187B
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China
Prior art keywords
adhesive
fiber
fiber mat
sound
honeycomb
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CN201880002172.9A
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English (en)
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CN109699187A (zh
Inventor
武纮一
中村智久
植木喜彦
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Shizuka Co ltd
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Shizuka Co ltd
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Publication of CN109699187A publication Critical patent/CN109699187A/zh
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Abstract

常规的吸音板，存在着纤维飞散、对皮肤造成刺激(刺痛感)，并且独立性能差、不易施工的课题。选用孔洞尺寸比纤维长度小的多孔板，比如拉制金属板，与蜂窝材之间置入纤维毡，进行叠层，且相互之间采用胶粘剂粘接制得吸音板，其中通过使涂敷在多孔板的胶粘剂，渗进由孔洞外露的纤维毡表层纤维，被固定了的表层纤维，可防止飞散，及对皮肤的刺激。此外，强力压缩蜂窝材的单格壁端部与对面的纤维毡，使得单格壁周围，形成胶粘剂树脂和蜂窝毡的复合构造，增大了强度，确保了吸音板的独立性能。

Description

吸音板
技术领域
本发明吸音板适用于工业机械、家居生活设备以及移动工具等噪声源的防音降噪。
背景技术
通常将作为吸音隔热材料使用的，由动物纤维、有机或无机(矿物类)纤维聚集成片状(面料形状)的无纺布制品称作毡。片状的制作有机械式、化学式、还有热处理等方式的板状压制法，或者利用针刺加工。通过针刺加工制成的产品称作针刺毡。针刺毡较柔软并成卷供应。
针刺毡由直径3～20μm、长度10～200mm的纤维加工成形。按5～20针/cm2的比例，经针刺机垂直于纤维长度方向针刺加工，使得纤维相互缠结制成片材。
关于纤维毡，据专利文献，专利5558315号段落0014、0015记载，当使用纤维毡时，有机或无机纤维均存在着纤维飞散、以及无机纤维对人体皮肤造成刺激(针刺感)的问题。
作为吸音材料，除纤维毡外，也用到金属纤维。关于金属纤维，据专利文献昭62-282922记载，采用的加工方法是在拉制金属板上加配铝纤维，再通过压制成形的金属多孔材料制作法。以吸音材“POAL”(Unix公司产品)登载在(一般财团法人)经济调查会发行的累计资料中，并市面有售。
背景技术文献
专利文献
专利文献1:专利5558315号公告
专利文献2:专利1894692号公告(专利文献昭62-282922号)
发明内容
(本发明解决的课题)
作为吸音材料，可取代金属纤维的有玻璃纤维、岩棉、陶瓷、硅石等无机纤维制成的片材，纤维长10～200mm、直径3～20μm，材料表面易出现纤维飞散、刺激人体皮肤等，造成对人体的影响。
为防止纤维飞散、以及对皮肤的刺激，作为必要的解决方法，除针刺加工外，还有采用胶粘剂等，表面化学固定法。尽管如此，也不能充分解决这一课题。那是因为表面化学方法处理后，很难维持通气性能和穿孔率，发生的孔隙堵塞，影响吸音效果。另外，若要维持好的穿孔率又难以充分防止纤维飞散以及对人体的刺激。
作为其它课题，还有因无机纤维的玻璃纤维、岩棉、陶瓷纤维制成的片材本身柔性强，即使顾及到其厚度和密度，但也缺少平整度和独立性以及抗摩等的表面强度。
作为纤维毡吸音材料的适合范围是密度70～160kg/m3，产品厚度3～20mm，但材质蓬松柔软，缺乏平整度和独立性，使用不便。不能单独作为吸音板的面板材料使用。
将铝纤维夹入拉制金属板中间制成的品名POAL C1(Unix公司产品)，虽然不会发生纤维飞散及对人体皮肤造成刺激，但问题是造价高。据(一般财团法人)经济调查会发行的累计资料(2016年10月)显示，1mX2mX1.6mm POAL C1的标价为23,800日元(11,900日元/m2)。
(解决技术问题的技术方案)
技术方案1和技术方案2的发明，是以下特征的吸音板及其制作方法。即涉及由数种材料胶合制成的层压板构造，作为该板构造的一部分，其中的纤维毡和蜂窝材通过胶粘剂相邻粘接，并且该蜂窝材的单格壁的端部会深深地嵌入纤维毡，使得该蜂窝材的单格壁附近的纤维毡和胶粘剂胶合成一体，该部分固化后即成复合结构，该蜂窝材的单格强度得到增大。
此外，技术方案3和技术方案4的发明，是以下特征的吸音板及其制作方法。即涉及数种材料胶合制成的层压板构造，作为该板构造的一部分，其中的纤维毡和多孔板通过水溶性胶粘剂相邻粘接，胶粘剂被全面地涂敷在多孔板孔洞部分外露的纤维毡上，并粘固表面附近的纤维，既可做到防止纤维飞散又可保持纤维间空隙，具备通气性能。
再之，技术方案5和技术方案6的发明，是以下特征的吸音板及其制作方法。即按照蜂窝材、纤维毡以及多孔板的顺序,通过水溶性胶粘剂粘接，并且所述胶粘剂以及蜂窝材的单格壁端部会深深地嵌入纤维毡，使得上述蜂窝材的单格壁附近的纤维毡纤维和胶粘剂胶合成一体，固化后该部分即成复合结构，上述蜂窝板的单格强度也得到增强，粘接所述纤维毡和多孔板的该胶粘剂，被全面地涂敷所述多孔板孔洞部位外露的所述纤维毡，并粘固表层纤维，既可防止纤维飞散又可保持纤维间空隙，具备通气性能。
再之，技术方案7和技术方案8的发明，是以其高构造强度为特征的吸音板及其制作方法。即涉及数种材料胶合制成的层压板构造，作为该板构造的一部分，其中的纤维毡和蜂窝材相邻粘接，并向叠层方向加压，使得蜂窝材的单格壁端部深深地嵌入纤维毡，效果是仅蜂窝材的单格壁附近的纤维被压陷而已，纤维密度增高。
再之，技术方案9和技术方案10发明，是以下构造特征的吸音板及其制造方法。即，按照多孔板、纤维毡、蜂窝材的顺序使用水溶胶粘剂彼此粘接，胶粘剂和蜂窝材的单格壁端部会深深嵌入纤维毡，并且蜂窝材的单格壁附近的纤维板纤维会和胶粘剂胶合成一体，凝固后该部分即构成复合结构，再向蜂窝材的单格空间内填充具有吸水性能的开孔型硬质酚醛泡沫。
再之，技术方案11发明中涉及到技术方案9所述发明的吸音板，特点是，采用胶粘剂在该蜂窝材表面胶合一层非通气性反光材料，具备高吸音性能构造。
再之，技术方案12发明涉及到技术方案10发明中所述吸音板材制造方法，特点是，采用胶粘剂在该蜂窝材表面胶合了一层非通气性反光材料，得到高吸音效果。
再之，技术方案13发明涉及到技术方案11发明中所述吸音板材，特点是，所述多孔板、纤维毡、还有反光材料均为非燃物质，所述蜂窝材和酚醛泡沫为难燃材料，固整体非燃。
再之，技术方案14发明涉及到技术方案12发明中所述吸音板材的制造方法，特点是，所述多孔板、纤维毡、还有反光材料均为非燃物质，所述蜂窝材和酚醛泡沫为难燃材料，固整体非燃。
再之，技术方案15发明涉及到技术方案3、或者技术方案5发明中所述吸音板，特点是，多孔板的孔径小于纤维毡纤维长度，即不会出现纤维漏出孔洞外。
再之，技术方案16发明涉及到技术方案4、或者技术方案6发明中所述吸音板制造方法，特点是采用的所述多孔板的孔径小于纤维毡纤维长度，即不会出现纤维漏出孔洞外的方法。
再之，技术方案17发明涉及到技术方案3、或者技术方案5、或者技术方案9发明中所述多孔板，是以采用了拉制金属板或穿孔金属板为特点的吸音板。
再之，技术方案18发明涉及到技术方案4、或者技术方案6、或者技术方案10发明中所述多孔板，是以采用了拉制金属板或穿孔金属板为特点的吸音板制作法。
再之，技术方案19发明涉及到技术方案11发明中所述吸音板，特点是蜂窝材、酚醛泡沫以及反光材料均经由水溶胶粘剂粘合，其一体化构造实现了高独立强度。
再之，技术方案20发明涉及到技术方案12发明中所述吸音板的制作方法，特点是蜂窝材、酚醛泡沫以及反光材料均由水溶胶粘剂粘合成一体，增加了吸音板强度。
简括如下，作为所述吸音板的层压板构造及其制造方法，是先将多孔板和纤维毡用胶粘剂涂敷叠层，经压力机整体施压粘接后，再用胶粘剂将蜂窝材和纤维毡的另一面粘合，再经压力机强力碾压，部分纤维毡受蜂窝材挤压的同时粘成一体，再是粘接具有吸水性能的开孔型硬质酚醛泡沫。还可再粘接一层反光材料。此时叠层整体经过压力机，一边受压一边粘接，当胶粘剂凝固时即使压力机不在施压，部分纤维毡也已得到压缩，而这种被压缩状态又恰好由胶粘剂固定。
详细说明吸音板的构成和作用。首先,说明如何解决纤维飞散以及给人体造成刺激的课题。方法是对纤维毡采取表面收紧处理,因为表面纤维间经粘接后,就可以解决纤维飞散以及碰触时产生的刺痛感。就是给纤维毡表面加配拉制金属板或穿孔金属板，纤维毡表面可从拉制金属板或穿孔金属板的孔洞部分外露。
在加配拉制金属板或穿孔金属板之前，要预先使其在水溶性(乳胶)胶粘剂槽内浸胶，使胶粘剂全面均匀粘附，由于张力作用孔洞部位形成胶膜。之后将纤维毡与拉制金属板或穿孔金属板重叠，胶膜则覆盖孔中外露的纤维毡表面。
接下来，强力加压纤维毡与拉制金属板或穿孔金属板，孔洞部分的胶膜与纤维毡表面接触，胶粘剂中水分蒸发，由于干燥(硬化反应)引起胶膜收缩，其结果膜破孔开，使得原先整体布满一根一根的纤维表面浸湿，胶粘剂展开。
之后胶粘剂水分进一步蒸发、干固，起到硬化作用，粘附在表层纤维附近的胶粘剂会使一根一根的附近纤维相互粘接胶合成一体，形成固化胶粘剂与纤维的复合结构，即纤维强化树脂层(FRP)。同时未粘接的一根一根的纤维部分仍保留空隙。之所以纤维间只是处于相互缠结状态，是因为大多数接触点被粘接而处于固定状态。
于拉制金属板或穿孔金属板的孔洞之外的部分，拉制金属板与纤维毡之间的胶粘剂会渗进表层纤维，与纤维胶合。硬化后成一整体，形成复合结构的纤维强化树脂(FRP)。
纤维毡表层纤维互相粘接的结果可防止纤维飞散，即使接触到孔洞部分也不会引起皮肤的刺痛感。假设万一出现未被固定的纤维，因多孔板的孔径小于10～200mm纤维长度，所以不会越孔外漏。针刺加工制成的片状纤维毡也是所述构造的对象。
这是因为利用了，显微观察纤维毡时，可以看到纤维之间空隙很大，水溶性(乳胶)胶粘剂会浸湿、渗入并列纤维的表面，而不会渗进厚度方向的原理。因此，胶粘剂将涂敷到拉制金属板或穿孔金属板的孔洞外露所有纤维毡表面。
接下说明如何解决独立性问题。前述纤维毡经粘合多孔板，即可得到平整度，也可得到一定程度的独立性。但是仅此远不能得到强固的独立性。本发明,为了得到强固的独立性，采取对粘接了多孔板的纤维毡的背面，再粘接蜂窝材，即夹心为纤维毡两边分别是蜂窝材和多孔板的层压板，确保了可独立的强度。
即，粘接纤维毡与蜂窝材时，压力机的施压强度要大于粘接多孔板时的压力。经过本工艺流程，蜂窝材的单格壁的端部会深深嵌入纤维毡，和端部接触附近的纤维毡被压缩至2分之1的厚度，由此密度增大、强度增强。
此外，预先涂敷在蜂窝材单格壁的胶粘剂，会在单格壁附近渗湿纤维毡表层及被压缩部分的纤维表面，经干燥粘固成一体，形成复合结构的纤维强化树脂(FRP)。
这种复合结构增加了蜂窝材的强度，结果得到理想的独立性。发明人曾经发明过的将蜂窝材嵌入海绵的粘接技术，只是单纯为了加大胶粘剂的粘接面积，而非似本发明，采用胶粘剂与纤维毡来制造复合结构。
再之，为提高前述制得的吸音板的吸音性能，可将另一种吸音材料即开孔型硬质酚醛泡沫填入蜂窝材的单格内部。
再之，对粘接了蜂窝材的纤维毡背面，再粘一层反光材料，便能得到更高的遮音性能，同时能保护蜂窝材的单格。还能得到强固的独立性能。
从造价来看，本发明所述多孔板(拉制金属板)、纤维毡、蜂窝材经过叠层粘接的构造，与对比对象的Unix公司的铝纤维与拉制金属板构造，品名POAL C1的价格1mX2m为23,800日元(11,900日元/m2)(一般财团法人：经济调查会发行累计资料(2016年10月))相比，便宜一半。
发明效果
取代金属纤维而采用纤维毡，例如选用了岩棉玻璃垫的吸音板，经确认由于纤维毡被拉制金属板与蜂窝材相夹粘接，解决了纤维飞散以及对皮肤刺激的课题。
确认到通过纤维毡被拉制金属板与蜂窝材的相夹粘接，得到方便处理使用且具有独立性的板材。若再粘接反光材料，则可解决独立性和表面强度课题，经得起现场施工时的磕碰。同时也提高了隔音性能。
相对于段落0011说明的铝纤维吸音材商品名称“POAL C-1”，重量2.6kg/m2而言，则实现了1.04kg/m2，60％的重量。
本发明的吸音板的价格是，(一般财团法人)经济调查会发行累计资料(2016年10月)中所记载的铝纤维吸音板的一半。
通过对本发明吸音板的吸音性能进行检测，确认到广范围频率带的高吸音遮燥性能。
附图说明
图1为多孔板(拉制金属板)的图。
图2为纤维毡和多孔板层压后的截面图。
图3为蜂窝材的图。
图4为蜂窝材与纤维毡以及多孔板层压后的截面图。
图5为蜂窝材的单格壁端部嵌入纤维毡后的状态概念图。
图6为蜂窝材的单格内填入开孔型硬质酚醛泡沫后的截面图。
图7为反光材料和蜂窝材和纤维毡和多孔板层压后的截面图。
图8为正常入射吸声系数图。
图9为微观下的纤维状态概念图。
附图标记说明
1      多孔板(拉制金属板)
2      蜂窝材
2w     单格壁
3      纤维毡(岩棉玻璃垫)
31     纤维
4      酚醛泡沫
5      反光材料(非透气性材料)
10     胶粘剂
11     胶粘剂
12     胶粘剂
14     胶粘剂
21     压力机上压盘
22     压力机下压盘
P      胶粘剂与单格壁端部附近纤维的复合构造
Q      胶粘剂与单格壁附近纤维的复合构造
R      胶粘剂与纤维毡表层纤维的复合构造。
具体实施方式
实施例1
图4(b)显示出由多孔板1和纤维毡3、以及蜂窝材2经层压制成的吸音板截面构造。图中压力机上压盘21以及压力机下压盘22非吸音板的一部分。而粘接多孔板1和纤维毡3的胶粘剂适合采用水溶性乳胶，具体可从乙酸乙烯酯树脂型、丙烯酸树脂型、乙烯乙酸乙烯酯共聚物树脂(EVA)型、还有其它如PVC型，偏二氯乙烯型、聚氨酯型、环氧型、聚酯型中选择。
选择时粘度很重要。选择的粘度范围应满足以下两个条件，如图2(b)截面图所示，在处理多孔板1粘附工艺流程中，因表面张力孔洞部分应出现胶膜，以及多孔板1与纤维毡3的粘接工序中，胶粘剂流至纤维毡3，但不应出现孔洞被堵塞，这种恰好吻合多孔板孔径的粘度范围。为此，也可以适当调整加水的分量。本实施例则采用了乙酸乙烯树脂(KONISHICX50不挥发成分45％，水分55％)，并调整了水分。
作为多孔板1，选择可实现轻量化的拉制金属板或穿孔金属板，适合本发明使用。所述实施例则选用了铝A1050，厚0.6mm，开口(孔)W4XH8mm的拉制金属板。该拉制金属板的平面图如图1(a)所示。交错切割金属薄板的同时，垂直于切割方向横拉金属薄板，切口部分则扩展为菱形。图1(c)是图1(b)AA‘所示位置的部分截面放大图。
本实施例中，作为防止纤维飞散的对策，开口孔径应小于最短纤维长度10mm，如图1(b)放大所示，采用了长度H＝8.0mm、宽度w＝4.0mm。因多孔板的厚度和宽度与独立性能有关，所以应选择与将来产品尺寸以及独立性适合的便可。
至于纤维毡3，为发挥吸音隔热性能，选用的材质是有机或无机纤维，经过多层重叠，并用细针反复针刺加工制成的片材。具体可用的纤维，如有机的(化学纤维、天然纤维)、无机的(玻璃纤维、岩棉等)。
作为纤维毡3，本实施例中使用了岩棉玻璃毡“RGM”(大和理研工业株式会社制造)。是将长度10～200mm岩棉纤维和玻璃纤维混合后，经针刺加工制成。具备非燃、耐热(700℃)以及优越的吸音性能。厚度可从3～15mm中选用。本实施例选用的是密度100～120kg/m3、厚度5mm。
关于纤维毡3，不选用岩棉纤维而选玻璃纤维毡也可。本实施例则选用了对皮肤刺激感少、玻璃含量不高的岩棉毡。因为是岩棉材质，与玻璃纤维比较，耐热程度高出100℃，可在700℃高温范围内使用，还具有不含石棉的优点。
图2(b)所示的是多孔板1和纤维毡3层压状态下的截面图。为减少繁杂，图2中只在所示多孔板1的截面图1处标上符号。其它图也如此。多孔板1为拉制金属板、纤维毡3为岩棉玻璃毡。
图2(a)所示的只是拉制金属板的截面。如图2(b)所示，将多孔板1放入装有胶粘剂10(是现成乙酸乙烯酯型乳液粘合剂(不挥发成分45％、水分55％)中，加入适量水再次乳化的)平放状态的容器内，全面浸胶，使粘合剂10粘附多孔板1、以及孔洞部位，以致因张力作用出现胶膜。
此时，加入乙酸乙烯酯型乳液粘合剂的水量，因拉制金属板孔洞大小决定了适量范围。是否适量可根据下述确认判定。即，拉制金属板孔洞的胶膜是否粘附足够的量？以及相反地，当胶粘剂硬化后孔洞部位的胶膜有否破开？还有，通气等性能检测时纤维毡3是否保留着通气性？
胶粘剂10干燥硬化前，如图2(c)所示，将针刺加工后的岩棉玻璃垫对面重叠，夹于隔离纸之间(图未示出)，并如图2(d)所示，置入压力机上压盘21与下压盘22之间，向叠层方向施压，此时孔洞部位的胶膜与纤维毡3接触，因干燥收缩引起胶膜破裂，胶粘剂展开至纤维毡3，并浸湿渗入纤维毡表层纤维。此时，整个纤维毡也同样被压缩。
在此，纤维毡的表面是被无数根绒毛(纤维)覆盖，由于其表面的微细结构和化学特性，呈现的泼水功能(所谓的莲花效应)使得胶粘剂10难以渗入纤维毡3的内部。为此，经上完胶粘剂10的拉制金属板挤压，一旦胶粘剂10以及纤维毡3的表面受重压，则失去呈现出的泼水功能，胶粘剂10则渗入纤维毡3内部。
如图2(d)所示，压力机施压时，涂敷多孔板1上的胶粘剂10与纤维毡3接触，当孔洞部位的胶粘剂10胶膜接触到纤维，胶粘剂中水分蒸发，发生干燥(硬化反应)引起膜层收缩，并发生破裂，另外纤维毡3失去表面的泼水功能，胶粘剂10渗湿毡面附近的每根纤维的表面。
此时，胶粘剂10几乎没有向纤维毡3的厚度方向渗入，而被渗湿的仅仅是，涂敷在多孔板1孔洞部位纤维毡3表面附近的、胶粘剂10所触到部位的纤维附近。产生这种现象的原因是，因为纤维毡3的纤维顺长度方向是平面展开方向，而且选用了表面张力大的水溶性胶粘剂。
图9所示微观下的纤维毡纤维状态的示意图。图9(a)所示，经针扎加工后纤维互相缠结状态。图9(b)所示纤维表面胶粘剂渗湿并展开的状态。图9(c)所示胶粘剂固化后纤维互相处于固定状态。图9(a)所示每根纤维仅部分接触或相邻。图9(b)中可以看到此时即使胶粘剂10渗入，该部位纤维仍留有间隙，存在空间。
即，胶粘剂10仅渗湿纤维表面，而一根一根的纤维与纤维之间并未被胶粘剂填埋，相互之间处于部分接触或相邻的构造。如此状态下干燥凝固后，其结果如图9(c)所示，与图9(b)相比，胶粘剂发生了干燥收缩，多孔板1孔洞外露的整个纤维毡3的纤维之间保留着通气性。也就是保证了吸音性能。
在此，将拉制金属板全面涂敷胶粘剂，是为了保证胶量足以促使孔洞部位出现胶膜，同时还可以达到防锈目的。乳胶类胶粘剂是液体的同时呈白色，硬化后则变透明。作为商品，此色系变化还能起到良好的美观效果。此外，经乳胶类胶粘剂涂敷后，拉制金属板的表面得到均匀的涂层，即使板面残留毛刺也会被遮盖，起到表面光滑作用。
但是，仅此将纤维毡即岩棉玻璃垫单面贴上拉制金属板，在长度上，岩棉玻璃垫和拉制金属板的合成板并不具备足够的刚度，若让其独立竖起则会发生板面弯曲不平。作为对策，可以采取在贴有拉制金属板的岩棉玻璃垫的另外一面，胶合一层结构材料以防止弯曲。
就其方法说明如下。如图3(a)所示，作为轻量、不收缩、且具有强度材料所采用的蜂窝材2的透视图。蜂窝材的六角形单格由薄壁形成。本实施例采用了轻量且具有强度的蜂窝材，单格尺寸20mm、厚30mm、单格壁厚度0.35mm(Taigarex公司的“硅酸镁混合纸蜂窝芯”)，与岩棉玻璃垫对面胶合。如图3(b)、图3(a)所示，处于截面A，蜂窝材2的截面图。
图4(a)详示的是，蜂窝材2的单格壁下侧端部涂有乙酸乙烯酯树脂乳胶类胶粘剂11的状态图，显示了蜂窝材2的单格壁2w下侧端部涂有胶粘剂11的状态。而图4以后的图则夸张描绘了，相对于蜂窝材2厚度纤维毡2的厚度。图4(a)的虚线是蜂窝材2单格壁2w的下端，其上下的波形线是单格壁2w下侧端部，涂有胶粘剂11的上端和下端。
即，放平蜂窝材2，并将蜂窝材2单格壁2w下侧端部浸入装有胶粘剂容器内，使乙酸乙烯酯树脂乳胶类胶粘剂11(不发挥成分45％、水分55％)适量涂敷。
如图4(b)所示，由上方将该蜂窝材2，对面叠放在前述多孔板1(即拉制金属板)和纤维毡3(即岩棉玻璃垫)的胶合板上，并如图4(b)所示，置入压力机上盘21与下盘22之间，如上下箭头所示施加压力，使蜂窝材2的单格壁下侧端部嵌入纤维毡3，压缩纤维毡3的对面部分。
此时施加的压力应大于纤维毡3与多孔板1粘接时的压力。其结果，仅有蜂窝材单格壁的端部和对面部位的纤维毡3被压缩，由原先的厚度5mm被压缩到2～3mm。
通过上述工艺流程，纤维毡3经压缩，密度加大的部位增强，以及蜂窝材2单格壁下部附着的胶粘剂11与纤维粘结形成FRP结构，增大了蜂窝材2单格强度。由此胶合板得到具备能够自立的强度构造。然而，就增强措施，并非仅限于所述蜂窝材2的厚度与材质。
图4(b)进一步显示出，蜂窝材2单格壁2w涂敷的胶粘剂11渗入纤维毡3内部的部位情况。而此图为了突出蜂窝材单格壁2w下侧端部受压、以及被压缩的一部分纤维毡3的情况，并没有显示出胶粘剂11，所以参照示有胶粘剂11的图5一并说明。
就图4(b)的制造工艺，再次反复详细说明。针对蜂窝材2涂有乙酸乙烯酯树脂乳胶类胶粘剂11(不发挥成分45％、水分55％)的一面，将胶合了多孔板1(即拉制金属板)的纤维毡3(即岩棉玻璃垫)的另一面，对面相接。
之后，置入压力机并按照箭头方向施压，嵌入纤维毡3(即岩棉玻璃垫)与蜂窝材2单格壁2w的对面部位，同时纤维板3厚度被压薄，即纤维之间的间隙变小，同时胶粘剂11渗入纤维板3单格壁2w附近的纤维中，使得胶粘剂11与纤维毡2形成FRP状复合结构。
上述说明了先粘接多孔板1(即拉制金属板)和纤维毡3(即岩棉玻璃垫)、再粘接蜂窝材的流程，按此流程中间会出现多孔板1容易变形的课题。为解决这一课题，作为流程也可先粘接纤维毡3(即岩棉玻璃垫)和蜂窝材2，之后再粘接多孔板1(即拉制金属板)。
图5放大显示出图4(b)中蜂窝材2的一个单格壁2w端部，同时描绘出图4(b)未示的胶粘剂11。图5(a)是透视了胶粘剂，显示出纤维，而图5(b)则为了容易看出胶粘剂而非透视地显示了胶粘剂。
在此，命名为R的部分，是指当单格壁2w端部嵌入岩棉玻璃垫中时，被纤维阻挡在表面的部分胶粘剂11、Q部分，是指蜂窝材2单格壁2w下部周围附着的部分胶粘剂、P部分，是指单格壁2w端部底下残留的部分胶粘剂。在P以及R部分的胶粘剂会在单格壁2w周围以尺寸1～2mm平面方向地(图为水平方向)展开，渗进岩棉玻璃垫表层纤维，形成纤维强化树脂(FRP)。
P部分是以蜂窝材2单格壁2w端部为中心、Q部分是同一单格壁的表面，胶粘剂11以0.5～1.0mm深度，渗入蜂窝材2单格壁2w附近呈U字形的纤维中，单格作为芯料，凝固后的胶粘剂树脂与纤维，合成一体，增强形成纤维强化树脂(FRP)，构造增强。
作为整个吸音板，P部分以及R部分在单格壁2w周围凝固，随之，岩棉玻璃垫整面形成连续六角形的FRP，其独立性能可发挥到，即使单立也不会出现弯曲或断开的程度。与蜂窝材2单格壁2w端部对面的岩棉玻璃垫部分，原先厚度尺寸为5mm则被压缩到2～3mm。如此，吸音板的的独立性，由多孔板、纤维毡被压缩部分、以及蜂窝材单格壁的复合结构(FRP)，这3种强度得到确立。
如图5所示，岩棉玻璃垫未与蜂窝材2单格壁2w相对，即未受到压缩的部分，则未被向厚度方向压陷，其厚度仍为4～5mm。若岩棉玻璃垫被压陷，吸音性能将恶化，但是蜂窝材单格壁2w很薄，被压陷部分面积与岩棉玻璃垫整个面积相比，比例不大，因此，作为吸音板的性能几乎不会变低。
如上所述，当多孔板和纤维毡、以及蜂窝材和纤维毡粘接时，就所施加的压力而言，与多孔板时相比较，蜂窝材时的应足够大，这样，多孔板侧纤维毡的表层纤维形成胶膜，不但防治纤维飞散，还可确保吸音性，另一侧的蜂窝材单格壁端部嵌入纤维毡内部，断面形状由平面变成U字形，蜂窝材单格壁附近形成的胶粘剂和纤维的复合结构增大了强度，并保证了整体的吸音性能。
作为纤维毡3的增强方法，可以增加针扎的加工次数来提高密度，但是，这种情况下，仅对必要部分的密度难以做到统一提高。本实施例中，利用蜂窝材，使其单格壁端部施压，仅压缩部分的密度得以提高，形成了强度支撑层。其实，上述实施例主要说明的是，纤维毡粘接完多孔板后再粘接蜂窝材的流程，也可以纤维毡粘接完蜂窝材后再粘接多孔板。
本实施例中，蜂窝材采用的是硅酸镁混合纸蜂窝芯材，当然不限于此，也可以采用金属、树脂以及其它纸质等蜂窝芯材。适合本发明采用的单格尺寸是15～25mm。若单格尺寸不够大，那么，单格壁2w将压陷岩棉玻璃垫相当大部分面积，使得厚度变薄，降低了吸音性能。相反，若单格尺寸过大，则会降低独立性能和强度，使用起来不便。若能如本实施例，选用适当的单格尺寸，就可以避免这一问题。
本实施例中，为提高独立性能，选用的岩棉玻璃垫密度130～150kg/m3、厚度5mm。
此外，蜂窝材2的单格形状不限于如图所示的六角形。纤维毡3也不限于岩棉玻璃垫。但有效密度范围为70～160kg/m3。
实施例2
图6所示的是，为了得到更好的吸音率，第2实施例的吸音板截面图。是在图4所示构造之上，给蜂窝材单格空间，加填开孔型吸水性酚醛泡沫。如图6(a)所示，将与蜂窝材相同厚度(28～29mm。但是本图为方便理解纤维毡3的厚度，采用了夸张描法，即未绘出相同厚度)的硬质、开孔型吸水性酚醛泡沫4，置于粘接了蜂窝材2的纤维板3的背面，对面重叠后，按图6(b)所示，置入压力机并向叠层方向强力施压，促使酚醛泡沫4填入单格空间。
酚醛泡沫4应是开孔型，并根据其吸音、吸水性能来选择，适合本发明的密度范围为16～30kg/m3。但并不仅限于所述酚醛泡沫材料，只要使用的泡沫是硬质、开孔型以及具有吸水性能即可。
硬质酚醛泡沫，是酚醛树脂经过各种改性处理后，发泡硬化制得，在泡沫塑料中，最具有高热稳定、和高化学稳定的特性，同时还有很好的遮音、绝热、阻燃的性能。根据发泡时条件不同，可制得闭孔型或开孔型的泡沫。正因为是开孔型，所以具有更高的吸音效果。
再有，在蜂窝材2和纤维毡3粘接阶段，为加快作业，必须尽快除去水溶性胶粘剂10中的水分，可将吸水性酚醛泡沫，挤压至蜂窝材2附着的胶粘剂10处，促使酚醛泡沫吸收水分，取得尽早干燥硬化的效果。
实施例3
图7所示的是，为了得到更佳遮音性能，所施另一例吸音板的截面图。图6所示的工艺基础上，给复合完纤维毡3的蜂窝材2的背面，用胶粘剂2再粘接一层非透气性(即非吸音性)反光材料5。反光材料5可从不透气的金属、木材、有机或无机材料中，斟酌其质量、价格以及隔音性能选择。本实施例，则从价格、重量、非燃性、美观方面，选用了1.2mm的涂装铝板材。并确认到该工艺制得的吸音板，达到图8所示的吸音性能。
粘接反光材料5和蜂窝材2使用的是环氧类胶粘剂。但作为胶粘剂，不限于环氧类型的。
实施例4
作为再进一步的实施例，是与实施例3所示图7相同构造的吸音板，但是反光材料5使用的是1.0mm的不燃纸(由Taigarex公司制造的产品，“不燃板GX10NA”、不燃认证NM-2285)。至于其它板材，多孔板1上复合厚度0.5mm拉制金属板、作为纤维板3厚度5mm的岩棉玻璃垫(大和理研工业株式会社制造，岩棉玻璃垫RGM5-100，不燃认证NM-8112)、作为蜂窝材2厚度30mm、在此使用的蜂窝材，即使往单格内填充开孔型硬质酚醛泡沫4，其厚度仍然为30mm，那么，整个吸音板总厚度可达37mm，经测量，重量达3.7kg/m2。
发明人另一发明、类似于如图7所示实施例的构成，即使用的其它材料，如多孔板1、纤维板3使用厚度1.6mm铝金属纤维毡、使用厚度1.2mm铝制板为反光材料5、加起来厚度总和32.8mm的吸音板，重量则达8kg/m2。相比之下，本实施例的总重减剩53.75％，实现轻量化。
本实施例图7所示吸音板构造中，选用铝A1050拉制金属板为多孔板、Taigarex公司制造的硅酸镁混合纸蜂窝芯材为蜂窝材2、岩棉玻璃纤维垫作为纤维毡3、开孔型吸水性酚醛泡沫作为酚醛泡沫4、以及不燃纸作为反光材料5使用，还有胶粘剂12、以及其它部位粘接用的胶粘剂则用了乙酸乙烯酯型乳胶，发明人确认到，与其它发明不燃认证(不燃认证NM-3167)吸音板相比，在不燃性能上具有同等效果。
在此，对吸音板整体不燃性的条件作一整理，即要求构成整体板的表面、背面、接触到外部的多孔板、纤维毡、反光材料，具有不燃性。然而，不直接接触到外部，置于吸音板内部的蜂窝材、酚醛泡沫材料，因不会直接接触到火焰，则要求在高温下不得出现自燃，这与不燃性相比条件略低，在此，为与不燃性区别，称其为难燃性。
此外，在胶合各层使用的水溶性乙酸乙烯型胶乳(KONISHI株式会社产品，CX-50)内含的固体成分(填充材料)具有难燃性，而且涂敷后，可使胶粘剂渗入吸水性不燃纸、开孔型硬质酚醛泡沫、蜂窝材，各种不燃材料间，紧密胶合，在吸音板内部，形成酚醛泡沫被蜂窝材与反光材料包围的密封结构。此密封结构可以隔绝外部来的氧气，即使吸音板外部起火，其内部也难以着火引发火焰。
然而，吸音板上的多孔板、纤维毡这一侧则保持着通气性。当吸音板外部高温状况时，受到高温影响，内部胶粘剂或酚醛泡沫中含有的有机成分，会分解释放出气体，而分解气体中，含有高浓度的二氧化碳。其结果，即使吸音板的多孔板、纤维毡这一侧具有通气性，氧气也不会由外部进入吸音板内部，阻止了吸音板内燃。
因此，密封结构、以及发生二氧化碳作用的结果是，吸音板内部不存在可供燃烧的氧气，所以组成吸音板的元材料，即便不全是不燃性物质，但部分元材料为难燃性的，则如图7所示，吸音板构造为不燃性。其结果就是，实现了比使用铝板来的更轻，同时也是不燃性质的吸音板。
另外，蜂窝材2、酚醛泡沫4、反光材料5均为吸水性材料，当将水溶性乙酸乙烯型乳胶(KONISHI株式会社产品CX-50)全面地涂敷反光材料5，再粘接蜂窝材2、酚醛泡沫4，之后涂敷在反光材料5上面的胶粘剂会渗入蜂窝材2、酚醛泡沫层4以及反光材料5，加工出来的层叠程度，几乎确认不出材料间的粘胶层。即层叠构造完全达到一体化，吸音板的独立强度得到增强。确认所述独立性能使用的板大小为450X910X37mm以及910X1820X37mm。

Claims (18)

1.一种吸音板，其特征在于，在胶合多种材料的层压板构造中，作为该板构造的一部分，其中采用水溶性胶粘剂，粘接纤维毡和蜂窝材，而所述蜂窝材单格壁端部嵌入该纤维毡内部，该纤维毡的断面形状由平面变成U字形，该U字形断面内的该蜂窝材单格壁附近的该纤维毡纤维被压缩，该被压缩的纤维材与该胶粘剂粘成一体、固化部分形成复合结构，作为纤维强化树脂，该纤维毡的独立强度得到增强。
2.一种吸音板的制造法，其特征在于，在胶合多种材料的层压板构造中，作为该板构造的一部分，其中采用水溶性胶粘剂，粘接纤维毡和蜂窝材时，给所述蜂窝材单格壁与所述纤维毡相对的端部，涂敷胶粘剂，并向叠层方向强力施压，促使该蜂窝材单格壁端部以及胶粘剂嵌入该纤维毡内部，该纤维毡的断面形状由平面变成U字形，在蜂窝材单格壁附近形成该胶粘剂和该纤维的复合结构的制造法。
3.一种吸音板，其特征在于，在胶合多种材料的层压板构造中，作为该板构造的一部分，其中采用水溶性胶粘剂，粘接纤维毡和多孔板，而所述胶粘剂，全面地扩展至该多孔板孔洞部分外露的纤维毡，并将表层纤维固定，制止纤维的飞散，且保持纤维间的通气性能。
4.一种吸音板的制造法，其特征在于，在胶合多种材料的层压板构造中，作为该板构造的一部分，其中采用水溶性胶粘剂，粘接纤维毡和多孔板，将该多孔板事先在胶粘剂槽内浸胶，由于胶粘剂的表面张力的作用孔洞部分形成胶膜，在该孔洞部分形成胶膜的状态下将该纤维毡与该多孔板重叠，胶膜则覆盖孔中外露的纤维毡表面，加压，从该孔洞部分外露的纤维材与该孔洞部分的该胶膜接触，胶粘剂中水分蒸发，由于干燥引起胶膜收缩，其结果膜破孔开，附着在孔洞上的胶粘剂浸湿了从孔洞外露的纤维材的一根一根的纤维表面，胶粘剂展开，接触或附近存在的纤维相互粘接成一体，通过胶粘剂的固化，形成纤维材与胶粘剂的复合结构，由此防止纤维的飞散，同时胶粘剂不遍布的纤维间仍保留空隙，使其具有通气性能的制造法。
5.一种吸音板，其特征在于，采用水溶性胶粘剂按照以下蜂窝材、纤维毡以及多孔板顺序粘接，所述胶粘剂与蜂窝材单格壁端部嵌入该纤维毡内部，该纤维毡的断面形状由平面变成U字形，该蜂窝材单格壁附近的纤维毡纤维被压缩，该被压缩的纤维材与胶粘剂粘成一体、固化部分形成复合结构，作为纤维强化树脂，该纤维毡的独立强度得到增强，粘接所述纤维毡和多孔板的该胶粘剂，全面扩展至该多孔板孔洞部分外露的该纤维毡，将表层纤维粘固，防止纤维飞散，并且纤维间留有空隙，具备通气性能的构造。
6.一种吸音板的制造法，其特征在于，采用水溶性胶粘剂按照蜂窝材、纤维毡以及多孔板顺序粘接时，在与该纤维毡相对的该蜂窝材单格壁端部预先涂敷该胶粘剂，使该多孔板朝下，向叠层方向，施强力加压所述纤维毡与蜂窝材，所述胶粘剂以及蜂窝材单格端部嵌入该纤维毡，该纤维毡的断面形状由平面变成U字形，形成该U字形断面的该蜂窝材单格壁作为芯料，附近的该胶粘剂与该纤维材成为一体固化，固化部分形成纤维强化树脂，该纤维毡的独立强度得到增强，将该多孔板事先在胶粘剂槽内浸胶，由于胶粘剂的表面张力的作用孔洞部分形成胶膜，在孔洞部分形成胶膜的状态下将该多孔板与该纤维毡和该蜂窝材重叠，向叠层方向加压，从孔洞部分外露的纤维材与孔洞部分的胶膜接触，胶粘剂中水分蒸发，由于干燥引起胶膜收缩，其结果膜破孔开，附着在孔洞上的胶粘剂浸湿了从孔洞外露的纤维材的一根一根的纤维表面，胶粘剂展开，接触或附近存在的纤维相互粘接，通过胶粘剂的固化，形成纤维材与胶粘剂的复合结构，即纤维强化树脂FRP，由此防止该纤维材的飞散，同时胶粘剂不遍布的纤维间仍保留空隙，具备通气性能的制造法。
7.根据权利要求1所述的吸音板，其特征在于，采用硬质吸水性开孔型酚醛泡沫，填充所述蜂窝材的单格空间。
8.根据权利要求2所述的吸音板的制造法，其特征在于，在该蜂窝材与纤维毡相对的面的相反侧的表面，对面重叠一层硬质吸水性开孔型酚醛泡沫，并向整个叠层方向施强压，将该酚醛泡沫挤入所述蜂窝材的单格空间，进行充填。
9.根据权利要求7所述的吸音板，其特征在于，于所述蜂窝材表面，采用胶粘剂粘合一层非通气性能的反光材料，得到吸音板。
10.根据权利要求8所述的吸音板的制造法，其特征在于，于所述蜂窝材表面，采用胶粘剂与非通气性能的反光材料粘接胶合。
11.根据权利要求9所述的吸音板，其特征在于，所述纤维毡、反光材料均为不燃材料，而所述蜂窝材以及所述酚醛泡沫均为难燃材料，整体为不燃性质特征的吸音板。
12.根据权利要求10所述的吸音板的制造方法，其特征在于，所述纤维毡、反光材料均为不燃物，所述蜂窝材以及酚醛泡沫均为难燃材料，整体为不燃性质。
13.根据权利要求3或5所述的吸音板，其特征在于，所述多孔板的孔洞尺寸小于所述纤维毡纤维的长度，且所述纤维不会越出孔洞外漏的吸音板。
14.根据权利要求4或6所述的吸音板的制造法，其特征在于，所述多孔板孔洞尺寸小于所述纤维毡纤维的长度，且使该纤维不越出孔洞外漏。
15.根据权利要求3、5中任一项所述的吸音板，其特征在于，所述多孔板是拉制金属或穿孔金属。
16.根据权利要求4、6中任一项所述的吸音板的制造法，其特征在于，所述多孔板使用拉制金属或者穿孔金属。
17.根据权利要求9所述的吸音板，其特征在于，所述蜂窝材、所述酚醛泡沫以及所述反光材料之间分别用水溶性胶粘剂粘接，形成一体结构，得到高独立强度特征的吸音板。
18.根据权利要求10所述的吸音板的制造法，其特征在于，所述蜂窝材、酚醛泡沫以及反光材料之间分别用水溶性粘接，形成一体结构。
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