JP2003181961A - Honeycomb core material for sound-insulating panel, and sound-insulating panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a honeycomb core material having excellent sound- insulating properties suitable for doors and partitions and a sound-insulating panel comprising a surface material joined to at least one side of the honeycomb core material. <P>SOLUTION: This honeycomb core material for a sound-insulating panel includes a honeycomb body and a porous foam which has been filled into at least not less than 20% of the cell volume of the honeycomb body. The honeycomb body is a paper honeycomb having a cell size of 3 to 50 mm which satisfies the requirement specified in JIS A 6931. The porous foam includes a cured product of urethane prepared from an NCO group-containing urethane prepolymer and a polyvalent metal phosphate. The content of the cured product of urethane in the porous foam is 5 to 20% by mass. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb core material for a sound insulation panel and a sound insulation panel in which a surface material is joined to at least one surface thereof. The sound insulation panel of the present invention is particularly suitable for use as an indoor / outdoor door or a partition.

[0002]

2. Description of the Related Art Conventionally, a panel having a sandwich structure in which both sides of a honeycomb core material are sandwiched by rigid surface materials such as steel plates has been widely used in vehicles, ships, aircraft, buildings and the like. Among the various properties required for these structures, a honeycomb core material in which resin foam is filled in the cells of the honeycomb in order to improve the sound insulation property and the heat insulation property is disclosed in JP-A-3-61581 or JP-A-8-61581. -174
No. 731, etc.

However, in recent years, there has been an increasing demand for non-combustible materials in order to ensure safety in fire prevention in the event of a fire. However, as a building material for doors, partition panels, etc., resin cells are filled in honeycomb cells. When the above honeycomb core material is used, since the resin foam is an organic material such as phenol resin or urethane resin, there is a limit in characteristics in use as a non-combustible material or a fireproof material.

In order to improve the properties of the honeycomb core material filled with the resin foam as an incombustible material or a fireproof material,
Various proposals have been made. For example, Japanese Utility Model Application Laid-Open No. 59-120212 discloses an example of a single layer or a multi-layer structure having a honeycomb or the like of a fibrous plate such as glass wool or rock wool as a core material. These structures have excellent properties in fire resistance and nonflammability.

However, recently, due to protection of noise and privacy, there is an increasing demand for sound insulation in addition to the above-mentioned fireproofness and nonflammability. Especially, these structures are used for indoor and outdoor doors and partition panels. When used as, the large sound insulation performance is desired.

Regarding the sound insulation performance, in the case of a structure in which a fibrous plate, which is a soft material such as glass wool or rock wool, is formed in a single layer or a multi-layer such as a honeycomb in the core material as described above, the fibrous material is used. 1000Hz due to the sound absorption performance of the board
Excellent sound insulation performance in the above high range, 500Hz
In the following low sound range, the sound absorbing performance of the fibrous plate is poor and, at the same time, the sound insulating performance by resonance transmission is deteriorated. Further, in the above structure, when a hard material such as a foaming agent having a relatively high density is used instead of the fibrous plate such as glass wool or rock wool, the sound insulation performance in the low and middle sound range of 1000 Hz or less is excellent. , In the high frequency range of 1000Hz or more, called the coincidence effect, in a specific frequency band,
The problem is that the sound transmission loss drops sharply and the characteristics deviate from the mass law.

[0007]

The object of the present invention is excellent in non-combustibility, fire resistance, and heat insulation, and is excellent in a low-pitched sound range and a high-pitched sound range without causing deterioration of sound insulation due to the resonance transmission and the coincidence effect. To provide a honeycomb core material for a sound insulation panel and a sound insulation panel in which a surface material is bonded to at least one surface thereof, which has a sound insulation performance, particularly a sound insulation performance excellent in a high sound range and is suitable for a door, a partition panel and the like.

[0008]

The present invention achieves the above object and comprises a honeycomb body and a porous foam filled in at least 20% or more of the cell volume of the honeycomb body, The honeycomb body is JIS-A6931.
A cell honeycomb having a cell size of 3 to 50 mm, the porous foam containing a urethane cured product obtained from a urethane prepolymer having an NCO group and a polyvalent metal phosphate, and the urethane cured product. Is contained in a porous foam in an amount of 5 to 20% by mass, and a sound insulation panel in which a surface material is bonded to at least one surface of the honeycomb core material for a sound insulation panel.

The Applicant used to describe WO 01/3808
No. 1 discloses a honeycomb body and a filler filled in at least a part of the cells thereof, wherein the honeycomb body has a cell size defined by JIS-A6931 of 3 to 100 mm and a porosity of 92 to 99. Honeycomb having 0.5% and the filling is a composite foam of an inorganic foam comprising phosphoric acid, a curing agent and optionally a foaming agent, and an organic foam comprising a urethane prepolymer having an NCO group. We proposed a honeycomb structure in which surface materials are sandwiched on both surfaces of a core material.

In such a honeycomb structure, since the filling material for the honeycomb body is a composite foam of organic and inorganic, the flexibility and resilience of the organic foam and the flame retardancy and noncombustibility of the inorganic foam. It is an excellent structure that has both. However, the sound insulation performance of this honeycomb structure is not particularly described in WO 01/38081 and is not clarified.

The present inventor has conducted research into the sound insulation performance of the above-mentioned honeycomb structure. As a result, the cell size of the honeycomb body, the amount of the porous foam in the honeycomb body, and the NCO group in the porous foam are determined. It has been found that the sound insulation properties of the obtained sandwich panel are greatly different depending on the content of the urethane cured product obtained from the urethane prepolymer, and further the components and the contents contained in the honeycomb body and the porous foam. Then, depending on the combination of the plurality of elements described above, as seen in the comparative example described later, in the specific range from the low range to the high range, the sound insulation due to the resonance transmission and the coincidence effect, as in the conventional structure. Occurs, and good sound insulation performance cannot be obtained.

On the other hand, when the above plurality of elements are appropriately selected, the sound insulation performance is not deteriorated due to the resonance transmission and the coincidence effect described above, and the excellent sound insulation performance is obtained from the low sound range to the high sound range. Specifically, the sound insulation panel sandwiched by a galvanized steel sheet having a thickness of 0.5 mm, which is obtained by the present invention, has a low sound range of 250 Hz to 4000.
In the high frequency range of Hz, the sound insulation performance specified in JIS-A4702 is T-2 level or higher, and it is difficult to obtain a structure of this type conventionally, for example, in the high temperature range of 2000 Hz, the transmission loss is 35 dB or more. It was found that a honeycomb structure having excellent sound insulation performance was obtained, and particularly excellent sound insulation performance required for doors and partition panels was obtained.

The mechanism of why the sandwich panel using the honeycomb core material of the present invention achieves the above-mentioned excellent sound insulation performance is not necessarily clear, but the organic material filled in the honeycomb body of the present invention is The inorganic composite foam has appropriate flexibility, does not cause a decrease in sound insulation due to the coincidence effect in the high range, and also has good adhesion between the honeycomb body and the foam in the low range, Moreover, since the honeycomb body and the surface material thereof are mechanically joined, there is no deterioration in sound insulation performance due to resonance transmission by an air layer between the surface materials or an elastic body. Furthermore, by adjusting the content of the urethane cured product that constitutes the foam to a specific amount, a foam with moderately continuous bubbles can be obtained, so high sound absorption can be obtained, and sound insulation in the high frequency range can be obtained. Excel. And, as a result of these, it is considered that excellent sound insulation performance can be obtained from a low sound range to a high sound range which cannot be obtained by the conventional structure.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail below. The honeycomb body forming the honeycomb core material for a sound insulation panel of the present invention is substantially continuous such as a hexagon, a quadrangle, a polygon such as a triangle, a circle, a scalene polygon, etc., which is partitioned by partition walls made of continuous members. It has the shape of a simple geometric cell (through hole). The cell size and porosity of the honeycomb body are related to the rigidity of the manufactured honeycomb core material,
These are specified by JIS-A6931. Cell size is 3 to 50 mm, preferably 10 to 30 m
m, especially 14 to 20 mm is preferable. Cell size is 3m
When it is smaller than m, the strength of the honeycomb core material is improved, but the sound insulation performance is deteriorated due to the increase of the sound bridge, and when it is used for the door and the partition, the weight and the cost are increased, which is not preferable. On the other hand, when the cell size exceeds 50 mm, the sound insulation performance in the low sound range tends to be deteriorated, and when the door and the partition panel are used, the required strength is not satisfied, which is not preferable.

As the material of the honeycomb body, a paper honeycomb is used in terms of heat insulation and cost. As the paper honeycomb material, it is preferable to use pulp as a raw material, and if necessary, a fibrous material such as aramid fiber, graphite fiber, glass fiber, rock wool and magnesium silicate can be used. The paper honeycomb may be mixed or impregnated with a phenol resin, a polyimide resin, aluminum hydroxide, antimony oxide, a phosphorus compound, a halogen compound, a boron compound, or the like. In such mixed papermaking or impregnation, the above-mentioned substances used therefor can be mixed and added at the time of paper making, or can be made after paper making or honeycomb making. A paper honeycomb made flame-retardant in this manner, and a paper honeycomb made of ceramic fibers such as alumina and alumina-silica fibers can also be used.

In the paper honeycomb of the present invention, the content of the paper honeycomb material is preferably pulp in an amount of 10% by mass or more, particularly 20 to 60% by mass. Further, in particular, a flame-retardant paper honeycomb having an ash residue of 40% by mass or more in the test specified in JIS-P8128 is preferable. Further, the honeycomb body has a high reactivity with the polyvalent metal phosphate in the mixture when the mixture for forming the porous foam is filled into the cells, and as a result, When the core material contains a large amount of a component that significantly increases the rigidity, such as magnesium silicate, the sound insulation performance may be deteriorated due to the coincidence effect. For this reason, it is preferable to include a component which does not have high reactivity with the polyvalent metal phosphate, preferably pulp, rock wool, glass fiber, aluminum hydroxide or the like. In particular, in terms of contributing to heat resistance and flame retardancy, a paper honeycomb containing aluminum hydroxide as the inner content is preferably 40% by mass or more, and particularly preferably 45 to 80% by mass. It is preferable to use.

In the present invention, the porous foam filled in at least 20%, preferably 40 to 80% of the cell volume of the honeycomb body is an organic foam of a urethane cured product obtained from a urethane prepolymer having an NCO group. And a composite foam of an inorganic foam of a polyvalent metal phosphate. Such a composite foam has the advantages of an inorganic foam having excellent flame retardancy and rigidity and an organic foam having excellent flexibility and elasticity.

In the above-mentioned porous foam, it is necessary that the urethane cured product is contained in the porous foam in an amount of 5 to 20% by mass. The amount of the urethane cured product is 20
When the content is more than mass%, the closed cell rate of the foam becomes high, and the sound absorbing performance of the foam itself is deteriorated as in the case of filling the resin foam which is usually used. On the other hand, if it is less than 5% by mass, the foam shape becomes non-uniform and the sound absorbing performance is poor, and the rigidity of the foam and eventually the core material increases, so that the coincidence effect in the high range occurs. . Above all, the urethane cured product is 7-1 in the porous foam.
It is preferably 2% by mass.

The polyvalent metal phosphate contained in the porous foam is obtained by phosphoric acid and its curing agent. Examples of phosphoric acid include phosphoric acid, phosphorous acid and phosphoric anhydride. , Condensed phosphoric acid, polyvalent metal salts thereof, or a mixture of two or more thereof. Above all, it is preferable to use an acidic polyvalent metal salt of phosphoric acid such as a polyvalent metal salt of primary phosphoric acid and a polyvalent metal salt of secondary phosphoric acid for reasons such as water resistance, moisture resistance and high cell strength of the foam. As the polyvalent metal, magnesium, calcium, aluminum, zinc, barium,
Examples include iron. In the present invention, the polyvalent metal phosphate, in addition to the method of adding in its form, phosphoric acid, phosphoric acid and other phosphoric acid and chemically active metal compounds, for example,
Add polyvalent metal oxides such as magnesium oxide and calcium oxide and polyvalent metal hydroxides such as aluminum hydroxide, magnesium hydroxide and calcium hydroxide separately from the above phosphoric acids into the system, It is also possible to use the method of reacting with

As the phosphoric acid, it is preferable to use phosphoric acid, magnesium monophosphate, aluminum monophosphate, zinc monophosphate, or a mixture of two or more of these. The reason is that water resistance, moisture resistance, and cell strength of the foam are high. As the phosphoric acid, a polyvalent metal salt of acidic phosphoric acid is selected, and preferably, a method of using the polyvalent metal salt of acidic phosphoric acid and a water-soluble amine such as diethylamine or triethylamine in combination is also adopted.

In the present invention, as a curing agent for phosphoric acid which reacts with the above phosphoric acid to form a foam of polyvalent metal phosphate, a polyvalent metal carbonate, a polyvalent metal oxide or a polyvalent metal can be used. Hydroxides and / or light metals which react with acids or alkalis to generate gas are used.

Preferred examples of the polyvalent metal carbonate include sodium carbonate, sodium hydrogen carbonate, potassium carbonate, calcium carbonate, barium carbonate, basic magnesium carbonate, basic zinc carbonate and the like. Also, ammonium carbonate can be used. Of these, basic magnesium carbonate is preferable.

Preferred examples of polyvalent metal oxides include sodium oxide, potassium oxide, calcium oxide, barium oxide, magnesium oxide and zinc oxide, and polyvalent metal hydroxides) are sodium hydroxide and potassium hydroxide. ,
Examples thereof include calcium hydroxide, barium hydroxide, magnesium hydroxide and zinc hydroxide. Preferred examples of the light metal include magnesium, aluminum, zinc and the like.

The content of phosphoric acids in the porous foam of the present invention is preferably 3 to 20% by mass, and particularly preferably 4 to 18% by mass in terms of the atomic weight conversion value of phosphorus in the foam of the present invention. . If this content is less than 3% by mass, the fire resistance of the resulting foam may be reduced. On the contrary, the content is 20
When the content is more than mass%, the urethane cured product may have poor dispersibility and a uniform foam may not be obtained.
On the other hand, the amount of the phosphoric acid curing agent used in the porous foam is preferably 5 to 50% by mass, particularly preferably 10%.
-30 mass% is suitable.

When forming the porous foam of the present invention, a foaming agent can be used if necessary. The foaming agent preferably includes a volatile low boiling point organic solvent or a volatile low boiling point organic solvent. Examples of the volatile organic solvent having a low boiling point (boiling point 120 ° C. or lower) include ethers, ketones, hydrocarbons, and freons, and among them, halogenated hydrocarbons and ketones having a boiling point of 0 to 100 ° C. Preferred are halogenated hydrocarbons and acetone, which are liquid at room temperature. These foaming agents can be used alone or as a mixture of two or more kinds.

The amount of the foaming agent used above can be arbitrarily set according to the target expansion ratio. When a metal oxide is used as the phosphoric acid curing agent, the foaming time for the curing reaction can be appropriately adjusted by appropriately selecting the foaming agent for the curing agent because a foaming agent is used separately. The filling of the foam into the honeycomb body is easily controlled. Further, since the amounts of the curing agent and the foaming agent can be adjusted respectively, it is possible to have a wide range from a desired softness to a hardness, and it is easy to determine it according to the expansion ratio.

In order to obtain a urethane cured product which constitutes the porous foam of the present invention, it is preferable to use a urethane prepolymer having an NCO group. The urethane prepolymer having an NCO group is derived from an organic polyisocyanate compound and an active hydrogen-containing compound, and is NC
Those having an O group in the molecule are preferable. Preferred examples of the organic polyisocyanate compound include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), dicyclohexylmethane-4,
4'-diisocyanate (hydrogenated MDI), methylcyclohexane-2,4-diisocyanate (hydrogenated TDI),
2,4- or 2,6-toluene diisocyanate (T
DI) or 4,4'-diphenylmethane diisocyanate (MDI).

Examples of the active hydrogen-containing compound include low molecular weight polyols and high molecular weight polyols, and particularly preferable ones are ethylene oxide adducts of polyoxyalkylene polyols. Alternatively, it is preferably used as a part of the active hydrogen-containing compound. In this case, the content of oxyethylene units in the active hydrogen-containing compound is
It is preferably from 10 to 95% by mass, particularly preferably from 50 to 90% by mass. The use of the ethylene oxide adduct improves the dispersibility of the above prepolymer in forming an aqueous mixture.

Aluminum hydroxide is preferably contained in the porous foam of the present invention. As will be described later, aluminum hydroxide can function as a flame retardant, and can reduce the foaming ratio of the porous foam to further improve the sound absorbing property from a low frequency region to a high frequency region. The amount of aluminum hydroxide contained in the porous foam is preferably 5 to 70% by mass, particularly 10 to
50% by mass is preferred. If the amount is less than 5% by mass, the flame retardancy is poor, and conversely, if it exceeds 70% by mass, the brittleness increases and the handleability is poor, which is not preferable.

In addition, the porous foam of the present invention may contain an inorganic filler or an organic filler as necessary in consideration of physical properties and cost. Examples of the inorganic filler include water-insoluble inorganic powder materials such as cement, clay mineral, inorganic lightweight aggregate, inorganic fiber, fly ash, silica fume, silica stone powder, ceramic powder, alumina and calcium sulfate. In addition, it is possible to include organic fibers in order to improve the tensile strength and bending strength of the foam. The addition amount of these is
There is no particular limitation, and 1800 parts by mass or less, particularly 500 parts by mass or less is suitable for 100 parts by mass of phosphoric acid.

Furthermore, the porous foam of the present invention can be foam-cured by adding a flame retardant in order to impart high fire resistance. Preferred examples of the flame retardant include non-halogen phosphate ester, halogen-containing phosphate ester, active hydrogen-containing flame retardant, antimony trioxide, antimony pentoxide, zinc oxide and the like, in addition to the above-mentioned aluminum hydroxide. These can be used in combination of two or more. The content of the flame retardant is preferably 40 parts by mass or less, particularly 0.1 to 30 parts by mass, relative to 100 parts by mass of the urethane prepolymer.

In the case of producing the sound insulation panel core material of the present invention, phosphoric acid, a curing agent, a prepolymer, water and, if necessary, a foaming agent, etc., which form the above-mentioned porous foam, are mixed to form an aqueous mixture, This is filled in the cells of the honeycomb,
Foam and cure. The amount of water in the aqueous mixture does not need to be added more than necessary as long as it can be slurried. The more water, the more time and labor is required to dry the foamed cured product. The amount of water is preferably such that the concentration of solid content in the aqueous mixture is about 50 to 90% by mass.

In the present invention, for example, a catalyst can be used to control the curing rate of the prepolymer forming the organic foam. As a preferable example of the catalyst,
Dibutyltin dilaurate, alkyl titanate, organosilicon titanate, stannas octoate, lead octylate, zinc octylate, bismuth octylate, dibutyltin diorthophenylphenoxite, tin oxide and ester compounds (dioctyl phthalate, etc.) Metal-based catalysts such as reaction products of, monoamines (triethylamine, etc.),
Diamines (N, N, N ′, N′-tetramethylethylenediamine, etc.), triamines (N, N, N ′, N ″,
N "-pentamethyldiethylenetriamine etc.), amine catalysts such as cyclic amines (triethylenediamine etc.) and the like. The amount of the catalyst is preferably 0.001 to 5 parts by mass relative to 100 parts by mass of the prepolymer. It is a department.

Further, in the present invention, a foam stabilizer can be used in order to control the cell structure of the foam to be formed. Preferred examples of the foam stabilizer include silicone-based surfactants, such as "SH-192" and "SH-193" manufactured by Toray Dow Corning Silicone,
"SH-194", "SF-2935", "SF-29"
45 "," SF-2939 "," TFA-4200 "manufactured by Toshiba Silicone," L-5 "manufactured by Unicar Japan.
320 "," L-5340 "," L-5350 "," S
Z-1698 "," SZ-1669 "," F-121 "," F-122 "," F-50 "manufactured by Shin-Etsu Silicon Co., Ltd.
2 "and" F-305M ". The amount of the foam stabilizer added is preferably 0.001 to 1 part by mass relative to 100 parts by mass of the urethane prepolymer.

The sound-insulating panel core material comprising a honeycomb body in which cells are filled with the porous foam containing the urethane cured product and the polyvalent metal phosphate of the present invention is the above-mentioned phosphoric acid,
It is produced by filling an aqueous mixture containing a curing agent, a foaming agent, a urethane prepolymer having an NCO group, and water, and foam-curing.

A preferred method for filling the above-mentioned aqueous mixture into the cells of the honeycomb body and foaming and hardening is as follows.
The aqueous mixture may contain, in addition to the above-mentioned components, a foaming agent and an inorganic or organic filler which are used if necessary. The components contained in the aqueous mixture may be mixed all at once, or after the phosphoric acid or its aqueous solution and the prepolymer are mixed, a curing agent and, if necessary, a foaming agent, an inorganic or organic filler. Separately,
Alternatively, these may be mixed in advance and made into a slurry to be mixed.

The method of filling the cells of the honeycomb body with the above-mentioned aqueous mixture is not particularly limited, and a method of pouring a slurry-like aqueous mixture into the cells, a method of filling by spraying, or a method of flattening the aqueous mixture into a planar shape After getting used to
Examples include a method of pressing the honeycomb body from above and filling it. In these methods, it is preferable that after filling the honeycomb body with the aqueous mixture, a smooth face material is brought into contact with the surface of the filled honeycomb body and sufficiently fixed. This can prevent the foam from expanding outside the cells of the honeycomb body. Further, the aqueous mixture does not need to be filled in all cells or the entire cells, but needs to be filled in the cells by 20% or more. If the filling rate is less than 20%, the sound insulation performance is poor, which is not preferable.

After being filled in the cells of the honeycomb body, the above aqueous mixture is preferably foamed for several seconds to several tens of minutes under normal temperature and pressure conditions, and then the curing is completed to form a foamed body.
However, in winter, when the temperature is low, or when it is desired to shorten the foam hardening time in the process, it may be heated to about 50 ° C. during standing. Thereafter, if necessary, the excess water may be removed by heating to 80 to 150 ° C.

The inorganic / organic porous composite foam of the present invention produced in this manner has excellent properties as described above, but in particular, the polyvalent metal carbonate, light metal, By controlling the amount of foaming agent added,
Its specific gravity can be adjusted in a wide range of 0.01 to 1.5.
In particular, in the foam of the present invention, when the specific gravity is 0.1 or less, the flexibility of the foam is strongly expressed, and as a result, the obtained honeycomb core material has flexibility.

Thus, according to the present invention, it is possible to obtain a honeycomb core material having a composite foam made of a wide variety of materials, from hard to soft ones. Further, in the present invention, the heat insulation performance of the obtained honeycomb core material is controlled, for example, by controlling the selection of the material of the honeycomb body and the composition of the above-mentioned aqueous mixture, particularly the specific gravity and the diameter and shape of the foamed cells. .04kc
It is possible to impart a low thermal conductivity of al / m · hr · ° C or less, and the flame retardancy is at a level equivalent to a non-combustible material based on the Building Standards Act.

Further, the honeycomb core material obtained by the present invention preferably has a flow resistance defined by JIS-A6306-1991 of 10 to 1000 Pa · s / cm ³ . Flow resistance of the honeycomb core material is 10 Pa · s / c
If it is less than m ³ , the sound absorbing performance of the foam is inferior, and if the flow resistance is less than 1000 Pa · s / cm ³ , the foam becomes a foam having many closed cells, and the sound absorbing performance is inferior. Above all,
The flow resistance is preferably ³⁰ to 500 Pa · s / cm ³ .

The surface material to be bonded to at least one surface of the honeycomb core material in the present invention is not particularly limited,
The thickness is preferably 0.3 to 1.6 mm.
If the thickness is less than 0.3 mm, the sound insulation performance is inferior, and if it exceeds 1.6 mm, the panel weight increases, which is not preferable.

The surface material may be a metal plate, a wood plate,
Examples include inorganic boards and natural stone boards. In addition, one or more kinds of these surface materials may be combined with one or more kinds of coating, plating, laminating with a surface decorative material, resin makeup or coating, primer, rust prevention, antibacterial, antifungal treatment, etc., if necessary. Is given. Of these, metal plates are preferable, steel plates, aluminum alloy plates,
Examples include stainless steel plates and titanium alloy plates. Among them, in terms of fire resistance, flame retardancy, strength, design, etc., steel sheets including color steel sheets, galvanium steel sheets, bonde steel sheets, galvanized steel sheets, etc., aluminum alloy sheets including A5052, A5005, A1100 etc., SUS430, SUS304.
It is preferable to use a stainless plate including the above, and a metal plate such as a titanium alloy plate.

In the case of joining the honeycomb core material and the surface material, an adhesive agent, a brazing material, or a method such as diffusion bonding can be used. Among them, the method of using an adhesive is common. For the adhesive, thermosetting adhesive such as epoxy, urethane, vinylphenolic, etc.,
There are synthetic rubber-based or vinyl acetate-based thermoplastic adhesives, and their forms are solution, paste, solid,
It is in the form of a film.

The above-mentioned adhesive is selected as appropriate depending on the material of the surface material and the honeycomb body, the adhesive strength, the curing conditions, the adhesive equipment, the durability, the price and the like. The adhesion method includes a turnback method, a pinch roller method, a hot press method, a vacuum back method, an autoclave method and the like, and these methods can be used alone or in combination. Further, the bonding surface of the surface material to be bonded may be subjected to a primer treatment, a degreasing treatment, a sanding treatment or the like for roughening the bonding surface depending on the adhesive material.

The panel obtained by bonding the surface material to at least one surface of the honeycomb core material of the present invention thus obtained is excellent in non-combustibility, fire resistance and heat insulation, and also has sound insulation due to the resonance transmission and the coincidence effect. Excellent sound insulation performance can be obtained in the low to high range without causing deterioration in performance. Specifically, the sound insulation panel obtained by the present invention has a sound insulation performance of T-2 specified in JIS-A1416 in the low sound range of 250 Hz to the high sound range of 4000 Hz.
It is above the level, and in particular, it is possible to achieve a sound transmission loss of 35 dB or more in the high frequency range of 2000 Hz, which could not be achieved in the past.

[0047]

EXAMPLES The present invention will be described in more detail below with reference to examples, but it goes without saying that the interpretation of the present invention is not limited by these examples. [Manufacture of Honeycomb Core Material] 50% by mass aqueous solution of primary magnesium phosphate, water, basic magnesium carbonate, magnesium oxide, zinc oxide, aluminum hydroxide, and nitrogen substituted so as not to react with moisture in the air A powder mixture prepared by mixing the TDI prepolymer in the tank at a predetermined mass ratio shown in Table 1 (first magnesium phosphate is calculated as a solid matter) was supplied to a continuous mixer, and the foaming liquid was produced from the continuous mixer. It was discharged onto a PET (polyethylene terephthalate) film so as to be smooth.

Next, a paper honeycomb material having the physical properties shown in Table 1 was placed on the smoothed foaming liquid, and pressed from above with a PET film and a smooth face material to foam and cure in a honeycomb cell. PE after foaming and curing
The T film was peeled off and dried to obtain a honeycomb core material in which the porous foam was filled with 80% of the volume of the cells of the honeycomb body.

The TDI prepolymer (d-1) used in the present invention is as follows. [TDI-8
0; Nippon Polyurethane Co., Ltd., trade name: Coronate T
-80] 100 parts by mass of polyoxyethylene polyoxypropylene glycol [molecular weight 2188, ethylene oxide 60% by mass and propylene oxide 40
A block copolymer with 4% by weight, a prepolymer by reacting 420 parts by weight. The NCO content of the prepolymer is 6.2% by mass, the number average molecular weight is 1355, and a viscous resin solution at room temperature.

[Manufacture of Sound Insulation Panel] A commercially available 0.6 mm thick galvanized color steel sheet is used, and an epoxy adhesive is applied to the adhesive surface where the steel sheet adheres to the honeycomb core material (application amount:
After about 200 g / m ² ) and pressure-bonded on both sides of the honeycomb core material, the honeycomb core material was left at 50 ° C. for 10 hours to obtain a sandwich panel.

Examples 1 to 5 (Examples) and Examples 6 to 8 (Comparative Examples) A 50 mass% aqueous solution of magnesium monophosphate (a),
The TDI prepolymer (b) and the powder raw material (c) were blended as shown in Table 1 to form a foaming liquid, which was also filled in the cells of the paper honeycomb body shown in Table 1 by the above-described manufacturing method.
A honeycomb core material having cells filled with a porous foam was obtained. In addition, a panel in which a surface material was sandwiched on both sides of a honeycomb core material was obtained by the above manufacturing method. The unit of the content of each component in the aqueous mixture in Table 1 is parts by mass.

Table 2 shows the physical property values of the honeycomb core material and the sandwich panel obtained in each case. The test method is as follows. Compressive strength: According to JIS-A9511. Sound insulation: A test conducted according to JIS-A1416 is judged according to the standard of A4702.

[0053]

[Table 1]

[0054]

[Table 2]

The sound insulation panels obtained in Example 1 (Example), Example 6 (Comparative Example), and Example 8 (Comparative Example) were measured according to JIS-A1416 in frequency (Hz)- The transmission loss (dB) relationship was tested. The respective results are shown in FIGS.

As is clear from these results, the panel of Example 1 (Example) did not fall below the 30 grade line (sound insulation T-2 level) shown by the straight line in all the measured 16 frequency ranges, and had excellent sound insulation. Performance was also shown, and the sharp reduction in transmission loss in the low frequency region and the high frequency region, which was observed in the panels of Example 6 (Comparative Example) and Example 8 (Comparative Example), was not observed.
On the other hand, in the panels of Example 6 (Comparative Example) and Example 8 (Comparative Example), a sharp decrease in transmission loss was observed in the low frequency region and the high frequency region, respectively, and the sound insulation T-2 level was not reached.

[0057]

EFFECTS OF THE INVENTION According to the present invention, in addition to being excellent in non-combustibility, fire resistance and heat insulation, excellent sound insulation performance from low range to high range, in particular, no deterioration of sound insulation due to the resonance transmission and the coincidence effect is produced. Provided is a novel honeycomb core material for a sound insulation panel, which has excellent sound insulation performance in a high temperature range and is suitable for a door, a partition panel, and the like, and a sound insulation panel in which a surface material is bonded to at least one surface thereof.

Specifically, the sound insulation panel obtained by the present invention has a sound insulation performance defined by JIS-A1416 of T-2 in the low sound range of 250 Hz to the high sound range of 4000 Hz.
It is higher than the level, and in particular, as shown in the later examples, which are difficult to obtain with this type of structure, for example, 2
It was found that a honeycomb structure having excellent sound insulation performance with a transmission loss of 35 dB or more can be obtained in a high temperature range of 000 Hz. The present invention also provides a honeycomb core material for a sound insulation panel having the above-mentioned excellent properties and a method for easily and efficiently manufacturing a sound insulation panel using the same.

[Brief description of drawings]

FIG. 1 shows frequency (Hz) -transmission loss (dB) characteristics of a sound insulation panel of Example 1 (Example) of the present invention.

FIG. 2 shows characteristics of frequency (Hz) -transmission loss (dB) possessed by the sound insulation panel of Example 6 (Comparative Example) of the present invention.

FIG. 3 shows the frequency (Hz) -transmission loss (dB) characteristics of the sound insulation panel of Example 6 (Comparative Example) of the present invention.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) G10K 11/16 G10K 11/16 A 11/162 D (72) Inventor Satoshi Watanabe Kanda Blacksmith Town, Chiyoda-ku, Tokyo 3-chome 6 address 3 Asahi fiber glass Co., Ltd. in the F-term (reference) 2E001 DD01 DE01 DF02 DF04 FA33 GA07 GA87 HC00 HD03 JA22 JA25 JC02 JD02 JD04 JD05 2E039 BB02 4F100 AA01A AA01H AA04A AA04H AA19A AA19H AB03B AK51A BA01 BA02 BA10A BA10B DC07A DG02A DG02H DG10A DJ01A EJ022 EJ082 GB07 JA20A JA20B JH01 YY00A YY00B 5D061 AA06 AA16 AA26 BB13

Claims (8)

[Claims] 1. A paper having a honeycomb body and a porous foam filled in at least 20% or more of the cell volume of the honeycomb body, the honeycomb body having a cell size of 3 to 50 mm specified in JIS-A6931. Is a honeycomb,
The porous foam contains a urethane cured product obtained from a urethane prepolymer having an NCO group, and a polyvalent metal phosphate, and the urethane cured product is contained in the porous foam in an amount of 5 to 20% by mass. Honeycomb core material for sound insulation panels. 2. With respect to 100 parts by mass of the porous foam,
The honeycomb core material for a sound insulation panel according to claim 1, further comprising 5 to 70 parts by mass of aluminum hydroxide. 3. The paper honeycomb contains pulp in an amount of 10 to 60% by mass and aluminum hydroxide in an amount of 40% by weight, respectively.
The honeycomb core material for a sound insulation panel according to claim 1 or 2, wherein the honeycomb core material is contained in an amount of -80% by mass. 4. The honeycomb core material is JIS-A6306.
-1000 as the flow resistance specified in 1991
The honeycomb core material for a sound insulation panel according to claim 1, 2 or 3, which has Pa · s / cm ³ . 5. A sound insulation panel in which a steel plate having a thickness of 0.3 to 1.6 mm is joined to at least one surface of the honeycomb core material according to any one of claims 1 to 4. 6. The sound transmission loss at 2000 Hz is 35.
The sound insulation panel according to claim 5, which has a dB or more. 7. A mixture containing phosphoric acid, a curing agent, a foaming agent, a urethane prepolymer having an NCO group, and water for a cell of a paper honeycomb body having a cell size of 3 to 50 mm defined by JIS-A6931. Is filled, the mixture is foamed and cured, and a porous foam having a urethane cured product content of 5 to 20% by mass is filled into the cells of the honeycomb body to produce a honeycomb core material for a sound insulation panel. 8. The method for manufacturing a honeycomb core material for a sound insulation panel according to claim 7, wherein the mixture further contains aluminum hydroxide.