JP2004278299A - 防音断熱構造要素 - Google Patents

防音断熱構造要素 Download PDF

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JP2004278299A
JP2004278299A JP2004068848A JP2004068848A JP2004278299A JP 2004278299 A JP2004278299 A JP 2004278299A JP 2004068848 A JP2004068848 A JP 2004068848A JP 2004068848 A JP2004068848 A JP 2004068848A JP 2004278299 A JP2004278299 A JP 2004278299A
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outer layer
foam panel
polyurethane rigid
foam
rigid foam
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JP2004278299A5 (ja
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Thorsten Dreier
トルステン・ドライヤー
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Covestro Deutschland AG
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Abstract

【課題】基準を満たす表面のくぼみを用いることによって良好な断熱性及び向上した吸音性を有する独立気泡ポリウレタン硬質フォームを提供する。
【解決手段】９０％以上の独立気泡部分を有し、直径が０．１ｍｍから１０ｍｍ、深さが１０ｃｍから７ｃｍのくぼみを表面に１平方センチメートルあたり１から１８有する、少なくとも２種類のタイプのくぼみが存在するポリウレタン硬質フォームのパネルを製作する。
【選択図】なし

Description

本発明は、良好な断熱特性及び向上した吸音特性を有する独立気泡ポリウレタン硬質フォームから成る構造要素に関する。
ポリマーフォームのパネル（又は板）、特にポリウレタン硬質フォームは、建築物の断熱（又は絶縁）のために種々の用途に用いられる。屋根の絶縁区域において、例えば、取付可能絶縁材料として、厚さが４０ｍｍ〜１８０ｍｍのパネルが用いられる。これらのパネルの主な目的は、断熱を確実に行うことである。このために、使用される材料は、通常２０〜３５ｍＷ／ｍＫの範囲の熱伝導率を有する。可撓性の外側層を用いると、この熱伝導率の値を、更に一層向上することができる。更に、これらのパネルを積んだ際に屋根材に対する耐荷力を確保しなければならないから、少なくとも０．１０Ｎ／ｃｍ２の圧縮強さも、備えなければならない。断熱性の他に、外部のノイズに対する遮音性も確保しなければならず、部屋の間の音の伝導、特に１０００Ｈｚ〜５０００Ｈｚの周波数範囲の音の伝導も防止するパネル材料が都合がよい。
絶縁装置のハウジングに用いられる表面が圧縮され穴があけられたポリウレタンフォーム成型部品が、ドイツ国特許明細書 DE-A 199 62 865 に記載されている。表層被覆フォームは、表面付近で穴が開けられており、従って音波がフォームに侵入することができるということによって、吸音が達成される。しかし、記載されたフォームは、圧縮強さも断熱性も不十分であるという短所を有する。
発明の要約
音に対する防護を通常保証しない独立気泡ポリウレタン硬質フォームの吸音効果を、表面のくぼみ（凹部又は穴）が種々のサイズ（又は寸法）を有する場合、１０００〜５０００Ｈｚの周波数の範囲で著しく向上することができることが、見出された。独立気泡ポリウレタンフォームの良好な断熱性は、これらのくぼみによってほとんど影響を受けない。
本発明は、９０％以上の独立気泡部分を有し、直径が０．１〜１０ｍｍ、深さが１０〜７ｃｍのくぼみを表面に１平方センチメートル当たり１〜１８有し、少なくとも一つの寸法で相違する少なくとも二種のタイプのくぼみが存在する、ポリウレタン硬質フォームのパネルを有して成る防音及び断熱構造要素を提供する。
構造要素の表面は、０．１〜１０ｍｍの直径、好ましくは０．２〜４ｍｍの直径のくぼみを有する。くぼみは、円形状、長円形状、十字状又は裂け目状であってよく、更に種々の形状の組み合わせであってよい。くぼみの深さは、０．１〜７ｃｍ、好ましくは１〜４ｃｍであり、パネルの厚さより浅い。くぼみの深さとパネルの厚さとの間の相違は、少なくとも５ｍｍあることが好ましい。構造要素のくぼみの数は、１平方ｃｍ当たり１〜１８であり、１平方ｃｍ当たり４〜１５であることが好ましい。構造要素は、くぼみを前面又は後面に、又は両方の面に有してよい。
更に、外側層を使用すると、本発明に基づく構造要素の吸音性の向上をもたらすことも見出された。本発明においては、構造要素のポリウレタン硬質フォームパネルの片方の面のみに、又は両方の面に、外側層を設けてもよい。前面又は後面に、同じ外側層又は異なる外側層を設けてもよい。４０〜８０ｋｇ／ｍ３のかさ密度を有する無機質（又は鉱物質）のフリース（fleece）を、外側層として用いることが好ましい。しかし、ナトロンクラフト紙（Natron kraft paper）、ビツメン紙（歴青で処理された紙：bituminized paper）、歴青で処理されたフェルト、クレープ紙、ポリエチレン−コートガラスフリース（polyethylene-coated glass fleece）及びアルミニウム箔も、外側層として使用してよい。使用される外側層の厚さは、用いられる材料に依存する。例えば、アルミニウム箔では、厚さは０．０３ｍｍが好ましい。歴青で処理されたフェルトには、３ｍｍまでの厚さが好ましい。他の適当な外側層は、G. Oertel (Editor): "Polyurethane", 3rd Edition, Carl Hanser Vlg., Munich 1993, p.272 以降に記載されている。好ましい態様において、構造要素は、音に面する前面に、無機質のフリースの外側層を有し、音から離れた後面に、アルミニウム箔の外側層を有する。
２０〜１２０ｋｇ／ｍ３、好ましくは２０〜８０ｋｇ／ｍ３、もっとも好ましくは２５〜４０ｋｇ／ｍ３、の密度を有する独立気泡系（又はシステム）は、ポリウレタン硬質フォームとして使用される。ポリウレタン硬質フォームは、典型的には、１００〜６００、好ましくは１００〜４００のインデックス（イソシアネート基のイソシアネート反応性基に対するモル比に１００を掛けたもの）で、発泡されている。
本発明の構造要素に用いられるパネルは、主に当業者に既知の方法で製造される。外側層を用いる場合、例えば、二重コンベヤーベルトを用いてパネルを製造する場合、フォームを製造する間に、直接発泡することが好ましい。例えば、ドリリング（又はドリルで穴をあける：drilling）、ミリング（又はフライス削りをする：milling）等の常套の機械的な方法で、くぼみをフォームに作ることができる。
ポリウレタン硬質フォームを、
１６重量部の （防炎加工剤として）トリクロロプロピルホスフェート；
１３．２重量部の ｎ−ペンタン；
１．２重量部の 水；
１．６重量部の 市販のポリエーテル／ポリシロキサンフォーム安定剤（Air products 社から Dabco（登録商標）DC5598（商品名）で市販）；
３．６重量部の２５％の酢酸カリウムのジエチレングリコール溶液；及び
０．５６重量部のジメチルシクロヘキシルアミン
の存在下、
下記成分を反応させることにより製造した：
６４重量部の アジピン酸、無水フタル酸及びジエチレングリコールに基づくポリエステルポリオールであり、水酸基価２１０（バイエル社から、Desmophen（登録商標）DE S-053（商品名）で市販）；
１６重量部の エチレンオキサイドとプロピレンオキサイドの混合物とトリメチロールプロパンを反応させることにより製造される水酸基価２５５のポリエーテルポリオール（バイエル社から、Desmophen（登録商標）VP.PU 1657（商品名）で市販）；及び
１６０重量部の ＭＤＩ異性体とそれらの高級同族体の混合物（バイエル社から、Desmodur（登録商標）44V20（商品名）で市販）。
３０ｋｇ／ｍ３の密度及び１０体積％の連続気泡構造を有するポリウレタン硬質フォーム（インデックス２３６）を得た。ＤＩＮ５２６１６に基づく熱伝導率は、２５．８ｍＷ／ｍＫであった。
例１（比較）
この硬質フォームから、厚さ４０ｍｍ、長さ２００ｍｍ、幅２００ｍｍの平坦な成型部品を切り離した。周波数に依存する吸音を、３０ｍｍと９０ｍｍの直径の吸音チューブの中で、ＡＳＴＭ Ｅ １０５０−９０に基づいて測定した。図１は、試料の吸音を示す。熱伝導率は、２５．８ｍＷ／ｍＫであった。
例２（比較）
例１に基づいて製造した試験体の表面に、直径２ｍｍで深さ１５ｍｍの円柱状のくぼみを、一平方センチメートル当たり５つ設けた。図１は、試料の吸音を示す。熱伝導率は、２６．３ｍＷ／ｍＫであった。
例３（比較）
例１に基づいて製造した試験体の表面に、直径４ｍｍで深さ２０ｍｍの円柱状のくぼみを、一平方センチメートル当たり５つ設けた。図１は、試料の吸音を示す。熱伝導率は、２８．０ｍＷ／ｍＫであった。
例４
例１に基づいて製造した試験体の表面に、直径２ｍｍで深さ１５ｍｍの円柱状のくぼみ（一平方センチメートル当たり１つ）と、直径４ｍｍで深さ２０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）と、直径４ｍｍで深さ３０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）を設けた。図１は、試料の吸音を示す。熱伝導率は、２９．４ｍＷ／ｍＫであった。
例５
例１に基づいて製造した試験体の片面（音に向かう面）に、市販の Vliepatex（登録商標）surface （５０ｇ／ｍ２の密度の無機質コートガラスフリース：mineral-coated glass fleece）を設けた。その後、直径２ｍｍで深さ１５ｍｍの円柱状のくぼみ（一平方センチメートル当たり１つ）と、直径４ｍｍで深さ２０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）と、直径４ｍｍで深さ３０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）を、表面にあけた。図１は、試料の吸音を示す。熱伝導率は、３０．７ｍＷ／ｍＫであった。
例６
例１と同様にして製造した厚さ５０ｍｍの試験体の片面（音に向かう面）に、市販の Vliepatex（登録商標）surface （５０ｇ／ｍ２の密度の無機質コートガラスフリース）を設けた。その後、直径４ｍｍで深さ２０ｍｍの円柱状のくぼみ（一平方センチメートル当たり１つ）と、直径４ｍｍで深さ３０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）と、直径４ｍｍで深さ４０ｍｍの円柱状のくぼみ（一平方センチメートル当たり２つ）を、表面にあけた。図１は、試料の吸音を示す。熱伝導率は、３２．２ｍＷ／ｍＫであった。
本発明を説明することを目的として、本発明を詳細に説明したが、そのような詳細な説明は単にその目的のためのものであり、特許請求の範囲によって制限され得ることを除いて、当業者であれば、本発明の精神及び範囲から離れることなく、変更することが可能であることが、理解されよう。
図１は、例１〜６にて製造した各フォームの吸音を示す。

Claims (10)

  1. 独立気泡の割合が９０％以上であり、表面に１平方センチメートル当たり１〜１８のくぼみを有し、くぼみは０．１〜１０ｍｍの直径と１０〜７０ｍｍの深さを有する、ポリウレタン硬質フォームのパネルを有して成る防音及び断熱要素であって、少なくとも一つの寸法で相違する少なくとも二種類のくぼみが存在する防音及び断熱要素。
  2. くぼみは、フォームのパネルの前面と後面の両方に存在する請求項１に記載の要素。
  3. ポリウレタン硬質フォームのパネルは、前面又は後面に外側層が設けられている請求項２に記載の要素。
  4. 外側層は、アルミニウム箔又は無機質繊維フリースである請求項３に記載の要素。
  5. 独立気泡ポリウレタン硬質フォームのパネルは、前面及び後面に外側層が設けられている請求項４に記載の要素。
  6. フォームのパネルの前面の外側層は、フォームのパネルの後面の外側層と、材料が異なる請求項５に記載の要素。
  7. ポリウレタン硬質フォームのパネルは、その前面及び後面に外側層が設けられている請求項１に記載の要素。
  8. 外側層は、アルミニウム箔又は無機質繊維フリースである請求項７に記載の要素。
  9. フォームのパネルは、その前面及び後面の両方に外側層が設けられる請求項８に記載の要素。
  10. フォームの前面の外側層は、フォームの後面の外側層と、材料が相違する請求項９に記載の要素。

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