JP2018140553A - Composite materials and devices using such composite materials - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide composite materials with high sound-absorbing properties capable of effectively cutting off noises and at the same time with high heat-insulating properties capable of offering warmth/coldness keeping functions and heat-flow control functions, and also to provide devices using such composite materials.SOLUTION: The present invention relates to a composite material in which a form-type sound-absorbing material with an uneven structure on one side and a heat-insulating material are layered one on the other. The invention also relates to a composite material in which a form-type sound-absorbing material with a porous structure on one side and a heat-insulating material are layered one on the other. The invention further relates to a device with one of the abovementioned composite materials arranged between a heat source and a housing.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite material and a device using the composite material. In particular, the present invention relates to a composite material composed of a sound absorbing material having an effective sound absorbing structure and a high-performance heat insulating material, and a device using the same.

  In recent years, in the field of automobiles and industrial equipment, it is necessary to simultaneously establish heat insulation / cold insulation and sound absorption in a limited narrow space. If the space is not limited, a certain heat insulating property can be secured by increasing the thickness even if the thermal conductivity is high.

  Moreover, sound absorption can also be ensured by increasing the thickness of the foam so as to satisfy sound absorption. However, when there was not enough space, the method of increasing the thickness was not effective due to physical limitations. Therefore, ideally, it is desirable to select a material that has both heat insulating properties and sound absorbing properties as high as possible. However, there has been no material that has both heat insulation and sound absorption in addition to thinness. For this reason, there is a demand for an unprecedented composite material that has both excellent heat insulating properties that can effectively block heat even if it is thin, and soundproofing properties.

  Here, silica airgel is known as a material with high heat insulation. Silica liquid aerogel has a network structure in which silica particles of the order of several tens of nm are connected by point contact, and the average pore diameter is 68 nm or less in the mean free path of air. For this reason, it is lower than the thermal conductivity of still air. Patent Document 1 discloses a composite material that includes airgel particles, a binder that binds the airgel particles, and a flexible structure, and has heat insulating properties and soundproofing properties.

Japanese Patent Application No. 2014-77195

  However, in patent document 1, although heat insulation is excellent, sound-absorbing property was not enough. Thus, there was a problem that there was no material having both excellent sound absorption and heat insulation properties.

  Therefore, an object of the present application is to provide a composite material having both sound absorption properties and heat insulation properties and a device using the composite material.

  In order to solve the above problems, a composite material in which a foam-like sound absorbing material having an uneven structure and a heat insulating material are stacked is used.

  Further, a composite material in which a foam-like sound absorbing material having an uneven structure, a foam-like sound absorbing material not having an uneven structure, and a heat insulating material is used is used.

  Further, the foam-shaped first sound absorbing material having the first concavo-convex structure, the foam-shaped second sound absorbing material having the second concavo-convex structure, and the first sound absorbing material and the second sound absorbing material. A composite material in which the first unevenness and the second unevenness are formed on a different side from the heat insulating material.

A composite material in which a foam-like sound absorbing material having a perforated structure and a heat insulating material are laminated.
A foam-like sound absorbing material having a perforated structure, and a foam-like sound absorbing material having no perforated structure;
A composite material in which a heat insulating material is laminated is used.

  Further, a composite material in which a foam-like sound absorbing material having an uneven structure, a foam-like sound absorbing material having a perforated structure, and a heat insulating material are stacked is used.

  Moreover, the apparatus which has arrange | positioned one of the said composite materials between a heat source and a housing | casing is used.

  According to the composite material of the present invention, since it has excellent sound absorbing properties and heat insulating properties, it provides a remarkably effective action not only for noise reduction but also for applications where heat countermeasures such as heat retention or heat flow control are required at the same time. The sound absorbing material having excellent sound absorbing properties has a sound absorbing structure, and the heat insulating property is based on airgel, and both are combined so that these advantages are not offset.

Sectional drawing of the composite member of Embodiment 1 Sectional drawing of the composite member of Embodiment 2 Sectional drawing of the composite member of Embodiment 3 Sectional drawing of the composite member of Embodiment 4 Sectional drawing of the composite member of Embodiment 5 Sectional drawing of the composite member of Embodiment 6 Sectional drawing of the composite member of Embodiment 7

Next, this embodiment will be described with reference to an embodiment of a preferred invention.

(Embodiment 1)
A composite member 103 according to Embodiment 1 is shown in a cross-sectional view in FIG.
The composite member 103 includes a sound absorbing material 101 having a concavo-convex structure on the surface and a heat insulating material 102. The sound absorbing material 101 has a three-layer structure in which the heat insulating material 102 is sandwiched therebetween.

  In this structure, the surface of the sound absorbing material 101 located on the upper and lower surfaces has an uneven structure. For this reason, the sound can be effectively multiple-reflected, and the transmitted sound wave can be efficiently converted into thermal energy. Therefore, the composite member 103 in FIG. 1 is suitably used for a portion that has a high sound pressure level and does not depend on the frequency and requires heat insulation.

  The role of each layer will be described.

  The sound absorbing material 101 is the main layer of the composite member 103 and is the thickest. This layer is a layer that has a foam shape (resin foam) as a main component and determines the sound absorption performance of the composite member 103. The foam shape is a shape after foaming of resin or the like.

  The heat insulating material 102 is a layer that determines the heat insulating performance of the composite member 103. The heat insulating material 102 is thinner than the sound absorbing material 101.

<Surface uneven structure of the sound absorbing material 101>
The sound absorbing material 101 has a concavo-convex structure for multiple reflection of sound on the surface. As the concavo-convex structure, a protrusion shape such as a cone shape, a tetrahedron shape, a columnar shape, a triangular pyramid shape, or a ridge line shape may be provided on the surface. These protrusions may be arranged in parallel or alternately, but are preferably on the entire surface, and are preferably provided in a range where 25 is the lower limit and 10 is the upper limit per 10 cm square. That is, the size of the protrusion shape per one is from 0.5 cm square to 2 cm square.

<Material of sound absorbing material 101>
From the viewpoint of having a heat resistance of 100 ° C., the sound absorbing material 101 is made of a thermoplastic resin, polypropylene (PP), polycarbonate (PC), PVDC, thermosetting resin, melamine (MF), Phenol (PF) is preferred. The same applies to the following sound absorbing materials 104 and 107.

<Skeleton structure of sound absorbing material 101>
The sound absorbing material 101 is a resin foam in order to effectively attenuate sound and convert it into heat energy. The skeleton structure preferably has a pore distribution in the range of 50 nm to 3 μm. The same applies to the following sound absorbing materials 104 and 107.

<Thickness of sound absorbing material 101>
The thickness of the sound absorbing material 101 depends on the thickness of the heat insulating material 102 laminated inside, but is preferably thicker than the heat insulating material 102, and 3 mm to 50 mm is used. The same applies to the following sound absorbing materials 104 and 107.

<Material and thermal conductivity of heat insulating material 102>
The heat insulating material 102 has at least one type of silica airgel, and in order to effectively insulate, the thermal conductivity is preferably 0.024 W / mK or less. As the material form, bulk, beads, powder, sheet, blanket, etc. are used.

  The heat insulating material 102 has at least one type of aerogel, and may be a single body or a composite of aerogel and non-woven fiber.

<Thickness of heat insulating material 102>
The thickness of the heat insulating material 102 depends on the heat insulating performance or thickness required for the composite member, but is preferably thinner than the sound absorbing material 101, and 0.5 to 10 mm is used.

<Method for Manufacturing Composite Member 103>
The sound absorbing material 101 fires a thermoplastic resin or a thermosetting resin with a mold having an uneven structure on the surface. That is, in the case of a thermoplastic resin, it is polypropylene (PP), polycarbonate (PC), or PVDC, and in the case of a thermosetting resin, melamine (MF) or phenol (PF) is foam-molded. The perforated structure is a structure in which holes are formed on the surface, and the hole shape indicates a structure such as a circle, a rectangle, a hexagon, a triangle, and a trapezoid. These hole shapes may be either a parallel arrangement or an alternating arrangement, but are preferably provided on the entire surface, and are preferably provided in a range where 25 per 10 cm square is the lower limit and 400 is the upper limit. That is, the size of each hole shape is from 0.5 cm square to 2 cm square.

  After the heat insulating material 102 is laminated so as to be sandwiched between the sound absorbing materials 101, the ends of the sound absorbing material 101 are joined by hot pressing and welding. Some fibers melt and can be bonded. The heat insulating material 102 may be basically any known manufacturing method, and if it is a silica airgel, a hydrogel is synthesized by a sol-gel reaction using alkoxysilane and water glass as a raw material, and then hexamethyldisilazane or trimethyl. Hydrophobized with chlorosilane or the like, and manufactured by supercritical drying or normal pressure drying. When combining non-woven fiber with silica aerogel, silica aerogel powder and beads may be mixed with a binder and applied to the non-woven fiber and dried, or the sol-gel reaction proceeds after impregnating the non-woven fiber with the raw material And may be hydrophobized and dried.

  The manufacturing method of the following composite members 105, 108, and 109 is the same.

(Embodiment 2)
FIG. 2 is a cross-sectional view of the composite member 105 according to the second embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 105 includes a sound absorbing material 101 having a concavo-convex structure on the surface, a heat insulating material 102, and a sound absorbing material 104 having a smooth surface.

  In this structure, although the sound absorbing material 101 is laminated on the upper and lower surfaces of the heat insulating material 102, only one of them has a surface uneven structure, so that the sound pressure level is lower than that in the first embodiment. However, since there is no surface irregularity, the heat insulating material 102 can be made thicker, and the heat insulating properties are further improved. For example, it is used around the engine room of a car. The advantage of being flat only is that it is easy to bond to a smooth surface with an adhesive or the like.

(Embodiment 3)
FIG. 3 is a cross-sectional view of the composite member 106 according to the third embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 106 includes a sound absorbing material 101 having a concavo-convex structure on the surface and a heat insulating material 102. 1 and 2, this structure is composed of only one sound absorbing material 101 and one heat insulating material 102. The sound pressure level is preferably lower than those in FIGS. 1 and 2 and is preferably used in a wide range of areas where heat insulation is required. Since the sound absorbing material 101 is not present on one side, the heat insulating material 102 can be made thicker and the heat insulating properties are improved.

<Method for Manufacturing Composite Member 106>
The sound absorbing material 101 is fired with a thermoplastic resin or a thermosetting resin with a mold in order to form an uneven structure or an effective structure on the surface. That is, in the case of a thermoplastic resin, it is polypropylene (PP), polycarbonate (PC), or PVDC, and in the case of a thermosetting resin, melamine (MF) or phenol (PF) is foam-molded.

  As the heat insulating material 102, a composite of fibers and silica airgel can be used. The heat insulating material 102 may be basically any known manufacturing method, and if it is a silica airgel, a hydrogel is synthesized by a sol-gel reaction using alkoxysilane and water glass as a raw material, and then hexamethyldisilazane or trimethyl. Hydrophobized with chlorosilane or the like, and manufactured by supercritical drying or normal pressure drying. When combining non-woven fiber with silica aerogel, silica aerogel powder and beads may be mixed with a binder and applied to the non-woven fiber and dried, or the sol-gel reaction proceeds after impregnating the non-woven fiber with the raw material And may be hydrophobized and dried.

  The sound absorbing material 101 and the heat insulating material 102 may be overlapped and bonded by hot pressing and welding. Alternatively, a gel liquid, which is a raw material of silica airgel, may be partially impregnated into the sound-absorbing material 101 and then dried to obtain the heat insulating material 102 of the airgel.

  In this case, the composite member 106 is an integrated composite of the sound absorbing material 101 and the silica airgel heat insulating material 102. The following manufacturing method of the composite member 110 is also the same.

(Embodiment 4)
FIG. 4 is a cross-sectional view of the composite member 108 according to the fourth embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 108 includes a sound absorbing material 120 having a perforated structure on the surface and a heat insulating material 102, and has a three-layer structure in which the sound absorbing material 120 is stacked so as to sandwich the heat insulating material 102 therebetween.

  In this structure, since the upper and lower surfaces of the sound absorbing material 120 have a perforated structure, the sound is effectively multiple-reflected and the transmitted sound wave is efficiently converted into thermal energy. The perforated structure is a structure having large and small holes as in the foamed material. It is a hole shape such as a columnar shape, a four-sided shape, a columnar shape, or a triangular pyramid shape, and the diameter of the hole is about 1 mm to 10 mm.

  Therefore, the sound pressure level is high regardless of the frequency, and it is preferably used for a portion where heat insulation is required. Although it depends on the perforated structure used, it has basically the same multiple reflection performance of sound waves as the concavo-convex structure, so whether to use the concavo-convex structure or the perforated structure depends on the shape, space and economics of the application site. It is preferable to select it in view of assembly property and the like.

  The role of each layer will be described.

  The sound absorbing material 120 is the main layer of the composite member 108 and is the thickest. In this layer, foam (resin foam) is a main component, and is a layer that determines the sound absorption performance of the composite member 108.

  The heat insulating material 102 is a layer that determines the heat insulating performance of the composite member 108. The heat insulating material 102 is thinner than the sound absorbing material 120.

  The perforated structure on the surface of the sound-absorbing material 120 is for reducing the transmittance by multiple reflection of sound.

(Embodiment 5)
FIG. 5 is a cross-sectional view of the composite member 109 according to the fifth embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 109 is a composite member 109 composed of a sound absorbing material 120 having a perforated structure on the surface, a heat insulating material 102, and a sound absorbing material 104 having a smooth surface.

  In this structure, although the sound absorbing material 120 is laminated on the upper and lower surfaces, only one of them has a surface perforated structure, so that the sound pressure level is lower than that in FIG. 4 and heat insulation is required. Applies to

(Embodiment 6)
FIG. 6 is a cross-sectional view of the composite member 110 according to the sixth embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 110 is a two-layer composite member 110 including a sound absorbing material 120 having a perforated structure on the surface and a heat insulating material 102.

  This structure is composed of only the sound absorbing material 120 and the heat insulating material 102, unlike FIGS. The sound pressure level is preferably lower than those in FIGS. 4 and 5 and is preferably used in a wide range of areas where heat insulation is required. The heat insulating material 102 can be made thicker because the sound absorbing material 120 is less.

(Embodiment 7)
FIG. 7 is a cross-sectional view of the composite member 111 according to the seventh embodiment. Matters not described are the same as those in the first embodiment.

  The composite member 111 is a composite member 111 having a three-layer structure including a sound absorbing material 101 having an uneven structure on the surface, a heat insulating material 102, and a sound absorbing material 120 having a perforated structure on the surface.

The sound absorbers on the upper and lower surfaces are different in type, so they can absorb a wider range of sounds (as a whole)
The above embodiments can be combined.

  In a device such as an electronic device, any one of the above composite materials can be disposed between a heat source and a housing.

  The heat insulating material of the present embodiment is widely used because it can sufficiently exhibit heat insulating and sound absorbing effects even in a narrow space in electronic equipment, in-vehicle equipment, and industrial equipment. It is applied to all products related to heat, such as information equipment, portable equipment, displays, and electrical components.

DESCRIPTION OF SYMBOLS 101 Sound absorbing material 102 Heat insulating material 103 Composite member 104 Sound absorbing material 105 Composite member 106 Composite member 108 Composite member 109 Composite member 110 Composite member 111 Composite member 120 Sound absorbing material

Claims (10)

A foam-like sound absorbing material having an uneven structure;
A composite material in which insulation is laminated. A foam-like sound absorbing material having an uneven structure;
A foam-like sound-absorbing material that does not have an uneven structure;
A composite material in which insulation is laminated. A foam-like first sound-absorbing material having a first uneven structure;
A foam-like second sound absorbing material having a second uneven structure;
A heat insulating material positioned between the first sound absorbing material and the second sound absorbing material;
A composite material in which the first unevenness and the second unevenness are formed on a different side from the heat insulating material. A foam-like sound absorbing material having a perforated structure;
A composite material in which insulation is laminated. A foam-like sound absorbing material having a perforated structure;
A foam-like sound absorbing material that does not have a perforated structure;
A composite material in which insulation is laminated. A foam-like sound absorbing material having an uneven structure;
A foam-like sound absorbing material having a perforated structure;
A composite material in which insulation is laminated. The composite material according to any one of claims 1 to 6, wherein the sound absorbing material is made of any one of polypropylene foam, polycarbonate foam, melamine foam, and phenol foam. The said heat insulating material is a composite material of any one of Claim 1 to 7 containing a silica airgel. The composite material according to claim 8, wherein the heat insulating material includes the silica airgel and fibers. The apparatus which has arrange | positioned the composite material of any one of Claims 1-9 between the heat source and the housing | casing.

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