JP5635346B2 - Flexible silencer duct - Google Patents

Description

  The present invention relates to a muffler duct having flexibility. Specifically, the present invention relates to a duct mainly used for transferring air for air conditioning.

  Ducts are used to transfer air for air conditioning. The required performance for this duct includes flexibility. The duct having flexibility is bendable. Therefore, in the air conditioning equipment using this duct, an “L” -shaped joint called “elbow” is unnecessary. Another required performance for this duct is excellent silence. In air-conditioning equipment using ducts with excellent sound deadening properties, noise generated from air-conditioning equipment is difficult to propagate. Furthermore, in this air conditioning equipment, sounds and voices emitted indoors are not easily transmitted to the adjacent room.

  Japanese Patent Application Laid-Open No. 11-63380 discloses a duct including a breathable fiber layer, an open cell layer, and an airtight layer. The hermetic layer is located outside the open cell layer. In this duct, the open cell layer contributes to the silence.

  Japanese Patent Application Laid-Open No. 2004-170073 discloses a hose provided with a first foamed resin layer having open cells and a second foamed resin layer located outside the first foamed resin layer and having closed cells. Is disclosed. The second foamed resin layer is obtained by winding a foamed resin tape in a spiral shape. The side edges of the tape are heat-sealed with the adjacent side edges. In this hose, the first foamed resin layer contributes to silence, and the second foamed resin layer contributes to heat insulation and airtightness.

JP-A-11-63380 JP 2004-170073 A

  In the conventional duct, when the open cell layer is thin, the sound deadening property is insufficient. A duct having a thick open cell layer is excellent in noise reduction. However, due to the thick open cell layer, the outer diameter of this duct is large. This duct cannot be installed in a narrow space.

  An object of the present invention is to provide a duct that is compact and has excellent sound deadening properties.

The flexible silencer duct according to the present invention is:
(1) A cylindrical main body including a sound deadening layer and having air permeability, and (2) an outer layer laminated on the outer peripheral surface of the main body and having an air permeable portion and a non air permeable portion.

  Preferably, the breathable part is spiral. Preferably, the ratio between the axial width of the breathable portion and the helical pitch of the breathable portion is 1/50 or more and 1/6 or less.

  Preferably, the outer layer includes a breathable sheet and a non-breathable sheet that is positioned on the front side or the back side of the breathable sheet and integrated with the breathable sheet.

  In the muffler duct according to the present invention, the outer layer having the air permeable portion contributes to the muffler. This duct does not require a large sound deadening layer. The duct is therefore compact.

FIG. 1 is a sectional perspective view showing a part of a muffler duct according to an embodiment of the present invention. FIG. 2 is a partially cutaway front view showing a part of the duct of FIG. FIG. 3 is a perspective view showing how the duct of FIG. 1 is manufactured. 4 (a) is a front view showing a part of a duct according to another embodiment of the present invention, and FIG. 4 (b) is an enlarged cross-sectional view taken along line BB of FIG. 4 (a). It is. FIG. 5 (a) is a partially cutaway front view showing a part of a duct according to still another embodiment of the present invention, and FIG. 5 (b) is taken along line BB in FIG. 5 (a). FIG.

  Hereinafter, the present invention will be described in detail based on preferred embodiments with appropriate reference to the drawings.

  The duct 2 shown in FIGS. 1 and 2 includes a main body 4 and an outer layer 6. The outer layer 6 is laminated on the outer peripheral surface of the main body 4. The main body 4 is cylindrical. The main body 4 includes an inner layer 8 and a foam layer 10 which is a sound deadening layer. The foam layer 10 is laminated on the outer peripheral surface of the inner layer 8. The inner layer 8 includes a first ventilation layer 12 and a reinforcing body 14. The outer layer 6 includes a second gas permeable layer 16 and a non-air permeable layer 18. The outer diameter D1 of the duct 2 is typically 50 mm or greater and 250 mm or less. The inner diameter D2 of the duct 2 is typically 40 mm or greater and 220 mm or less.

The 1st ventilation layer 12 consists of a nonwoven fabric. A nonwoven fabric consists of fibers. The non-woven fabric is formed so that the fibers are not woven and have a sheet shape. In the first breathable sheet,
(1) Non-woven fabric in which fibers are entangled by needle punching method (2) Both non-woven fabrics in which fibers are bonded together by heat fusion or by an adhesive can be used, such as a spunbond nonwoven fabric. The nonwoven fabric is breathable. The thickness of this nonwoven fabric is typically 0.3 mm or more and 1 mm or less.

  The first ventilation layer 12 is formed by winding a tape-shaped nonwoven fabric in a spiral shape. As shown in FIG. 2, the side edge 20 of the nonwoven fabric is abutted against the adjacent side edge 20. The vicinity of the side edge 20 may be overlapped with the vicinity of the adjacent side edge 20. The first ventilation layer 12 defines the inner peripheral surface of the duct 2.

  A preferred material for the nonwoven fabric is a thermoplastic resin such as polypropylene. For the first gas permeable layer 12, various sheets having air permeability can be used in addition to the nonwoven fabric. For example, a mesh-like sheet (net-like sheet), a punching sheet, and a woven fabric can be used for the first ventilation layer 12.

  The reinforcing body 14 is linear. The reinforcing body 14 is spirally wound on the outer peripheral surface of the first ventilation layer 12. As shown in FIG. 2, the width of the reinforcing body 14 is smaller than the helical pitch. Therefore, the side edge of the reinforcing body 14 is separated from the adjacent side edge. This separation can contribute to the flexibility of the duct 2.

  The reinforcing body 14 includes a bottom portion 22 and a convex portion 24. The bottom 22 is positioned over two adjacent nonwoven fabrics. In other words, the reinforcing body 14 is located immediately above the side edge 20 of the nonwoven fabric. The reinforcing body 14 is typically made of a material that is higher in rigidity than the material constituting the other part of the duct 2. As will be described in detail later, the bottom 22 is bonded to the nonwoven fabric. By this joining, the first ventilation layer 12 and the reinforcing body 14 are integrated. The reinforcing body contributes to the inner layer 8 maintaining a cylindrical shape. A preferable material of the reinforcing body 14 is a thermoplastic resin such as polypropylene. The reinforcing body 14 may be made of a monofilament. The reinforcing body 14 may be made of a metal wire.

  The foam layer 10 is located outside the first ventilation layer 12 and the reinforcement body 14. The foam layer 10 defines the outer peripheral surface of the main body 4. The foam layer 10 is in contact with the convex portion 24 of the reinforcing body 14. The foam layer 10 is not joined to the reinforcing body 14. The fact that they are not joined contributes to the flexibility of the duct 2. The foam layer 10 may be joined to the reinforcing body 14.

  The foam layer 10 is made of a polymer molded body having open cells. Typically, the bubbles are formed by foaming of a pyrolytic foaming agent. Examples of the thermally decomposable foaming agent used include azo compounds, nitroso compounds, and triazole compounds. The polymer molded body may be obtained by a physical foaming method such as a mechanical stirring method. Since it has open cells, this polymer molding is breathable. The polymer molded body can pass sound waves. Therefore, this polymer molded body absorbs sound. This polymer molded body contributes to the silence of the duct 2.

  From the viewpoint of silence, the thickness of the polymer molded body is preferably 5 mm or more, and particularly preferably 7 mm or more. As will be described later, in this duct 2, the outer layer 6 contributes to muffling properties. Therefore, even when a polymer molded body having a small thickness is used, the excellent silencing property of the duct 2 can be maintained. The duct 2 having a polymer molded body with a small thickness is compact. From the viewpoint of compactness, the thickness of the polymer molded body is preferably 15 mm or less, and particularly preferably 10 mm or less.

  The foam layer 10 is formed by spirally winding a tape-shaped polymer molded body. As shown in FIG. 2, the side edge 26 of the polymer molded body is abutted with the adjacent side edge 26. The side edge 26 is not joined to the adjacent side edge 26. The fact that they are not joined contributes to the flexibility of the duct 2. A side edge 26 may be joined to an adjacent side edge 26. The foam layer 10 may be formed such that there is a gap between the side edge 26 and the side edge 26 adjacent thereto.

  A typical polymer molding is a polyurethane foam. The sound deadening layer may be formed from another material capable of absorbing sound instead of or together with the polymer molded body. Examples of other materials include cotton such as cotton, glass wool, and a thick nonwoven fabric.

  As described above, the first breathable layer 12 is breathable, and the foam layer 10 is also breathable. Furthermore, the non-breathable reinforcing body 14 covers only a part of the first breathable layer 12. Therefore, the main body 4 is breathable as a whole.

  The 2nd ventilation layer 16 consists of a nonwoven fabric ("breathable sheet" said to this invention). A non-woven fabric equivalent to the non-woven fabric of the first ventilation layer 12 can be used for the second ventilation layer 16. The second ventilation layer 16 is formed by winding a tape-shaped nonwoven fabric spirally. As shown in FIG. 2, the side edge 28 of the nonwoven fabric is abutted against the adjacent side edge 28. The vicinity of the side edge 28 may be overlapped with the vicinity of the adjacent side edge 28. A mesh-like sheet (net-like sheet), a punching sheet, and a woven fabric may be used for the second ventilation layer 16.

  The second ventilation layer 16 is not joined to the foam layer 10. The fact that they are not joined contributes to the flexibility of the duct 2. The second ventilation layer 16 may be bonded to the foam layer 10.

  The non-breathing layer 18 is made of a resin film (“non-breathable sheet” referred to in the present invention). The non-air-permeable layer 18 is obtained by winding a tape-like resin film on the outer peripheral surface of the second air-permeable layer 16 in a spiral shape. As will be described in detail later, the resin film is bonded to the second ventilation layer 16. A preferred material for the resin film is a thermoplastic resin such as polypropylene. A resin film may be present inside the second ventilation layer 16.

  From the viewpoint of the flexibility of the duct 2, the thickness of the resin film is preferably 0.5 mm or less, and particularly preferably 0.1 mm or less. From the viewpoint of easy formation of the non-breathing layer 18, this thickness is preferably 0.05 mm or more.

  As shown in FIG. 2, the width W1 of the resin film is smaller than the helical pitch P. Therefore, the side edge 30 of the resin film is separated from the adjacent side edge 30. Due to this separation, a groove 32 is formed on the surface of the duct 2. In the groove 32, the second ventilation layer 16 is exposed. In this duct 2, the groove 32 corresponds to a breathable part. On the other hand, the resin film corresponds to a non-breathable part. In this duct 2, the outer layer 6 has a breathable part and a non-breathable part. Since the resin film is spirally wound, the groove 32 also has a spiral shape. In FIG. 2, the width of the groove 32 is indicated by an arrow W2. The depth of the groove 32 matches the thickness of the resin film. In the present embodiment, the spiral pitch is set to 30 mm, and the width W2 of the groove 32 is set to 2 mm.

  In the duct 2, the internal air can move from the groove 32 to the outside through the main body 4 and the air-permeable portion of the outer layer 6. Therefore, the sound passing through the inside of the duct 2 can be emitted to the outside. Therefore, in this duct 2, the propagation of sound inside the duct 2 can be suppressed.

  In this duct 2, since the outer layer 6 has a breathable part, the behavior of the air seen from the inside of the duct 2 is as if the back air layer is locally present outside the foam layer 10. Match. In other words, as if there is a back air layer, the particle velocity when the vibrating air passes through the sound deadening layer increases, and the sound deadening layer can more efficiently attenuate air vibration. The sound deadening property of the duct 2 is superior to that of a duct whose entire outer layer is a non-breathable portion. According to the knowledge obtained by the present inventor, when the urethane foam having a thickness of 7 mm is used as the foam layer 10, the silence of the duct 2 is that the entire outer layer is a non-breathable portion and the thickness is 25 mm. It is equivalent to the silence of a conventional duct using a certain glass wool. The duct 2 according to the present invention can achieve both silence and compactness.

  In the duct 2, breathable portions and non-breathable portions appear alternately along the axial direction. Therefore, the silencing effect is exhibited over the entire length of the duct 2. The breathable portion (groove 32) further contributes to the flexibility of the duct 2.

  Cold air or warm air moving inside the duct 2 passes through the air-permeable portion and leaks to the outside. However, since the area of the air-permeable portion is small, the degree of leakage is small, and therefore, the air conditioning efficiency is not greatly adversely affected.

  The ratio between the axial width W2 of the air permeable portion (groove 32) and the helical pitch P of the air permeable portion is preferably 1/50 or more, and particularly preferably 1/30 or more, from the viewpoint of sound deadening and flexibility. . From the viewpoint of cooling and heating efficiency, this ratio is preferably 1/6 or less, and particularly preferably 1/10 or less.

  From the viewpoint of noise reduction and flexibility, the width W2 is preferably 1 mm or more. From the viewpoint of cooling and heating efficiency, the width W2 is preferably 5 mm or less, and particularly preferably 3 mm or less. The pitch P is preferably 20 mm or greater and 40 mm or less.

  FIG. 3 shows how the duct 2 of FIG. 1 is manufactured. The device 33 used for this production includes a forming shaft 34. The forming shaft 34 is driven by a driving means (not shown) to perform a rotation feeding operation. The direction of rotation is indicated by the symbol R in FIG. The feed direction is indicated by arrow A in FIG. This manufacturing apparatus 33 is known. A manufacturing method in which the manufacturing apparatus 33 is used is referred to as a “spiral method”.

  In the manufacturing method using the apparatus 33 shown in FIG. 3, the tape-shaped nonwoven fabric 36 is supplied onto the forming shaft 34 and is wound spirally around the forming shaft 34. The side edge 20 of the nonwoven fabric 36 is abutted against the adjacent side edge 20. The first ventilation layer 12 is formed by the nonwoven fabric 36.

  The polymer composition is heated and melted. This polymer composition is extruded from the extruder, and a semi-molten wire 38 is obtained. This wire 38 is supplied onto the first air-permeable layer 12 and is wound spirally. The wire 38 is disposed immediately above the side edge 20 of the nonwoven fabric of the first ventilation layer 12. The reinforcing member 14 is obtained by solidifying the wire 38. The first ventilation layer 12 and the reinforcing body 14 are fused by solidification. The inner layer 8 is obtained by fusing.

  A tape-shaped polymer molded body 40 is supplied onto the inner layer 8 and is wound spirally. The side edge 26 of the polymer molded body 40 is abutted with the adjacent side edge 26. The polymer layer 40 forms the foam layer 10.

  A tape-like non-woven fabric 42 is supplied on the foam layer 10 and is wound spirally. The side edge 28 of the nonwoven fabric is abutted against the adjacent side edge 28. The second ventilation layer 16 is formed by this nonwoven fabric.

  A tape-shaped resin film 44 is supplied on the second ventilation layer 16 and is wound spirally. As described above, since the width W1 of the resin film 44 is slightly smaller than the pitch P, the groove 32 is formed by this winding. The resin film 44 is heated and melted by a heater, and is cooled and solidified. The second ventilation layer 16 and the resin film 44 are fused by melting and solidification. The non-breathing layer 18 is formed from the resin film 44.

  By this method, the duct 2 can be manufactured easily and at low cost. In this method, the width W2 of the groove 32 can be adjusted only by changing the width W1 of the resin film 44. Therefore, the silence of the duct 2 can be adjusted.

  In this duct 2, the second ventilation layer 16 is formed from a nonwoven fabric 44. By selecting the nonwoven fabric 44 having an appropriate density, air leakage from the air-permeable portion (groove 32) can be appropriately suppressed. The nonwoven fabric 44 can further contribute to noise reduction.

  In this duct 2, the second gas permeable layer 16 and the non-air permeable layer 18 are joined by fusion. The second gas permeable layer 16 and the non-air permeable layer 18 may be joined by an adhesive or an adhesive. A typical adhesive is a hot melt adhesive. A duct using an adhesive can also be manufactured by the apparatus 33 shown in FIG.

  This duct 2 has one spiral reinforcing body 14. The number of reinforcing bodies may be two or more. Ducts having two or more reinforcements can also be produced by the device 33 shown in FIG.

  The outer layer 6 may be made of a breathable sheet (for example, woven fabric) that is locally sealed. Examples of the sealing treatment include application of latex or emulsion. In this case, the part to which latex or emulsion is applied is a non-breathable part, and the part not coated is a breathable part. A duct having a breathable sheet that has been sealed can also be produced by the apparatus 33 shown in FIG.

  There may be a plurality of spiral strips of the breathable portion and the non-breathable portion of the outer layer. For example, the duct may be provided with an outer layer in which the breathable portion and the non-breathable portion are respectively two spirals. When there are a plurality of spirals, the widths of the respective grooves existing in one pitch of the spiral are summed to calculate the width W2 of the air-permeable portion. Also in this case, the ratio between the width W2 and the helical pitch P of the air-permeable portion is preferably 1/50 or more, particularly preferably 1/30 or more. This ratio is preferably 1/6 or less, and particularly preferably 1/10 or less.

  FIG. 4 shows a duct 52 according to another embodiment of the present invention. The duct 52 includes a main body 54 and an outer layer 56. The outer layer 56 is laminated on the outer peripheral surface of the main body 54. The main body 54 is cylindrical. The main body 54 includes an inner layer 58 and a foam layer 60. The foam layer 60 is laminated on the outer peripheral surface of the inner layer 58. The inner layer 58 includes a first ventilation layer 62 and a reinforcing body 64. The outer layer 56 includes a second ventilation layer 66 and a non-breathing layer 68. The configuration of the inner layer 58 of the duct 52 is equivalent to the configuration of the inner layer 8 of the duct 2 shown in FIGS. The foam layer 60 of the duct 52 is formed by abutting side edges of a band-shaped polymer foam extending in the axial direction of the duct 52. The second ventilation layer 66 of the duct 52 is formed by overlapping side edges of a strip-shaped nonwoven fabric extending in the axial direction of the duct.

  In this duct 52, the non-breathing layer 68 is formed by joining a resin film extending in the axial direction (left-right direction in FIG. 4A) to the second breathing layer 66. The resin film can be bonded to the second ventilation layer 66 by fusion bonding or by adhesive bonding or adhesive bonding. As apparent from FIG. 4B, six resin films are bonded to the second ventilation layer 66. By fixing the resin film so as to cover the overlapping portion of the nonwoven fabric in the second ventilation layer 66, the second ventilation layer 66 can be fixed with the resin film. The resin film is separated from the adjacent resin film. Due to this separation, a groove 70 is formed on the surface of the duct 52. In the groove 70, the second ventilation layer 66 is exposed. In this duct 52, the groove 70 corresponds to a breathable part. On the other hand, the resin film corresponds to a non-breathable part. Since the resin film extends in the axial direction, the groove 70 also extends in the axial direction. The groove 70 (breathable portion) can contribute to the sound deadening property of the duct 52.

  In manufacturing the duct 52, the inner layer 58 is formed by a spiral method using the apparatus 33 shown in FIG. With the inner layer 58 as a core, a band-shaped polymer foam or a band-shaped non-woven fabric (which constitutes the second air-permeable layer 66) is wound in a so-called “strip winding”. The side edges of the nonwoven fabric are overlapped, and the overlapping portion is fixed with a resin film (which constitutes the non-breathable layer 68), and the resin film is bonded to the nonwoven fabric.

  FIG. 5 shows a duct 72 according to still another embodiment of the present invention. The duct 72 includes a main body 74 and an outer layer 76. The outer layer 76 is laminated on the outer peripheral surface of the main body 74. The main body 74 is cylindrical. The main body 74 includes an inner layer 78 and a foam layer 80. The foam layer 80 is laminated on the outer peripheral surface of the inner layer 78. The inner layer 78 includes a first ventilation layer 82 and a reinforcing body 84. The outer layer 76 includes a second gas permeable layer 86 and a non-air permeable layer 88. The configurations of the main body 74 and the second ventilation layer 86 of the duct 72 are the same as the configurations of the main body 4 and the second ventilation layer 16 of the duct 2 shown in FIGS.

  In this duct 72, the non-venting layer 88 is formed by joining a large number of resin films extending in the circumferential direction in a ring shape and joining to the second ventilation layer 86. The resin film can be bonded to the second ventilation layer 86 by fusion bonding or adhesive bonding. The resin film is separated from the adjacent resin film. Due to this separation, a groove 90 is formed on the surface of the duct 72. In the groove 90, the second ventilation layer 86 is exposed. In this duct 72, the groove 90 corresponds to a breathable part. On the other hand, the resin film corresponds to a non-breathable part. Since the resin film extends in the circumferential direction, the groove 90 also extends in the circumferential direction. The groove 90 (breathable portion) can contribute to the sound deadening and flexibility of the duct 72.

  The duct according to the present invention can be used for transfer of air for cooling and heating, ventilation, discharge of gas, and the like.

2, 52, 72 ... Duct 4, 54, 74 ... Main body 6, 56, 76 ... Outer layer 8, 58, 78 ... Inner layer 10, 60, 80 ... Foam layer 12, 62 , 82 ... First ventilation layer 14, 64, 84 ... Reinforcing body 16, 66, 86 ... Second ventilation layer 18, 68, 88 ... Non-breathing layer 32, 70, 90 ... Groove 36, 42 ... Non-woven fabric 38 ... Wire rod 40 ... Polymer molded body 44 ... Resin film

Claims (3)

A duct having a cylindrical shape, including a sound deadening layer and having air permeability, laminated on the outer peripheral surface of the main body, and having an outer layer having a breathable portion and a non-breathable portion,
A flexible muffler duct in which the air-permeable portion has a continuous spiral shape over the entire length of the duct.   2. The muffler duct according to claim 1, wherein a ratio between an axial width of the air-permeable portion and a helical pitch of the air-permeable portion is 1/50 or more and 1/6 or less.   3. The muffler duct according to claim 1, wherein the outer layer includes a breathable sheet and a non-breathable sheet that is positioned on a front side or a back side of the breathable sheet and is integrated with the breathable sheet.

Images