JP5956785B2 - Crosspiece, sound insulation panel and sound insulation method - Google Patents

Description

  The present invention relates to a crosspiece for improving the sound insulation of a panel used as a building component (a door, a door, a wall, a partition, a partition, a ceiling, etc.), and a sound insulation panel and a sound insulation using the crosspiece Regarding the method.

  Conventionally, a sound insulation effect has been achieved by increasing sound transmission loss of panels (sound insulation panels) used for structural members such as doors, doors, walls, partitions, partitions, and ceilings of buildings. And it is widely known that the sound transmission loss follows the mass law. However, in a sound insulation panel used for a building having a lightweight structure such as a wooden structure or a steel structure, there is a limit to increase the mass due to structural limitations and economic limitations. In particular, movable partitions and joinery are required to be lightweight in order to improve operability.

  As a sound insulation panel that is lightweight and has a large sound transmission loss, it is difficult to improve the sound insulation effect with a single wall (single plate) structure panel, and therefore, a sound insulation panel with a double wall structure is well known. In the case of a double wall structure, wooden or metal crosspieces are used to secure the front and rear face materials at a distance, but this crosspiece transmits solid propagation sound, and sound insulation. The sound transmission loss of the panel is reduced.

  In contrast, Japanese Patent No. 3422903 (Patent Document 1) includes a first surface plate and a second surface plate provided between the first surface plate and a reinforcing bar. In the panel structure, a damping member made of an elastic body having a size about the width of the reinforcing bar is interposed between the reinforcing bar and one of the surface plates, and the damping member is a stapler. The panel structure currently fixed to the said reinforcement bar only by is disclosed.

  In JP 2009-150133 A (Patent Document 2), face plates are provided on both sides of a peripheral frame provided with a plurality of reinforcing ground bars, and some of the plurality of reinforcing ground bars are provided. The one surface is biased to be located on the side of the one face material and is separated from the other face material, and the remaining part of the reinforcing base bar is located to be biased to the side of the other face material. A buffer for supporting the press between the part of the reinforcing base bars and the other face material and between the remaining part of the reinforcing base bars and the one face material. A sound insulating material characterized in that a material is interposed and the part of the reinforcing base bar and the one surface material are pressed and the remaining part of the reinforcing base bar and the other surface material are pressed and joined. Joinery is disclosed. Also in this document, a rubber-like material is described as a press support cushioning material.

  However, since the elastic body and rubber-like material used for these reinforcing (underlying) bars have low strength, it is difficult to ensure sufficient strength against the pressing force of the face material. Furthermore, since elastic bodies and rubber-like materials have low sound absorption, they hardly contribute to sound insulation.

Japanese Patent Application Laid-Open No. 2010-229809 (Patent Document 3) includes a non-woven fiber structure including a wet heat adhesive fiber and a fiber fixed to the wet heat adhesive fiber by fusing. Further, there is disclosed a sound insulation panel in which the nonwoven fiber structure has a fiber adhesion rate of 3 to 85% and an apparent density of 0.03 to 0.7 g / cm ³ . In this document, a mode in which a layer composed of the non-woven fiber structure is interposed between facing material members, and a layer in which a frame frame (frame) and an intermediate beam are composed of the non-woven fiber structure are interposed. The embodiment to be performed is described.

  However, even this sound insulation panel does not have sufficient sound insulation.

Japanese Patent No. 3422903 (Claims) JP 2009-150133 A (claims, paragraph [0021]) JP 2010-229809 A (Claims)

  Accordingly, an object of the present invention is to provide a crosspiece that can improve the sound insulation of a panel used as a structural member of a building (door, door, wall, partition material, partition, ceiling, etc.) and a sound insulation panel using this crosspiece. And providing a sound insulation method.

  Another object of the present invention is to provide a crosspiece capable of improving sound insulation in a low frequency region, a sound insulation panel and a sound insulation method using the crosspiece.

  Still another object of the present invention is to provide a sound insulation panel and a sound insulation method having high strength and high sound insulation properties for both solid-borne sound and air-borne sound despite having a simple structure and light weight. Is to provide.

  Another object of the present invention is to provide a sound insulation panel and a sound insulation method that are excellent in sound insulation over a wide frequency range.

  Still another object of the present invention is to provide a sound insulation panel and a sound insulation method in which a decrease in sound insulation effect due to transmission resonance is suppressed.

  Another object of the present invention is to provide a sound insulation panel and a sound insulation method that have a ventilation function and can improve sound insulation.

  As a result of intensive studies to achieve the above-mentioned problems, the present inventors have found that a crosspiece having a laminated structure including a non-woven fiber layer formed of a specific non-woven fiber structure to which wet heat adhesive fibers are fixed and a reinforcing layer. The present invention was completed by finding that the material can improve the sound insulation of a panel used as a structural member of a building.

  That is, the crosspiece of the present invention is a crosspiece having a laminated structure including a non-woven fiber layer and a reinforcing layer, wherein the non-woven fiber layer is entangled with fibers containing wet heat adhesive fibers, and the wet heat It is formed of a nonwoven fiber structure in which fibers are fixed by fusion of adhesive fibers. The crosspiece of the present invention may have a two-layer structure of a nonwoven fiber layer and a reinforcing layer. The crosspiece of the present invention may have a three-layer structure in which a first reinforcing layer and a second reinforcing layer are laminated via a non-woven fiber layer. The crosspiece of the present invention may be a rod having a square cross section, and the reinforcing layer may be formed of a wood material or a metal material. The non-woven fiber structure may further include a composite fiber in which a plurality of resins having different heat shrinkage rates form a phase separation structure, and the composite fiber may be crimped and entangled with other fibers. Good.

  The present invention provides a sound insulation panel in which a crosspiece including the crosspiece is interposed between a first facepiece and a second facepiece, wherein the non-woven fiber layer and the reinforcing layer of the crosspiece are first. And the sound insulation panel arrange | positioned in parallel with the surface direction of a 2nd surface material is also contained. In the sound insulation panel of the present invention, a plurality of crosspieces may be arranged in parallel at intervals between the first face material and the second face material. In this sound insulation panel, the crosspiece has a two-layer structure of a non-woven fiber layer and a reinforcing layer, and the plurality of crosspieces are a non-woven fiber layer with respect to the first and second face members. The reinforcing layers may be arranged in contact with each other alternately. The sound insulation panel of the present invention includes a first face member, a frame rail disposed in a frame shape on the four peripheral ends of the first face member, an intermediate rail disposed between these frames, A sound insulation panel including a first face member and a second face member laminated via the frame crosspiece and the intermediate crosspiece, wherein the middle crosspiece may be formed of the crosspiece.

In the sound insulation panel of the present invention, the first and second face members are formed with first and second openings, respectively, and the first opening is formed at a position different from the second opening. Also good. This sound insulation panel is suitable as a ventilation sound insulation panel having a ventilation function in addition to the sound insulation function. In the ventilation and sound insulation panel of the present invention, a sound absorbing material may be disposed between the adjacent bars, leaving a space for ventilation. The space portion between the adjacent crosspieces may have a cross-sectional area of 18 cm ² or less in a cross section perpendicular to the longitudinal direction of the crosspiece.

  In the sound insulation panel of the present invention, a damping layer may be interposed between the crosspiece and the first face material and / or the second face material. In particular, the first damping layer is interposed between the crosspiece and the first face member, and the second damping layer is interposed between the crosspiece and the second face piece. Also good. The vibration damping layer may contain asphalt.

  The present invention also includes a sound insulation method using the sound insulation panel.

  In this specification, the term “sound insulation panel” means a sound insulation panel used for building components such as doors, doors, walls, partitions, partitions, ceilings, partitions, etc. What is necessary is just to laminate | stack, and it is not limited to the panel provided with the frame and the frame crosspiece.

  In the present invention, since the crosspiece has a laminated structure including a non-woven fiber layer formed of a specific non-woven fiber structure to which wet heat-adhesive fibers are fixed and a reinforcing layer, the structural member (door, door) , Walls, partition materials, partitions, ceilings, etc.) and sound insulation of panels used for partitions (especially in the low frequency range) can be improved. In addition, the sound insulation panel obtained using this crosspiece has a high strength despite its simple structure and light weight, and improves the sound insulation against both solid-borne sound and air-borne sound. it can. In addition, sound insulation can be improved over a wide frequency range. Furthermore, since the conventional fibrous sound absorbing material is not included, it is possible to suppress a decrease in the sound insulation effect due to transmission resonance. In addition, by providing a face material having an opening, a ventilation function can be provided and sound insulation can be improved.

FIG. 1 is a schematic perspective view showing an example of a crosspiece of the present invention. FIG. 2 is a schematic sectional view showing a laminated structure of another example of the crosspiece of the present invention. FIG. 3 is a partially cutaway schematic perspective view showing an example of the structure of the sound insulation panel of the present invention. 4 is a schematic cross-sectional view taken along line AA of the sound insulation panel of FIG. FIG. 5 is a partially cutaway schematic perspective view showing an example of the structure of the ventilation and sound insulation panel of the present invention. 6 is a schematic cross-sectional view taken along line AA of the ventilation sound insulation panel of FIG. FIG. 7 is a schematic sectional view showing another example of the ventilation and sound insulation panel of the present invention. FIG. 8 is a schematic diagram for explaining a method of measuring the wind speed and the ventilation amount in the embodiment. FIG. 9 is a graph showing the measurement results of the sound transmission loss of the sound insulation panel in Experimental Example 1. FIG. 10 is a graph showing the measurement results of the sound transmission loss of the sound insulation panel in Experimental Example 2. FIG. 11 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 3. FIG. 12 is a graph showing the measurement results of the sound transmission loss of the sound insulation panel in Experimental Example 4. FIG. 13 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 5. FIG. 14 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 6. FIG. 15 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 7. FIG. 16 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 8. FIG. 17 is a graph showing a measurement result of sound transmission loss of the sound insulation panel in Experimental Example 9. FIG. 18 is a graph showing the measurement results of the sound transmission loss of the sound insulation panel in Experimental Example 10. FIG. 19 is a graph showing measurement results of sound transmission loss of the sound insulation panel in Experimental Example 11.

[Bar material]
The crosspiece of the present invention has a laminated structure including a nonwoven fiber layer and a reinforcing layer.

(Nonwoven fiber layer)
The non-woven fiber layer is formed of a non-woven fiber structure including wet heat-adhesive fibers and having the fibers fixed by fusion of the wet heat-adhesive fibers.

(1) Non-woven fiber structure The non-woven fiber structure is a molded body containing wet heat adhesive fibers and having a non-woven fiber structure. Furthermore, the non-woven fiber structure in the present invention has fibers fixed by fusion of the wet heat-adhesive fibers, and has high sound-absorbing and heat-insulating properties and shock-absorbing properties peculiar to the fiber structure, and has a non-woven fiber structure. By adjusting the arrangement of the fibers to be configured and the bonding state between these fibers, the dropping of the fibers can be suppressed, and the shape stability and lightness can be improved. The mechanical strength can be adjusted by combining with.

  Such a non-woven fiber structure causes high temperature (overheated or heated) water vapor to act on the web containing the wet heat adhesive fibers, and exhibits an adhesive action at a temperature below the melting point of the wet heat adhesive fibers. It can be obtained by partial adhesion. That is, it is obtained by point-bonding or partial-bonding single fibers and bundle-like bundled fibers so as to form a “scrum” while holding moderately small voids under wet heat.

The wet heat adhesive fiber is composed of at least a wet heat adhesive resin. The wet heat adhesive resin only needs to be able to flow or easily deform at a temperature that can be easily realized by high-temperature steam and to exhibit an adhesive function. Specifically, a thermoplastic resin that is softened with hot water (for example, about 80 to 120 ° C., particularly about 95 to 100 ° C.) and can be self-adhered or bonded to other fibers, such as an ethylene-vinyl alcohol copolymer. And vinyl alcohol polymers, polylactic acid resins such as polylactic acid, and (meth) acrylic copolymers containing (meth) acrylamide units. Further, it may be an elastomer (for example, polyolefin elastomer, polyester elastomer, polyamide elastomer, polyurethane elastomer, styrene elastomer, etc.) that can be easily fluidized or deformed by high-temperature steam. These wet heat adhesive resins can be used alone or in combination of two or more. Of these, vinyl alcohol polymers containing α-C _2-10 olefin units such as ethylene and propylene, particularly ethylene-vinyl alcohol copolymers are preferred.

  In the ethylene-vinyl alcohol copolymer, the ethylene unit content (copolymerization ratio) is, for example, 5 to 65 mol% (for example, 10 to 65 mol%), preferably 20 to 55 mol%, and more preferably. It is about 30-50 mol%. When the ethylene unit is in this range, a unique property of having wet heat adhesiveness but not hot water solubility is obtained. If the proportion of the ethylene units is too small, the ethylene-vinyl alcohol copolymer easily swells or gels with low-temperature steam (water), and its form is likely to change only once wetted with water. On the other hand, when the ratio of the ethylene unit is too large, the hygroscopicity is lowered, and fiber fusion due to wet heat is difficult to be exhibited, so that it is difficult to ensure practical strength. When the ratio of the ethylene unit is particularly in the range of 30 to 50 mol%, the processability into a sheet or plate is particularly excellent.

  The saponification degree of the vinyl alcohol unit in the ethylene-vinyl alcohol copolymer is, for example, about 90 to 99.99 mol%, preferably 95 to 99.98 mol%, more preferably 96 to 99.97 mol. %. When the saponification degree is too small, the thermal stability is lowered, and the stability is lowered by thermal decomposition or gelation. On the other hand, if the degree of saponification is too large, it is difficult to produce the fiber itself.

  Although the viscosity average degree of polymerization of an ethylene-vinyl alcohol-type copolymer can be selected as needed, it is 200-2500, for example, Preferably it is 300-2000, More preferably, it is about 400-1500. When the degree of polymerization is within this range, the balance between spinnability and wet heat adhesion is excellent.

  The cross-sectional shape (cross-sectional shape perpendicular to the length direction of the fiber) of the wet heat-adhesive fiber is a general solid cross-sectional shape such as a round cross-section or an irregular cross-section [flat, elliptical, polygonal, etc.] It is not limited, A hollow cross-section etc. may be sufficient. The wet heat adhesive fiber may be a composite fiber composed of a plurality of resins including at least a wet heat adhesive resin. The composite fiber only needs to have a wet heat adhesive resin on at least a part of the fiber surface, but it is preferable to have a wet heat adhesive resin continuous in the length direction on the fiber surface from the viewpoint of adhesiveness. The coverage of the wet heat adhesive resin is, for example, 50% or more, preferably 80% or more, and more preferably 90% or more.

  Examples of the cross-sectional structure of the composite fiber in which the wet heat adhesive resin occupies the surface include a core-sheath type, a sea-island type, a side-by-side type, a multi-layer bonding type, a radial bonding type, and a random composite type. Among these cross-sectional structures, a core-sheath structure in which the wet heat adhesive resin covers the entire surface of the fiber (that is, the sheath portion is made of the wet heat adhesive resin because it is a structure with high adhesiveness. A core-sheath structure) is preferred. The core-sheath structure may be a fiber in which a wet heat adhesive resin is coated on the surface of a fiber composed of another fiber-forming polymer.

  In the case of a composite fiber, wet heat adhesive resins may be combined with each other, but may be combined with non-wet heat adhesive resins. Non-wet heat adhesive resins include water-insoluble or hydrophobic resins such as polyolefin resins, (meth) acrylic resins, vinyl chloride resins, styrene resins, polyester resins, polyamide resins, polycarbonate resins, Examples include polyurethane resins and thermoplastic elastomers. These non-wet heat adhesive resins can be used alone or in combination of two or more.

  Among these non-wet heat adhesive resins, from the viewpoint of heat resistance and dimensional stability, resins having a melting point higher than that of wet heat adhesive resins (particularly ethylene-vinyl alcohol copolymers), such as polypropylene resins and polyester resins. Resins and polyamide resins, particularly polyester resins and polyamide resins are preferred from the standpoint of excellent balance between heat resistance and fiber-forming properties. As the polyester resin and the polyamide resin, resins described in JP 2010-229809 A (Patent Document 3) can be used.

  In the case of a composite fiber composed of a wet heat adhesive resin and a non-wet heat adhesive resin (fiber-forming polymer), the ratio (mass ratio) of both can be selected according to the structure (for example, core-sheath structure). The wet heat adhesive resin is not particularly limited as long as it exists on the surface. For example, wet heat adhesive resin / non-wet heat adhesive resin = 90/10 to 10/90, preferably 80/20 to 15/85, more preferably It is about 60/40 to 20/80. If the proportion of wet heat adhesive resin is too large, it will be difficult to ensure the strength of the fiber, and if the proportion of wet heat adhesive resin is too small, it will be difficult to have the wet heat adhesive resin continuously in the length direction of the fiber surface. Thus, the wet heat adhesiveness is lowered. This tendency is the same when the wet heat adhesive resin is coated on the surface of the non-wet heat adhesive fiber.

  The average fineness of the wet heat adhesive fiber can be selected, for example, from the range of about 0.01 to 100 dtex, preferably 0.1 to 50 dtex, more preferably 0.5 to 30 dtex (particularly 1 to 10 dtex) depending on the application. Degree. When the average fineness is in this range, the balance between the strength of the fiber and the expression of wet heat adhesion is excellent.

  The average fiber length of the wet heat adhesive fibers can be selected from a range of, for example, about 10 to 100 mm, preferably 20 to 80 mm, and more preferably about 25 to 75 mm. When the average fiber length is within this range, the fibers are sufficiently entangled, so that the mechanical strength of the fiber structure is improved.

  The crimp rate of the wet heat adhesive fiber is, for example, 1 to 50%, preferably 3 to 40%, and more preferably about 5 to 30%. The number of crimps is, for example, about 1 to 100 pieces / 25 mm, preferably about 5 to 50 pieces / 25 mm, and more preferably about 10 to 30 pieces / 25 mm.

(Other fibers)
The nonwoven fibrous structure may further contain non-wet heat adhesive fibers. Non-humid heat adhesive fibers include organic fibers and inorganic fibers. Examples of the organic fibers include cellulose fibers (for example, natural fibers, rayon fibers, acetate fibers, etc.) in addition to fibers formed from the non-wet heat adhesive resin of the composite fibers. Examples of the inorganic fiber include carbon fiber, glass fiber, and metal fiber. These non-wet heat adhesive fibers can be used alone or in combination of two or more.

  In order to improve the strength of these non-wet heat adhesive fibers, it is preferable to use hydrophilic fibers with high hygroscopicity, for example, polyvinyl fibers or cellulose fibers, particularly cellulose fibers. Cellulosic fibers include natural fibers (cotton, wool, silk, hemp, etc.), semi-synthetic fibers (acetate fibers such as triacetate fiber), regenerated fibers (rayon, polynosic, cupra, lyocell (for example, registered trademark name: “ Tencel "etc.)). Among these cellulosic fibers, for example, semi-synthetic fibers such as rayon can be suitably used. When combined with wet heat adhesive fibers, the affinity with wet heat adhesive fibers is high, so the shrinkage proceeds and the adhesiveness is also improved. Improved, high density and high mechanical properties can be obtained.

  On the other hand, when further improving vibration absorption, etc., hydrophobic fibers with low hygroscopicity, such as polyolefin fibers, polyester fibers, polyamide fibers, especially polyester fibers (polyethylene terephthalate) having an excellent balance of properties. It is preferable to use fibers. When these hydrophobic fibers are combined with wet heat adhesive fibers, the fusion point of the fibers can be reduced, and a crosspiece having excellent sound absorption can be obtained.

  The average fineness and average fiber length of these non-wet heat adhesive fibers are the same as those of the wet heat adhesive fibers.

  Furthermore, in order to improve the sound absorption, among the hydrophobic fibers, in particular, use is made of composite fibers (latently crimped conjugate fibers) in which a phase structure is formed from a plurality of resins having different thermal shrinkage rates (or thermal expansion rates). It is preferable to do this.

(Latent crimped composite fiber)
The latent crimpable conjugate fiber is a fiber having an asymmetric or layered (so-called bimetal) structure that causes crimping by heating due to a difference in thermal contraction rate (or thermal expansion rate) of a plurality of resins (latent crimped fiber) ). A plurality of resins usually have different softening points or melting points. The plurality of resins may be selected from, for example, a non-wet heat adhesive resin similar to the composite fiber and other fibers, and a wet heat adhesive resin of the wet heat adhesive fiber. Among these resins, a non-wet heat adhesive resin (or heat-resistant hydrophobic resin or a softening point or a melting point of 100 ° C. or higher from the point that the fiber does not melt and soften even when heated and humidified with high-temperature steam. Non-aqueous resins), for example, polypropylene resins, polyester resins, and polyamide resins are preferable, and aromatic polyester resins and polyamide resins are particularly preferable from the viewpoint of excellent balance between heat resistance and fiber forming properties. In the present invention, the resin exposed on the surface of the composite fiber is preferably a non-wet heat adhesive fiber so that the fusion by the composite fiber does not occur even when treated with high-temperature steam.

  The plurality of resins constituting the composite fiber may have different heat shrinkage rates, and may be a combination of resins of the same system or a combination of different resins.

  In this invention, it is preferable that it is comprised with the combination of resin of the same type | system | group from the point of adhesiveness. In the case of a combination of resins of the same system, a combination of a component (A) that forms a homopolymer (essential component) and a component (B) that forms a modified polymer (copolymer) is usually used. In other words, the homopolymer that is an essential component is crystallized more than the homopolymer by, for example, copolymerizing and modifying a copolymerizable monomer that lowers the crystallinity, melting point, or softening point. The melting point or the softening point may be lowered as compared with the homopolymer. Thus, a difference may be provided in the thermal shrinkage rate by changing the crystallinity, melting point or softening point. The difference in melting point or softening point may be, for example, about 5 to 150 ° C, preferably about 50 to 130 ° C, and more preferably about 70 to 120 ° C. The ratio of the copolymerizable monomer used for the modification is, for example, 1 to 50 mol%, preferably 2 to 40 mol%, more preferably 3 to 30 mol% (particularly 5 to 5 mol%) with respect to all monomers. 20 mol%). The composite ratio (mass ratio) of the component forming the homopolymer and the component forming the modified polymer can be selected according to the structure of the fiber. For example, the homopolymer component (A) / modified polymer component (B) = 90/10 to 10/90, preferably 70/30 to 30/70, more preferably about 60/40 to 40/60.

  In the present invention, the composite fiber is a combination of an aromatic polyester resin, particularly a polyalkylene arylate resin (a) and a modified polyalkylene arylate resin (b) because it is easy to produce latent crimpable conjugate fibers. It may be a combination. In particular, in the present invention, a type that develops crimp after web formation is preferable, and the combination is also preferable in this respect. By producing crimp after the web formation, the fibers can be efficiently entangled and the web shape can be maintained with a smaller number of fusion points, so that appropriate flexibility can be realized.

Polyalkylene arylate-series resin (a) is an aromatic dicarboxylic acid (terephthalic acid, such as symmetric aromatic dicarboxylic acids such as naphthalene-2,6-dicarboxylic acid) and the like alkanediol component (ethylene glycol or butylene glycol C _{3- 6} alkanediol etc.) and a homopolymer may be sufficient. Specifically, poly C _2-4 alkylene terephthalate resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) are used, and general PET having an intrinsic viscosity of about 0.6 to 0.7 is usually used. PET used for fibers is used.

On the other hand, in the modified polyalkylene arylate resin (b), the melting point or softening point of the polyalkylene arylate resin (a), which is an essential component, is a copolymer component that lowers the crystallinity, such as an asymmetric aromatic dicarboxylic acid. Further, a dicarboxylic acid component such as alicyclic dicarboxylic acid or aliphatic dicarboxylic acid, an alkanediol component having a chain length longer than the alkanediol of the polyalkylene arylate resin (a) and / or an ether bond-containing diol component can be used. These copolymerization components can be used alone or in combination of two or more. Among these components, as dicarboxylic acid components, asymmetric aromatic carboxylic acids (isophthalic acid, phthalic acid, 5-sodium sulfoisophthalic acid, etc.), aliphatic dicarboxylic acids (C _6-12 aliphatic dicarboxylic acids such as adipic acid, etc.) ) And the like, and as the diol component, alkanediol (C _3-6 alkanediol such as 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, etc.), (poly) Oxyalkylene glycols (polyoxy C _2-4 alkylene glycols such as diethylene glycol, triethylene glycol, polyethylene glycol, polytetramethylene glycol, etc.) are widely used. Of these, asymmetric aromatic dicarboxylic acids such as isophthalic acid, polyoxy C _2-4 alkylene glycols such as diethylene glycol, and the like are preferable. Further, the modified polyalkylene arylate resin (b) may be an elastomer having a C _2-4 alkylene arylate (ethylene terephthalate, butylene terephthalate, etc.) as a hard segment and (poly) oxyalkylene glycol as a soft segment. .

  In the modified polyalkylene arylate resin (b), as the dicarboxylic acid component, the ratio of the dicarboxylic acid component (for example, isophthalic acid) for lowering the melting point or the softening point is, for example, relative to the total amount of the dicarboxylic acid component, It is 1-50 mol%, Preferably it is 5-50 mol%, More preferably, it is about 15-40 mol%. The ratio of the diol component (for example, diethylene glycol) for reducing the melting point or the softening point as the diol component is, for example, 30 mol% or less, preferably 10 mol% or less (for example, 0 mol%) with respect to the total amount of the diol component. .About 1 to 10 mol%). When the ratio of the copolymer component is too low, sufficient crimps are not exhibited, and the morphological stability and stretchability of the nonwoven fibrous structure after the crimps are reduced are deteriorated. On the other hand, if the proportion of the copolymer component is too high, the crimping performance will be high, but it will be difficult to spin stably.

  Modified polyalkylene arylate resin (b) is used in combination with polyvalent carboxylic acid components such as trimellitic acid and pyromellitic acid, and polyol components such as glycerin, trimethylolpropane, trimethylolethane, and pentaerythritol as necessary. And may be branched.

  The cross-sectional shape (cross-sectional shape perpendicular to the fiber length direction) of the latent crimpable conjugate fiber is a general solid cross-sectional shape, such as a round cross-section or an irregular cross-section [flat, elliptical, polygonal] 3-14 leaf shape, T-shape, H-shape, V-shape, dogbone (I-shape, etc.), and may be a hollow cross-section, but is usually a round cross-section. .

  As the cross-sectional structure of the composite fiber, a phase separation structure formed in a plurality of resins, for example, a core-sheath type, a sea-island type, a blend type, a parallel type (side-by-side type or multilayer bonding type), a radial type (radial bonding) Type), hollow radiation type, block type, random composite type and the like. Among these cross-sectional structures, a structure in which the phase portions are adjacent (so-called bimetal structure), a structure in which the phase separation structure is asymmetrical, for example, an eccentric core-sheath type, A parallel structure is preferred.

  If the latent crimpable conjugate fiber has a core-sheath type structure such as an eccentric core-sheath type, it can be crimped if it has a heat shrinkage difference from the non-wet heat adhesive resin of the sheath located on the surface. The core portion is a wet heat adhesive resin (for example, a vinyl alcohol polymer such as ethylene-vinyl alcohol copolymer or polyvinyl alcohol) or a thermoplastic resin having a low melting point or softening point (for example, polystyrene or low density polyethylene). Etc.).

  The average fineness of the latent crimpable conjugate fiber can be selected, for example, from a range of about 0.1 to 50 dtex, preferably about 0.5 to 10 dtex, more preferably about 1 to 5 dtex (particularly about 1.5 to 3 dtex). . If the fineness is too thin, it is difficult to produce the fiber itself, and it is difficult to secure the fiber strength. Moreover, it becomes difficult to express a beautiful coiled crimp in the step of expressing crimp. On the other hand, if the fineness is too thick, the fiber becomes stiff and it is difficult to express sufficient crimp.

  The average fiber length of the latent crimpable conjugate fiber can be selected from a range of, for example, about 10 to 100 mm, preferably 20 to 80 mm, more preferably about 25 to 75 mm (particularly 40 to 60 mm). If the fiber length is too short, it becomes difficult to form a fiber web, and in addition, in the step of developing crimps, entanglement between fibers becomes insufficient, and it becomes difficult to ensure strength and stretchability. In addition, if the fiber length is too long, it becomes difficult to form a fiber web with a uniform basis weight, and a lot of fibers are entangled at the time of web formation, which interferes with each other when crimping occurs. Therefore, it is difficult to develop sound absorption.

  This latent crimpable conjugate fiber is subjected to heat treatment to develop (emergence) crimp and become a fiber having a substantially coiled (spiral or helical spring) three-dimensional crimp.

  The number of crimps before heating (mechanical crimp number) is, for example, about 0 to 30 pieces / 25 mm, preferably about 1 to 25 pieces / 25 mm, and more preferably about 5 to 20 pieces / 25 mm. The number of crimps after heating is, for example, 30 pieces / 25 mm or more (for example, 30 to 200 pieces / 25 mm), preferably about 35 to 150 pieces / 25 mm, and more preferably about 40 to 120 pieces / 25 mm. It may be about 45 to 120 pieces / 25 mm (especially 50 to 100 pieces / 25 mm).

  Since the nonwoven fiber structure containing the latent crimpable conjugate fiber is crimped with high-temperature steam, the conjugate fiber has a feature that the crimp of the conjugate fiber appears substantially uniformly inside the structure. Specifically, for example, in the cross section in the thickness direction, the number of fibers forming one or more coil crimps in the central portion (inner layer) of each region divided in three in the thickness direction is, for example, 5-50 pieces / 5 mm (length in the surface direction) × 0.2 mm (thickness), preferably 8-45 pieces / 5 mm (length in the surface direction) × 0.2 mm (thickness), more preferably 10-40 pieces / 5 mm (length in the surface direction) × 0.2 mm (thickness). In the present invention, most of the crimped fibers and the inside of the structure (from the vicinity of the surface of the structure to the center) have a uniform number of crimps, and thus have high sound absorption and contain an adhesive. Even if not, it has practical strength. In the present specification, the “region divided into three in the thickness direction” means each region divided into three equal parts by slicing in a direction orthogonal to the thickness direction of the nonwoven fibrous structure.

  Furthermore, the uniformity of crimping inside the nonwoven fiber structure can be evaluated by the uniformity of fiber curvature in the thickness direction, for example. The fiber curvature is a ratio (L2 / L1) of the fiber length (L2) to the distance (L1) between both ends of the fiber (crimped fiber), and the fiber curvature (particularly in the central region in the thickness direction). The fiber curvature ratio is, for example, 1.3 or more (for example, 1.35 to 20), preferably 2 to 10 (for example, 2.1 to 9.5), more preferably 4 to 8 (particularly 4.5). About 7.5). In the present invention, as will be described later, in order to measure the fiber curvature based on the electron micrograph of the cross section of the fiber structure, the fiber length (L2) is a straight line obtained by stretching the three-dimensionally crimped fiber. It does not mean the fiber length (actual length) made into a shape, but the fiber length (fiber length on the photograph) obtained by stretching the two-dimensionally crimped fibers shown in the photograph into a straight line. That is, the fiber length (fiber length on the photograph) in the present invention is measured shorter than the actual fiber length.

  Furthermore, in the present invention, since the crimps are expressed substantially uniformly inside the structure, the fiber curvature is uniform. In the present invention, the uniformity of the fiber bending rate can be evaluated by, for example, comparing the fiber bending rate in each layer that is divided into three equal parts in the thickness direction in the cross section in the thickness direction of the structure. That is, in the cross section in the thickness direction, the fiber curvature rate in each region divided in three in the thickness direction is in the above range, and the ratio of the minimum value to the maximum value of the fiber curvature rate in each region (the fiber curvature rate is the maximum). The ratio of the minimum area to the above area is, for example, about 75% or more (for example, 75 to 100%), preferably about 80 to 99%, and more preferably about 82 to 98% (particularly 85 to 97%).

  As a specific method for measuring the fiber curvature and its uniformity, a method of taking a cross-section of the fiber structure with an electron micrograph and measuring the fiber curvature for a region selected from each region divided in three in the thickness direction Is used. The area to be measured is measured in an area of 2 mm or more in the length direction for each of the surface layer (surface area), inner layer (center area), and back layer (back area) divided into three. Further, the thickness direction of each measurement region is set so that each measurement region has the same thickness width in the vicinity of the center of each layer. Furthermore, each measurement region includes 100 or more (preferably about 300 or more, more preferably about 500 to 1000) fiber pieces that are parallel in the thickness direction and capable of measuring the fiber curvature in each measurement region. Set as follows. After setting each of these measurement regions, after measuring the fiber curvature rate of all the fibers in the region, calculating the average value for each measurement region, the region showing the maximum average value and the minimum average value The uniformity of the fiber curvature is calculated by comparison with the region shown.

  As described above, the crimped fiber constituting the nonwoven fiber structure has a substantially coil-shaped crimp after the crimp is developed. The average radius of curvature of the circle formed by the coil of crimped fibers can be selected, for example, from a range of about 10 to 250 μm, for example, 20 to 200 μm (for example, 50 to 200 μm), preferably 20 to 160 μm (for example, 60 to 150 μm), more preferably about 25 to 130 μm, and usually about 20 to 150 μm (for example, 30 to 100 μm). Here, the average radius of curvature is an index representing the average size of the circle formed by the coil of crimped fibers, and when this value is large, the formed coil has a loose shape, in other words It means having a shape with a small number of crimps. In addition, when the number of crimps is small, the entanglement between the fibers is also reduced, which is disadvantageous for exhibiting sufficient cushioning properties and flexibility. Conversely, when a coiled crimp having an average radius of curvature that is too small is manifested, the fibers are not sufficiently entangled, making it difficult to ensure web strength, and also exhibiting such a crimp. Production of latent crimpable conjugate fibers is also very difficult.

  In the composite fiber crimped into a coil shape, the average pitch of the coil is, for example, about 0.01 to 0.5 mm, preferably 0.015 to 0.3 mm, and more preferably about 0.02 to 0.2 mm.

  The ratio (mass ratio) between the wet heat adhesive fibers and other fibers can be selected from the range of the former / the latter = 100/0 to 1/99, for example, depending on the type and application of the panel. It is 0-10 / 90, Preferably it is 100 / 0-50 / 50 (for example, 95 / 5-50 / 50), More preferably, it is about 100 / 0-70 / 30. When the ratio of wet heat adhesive fibers is too small, the hardness decreases and it becomes difficult to maintain the handleability as a fiber structure.

  Furthermore, when the other fiber is a latent crimpable conjugate fiber, the ratio (mass ratio) of the wet heat adhesive fiber and the latent crimpable conjugate fiber is, for example, the former / the latter = about 99/1 to 1/99. For example, it is about 90/10 to 5/95, preferably 70/30 to 10/90, and more preferably about 60/40 to 15/85 (particularly 50/50 to 20/80). If the ratio of the latent crimpable conjugate fiber is too large, the strength is lowered, and if it is too small, the sound absorption cannot be sufficiently improved.

  In the fiber structure (or fiber), a conventional additive, for example, an additive described in JP 2010-229809 (Patent Document 3) may be supported on the surface of the structure. May be included.

  In addition, when a nonwoven fabric structure is used for the use for which a flame retardance is requested | required, it is effective to add a flame retardant. As the flame retardant, a conventional inorganic flame retardant or organic flame retardant can be used, and a halogen flame retardant or a phosphorus flame retardant which is widely used and has a high flame retardant effect may be used. There is a problem of acid rain accompanying the generation of halogen gas, and phosphorus-based flame retardants have a problem of eutrophication of lakes accompanying phosphorus compound runoff by hydrolysis. Therefore, in the present invention, as the flame retardant, it is preferable to use a boron-based flame retardant and / or a silicon-based flame retardant from the viewpoint of avoiding these problems and exhibiting high flame retardancy. As the boron-based flame retardant and the silicon-based flame retardant, flame retardants described in JP 2010-229809 A (Patent Document 3) can be used.

  The proportion of the flame retardant may be selected according to the use of the nonwoven fiber structure. For example, 1 to 300% by mass, preferably 5 to 200% by mass with respect to the total mass of the nonwoven fiber structure. More preferably, it is about 10 to 150% by mass.

  As a method of flame retardancy, in the same manner as conventional dip-nip processing, a fiber structure is impregnated or sprayed with an aqueous solution or emulsion containing a flame retardant, and is dried by a twin-screw extruder during fiber spinning. It is possible to use a method of extruding and spinning a resin kneaded with a flame retardant and using this fiber.

(2) Characteristics of non-woven fiber structure In order to have a non-woven fiber structure having a good balance between sound absorption and light weight (low density) while having a fiber structure in the non-woven fiber structure, It is necessary that the arrangement state and the adhesion state of the fibers constituting the nonwoven fiber web are appropriately adjusted.

  Specifically, in the nonwoven fiber structure, the fiber constituting the nonwoven fiber structure has a fiber adhesion rate of 1 to 85% (for example, 1 to 60%), preferably 1 by fusion of the wet heat adhesive fibers. It is about -50% (for example, 1-35%), More preferably, it is about 3-35% (especially 3-30%). In this invention, since the fiber is adhere | attached in such a range, the freedom degree of each fiber is high and can express high sound absorption. Furthermore, in the case where the sound insulation panel requires strength, the fiber adhesion rate may be, for example, 3 to 60%, preferably 6 to 50%, and more preferably about 8 to 50%.

  Although the fiber adhesion rate in this invention can be measured by the method as described in the Example mentioned later, the ratio of the cross section number of the fiber which adhered 2 or more with respect to the cross section number of all the fibers in a non-woven fiber cross section is shown. Therefore, a low fiber adhesion rate means that a ratio of a plurality of fibers fused to each other (a ratio of fibers fused by fusing) is small.

  In the present invention, the fibers constituting the non-woven fiber structure are bonded at the contact points of the respective fibers. In order to express a large bending stress with as few contacts as possible, this bonding point is the thickness direction. It is preferable that the fiber structure is uniformly distributed from the surface of the fiber structure to the inside (center) and back. When the adhesion points are concentrated on the surface or inside, not only is it difficult to ensure excellent mechanical properties and moldability, but also the shape stability in the portion where the adhesion points are small is lowered.

  Therefore, in the cross section in the thickness direction of the fiber structure, it is preferable that the fiber adhesion rate in each of the regions divided in three in the thickness direction is in the above range. Furthermore, the ratio of the minimum value to the maximum value of the fiber adhesion rate in each region (minimum value / maximum value) (the ratio of the minimum region to the region with the maximum fiber adhesion rate) is, for example, 50% or more (for example, 50 to 100%), preferably 55 to 99%, more preferably 60 to 98% (especially 70 to 97%). In the present invention, since the fiber adhesion rate has such uniformity in the thickness direction, the hardness, bending strength, bending resistance and toughness are excellent even though the fiber adhesion area is low. . Furthermore, since the bonding area of the fibers is low, there are many fibers that can vibrate freely and have excellent vibration absorption. Therefore, the sound wave that has passed through the face material is absorbed by the non-woven fiber structure, and solid propagation sound can be reduced. That is, the nonwoven fiber structure in the present invention has both mechanical properties as a board and sound absorption as a fiber structure.

  The fiber adhesion rate can be easily measured based on the number of bonded fiber cross sections in a predetermined region by taking a photograph of an enlarged cross section of the nonwoven fiber structure using a scanning electron microscope (SEM). However, when fibers are fused in a bundle, each fiber is fused in a bundle or at an intersection, making it difficult to observe as a single fiber, especially when the density is high. easy. In this case, for example, when the fiber structure is bonded with a core-sheath type composite fiber formed of a sheath part made of wet heat adhesive fiber and a core part made of a fiber-forming polymer, The fiber adhesion rate can be measured by releasing the adhesion of the bonded portion by means such as melting or washing and comparing it with the cut surface before the release.

  The orientation of each fiber is not particularly limited. For example, in the case of a sheet shape or a plate shape, the arrangement state of fibers constituting the nonwoven fiber structure may be appropriately adjusted. That is, the fibers constituting the fiber structure (in the case of a coiled crimped fiber, the axial direction of the coil) may be arranged so as to intersect each other while being arranged substantially parallel to the sheet surface. . In the present specification, “oriented substantially parallel to the surface direction” means, for example, a portion where a large number of fibers are locally oriented along the thickness direction, such as entanglement by needle punching. Means a state where does not exist repeatedly. When the fiber structure is entangled with a needle punch, the ratio of the fibers along the thickness direction increases, so it becomes difficult to deform the fiber structure in the surface direction. It will not return. Therefore, from the viewpoint of arranging the fibers in parallel, it is preferable to reduce the degree of fiber entanglement by needle punching or not to entangle.

  Further, in such a non-woven fiber structure, when coiled crimped fibers are contained, adjacent or intersecting fibers are entangled with each other in the crimped coil portion, but the thickness direction (or diagonally) of the fiber structure Direction), the fibers are slightly entangled. In particular, in the present invention, in the fiber structure, after the web is formed, the fibers are entangled in the process of contracting into a coil shape, and the fibers are appropriately restrained by the entangled coil portion. Furthermore, since the entangled fibers are fused by the wet heat adhesive fibers, appropriate strength is expressed.

  Among the fiber structures, structures with a small proportion of coiled crimped fibers (particularly structures formed with wet-heat adhesive fibers alone) have high toughness and bending stress, and also exhibit excellent bending behavior. one of. In the present invention, in order to express this bending behavior, the repulsive force of the sample generated when the sample is gradually bent is measured according to JIS K7017 “Fiber-Reinforced Plastics—How to Obtain Bending Properties” to obtain the maximum stress (peak stress). ) As a bending stress and used as an index of bending behavior. That is, the larger the bending stress is, the harder the structure is, and the more the bending amount (displacement) until the measurement object is broken is, the more the structure is bent.

  Such a fiber structure has a maximum bending stress in at least one direction (preferably in all directions) of 0.05 MPa or more, preferably 0.05 to 30 MPa, more preferably 0.05 to 20 MPa (particularly 0.005). 06 to 10 MPa). If the maximum bending stress is too small, it is easily broken by its own weight or a slight load when used in a plate shape. Further, if the maximum bending stress is too high, it becomes too hard, and if it is bent beyond the peak of the stress, it is easily broken and broken.

  Looking at the correlation between the bending amount (displacement) and the bending stress caused by the bending amount, the stress increases as the bending amount increases. For example, the bending amount increases approximately linearly. In the fiber structure in the present invention, when the measurement sample reaches a specific bending amount, the stress gradually decreases thereafter. That is, when the amount of bending and the stress are graphed, a correlation is shown in which an upward convex parabola is drawn. The fiber structure in the present invention has a so-called “stickiness (or toughness)” without causing a sudden stress drop even when the fiber structure exceeds the maximum bending stress (bending stress peak) and is further bent. Is also one of the features. In the present invention, as an index representing such “stickiness”, the bending stress remaining in a state exceeding the bending amount (displacement) at the peak of the bending stress can be used. That is, the fiber structure in the present invention has a maximum stress (hereinafter sometimes referred to as “1.5 times displacement stress”) when bent to a displacement of 1.5 times the bending amount indicating the maximum bending stress. The bending stress (peak stress value) is maintained at 1/20 or more, preferably 3/20 or more (for example, 3/20 to 1), more preferably 6/20 or more (for example, 6/20 to 18 / 20) You may maintain about.

  Moreover, the fiber structure may adjust the compression elastic modulus by containing a coiled crimp fiber, and the compression elastic modulus is a method based on JIS K7181 (compressed by 10 to 20% with respect to the original thickness). For example, it may be adjusted to 0.05 to 5000 kPa, preferably 0.1 to 1000 kPa, and more preferably about 0.1 to 800 kPa.

  Since the non-woven fiber structure has a non-woven fiber structure, the non-woven fiber structure has voids generated between the fibers, and thus has high lightness. Further, unlike the resin foam such as sponge, these voids are not independent voids but are continuous, and thus have air permeability.

That is, the nonwoven fiber structure has a low density. Specifically, the apparent density is, for example, 0.03 to 0.7 g / cm ³ , preferably 0.035 to 0.4 g / cm ³ , and more preferably. Is about 0.04 to 0.35 g / cm ³ . If the apparent density is too low, the sound absorbing property is high and light, but the strength is reduced. Conversely, if the apparent density is too high, the strength can be ensured, but the sound absorbing property and light weight are reduced.

The basis weight of the nonwoven fiber structure can be selected, for example, from a range of about 50 to 10000 g / m ² , preferably 100 to 8000 g / m ² , more preferably about 200 to 6000 g / m ² . If the basis weight is too small, it is difficult to ensure the hardness. If the basis weight is too large, the web is too thick and high-temperature steam cannot sufficiently enter the inside of the web in wet heat processing, and the structure is uniform in the thickness direction. It becomes difficult to make a body.

  Furthermore, since the structure in the present invention has a non-woven fiber structure, it has excellent breathability. When a face material is bonded to the structure, air between the structure and the face material or the reinforcing layer is the structure. By passing through, it is possible to avoid floating and peeling of the face material and the reinforcing layer after joining with the face material and the reinforcing layer. When an adhesive is used, the adhesive sticks to the constituent fibers on the surface and enters the fiber gap like a wedge, so that strong adhesion can be realized.

Specifically, the air permeability according to the fragile method is 0.1 cm ³ / (cm ² · sec) or more [eg, 0.1 to 300 cm ³ / (cm ² · sec)], preferably 1 to 250 cm ³ / (cm ² · sec), more preferably about 5 to ²⁰⁰ cm ³ / (cm ² · sec). If the air permeability is too small, it is necessary to apply pressure from the outside in order to allow air to pass through the structure, making it difficult for natural air to enter and exit. On the other hand, if the air permeability is too high, the air permeability becomes high, but the fiber voids in the structure become too large, and the sound absorption and bending stress decrease.

  Furthermore, the non-woven fiber structure according to the present invention (especially a structure formed of wet heat-adhesive fibers alone) has a uniform fiber bonding point in the thickness direction as described above, and therefore has a good shape retention. ing. That is, in a normal fiber structure, even if the necessary strength can be ensured by a binder or the like, basically, there is little adhesion between fibers, so when it is cut into small pieces of about 5 mm square, for example, the structure with a slight external force Are separated from each other, and finally are subdivided for each fiber. On the other hand, since the fiber structure in the present invention is densely and uniformly bonded to each other, even when cut into small pieces, it is not subdivided into fiber units and can sufficiently retain its form. This also means that dust generation when the structure is cut is small.

(3) Manufacturing method of non-woven fiber structure The non-woven fiber structure manufacturing method includes the steps of forming a fiber containing the wet heat adhesive fiber into a web, and heating and humidifying the generated fiber web with high-temperature steam to melt the non-woven fiber structure. Wearing.

  In the method for producing a non-woven fiber structure, first, the fiber containing the wet heat adhesive fiber is formed into a web. As a method for forming the web, a conventional method, for example, a direct method such as a spun bond method or a melt blow method, a card method using melt blow fibers or staple fibers, a dry method such as an air array method, or the like can be used. Among these methods, a card method using melt blown fibers or staple fibers, particularly a card method using staple fibers is widely used. Examples of the web obtained using staple fibers include a random web, a semi-random web, a parallel web, and a cross-wrap web.

  The resulting fibrous web is then sent to the next step by a belt conveyor and then exposed to superheated or high temperature steam (high pressure steam) flow to obtain a structure having a non-woven fibrous structure. That is, when the fiber web conveyed by the belt conveyor passes through the high-speed and high-temperature steam flow ejected from the nozzle of the steam injection device, the fibers are three-dimensionally bonded to each other by the sprayed high-temperature steam. In particular, since the fiber web in the present invention has air permeability, high-temperature water vapor penetrates into the inside, and a structure having a substantially uniform fusion state can be obtained.

  In addition, when the latent crimpable conjugate fiber is contained, the fibers are bonded together in a three-dimensional manner by fusion of the wet heat adhesive fibers, and the fibers are bonded by the expression of the crimps of the latent crimpable fibers. Entangled. Moreover, in the inside of a fiber assembly, a uniform crimp can be expressed from the surface of a fiber structure to the inside with uniform fusion. That is, due to the expression of the crimp of the latent crimpable fiber, the latent crimpable conjugate fiber moves while changing its shape into a coil shape having a specific radius of curvature, and three-dimensional entanglement between the fibers is expressed. In particular, since the fiber web in the present invention has air permeability, high-temperature water vapor penetrates into the inside, and a substantially uniform structure or structure (bonding point of wet heat adhesive fiber and crimping of composite fiber, uniform entanglement) Property).

  Specifically, the non-woven fiber structure has a temperature of 70 to 150 ° C., preferably 80 to 120 ° C., more preferably 90 to 110 ° C. 2 MPa, preferably 0.2 to 1.5 MPa, more preferably about 0.3 to 1 MPa, treatment speed of 200 m / min or less, preferably 0.1 to 100 m / min, more preferably about 1 to 50 m / min. As a detailed manufacturing method, the manufacturing methods described in International Publication WO2007 / 116676 and International Publication WO2009 / 28564 can be used.

  The obtained non-woven fiber structure is usually obtained as a plate-like or sheet-like molded body and is used by cutting or the like, but may be subjected to secondary molding by conventional thermoforming as required. Examples of thermoforming include compression molding, pressure forming (extrusion pressure forming, hot plate pressure forming, vacuum pressure forming, etc.), free blow molding, vacuum forming, bending, matched mold forming, hot plate forming, wet heat press forming, etc. Is available.

  The non-woven fiber structure (molded body) has a non-woven fiber structure obtained from the web composed of the above-mentioned fibers, and is usually obtained by cutting or hollowing out the obtained sheet-like structure. It can be easily manufactured in the shape of

(Reinforcing layer)
The reinforcing layer is laminated with the non-woven fiber layer and is formed of any of an inorganic material and an organic material in order to improve the sound insulation and secure the strength of the crosspiece to improve the strength of the sound insulation panel. It may be.

  Examples of inorganic materials include metal materials (eg, aluminum, iron, stainless steel, steel, etc.), metal compound materials (eg, gypsum, calcium silicate, glass, etc.), and the like. These inorganic materials can be used alone or in combination of two or more. Of these inorganic materials, metal materials such as iron and aluminum are preferable.

  Examples of organic materials include wood materials (for example, natural wood, solid wood, plywood (laminated wood board), wood fiber board (medium density fiber board MDF, particle board, oriented strand board, insulation board, etc.), etc. ], Hard fiber sheets (heat-set needle felt, paper board, etc.), synthetic resin materials (eg, polyethylene, polypropylene, polystyrene, polyvinyl chloride resin, polymethyl methacrylate, polyester, polycarbonate, polyamide, etc.) Can be mentioned. These organic materials can be used alone or in combination of two or more. Of these organic materials, woody materials such as MDF, laminated plywood, natural wood, and solid wood are preferable because they can achieve both lightness and strength.

  Further, the reinforcing layer may be a combination of the inorganic material and the organic material. For example, a composite of inorganic and organic materials such as glass fiber-containing FRP and polyvinyl chloride steel plate (polyvinyl chloride coated metal plate). It may be a system or laminated face material.

  In the present invention, the mechanism by which the sound insulation is improved by the presence of the reinforcing layer is not clear, but the sound insulating performance is improved by laminating the reinforcing layer made of a wood material or a metal material with the non-woven fiber layer.

(Structure and shape of the crosspiece)
FIG. 1 is a schematic perspective view showing an example of a crosspiece of the present invention. In this example, the crosspiece 1 has a structure in which a non-woven fiber layer 1a and a reinforcing layer 1b are laminated and has a rod-like shape having a substantially square cross section (a cross section perpendicular to the longitudinal direction is a substantially square shape). Or the thickness of the reinforcing layer 1b is about 2 to 3 times the thickness of the non-woven fiber layer 1a.

  The laminated structure of the crosspieces may be a laminated structure including a nonwoven fiber layer and a reinforcing layer. For example, the laminated structure is not limited to the two-layer structure shown in FIG. A two-layer structure with a woven fiber layer, a two-layer structure in which both layers have the same thickness, a laminated structure of three or more layers, and the like may be used. The crosspiece is usually a laminated structure of about 2 to 6 layers, for example, a 2 to 5 layer structure, preferably a 2 to 4 layer structure, and more preferably a 2 to 3 layer structure. Furthermore, in the laminated structure of three or more layers, in addition to the reinforcing layer and the non-woven fiber layer, other layers may be included. As the other layers, various functional layers can be used according to the purpose, and examples thereof include a vibration damping layer described later.

  As a specific example of the laminated structure of the crosspieces, FIG. 2 shows a schematic sectional view of a laminated structure other than the laminated structure of FIG. As another specific example of the laminated structure of the crosspieces, for example, a two-layer structure in which a reinforcing layer 11b and a non-woven fiber layer 11a having a thickness of about 2 to 3 times the thickness of the reinforcing layer 11b are laminated. (A) A three-layer structure (b) in which a first reinforcing layer 12a and a second reinforcing layer 12c having the same thickness are laminated on both surfaces of the non-woven fiber layer 12b, and on both surfaces of the reinforcing layer 13b. A three-layer structure (c) in which first non-woven fiber layers 13a and 13c having a certain thickness are laminated, and a first reinforcing layer 14a and a second layer having the same thickness on both sides of the non-woven fiber layer 14b. A four-layer structure (d) in which a damping layer 14c is further interposed between the non-woven fiber layer 14b and the reinforcing layer 14d in the structure in which the reinforcing layers 14d are laminated.

  Among these laminated structures, a laminated structure in which the reinforcing layer can be in direct contact with a face material [or a layer interposed between the face material and the crosspiece (for example, a vibration damping layer described later)] on at least one surface. For example, a two-layer structure of a non-woven fiber layer and a reinforcing layer, or a three-layer structure in which a reinforcing layer is laminated on both sides of the non-woven fiber layer is preferable. The reason why the sound insulation performance is improved when the reinforcing layer is in contact with the face material or the like is not clear, but the sound insulation performance is improved as compared with the laminated structure in which the surface in contact with the face material is formed only by the non-woven fiber layer.

  The thickness ratio of the thickness of the non-woven fiber layer (in the case of a plurality of layers) and the thickness of the reinforcing layer (the total thickness in the case of a plurality of layers) according to the type of the reinforcing layer is non-woven fiber layer / reinforcing layer = 1. It can be selected from the range of about / 10 to 30/1, for example, 1/8 to 20/1, more preferably about 1/5 to 15/1. The non-woven fiber layer and the reinforcing layer are not limited to an integral layer, and a plurality of layers may be laminated and adjusted to a desired thickness.

  When the reinforcing layer is made of a wood material, the thickness ratio between the two layers is the non-woven fiber layer (total thickness in the case of a plurality) / reinforcement layer (total thickness in the case of a plurality) = 1/10 to 10/1, preferably 1. It may be about / 6 to 5/1, more preferably about 1/5 to 4/1.

  When the reinforcing layer is a metal material, the thickness of the reinforcing layer is preferably thinner than the thickness of the non-woven fiber layer from the viewpoint of lightweight, and the thickness ratio of both layers is, for example, a non-woven fiber layer (in the case of a plurality of layers) Total thickness) / reinforcing layer (total thickness in the case of a plurality) = 1/1 to 30/1, preferably 1.2 / 1 to 20/1, more preferably about 1.5 / 1 to 13/1. May be.

  The shape of the crosspiece is not limited to a bar shape (long shape) having a substantially square cross section, and may be a bar shape corresponding to the length of one side in the vertical or horizontal direction of the face material. From the viewpoint of workability, a long shape having a cross-sectional shape having parallel sides facing each other is preferable. In addition to a square shape, for example, a rod shape or a long shape having a square cross-sectional shape such as a rectangular shape or a trapezoidal shape. It may be. Of these shapes, quadrangular shapes such as a square shape and a rectangular shape are widely used.

  The size of the crosspiece can be appropriately selected according to the size of the face material, but the thickness (thickness of the cross-sectional shape) is 2 mm or more (for example, 2 to 200 mm) from the viewpoint of improving the sound insulation against the solid propagation sound. For example, it may be 3 to 150 mm, preferably 5 to 100 mm, and more preferably about 8 to 50 mm.

  The width of the crosspiece (the width of the cross-sectional shape) can be selected from a width of 5 mm or more depending on the size of the face material, and is, for example, 10 to 100 mm, preferably 15 to 50 mm from the viewpoint of achieving both sound insulation and strength. More preferably, it is about 20 to 40 mm.

  The layers of the crosspieces may not be joined, but are preferably joined from the viewpoint of panel stability. The joining method may be a method using an adhesive or a pressure-sensitive adhesive, or a method using a fixture.

  In the method using an adhesive or pressure-sensitive adhesive, the adhesive or pressure-sensitive adhesive can be selected from conventional adhesives or pressure-sensitive adhesives according to the material of the nonwoven structure and the face material. Adhesives include natural polymer adhesives such as starch and casein, vinyl adhesives such as polyvinyl acetate, thermoplastic adhesives such as acrylic adhesives, polyester adhesives, polyamide adhesives, Examples thereof include thermosetting resin adhesives such as epoxy resins. Examples of the adhesive include thermoplastic resin adhesives such as rubber adhesives and acrylic adhesives. As the adhesive and the pressure-sensitive adhesive, different types of adhesives or pressure-sensitive adhesives may be used depending on the type of the reinforcing layer. In the present invention, since the non-woven fiber layer has a fiber structure, an adhesive or a pressure-sensitive adhesive is impregnated in the fiber structure, and air that causes a decrease in adhesive strength is released to the outside through the fiber structure. Therefore, high adhesion can be realized. The adhesive or pressure-sensitive adhesive may be applied to the entire surface of the interlayer or may be applied to a part of the interlayer.

  Examples of the method using the fixing tool include a method of partially fixing using staples such as nails and staples, screws, bolts, a method using an adhesive tape, and a method using a hook-and-loop fastener.

  Among these fixing methods, a bonding method using an adhesive or a pressure-sensitive adhesive and a method using staples are preferable from the viewpoint of lightness and productivity. In the method using staples, screws, bolts, etc., bonding may be performed together with the face material or the vibration damping layer (through the face material or the vibration damping layer).

[Sound insulation panel]
The sound insulation panel (sound absorbing panel or sound insulation panel) of the present invention is a sound insulation panel in which a cross including the cross member is interposed between a first face member and a second face member, and the non-use of the cross member. The woven fiber layer and the reinforcing layer are arranged in parallel to the surface directions of the first and second face materials. In this sound insulation panel, a vibration damping layer may be interposed between the crosspiece and the first face material and / or the second face material.

  FIG. 3 is a partially cutaway schematic perspective view showing an example of the structure of a sound insulation panel using the crosspiece of the present invention as an intermediate cross, and FIG. 4 is a schematic cross-sectional view taken along line AA of the sound insulation floor panel of FIG. It is.

  The sound insulation panel 21 includes a plate-like first face material 22 and second face material 27 having a square shape (for example, a substantially square shape or a rectangular shape), a first face material 22 and a second face material. A rod-shaped frame bar 24 arranged in a frame shape at the four peripheral ends (vertical end portions and lateral end portions) between the face member 27, and the first and second face members 22, 27, a plurality of (four in this example) rod-shaped intermediate bars 25 are provided between these frames at equal intervals in parallel in the longitudinal direction of the frame bars 24. The first and second face materials 22 and 27 are face materials for constituting a wall surface in a door, wall, partition, etc. of a building, and a frame rail 24 and an intermediate rail 25 are interposed between both side materials. As a result, a space is formed inside the sound insulation panel 21, and the lightness can be improved, and solid propagation sound can be suppressed. Further, in order to improve the sound insulation performance, a first vibration damping layer 23 is interposed between the frame beam 24 and the middle beam 25 and the first face member 22, and the frame beam 24 and the middle beam 25. The second damping layer 26 is interposed between the second face member 27 and the second face member 27.

(Middle pier)
Each of the plurality of middle rails 25 has a structure in which a non-woven fiber layer 25b and a reinforcing layer 25a are laminated, and has a rod-like shape having a substantially square cross section (a cross section perpendicular to the longitudinal direction is substantially square). Or the length of the reinforcing layer 25a is about 2 to 3 times the thickness of the non-woven fiber layer 25b. In these middle rails 5, the non-woven fiber layer 25 b and the reinforcing layer 25 a are both arranged in parallel to the surface direction of the face material, but the non-woven fiber is formed with respect to the first and second face materials. The layers and the reinforcing layers are arranged so as to contact each other alternately. That is, the adjacent middle rails are arranged in an inverted manner. In this way, by alternately inverting a plurality of middle rails and arranging them in a staggered structure, the sound insulation performance of the sound insulation panel is isotropic between the first face material side and the second face material side. Therefore, sound insulation from any direction can be improved.

  In the present invention, when a plurality of crosspieces having an asymmetrical shape (or anisotropic shape) in the thickness direction are arranged in parallel in the thickness direction, the crosspieces are alternately reversed in order to exhibit uniform sound insulation. It is preferable to arrange them. It should be noted that the asymmetric structure is preferably a two-layer structure or a three-layer structure where the thicknesses of the surface layer and the back layer are asymmetric, so that they are alternately inverted. For example, in the laminated structure of the crosspieces shown in FIG. 2, the three-layer structures (b) and (c) are symmetrical (or isotropic) in the thickness direction, but the other structures are asymmetric in the thickness direction. (Or anisotropic shape).

  In the sound insulation panel of the present invention, by controlling the width and number of the middle rails, the volume of the middle rail is set to 5 with respect to the volume of the entire gap formed between the first surface material and the second surface material. It is preferable to adjust to the range of about -70%, for example, you may adjust to about 8-60%, Preferably it is 10-50%, More preferably, it is about 12-40% (especially 15-30%).

  The interval at which the intermediate beam is disposed is not limited to an equal interval, and the interval may be changed according to a site where sound insulation is required. For example, in a region where sound insulation against solid propagation sound is required, A large interval may be provided. Further, when a plurality of middle rails are arranged, the intervals may be regularly changed as described in JP 2009-150133 A (Patent Document 2). Among these, it is preferable to arrange them uniformly at equal intervals from the viewpoint of expressing uniform sound insulation characteristics.

  The crosspiece may be combined with the crosspiece of the present invention and another crosspiece. Examples of other crosspieces include crosspieces that can be used as a frame crosspiece described later. Moreover, in the sound insulation panel in which the frame rail described later is formed of the crosspieces of the present invention, all of the middle crosspieces may be formed of other crosspieces.

(Frame frame)
Each of the frame bars 24 has an elongated shape with a substantially square cross section and is made of a wood material (MDF, laminated plywood, natural wood, solid wood, etc.). The frame rail is not limited to the wood material, and the inorganic material (metal material, etc.) exemplified in the reinforcing layer, the organic material (wood material, synthetic resin material, etc.), and the non-woven fiber layer. It may be a woven fiber structure. Furthermore, you may use the crosspiece of this invention as a frame crosspiece.

  The shape of the frame rail may be any shape having the same thickness as that of the middle rail, and can be selected from the shapes of the rail materials exemplified in the section of the rail material. The size and width of the frame beam can also be selected according to the size of the face material, but can be selected from the size and width of the frame material exemplified in the section of the beam material.

  The intermediate rail and the frame rail may be interposed between the first face material and the second face material (or between the first damping layer and the second damping layer). The face material or the second face material may not be fixed to the middle crosspiece and the frame crosspiece, but are preferably fixed in view of the strength and workability of the panel. As a fixing (joining) method, a method similar to the method of fixing the laminated structure of the middle rails can be used, and a method using an adhesive or a pressure sensitive adhesive or a method using a fixture may be used. . For example, the fixing method may be changed between the middle rail and the frame rail. For example, the frame rail may be fixed with staples, and the middle rail may be fixed with an adhesive or an adhesive. Furthermore, when fixing the middle rail with an adhesive or a pressure-sensitive adhesive, all the parts that come into contact with the first face material and the second face material may be fixed with an adhesive or a pressure-sensitive adhesive. Or you may fix with an adhesive. As a method of partially fixing with an adhesive or a pressure-sensitive adhesive, for example, an intermediate beam is formed with a two-layer structure of a reinforcing layer and a non-woven fiber layer, and a plurality of intermediate beams are alternately reversed and arranged. In the case where the reinforcing layer and the first face material or the second face material are in contact with each other, a method of fixing with an adhesive or an adhesive, a contact portion between the middle rail or the frame rail and the face material, The method etc. which apply | coat an adhesive agent or an adhesive to a part are mentioned.

  The sound insulation panel of the present invention is not limited to a panel provided with a frame rail, but is a sound insulation panel fixed with a frame instead of the frame rail (for example, from the outside of the panel using a frame material without interposing the frame rail). A fixed sound insulation panel), a sound insulation panel not provided with a frame rail, and the like may be used.

(First and second face materials)
The first face material 22 and the second face material 27 are substantially square and have the same size, and both are formed of MDF.

  The first face material and the second face material are not limited to MDF, and inorganic materials and organic materials exemplified in the reinforcing layer can be used. These face materials can be selected depending on the application, but from the viewpoint of satisfying lightness and strength, wood-based boards such as plywood and MDF, and hard fiber sheets such as paper boards are preferable. A board is particularly preferred. Further, the first face material and the second face material may be the same face material or different kinds of face materials. For example, a metal plate or plywood may be used as one face material, and an effect like a reflector may be imparted.

  The planar shape of the face material is not limited to a square shape, and may be a rectangular shape. The plane size is not particularly limited, and can be appropriately selected from the range of about 100 mm to 10 m depending on the required sound insulation panel. When used for architectural purposes, the width can be selected from a range of about 100 to 2000 mm and a height of about 100 to 3500 mm. For example, it is often used in a plane size such as 910 mm × 1820 mm, 1000 mm × 2000 mm.

  The thickness of the face material can also be selected from a range of about 0.1 to 100 mm depending on the application and material, but for example, 0.2 to 50 mm, preferably 0.5, from the viewpoint of achieving both lightness and sound insulation. It is about -30 mm, More preferably, it is about 0.7-20 mm (especially 1-10 mm). In the present invention, even if the thickness is about several mm, high sound insulation can be expressed. The first face material and the second face material may have different thicknesses or the same. It should be noted that face materials having various thicknesses are commercially available, and commercially available face materials may be overlaid so as to have a desired sound insulation property. In particular, the thickness may be adjusted, or different types of face materials may be combined to reduce the drop in sound insulation performance due to the coincidence effect seen in a single-layer panel.

(Vibration control layer)
The first damping layer 23 and the second damping layer 26 are arranged in a size corresponding to the first face material 22 and the second face material 27 in order to improve sound insulation in a wide frequency range. It is made of damping material containing heavy materials such as asphalt.

  The vibration damping material only needs to contain a weight material such as asphalt, and may be a metal foil such as iron foil, a gypsum board, or the like, or a mixture of a binder component and a filler. Among these, a mixture of a binder component and a filler is preferable from the viewpoint of effectively improving vibration damping properties while ensuring light weight.

Examples of the binder component include bituminous substances such as asphalt, synthetic resins, rubbers, and elastomers. In order for the binder component to exhibit a vibration damping effect, it is usually preferable that the mass per unit area is 1 kg / m ² or more. From the viewpoint of having such a high specific gravity, the binder component is an asphalt as a weighting material. It is preferable to contain. The asphalt is not particularly limited, and general asphalt, for example, petroleum asphalt such as natural asphalt, straight asphalt, blown asphalt, and the like can be used. These asphalts can be used alone or in combination of two or more.

  Further, the binder component may contain a soft resin or an elastomer component in addition to asphalt in order to impart flexibility to the vibration damping material. Examples of the soft resin or elastomer component include polyolefin, vinyl polymer (polyvinyl chloride, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene-acrylic acid copolymer, ethylene-methyl acrylate). Copolymer, ethylene-ethyl acrylate copolymer, etc.), polyamide, polyester, synthetic rubber (polybutadiene, polyisoprene, styrene-butadiene copolymer, etc.), natural rubber, rosin resin (natural rosin, modified rosin, etc.) Etc. These soft resins or elastomer components can be used alone or in combination of two or more. Of these soft resins or elastomer components, styrene-diene copolymers such as styrene-butadiene block copolymers are preferred.

  In the damping material containing asphalt, the ratio of the soft resin or elastomer component is, for example, 0 to 100 parts by weight, preferably 1 to 80 parts by weight, and more preferably about 3 to 50 parts by weight with respect to 100 parts by weight of asphalt. It is.

  The filler may be an organic filler, but is preferably an inorganic filler from the viewpoint of high specific gravity. Examples of the inorganic filler include metal particles (powder) such as iron, copper, tin, zinc, nickel, and stainless steel, iron oxide, iron sesquioxide, iron tetroxide, ferrite, tin oxide, zinc oxide, zinc white, Metal oxide particles such as copper oxide, aluminum oxide, metal salt particles such as barium sulfate, calcium sulfate, aluminum sulfate, calcium sulfite, calcium carbonate, calcium bicarbonate, barium carbonate, magnesium hydroxide, steelmaking slag, mica, clay, Examples include mineral particles such as talc, wollastonite, diatomaceous earth, silica sand, and pumice powder.

  These inorganic fillers can be used alone or in combination of two or more. Among these inorganic fillers, iron particles, various iron oxide particles, steelmaking slag particles, (heavy) calcium carbonate particles and the like are preferable.

  Examples of the shape of the inorganic filler include a particle shape or a powder shape, an indefinite shape, a fiber shape, and the like. The average particle size of the inorganic filler is, for example, about 0.5 mm or less (for example, 0.01 to 0.5 mm), preferably about 0.2 mm or less (for example, 0.05 to 0.2 mm). Use of such a finely divided inorganic filler improves molding processability when producing a vibration damping material and allows a large amount of inorganic filler to be uniformly dispersed and blended in the asphalt base material. The surface density and thermal stability of the vibration material can be improved.

The proportion of the inorganic filler is, for example, about 100 to 2000 parts by weight, preferably 200 to 1800 parts by weight, and more preferably about 300 to 1500 parts by weight with respect to 100 parts by weight of asphalt. If the amount of the inorganic filler is too small, the sound insulation effect is lowered. On the other hand, if the amount is too large, the whole becomes brittle and molding becomes difficult, and workability is lowered. The surface density of the damping material is preferably adjusted to be 1.0 kg / m ² or more (particularly 5.0 kg / m ² or more).

  Such a damping material can be obtained, for example, by a method in which a binder component and an inorganic filler are heated and mixed and molded into a plate shape. When blending a soft resin or an elastomer component, an inorganic filler may be added to a mixture in which asphalt and a soft resin or an elastomer component are mixed in advance.

  The size of the damping layer is not limited to the size corresponding to the face material, and may be formed in a region where damping property is required when it is desired to partially exhibit damping property.

  The thickness of the damping layer is, for example, about 0.5 to 20 mm, preferably about 0.8 to 15 mm, and more preferably about 1 to 15 mm. The specific gravity of the damping layer is, for example, about 1.0 to 12.1, preferably about 1.0 to 10.2, and more preferably about 1.2 to 9.2.

  In the present invention, the vibration damping layer may be disposed arbitrarily, and may be interposed between the frame rail and the middle rail and the face material according to the application. May be laminated and interposed between the finishing material and the face material. Moreover, it is not limited to the aspect interposed on both surfaces of a frame crosspiece and an intermediate crosspiece, You may interpose only on one side. For example, in applications that place importance on lightness, a sound insulation panel that does not have a vibration damping layer may be used, and in applications that place importance on sound insulation, a panel (for example, a panel provided on at least one surface of a frame rail and a middle rail) It may be a panel in which vibration damping layers are interposed on both sides.

  The damping layer and the face material do not need to be fixed, but are preferably fixed from the viewpoint of the strength and workability of the panel. As a fixing (joining) method, a method similar to the method of fixing the laminated structure of the middle rails can be used, and a method using an adhesive or a pressure sensitive adhesive or a method using a fixture may be used. .

  In the sound insulation panel of the present invention, if necessary, a reflector, a finishing material and the like may be further laminated on the first face material and / or the second face material. As a method of fixing the reflector and the finishing material, the same method as the method of fixing the laminated structure of the middle rails can be used.

  The reflector is not particularly limited as long as it has a sound wave reflection effect, but from the viewpoint of lightness, for example, a vinyl chloride steel plate (polyvinyl chloride coated metal plate), a plywood (laminated wood board), a synthetic resin plate, Inorganic fiber nonwoven fabrics are widely used. As described above, a material having the function of a reflector may be used as the face material, and in this specification, the reflector means a reflector further laminated on the face material. The thickness of the reflector is, for example, about 0.01 to 10 mm, preferably about 0.02 to 5 mm, and more preferably about 0.03 to 3 mm.

  As the finishing material, a conventional finishing material can be used. For example, cloth cloth, wood-based finishing material, film, paper and the like can be used. Furthermore, when decorating the sound insulation panel, a decorative cloth having air permeability may be used. The thickness of the finishing material is, for example, about 0.1 to 5 mm, preferably about 0.3 to 3 mm, and more preferably about 0.5 to 2 mm.

  When the sound insulating panel of the present invention is used, it is possible to realize excellent sound absorbing performance over a wide frequency range, and particularly to realize excellent sound absorbing performance in a low frequency range. Specifically, the sound insulation panel of the present invention exhibits sound insulation for a frequency range (about 10 to 20000 Hz) that can be sensed as sound, and is usually used for sound having a frequency of about 100 to 10000 Hz. In particular, the sound insulation panel of the present invention has a low frequency region, for example, 100 to 500 Hz (preferably 100 to 300 Hz, more preferably 100 to 300 Hz) by bringing the reinforcing layer of the middle rail into contact with the face material (or vibration damping layer). Sound transmission loss can be increased in the frequency range of about 200 Hz. Furthermore, by interposing the damping layer, it is possible to improve the sound insulation in a wide frequency range extending from 100 to 2000 Hz.

[Ventilation sound insulation panel]
The sound insulation panel of the present invention may be a ventilation sound insulation panel having a ventilation function in addition to the sound insulation function. The ventilation sound insulation panel of the present invention may have a structure that allows ventilation from one surface to the other surface of the sound insulation panel, and the first and second face members have first and second openings, respectively. A panel formed and formed at a position where the first opening is different from the second opening is preferable. In the present invention, since the first opening and the second opening are formed at different positions (positions that do not face each other or shifted positions), the sound wave does not pass through the opening as it is inside the panel. The sound insulation function can be maintained by absorbing the sound with a crosspiece having a sound insulation function. In this ventilation sound insulation panel, in order to further improve the sound insulation, a sound absorbing material may be disposed between adjacent bars. Further, also in the ventilation sound insulation panel, a damping layer may be interposed between the crosspiece and the first face material and / or the second face material, similarly to the sound insulation panel. When the damping layer is interposed, an opening is formed at a portion corresponding to the opening of the face material on the surface of the damping layer as well as the face material.

  FIG. 5 is a partially cutaway schematic perspective view showing an example of the structure of the ventilation and sound insulation panel of the present invention (a schematic perspective view in which a part of the first face material, the sound absorbing material, and the middle rail is cut out), and FIG. These are the AA line schematic sectional drawing of the ventilation sound insulation panel of FIG.

  The ventilation sound insulation panel 31 includes a plate-like first face member 32 and second face member 37 having a four-sided planar shape, and a four-circumferential end between the first face member 32 and the second face member 37. Between the rod-shaped frame bar 34 arranged in the form of a part frame and the first and second face members 32, 37, between these frames, in parallel to the vertical direction of the frame bar 34, etc. It is the same as the sound insulation panel 21 in that it is provided with a plurality of (four in this example) rod-shaped intermediate rails 35 that are arranged at intervals and have a structure in which a nonwoven fiber layer 35b and a reinforcing layer 35a are laminated. It has the structure of.

  In the ventilation and sound insulation panel 31, in addition to the structure described above, as a ventilation hole for ventilation, a substantially rectangular second extending in the direction intersecting with the longitudinal direction of the middle rail 35 on the surface on the lower end side of the first face member 32 is provided. On the other hand, on the surface on the upper end side of the second face member 37, a substantially rectangular second opening 37a extending in a direction intersecting with the longitudinal direction of the intermediate rail 35 is formed. Has been. In the ventilation sound insulation panel 31, by forming the first and second openings, a structure is formed in which air flowing from one opening can pass through the space inside the panel and be discharged to the other opening. ing.

  Further, in the ventilation sound insulation panel 31, the bar-shaped sound absorbing material 33 having a substantially square cross section has a longitudinal direction of the middle rail 35 between the adjacent frame rail 34 and the intermediate rail 35 and between the adjacent middle rails 35. However, the length of the sound absorbing material 33 in the width direction is larger than the interval (distance) between the adjacent frame rails 34 and the intermediate rails 35 and the interval between the adjacent intermediate rails 35. Since it is small, a space (gap) 36 is formed between the sound absorbing material 33 and the intermediate cross 35 or the frame cross 34. In the present invention, the air can be ventilated through the space portion 36. However, since the size of the space portion is controlled and the sound absorbing material 33 is provided, the sound wave entering the panel from the opening portion is effectively prevented. Sound absorption can be maintained while having a ventilation function. Furthermore, since the sound absorbing material 33 is formed of a non-woven fiber structure similar to the non-woven fiber layer of the middle rail, the shape retention is excellent and the adjustment of the space portion is easy.

(Aperture)
The shape of the opening is not limited to a rectangular shape, and may be any shape that allows air to pass through the space between the rails, and may be an elliptical shape, a circular shape, or a square shape. A substantially rectangular shape, an elliptical shape, etc. are preferable from the point which can cross | intersect between several crosspieces by a small opening part area by crossing the longitudinal direction of a material.

  The opening may be crossed with the longitudinal direction of the crosspiece and may be ventilated through the space (gap) between the crosspieces, and is not limited to an aspect that intersects the longitudinal direction of the crosspiece substantially at right angles. However, it is preferable that they intersect at substantially right angles from the viewpoint that the distance of the space (gap) for insulating or absorbing sound waves passing through the panel can be ensured uniformly and sufficiently.

  The position of the opening may be formed at different positions without the first opening and the second facing part facing each other, and it is only necessary to secure a path capable of sound insulation in the process of sound waves passing through the panel. It is not limited to the lower end side and the upper end side of the face material, for example, the first and second openings extending in the direction intersecting the longitudinal direction of the crosspiece respectively, and the first opening is one end The second opening may be formed at a position not facing the first opening. The first opening and the second opening are preferably formed at positions as far apart as possible from the viewpoint that a passage for insulating or absorbing sound waves passing through the panel can be sufficiently formed. Preferably, the first face material is formed on the lower end side (or upper end side) surface and the second opening part is formed on the upper end side (or lower end side) surface of the second face material. . Although the space | interval (shortest distance) from the lower end (or upper end) of a face material to an opening part can be selected according to a use or a panel size, For example, 10-500 mm, Preferably it is 30-300 mm, More preferably, it is 50-200 mm. Degree.

  The area of the opening is, for example, about 1 to 30%, preferably 2 to 25%, more preferably 3 to 20% (particularly 5 to 15%) with respect to the area of the entire face material.

(Sound absorbing material)
The sound absorbing material only needs to have a sound absorbing function, and is not limited to the non-woven fiber structure, but a conventional sound absorbing material such as synthetic fiber (polyolefin fiber, acrylic fiber, polyvinyl alcohol fiber, vinyl chloride). A fibrous sound-absorbing material (woven or knitted fabric, non-woven fabric, etc.) made of fiber, styrene fiber, polyester fiber, polyamide fiber, polycarbonate fiber, polyurethane fiber, or composite fiber containing these fibers) Fibrous structural body) or a fibrous sound absorbing material formed of inorganic fibers (glass fiber, carbon fiber, etc.), but from the point of being able to achieve both sound absorption, light weight and form retention, Non-woven fiber structure described in the section of non-woven fiber layer of crosspiece (non-woven fiber structure including wet-heat-adhesive fibers and having the fibers fixed by fusion of the wet-heat-adhesive fibers is preferred. In particular, the sound absorbing material formed of the non-woven fiber structure can control the cross-section of the space precisely due to its high form retention, so the balance between the ventilation function and the sound insulation function that require fine adjustment is required. It becomes easy to take.

  The shape of the sound-absorbing material is not particularly limited as long as a space for ventilation can remain between adjacent crosspieces.For example, the sound-absorbing material may be partially formed in the length direction between the crosspieces. A continuous bar shape having substantially the same length as the middle rail is preferable. In addition, the cross-sectional shape of the sound absorbing material is not limited to a substantially square shape, and may be an elliptical shape, a circular shape, or the like, but in terms of being easily fixed to the panel, at least a shape having a planar shape, for example, a square shape or A polygonal shape such as a rectangular shape (particularly a rectangular shape) is preferred.

  The sound-absorbing material is not limited to a mode in which one (one) sound-absorbing material (integrated sound-absorbing material) is disposed between adjacent bars, and a plurality of sound-absorbing materials (separate-type sound-absorbing materials) are disposed between adjacent bars. ) May be provided. FIG. 7 is a schematic cross-sectional view showing another example of a ventilation sound insulation panel according to the present invention in which a separate type sound absorbing material is disposed. In this ventilation and sound insulation panel 41, a plurality of rod-shaped structures having a structure in which a rod-shaped frame bar 44, a non-woven fiber layer 45b, and a reinforcing layer 45a are laminated between a first face member 42 and a second face member 47. The middle rail 45 is disposed in the same structure as the ventilation sound insulation panel 31, and the sound absorbing material 43 has a rectangular cross section fixed to the first face member 42 and has a rod shape. Unlike the ventilation and sound insulation panel 31, the sound absorbing material 43 a is a separate type sound absorbing material formed by the first sound absorbing material 43 a and the rod-shaped second sound absorbing material 43 b fixed to the second face material 47. Yes. In this sound absorbing material, the sound absorbing material 43a and the sound absorbing material 43b have substantially the same thickness, the length in the width direction is the same as the interval (distance) between the crosspieces, and the total thickness of both the sound absorbing materials is the first. It is smaller than the gap between the face material 42 and the second face material 47. That is, in this ventilation sound insulation panel, a bar-shaped space 46 having a rectangular cross section is formed as a space sandwiched between sound absorbing materials inside the thickness direction, and the opening is closed with the sound absorbing material. The space is not exposed. Therefore, unlike the ventilation and sound insulation panel of FIG. 6 in which the space is exposed at the opening, the sound absorbing material has a filter role, so that, for example, entry of dust and the like from the outside can be suppressed. The thickness of each of the separation-type sound absorbing materials is not limited to the same, and may be different.

  Further, the integrated sound absorbing material is not limited to the shape of FIG. 6, and the length in the width direction is the same as the interval between the crosspieces as in the case of the separated sound absorbing material of FIG. 7. The shape may be smaller than the gap between the first face material and the second face material.

  That is, the shape of the sound-absorbing material is not particularly limited as long as the cross-sectional area of the space portion can be formed in a predetermined area in order to ensure sound insulation, as will be described later. You may choose. For example, as described above, when the sound absorbing material is required to have a filter role, the shape of the opening may be closed by the sound absorbing material (for example, the panel shown in FIG. 7), which is high. When the air permeability is required, a panel (for example, a panel shown in FIG. 6) in which the opening is not blocked by the sound absorbing material may be used.

  The sound absorbing material may be interposed between the first face material and the second face material (or between the first vibration damping layer and the second vibration damping layer). The second face material and the sound absorbing material may not be fixed, but are preferably fixed from the viewpoint of the strength and workability of the panel. As a fixing (joining) method, a method similar to the method of fixing the laminated structure of the middle rails can be used, and a method using an adhesive or a pressure sensitive adhesive or a method using a fixture may be used. .

(Space part)
In a ventilation sound insulation panel, the air that has entered the panel from one opening passes through the space formed between the crosspieces or between the crosspiece and the sound absorbing material and reaches the other opening, If it is too large, sound waves are likely to leak through the space along with the ventilation. Therefore, in this invention, it is preferable to control the magnitude | size of the space part between adjacent crosspieces.

Specifically, the size of the space between adjacent crosspieces can be selected according to the application and the size of the panel. For example, the cross-sectional area perpendicular to the longitudinal direction of the crosspieces (a sound absorbing material is provided). If the cross-sectional area obtained by dividing the cross-sectional area of the sound absorbing material) is 18cm ² or less (e.g., it may be a 0.01～18Cm ^2), for example, 0.1～15Cm ^2, preferably 0.5 12cm ^2, more preferably from 1 to 10 cm ² (particularly 3~8cm ²⁾ about. The cross-sectional area of the space portion is, for example, 0.1 to 50%, preferably 5 to 30% with respect to the cross-sectional area of the entire gap formed between the first face material and the second face material. More preferably, it may be about 10 to 20%. If the cross-sectional area of the space portion is too large, the sound insulation performance is lowered. Conversely, if the space portion is too small, the air permeability is lowered.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples. Each physical property value in the examples was measured by the following method. In the examples, “parts” and “%” are based on mass unless otherwise specified.

(1) Weight per unit area (g / m ² )
Measured according to JIS L1913 “Testing method for general short fiber nonwoven fabric”.

(2) Thickness (mm), apparent density (g / cm ³ )
The thickness was measured according to JISL 1913 “Test method for general short fiber nonwoven fabric”, and the apparent density was calculated from this value and the basis weight value.

(3) Air permeability According to JIS L1096, it measured by the fragile type method.

(4) Compression modulus Based on JIS K7181, the inclination at the time of 10-20% compressive strain was measured with respect to the original thickness.

(5) Bending stress It measured according to A method (three-point bending method) among the methods as described in JIS K7017. At this time, the measurement sample was a 25 mm wide × 80 mm long sample, the distance between fulcrums was 50 mm, and the test speed was 2 mm / min. In the present invention, the maximum stress (peak stress) in this measurement result chart is defined as the maximum bending stress. The bending stress was measured in the MD direction and the CD direction. Here, the MD direction refers to a state in which the measurement sample is collected so that the web flow direction (MD) is parallel to the long side of the measurement sample, while the CD direction refers to the long side of the measurement sample. A state in which a measurement sample is collected so that the web width direction (CD) is parallel.

(6) 1.5 times displacement stress Stress at the time of bending stress measurement that exceeds the bending amount (displacement) indicating the maximum bending stress (bending peak stress) and continues to bend to 1.5 times the displacement. Was defined as a 1.5 times displacement stress.

(7) Fiber Adhesion Rate Using a scanning electron microscope (SEM), a photograph in which the cross section of the structure was magnified 100 times was taken. The photograph of the cross section in the thickness direction of the photographed structure is divided into three equal parts in the thickness direction, and the number of fiber cut surfaces (fiber end faces) that can be found in each of the three divided areas (front surface, inside (center), back surface) On the other hand, the ratio of the number of cut surfaces where the fibers are bonded to each other was determined. Of the total number of fiber cross sections that can be found in each region, the ratio of the number of cross sections in a state where two or more fibers are bonded is expressed as a percentage based on the following formula. In addition, in the part which fibers contact, there exists a part which is simply contacting, without melt | fusion, and a part which has adhere | attached by melt | fusion. However, by cutting the structure for microscopic photography, the fibers in contact with each other are separated from each other by the stress of each fiber on the cut surface of the structure. Therefore, in the cross-sectional photograph, it can be determined that the contacting fibers are bonded to each other.

Fiber adhesion rate (%) = (number of cross sections of fibers bonded two or more) / (total number of cross sections of fibers) × 100
However, for each photograph, all the fibers with visible cross sections were counted, and when the number of fiber cross sections was 100 or less, a photograph to be observed was added so that the total fiber cross section number exceeded 100. In addition, the fiber adhesion rate was calculated | required about each area | region divided into three equally, and the ratio (minimum value / maximum value) of the minimum value with respect to the maximum value was also calculated | required together.

(8) Sound transmission loss The sound transmission loss was measured according to JIS A1416.

(9) Wind speed and ventilation volume In the ventilation sound insulation panel 51 obtained in Examples 21 to 26, Reference Examples 1 to 2 and 4 to 5, as shown in FIG. 8, suction provided with a ventilation fan 52a in one opening. The duct 52 was attached, and the wind speed (m / sec) was measured at the other opening 51a by using an anemometer (“Anemo Master Anemometer MODEL6151” manufactured by Nippon Canomax Co., Ltd.). Moreover, ventilation volume (m < ³ > / hour) was computed from the cross-sectional area (m < ² >) and air volume of the opening part. The wind speed near the opening of the duct was 15 m / second, and the ventilation volume calculated from this wind speed was 1890 m ³ / hour.

[Components used in Examples]
(Nonwoven fiber layer 1)
The nonwoven fiber layer 1 was produced as follows. That is, as a wet heat adhesive fiber, a core-sheath type composite staple fiber having a core component of polyethylene terephthalate and a sheath component of ethylene-vinyl alcohol copolymer (ethylene content 44 mol%, saponification degree 98.4 mol%) (( Kuraray Co., Ltd., “Sophista”, fineness 3 dtex, fiber length 51 mm, core-sheath mass ratio = 50/50, number of crimps 21/25 mm, crimp rate 13.5%) was prepared.

  On the other hand, the latent crimpable fiber is composed of a polyethylene terephthalate resin (component A) having an intrinsic viscosity of 0.65 and a modified polyethylene terephthalate resin (component B) obtained by copolymerizing 20 mol% of isophthalic acid and 5 mol% of diethylene glycol. Side-by-side type composite staple fiber (manufactured by Kuraray Co., Ltd., “PN-780”, 1.7 dtex × 51 mm length, mechanical crimp number of 12/25 mm, 130 ° C. × 1 minute after heat treatment of 62/25 mm ) Was prepared.

The core-sheath type composite staple fiber (wet heat adhesive fiber) and the side-by-side type composite staple fiber (latent crimpable conjugate fiber) are wet heat adhesive fiber / latent crimped conjugate fiber = 30 / After blending at a ratio of 70, a card web having a basis weight of about 100 to 200 g / m ² is produced by the card method, and this web is laminated in accordance with the desired basis weight, and a card web having a total basis weight of 300 to 2500 g / m ² It was.

  The card web was transferred to a belt conveyor equipped with a 50 mesh, 500 mm wide stainless steel endless wire mesh. In addition, the belt conveyor which has the same metal mesh is equipped in the upper part of the metal mesh of this belt conveyor, and it rotated in the same direction at the same speed, respectively, and used the belt conveyor which can adjust the space | interval of these metal meshes arbitrarily. .

  Next, the steam web is introduced into the steam jetting device provided in the lower belt conveyor, and 0.4 MPa of high-temperature steam is ejected (perpendicularly) from the device so as to pass in the thickness direction of the card web. After the steam treatment, the molded body having a nonwoven fiber structure was obtained by drying with hot air at 120 ° C. for 1 minute. In this steam spraying device, a nozzle is installed in the lower conveyor so as to spray high-temperature steam toward the web via a conveyor net, and a suction device is installed in the upper conveyor. Further, another jetting device, which is a combination of the arrangement of the nozzle and the suction device reversed, is installed on the downstream side in the web traveling direction of the jetting device, and steam treatment is performed on both the front and back sides of the web. did.

  In addition, the hole diameter of the water vapor | steam injection nozzle was 0.3 mm, and the vapor | steam injection apparatus with which the nozzle was arranged in 1 row at 1 mm pitch along the width direction of the conveyor was used. The processing speed was 3 m / min, and the interval (distance) between the upper and lower conveyor belts on the nozzle side and the suction side was adjusted so that a structure having a thickness of 8 mm was obtained. The nozzles were arranged on the back side of the conveyor belt so as to be almost in contact with the belt.

  The properties of the obtained nonwoven fiber structure are shown in Table 1.

  This non-woven fiber structure was cut into a long structure having a width of 30 mm and a length of 840 mm to produce a non-woven fiber layer.

(Nonwoven fiber layer 2)
The non-woven fiber layer 2 was produced as follows. That is, as a wet heat adhesive fiber, a core-sheath type composite staple fiber having a core component of polyethylene terephthalate and a sheath component of ethylene-vinyl alcohol copolymer (ethylene content 44 mol%, saponification degree 98.4 mol%) ( “Sophista” manufactured by Kuraray Co., Ltd., fineness 3 dtex, fiber length 51 mm, core-sheath mass ratio = 50/50, number of crimps 21/25 mm, crimp ratio 13.5% was prepared.

Using this core-sheath type composite staple fiber, a card web having a basis weight of about 100 to 200 g / m ² is produced by the card method, and this web is laminated in accordance with the target basis weight, and the total basis weight is 300 to 2500 g / m ^2. The card web.

  Using this card web, in the production example of the nonwoven fiber structure of the nonwoven fiber layer 1, a non-woven fiber structure having a thickness of 10 mm was produced by adjusting the interval between the upper and lower conveyor belts.

  The properties of the obtained nonwoven fiber structure are shown in Table 2.

  This non-woven fiber structure was cut into a long structure having a width of 30 mm and a length of 840 mm.

(Nonwoven fiber layer 3)
In the manufacturing example of the non-woven fiber structure of the non-woven fiber layer 1, a non-woven fiber structure having a thickness of 5 mm was manufactured by adjusting the interval between the upper and lower conveyor belts using a card web of 520 g / m ² . .

  Table 3 shows the characteristics of the obtained nonwoven fiber structure.

  This non-woven fiber structure was cut into a long structure having a width of 30 mm and a length of 840 mm to produce a non-woven fiber layer.

(Nonwoven fiber layer 4)
In the manufacturing example of the nonwoven fiber structure of the nonwoven fiber layer 2, a non-woven fiber structure having a thickness of 20 mm was manufactured by adjusting the interval between the upper and lower conveyor belts using a card web of 2000 g / m ² . .

  Table 4 shows the characteristics of the obtained nonwoven fiber structure.

  This non-woven fiber structure was cut into a long structure having a width of 30 mm and a length of 840 mm to produce a non-woven fiber layer.

(Reinforcing layer 1)
As the reinforcing layer 1, a wood board (laminated plywood) having a width of 30 mm, a thickness of 11 mm, and a length of 840 mm was used.

(Reinforcing layer 2)
As the reinforcing layer 2, an iron plate having a width of 30 mm, a thickness of 1 to 4 mm, and a length of 840 mm was used.

(Frame frame)
A wooden board (laminated plywood) having a width of 30 mm and a thickness of 30 mm (or 31.5 mm, 32 mm, 24 mm, and a length of 900 mm (or 840 mm) was used as the frame crosspiece.

(Face material 1)
As the face material 1, an MDF board having a plane size of 900 mm × 900 mm, a thickness of 2.7 mm, and a density of 0.96 g / cm ³ was used.

(Face material 2)
As the face material 2, a paper board having a plane size of 900 mm × 900 mm, a thickness of 3 mm, and a density of 1.16 g / cm ³ was used.

(Face material 3)
As the face material 3, a glass fiber-containing FRP board having a plane size of 900 mm × 900 mm, a thickness of 1.2 mm, and a density of 1.75 g / cm ³ was used.

(Vibration suppression layer 1)
As the damping layer 1, an asphalt base material having a plane dimension of 900 mm × 900 mm (or 840 mm × 30 mm), a thickness of 2.4 mm, and a density of 3.0 g / cm ³ (manufactured by Nanao Industry Co., Ltd., trade name “SUPER” Shizuka Kabe FK-240 ") was used.

(Vibration suppression layer 2)
As the damping layer 2, an iron foil having a plane size of 900 mm × 900 mm and a thickness of 0.27 mm was used.

[Experiment 1]
As Experimental Example 1, the following Examples 1 to 3 were performed on a sound insulation panel using an intermediate rail in which reinforcing layers were laminated on both sides of a nonwoven fiber layer, and the influence of the thickness of the nonwoven fiber layer was examined.

Example 1
After laminating the reinforcing layer 1 (wood board) having a thickness of 11 mm on both sides of the non-woven fiber layer 1 having a thickness of 8 mm, the nonwoven fiber layer 1 and the reinforcing layer 1 are fixed by driving three staples at 210 mm intervals. An intermediate cross was made. With respect to the number and arrangement of the middle beam and the frame beam between the two face members 1 (MDF board), the middle beam and the frame beam are arranged as shown in FIG. 3 (in FIG. 3, no damping layer is interposed). A sound insulation panel having a mass of 7.0 kg was produced by interposing the intermediate crosspieces in a manner using a symmetrical intermediate crosspiece in the thickness direction. The middle rail and the face material were joined using an adhesive (Konishi Co., Ltd., trade name “bond CH18”).

(Example 2)
A sound insulation panel having a mass of 7.0 kg was produced in the same manner as in Example 1 except that the nonwoven fiber layer 2 having a thickness of 10 mm was used instead of the nonwoven fiber layer 1 having a thickness of 8 mm.

Example 3
Insulation with a mass of 7.0 kg is carried out in the same manner as in Example 1 except that a 10 mm thick nonwoven fiber layer obtained by laminating two 5 mm thick nonwoven fiber layers 3 is used instead of the 8 mm thick nonwoven fiber layer 1. A panel was produced.

  The results of measuring sound transmission loss for the sound insulation panels obtained in Examples 1 to 3 are shown in FIG. As is clear from the results of FIG. 9, all the examples show the same excellent sound insulation performance.

[Experiment 2]
As Experimental Example 2, the following Examples 4 to 7 were performed on a sound insulation panel using an intermediate rail in which a reinforcing layer was formed of an iron plate, and the sound insulating properties when a metal material was used as the reinforcing layer were measured.

Example 4
Using a vinyl acetate hot melt adhesive, a non-woven fiber layer 2 having a thickness of 10 mm was laminated and bonded to both surfaces of a reinforcing layer 2 (iron plate) having a thickness of 4 mm to produce an intermediate beam. Between the two face materials 1 (MDF board), the middle rail and the frame rail are disposed in the arrangement shown in FIG. 3, and a vinyl acetate hot melt adhesive is applied only to the one side surface material. The damping layer 2 (iron foil) is used and the damping layer is disposed between the face material, the frame rail, and the middle rail (in FIG. 3, the damping layer is provided only on one side). A sound insulation panel having a mass of 9.9 kg was prepared by interposing and using an intermediate beam symmetrical in the thickness direction as an intermediate beam.

(Example 5)
Using a vinyl acetate hot melt adhesive, a reinforcing layer 2 (iron plate) having a thickness of 2 mm was laminated and bonded to both surfaces of the non-woven fiber layer 4 having a thickness of 20 mm to produce an intermediate beam. Between the two face members 1 (MDF board), the middle beam and the frame beam are arranged as shown in FIG. 3 (in FIG. 3, a vibration beam is not interposed, and the middle beam is symmetrical in the thickness direction. A sound insulation panel having a mass of 8.2 kg was prepared by interposing in a manner using an intermediate beam.

(Example 6)
A damping layer 2 (iron foil) is attached only to the face material on one side using a vinyl acetate-based hot melt adhesive, and the damping layer 2 is interposed between the face material, the frame rail, and the middle rail. A sound insulation panel with a mass of 9.9 kg was produced in the same manner as Example 5 except for the above.

(Example 7)
Using a vinyl acetate hot melt adhesive, a 10 mm thick non-woven fiber layer 2 is laminated and bonded, and on each side of the obtained 20 mm non-woven fiber layer, a 1 mm thick reinforcing layer 2 (iron plate) and A reinforcing layer 2 (iron plate) having a thickness of 3 mm was laminated and joined to produce an intermediate beam. Between the two face members 1 (MDF board), the middle beam and the frame beam are arranged as shown in FIG. 3 (in FIG. 3, the vibration beam is not interposed, and the middle beam has an asymmetric shape in the thickness direction. A sound insulation panel having a mass of 8.2 kg was prepared by interposing in a manner using a three-layer structure middle rail. The intermediate rails were alternately arranged in the same manner as in FIG. 3, but the intermediate rails and the face material were joined using a vinyl acetate hot melt adhesive on all contact surfaces.

  About the sound insulation panel obtained in Examples 4-7, the result of having measured the sound transmission loss is shown in FIG. As is apparent from the results of FIG. 10, Examples 4 and 6 having the damping layer 2 formed of iron foil are different from Examples 5 and 7 having no damping layer 2 formed of iron foil. In comparison, the sound insulation is improved. Furthermore, from a comparison between Example 4 in which the reinforcing layer is not in contact with the face material or the damping layer and Example 6 in which the reinforcing layer is in contact with the face material or the damping layer, Example 4 is shown in the frequency range 250 to 300 Hz. Although high sound insulation is shown, in general, Example 6 shows excellent sound insulation.

[Experiment 3]
As Experimental Example 3, the sound insulation panel using the middle beam with the laminated structure changed with respect to the middle beam used in Example 1 was subjected to the following Examples 8 and 9, and the influence of the laminated structure of the middle beam was examined. .

(Example 8)
After laminating two reinforcing layers 1 (wood boards) having a thickness of 11 mm on one side of the nonwoven fiber layer 1 having a thickness of 8 mm, three staples are driven from above the nonwoven fiber layer at intervals of 210 mm, thereby the nonwoven fiber layer 1. And the reinforcing layer 1 were fixed to produce an intermediate beam. Between the two face members 1 (MDF board), the middle crosspiece and the frame crosspiece are arranged in the arrangement shown in FIG. 3 (a mode in which no damping layer is interposed in FIG. 3), and the mass is 7 kg. A sound insulation panel was prepared. Note that only the contact surface between the reinforcing layer and the face material was joined to the intermediate rail and the face material using an adhesive (bond CH18).

Example 9
After laminating the non-woven fiber layer 1 having a thickness of 8 mm on both sides of the reinforcing layer 1 having a thickness of 11 mm (wood board), the staple layer and the non-woven fiber are driven by placing three staples on the non-woven fiber layer at intervals of 210 mm. Layer 1 was fixed to produce an intermediate beam. A sound insulation panel having a mass of 6.4 kg was produced in the same manner as in Example 1 by using this middle rail.

  FIG. 11 shows the results of measuring sound transmission loss for the sound insulation panels obtained in Examples 8 and 9. FIG. 11 also shows the results of Example 1 for comparison. As is apparent from the results of FIG. 11, Examples 1 and 8 in which the reinforcing layer is in contact with the face material exhibit higher sound insulation than Example 9 in which the reinforcing layer is not in contact with the face material. Furthermore, when Example 1 and Example 8 are compared, Example 1 having a three-layer structure shows high sound insulation in a low frequency range of about 100 to 300 Hz.

[Experimental Example 4]
As Experimental Example 4, the sound insulation panels having the increased number of middle bars used in Example 1 were subjected to the following Examples 10 and 11, and the influence of the number of middle bars disposed was examined.

(Example 10)
A sound insulation panel with a mass of 7.6 kg was produced in the same manner as in Example 1 except that the number of middle rails was set to 6 and arranged at equal intervals.

(Example 11)
A sound insulation panel with a mass of 8.3 kg was produced in the same manner as in Example 1 except that the number of middle rails was set to 8 and arranged at equal intervals.

  FIG. 12 shows the results of measuring the sound transmission loss for the sound insulation panels obtained in Examples 10 and 11. FIG. 12 also shows the results of Example 1 for comparison. As is clear from the results of FIG. 12, when the number of middle rails is increased to six, high sound insulation is exhibited in a high frequency range of 1000 Hz or more, and when the number is increased to eight, the frequency is about 300 to 1000 Hz. High sound insulation.

[Experimental Example 5]
As Experimental Example 5, the sound insulation panel in which the damping layer was laminated on the middle beam used in Example 1 was subjected to the following Example 12, and the influence of the damping layer on the middle beam was examined.

(Example 12)
After laminating the nonwoven fiber layer 1 having a thickness of 8 mm and the vibration damping layer 1 (asphalt base material) having a planar dimension of 840 mm × 30 mm and a thickness of 2.4 mm, a reinforcing layer having a thickness of 11 mm is formed on both surfaces of the obtained laminate. After laminating 1 (wood board), staples were driven in three places at intervals of 210 mm to fix the reinforcing layer 1, the non-woven fiber layer 1 and the damping layer 1 to produce an intermediate beam. Between the two face members 1 (MDF board), the middle rail and the frame rail (thickness 30 mm) are arranged as shown in FIG. 3 (in FIG. 3, no damping layer is interposed, and the middle rail is used in the thickness direction). A sound insulation panel having a mass of 7.7 kg was prepared by interposing and arranging in an asymmetrical form using a four-layered middle beam. In addition, although the middle crosspieces were alternately arranged in the same manner as in FIG. 3, the intermediate crosspieces and the face material were bonded using an adhesive (bond CH18) on all contact surfaces.

  FIG. 13 shows the result of measuring sound transmission loss for the sound insulation panel obtained in Example 12. FIG. 13 also shows the results of Example 1 for comparison. As is clear from the results of FIG. 13, in Example 12 in which the damping layer is laminated on the middle rail, the sound insulation is slightly improved, but the resonance peak does not change. It can be seen that the resonance peak varies depending on the weight of the face material.

[Experimental Example 6]
As Experimental Example 6, the sound insulation panel in which the vibration damping layer was laminated on the sound insulation panel of Example 8 was subjected to the following Examples 13 to 14, and the influence of the vibration damping layer was examined.

(Example 13)
The damping layer 1 (asphalt base material) is attached only to the face material on one side using an adhesive (bond CH18), and the damping layer is interposed between the face material, the frame rail, and the middle rail. A sound insulation panel with a mass of 13.3 kg was produced in the same manner as Example 8 except for the above.

(Example 14)
The same as in Example 8 except that a damping layer is bonded to each side face material using an adhesive (bond CH18), and the damping layer is interposed between the face material, the frame rail, and the middle rail. A sound insulation panel having a mass of 19.7 kg was produced.

  FIG. 14 shows the result of measurement of sound transmission loss for the sound insulation panels obtained in Examples 13 and 14. FIG. 14 also shows the results of Example 8 for comparison. As is apparent from the results of FIG. 14, Example 14 in which vibration damping layers are provided on both sides exhibits excellent sound insulation performance in the frequency range of 200 to 1000 Hz.

[Experimental Example 7]
As Experimental Example 7, the following Examples 15 to 17 were performed on the sound insulation panel using the middle rail in which the reinforcing layers were laminated on both surfaces of the nonwoven fiber layer, and the influences of the vibration damping layer and the face material were examined.

(Example 15)
Of the front and back face materials, the face material 1 (MDF board) is used as the face material on one side, and the face material 2 (paper board) is used as the face material on the other side. A sound insulation panel having a mass of 7.61 kg was produced.

(Example 16)
A sound insulation panel with a mass of 8.32 kg was produced in the same manner as in Example 1 except that the face material 2 (paper board) was used as the face material.

(Example 17)
A sound insulation panel with a mass of 6.2 kg was produced in the same manner as in Example 1 except that the face material 3 (glass board) was used as the face material.

  About the sound insulation panel obtained in Examples 15-17, the result of having measured the sound transmission loss is shown in FIG. FIG. 15 also shows the results of Example 1 for comparison. As is clear from the results of FIG. 15, Example 15 using the MDF board shows higher sound insulation performance than Example 17 using a glass board, and further, a paper board and a damping layer are laminated. Thus, the sound insulation performance is improved in a frequency range of about 200 to 500 Hz.

[Experimental Example 8]
As Experimental Example 8, with respect to the sound insulation panel using paper board as the face material for the sound insulation panels of Example 13 and Example 14, the following Examples 18 and 19 were performed, and the influence of the type of the face material was examined. .

(Example 18)
A sound insulation panel with a mass of 14.68 kg was produced in the same manner as in Example 13 except that the face material 2 (paper board) was used as the face material.

(Example 19)
A sound insulation panel having a mass of 20.93 kg was produced in the same manner as in Example 14 except that the face material 2 (paper board) was used as the face material.

  FIG. 16 shows the result of measuring sound transmission loss for the sound insulation panels obtained in Examples 18 and 19. FIG. 16 also shows the results of Examples 8 and 13 for comparison. As is apparent from the results of FIG. 16, Example 19 in which the damping layers are laminated on both sides of the paper board exhibits high sound insulation in a wide frequency range.

[Experimental Example 9]
As Experimental Example 9, the following Example 20 was performed for sound insulation of the face material.

(Example 20)
A sound insulation panel having a mass of 9.20 kg was produced by applying the damping layer 1 (asphalt base material) on a surface material on one side of the sound insulation panel obtained in Example 1 using a double-sided tape.

  FIG. 17 shows the result of measuring the sound transmission loss for the sound insulation panel obtained in Example 20. FIG. 17 also shows the results of Example 1 for comparison. As is clear from the results of FIG. 17, the sound insulation performance is improved in the frequency range of 150 to 800 Hz by laminating the damping layer.

[Experimental Example 10]
As Experimental Example 10, the following Examples 21 to 24 and Reference Examples 1 to 3 were performed on the ventilation and sound insulation of a sound insulation panel in which an opening was formed in a face material and an integrated sound absorbing material was disposed.

(Example 21)
After laminating a reinforcing layer 1 (wood board) having a thickness of 11 mm on one side of the nonwoven fiber layer 2 having a thickness of 10 mm, three staples are driven from above the nonwoven fiber layer at intervals of 210 mm to reinforce the nonwoven fiber layer 2. Layer 1 was fixed to produce an intermediate beam. The damping material 1 (asphalt base material) was affixed on one side of the face material 1 using an adhesive (bond CH18 ”) to produce a face material. Further, a rectangular opening having a width of 50 mm and a length of 700 mm was formed at an interval of 100 mm from the end of the face material.

Nonwoven fiber layer 4 molded to a thickness of 21 mm was used as a sound absorbing material. That is, the non-woven fiber layer 4 is cut to a width 5 mm smaller than the distance between the crosses so that the cross-sectional area obtained by removing the cross-sectional area of the sound absorbing material from the cross-sectional area between the crosses (the cross-sectional area of the space) is 1 cm ^2. The sound absorbing material shown in FIGS. 5 and 6 was produced by processing.

  The face material, the middle crosspiece, and the frame crosspiece are disposed with the arrangement shown in FIG. 3 (distance between the crosspieces 144 mm), and the sound absorbing material is arranged between the crosspieces with the arrangement shown in FIG. . In addition, the two face members are arranged as shown in FIG. 5 (the longitudinal direction of the openings of the two face members intersects the longitudinal direction of the middle rail, and the openings of the two face members do not face each other. Arrangement). The ventilation sound insulation panel had a mass of 21.1 kg.

(Example 22)
A ventilation sound-insulating panel was produced in the same manner as in Example 21 except that the width of the sound-absorbing material was cut to a width 30 mm smaller than the distance between the crosspieces, and the cross-sectional area of the space was 6 cm ² .

(Example 23)
A ventilation sound insulation panel was manufactured in the same manner as in Example 21 except that the width of the sound absorbing material was cut to a width 60 mm smaller than the distance between the crosspieces, and the sectional area of the space was 13 cm ² .

(Reference Example 1)
A ventilation sound-insulating panel was produced in the same manner as in Example 21 except that the width of the sound-absorbing material was cut to 95 mm smaller than the distance between the crosspieces, and the cross-sectional area of the space was 20 cm ² .

(Reference Example 2)
A ventilation sound insulation panel was produced in the same manner as in Example 21 except that the width of the sound absorbing material was cut to a width 120 mm smaller than the distance between the crosspieces, and the cross-sectional area of the space was 25 cm ² .

(Reference Example 3)
A ventilation sound insulation panel was produced in the same manner as in Example 21 except that no opening was formed in the face material.

  About the ventilation sound insulation panel obtained in Examples 21-23 and Reference Examples 1-3, the measurement result of sound transmission loss is shown in FIG. 18, and the result of measuring sound transmission loss in 500 Hz is shown in Table 5. Furthermore, Table 5 also shows the results of measuring the wind speed and ventilation volume for the ventilation sound insulation panels obtained in Examples 21 to 23 and Reference Examples 1 and 2.

  As is clear from the results of FIG. 18 and Table 5, the ventilation sound insulation panels of Examples 21 to 23 have the same degree as Reference Example 3 in which the opening is formed and the ventilation is formed, but the opening is not formed. It has a sound insulation property. On the other hand, in the ventilation sound insulation panels of Reference Examples 1 and 2, the sound insulation is greatly deteriorated because the sectional area of the space is large.

[Experimental Example 11]
As Experimental Example 11, the following Examples 24 to 26 and Reference Examples 4 to 5 were performed on the ventilation and sound insulation of a sound insulation panel in which an opening was formed in a face material and a separation type sound absorbing material was disposed.

(Example 24)
Nonwoven fiber layer 4 was used as a sound absorbing material. That is, the cross-sectional area obtained by removing the cross-sectional area of the sound absorbing material from the cross-sectional area between the crosspieces (the cross-sectional area of the space) is cut to be 0.8 mm thinner than the crosspiece thickness so that the cross-sectional area is 1 cm ² , The sound absorbing material shown in FIG. 7 was produced by dividing it into two equal parts in the thickness direction.

  The face material obtained in Example 21 and the intermediate crosspieces and frame crossings are arranged with the arrangement shown in FIG. 3 (distance 125 mm between the crosspieces), and the sound absorbing material is shown in FIG. 7 between the crosspieces. Arranged by arrangement. Further, the two face materials were arranged in the arrangement shown in FIGS. The sound-absorbing material and the face material were bonded using an adhesive (bond CH18 ”).

(Example 25)
A ventilation sound insulation panel was manufactured in the same manner as in Example 24 except that the thickness of the sound absorbing material was cut 4 mm thinner than the thickness of the crosspiece and the cross-sectional area of the space was 6 cm ² .

(Example 26)
A ventilation sound insulation panel was manufactured in the same manner as in Example 24 except that the thickness of the sound absorbing material was cut 9 mm thinner than the crosspiece and the cross-sectional area of the space was 13 cm ² .

(Reference Example 4)
A ventilation sound insulation panel was produced in the same manner as in Example 24 except that the thickness of the sound absorbing material was cut 14 mm thinner than the thickness of the crosspiece and the cross-sectional area of the space was 20 cm ² .

(Reference Example 5)
A ventilation sound insulation panel was produced in the same manner as in Example 24 except that the thickness of the sound absorbing material was cut 18 mm thinner than the thickness of the crosspiece and the cross-sectional area of the space portion was 25 cm ² .

  About the ventilation sound insulation panel obtained in Examples 24-26 and Reference Examples 4-5, the measurement result of sound transmission loss is shown in FIG. 19, and the result of measuring sound transmission loss in 500 Hz is shown in Table 6. Furthermore, Table 6 also shows the results of measuring the wind speed and the ventilation volume for the ventilation sound insulation panels obtained in Examples 24-26 and Reference Examples 4-5. 19 and Table 6 also show the results of Reference Example 3 for comparison.

  As is apparent from the results of FIG. 19 and Table 6, the ventilation sound insulation panels of Examples 24 to 26 are less air permeable than the ventilation sound insulation panels of Examples 21 to 23, but an opening is formed to allow ventilation. The sound insulation property is comparable to that of Reference Example 3 in which no opening is formed. On the other hand, in the ventilation sound insulation panels of Reference Examples 4 and 5, since the cross-sectional area of the space portion is large, the sound insulation performance is greatly reduced.

  The crosspiece of the present invention is useful for ensuring sound insulation of various panels. Specifically, the crosspiece of the present invention is used to improve the sound insulation of the panel by incorporating it into a new panel or adding it to an existing panel.

  Since the sound insulation panel of the present invention using this crosspiece has high sound absorption or sound insulation, it can be used for buildings (eg, houses, factory houses and facilities, buildings, hospitals, schools, gymnasiums, cultural halls, public halls). It can be effectively used as a sound insulation panel for use in a soundproof wall of a highway) and a vehicle (for example, a vehicle such as an automobile, an aircraft, etc.). In particular, because it is lightweight, has moderate strength, and is excellent in sound insulation, it is a partition panel, movable partition panel, wall material, ceiling used in buildings (such as houses) that require sound insulation and strength. Suitable for materials, partitions, doors, shutters, screens, folding screens, especially panels of houses, doors or doors (particularly walls or partition panels). In addition, because it has high sound absorption even in the high frequency range, construction sites, main roads or highways, airfields, pachinko shops, karaoke rooms, Internet cafes and other entertainment facilities, restaurants, etc. It is also useful as a panel for a house in the neighborhood where this occurs.

DESCRIPTION OF SYMBOLS 1 ... Bar material 1a, 11a, 12b, 13a, 13c, 14b, 25b, 35b, 45b ... Nonwoven fiber layer 1b, 11b, 12a, 12c, 13b, 14a, 14d, 35a, 45a ... Reinforcement layer 21 ... Sound insulation panel 22, 32, 42 ... first face material 23 ... first damping layer 24, 34, 44 ... frame beam 25, 35, 45 ... middle beam 26 ... second damping layer 27, 37, 47 ... first 2 face materials 31, 41 ... ventilation sound insulation panel 32a ... 1st opening part 37a ... 2nd opening part 36, 46 ... space part

Claims (10)

A first face member, a frame rail disposed in a frame shape on the four peripheral ends of the first face member, and a plurality of middle rails disposed in parallel with a space between the frames. And a second face material laminated with the first face material through the frame and the middle rail, and have a ventilation function, and the first and second face materials have first and second surfaces, respectively. A ventilation sound insulation panel in which a second opening is formed and the first opening is formed at a position different from the second opening,
Fibers wherein during crosspiece is, have a layered structure including a non-woven fibrous layer and the reinforcing layer, the non-woven fibrous layer, the fibers are entangled, including a thermal adhesive fiber under moisture, and by fusion of the thermal adhesive fiber under moisture Including a crosspiece formed of a fixed non-woven fiber structure ,
The non-woven fiber layer and the reinforcing layer of the crosspiece are disposed in parallel with the surface directions of the first and second face members,
A ventilation sound insulation panel in which the space between adjacent crosspieces has a cross-sectional area of 18 cm ² or less in a cross section perpendicular to the longitudinal direction of the crosspiece . The ventilation / sound insulation panel according to claim 1 , wherein the laminated structure of the crosspieces is a two-layer structure of a non-woven fiber layer and a reinforcing layer. The ventilation sound insulation panel according to claim 1 , wherein the laminated structure of the crosspieces is a three-layer structure in which a first reinforcing layer and a second reinforcing layer are laminated via a non-woven fiber layer. The ventilation sound insulation panel according to any one of claims 1 to 3, wherein the crosspiece is a rod having a quadrangular cross section, and the reinforcing layer is formed of a wood material or a metal material. The non-woven fiber structure further includes a composite fiber in which a plurality of resins having different heat shrinkage rates form a phase separation structure, and the composite fiber has a structure in which the composite fiber is crimped and entangled with other fibers. The ventilation sound insulation panel in any one of 1-4. The crosspiece has a two-layer structure of a non-woven fiber layer and a reinforcing layer, and the non-woven fiber layers and the reinforcing layer are alternately in contact with the first and second face materials in the plurality of crosspieces. The ventilation sound insulation panel according to any one of claims 1 to 5, wherein the ventilation sound insulation panel is disposed. The ventilation sound-insulating panel according to any one of claims 1 to 6, wherein a sound-absorbing material is disposed between adjacent bars, leaving a space for ventilation . The ventilation sound insulation panel according to any one of claims 1 to 7 , wherein a damping layer is interposed between the crosspiece and the first face material and / or the second face material. The first damping layer is interposed between the crosspiece and the first face material, and the second damping layer is interposed between the crosspiece and the second facepiece. The ventilation sound insulation panel in any one of 8 . The ventilation sound insulation panel according to claim 8 or 9, wherein the damping layer contains asphalt.

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