JP7216990B2 - soundproof material - Google Patents

Description

Application of Article 30, Paragraph 2 of the Patent Law (1) Exhibition date: October 17 and 18, 2018 (2) Exhibition name and venue: Osaka Industrial Exhibition 2018 My Dome Osaka (2-5 Honmachibashi, Chuo-ku, Osaka) ) (3) Publisher: Matsumura Kogei Co., Ltd. (4) Contents of exhibited items Matsumura Kogei Co., Ltd. exhibited the soundproofing materials invented by Kuniaki Tanaka, Satoshi Kashiwabara, and Hidenori Matsushima at the Osaka Industrial Exhibition 2018.

This invention provides a sound insulating material for preventing sound generated in a room, construction site, etc. from leaking to the outside, or conversely, preventing external sound from being transmitted to a room, etc., or for absorbing sound energy. The present invention relates to a panel-like soundproof material used as a sound absorbing material for absorbing and adjusting sound pressure.

As this type of soundproofing material, there is known a honeycomb material having a core material filled with a synthetic resin foam such as phenolic foam in each cell. (For example, see Patent Document 1 below). Phenolic resin foam is widely used as a material for soundproofing panels because it has a superior sound absorbing effect and a certain degree of self-supporting property compared to glass fiber soundproofing materials.

The soundproof material described in Patent Literature 1 forms a sandwich panel structure composed of a breathable surface material, a honeycomb material, and a non-breathable surface material. The air-permeable surface material, the non-air-permeable surface material, and the top of the honeycomb material are adhered to each other with an emulsion-based adhesive, and the cell spaces of the honeycomb material are filled with a water-absorbing open-cell rigid foam material, The open-cell rigid foam material and the wall surface of the honeycomb material are adhered with an emulsion adhesive.

The soundproofing material described in Patent Document 1 has an air-permeable surface material adhered to one end face of a honeycomb material and a non-air-permeable surface material adhered to the other end face thereof with an adhesive, and a hard foam material having open cells inside the cells of the honeycomb material. A phenolic resin foam is used for this open-cell rigid foam material.

JP 2017-107214 A

Since the synthetic resin foam may fall out from each cell of the honeycomb material, in the case of the above soundproof material, prior to the process of pressing and integrating the honeycomb material and the synthetic resin foam, the cell end faces of the honeycomb material are treated. Adhesive is applied to the surface, and during pressure integration, the adhesive is stretched and adheres to the inner wall of each cell of the honeycomb material, and this stretched adhesive joins the cells and the synthetic resin foam. It has been done to bond with.

As a soundproofing material used for soundproofing panel materials and the like, there is a demand for a soundproofing material that is lightweight and can be easily cut at the installation site. There is also a demand for a soundproof panel that can be easily manufactured in the production of soundproof panels.

The soundproofing material described in Patent Document 1 consists of an air permeable surface material, a honeycomb material, a non-air permeable surface material, and a rigid foam material with open cells, and has a complicated structure, which hinders weight reduction and ease of cutting at the installation site. It has become. In addition, in the process of pressing the honeycomb material into the interconnected-cell rigid foam material, the bonding work must be done at the same time, so it is necessary to complete the work while the adhesive dries.

The cause of these problems is the presence of honeycomb material. If a reinforcing material can be attached to at least one end face of the phenolic resin foam to reinforce it, and the sound absorption performance can be maintained, it will be lightweight. Moreover, it is possible to provide a soundproof material that can be easily cut at the place of installation.

However, phenolic resin foam is a material that is prone to plastic deformation when pressed and generates fine powder on the surface. It is very difficult to adhere the reinforcing material only to the fine powder layer on the surface of the resin foam.

The present invention has been made in view of the above problems, and is a panel-shaped soundproof material that combines a phenolic resin foam and a reinforcing material. To provide a product that is easy to cut in

This invention consists of the following aspects in order to achieve said objective.

[1] A soundproof material comprising a phenolic resin foam having interconnected cells and a resin mesh sheet attached to at least one of one surface and the other surface of the phenolic resin foam with an adhesive. a part of the thickness of the mesh sheet is substantially evenly embedded in the phenolic resin foam, and the adhesive is soaked into the communicating cells of the phenolic resin foam; .

[2] A soundproofing material in which the mesh sheet is adhered to one surface of the phenolic resin foam, and a non-porous flat sound insulating plate is adhered to the other surface with an adhesive, wherein the adhesive is the phenolic resin. The soundproofing material of [1] soaked into the open cells of the foam.

[3] The soundproofing material according to [1] or [2], wherein a reinforcing angle material is attached to the periphery of the soundproofing material in which a mesh sheet and/or a sound insulating plate is attached to the phenolic resin foam.

[4] The soundproofing material according to any one of [1] to [3], wherein a decorative sheet is attached to the surface of the mesh sheet opposite to the adhesion side.

In the soundproofing material of [1] above, the phenolic resin foam is reinforced with a resin mesh sheet adhered to at least one of one side and the other side of the phenolic resin foam with an adhesive. A portion of the thickness of the mesh sheet is substantially evenly embedded in the phenolic resin foam. Since the adhesive is soaked into the communicating cells of the phenolic resin foam, the phenolic resin foam and the mesh sheet are strongly bonded. This makes the soundproofing material easy to manufacture, lightweight, and easy to cut at the ground contact site.

In the soundproofing material of [1] above, the phenolic resin foam and the mesh sheet are firmly bonded together at the bonding stage so that part of the thickness of the mesh sheet is almost evenly embedded in the phenolic resin foam. This is because the adhesive is pressurized and the adhesive penetrates into the communicating cells of the phenolic resin foam by capillary action.

By attaching a mesh sheet, the phenolic resin foam can be made into a panel, which improves its self-standing and enables flexible usage such as installation with jigs and suspension. By sticking mesh sheets on both sides, both sides can be used as sound absorbing material, and can be cut to any size according to the place of use.

In the soundproofing material of [2] above, the mesh sheet is adhered to one surface of the phenolic resin foam, and the non-perforated flat plate sound insulating plate is adhered to the other surface. The incoming sound is absorbed in the phenolic resin foam, and the sound insulation board is attached to the other side, so the sound insulation board also reflects it, increasing the soundproofing effect.

According to the soundproofing material of [3] above, since the angle material for reinforcement is attached to the periphery of the soundproofing material in which the mesh sheet and/or the sound insulating plate are attached to the phenolic resin foam, the soundproofing material The edges are reinforced and can be used as a strong soundproof material.

According to the soundproofing material of [4] above, since the decorative sheet is attached to the opposite side of the mesh sheet to the adhesion side, the mesh sheet can be hidden from view by the decorative sheet. Designability can be improved. Various materials such as paper, film, and cloth can be used as the decorative sheet. Among them, nonwoven fabric is preferable from the viewpoint of durability, design and cost.

1 is a perspective view of a soundproof material according to a first embodiment of the invention; FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1; FIG. It is a perspective view of a sound insulation board. FIG. 5 is a perspective view of a soundproof material according to a second embodiment of the invention; FIG. 5 is a cross-sectional view taken along line VV of FIG. 4; 1 is a perspective view of a honeycomb material; FIG. FIG. 5 is a cross-sectional view of a soundproof material according to a third embodiment of the invention; 4 is a graph showing the measurement results of the reverberation room method sound absorption coefficient of the soundproofing material of Example 1. FIG.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
1 and 2 show a soundproof material of a first embodiment according to the invention. The illustrated soundproofing material (1) comprises a phenolic resin foam (10) shaped like a plate and mesh sheets (20) attached to the upper and lower surfaces of the phenolic resin foam (10). About half of the thickness of the mesh sheet (20) is pressed into the phenolic resin foam (10) and adhered thereto.

The material of the mesh sheet (20) is not particularly specified, but a general-purpose synthetic resin mesh sheet is preferable because it is easy to cut. Among synthetic resins, mesh sheets made of nylon or polyester are more preferable because of their low cost.

FIG. 2 is a cross-sectional view of Example 1 (FIG. 1), showing a state in which the phenolic resin foam (10) and the mesh sheet (20) are adhered. The adhesive (21) applied to one side of the mesh sheet (20) permeates the inside of the phenolic resin foam (10) due to capillary action, and the permeated portion becomes the adhesive permeated portion (22). there is

As the adhesive, a water-soluble emulsion-based adhesive is preferable due to the ease with which capillary action occurs. Vinyl acetate resin-based emulsion-based adhesives, ethylene/vinyl acetate copolymer resins, α-olefin (isobutene-maleic anhydride resin)-based adhesives are preferred. Adhesives, acrylic resin emulsion adhesives and styrene-butadiene rubber latex adhesives are preferred because water can be used as the solvent. Among them, vinyl acetate resin-based emulsion-type adhesives are widely used as adhesives for woodworking, and are more preferable in terms of cost and ease of handling.

About half of the thickness of the mesh sheet (20) is embedded in the phenolic resin foam (10). It can be done by putting a load on the mesh sheet (20) on the side opposite to the side on which the adhesive (21) is applied by putting it on (10). The load to be applied is preferably about 24 kg per 1 m ² . The adding method may be either a method using a weight or a method using a press machine.

FIG. 3 is a perspective view of the sound insulation plate (30). Any material can be used for the sound insulation plate as long as it blocks sound. It is preferably made of synthetic resin in order to improve cutability on site. For example, a synthetic resin sound insulating plate made of polycarbonate resin or acrylic resin is preferable.

[Second embodiment]
4 and 5 show the soundproof material of the first embodiment according to the invention. FIG. 4 is a perspective view of a soundproofing material (1) in which a mesh sheet (20) is adhered to the upper surface of a phenolic resin foam (10) and a sound insulating plate (30) is adhered to the bottom surface of the phenolic resin foam (10). is shown. The phenolic resin foam (10) and the sound insulating plate (30) are preferably bonded with the adhesive used in the first embodiment. However, since the bonding area between the sound insulating plate (30) and the phenol resin foam (10) is much wider than in the first embodiment, the sound insulating material (1) of the first embodiment cannot be manufactured. Bonding can be performed without applying the load at the time of bonding.

5 is a cross-sectional view taken along line VV of FIG. 4. FIG. The sound insulating plate (30) and the phenolic resin foam (10) are firmly adhered to each other through the adhesive permeated portion (32) exuded from the adhesive (31) interposed between them.

FIG. 6 is a perspective view of the honeycomb material (40) that was not used in the first and second embodiments. Embedding the honeycomb material in the phenolic resin foam (10) is not preferable from the viewpoint of ease of cutting the soundproofing material at the site of installation, but it is preferable to use the mesh sheet (20) or the soundproofing plate (30). If more strength is desired, it may be preferable to embed the honeycomb material (40) in the phenolic resin foam (10) so as not to hinder ease of cutting.

The honeycomb material (40) functions as a reinforcing material that enhances the strength of the phenolic resin foam (10), and has effects such as sound attenuation due to its cell structure. As the honeycomb material (40), paper is generally used. or made of synthetic resins such as polyvinyl chloride, polypropylene, and FRP.

The cross-sectional shape of the cells of the honeycomb material (40) is not particularly limited, and may be hexagonal as shown in the drawing, or may be square, triangular, or the like. Also, the size of the cells may be appropriately set according to the use of the soundproof material (1).

The soundproof material (1) of the third embodiment shown in FIG. 7 is obtained by bonding a mesh sheet (20) to the upper surface of a phenolic resin foam (10) with an adhesive (21), and using a press to form a honeycomb sheet. The material (40) is embedded inside the phenolic resin foam (10), and the sound insulating plate (30) is adhered to the lower surface of the phenolic resin foam (10) with an adhesive (31). The adhesives (21) and (31) permeate into the adhesive permeated parts (22) and (32) inside the phenolic resin foam (10) by capillary action, and the phenolic resin foam (10) and the mesh sheet ( 20) and the phenolic resin foam (10) and the sound insulation plate (30) are firmly joined.

Next, specific examples of the invention will be described, but the invention is not limited to these examples.

<Example 1>
A soundproof material (1) of the first embodiment was produced. As the phenol resin foam (10) of the soundproof material (1), an open-cell phenol foam material having a density of 21 kg/m ³ was prepared. The size was 1000 mm long, 1000 mm wide and 25 mm thick. The mesh sheet (20) was made of polyester and had a thickness of 0.5 mm, a mesh unit having a square shape of 4 mm, and a width of a side constituting the mesh unit being 0.8 mm.

As the adhesive (21), a woodworking adhesive (manufactured by Konishi Co., Ltd.), which is a vinyl acetate resin-based emulsion adhesive, was used. Water was added to this adhesive to adjust the concentration to about half. This made it easier for the adhesive component to penetrate into the open cells of the phenolic resin foam (10) due to capillary action.

The adjusted adhesive (21) was applied to one side of the mesh sheet (29), covered on one side of the phenolic resin foam (10), and a weight load of 24 kg per ^1m2 was applied from above. and crimped. The load was applied for 10 minutes, after which the weight load was removed to complete the adhesion. The mesh sheet (20) was adhered to the other side of the phenolic resin foam (10) in the same manner to complete the soundproof material (1).

<Sound absorption performance measurement test>
For Example 1 and Comparative Example, the sound absorption coefficient of the reverberation chamber method was measured at a public institution (Tottori Prefectural Industrial Technology Center) for the soundproofing material consisting only of the phenolic resin foam (10). The measurement was performed in accordance with JIS A 1409 "Method for measuring sound absorption coefficient by reverberation room method". The measurement results are shown in FIG. As can be seen from FIG. 8, with the soundproof material (1) of Example 1, a large sound absorbing effect was obtained in the range where the ⅓ octave band center frequency was 250 Hz or higher. In the region of 500 Hz or higher, the soundproofing material (1) of Example 1 exhibited a greater sound absorbing effect than the soundproofing material of the comparative example.

(1) : Soundproof material
(10): Phenolic resin foam
(20): Mesh sheet
(21): Adhesive
(22): Adhesive penetration part
(30): Sound insulation plate
(31): Adhesive
(32): Adhesive penetration part
(40): honeycomb material

Claims (4)

a phenolic resin foam having interconnected cells;
and a resin mesh sheet attached to at least one of one surface and the other surface of the phenolic resin foam with an adhesive,
Part of the thickness of the mesh sheet is substantially uniformly embedded in the phenolic resin foam,
The adhesive is a soundproofing material that has soaked into the communicating cells of the phenolic resin foam. A soundproofing material in which the mesh sheet is adhered to one surface of the phenolic resin foam and a non-porous flat plate-shaped sound insulation plate is adhered to the other surface with an adhesive,
2. The soundproofing material according to claim 1, wherein the adhesive is soaked into the communicating cells of the foam. 3. The soundproofing material according to claim 1, wherein a reinforcing angle material is attached to the periphery of the soundproofing material in which the mesh sheet and/or the sound insulating plate are attached to the phenolic resin foam. The soundproof material according to any one of claims 1 to 3, wherein a decorative sheet is attached to the surface of the mesh sheet opposite to the adhesion side.

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