JP7537105B2 - Interior materials - Google Patents

Description

The present invention relates to interior materials with sound absorbing properties.

In the past, interior materials have been proposed in which a decorative sheet made of a polyvinyl chloride resin film, glass cloth, or the like is attached to the surface of a base material made of glass wool or the like (see, for example, Patent Document 1 below). Such interior materials described in Patent Document 1 can improve sound absorption.

Japanese Patent Application Publication No. 9-207286

In spaces where the walls and floors are decorated with hard materials, such as commercial facilities and train stations, the reverberation is louder than in ordinary homes. Also, in office conference rooms, carpet tiles are mainly used for the floors, but there are multiple sound sources in a relatively small space, so the reverberation naturally becomes louder.

For this reason, it is possible to absorb sound so as to almost completely eliminate reverberation by placing a large amount of sound-absorbing material in the space described above, but eliminating reverberation would make people feel uneasy and would no longer be a comfortable space.

For this reason, the present invention aims to provide interior materials with sound-absorbing properties that can create a comfortable space.

In order to solve the above-mentioned problems, the interior material of the present invention is an interior material having sound-absorbing properties, and comprises a sound-absorbing body having sound-absorbing properties, and a surface material having a triaxial fabric provided on the surface side of the sound-absorbing body, wherein a plurality of depressions are formed in the surface side of the sound-absorbing body and the surface material so as to form an integral concave shape , and the triaxial fabric of the surface material has an area ratio of voids in the range of 5% or more and 50% or less .

The interior material of the present invention can adjust the amount of sound absorbed by the sound absorber by adjusting the area ratio of the voids in the surface material having triaxial fabric, and the shape of the depressions can adjust the angle of incidence of sound to the sound absorber, thereby adjusting the sound absorption wavelength (sound absorption frequency) of the sound absorber. Therefore, by appropriately combining the area ratio of the voids in the surface material with the shape of the depressions, it is possible to absorb sounds of the desired wavelength (frequency), and thus obtain sound absorption properties that create a comfortable space.

1 is a cross-sectional view showing a schematic configuration of a first embodiment of an interior material according to the present invention. FIG. 2 is a schematic diagram of a surface material of the interior material of FIG. 1 . FIG. 2 is a cross-sectional view showing a schematic configuration of a second embodiment of an interior material according to the present invention.

The following describes an embodiment of the interior material according to the present invention with reference to the drawings, but the present invention is not limited to the following embodiment described with reference to the drawings.

First Embodiment
A first embodiment of an interior material according to the present invention will be described with reference to FIGS.

As shown in FIG. 1, the interior material according to this embodiment is an interior material 10 having sound-absorbing properties, and includes a sound-absorbing body 11 having sound-absorbing properties, a surface material 12 having a triaxial fabric and provided on the surface side (the upper surface side in FIG. 1) of the sound-absorbing body 11, and an intermediate sheet 13 provided between the sound-absorbing body 11 and the surface material 12, and the surface side of the sound-absorbing body 11, the surface material 12, and the intermediate sheet 13 have a plurality of depressions 10a formed therein so as to form an integral concave shape.

It is preferable that the depth Ds of the recess 10a is 1 mm or more and 10 mm or less. If the depth Ds is less than 1 mm, it will be difficult to achieve sufficient sound absorption performance, which is not preferable. On the other hand, if the depth Ds exceeds 10 mm, the surface area will be too large and there is a risk that it will fall outside the non-flammable certification range, which is also not preferable.

The sound absorber 11 is in the form of a plate and contains glass wool, glass paper, felt material solidified with an inorganic adhesive, etc. Examples of inorganic adhesives include silica-based adhesives whose main component is silica, ceramic-based adhesives whose main component is ceramic, and cement-based adhesives whose main component is cement. By containing glass wool, etc., the sound absorber 11 becomes porous, and is able to exhibit great lightness and sound absorption properties.

In particular, glass wool (approximately 2 kg/ ^m2 ) is highly preferred because, although this varies slightly depending on the thickness, it has sound absorption performance of an average sound absorption rate of approximately 0.5% to 1.0% in the reverberation room method by itself.

Furthermore, when the sound absorber 11 is made of glass wool (approximately 2 kg/ ^m2 ), the thickness Ta is preferably 8 mm or more and 24 mm or less. If the thickness Ta is less than 8 mm, it is difficult to fully exhibit the sound absorbing performance (average sound absorption coefficient of 5% or more in the reverberation chamber method), which is not preferable. On the other hand, if the thickness Ta is greater than 24 mm, it is not preferable because it is easy to cause problems with light weight and non-flammability.

Furthermore, it is preferable that the thickness Ta of the sound absorber 11 is at least 3 mm greater than the depth Ds of the recess 10a (Ta ≥ Ds + 3 (mm)). (For example, when the depth Ds of the recess 10a is 10 mm, the thickness Ta of the sound absorber 11 is at least 13 mm.) This is because if it is less than 3 mm, the binder and glass fiber of the glass wool tend to crumble, making it difficult to maintain moldability, which is undesirable.

It is preferable that the sound absorber 11 is non-combustible and satisfies the following conditions in a heat generation test using a cone calorimeter tester in accordance with ISO 5660-1 and in accordance with the fire resistance test method and performance evaluation standard based on Article 2, Paragraph 9 of the Building Standards Act and Article 108-2 of the Enforcement Order of the Building Standards Act: (1) the total heat generation (MJ/ ^m2 ) for 20 minutes after heating begins is 4 MJ/ ^m2 or less, (2) the maximum heat generation rate for 20 minutes after heating begins does not exceed 200 kW/ ^m2 for 10 seconds or more, and (3) there are no cracks or holes that are harmful to fire prevention that penetrate to the back surface for 20 minutes after heating begins.

The sound absorbing body 11 has such non-flammability, which allows for a margin in the overall heat generation of the interior material 10, so that while imparting non-flammability to the interior material 10, it is possible to apply decoration to the surface material 12, thereby enhancing the design of the interior material 10.

As shown in Figures 1 and 2, the surface material 12 includes a triaxial fabric in which glass fiber threads 12a are woven in three axial directions so as to have voids 12b penetrating between one side and the other side, and the area ratio of the voids 12b is adjusted to a range of 5% to 50%.

The triaxial fabric is preferably 100 μm to 1 mm thick and 500 g/ ^m2 or less in weight reduction. The surface material 12 is highly rigid because the glass fibers of the threads 12a of the fabric are impregnated with resin and hardened. Examples of the impregnated resin include thermoplastic resin, thermosetting resin, and ultraviolet-curable resin.

Examples of the thermoplastic resins include polyester resins such as polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN) resin, and liquid crystal polyester resin; polyolefin resins such as polyethylene (PE) resin, polypropylene (PP) resin, and polybutylene resin; styrene-based resins; polyoxymethylene (POM) resin, polyamide (PA) resin, polycarbonate (PC) resin, polymethylene methacrylate (PMMA) resin, polyvinyl chloride (PVC) resin, polyphenylene sulfide (PPS) resin, polyphenylene ether (PPE) resin, modified PPE resin, thermoplastic polyimide (PI) resin, and polyamide-imide (PAI). Resins, polyetherimide (PEI) resins, polysulfone (PSU) resins, modified PSU resins, polyethersulfone (PES) resins, polyketone (PK) resins, polyetherketone (PEK) resins, polyetheretherketone (PEEK) resins, polyetherketoneketone (PEKK) resins, polyarylate (PAR) resins, polyethernitrile (PEN) resins, thermoplastic phenolic resins, phenoxy resins, fluorine-based resins such as polytetrafluoroethylene resins, and further, thermoplastic elastomers such as polystyrene resins, polyolefin resins, polyurethane resins, polyester resins, polyamide resins, polybutadiene resins, polyisoprene resins, and fluorine-based resins, as well as copolymers, modified products, and resins made by blending two or more of these resins.

Examples of the thermosetting resin include phenolic resin (PF), epoxy resin (EP), melamine resin (MF), urea resin (UF), unsaturated polyester resin (UP), alkyd resin, polyurethane (PUR), thermosetting polyimide (PI), etc.

Examples of the UV-curable resin include acrylic and epoxy resins.

As shown in FIG. 1, the intermediate sheet 13 is arranged to cover the sound absorber 11 and contains a glass nonwoven fabric having a thickness and density that satisfy the requirements for noncombustibility and sound absorption properties.

In addition, between the sound absorber 11 and the surface material 12, i.e., between the sound absorber 11 and the intermediate sheet 13 and between the intermediate sheet 13 and the surface material 12, there is an adhesive layer (not shown) that bonds them together.

Examples of the adhesive layer include a hot melt adhesive with a solid content of 100%, a moisture-curing adhesive with a solid content of 100% (e.g., polyurethane (PUR) resin), a high-viscosity rubber adhesive, and a high-viscosity urethane resin adhesive. Examples of hot melt adhesives include ethylene-vinyl acetate copolymer resin (EVA resin), polyamide resin, etc.

When the above-mentioned adhesive is applied to the adhesive layer, it is highly preferable because it prevents the adhesive from penetrating into the pores of the sound absorber 11, the surface material 12, and the intermediate sheet 13, and into the gaps 12b of the surface material 12, thereby preventing a decrease in the adhesive strength between the sound absorber 11, the intermediate sheet 13, and the surface material 12. Note that it is preferable to use a high-viscosity rubber-based adhesive or a high-viscosity urethane resin-based adhesive with a viscosity of 40 Pa·s or more, more preferably 50 Pa·s or more.

A method for manufacturing the interior material 10 according to this embodiment will now be described.
First, the above-mentioned resin (e.g., a thermosetting resin) is dissolved or dispersed in a solvent such as water to prepare an impregnation liquid, and the surface material 12 is immersed in the impregnation liquid to impregnate the resin between the glass fibers of the yarns 12a of the fabric of the surface material 12.

Examples of the resin impregnation method include immersing the sheet-like surface material 12 directly in the impregnation liquid in a container, or running a web-like surface material between a pair of rolls to which the impregnation liquid is applied to impregnate the surface material with the impregnation liquid, and then cutting the web.

Next, on the surface of the sound absorber 11 (top surface in FIG. 1), a sheet-shaped adhesive layer (e.g., hot melt adhesive), an intermediate sheet 13, a mesh-shaped adhesive layer (e.g., hot melt adhesive), and a surface material 12 impregnated with resin are laminated in this order.

Next, a mold having multiple convex shapes is pressed against the surface material 12 while being heated (for example, at about 100°C for about 30 seconds) so that the surface side of the sound absorber 11, the surface material 12, and the intermediate sheet 13 form an integrated concave shape. This causes the resin to harden and the adhesive to melt, hardening the surface material 12 while bonding the sound absorber 11, the intermediate sheet 13, and the surface material 12 with the adhesive layer, resulting in an interior material 10 having multiple depressions 10a formed to form an integrated concave shape.

The sound absorber 11 and intermediate sheet 13 are flexible, so they easily return to their original shape even when pressed with a convex mold. On the other hand, the surface material 12 is impregnated with resin, so when it is heated while being pressed with a convex mold, it hardens into a shape that conforms to the shape of the mold and can continue to maintain that shape. This allows the interior material 10 to maintain the shape with the recess 10a.

In addition, if the surface material is made of a biaxial (warp and weft) fabric, the directionality is vertical and horizontal, so when the resin is impregnated and cured, it tends to bend vertically or horizontally. In contrast, since the surface material 12 is made of a triaxial (axial thread, right-up bias thread, left-up bias thread) fabric, the directionality is diagonal, so it can maintain its rigidity when the resin is impregnated and cured.

The interior material 10 obtained in this manner can adjust the amount of sound absorbed by the sound absorber 11 by adjusting the area ratio of the voids 12b in the surface material 12, and the shape of the recesses 10a (e.g., the inclination angle, etc.) can be used to adjust the angle of incidence of sound on the sound absorber 11, thereby adjusting the sound absorption wavelength (sound absorption frequency) of the sound absorber 11.

Specifically, for example, when the width W of the glass fiber threads 12a is 4 mm and the weave angle θ is 60°, the area ratio of the voids 12b in the surface material 12 can be approximately 30%. In this case, if the width W of the threads 12a is reduced or the weave angle θ is increased, the area ratio of the voids 12b in the surface material 12 can be increased. On the other hand, if the width W of the threads 12a is increased or the weave angle θ is reduced, the area ratio of the voids 12b in the surface material 12 can be reduced.

In this way, by appropriately combining the area ratio of the voids 12b of the surface material 12 (5% to 50%) and the shape of the recesses 10a, it is possible to absorb sound of the desired wavelength (frequency).

Specifically, a man's speaking voice generally has a frequency of around 500 Hz, a woman's speaking voice has a frequency of 1000 Hz, and sounds that people find unpleasant are generally around 2000-4000 Hz. Therefore, the sound absorption frequency is adjusted so that sounds that people find unpleasant (2000-4000 Hz) are primarily absorbed, and noise that people do not find unpleasant (white noise) is left in the space with almost no absorption.

Therefore, the interior material 10 according to this embodiment has sound-absorbing properties that create a comfortable space.

In addition, since the sound absorber 11 (approximately 2 kg/ ^m2 ) and the surface material 12 (500 g/ ^m2 or less) are lightweight, they can be used not only as wall materials but also as ceiling materials.

In this case, the rectangular frame can hold the four sides of the interior material 10 and suspend it, and the surface material 12 can be molded and hardened. For example, if a groove for fitting the frame is formed in the center of the interior material 10 and the center of the interior material 10 can be held and suspended by the frame, the number of frames can be reduced. In addition, since it is possible to mold it into a curved shape or a shape with a partial step, it can also be used as a ceiling material for a dome-shaped ceiling or a ceiling with steps such as beams.

Second Embodiment
A second embodiment of the interior material according to the present invention will be described with reference to Fig. 3. However, for parts similar to those described in the above embodiment, the same reference numerals as those used in the above embodiment are used, and descriptions that overlap with the above embodiment will be omitted.

As shown in FIG. 3, the interior material according to this embodiment is an interior material 20 having sound absorbing properties, and includes a sound absorbing body 21 having sound absorbing properties, a surface material 12 having a triaxial fabric provided on the surface side (the upper surface side in FIG. 3) of the sound absorbing body 21, and an intermediate sheet 13 provided between the sound absorbing body 21 and the surface material 12, and multiple depressions 10a are formed so that the surface side of the sound absorbing body 21, the surface material 12, and the intermediate sheet 13 form an integrated concave shape.

The sound absorber 21 is a sound absorbing structure that has multiple hollow sound absorbing chambers 21A formed therein. The sound absorber 21 is provided with a back panel 21a that is arranged to face the surface material 12, multiple wall panels 21b that are arranged between the surface material 12 and the back panel 21a and connect the intermediate sheet 13 and the back panel 21a, and multiple partition panels 21c that are arranged between adjacent wall panels 21b and connect the adjacent wall panels 21b and the back panel 21a and the surface material 12.

The back panel 21a is large enough to face the entire surface area of the surface material 12 and the intermediate sheet 13. The base end side (lower end side in FIG. 3) of the wall panel 21b is erected vertically over the entire length of the back panel 21a in the direction perpendicular to the paper surface in FIG. 3, and the tip end side (upper end side in FIG. 3) is fixed to the recessed portion 20a of the surface material 12 and the intermediate sheet 13. A plurality of partition panels 21c are arranged at regular intervals along the longitudinal direction of the wall panel 21b (perpendicular to the paper surface in FIG. 3).

The back panel 21a, wall panels 21b, and partition panels 21c are made of a non-flammable and lightweight material (for example, Dailite (registered trademark) manufactured by Daiken Corporation or Megaboard (registered trademark) manufactured by MF Corporation), and preferably have a thickness of 3 mm to 6 mm. If the thickness is less than 3 mm, it is not preferable because the rigidity is low and the material is easily bent, making it difficult to form a structure. On the other hand, if the thickness exceeds 6 mm, the amount of heat generated increases, which makes it easy for problems with non-flammability to arise, and this is also not preferable.

In addition, it is preferable that the sound absorber 21 is non-combustible and satisfies the following conditions in a heat generation test using a cone calorimeter tester in accordance with ISO 5660-1 and in accordance with the fire resistance test method and performance evaluation standard based on Article 2, Paragraph 9 of the Building Standards Act and Article 108-2 of the Enforcement Order of the Building Standards Act: (1) the total heat generation (MJ/ ^m2 ) for 20 minutes after heating begins is 4 MJ/ ^m2 or less, (2) the maximum heat generation rate for 20 minutes after heating begins does not exceed 200 kW/ ^m2 for 10 seconds or more, and (3) there are no cracks or holes that penetrate to the back surface that are harmful to fire prevention for 20 minutes after heating begins.

In the interior material 20 according to this embodiment, similar to the above-mentioned embodiment, the intermediate sheet 13, a mesh-shaped adhesive layer (e.g., hot melt adhesive), and the surface material 12 impregnated with resin are laminated, heated (e.g., around 100°C for around 30 seconds) while pressing a mold to form the recesses 20a, and then the wall panel 21b of the sound absorber 21 is fixed to the recesses 20a of the surface material 12 and the intermediate sheet 13 with adhesive or screws, etc., to obtain the interior material 20 according to this embodiment.

In the interior material 20 thus obtained, as in the case of the above-mentioned embodiment, the amount of sound absorbed by the sound absorber 21 can be adjusted by adjusting the area ratio of the voids 12b in the surface material 12, and the sound absorption wavelength (sound absorption frequency) of the sound absorber 21 can be adjusted by adjusting the angle of incidence of sound to the sound absorber 21 by adjusting the shape of the recesses 20a (e.g., the inclination angle, etc.). Furthermore, the sound absorption performance can be adjusted by the spatial size of the sound absorption chamber 21A of the sound absorber 21 (e.g., the spacing between the partition plates 21c).

Specifically, for example, by setting the thickness of the back panel 21a, wall panel 21b, and partition panel 21c to 3 mm, and the length between opposing wall panels 21b, the length between opposing partition panels 21c, and the height of wall panel 21b to 15 mm, the sound absorbed in the sound absorbing chamber 21A can be effectively scattered, enhancing the sound absorbing effect.

Therefore, the interior material 20 according to this embodiment can not only obtain the same effect as the previously described embodiment, but also absorbs sound more efficiently than the previously described embodiment.

Other Embodiments
In the above-mentioned embodiment, the interior materials 10, 20 are described in which an adhesive is provided between the sound absorber 11, 21 and the intermediate sheet 13, and between the intermediate sheet 13 and the surface material 12, to form adhesive layers, but the present invention is not limited to this. As another embodiment, for example, it is possible to omit the adhesive and use a resin impregnated in the surface material 12 to bond the sound absorber 11, 21 and the surface material 12 to each other, thereby forming an interior material.

In the above-mentioned embodiment, the interior materials 10 and 20 are described as having the surface material 12 hardened by the resin impregnated in the surface material 12, but the present invention is not limited to this. As another embodiment, for example, it is possible to use a surface material that is not impregnated with resin, and provide an adhesive between the sound absorber 11, 21 and the surface material to form an adhesive layer, thereby forming an interior material in which the surface material is hardened by the adhesive.

In the above-described embodiment, the interior materials 10, 20 are described as having an intermediate sheet 13 between the sound absorber 11, 21 and the surface material 12, but the present invention is not limited to this. As another embodiment, for example, it is possible to use an interior material in which the intermediate sheet 13 is omitted.

In the above-described embodiment, a decorative layer can be further provided on the surface of the surface material 12 to provide an interior material with enhanced design. The decorative layer is a layer formed by applying printing ink. Examples of printing ink include inorganic inks and organic inks. Examples of printing methods include inkjet printing, hot-dip dipping, and silk printing. For example, inkjet printing is suitable for expressing a variety of gradations. Also, the hot-dip dipping method is suitable for expressing a single color. Examples of printing ink curing methods include UV curing and heat curing.

For example, such interior materials can be obtained by attaching a back sheet to the back surface of a surface material to prevent ink from bleeding through during printing, applying ink to the surface of the surface material by inkjet printing or the like to form a decorative layer, and then peeling the back sheet off of the surface material, and then carrying out the same process as in the above-mentioned embodiment.

It is preferable that the adhesive strength of the back sheet is 2.5 N/25 mm or more and 3.5 N/25 mm or less. If the adhesive strength is less than 2.5 N/25 mm, the adhesive strength is too weak and the back sheet will peel off easily, which is not preferable. On the other hand, if the adhesive strength exceeds 3.5 N/25 mm, the edges of the surface material may fray when the back sheet is peeled off after printing is completed, which is not preferable.

In addition, in the above-mentioned embodiment, it is also possible to make the interior material by further providing an uneven shape (pattern) on the surface of the surface material. By providing an additional uneven shape on the inner surface of the mold used in the above-mentioned embodiment, such an interior material can be easily manufactured, and at the same time, the design can be improved and further sound absorbing properties can be achieved.

The interior material of the present invention has sound-absorbing properties that create a comfortable space, and can be used to great advantage in a variety of industries, including the construction industry.

REFERENCE SIGNS LIST 10 Interior material 10a Depression 11 Sound absorber 12 Surface material 12a Thread 12b Void 13 Intermediate sheet 20 Interior material 20a Depression 21 Sound absorber 21A Sound absorbing chamber 21a Back panel 21b Wall panel 21c Partition panel

Claims (11)

An interior material having sound absorbing properties,
A sound absorbing body having sound absorbing properties;
A surface material having a triaxial fabric provided on a surface side of the sound absorber;
Equipped with
A surface side of the sound absorbing body and the surface material are formed with a plurality of recesses so as to form an integral concave shape,
The interior material, characterized in that the triaxial woven fabric of the surface material has an area ratio of voids in the range of 5% to 50%. 2. The interior material according to claim 1, wherein the fibers of the triaxial fabric are hardened by a resin. 3. The interior material according to claim 1, wherein the triaxial woven fabric contains glass fibers. The interior material according to any one of claims 1 to 3, further comprising an intermediate sheet provided between the sound absorbing body and the surface material. 5. The interior material according to claim 4, wherein the intermediate sheet includes a glass nonwoven fabric. 6. The interior material according to claim 1, further comprising an adhesive layer interposed between the sound absorbing body and the surface material. 7. The interior material according to claim 6, wherein the adhesive layer contains at least one of a hot melt adhesive having a solid content of 100%, a moisture-curing adhesive having a solid content of 100%, a rubber-based adhesive having a viscosity of 40 Pa·s or more, and a urethane resin-based adhesive having a viscosity of 40 Pa·s or more. The interior material according to any one of claims 1 to 7, wherein the recess has a depth of 1 mm or more and 10 mm or less. The interior material according to any one of claims 1 to 8, wherein the sound absorbing body is in the form of a plate containing glass wool. 10. The interior material according to claim 9, wherein the sound absorbing body has a thickness of 8 mm to 24 mm, and is at least 3 mm greater than the depth of the recess. 9. The interior material according to claim 1, wherein the sound absorbing body is a sound absorbing structure having a plurality of hollow sound absorbing chambers.

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