JPH0592441A - Sound-insulating panel - Google Patents

Abstract

PURPOSE:To obtain a sound-insulating panel having a simple structure, simple to produce and requiring no shape retaining material especially at the time of use because of its rigidity. CONSTITUTION:A plate-shaped part 2 and many hollow body parts 3 protruding from the single surface or both surfaces of the plate-shaped part 2 and opened at the leading ends thereof are integrally molded from a resin and at least the plate-shaped part 2 is molded using a fiber reinforced resin. As the resin, nylon or a cyclopentadiene resin molded by reactive injection molding and excellent in shock absorbing properties is used.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound insulating plate and a method for manufacturing the same, and is mainly suitable as a sound insulating material for houses and various structures, a sound insulating wall for roads and railway tracks, and a sound insulating material for ships, automobiles, and railway vehicles. Used in particular, the rigidity of the sound insulation plate is improved by using fiber reinforced resin, and the structure of the structure is simplified by integrally molding the plate-shaped support part, which is responsible for rigidity, and the hollow body part, which is responsible for sound insulation. It is a thing.

[0002]

2. Description of the Related Art Conventionally, as this type of sound insulation plate, a sound insulation material such as blaster board or asbestos board is attached to one side of a fiber material such as glass wool or rock wool, or the above sound insulation material is formed into a foam material such as polyurethane foam. The one that is pasted is provided.

In the above-described conventional sound insulation plate, since the rigidity of the fiber material and the foam material is low, the rigidity of the sound insulation plate itself is insufficient. As a result, the sound insulation plate is shaped by the frame and attached to the structural wall. ..

In order to make up for the lack of rigidity, a sound insulation wall has been proposed in which a sound insulation material made of plywood, blaster board, asbestos board or the like is attached to one side surface of the honeycomb core material, and the other side surface of the honeycomb core material is attached to the wall surface. .. (Jpn. Pat. Appln. No. 3-128484)

[0005]

Among the conventional sound insulating plates described above, in the sound insulating plate, the sound insulating portion made of a fiber material or foam material and the plate-shaped support portion such as a blaster board are made of different materials. The sound insulating material requires a step of adhering a fiber material or a foam material to a sound insulating material such as a blaster board when forming the sound insulating material itself, and as described above, the sound insulating material itself has a low rigidity.

Further, when the sound insulation plate is attached to a structural wall for use, first, a frame-shaped crosspiece is provided, and then,
It is necessary to assemble a sound insulating plate to the crosspiece and then to attach it to the structural wall, which increases the number of steps and the number of necessary parts.

Further, when the sound insulation material is attached to the honeycomb core material, which will be described later, another material is used and there is a drawback that an attaching step is required. Moreover, since the sound insulating plate has a sound insulating material such as plywood or a blaster board disposed on the surface side, it has a drawback that the sound insulating property is inferior.

The present invention is intended to solve the above-mentioned drawbacks by integrally forming a portion having a sound insulating property and a portion having a supporting rigidity with a resin, and a fiber reinforced resin in a supporting portion. It does not provide a sound insulation plate that has improved rigidity and can be attached to a structural wall without the need for a shape-retaining means that was conventionally required, and that also has excellent sound insulation performance. It is what

[0009]

That is, according to the present invention, there are provided a plate-like portion for supporting rigidity and a hollow body portion for projecting from one or both surfaces thereof and for opening a plurality of sound-insulating portions. A sound insulating plate integrally formed of resin is provided.

The above-mentioned resin sound insulation plate is a reaction injection molding method.
It is preferable to use a nylon resin or a cyclopentadiene resin, which is molded by (hereinafter abbreviated as RIM method) and has excellent impact absorption. In addition, in order to eliminate the need for shape retention made of crosspieces at the time of use, the resin is molded with a resin having excellent impact absorption as described above, and at least the plate-shaped portion has fibers made of continuous fibers and / or long fibers. It is preferable to fill the reinforcing material to obtain a fiber reinforced resin.

Further, from the viewpoint of improving rigidity as a whole, it is preferable to mold the whole body including the hollow body portion with a fiber reinforced resin. In this case, it is preferable to arrange a large number of hollow body portions densely. Since it is desirable in terms of function, the wall thickness of the hollow body portion is set thin. As described above, it is preferable to use the above-mentioned RIM molding in which the viscosity of the raw material is low and the resin is penetrated into the fiber in order to mold the hollow body portion from a thin fiber-reinforced resin.

In order to improve the sound insulation performance, it is preferable that the hollow body portion has a height higher than the maximum length of the portion in contact with the plate-like portion so as to protrude from the plate-like portion. Moreover, it is preferable to make the area of the tip opening narrower than the area of the portion in contact with the plate-shaped portion.

The shape of the hollow body is, specifically, a cylindrical shape with one end closed by a plate-like portion and an opening at the other end, a rectangular tube shape,
It may have a tubular shape such as a conical shape and all have the same tubular shape, or may have tubular shapes different from each other. It is preferable that the cross-sectional shapes of the hollow body portions are not the same, and if the cross-sectional shape is as random as possible, the frequency can be cut off in a wide band. Further, the hollow body portions are preferably arranged densely as described above, but they may be spaced apart or unevenly distributed depending on the use place.

Continuous fibers used for the above fiber reinforced resin and /
Alternatively, as the fiber reinforcement of the long fiber, carbon fiber, glass fiber, aramid fiber, silicon carbide fiber, steel fiber, amorphous metal fiber, organic fiber and / or a mixture thereof is used. Further, a non-woven fabric of the above fiber is also used, if necessary.

When the resin used in the above reaction injection molding method (including resin transfer molding which is a kind of the reaction injection molding method and has a delayed reaction time) is, for example, RIM nylon, a polymerization catalyst and a polymerization start are introduced in a mold. Molten lactams containing an agent are injected, and this is heated to form a polyamide polymerized by the monomer casting method.

The ω-lactams which are the above-mentioned monomers include α-pyrrolidone, α-piperidone, ω-enanthlactam, ε-caprolactam, ω-caprylolactam,
ω-pelargonolactam, ω-decanolactam, ω-undecanolactam, ω-laurolactam, c-alkyl-substituted-ω-lactams thereof, and mixtures of two or more of these ω-lactams. Also,
The ω-lactam can optionally contain an improving component (soft component). The soft component is a compound having a functional group that reacts with the initiator used in the molecule and has a low Tg, and a polyether or liquid polybutadiene having a normal functional group is used.

Commercially available raw materials used as the above-mentioned ω-lactams include UBE nylon (U manufactured by Ube Industries, Ltd.).
X-21) etc. It is composed of an A component consisting of an alkali catalyst and caprolactam, a prepolymer containing a soft component and a B component consisting of caprolactam.

As the above-mentioned polymerization catalyst, sodium hydride is preferable, but other known .omega.-lactam polymerization catalysts such as sodium, potassium and lithium hydride can be used. The amount added is 0 for ω-lactam.
The range of 1-0.5 mol% is preferable.

As the polymerization initiator (activator), N-
Acetyl-ε-caprolactam is used, but other triallyl isocyanurates, N-substituted ethyleneimine derivatives, 1.1′-carbonylbisaziridine, oxazoline derivatives, 2- (N-phenylbenzimidoyl) acetanilide, 2- Compounds such as (N-phenylbenzimidoyl) acetanilide, 2-N-morpholino-cyclohexene-1.3-dicarboxanilide, and known isocyanates and carbodiimides can be used. The addition amount of the above-mentioned polymerization initiator is preferably within the range of 0.05 to 1.0 mol% with respect to the amount of ω-lactam.

When a cyclopentadiene resin is used as the matrix resin, dicyclopentadiene may be used as the polymerizable monomer for the cyclopentadiene resin.
Dihydrodicyclopentadiene, tricyclopentadiene, tetracyclopentadiene, cyclopentadiene-
A methylcyclopentadiene co-duplex or the like is used.

As the polymerization catalyst for the cyclopentadiene resin, halides such as tungsten, molybdenum and tantalum, oxyhalides, oxides, organic ammonium salts and the like are preferably used. As the polymerization initiator, an organometallic compound centered on an alkylated compound of a metal of Group I to Group III of the periodic table, an oxygen-containing compound such as alcohol or phenol, and the like are preferably used.

Furthermore, since the polymerization reaction of the solution containing the above-mentioned polymerization catalyst and activator (polymerization initiator) is initiated very quickly, curing may occur before the solution sufficiently flows into the molding die. A monoether and / or monoester of a glycol compound selected from alkylene glycol and polyalkylene glycol is preferably used as the activity modifier. When injecting into a mold, the mold temperature is usually set in the range of 40 to 130 ° C.
It is preferable to carry out the polymerization reaction for 5 minutes.

In injection molding into the above mold, the mold temperature is usually in the range of 40 to 130 ° C., and the polymerization reaction is usually carried out for 1 to 5 minutes.

In addition, an internal pressure holding body is arranged as a core of the hollow body portion during molding, and the core is flexible as long as the core is flexible by injecting air or the like. well,
A tube-shaped or bag-shaped material such as nylon, cellophane, rubber, polyester, polyetherketone is used.

[0025]

The sound-insulating plate made of the above nylon or cyclopentadiene resin can impart rigidity and sound-insulating property to the sound-insulating plate because these resins have shock absorption resistance and vibration damping characteristics. In particular, since at least the plate-like portion serving as the supporting portion is molded with the fiber-reinforced resin reinforced with the fiber reinforcing material including continuous fibers and / or long fibers, it is possible to enhance the rigidity by the mechanical properties of these fibers. I can. Therefore, it is possible to eliminate the shape-maintaining bar which is required in the case of a sound insulating plate formed by pasting a supporting plate such as a blaster board of a conventional fiber material or foam material.

Further, in order to integrally form the plate-like portion serving as the support portion and the hollow body portion for sound insulation, the sound insulation plate itself can be easily formed and the rigidity can be improved as compared with the case where separate members are attached. Can be improved.

In particular, the outer shape, the cross-sectional shape of the shape of the hollow body,
Since the arrangement state can be designed arbitrarily, it is possible to provide sound insulation characteristics according to the installation location.

[0028]

Embodiments of the present invention will now be described in detail with reference to the drawings. 1 and 2 show a first embodiment according to the present invention, in which a sound insulating plate 1 is a plate member 2 for supporting the rigidity.
And a hollow body portion 3 that is responsible for sound insulation.

The plate-like portion 2 has a flat plate shape, and cylindrical hollow body portions 3 are densely arranged from one surface of the plate-like portion 2 so as to project at right angles to the plate-like portion 2. A large number of hollow body parts 3 have a connecting surface 3a with the plate-like part 2 side closed by the plate-like part 2, and the other end on the protruding side is an open end 3b.

The hollow bodies 3 have the same outer shape, and the outer diameter D1 of the connecting surface 3a with the plate portion 2 is set to be smaller than the height H in the direction perpendicular to the plate portion 2. (D1
<H) Further, as shown in FIG. 2, the hollow body portion 3 has the same outer diameter (D1) in the height direction, but the inner diameter is larger than the inner diameter (D2-1) of the connecting surface 3a and the open end 3b. Inner diameter (D2-2)
It is set to gradually decrease over time. That is, the hollow body portion 3
The wall thickness W is gradually increased toward the opening end 3b. In this way, the shape of the hollow body portion 3 is set such that the area of the opening surface at the tip is narrower than the area of the portion in contact with the plate-like body 2. I am changing. That is, the shape of the void 4 of the hollow body portion 3 is changed.

In the first embodiment, the plate-shaped portion 2 has a wall thickness of 5 mm, and the hollow body 3 has an outer diameter D1 of 15 mm and a height H of 20 mm.
The wall thickness is 0.5mm at the thinnest part (connection part with plate part).
I am trying. Also, the distance between the closely arranged hollow body portions 3 is about 2 mm.

The plate-like portion 2 is filled with a glass continuous strand mat 5 and one layer of carbon fiber cloth 6 as a fiber reinforcing material, and the plate-like portion 2 and the hollow body portion 3 are filled with RIM nylon 7. Are integrally molded by. That is, the plate-like portion 2 is formed of a fiber reinforced resin using the glass continuous strand mat 5 and the carbon fiber cloth 6 as a reinforcing material and RIM nylon 7 as a matrix resin,
The hollow body portion 3 is formed only from RIM nylon 7 which is not reinforced with fibers.

As shown in FIG. 3, the manufacture of the sound insulation plate 1 is as follows.
Using a mold composed of upper and lower molds 10 and 11, a glass continuous strand mat 5 is placed in advance inside the molding cavity 11a of the plate-like portion 2, and 1 is placed on the glass continuous strand mat.
The layers of carbon fiber cloth 6 are arranged. On the other hand, in the upper mold 10, the molding cavities 10a of the hollow body portion 3 are arranged in parallel so as to be continuous with the cavities 10a of the lower mold 11, and the core 12 is arranged in each cavity 10a.
The core 12 is made of a bag-shaped elastic body and is filled with air to have a shape as shown in FIG. That is, the core 12 is inserted in the cavity 10a in a flexible state with air removed, and then air is introduced to expand the core 12, so that the void 4 of the hollow body 3 can be formed. I am trying.

The mold is heated to 150 ° C. while the fiber reinforcing material and the core are arranged, and the insides of the cavities 10a and 11a are depressurized.

From the inlet 13 into the cavity,
RIM containing a polymerization catalyst and a polymerization initiator and melted at 90 ° C.
Inject nylon (Ube Industries UX-21). Specifically, the required amount of RIM nylon was divided into two containers, a polymerization catalyst was added to one, and a polymerization initiator and an activity modifier were added to the other to prepare two types of stable reaction solutions. is doing. The two types of reaction solutions are instantaneously mixed by a mixing head of a two-liquid reaction injection molding apparatus, and the mixed solution is immediately injected into the cavity of the mold.

The mixed liquid injected into the cavity causes a reaction while impregnating the fiber reinforcing material previously arranged in the cavity. Polymerization is completed in 2 minutes, the mold is opened, and the molded sound insulating plate 1 is taken out.

In the first embodiment, each hollow body portion 3
The shapes of the cavities 10a for forming the molds are the same, and the hollow bodies 3 having different cross-sectional shapes can be formed by changing the outer shape of the core 12 arranged in each of the cavities 10a. Therefore, there is an advantage that the cavity shape of the mold can be simplified.

FIGS. 4 and 5 show a sound insulation board according to the second embodiment of the present invention. The hollow body portion 3 of the sound insulating plate 1 of the second embodiment has a trapezoidal conical shape, and the wall thickness W thereof makes the connecting surface 3a with the plate portion 2 and the opening end 3b constant. The distance between the hollow body portions 3 is about 5 mm, and the hollow body portions 3 are arranged with a distance larger than that in the first embodiment. The other conditions of the hollow body portion 3 are the same as those in the first embodiment. That is, in the hollow body portion 3 of the second embodiment, the wall thickness W
Is 0.5 mm and the diameter (outer diameter) on the connecting surface 3a side is 1
0 mm, the diameter (outer diameter) of the open end 3b is 8 mm, and the height H is 1
It is set to 5 mm. The thickness of the plate-shaped portion 2 is 3 mm.

As described above, in the second embodiment, the thickness of the plate-like portion 2 is thinner than that in the first embodiment, so that the plate-like portion 2 is reinforced only by the glass continuous strand mat 5. There is.

The sound insulation plate of the second embodiment is also formed of RIM nylon, and its forming method is the same as that of the first embodiment, so the description thereof will be omitted.

FIG. 6 and FIG. 7 show the sound insulation plate of the third embodiment. Also in the third embodiment, the hollow body portion 3 having a tip opening is provided on one surface of the plate-like portion 2 so as to be densely projected as in the first embodiment. In the first and second embodiments, the hollow body portion 3 has the same outer shape, but the hollow body portion 3 of the third embodiment is made of another kind of tubular portion as shown.

That is, the hollow body portion 3 is composed of a cylindrical portion 3-1, a trapezoidal conical portion 3-2, a polygonal tubular portion 3-3, and a trapezoidal pyramid portion 3-4, and a height H of these tubular portions. Is also random. However, in all cases, the height H is made larger than the condition of the hollow body portion 3 described in the first embodiment, that is, the maximum length of the connecting surface 3a with the plate portion 2 and the opening area on the plate portion 2 side. The opening area of the tip open end 3b is set narrower. in this way,
Since the hollow bodies 3 having other types of cross-sectional shapes are provided, the wall thickness W of these hollow bodies 3 is constant,
Even if the wall thickness is constant, there is a sound insulation effect in a wide frequency band.

In the sound insulating plate 1 of the third embodiment, the thickness of the plate-like portion 2 is 5 mm, the thickness of the hollow body portion 3 is 0.5 mm, and the diameter is 8-2.
The height is set to 5 mm and the height is set to 8 to 30 mm.

In addition to the glass continuous strand mat 5, two layers of aramid fiber woven fabric 21 and one layer of steel fiber woven fabric 22 are laminated on the plate-like portion 2 of the sound insulating plate 1 of the third embodiment. It is used as a fiber reinforcement. Further, as the matrix resin, the cyclopentadiene resin 23 produced by the RIM method is used, and the hollow body portion 3 has the cyclopentadiene resin 23.
Only molded from.

Since the cyclopentadiene resin is used, the mold is heated to 70 ° C. and the monomer of the cyclopentadiene resin is injected into the mold during molding. R
The polymerization of IM cyclopentadiene is completed in 1 minute in the mold, and the sound insulating plate having the above-mentioned shape can be obtained by demolding from the mold.

In the sound insulating board of the third embodiment, the thickness of the plate-like portion 2 is increased to increase the filling amount of the fiber reinforcing material.
The rigidity can be made extremely high. Also, the hollow body portion 3
Since a large number of shapes are provided, it has a unique effect of cutting off a wide range of frequencies.

FIG. 8 shows a fourth embodiment, which has the same shape as the first embodiment, but the inside of the hollow body portion 3 is filled with a glass nonwoven fabric 25. That is, the plate-like portion 2 uses the glass continuous strand mat 5 and the carbon fiber cloth 6 as a fiber reinforcing material, while the hollow body portion 3 includes the glass nonwoven fabric 2
5 is a fiber reinforcing material, and each of them is a fiber reinforcing resin in which the matrix resin is RIM nylon.

The hollow body portion 3 made of the above fiber reinforced resin is molded by prefilling the glass nonwoven fabric 25 along the mold surface in the cavity for molding the hollow body portion of the mold. The wall thickness W of the hollow body portion 3 is as thin as about 0.5 mm, but since the glass nonwoven fabric 25 has a good resin flow, the RIM nylon solution can be sufficiently permeated.

As described above, the sound insulation plate of the fourth embodiment is
The plate-shaped portion 2 that imparts rigidity and the hollow body portion 3 that imparts sound insulation are also formed of fiber reinforced resin to improve the rigidity.

FIG. 9 shows a sound insulation board of the fifth embodiment. In each of the first to fourth embodiments, the hollow body portion 3 is projected only on one surface of the plate-shaped portion 2, but in the fifth embodiment, the hollow body portion 3 is projected on both surfaces of the plate-shaped portion 2. is doing. The hollow body portions 3 protruding from both sides of the plate-shaped portion 2 are hollow body portions having the same random shape as in the third embodiment.

The plate-like portion 2 has a thickness of 5 mm, and the carbon fiber woven cloth 26 and the glass fiber woven cloth 27 are laminated in three layers with the glass fiber nonwoven cloth 28 sandwiched therebetween, that is, a total of 6 layers. The layers are filled with a reinforcing fiber layer. The hollow body 3 has a fourth
A glass non-woven fabric 25 is filled as in the embodiment. RIM nylon is used as the matrix resin, and the plate-like portion 2 and the hollow body portions 3 on both sides are all formed of fiber reinforced resin.

FIG. 10 shows a sound insulating plate 1 of the sixth embodiment. In all of the above-mentioned first to fifth embodiments, the hollow body portions 3 have independent cylindrical shapes, but in the sixth embodiment, the walls of adjacent hollow body portions 3 are common, in other words, plate-shaped. Thin wall 3 on one side or both sides of section 2
Hollow part forming part 3 in which a gap 4 at the tip opening is bored through
1 is provided.

[0053]

As is apparent from the above description, in the sound insulation plate according to the present invention, the supporting plate-like portion for imparting rigidity and the hollow body portion for imparting sound insulation are integrally molded of resin. Therefore, the structure can be easily and easily manufactured as compared with the conventional sound insulating plate in which the supporting portion and the sound insulating portion are formed by separate members and bonded together.

At least the plate-like portion is made of continuous fibers and / or
Alternatively, it is extremely excellent in rigidity because it is filled with a fiber reinforcement made of long fibers and uses RIM nylon or cyclopentadiene resin having excellent impact absorption as a matrix resin. Therefore, in the conventional sound insulation plate, the shape-maintaining bar, which is required at the time of use, can be eliminated.

Further, since the shape of the hollow body can be arbitrarily set, there is a unique advantage that the sound insulation characteristic corresponding to the place of use can be imparted.

[Brief description of drawings]

FIG. 1 is a perspective view showing a first embodiment of a sound insulation plate of the present invention.

FIG. 2 is a partial cross-sectional view of FIG.

FIG. 3 is a cross-sectional view of a mold for molding the sound insulation plate of the first embodiment.

FIG. 4 is a perspective view of a second embodiment of the present invention.

5 is a partial cross-sectional view of FIG.

FIG. 6 is a perspective view of a third embodiment of the present invention.

FIG. 7 is a partial cross-sectional view of FIG.

FIG. 8 is a partial sectional view of a fourth embodiment of the present invention.

FIG. 9 is a partial sectional view of a fifth embodiment of the present invention.

FIG. 10 is a partial cross-sectional view of a sixth embodiment of the present invention.

[Explanation of symbols]

 1 Sound insulation board 2 Plate part 3 Hollow body part 4 Void 5 Glass continuous strand mat 6 Carbon fiber cloth 7 RIM nylon 25 Glass non-woven fabric

Claims (2)

[Claims] 1. A plate-shaped portion and a large number of hollow bodies which project from one or both surfaces of the plate-shaped portion and have open ends, and are integrally molded with resin, and at least the plate-shaped portion is Sound insulation board characterized by being molded with fiber reinforced resin. 2. The sound insulating board according to claim 1, wherein the resin is a nylon or cyclopentadiene resin molded by reaction injection molding.