JPH09242212A - Sound absorbing material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sound absorbing material favourable in an adhesive property which can be carried under a sucker suction transport method without spoiling sound absorbing performance and its manufacturing method. SOLUTION: A sound absorbing material 10 has a non-gas permeable film or sheet 14 integrally provided on one surface of a base material layer 12 of void percentage 5-50volume% constituted by binding an inorganic granular body 11 by thermosetting resin directly or through another layer. Thereby, its manufacturing method is at least furnished with a process to accumulate the inorganic granular body 11 covered with the thermosetting resin by spreading it as base material particulates, a process to arrange the non-gas permeable film or sheet 14 on one surface of a layered matter of these base material layer particulates and a process to simultaneously and thermocompression- integrally molding the non-gas permeable film or sheet 14 and the layered matter of the base material layer particulates.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound absorbing material used for providing a sound absorbing performance to a building such as a music hall, a recording studio, a music room, a house and the like, and a method for producing the same. By integrally providing a non-breathable film or sheet on one surface of a base material layer having a porosity of 5 to 50 volume% formed by binding with a water-soluble resin, without impairing sound absorption performance, The present invention relates to a sound absorbing material that can be transported by a suction transportation method using a suction cup and has good adhesiveness, and a method for producing the same.

[0002]

2. Description of the Related Art An example of a conventional sound absorbing material is shown in FIG. This sound absorbing material 1 is formed by integrally bonding inorganic particles 2 such as foundry sand and ceramic particles with a thermosetting resin, and forming a gap between the inorganic particles coated with the thermosetting resin. It has breathability and sound absorption performance (Japanese Patent Application Laid-Open No. 5-20.
4385).

However, since the sound absorbing material 1 of this type has a low rigidity, the conveying method during the secondary processing step, such as cutting the sound absorbing material 1, is a suction conveyance in which a glass plate is conveyed by using a suction cup. It is desirable to carry in the same manner as the law,
Since the surface of the sound absorbing material 1 is not smooth and has air permeability, air flows in through the gap between the sucker and the sound absorbing material 1 or the gap between the inorganic particles, and it is impossible to carry by the suction sucking and conveying method. Therefore, I could not mechanize the transportation work. Further, if the density of the sound absorbing material 1 in a good sound absorbing range is about 0.1 g / cm ³ , the sound absorbing material 1 is not rigid and cannot be used independently. At times, it is necessary to bond and fix to a wall substrate or other plate material, but at that time, if an adhesive with low viscosity is used, it will be difficult to bond because it will penetrate into the gaps between the inorganic particles. However, there is a problem in that even if an adhesive having a high viscosity is used, it penetrates to some extent, and as a result, the amount of the adhesive used increases.

Therefore, in order to provide a self-sustaining sound absorbing material, a sound absorbing material as shown in FIG. 19 has been considered (Japanese Patent Laid-Open No. Hei 5-273984). This sound absorbing material is obtained by sticking the mesh-like reinforcing fiber layers 3 on both surfaces of the sound absorbing material 1 shown in FIG. 18 using an adhesive. However, in such a sound absorbing material, since the reinforcing fiber layer 3 has many openings,
Air flowed through the opening, and it was impossible to carry it by the suction cup suction carrying method.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and a sound absorbing material which can be conveyed by a suction cup suction conveying method without impairing the sound absorbing performance and has a good adhesive property, and the same. The task is to provide a manufacturing method.

[0006]

According to a first aspect of the present invention, a surface of a base material layer having a porosity of 5 to 50% by volume, which is formed by binding an inorganic granular material with a thermosetting resin, is directly or A sound absorbing material integrally provided with a non-breathable film or sheet via another layer is used as a means for solving the above problems. Further, in the invention of claim 2, the porosity is 5 to the surface opposite to the side where the non-breathable film or sheet is provided centering on the base material layer directly or through another layer. The sound absorbing material according to claim 1, wherein a surface decorative layer (50% by volume) is integrally provided.

Further, in the invention according to claim 3, the other layer is a fibrous reinforcing layer having an opening of 5 to 95% by area, and the reinforcing layer is provided on both surfaces or one surface of the base material layer. The sound absorbing material according to claim 1 or 2 is a means for solving the above-mentioned problems. Further, in the invention according to claim 4, a step of spraying the inorganic particles coated with a thermosetting resin as base material layer particles and laminating the particles, and a step of laminating the base material layer particles on one surface thereof. A method for producing a sound-absorbing material, comprising at least a step of disposing a non-breathable film or sheet, and a step of simultaneously thermocompressively molding the non-breathable film or sheet and a laminate of base layer particles. Was used as a means for solving the above problems. The term “opening” means the ratio (%) of the total area of the reinforcing layer minus the projected area of the fibers to the total area.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is described in detail below.
FIG. 1 shows a first example of the sound absorbing material of the present invention. In the figure, reference numeral 10 is the sound absorbing material. The sound absorbing material 10 is formed by integrally providing a non-breathable film or sheet 14 on the lower surface of a base material layer 12 formed by binding an inorganic granular material 11 with a thermosetting resin.

As the inorganic granular material 11 as a main material of the base material layer 12, there are uncolored or colored natural stones having a particle size of about 0.1 to 2 mm, sand, ceramic particles or obsidian, pearl stone,
Foams of natural stone such as anti-fire stones and shirasu, and foams of glass and various ceramics are used. The bulk density of the inorganic particulate material 11 is 0.05 to 1.0 g.
It is preferable to use an inorganic lightweight particulate material having a density of / cm ³ .
If it is less than 0.05 g / cm ^3, is insufficient particle strength, because light is impaired exceeds 1.0 g / cm ^3. As the thermosetting resin that binds the inorganic particles 11, a phenol resin, a melamine resin, an unsaturated polyester resin, an epoxy resin, or the like can be used. Further, as the thermosetting resin used here, it is desirable to use one having excellent weather resistance.

The base material layer 12 is porous having innumerable minute voids therein and has air permeability, and the void ratio is 5 to 50% by volume, preferably 15 to 40% by volume. %. This is because when the porosity of the base material layer 12 is less than 5% by volume, sufficient sound absorbing performance cannot be obtained, while when it exceeds 50% by volume, the strength of the sound absorbing material itself is reduced.

As a material for forming the non-breathable film or sheet 14, a material that hardly permeates air and has heat resistance is used. A polymer film such as a polyamide film or a polyester film, a metal film such as an aluminum foil, etc. , Paper such as kraft paper, phenolic resin,
Diallyl phthalate resin, melamine resin, urea resin,
A resin-impregnated paper such as an epoxy resin or a resin-impregnated paper laminated cured plate obtained by laminating and curing these resin-impregnated papers is used.

The air flow resistance of the non-breathable film or sheet 14 is 10 Pa or more, preferably 100 Pa or more. The air flow resistance here is JIS A
The pressure difference between the films or sheets at a flow velocity (wind velocity) of 0.5 mm / sec was measured according to the measurement method specified in 6306. When the air flow resistance of the non-breathable film or sheet 14 is less than 10 Pa, even when trying to suck the non-breathable film or sheet 14 with a suction cup, the air passes through the gaps between the base layer particles to cause the non-breathable film or sheet to flow. The sound absorbing material flows into the voids and cannot be conveyed by the suction suction method, and when the sound absorbing material is adhered and fixed to the wall substrate or other plate material, the adhesive passes through the non-breathable film or sheet. Since it penetrates into the gaps between the base layer particles, there are disadvantages that the amount of the adhesive used increases or the adhesion becomes difficult.

The base layer 12 usually has a thickness of 5 to 50 mm,
The thickness of the non-breathable film or sheet 14 is typically 0.0
The thickness of the sound absorbing material 10 can be 1 to 2 mm, and the thickness can be 5 to 52 mm. When the thickness of the non-breathable film or sheet 14 is usually less than 0.01 mm, it is too thin and the handleability deteriorates, making it difficult to laminate at the time of molding. On the other hand, if the thickness exceeds 2 mm, the effect cannot be expected to increase any more, which is economically disadvantageous.

In the sound absorbing material 10 of the first example, the surface on the side where the non-breathable film or sheet 14 is provided is smooth, and the non-breathable film or sheet 14 is also provided.
Since it becomes difficult for air to pass through, the suction cup can suck the non-breathable film or sheet 14, and
The sound absorbing material 10 can be transported by the suction suction method, and the transportation work during the secondary processing step can be mechanized. Further, since the non-breathable film or sheet 14 has almost no penetration of the adhesive and has a smooth surface, if a wall substrate or another plate material is adhered to the non-breathable film or sheet 14 side, the viscosity is Adhesiveness is good even when a low-adhesive adhesive is used, and the amount of the adhesive used is small. Also,
A non-breathable film or sheet 14 is formed on the lower surface of the base material layer 12.
By providing, the heat insulating property is improved.

Further, in the sound absorbing material 10 of the first example, since the base material layer 12 is a porous material having innumerable minute voids and has air permeability, it has excellent sound absorbing performance. By changing the density of the inorganic particles or the porosity of the base material layer 12, the sound absorption coefficient can be set arbitrarily. Further, by using the inorganic lightweight granular material as the main material of the base material layer 12, it is lightweight and easy to cut. Particularly, when a hollow particle body or a hollow expanded particle body is used as the inorganic lightweight granular material, a heat insulating effect is obtained. Can also be obtained. Further, since the inorganic granular material or the inorganic lightweight granular material is the main material, it has a high nonflammability and therefore a fireproof property. Further, in the sound absorbing material 10 of the first example, since the non-breathable film or sheet 14 and the base material layer 12 can be simultaneously thermocompression-molded as described later, the manufacturing process is simplified. It is possible to manufacture at low cost.

Next, a method of manufacturing the sound absorbing material of the first example will be described. FIG. 2 shows an example of manufacturing the sound absorbing material 10 shown in FIG. 1 in the order of steps. In the figure, reference numeral 15 is a base layer particle conveying means, 16 is a metal plate for molding, and 17 is a pair of molding materials. The heating plate 18 is a suction cup for suction conveyance. (Material Preparation Step) The inorganic granular material 11 adjusted to a predetermined particle size is heated to 80 to 200 ° C. and charged into a water-cooled stirring container. After the stirring is started, a thermosetting resin is added to cover the inorganic granular body 11 with the thermosetting resin to prepare base layer particles 19. At this time, the coating amount of the thermosetting resin on the inorganic particles is 2 to 10% by weight. If it is less than 2% by weight, the inorganic particles cannot be sufficiently bound, and if it exceeds 10% by weight, a sufficient porosity of the base material layer cannot be secured. On the other hand, a non-breathable film or sheet 14 having a predetermined thickness is prepared and cut into a predetermined size.

(Forming and Molding Step) Base layer particles 19 are sprayed from the base layer particle conveying means 15 to the surface of the metal plate 16 for molding coated with the release agent so as to be 3 to 30 kg / m ^2. And stack. Then, a non-breathable film or sheet 14 is placed on the laminate 20 of the base layer particles.
Then, it is sandwiched between a pair of molding hot plates 17 and
Thermal pressure integral molding is performed under the conditions of ~ 200 ° C, 0.1-2 MPa, and 5-30 minutes. Immediately after the pressure is released, the mold is removed to obtain the desired sound absorbing material 10. In order to change the porosity of the base material layer 12 of the sound absorbing material 10, the particle size of the inorganic granular material 11 which is the main material of the base material layer 12 is changed, or the amount of the base material layer particles 19 dispersed during forming is applied. Should be changed. And
The surface of the sound absorbing material 10 on the side of the non-breathable film or sheet 14 is sucked by the suction / transport suction cup 18, and is transported to the secondary processing step of cutting into a predetermined size by suction suction suction transport.

In the above-described method for manufacturing the sound absorbing material 10, the base layer particles 19 are superposed and scattered, and laminated, and the non-breathable film or sheet 14 is placed on the laminate 20 of the base layer particles. Since the sound absorbing material 10 can be obtained by simultaneously heat-pressing and integrally molding, the manufacturing process is simple,
Manufacturing cost can be reduced.

Next, a second example of the sound absorbing material of the present invention will be described with reference to FIG. The sound absorbing material 30 of the second example shown in FIG. 3 differs from the sound absorbing material 10 of the first example shown in FIG. 1 in that a non-breathable film or sheet 14 is provided around the base material layer 12. The point is that the surface decorative layer 31 is integrally provided on the surface opposite to the side where the surface is made, that is, on the upper surface of the base material layer 12. As the material forming the surface decorative layer 31, a material formed by binding an inorganic granular material 32 containing colored particles with a weather resistant transparent resin is used.

As the inorganic granular material 32 which is the main material of the surface decorative layer 31, the same inorganic granular material 11 used in the sound absorbing material 10 of the first example can be used. The weather resistant transparent resin that binds the inorganic particles 32 includes
A thermoplastic resin or a thermosetting resin having excellent weather resistance is used, and specifically, an acrylic resin, a polyester resin, a melamine resin, an epoxy resin or the like can be used.

The surface decorative layer 31 is porous having a myriad of minute voids therein and has air permeability,
The porosity is 5 to 50% by volume, preferably 15
It is -40% by volume. This is because if the porosity is less than 5% by volume, sufficient sound absorbing performance cannot be obtained, while if it exceeds 50% by volume, the strength of the sound absorbing material itself decreases. The surface decorative layer 31 usually has a thickness of about 1 to 5 mm. The base material layer 12 and the surface decorative layer 31 of the sound absorbing material 30 of the second example are bonded and integrated with the resin forming each layer.

In the sound absorbing material 30 of the second example, the inorganic granular material 3 containing colored particles is provided on the upper surface of the base material layer 12 in particular.
By providing the surface decorative layer 31 obtained by binding 2 with the weather resistant transparent resin, the same effect as that of the sound absorbing material 10 of the first example is obtained, and the sound absorbing performance is not impaired, and the inorganic granular material It has a beautiful texture, has a beautiful appearance with a deep stone tone, and does not deteriorate due to weathering. In the second sound absorbing material 30 described above, the case where the material forming the surface decorative layer 31 is formed by binding the inorganic particles 32 including colored particles with the weather resistant transparent resin has been described. ~
It may be 50% by volume and can be integrally molded with the base material layer 12 by heat and pressure, and for example, wood veneer, cloth, non-woven fabric, etc. may be used.

As a method of manufacturing the sound absorbing material 30 of the second example, the surface decorative layer particles are dispersed before the base layer particles 19 are dispersed and laminated on the surface of the molding metal plate 16 coated with the release agent. It can be manufactured in substantially the same manner as in the manufacturing method example of the sound absorbing material 10 of the first example, except that the base layer particles 19 are sprayed and laminated on the surface decorative layer particle laminate. it can.
The surface decorative layer particles used here heat the inorganic granular material 32 containing colored particles to be the surface decorative layer 31 adjusted to a predetermined particle size to 80 to 200 ° C., and put into a water-cooled stirring container, After the stirring is started, powdery or liquid uncured weather resistant transparent resin is added, and the inorganic granular material 32 is coated with this weather resistant transparent resin. In the method for manufacturing the sound absorbing material of the second example described above, the surface decorative layer particles, the base layer particles 19 and the non-air-permeable film or sheet 14 are laminated, and these are simultaneously heat-molded integrally. It is simple, and it is possible to give a beautiful appearance without increasing the manufacturing cost.

Next, a third example of the sound absorbing material of the present invention will be described with reference to FIG. The sound absorbing material 40 of the third example shown in FIG. 4 differs from the sound absorbing material 10 of the first example shown in FIG. 1 in that the fibrous reinforcing layers (upper surface side reinforcement) are formed on the upper surface and the lower surface of the base material layer 12. Layer) 41a, fibrous reinforcing layer (lower surface side reinforcing layer) 4
1b is provided, and the non-breathable film or sheet 14 is provided via the reinforcing layer 41b provided on the lower surface side of the base material layer 12. The fibrous reinforcing layers 41a, 41b
As a material for forming, a fibrous reinforcing material impregnated with a thermosetting resin and semi-cured to form a prepreg is used. As the fibrous reinforcing material here, a non-woven fabric made of fibers such as glass fiber, carbon fiber, and synthetic fiber,
Woven cloth, knitted cloth, braided cloth and the like are used, and among them, glass cloth, glass mat and the like are preferably used. The openings of the fibrous reinforcing layers 41a and 41b are 5 to 95 area%. If the opening is less than 5 area%, sound absorbing performance cannot be obtained, and if it exceeds 95 area%, sufficient rigidity cannot be imparted to the sound absorbing material. Generally, a phenol resin, a polyester resin, an epoxy resin, a melamine resin or the like can be used as the resin for forming the fibrous reinforcing material into a prepreg, but it is preferable to use the same resin as the resin for binding the base material layer 12 to each layer. It is preferable because the adhesion state of the above is the same, and the manufacturing conditions can be easily set.

The base material layer 12 of the third sound absorbing material 40 and the reinforcing layers 41a and 41b on both sides thereof are bonded and integrated by the resin constituting each layer.

In the sound absorbing material 40 of the third example, particularly, the sound absorbing material of the first example is provided by providing the breathable reinforcing layers 41a and 41b on the upper surface and the lower surface of the base material layer 12. In addition to providing the same effect as 10, the rigidity can be imparted without impairing the sound absorbing performance, and the device can be self-supported and directly attached to a wall surface or the like. Further, in the sound absorbing material 40 of the third example, the case where one reinforcing layer is provided on each of both surfaces of the base material layer 12 has been described, but the number and arrangement position of the reinforcing layers are not necessarily limited to this, It may be either the upper surface or the lower surface of the material layer 12, and the base material layer 12
It is also possible to provide a breathable reinforcing layer in the middle. In the case of using the sound absorbing material 40 of the third example, as the material forming the lower surface side reinforcing layer 41b, a fibrous reinforcing material impregnated with a thermosetting resin and semi-cured to form a prepreg is used. However, as long as the non-breathable film or sheet 14 and the laminate 20 of the base layer particles can be simultaneously thermocompression integrally molded, even a fibrous reinforcing material not impregnated with a thermosetting resin can be used. Good.

As a method of manufacturing the sound absorbing material 40 of the third example, the reinforcing layer 41a is formed before the base layer particles 19 are dispersed and laminated on the surface of the molding metal plate 16 coated with the release agent. After disposing the reinforcing layer material, the base layer particles 1 are provided on the reinforcing layer material.
9 is sprayed and laminated, and further, a laminate 2 of the base layer particles
0 in the same manner as in the manufacturing method of the sound absorbing material 10 of the first example, except that the reinforcing layer material to be the reinforcing layer 41b is disposed on the surface of the first layer and then the non-breathable film or sheet 14 is placed on the reinforcing layer material. Can be manufactured. The reinforcing layer material used here is a fibrous reinforcing material, and the fibrous reinforcing material is 20 to
It can be prepared by impregnating with 50% by weight of a thermosetting resin and semi-curing to form a prepreg, and then cutting into a predetermined size. The curing temperature of the resin at the time of prepreg formation is, for example, phenol resin. In case of about 10
0 ° C.

Reinforcing layer 41 of the sound absorbing member 40 of the third example
In order to change the porosity of a and 41b, the reinforcing layers 41a and 41a,
It suffices to change the ratio of the openings of the fibrous reinforcing material to be 41b. In the manufacturing method of the sound absorbing material of the third example described above,
Similar to the manufacturing method of the sound absorbing material of the example shown in FIG. 1, since it is thermocompression-integrally molded, it is possible to impart rigidity without increasing the manufacturing cost.

Next, a fourth example of the sound absorbing material of the present invention will be described with reference to FIG. The sound absorbing material 50 of the fourth example shown in FIG. 5 is different from the sound absorbing material 40 of the third example shown in FIG. 4 in that a non-breathable film or sheet 14 is provided around the base material layer 12. That is, the surface decorative layer 31 is integrally provided on the surface opposite to the side where the surface is provided, that is, on the upper surface of the base material layer 12 via the reinforcing layer 41a.

In the sound absorbing material 50 of the fourth example, in particular, breathable reinforcing layers 41a and 41b are provided on the upper surface and the lower surface of the base material layer 12, and the surface decorative layer is further provided on the reinforcing layer 41a. Since 31 is provided, the same effects and sound absorbing performance as the sound absorbing material 10 of the first example are not impaired,
It can be given rigidity, can be mounted on a wall surface, etc. by itself as it is. Furthermore, it has the texture of an inorganic granular material, has a beautiful appearance with a deep stone tone, and is weather-deteriorated. There is no. Further, in the sound absorbing material 50 of the fourth example, the reinforcing layers 41 a, 4 are formed on both surfaces of the base material layer 12.
Although the case where the non-breathable film or sheet 14 and the surface decorative layer 31 are provided to the one provided with 1b is not limited to this, the reinforcing layer 41b is provided only on the lower surface of the base material layer 12. 6 is provided with a non-breathable film or sheet 14 and a facing layer 31.
The sound absorbing material 60 as shown in FIG.

As a method of manufacturing the sound absorbing material 50 of the fourth example, the surface decorative layer particles are provided before the reinforcing layer material serving as the reinforcing layer 41a is provided on the surface of the molding metal plate 16 coated with the release agent. In the same manner as in the production example of the sound absorbing material 40 of the third example, except that the reinforcing layer material serving as the above-mentioned reinforcing layer 41a is arranged on the laminate of the surface decorative layer particles. Can be manufactured. In the method for producing the sound absorbing material of the above-mentioned fourth example, the surface decorative layer particles, the reinforcing layer material to be the reinforcing layer 41a, the base layer particles 19, the reinforcing layer material to be the reinforcing layer 41b, and the non-air-permeable material. Since the films or sheets 14 are laminated and thermo-compressed integrally at the same time, the manufacturing process is simple, and rigidity can be imparted without increasing the manufacturing cost, and a beautiful appearance is imparted. It is possible to

[0032]

EXAMPLES In order to make the present invention easier to understand,
An example will be described. Such an example shows one aspect of the present invention, does not limit the present invention, and can be arbitrarily modified within the scope of the present invention. (Example 1) A sound absorbing material was produced as follows. (Material preparation step) A glass powder granulation foam (particle size: 0.3 to 1.2 mm, trade name: G-light, manufactured by Sunlite Co., Ltd.) that serves as a base material layer is heated to 200 ° C., and this glass powder granulation is performed. 60 kg of foam is put into a water-cooled stirring container, and after starting stirring, uncured novolac-based phenol resin 4.2k
g, and the glass powder granulated foam was coated with a heat-melted resin to prepare base layer particles. The coating amount of the novolac phenolic resin at this time was 7% by weight based on the glass powder granulated foam. On the other hand, a non-breathable film or sheet was prepared by cutting a 75 μm-thick polyester film (manufactured by Toray Industries, Inc.) into predetermined dimensions.

(Forming and Molding Step) The surface of the metal plate for molding is coated with a diluting solution of a fluorine-based releasing agent, and the above-mentioned base layer particles are sprayed at 6.5 kg / m ² and laminated. . The above polyester film is placed on the laminate of the base layer particles. Then, cover the polyester film with the upper plate of the metal plate for molding, place it in the hot press surface plate,
Thermal compression integral molding was performed under the conditions of 180 ° C., 20 kgf / cm ² , and 20 minutes. Then, after decompressing, the mold was immediately released from the mold and naturally cooled to obtain a sound absorbing material having a structure similar to that shown in FIG. Then, the cooled sound absorbing material was cut into a predetermined size. The sound-absorbing material thus produced had a thickness of 10 mm, the substrate layer had a porosity of 20% by volume, and the polyester film had an air flow resistance of 200 Pa or more.

(Example 2) A sound absorbing material was produced in the same manner as in Example 1 except that an aluminum foil having a thickness of 0.3 mm was used as the non-breathable sheet. The sound-absorbing material thus produced had a thickness of 10 mm, the substrate layer had a porosity of 20% by volume, and the aluminum foil had an air flow resistance of 200 P.
It was a or more. (Example 3) As a non-breathable film, a thickness of 0.1 m
A sound absorbing material was produced in the same manner as in Example 1 except that kraft paper having m and basis weight of 84 g / m ² was used. The sound-absorbing material thus produced had a thickness of 10 mm, the substrate layer had a porosity of 20% by volume, and the kraft paper had an air flow resistance of 73 P.
a.

Example 4 A sound absorbing material was produced in the same manner as in Example 1 except that one sheet of phenol resin-impregnated paper having a thickness of 60 μm and a basis weight of 50 g / m ² was used as the non-breathable film. The phenol resin impregnated paper here has a basis weight of 13 g /
A paper prepared by impregnating m ² paper with a phenol resin so as to be 74% by weight to form a prepreg and cutting it into a predetermined size was used. The thickness of the sound absorbing material thus produced was 10 mm, the porosity of the base material layer was 20% by volume,
The air flow resistance of the phenol resin-impregnated paper was 10 Pa.

Example 5 A sound absorbing material was produced in the same manner as in Example 1 except that a phenol resin-impregnated paper laminated cured plate having a thickness of 1.15 mm was used as the non-breathable film. The phenolic resin impregnated paper laminated cured plate here has a basis weight of 13 g.
/ M ² paper impregnated with 74% by weight of a phenol resin was laminated, prepregized, and cut into a predetermined size. The sound-absorbing material thus produced had a thickness of 10 mm and the base layer had a porosity of 2 mm.
It was 0% by volume, and the air flow resistance of the phenol resin-impregnated paper laminated cured plate was 200 Pa or more.

(Example 6) A sound absorbing material was produced as follows. (Material preparation step) In the same manner as in Example 4, base layer particles,
A paper impregnated with phenolic resin as a non-breathable film was prepared. On the other hand, as the material for the upper surface side reinforcement layer, the thickness is 0.11 m.
m, an opening of 50% by area, and a weight of 84 g / m ² of glass cloth impregnated with 40% by weight of a phenol resin,
A phenol resin-impregnated glass cloth prepreg prepared by making a prepreg was cut into predetermined dimensions.
As the lower surface side reinforcing layer material, a glass fiber braid having a thickness of 0.45 mm, an opening of 80% by area and a basis weight of 125 g / m ² was cut into a predetermined size.

(Forming and Molding Step) The surface of a metal plate for molding is coated with a diluting solution of a fluorine-based release agent, the above-mentioned phenol resin-impregnated glass cloth prepreg is placed thereon, and the above-mentioned base layer particles are further placed thereon. It was sprinkled so as to be 6.5 kg / m ² and laminated. Then, the above glass fiber braid is placed on the laminate of the base layer particles, and further the above-mentioned phenol resin-impregnated paper is placed thereon, and then the metal plate upper plate for molding is placed on the phenol resin-impregnated paper, It was placed in a hot press surface plate and thereafter molded under the same molding conditions as in Example 1 to produce a sound absorbing material having a structure similar to that shown in FIG. The sound-absorbing material thus produced had a thickness of 10 mm, the substrate layer had a porosity of 20% by volume, and the phenol resin-impregnated paper had an air flow resistance of 10 Pa.

(Example 7) The amount of base layer particles dispersed was 9.8.
A sound absorbing material was produced in the same manner as in Example 6 except that the weight was changed to kg / m ² . The thickness of the sound absorbing material produced in this way is 15
The substrate layer had a porosity of 20% by volume and the phenol resin-impregnated paper had an air flow resistance of 10 Pa.

(Example 8) A sound absorbing material was produced as follows. (Material Preparation Step) In the same manner as in Example 6, base layer particles, phenol resin-impregnated paper as a non-breathable film, phenol resin-impregnated glass cloth prepreg as an upper surface side reinforcing layer material, glass as a lower surface side reinforcing layer material. A fiber braid was prepared. On the other hand, the color sand (particle size: 0.3 to 0.85 mm) that becomes the surface decorative layer is heated to 160 ° C., and 2 kg of this color sand is put into a water-cooled stirring container,
After the stirring was started, 100 g of an uncured unsaturated polyester resin powder coating material was added, and the color sand was coated with the heat-melted coating material to prepare surface decorative layer particles. The coating amount of the paint at this time was 5% by weight with respect to the color sand.

(Forming and molding step) Before placing the phenol resin-impregnated glass cloth prepreg on the surface of the metal plate for molding coated with the diluting solution of the fluorine-based releasing agent, 2.5 kg / m of the above-mentioned surface decorative layer particles are placed. ² and then laminated, after which a phenol resin-impregnated glass cloth prepreg is placed on the surface decorative layer particle laminate, and the above-mentioned base layer particles are further applied thereon in an amount of 5.2 kg / m ^2. 5 was carried out in the same manner as in Example 6 except that the mixture was sprayed so that
A sound absorbing material having a structure similar to that shown in was prepared. The sound-absorbing material thus produced had a thickness of 10 mm, the base layer had a porosity of 20% by volume, and the surface decorative layer had a porosity of 45%.
The air flow resistance of the phenol resin-impregnated paper was 10 Pa.

(Example 9) A sound absorbing material was produced as follows. (Material preparing step) In the same manner as in Example 6, base layer particles and phenol resin-impregnated paper as a non-breathable film,
A glass fiber braid as a lower surface side reinforcing layer material was produced.
On the other hand, the surface decorative layer has a thickness of 0.25 mm and a porosity of about 1
A 0%, oak veneer having a basis weight of about 200 g / m ² was cut into a predetermined size. (Forming and molding step) The above-mentioned oak veneer is placed on the surface of the metal plate for molding coated with the diluent for the fluorine-based release agent, and then the above-mentioned base layer particles are placed on the oak veneer. It was sprayed at 5 kg / m ² . Then, the above glass fiber braid is placed on the laminate of the base layer particles, and further the above-mentioned phenol resin-impregnated paper is placed thereon, and then the metal plate upper plate for molding is placed on the phenol resin-impregnated paper, It was placed in a hot press surface plate and integrally molded by heat and pressure under the conditions of 150 ° C., 2 MPa, and 20 minutes. Then, after decompressing, the mold was immediately released from the mold and naturally cooled to obtain a sound absorbing material having a structure similar to that shown in FIG. The thickness of the sound absorbing material produced in this way is 1
The porosity of the veneer veneer was about 10%, the porosity of the base material layer was 20% by volume, and the air flow resistance of the phenol resin-impregnated paper was 10 Pa.

(Comparative Example 1) A sound absorbing material was produced as follows. (Material Preparation Step) In the same manner as in Example 6, base layer particles and a phenol resin-impregnated glass cloth prepreg as the upper side reinforcing layer material and the lower side reinforcing layer material were produced. (Forming and molding step) After placing a phenol resin-impregnated glass cloth prepreg on the surface of a metal plate for molding coated with a diluting solution of a fluorine-based releasing agent, 6.5 kg / of the above-mentioned base layer particles are placed thereon. It was sprayed so that it would be m ² . Then, after placing the above-mentioned phenol resin-impregnated glass cloth prepreg on the laminate of the base material layer particles, cover the phenol resin-impregnated glass cloth prepreg with the molding metal plate upper plate, and place it in a hot press surface plate. After that, the sound absorbing material having the same structure as that shown in FIG. 19 was produced by molding under the same molding conditions as in Example 1. The sound-absorbing material thus produced had a thickness of 10 mm, and the substrate layer had a porosity of 20 mm.
% By volume.

With respect to the sound absorbing materials of Examples 1 to 9 and Comparative Example 1 produced as described above, the sound absorbing performance, the sucker suction transporting property and the adhesive property were evaluated. The sound absorption performance was determined by examining the frequency characteristics of the sound absorption coefficient according to the method of measuring the sound absorption coefficient (JIS A 1409) in the reverberation room method, and as shown in FIG. 7, samples (sound absorption of Examples 1 to 9 and Comparative Example 1) were used. Material 70 and the rigid wall 71 between the case where no back air layer is provided, and the sample 70
When a 50 mm back air layer 72 is provided between the hard wall 71 and the hard wall 71 (spacers 73, 73 are arranged at both ends of the back surface of the sample 70 so that the thickness of the air layer 72 is maintained at 50 mm at this time). .), And the measurement results are shown in FIG.
~ Shown in FIG.

FIG. 8 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of Example 1, and FIG. 9 is Example 2.
11 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of FIG. 10, FIG. 10 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of Example 3, and FIG. 13 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of FIG. 12, FIG. 12 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of Example 5, and FIG. 15 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of FIG. 14, FIG. 14 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of Example 7, and FIG. 17 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of FIG. 16, FIG. 16 is a graph showing the measurement results of the frequency characteristics of the sound absorption coefficient of the sound absorbing material of Example 9, and FIG. 3 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of FIG. In the graphs of FIGS. 8 to 17, the solid line shows the measurement result of the frequency characteristic of the sound absorption coefficient when the back air layer is not provided between the sound absorbing material and the rigid wall, and the dotted line shows the sound absorption when the back air layer is provided. It is a measurement result about the frequency characteristic of the rate. As is clear from the results shown in FIGS. 8 to 17, the sound absorbing maximum peak values of the sound absorbing materials of Examples 1 to 9 are almost the same as the sound absorbing maximum peak value of the sound absorbing material of Comparative Example 1, and the sound absorbing performance is impaired. I know that not. Table 1 shows the evaluation results of the sound absorbing performance. In the column of sound absorption performance evaluation results in Table 1, ◯ means that the sound absorption performance is good.

With respect to the sucker suction conveyance property, it was examined whether the sound absorbing materials produced in Examples 1 to 9 and Comparative Example 1 can be conveyed or cannot be conveyed by using the suction conveyance suction cup. The results are also shown in Table 1. In the column of the evaluation result of sucker suction conveyance property in Table 1, ◯ means that suction cup suction conveyance is possible, and × means that suction cup suction conveyance is impossible.

Adhesiveness is determined by the adhesive strength test method (JIS
K 6852), the sound absorbing materials of Examples 1 to 9 and Comparative Example 1 were used as finishing materials (adhesion materials), and a birch wood piece having a thickness of 10 mm was used as a base material. Vinyl urethane adhesive (PI bond 228
0 / curing agent H3 = 100/10 (weight ratio) (manufactured by Oshika Shinko Co., Ltd.) at a coating amount of 150 to 200 g / m ² , and then the sound absorbing material is pressed onto the above-mentioned base material at a pressing force of 5 kg / c.
A test piece was prepared by adhering at m ² and a pressing time of 72 hours (22 ° C.), and a shearing force was applied to the adhering surface until the maximum load until the sound absorbing material was broken or interfacial peeling of the adhering surface occurred. The maximum load was measured and the compression shear adhesive strength was calculated. As a result, the compression-shear adhesive strength of the test body using the sound absorbing material of Example 1 was 80 kgf / cm ² , and the bonded surface of this test body was sufficiently broken by material destruction.
The compressive shear adhesive strength of the test body using the sound absorbing material of Example 1
Almost the same results as those of the test bodies using the sound absorbing material were obtained, and the adhesive surface of these test bodies had insufficient adhesive force due to material destruction. On the other hand, the compression-shear adhesive strength of the test body using the sound absorbing material of Comparative Example 1 was 10 kgf / cm ² , and the adhesive surface of this test body had sufficient adhesive strength due to interfacial peeling. The results of evaluation of adhesiveness are also shown in Table 1. In the column of the evaluation result of the adhesiveness in Table 1, ◯ means that the adhesiveness is good, and x means that the adhesiveness is poor.

[0048]

[Table 1]

As can be seen from FIGS. 8 to 17 and Table 1, in the sound absorbing material of Comparative Example 1, the sheet on the back surface of the sound absorbing material is a glass cloth prepreg having openings of 50% by area. It could not be conveyed by suction, and the adhesiveness was poor. On the other hand, in the sound absorbing materials of Examples 1 to 9, since the sheet or film on the back surface of the sound absorbing material is non-breathable, the sound absorbing material is transported by the suction suction method without impairing the sound absorbing performance. Was possible and the adhesiveness was good.

Further, from the results of the sound absorbing materials of Examples 1 to 5 in which a non-breathable film or sheet was provided on the lower surface of the base material layer,
It can be seen that the above performance is good even when the material forming the breathable film or sheet is changed. Further, from the results of the sound absorbing materials of Examples 6 to 7, in which the reinforcing layers were provided on both surfaces of the base material layer, and the non-air-permeable film or sheet was integrally provided on the lower surface of the base material layer via the reinforcing layer, It can be seen that the above performance is good even if the thickness of the base material layer is changed. Furthermore, from the results of the sound absorbing materials of Examples 8 to 9, in which the surface decorative layer was provided on the surface opposite to the side on which the non-breathable film or sheet was provided centering on the substrate layer, the surface decorative layer was found to be the base material. It can be seen that the performance is good even if it is provided directly on the layer or via the reinforcing layer, or if the material forming the surface decorative layer is changed.

[0051]

As described above, according to the sound absorbing material of claim 1, by virtue of the above-mentioned constitution, the surface on the side where the non-permeable film or sheet is provided is smooth, Since the air-permeable film or sheet does not pass air, the non-air-permeable film or sheet can be sucked by the suction cup, and therefore the sound absorbing material can be transported by the suction cup suction transport method, and it can be transported during the secondary processing process. Work can be mechanized. Further, since the non-breathable film or sheet has almost no penetration of an adhesive and has a smooth surface, if a wall substrate or other plate material is adhered to the non-breathable film or sheet side, the viscosity is low. Adhesiveness is good even if an adhesive is used, and the amount of the adhesive used is small. Further, the heat insulating property is improved by providing the non-breathable film or sheet on the lower surface of the base material layer. Further, in the sound absorbing material according to claim 1, the base material layer is a porous material having innumerable minute voids and has air permeability, so that the sound absorbing material has excellent sound absorbing performance, and the base material layer By changing the density or the porosity of the inorganic granular material, the sound absorption coefficient can be arbitrarily set.

Further, by using the inorganic lightweight granular material as the main material of the base material layer, it is lightweight and easy to cut,
In particular, when a hollow particle body or a hollow foamed particle body is used as the inorganic lightweight granular material, a heat insulating effect can be obtained. Further, since the inorganic granular material or the inorganic lightweight granular material is the main material, it has a high nonflammability and therefore a fireproof property. Further, in the sound absorbing material according to claim 1, since the non-breathable film or sheet and the base material layer can be formed by thermocompression integral molding at the same time, the manufacturing process is simple and the manufacturing can be performed at low cost. Becomes

In the sound absorbing material according to claim 2, the surface decorative layer is formed on the surface opposite to the side on which the non-breathable film or sheet is provided centering on the base material layer directly or through another layer. By having the same effect as that of the sound absorbing material of claim 1, the sound absorbing performance is not impaired, the texture of the inorganic granular material is provided, and it has a beautiful appearance with a deep stone tone, Moreover, weather resistance does not deteriorate. In the sound absorbing material of claim 3, in particular, since the reinforcing layer is provided on both surfaces or one surface of the base material layer, the same effect as that of the sound absorbing material of claim 1 or the sound absorbing material of claim 2 is achieved. The rigidity can be imparted without impairing the sound absorbing performance, and it can be mounted as it is on a wall surface or the like. In the method for manufacturing the sound absorbing material of the present invention, by adopting the above-mentioned configuration, the above-mentioned sound absorbing material can be provided without complicating the manufacturing process, and the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 is a sectional view showing a first example of a sound absorbing material of the present invention.

FIG. 2 is a diagram showing a manufacturing example of the sound absorbing material shown in FIG. 1 in the order of steps.

FIG. 3 is a sectional view showing a second example of the sound absorbing material of the present invention.

FIG. 4 is a sectional view showing a third example of the sound absorbing material of the present invention.

FIG. 5 is a sectional view showing a fourth example of the sound absorbing material of the present invention.

FIG. 6 is a cross-sectional view showing another example of the sound absorbing material of the present invention.

FIG. 7 is a diagram showing a method of examining frequency characteristics of sound absorption coefficient with respect to the sound absorbing materials obtained in Examples 1 to 9 and Comparative Example 1.

FIG. 8 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 1.

FIG. 9 is a graph showing the measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 2.

FIG. 10 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 3.

FIG. 11 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 4.

FIG. 12 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 5.

FIG. 13 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 6.

FIG. 14 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 7.

FIG. 15 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 8.

16 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Example 9. FIG.

FIG. 17 is a graph showing measurement results of frequency characteristics of sound absorption coefficient of the sound absorbing material of Comparative Example 1.

FIG. 18 is a cross-sectional view showing an example of a conventional sound absorbing material.

FIG. 19 is a cross-sectional view showing another example of the conventional sound absorbing material.

[Explanation of symbols]

10, 30, 40, 50, 60 ... Sound absorbing material, 11 ... Inorganic granular material, 12 ... Base material layer, 14 ... Non-breathable film or sheet, 19 ... Base material layer particles , 20 ... Laminate of base layer particles, 31 ... Surface decorative layer, 41a, 41b ... Reinforcing layer.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masao Imanishi 10-1 Nakazawa-cho, Hamamatsu-shi, Shizuoka Prefecture Yamaha stock company (72) Inventor Akira Kaneko 10-1 Nakazawa-machi, Hamamatsu-shi, Shizuoka Prefecture (Yamaha stock company ( 72) Inventor Kenji Ito 10-1 Nakazawa-machi, Hamamatsu-shi, Shizuoka Yamaha stock company (72) Inventor Yasunori Nakamura 10-1 Nakazawa-machi, Hamamatsu-shi, Shizuoka Yamaha stock company

Claims (4)

[Claims] 1. A non-breathable film or sheet is integrally formed on one surface of a base material layer having a porosity of 5 to 50% by volume, which is formed by binding an inorganic granular material with a thermosetting resin, or through another layer. A sound absorbing material characterized by being provided. 2. A surface decorative layer having a porosity of 5 to 50% by volume is directly or through another layer on the surface opposite to the side on which the non-breathable film or sheet is provided with the base layer as the center. The sound absorbing material according to claim 1, wherein the sound absorbing material is provided integrally. 3. The other layer is a fibrous reinforcing layer having an opening of 5 to 95 area%, and the reinforcing layer is provided on both sides or one side of the base material layer. The sound absorbing material according to 2. 4. A step of spraying an inorganic granular material coated with a thermosetting resin as base layer particles and laminating the particles, and arranging a non-breathable film or sheet on one surface of the laminate of the base layer particles. And a step of simultaneously thermocompressively molding the non-breathable film or sheet and a laminate of base layer particles.