JPH10212772A - Sound absorption and insulation pannel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the sound insulation performance of the subject pannel with a light and low cost material by complexly integrating a sound absorbing plate made from inorganic grannular material and a sound insulating plate composed of a core layer formed of coal ash granular material and coal ash and upper and lower surface layers formed of coal ash and fibrous filler holding the core layer therebetween with a binder applied thereto, through air. SOLUTION: A sound absorbing material 1 is formed by hardening inorganic granular material and a fibrous filler 4 with a binder. A sound insulating plate 3 is formed by holding a core layer made of coal ash granular material formed by mixing coal ash and cement between both upper and lower surface layers made of fibrous binder 4, and hardening it with a binder. A sound absorbing and insulating pannel is manufactured by complexly integrating the material 1 and the material 3 through an air layer 2. Since the coal ash granular material is used as the core layer, the plate 3 has a high density and the sound insulation performance thereof is improved. With the constitution, the use of thermosetting resin used as a binder can be reduced, which provides the plate 3 with a high flame resistant characteristic.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound absorbing and insulating panel using a sound insulating plate mainly made of coal ash.

[0002]

2. Description of the Related Art Conventionally, various types of sound absorbing materials have been developed. For example, Japanese Utility Model Publication No. Hei 6-30820 discloses an aggregate obtained by granulating coal ash fine powder to a desired diameter with an inorganic binder. Further, a sound-absorbing material which is sintered and formed as a plate having continuous voids therein is disclosed. Further, according to JP-A-6-118965, the particle diameter is 0.8 to 3.0.
Also known is a sound absorbing material obtained by mixing inorganic coarse particles of 1 mm and inorganic fine particles of 0.1 to 0.8 mm in particle diameter at a predetermined ratio, mixing a resin such as isocyanate and polyol, and heat-curing and molding. Here, natural stone, sand, ceramic particles, and metal powder are used for the inorganic fine particles and coarse particles.

[0003] Further, various types of sound absorbing materials composed of a plurality of layers have been conventionally known. For example, Japanese Patent Application Laid-Open No. 6-108552 discloses a first sound absorbing material.
It is composed of a plurality of layers of an interlayer air layer, a second sound absorbing material, and a back air layer, and the layer thickness of the interlayer air layer is 30 times the total layer thickness of all the layers.
A sound-absorbing material characterized by being set to ％ 40% is disclosed.

On the other hand, the present inventors have previously conducted research and development of a sound absorbing and insulating panel having practical and excellent sound insulating performance, and added coal ash granules of coal ash and inorganic fibers as needed. From a foamed sound absorbing panel formed by molding and curing a filler and a binder, and a dense sound insulation panel formed by molding and curing a filler and a binder added as necessary such as coal ash and inorganic fibers. Filed a patent application for an invention relating to a composite sound absorbing and insulating panel (Japanese Patent Application No. 7-14)
No. 5218).

[0005]

SUMMARY OF THE INVENTION The present invention provides a sound absorbing and insulating panel having excellent sound insulating performance by using a light and inexpensive sound insulating plate mainly made of coal ash. It is an object of the present invention to make effective use of coal ash produced as a by-product.

[0006]

SUMMARY OF THE INVENTION The present invention provides a sound-absorbing and sound-insulating panel in which a porous sound-absorbing plate and a dense sound-insulating plate are combined and integrated via an air layer. And a fibrous filler added as needed is cured with a binder, and the sound insulating plate is formed of coal ash obtained by granulating coal ash and a coal ash. And cured with a binder in a state sandwiched from both sides by a surface layer comprising a fibrous filler added by the method.

Preferably, a fibrous intermediate material is provided in the air layer.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below.

First, the sound absorbing plate constituting the sound absorbing and insulating panel of the present invention will be described. As the sound absorbing material used for the sound absorbing plate, a porous material has been conventionally used, and in the present invention, a structure in which sound is easily absorbed by using a material in which voids are continuously formed therein is used. ing. In the present invention, inorganic particulate matter is used as a main material of the sound absorbing material.
As the inorganic particles, expanded particles of natural stones such as obsidian, pearlite, antifossil, and shirasu, or expanded particles of glass or various ceramics are preferable, and these are used alone or in combination. The particle size of the inorganic particulate matter is 0.1
It is preferably about 2 mm.

In the present invention, in order to increase the strength of the sound absorbing plate,
It is desirable to mix the filler into the sound absorbing material to reinforce the sound absorbing plate. As the filler, chopped strand, mat, or net-like fibrous materials are preferable, and glass fibers, rock wool, inorganic fibrous materials such as carbon fibers, and organic synthetic fibrous materials such as vinylon and polyester. Can be used. In addition, a prepreg formed by impregnating a fibrous material with a thermosetting resin such as a phenol resin, a polyester resin, an epoxy resin, or a melamine resin, and curing the fiber partially can also be suitably used. The portion to be reinforced with the filler may be in any position near or inside the surface of the sound absorbing plate.
Any structure of layers or more may be used.

The sound-absorbing plate of the present invention is obtained by molding and curing the above-mentioned inorganic particulate matter and a fibrous filler added as necessary with a binder. As the binder, any of organic and inorganic binders can be used, but in order to produce a sound absorbing material by adhering the inorganic particles in a spotted manner, the curing temperature is in the range of 80 to 200 ° C. It is preferable to use the thermosetting resin-based binder described in (1).
Examples of such a synthetic resin include a phenol resin, an epoxy resin, a melamine resin, a urea resin, and a lignin resin, and a phenol resin is particularly preferable. In the case of a phenol resin, the mixing ratio with respect to the inorganic particles is 1.5 to 25% by weight, particularly 5.0 to 15% by weight.
Is preferred. If the content is less than 1.5% by weight, the granular material cannot be firmly bonded to each other or the granular material and the filler, and the strength of the sound absorbing material decreases. On the other hand, if it exceeds 25% by weight, voids between the granular materials are filled, and a porous structure suitable for a sound absorbing material cannot be formed.

In order to manufacture a sound absorbing plate, inorganic particles, a filler and a binder may be simply mixed, or the surface of the inorganic particles may be coated in advance with a binder,
A filler and an additional binder may be mixed if necessary. Next, the mixture or the granular material is put in a mold or the like, and if necessary, a lubricant is mixed, and the mixture is heated and pressed to be formed by a dry manufacturing method. Of course, it may be manufactured by a wet manufacturing method.

The porosity of the sound-absorbing material thus obtained is about 5 to 75%, preferably about 10 to 50%. The porosity is determined by the types and blending ratios of the inorganic particulate matter, the filler and the binder, Alternatively, it can be adjusted by appropriately selecting a manufacturing method such as pressing pressure and temperature conditions.

Next, the sound insulating plate will be described. As described above, the sound insulating plate is formed using coal ash as a main raw material, and the core layer is formed of coal ash and coal ash granules obtained by granulating coal ash.

In the present invention, the coal ash includes fly ash, clinker ash, and cinder ash, and further includes coke ash. However, among these coal ashes, fly ash, which is obtained by collecting particulate ash in exhaust gas by a dust collector provided in a flue of a coal-fired power plant, is most easily used and is preferred. At present, fly ash is used not only for concrete admixtures, but also for roadbed materials, soil improvement materials, lightweight aggregates, etc., but a considerable amount of fly ash is dumped in ash dumps and landfills. Rise. The chemical composition and specific surface area of fly ash used in the present invention are not particularly limited, and those standardized by JIS and those other than JIS can be used.

In the present invention, coal ash granules refer to those obtained by mixing coal ash and cement to form granules. The content of cement in the coal ash granules is 5 to 50% by weight, preferably 10 to 40% by weight. If it is less than 5% by weight, the strength of the granular material is low, and the granular material is easily broken by molding pressure.
If it exceeds 50% by weight, the utilization rate of fly ash decreases. There is also a problem that it is difficult to form uniform particles outside the above range. The particle size of the coal ash particles is preferably as uniform as possible, but is not an absolute condition. For example, 90
% Or more of the particles preferably falls within the range of 0.2 to 4.0 mm. As the coal ash particulate matter, a commercially available product may be used, or the coal ash may be produced by directly mixing coal ash and cement.

The surface layer sandwiching the above-mentioned core layer in a sandwich structure is composed of coal ash and a fibrous filler added as necessary. Both the coal ash and the fibrous filler should be those described above. Can be.

The sound insulating plate of the present invention is manufactured by curing the core layer with a binder while sandwiching the core layer from both sides with the surface layer.

As the binder, those described in the method of manufacturing the sound absorbing plate can be used. For example, when a phenol resin is used, the mixing ratio to coal ash is 1.5%.
To 50% by weight, particularly preferably 5.0 to 20% by weight.
If it is less than 1.5% by weight, it is difficult to obtain sufficient strength,
If the content exceeds 0% by weight, the ratio of inexpensive coal ash decreases, and the economic efficiency deteriorates.

The sound insulating plate of the present invention uses coal ash granules in the core layer, so that the sound insulating plate has a high density, the sound insulating performance is improved, and the amount of the thermosetting resin used as a binder is used. Can be reduced, and as a result, a sound insulating plate with high nonflammability can be obtained.

The sound insulating plate of the present invention can be manufactured in the same manner as the above sound absorbing plate using a binder. In addition, continuous voids are not formed inside the sound insulating plate, which is a compact made of coal ash as a main raw material, and has a dense and substantial structure in which sound is easily reflected.

The sound-absorbing and sound-insulating panel of the present invention is one in which a sound-absorbing plate and a sound-insulating plate are combined and integrated via an air layer. FIG.
1 is a partial cross-sectional view of a sound absorbing and insulating panel according to a preferred embodiment of the present invention, in which a sound absorbing plate 1 and a sound insulating plate 3 are combined and integrated via an air layer 2. Reference numeral 4 denotes a fibrous filler. In this embodiment, the fibrous filler 4 is provided near the surface layers of both the sound absorbing plate 1 and the sound insulating plate 3.

In the present invention, in order to improve the sound absorption characteristics,
The air layer 2 may be provided with a fibrous intermediate material 5. Examples of such fibrous materials include glass fibers, rock wool, and various other synthetic fibers. In addition, intermediate material 5
For example, a flexible material such as a foamed resin material, vinyl chloride foam, polyethylene foam, or flexible urethane foam can be used.

[0024]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below.

Example 1 (Production of a sound absorbing plate) 90% or more has a particle size of 0.3 to 1.2 mm.
Glass powder fired foamed granulated material (G-light,
Sunlight) and phenolic resin (SP-115P)
D, manufactured by Asahi Organic Materials Co., Ltd.) coated with 7% by weight (hereinafter abbreviated as RCG).
Quartz sand particles in the range of 3 to 1.2 mm coated with 4% by weight of the phenolic resin (hereinafter abbreviated as RCS), and a plain woven glass cloth prepreg of 80 g weight impregnated with 40% of the phenolic resin (Matsuura) (hereinafter abbreviated as GCPP) is prepared.

Next, the GCPP, RC,
^{S3600g / m 2, RCG2400g / m} 2, RCS
3600 g / m ² , GCPP, RCG 1200 g / m ²
The laminate was placed in a hot press, thermally cured under the conditions of a heating temperature of 160 ° C., a pressure of 10 kg / cm ² and a time of 10 minutes, a thickness of 10 mm and a density of 1.04 g / cm.
^3. A sound absorbing plate having a bending strength of 143 kgf / cm ² was manufactured.

(Production of sound insulation plate) Plain value 2120cm
^A mixture consisting of 75 parts by weight of ² / g coal ash (manufactured by Chubu Electric Power Hekinan Thermal Power) and 10 parts by weight of a novolak-type phenol resin (NK-7001, manufactured by Nippon Steel Chemical) (hereinafter abbreviated as a surface layer composition). And 45 parts by weight of the coal ash, 3 parts by weight of the phenol resin, and 90% or more of the particles have a particle size of 0.
A mixture of 54 parts by weight of coal ash cement granules (Fire Beads, manufactured by Tohoku Electric Power Co., Inc.) in the range of 3 to 1.66 mm (hereinafter, abbreviated as a composition for a core layer) and a length of 38 mm Glass strand cut into pieces (RE
R240-SM30, manufactured by Nippon Sheet Glass) is prepared.

Next, the surface layer composition 5 is placed on a release plate.
60 g / m ² , glass strand 330 g / cm ² , surface layer composition 930 g / cm ² , core layer composition 3000
0 g / m ² , surface layer composition 420 g / m ² , glass strand 330 g / cm ² , surface layer composition 1660 g / c
m ² , and the resulting laminate was placed in a hot press. The heating temperature was 160 ° C., the pressure was 20 kg / cm ² , and the time was 2 hours.
Heat cured for 5 minutes, thickness about 25mm, density 1.30
A sound insulating plate having a g / cm ³ and a bending strength of 114 kgf / cm ² was produced.

(Production of sound-absorbing and sound-integrating panel) Next, the above-mentioned sound-absorbing plate and the sound-insulating plate were each 500 mm wide and 300 mm long
0mm, 25mm thick at both longitudinal ends of both plates
A square pipe having a 25 mm air space was provided on one side of the sound absorbing plate, and the other surface thereof was formed of a sound insulating plate (P1).

Example 2 A rock wool felt (felt K, manufactured by Nippon Steel Chemical Co., Ltd.) having a thickness of 25 mm and a density of 40 kg / m ³ was inserted into the air layer of the sound absorbing and insulating integrated panel (P1) manufactured in Example 1. A sound insulation integrated panel (P2) was manufactured.

Example 3 An integrated sound absorbing and insulating panel (P3) was manufactured under the same conditions as in Example 2 except that the structure of the sound absorbing plate was different as described below.

(Production of Sound Absorbing Plate) RCG, RCS and GCP described in (Production of Sound Absorbing Plate) in Example 1
Prepare P. Next, GCPP, R
CS 3600 g / m ² , RCG 3600 g / m ² , GC
PP and RCS were scattered and laminated in the order of 3600 g / m ² , and the laminated body was placed in a hot press and thermally cured under the same conditions as in Example 1 (sound absorbing plate) to have a thickness of 10 mm and a density of 1.04 g / cm 2.
^3. A sound absorbing plate having a bending strength of 100 kgf / cm ² was manufactured.

Comparative Example 1 (Production of a sound absorbing plate): 90% or more has a particle size of 0.3 to 1.66 m
phenolic resin (SP-690) to coal ash cement granulated material (Fire Beads, manufactured by Tohoku
5, coated by 5% by weight of Asahi Organic Materials Co., Ltd. (hereinafter abbreviated as RCF);
A mixture of 10 parts by weight of a novolak type phenol resin (NK-7001, manufactured by Nippon Steel Chemical Co., Ltd.) with 100 parts by weight of the coal ash cement granulated material falling within the range of 2 to 4.0 mm (hereinafter, referred to as MFB) Abbreviations) and 38 mm
Glass Strand Cut to Length (Rer240-S
M30, manufactured by Nippon Sheet Glass).

Next, RCF1250 was placed on the release plate.
g / m ² , glass strand 210 g / m ² , MFB4
850 g / m ² , glass strand 210 g / m ² , M
FB 4200 g / m ² were scattered and laminated in this order, and the laminate was placed in a hot press, heated at 160 ° C. and pressured at 10 kg / m ²
cm ² , thermosetting under the conditions of time 10 minutes, thickness 10 mm,
A sound absorbing plate having a density of 1.1 g / cm ³ and a bending strength of 65 kgf / cm ² was manufactured.

(Production of sound insulation plate) Plain value 2120cm
^A mixture of 900 parts by weight of ² / g coal ash (manufactured by Chubu Electric Power Hekinan Thermal Power) and 125 parts by weight of a novolak type phenol resin (NK-7001, manufactured by Nippon Steel Chemical) (hereinafter abbreviated as MF) and 38 mm A glass strand (RE240-SM30, manufactured by Nippon Sheet Glass) cut to length is prepared.

Next, 450 g of MF was placed on a release plate for release.
m ² , glass strand 195 g / cm ² , MF233
70 g / cm ² , glass strand 195 g / cm ² ,
MF 1340 g / cm ² was spread and laminated in this order, and the laminate was placed in a hot press, heated at a temperature of 160 ° C. and a pressure of 20 kg.
/ Cm ² , heat cured for 25 minutes, thickness about 25m
m, density 1.10 g / cm ³ , flexural strength 108 kgf /
A sound insulating plate of cm ² was produced.

(Production of Sound Absorbing and Sound Integrating Panel) Next, the above sound absorbing plate and the sound insulating plate were each 820 mm wide and 235 mm long.
0mm, 25mm thick at both longitudinal ends of both plates
Square pipe is fixed with screws, and rock wool felt (Felt K, manufactured by Nippon Steel Chemical Co., Ltd.) having a thickness of 25 mm and a density of 40 kg / m ³ is inserted between the two plates, and one surface absorbs sound. A sound absorbing and insulating integrated panel (P0) made of a material and the other surface was made of a sound insulating material.

Example 4 (Sound insulation performance test of sound absorbing and insulating integrated panel) The sound absorbing plate of each sound absorbing and insulating integrated panel was used as a sound source side according to JIS A-1416.
The sound transmission loss in the laboratory was measured by the method described in Table 1, and the results are shown in Table 1 and FIG. Also, place the panel in the reverberation room with the sound absorbing plate facing upward, measure the reverberation room method sound absorption coefficient,
The results are shown in Table 2 and FIG. In FIGS. 2 and 3, the symbol ▲ indicates P2, the symbol × indicates P3, and the symbol x indicates P0.

From the graph shown in FIG.
It can be seen that the sound absorbing and insulating panels P2 and P3 of Example 3 show a larger sound transmission loss over the entire frequency than the sound absorbing and insulating panel P0 of Comparative Example 1. In addition, from the graph shown in FIG. 3, the sound absorbing and insulating panels P2 and P3 of the second and third embodiments have the middle and high sound range in combination with the fact that the fibrous material is provided in the intermediate air layer. It can be seen that a high sound absorption coefficient is shown over a wide frequency range.

[0040]

[Table 1]

[0041]

[Table 2]

[0042]

The sound absorbing and insulating panel of the present invention can be manufactured by an inexpensive material and an economical manufacturing method, and has excellent sound insulating performance. That is, since coal ash granules are used for the core layer of the sound insulating plate, the density of the sound insulating plate is high, and the sound insulating performance is improved. Further, the use of the thermosetting resin as a binder can be reduced with the use of the coal ash granules, and as a result, a highly nonflammable sound insulating plate can be obtained.

Thus, the sound-absorbing and sound-absorbing panels of the present invention can be used as sound-insulating walls, sound-insulating walls in various factories, sound-insulating walls around boilers in thermal power plants and the like, and sound-insulating walls for buildings such as apartment houses and offices. It has an excellent effect that it can be widely applied to partition walls and the like.

[Brief description of the drawings]

FIG. 1 is a partial sectional view of a sound absorbing and insulating panel of the present invention.

FIG. 2 is a graph showing frequency characteristics of sound transmission loss for each sound absorbing and insulating panel.

FIG. 3 is a graph showing a frequency characteristic of a sound absorption coefficient in a reverberation room method for each sound absorbing and insulating panel.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 sound absorbing plate 2 air layer 3 sound insulating plate 4 fibrous filler 5 fibrous intermediate material

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hakuhiko Kato 1 at Kita-Sekiyama, Otaka-cho, Midori-ku, Nagoya-shi, Aichi, Japan 1 Within Chubu Electric Power Co., Inc. (72) Inventor Masanao Owaki Tsukuba, Ibaraki Oji Onigakubo 1043 Kumagaya Gumi Technical Research Institute Co., Ltd. (72) Inventor Yoji Sugiki Oji Onigakubo 1043 Kumagaya Gumi Technical Research Institute Co., Ltd. (72) Inventor Toshiyuki Suzuki 2 Hatazawa Minami, Kisarazu City, Chiba Prefecture 36-2 chome 2 (72) Inventor Yasunori Fukushima 3-2-5-5D-3 Kiyomidai, Kisarazu-shi, Chiba

Claims (2)

[Claims] 1. A sound-absorbing and sound-insulating panel in which a porous sound-absorbing plate and a dense and substantially sound-insulating plate are combined and integrated via an air layer, wherein the sound-absorbing plate is filled with inorganic particulate matter and fibrous material which is added as required. Material and cured with a binder,
The sound insulation plate is a binder in a state in which a core layer made of coal ash granulated coal ash and coal ash is sandwiched from both sides by a surface layer made of coal ash and a fibrous filler added as necessary. A sound absorbing and insulating panel characterized by being cured. 2. The sound absorbing and insulating panel according to claim 1, wherein a fibrous intermediate material is provided in the air layer.