WO2022209348A1 - Structure and manufacturing method of acoustic double-faced honeycomb panel - Google Patents

Structure and manufacturing method of acoustic double-faced honeycomb panel Download PDF

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WO2022209348A1
WO2022209348A1 PCT/JP2022/005519 JP2022005519W WO2022209348A1 WO 2022209348 A1 WO2022209348 A1 WO 2022209348A1 JP 2022005519 W JP2022005519 W JP 2022005519W WO 2022209348 A1 WO2022209348 A1 WO 2022209348A1
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honeycomb
face
core
adhesive
foam
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PCT/JP2022/005519
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French (fr)
Japanese (ja)
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智久 中村
喜彦 植木
俊二 高橋
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株式会社静科
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    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general

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  • a second object of the present invention is to provide a structure and a manufacturing method in which even when the thickness of the sound absorbing foam material is increased in order to improve the sound absorbing performance, the honeycomb material can be well filled. Furthermore, when attaching the face material to the honeycomb material in manufacturing the core material on both sides, it is important to minimize the influence of the adhesive hardening time, thereby shortening the manufacturing time and improving the productivity. This is the third issue. Furthermore, to reduce the thickness of the panel by avoiding the thickness of the panel from becoming larger than the thickness required from the acoustic characteristics due to the provision of the projection of the honeycomb material for attaching the face material. is the fourth problem.
  • the height of the cell walls of the honeycomb material that is, the thickness of the honeycomb material is naturally less than half the thickness of the foam material. It is possible to avoid the problem that the honeycomb material is deformed and cannot be pushed in when filling, and at the same time, the second problem can be solved.
  • FIG. 1(b) two straight lines connecting the upper and lower ends of the walls forming the cell are drawn. This straight line indicates that the edge of the cell wall beyond plane A is visible rather than a cross-section. This straight line is omitted in the following explanatory diagrams.
  • the honeycomb material is already filled with the foam material, and the tip of the honeycomb material protrudes from the foam material by more than 2 mm, for example, the same operation is performed. It is expected that the adhesive will not be touched. However, in practice, the honeycomb material and the foam material themselves bend due to the weight of the foam material, so that the surface of the foam material is often wetted with the adhesive. A projection length of, for example, 10 mm or more may be necessary to ensure that the surface of the foam material is not wetted by the adhesive.
  • FIG. 5 is a cross-sectional view showing the concept of a state in which an adhesive is attached to the tip of one wall surface of the honeycomb material. It can be seen that the adhesive material 15 adheres to the tip of the wall surface 111 of the honeycomb material in the form of water droplets.
  • the cross section of the tip portion of the wall surface 111 forming the cells of the honeycomb material 11 strongly pressed against the air-permeable material 13 is deformed into an inverted T shape.
  • a part of the adhesive 15 adhering to the tip portion of the wall surface 111 flows to the bottom of the inverted T shape and permeates the air-permeable material 13 .
  • the adhesive 15 flows along the surface of the air-permeable material 13 toward the wall surface of the adjacent cell, clogs the cell openings and impairs the sound absorption performance. is attached only to the tip of the wall surface 111 .
  • the core material is completed when the adhesive 15 that bonds the air-permeable material 13 and the honeycomb material 11 is completely solidified. Therefore, it can be said that the core material preparation time is governed by the time A (natural drying and complete solidification time) related to the adhesive.
  • the acoustic double-sided honeycomb panel can maintain a predetermined air permeability without spreading the adhesive attached to the tip of the honeycomb material to the surface of the air-permeable material 13a, the air-permeable material 13b, or the foam material 12, which is the first problem. structure was realized.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Laminated Bodies (AREA)

Abstract

[Problem] The first problem is to provide a structure and a manufacturing method in which a face material having desired air-permeability can be disposed on any face of an acoustic double-faced honeycomb panel. The second problem is to provide a structure in which a honeycomb material is satisfactorily filled even if the thickness of a sound absorbing foam material is increased. The third problem is to shorten a manufacturing time and improve productivity. The fourth problem is to reduce the thickness of the panel. [Solution] A desired panel can be achieved by a structure in which a face material is bonded to each of two honeycomb materials having a total thickness smaller than the thickness of a sound absorbing foam material to form two core materials, and the two core materials are pressed in from both faces of the sound absorbing foam material. Further, in this structure, the thickness of the honeycomb material can be less than or equal to half the thickness of the sound absorbing foam material, whereby, when being filled with the sound absorbing foam material, the honeycomb material is less susceptible to deformation, and is satisfactorily filled. Productivity is improved by overlapping adhesive solidification times. The thickness is reduced by preventing an end of the honeycomb material from protruding from the foam material.

Description

音響両面ハニカムパネルの構造ならびに製造方法Structure and manufacturing method of acoustic double-sided honeycomb panel
本発明は、産業用機械・住宅・生活機器・移動発生源等の騒音源に対する防音対策に用いる吸音または遮音するパネルに関する。 The present invention relates to a sound-absorbing or sound-insulating panel used for soundproofing measures against noise sources such as industrial machines, houses, household appliances, and mobile sources.
　人口集中に伴う都市環境の変化、交通網の発達、住宅の電化などにより、騒音に関する苦情は増加している。総務省の平成２８年度公害苦情調査では、騒音公害が大気汚染を抜き、第１の苦情要因となった。特に低周波音の苦情は、年々増加の傾向にある。そのため、軽量で薄型であり、簡易に扱える防音パネルの開発が強く望まれている。 Complaints about noise are increasing due to changes in the urban environment due to population concentration, the development of transportation networks, and the electrification of housing. According to the 2016 Pollution Complaint Survey conducted by the Ministry of Internal Affairs and Communications, noise pollution was the number one cause of complaints, surpassing air pollution. In particular, complaints about low-frequency noise tend to increase year by year. Therefore, it is strongly desired to develop a soundproof panel that is lightweight, thin, and easy to handle.
　従来技術としては、ハニカム材の１つの端面（図１で６角形のセルが見えている面）に予め通気性材を貼り付けたものを芯材として、該ハニカム材のセル空間に吸音フォーム材を充填し、さらにハニカム材の他の面（図１で、図の背面側の端面）には非通気性である面材を貼り付けた構造の吸音パネルが提案されている。（特許文献１） As a conventional technique, one end surface of the honeycomb material (the surface where the hexagonal cells are visible in FIG. 1) is used as a core material, and a sound absorbing foam material is used in the cell spaces of the honeycomb material. and a non-breathable surface material is attached to the other surface of the honeycomb material (the end surface on the back side in FIG. 1). (Patent Document 1)
　特許文献１の技術は、フォーム材を充填した後で、ハニカム材の表面に通気性の表面材（以降、面材と略称する）を貼り付けようとすると、ハニカム材の先端（先端とは端面を構成する位置であって、ハニカム材の厚み方向の端部を言う）に付着させる接着材が面材あるいはフォーム材の表面に拡がり、通気性を損なってしまう可能性がある。従って、フォーム材を充填する前に、パネルに予め通気性材を貼り付ける必要があるので、予め通気性材を張り付けた面だけしか通気性面とすることができず、他の面は非通気性面としなくてはならないという課題が有った。 According to the technique of Patent Document 1, when an air-permeable surface material (hereinafter abbreviated as a face material) is attached to the surface of the honeycomb material after the foam material is filled, the tip of the honeycomb material (the tip is the end face) and the end portion in the thickness direction of the honeycomb material) may spread over the surface of the face material or foam material, impairing air permeability. Therefore, since it is necessary to attach the breathable material to the panel in advance before filling the foam material, only the surface to which the breathable material is attached in advance can be used as the breathable surface, and the other surfaces are non-breathable. There was a problem that I had to make it a sexual aspect.
また、吸音性能を向上するために吸音フォーム材の厚みを大きくすると、それに合わせてセルの厚み方向の寸法が大きくなり、その結果ハニカム材をフォーム材に十分に押し込むことが難しくなり、セルが変形して充填が良好に行えないという課題も有った。 In addition, when the thickness of the sound absorbing foam material is increased to improve the sound absorption performance, the dimensions in the thickness direction of the cells also increase accordingly. There was also a problem that the filling could not be performed satisfactorily.
この問題を解決する方法として、フォーム材の一方の面から厚さ方向中間まで差し込まれている第１のハニカム材と、他方の面から同じくフォーム材の厚さ方向中間まで差し込まれた第２のハニカム材をハニカム材の構成する六角形を俯瞰する方向から観察したときに、それぞれのセルの六角形が完全に重ならないように配置したフォーム材を充填したパネル状の防音材が提案されている。（特許文献２） As a method to solve this problem, a first honeycomb material inserted from one side of the foam material to the middle of the thickness direction and a second honeycomb material inserted from the other side to the middle of the thickness direction of the foam material are used. There has been proposed a panel-shaped soundproofing material filled with a foam material arranged so that the hexagons of each cell do not completely overlap when the honeycomb material is viewed from above. . (Patent document 2)
　この特許文献２の技術は、ハニカム材とフォーム材を用いた防音パネルを構成するための基材の構造に関するものであり、該基材の両面に通気性のある面材あるいは非通気性である面材を具備させる必要が有るが、その構造および製造方法は開示されていない。 The technique of Patent Document 2 relates to the structure of a base material for constructing a soundproof panel using a honeycomb material and a foam material. Although it is necessary to have a face member, its structure and manufacturing method are not disclosed.
　また別の提案として、ハニカム材のセルにフォーム材を充填し、かつフォーム材の両面からハニカム材の先端が突出した芯材を用意し、この芯材の両面に表面材を接着する技術が提示されている（特許文献３）。この技術によると、フォーム材の厚さの半分以下の厚みをセル高として持つハニカム材をフォーム材の両面からハニカム材の先端を押し込む方法が提案されている。 Another proposed technique is to fill the cells of a honeycomb material with a foam material, prepare a core material in which the tips of the honeycomb material protrude from both sides of the foam material, and adhere surface materials to both sides of this core material. (Patent Document 3). According to this technique, a method is proposed in which a honeycomb material having a cell height that is half or less than the thickness of the foam material is pushed in from both sides of the foam material.
ここで表面材を通気性のある面材とする場合には、ハニカム材の先端に付着させる接着剤が通気性のある面材あるいはフォーム材の表面に拡がり、通気性を損なってしまうことがあるので、これを防ぐためにハニカム材先端の突出量を大きくしておく必要があり、これはパネル全体の厚さから見て無視できない寸法になるという問題もあった。
  Here, when the surface material is a breathable surface material, the adhesive attached to the tip of the honeycomb material may spread over the surface of the breathable surface material or foam material, impairing the breathability. Therefore, in order to prevent this, it is necessary to increase the amount of protrusion of the tip of the honeycomb material.
特許３８０６７４４号公報Japanese Patent No. 3806744 特許６４４１７０５号公報Japanese Patent No. 6441705 特許４４１８８６２号公報Japanese Patent No. 4418862
　これまでは、片面吸音性、片面遮音性の音響両面パネルが一般的であったが、両面吸音特性の音響両面パネルが求められるようになってきた。その理由の一つ目は、音響パネルを壁面と平行に配置したときに、壁面からの反射音を吸収することの必要性であり、二つ目は、楽器間に設置して、複数の楽器の音が、お互いに干渉しあわないようし、聴取者に楽器それぞれの音を出来るだけそのままの状態で届けることの必要性である。そこで、パネルのいずれの面も所望の通気性を持った面材を配置して、両面から吸音できる構造ならびに製造方法を提供することが第１の課題である。 Until now, double-sided acoustic panels with sound absorption on one side and sound insulation on the other side were common, but double-sided acoustic panels with sound absorption properties on both sides are now in demand. The first reason is the necessity of absorbing the reflected sound from the wall surface when the acoustic panel is placed parallel to the wall surface. It is necessary to prevent the sounds of the instruments from interfering with each other and to deliver the sound of each instrument to the listener as intact as possible. Therefore, the first problem is to provide a structure and a manufacturing method that can absorb sound from both sides by arranging a surface material having desired air permeability on both sides of the panel.
また、吸音性能を向上するために吸音フォーム材の厚さを増やした場合でもハニカム材への充填が良好に行われる構造ならびに製造方法を提供することが第２の課題である。また更に、両側の芯材を製作するにあたってハニカム材に面材を張り付けるとき、接着剤の固化時間の影響を出来るだけ受けないようにして、製造時間を短縮し生産性を向上することが第３の課題である。また更に、面材貼り付け用のハニカム材の突出部を設けたために、パネルの厚さが音響特性から必要とされる厚さ以上に大きくなってしまうのを避けて、パネルを薄型化することが第４の課題である。
  A second object of the present invention is to provide a structure and a manufacturing method in which even when the thickness of the sound absorbing foam material is increased in order to improve the sound absorbing performance, the honeycomb material can be well filled. Furthermore, when attaching the face material to the honeycomb material in manufacturing the core material on both sides, it is important to minimize the influence of the adhesive hardening time, thereby shortening the manufacturing time and improving the productivity. This is the third issue. Furthermore, to reduce the thickness of the panel by avoiding the thickness of the panel from becoming larger than the thickness required from the acoustic characteristics due to the provision of the projection of the honeycomb material for attaching the face material. is the fourth problem.
　第１の課題を解決するために、ハニカム材の先端部に限って接着剤を付着させて、用途・機能に応じた適宜材料からなる面材を予めこれに貼り付けた芯材を用意し、各種芯材を必要に応じて組み合わせて、吸音フォーム材の両面から押し込む方法が考えられる。
なお、この場合、両面通気性材の両面吸音パネルの制作が第一の課題の主目的であるが、両面の組み合わせは、両面通気性材に限定することなく、通気性材と非通気性材の組み合わせであっても、両面非通気性材であっても対応できる製作方法とすることが望ましいので、以降、音響両面ハニカムパネルの製作方法として、説明する。 In order to solve the first problem, a core material is prepared by applying an adhesive only to the tip of the honeycomb material and attaching a face material made of an appropriate material according to the purpose and function in advance to the core material. It is conceivable to combine various core materials according to need and press them from both sides of the sound-absorbing foam material.
In this case, the main purpose of the first task is to produce a double-sided sound absorbing panel with breathable materials on both sides. Since it is desirable to have a manufacturing method that can handle both a combination of the above and a double-sided non-air-permeable material, a method for manufacturing a double-sided acoustic honeycomb panel will be described below.
　この製造方法では、ハニカム材の先端に付着させた接着剤が固化した後で芯材を吸音フォーム材に押し込むことを前提とするので、接着剤が面材あるいはフォーム材の表面に拡がる恐れがなく、通気性すなわち音響特性を所望のものとすることができる。 In this manufacturing method, it is assumed that the core material is pushed into the sound-absorbing foam material after the adhesive attached to the tip of the honeycomb material has solidified, so there is no fear that the adhesive will spread over the face material or the surface of the foam material. , breathability or acoustic properties can be desired.
また、この製造方法ではハニカム材のセル壁の高さすなわちハニカム材の厚さは自ずとフォーム材の厚さの半分以下となるので、ハニカム材をフォーム材に押し込む時、すなわちハニカム材にフォーム材を充填する時に、ハニカム材が変形して押し込むことができないというトラブルを避けることができて、同時に第２の課題を解決することができる。 In this manufacturing method, the height of the cell walls of the honeycomb material, that is, the thickness of the honeycomb material is naturally less than half the thickness of the foam material. It is possible to avoid the problem that the honeycomb material is deformed and cannot be pushed in when filling, and at the same time, the second problem can be solved.
　第３の課題を解決するために、まず、第一工程として、ハニカム材の先端に接着材を必要最小限だけ付着させ、第二工程として、用途・機能に応じた適宜材料からなる面材を水平台座に設置し、第三工程として、該ハニカム材の先端部を水平に置かれた面材に当接して第１の芯材を組み立てる。第一工程で当該ハニカム材の先端に付着させる接着剤の量は、極力少量とし、当接する面材が通気性材の場合は、通気性開口部を塞ぐことのないように配慮する必要性がある。 In order to solve the third problem, the first step is to attach the minimum amount of adhesive to the tip of the honeycomb material, and the second step is to apply a surface material made of an appropriate material according to the purpose and function. It is placed on a horizontal pedestal, and in the third step, the tip of the honeycomb material is brought into contact with a horizontally placed face material to assemble the first core material. The amount of adhesive applied to the tip of the honeycomb material in the first step should be as small as possible, and if the surface material in contact is a breathable material, it is necessary to take care not to block the ventilation openings. be.
次に、該芯材作成の第三の工程の直後に、すなわち該接着剤が流動性をやや失った段階で、第四の工程として、面材に当接したハニカム材の面材とは反対側の端面から、フォーム材を該芯材に押し込み、続いて、該芯材を構成する面材とハニカム材を接着する接着剤が固化までには至っていないが、流動性を失った段階で、該芯材とフォーム材の上下を反転して、上述の第一から第三の工程と同じ製法による第２の芯材を水平台座にハニカム材を上にして配置し、その第２の芯材に、前記フォーム材を第一の芯材が押し込まれた面に対向する他の面から押し込む第五の工程からなる製造方法とする。 Next, immediately after the third step of manufacturing the core material, that is, at the stage when the adhesive has lost a little fluidity, as the fourth step, the face material of the honeycomb material that is in contact with the face material is pressed against the face material. The foam material is pushed into the core material from the side end surface, and then, at the stage when the adhesive that bonds the face material and the honeycomb material constituting the core material has not yet solidified but has lost its fluidity, The core material and the foam material are turned upside down, and a second core material manufactured by the same manufacturing method as the above-described first to third steps is placed on a horizontal pedestal with the honeycomb material facing up, and the second core material is Second, the manufacturing method comprises a fifth step of pressing the foam material from the other surface opposite to the surface where the first core material is pressed.
　上記の工程によって、第１の芯材のハニカム材の端部に付着させた接着剤が固化はしていないが、流動性を失った段階まで待って、芯材の上下反転を行うので、ハニカム材の端部に付着した接着剤が面材あるいはフォーム材の表面に拡がることを避けて、通気性を確保して、所望の音響特性を得ることができる。 Although the adhesive adhered to the edge of the honeycomb material of the first core material is not solidified by the above steps, the core material is turned upside down after it loses its fluidity. It is possible to prevent the adhesive adhering to the edge of the material from spreading on the surface of the face material or the foam material, thereby ensuring air permeability and obtaining desired acoustic characteristics.
また、特許文献１に示されているように、フォーム材が押し込まれた後の面材とハニカム材の接着固化の過程においては、フォーム材の吸水特性により固化が促進される。さらに、面材とハニカム材の接着が完全に固化する前に上記の第４の工程から第５の工程に移ることができるので、第１の芯材と第２の芯材の固化時間をオーバラップさせることで累計の固化時間が短縮できる。このようにして第３の課題が解決される。 Further, as shown in Patent Document 1, in the process of adhesion and solidification between the face material and the honeycomb material after the foam material is pushed in, solidification is promoted by the water absorbing properties of the foam material. Furthermore, since it is possible to move from the fourth step to the fifth step before the bonding between the face material and the honeycomb material is completely solidified, the solidification time of the first core material and the second core material may be excessive. By wrapping, the total solidification time can be shortened. Thus, the third problem is solved.
　ここで、これ以降での説明の為に、接着剤の固化に関する時間について次のように定義する。Ａ（自然乾燥完全固化時間）：ハニカム材と表面材を接着し、そのままの状態で自然乾燥し完全固化させるのに要する時間。Ｂ（フォーム材利用完全固化時間）：ハニカム材と表面材を接着した直後にフォーム材を押し込み、フォーム材などの吸水性を利用して完全固化させるのに要する時間。Ｃ（フォーム材利用半固化時間）：ハニカム材と表面材を接着した直後にフォーム材を押し込み、フォーム材などの吸水性を利用して、接着剤が流動しない程度に半固化させるのに要する時間。 Here, for the sake of explanation from here on, the time for the adhesive to solidify is defined as follows. A (natural drying and complete solidification time): The time required for the honeycomb material and the surface material to be adhered to each other, naturally dried as they are, and completely solidified. B (Complete solidification time using foam material): The time required for the foam material to be pushed in immediately after bonding the honeycomb material and the surface material, and completely solidified using the water absorbability of the foam material. C (semi-solidification time using foam material): The time required for the foam material to be pushed in immediately after bonding the honeycomb material and the surface material, and to semi-solidify to such an extent that the adhesive does not flow, using the water absorbency of the foam material. .
　このように、フォーム材の両面から二つの芯材を押し込む製法とすることによって、吸音フォーム材の厚さを大きくしても、吸音フォーム材にハニカム材を充填するときの充填深さをフォーム材の厚さの半分以下にすることができるので、吸音フォーム材を充填する時にハニカム材のセルが押し込めない、あるいはセルが変形するといったことを避けることができる程度に、ハニカム材の厚さを選択することで、充填が良好に行うことができる。 In this way, by adopting a manufacturing method in which two core materials are pushed in from both sides of the foam material, even if the thickness of the sound absorbing foam material is increased, the filling depth when filling the sound absorbing foam material with the honeycomb material can be reduced. The thickness of the honeycomb material can be less than half of the thickness of the honeycomb material, so the thickness of the honeycomb material is selected to the extent that it is possible to avoid the cells of the honeycomb material from being pushed in or deformed when the sound absorbing foam material is filled. By doing so, the filling can be performed satisfactorily.
またこの場合、２つのハニカム材の厚さの合計がフォーム材の厚さより小さいので、フォーム材がハニカム材のセル壁で切り離されてセル単位にバラバラとなることはなく、面方向（セル空間に対して垂直方向）に繋がるという利点が有る。 Also, in this case, since the total thickness of the two honeycomb materials is smaller than the thickness of the foam material, the foam material is not separated by the cell walls of the honeycomb material and separated into individual cells. There is an advantage that it is connected in the vertical direction).
　第１の課題の解決法では、面材を予めハニカム材に貼り付けた芯材を用意するとき、ハニカム材の先端に付着させた接着剤が完全に固化した後に、芯材を吸音フォーム材に押し込む。これによって、接着剤が面材あるいはフォーム材の表面に拡がることを避け得るために、ハニカム材の先端をフォーム材の表面から十分に突出させておいて接着剤を塗布するという必要が無くなるので、第４の課題も同時に解決される。なお、第３の課題を解決する方法でも第４の課題が同時に解決される。
  In the solution of the first problem, when preparing a core material in which a face material is attached in advance to a honeycomb material, after the adhesive attached to the tip of the honeycomb material is completely solidified, the core material is attached to the sound absorbing foam material. push in. As a result, it is not necessary to apply the adhesive while the tip of the honeycomb material protrudes sufficiently from the surface of the foam material in order to prevent the adhesive from spreading on the surface of the face material or the foam material. The fourth problem is also solved at the same time. The method for solving the third problem also solves the fourth problem at the same time.
　本発明によれば、パネルのいずれの面も通気性あるいは非通気性を問わず、任意の吸音性能を有する面材を配置した構造を提供することができる。また、吸音性能を向上するために吸音フォーム材の厚みを増やしてもハニカム材の充填が良好に行われる構造を提供することができる。また、従来はフォーム材に接着材が付着してセルの面積の一部を塞ぎ、吸音性能を損なわせているが、本発明では、ハニカム材を事前に通気性のある面材に接着することで、セルサイズの全面を吸音に有効活用する吸音パネルを提供できる。
  According to the present invention, it is possible to provide a structure in which face materials having arbitrary sound absorption performance are arranged on either side of the panel, regardless of whether they are breathable or non-breathable. Further, it is possible to provide a structure in which the honeycomb material is satisfactorily filled even when the thickness of the sound absorbing foam material is increased in order to improve the sound absorbing performance. Conventionally, an adhesive adheres to the foam material and blocks part of the area of the cells, impairing the sound absorption performance. Therefore, it is possible to provide a sound absorbing panel that effectively utilizes the entire surface of the cell size for sound absorption.
ハニカム材の斜視図および断面図Perspective and cross-sectional views of honeycomb material 通気性材の平面図および断面図Top view and cross section of breathable material ハニカム材と通気性材を重ねた状態を拡大して示す平面図A plan view showing an enlarged state in which the honeycomb material and the air-permeable material are stacked ハニカム材の壁面の先端部のみに接着剤を付着させる工程の概念を示す断面図Cross-sectional view showing the concept of the process of applying adhesive only to the tip of the honeycomb wall surface ハニカム材の１つの壁面の先端部に接着剤を付着させた状況の概念を示す断面図A cross-sectional view showing the concept of a situation in which an adhesive is attached to the tip of one wall surface of a honeycomb material. ハニカム材と通気性材を接着する工程の概念を示す断面図Cross-sectional view showing the concept of the process of bonding the honeycomb material and the air-permeable material 第１の芯材の概念を示す断面図Sectional view showing the concept of the first core material 第１の芯材にフォーム材を充填する工程の概念を示す断面図Sectional view showing the concept of the process of filling the first core material with the foam material 第２の芯材の概念を示す断面図Sectional view showing the concept of the second core material 第２の芯材にフォーム材を充填する工程の概念を示す断面図Sectional view showing the concept of the process of filling the second core material with the foam material 音響両面ハニカムパネルの断面図Cross section of acoustic double-sided honeycomb panel 実施例２の第１の芯材の概念を示す断面図Sectional view showing the concept of the first core material of Example 2 実施例２において第１の芯材にフォーム材を充填する工程の概念を示す断面図Sectional view showing the concept of the process of filling the first core material with the foam material in Example 2 実施例２において第１の芯材とフォーム材を上下反転した概念を示す断面図Sectional view showing a concept in which the first core material and the foam material are turned upside down in Example 2 実施例２において第２の芯材にフォーム材を充填する工程の概念を示す断面図Sectional view showing the concept of the process of filling the second core material with the foam material in Example 2 第２の面材が非通気性材である音響両面ハニカムパネルの断面図FIG. 2 is a cross-sectional view of an acoustic double-sided honeycomb panel in which the second face material is a non-breathable material; 異なる面材を持つ２つの芯材を使って音響両面ハニカムパネルを製造する工程の概念を示す断面図Cross-sectional view showing the concept of the process of manufacturing an acoustic double-sided honeycomb panel using two core materials with different face materials
　以下、本発明を実施するための形態について、図面を参照しつつ詳細に説明する。図１１は、本実施例の音響両面ハニカムパネル１ａの断面図である。フォーム材１２を充填したハニカム材の二つセル壁１１１ａと１１１ｂ及び、そのフォーム材１２の外側両面に隙間なく通気性材１３ａおよび１３ｂを積層した構造である。 Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. FIG. 11 is a cross-sectional view of the acoustic double-sided honeycomb panel 1a of this embodiment. It has a structure in which two cell walls 111a and 111b of a honeycomb material filled with a foam material 12 and air-permeable materials 13a and 13b are laminated on both outer sides of the foam material 12 without gaps.
　図１（ａ）はハニカム材の一部を切り取った斜視図を示しており、図１（ｂ）は図１（ａ）に１点鎖線で示した面Ａの一部における断面図を示している。図１（ｂ）ではハニカムセルの壁面１１１の断面が並んでいる状況を見ることができる。図１（ｂ）においてセルを形成する壁面は同じ形状のものが繰り返して描かれているので、図が煩雑になるのを避けるため、その内の１つにだけ符号を付けてある。また図１は、全体の一部分だけを示している。（これは以下の他の図についても同じである） FIG. 1(a) shows a perspective view of a part of the honeycomb material, and FIG. 1(b) shows a cross-sectional view of a part of plane A indicated by a dashed line in FIG. 1(a). there is In FIG. 1(b), it can be seen that the cross sections of the wall surfaces 111 of the honeycomb cells are arranged side by side. In FIG. 1(b), wall surfaces forming the cells have the same shape repeatedly, so only one of them is given a reference numeral in order to avoid complication of the drawing. Also, FIG. 1 shows only a part of the whole. (This is the same for the other figures below)
　また図１（ｂ）において、セルを形成する壁面の上下の端を結んだ２本の直線が描かれている。この直線は断面ではなく面Ａの向こう側にあるセルの壁の端部が見えていることを示している。以下の説明図ではこの直線は省略してある。 In addition, in FIG. 1(b), two straight lines connecting the upper and lower ends of the walls forming the cell are drawn. This straight line indicates that the edge of the cell wall beyond plane A is visible rather than a cross-section. This straight line is omitted in the following explanatory diagrams.
　本実施例で使用したハニカム材は吸水性ハニカム材（タイガレックス製セラミックハニカムＨＲ２０）である。吸水性ハニカム材の成分は例えば含水ケイ酸マグネシウム、パルプ、シリカ、接着剤類である。ハニカム材１１の六角形のセルサイズは２０ｍｍであり、セルを形成する壁面の高さ寸法（すなわちハニカム材の厚さ）は２５ｍｍ、壁面の厚さ寸法は０．３ｍｍである。
  なお、ハニカム材は含水ケイ酸マグネシウムの代わりに水酸化アルミニウムを成分として含むものであっても構わない。 The honeycomb material used in this example is a water absorbing honeycomb material (Ceramic honeycomb HR20 manufactured by Tigalex). Components of the water-absorbent honeycomb material are, for example, hydrous magnesium silicate, pulp, silica, and adhesives. The hexagonal cell size of the honeycomb material 11 is 20 mm, the height dimension of the walls forming the cells (that is, the thickness of the honeycomb material) is 25 mm, and the wall thickness dimension is 0.3 mm.
The honeycomb material may contain aluminum hydroxide as a component instead of hydrous magnesium silicate.
　図２に、通気性材の一部の平面図および断面図が示してある。図２（ｂ）は、図２（ａ）において一点鎖線Ａ－Ａ`によって示す位置の内の丸印で示す範囲を拡大して示した断面図である。通気性材１３はアルミニウム合金繊維不織布１３１の両面をアルミニウム合金製エキスパンドメタル１３２でサンドイッチした構造である。 　Fig. 2 shows a plan view and a cross-sectional view of part of the breathable material. FIG. 2(b) is a cross-sectional view showing an enlarged area indicated by a circle within the position indicated by the dashed-dotted line AA' in FIG. 2(a). The breathable material 13 has a structure in which both sides of an aluminum alloy fiber nonwoven fabric 131 are sandwiched between aluminum alloy expanded metals 132 .
　図３は、ハニカム材と通気性材を重ねた状態を拡大して示す平面図である。全体から一部を切り取って、ハニカム材の有る方向から（図７で上側から）見たものである。ハニカム材１１の向こう側に通気性材１３の表面のアルミニウム合金製エキスパンドメタルが見えている。音響両面ハニカムパネルにおいて、吸収または遮断されるべき音響が入射する方向は通気性材１３の有る面（図で紙面の裏面側）である。 Fig. 3 is an enlarged plan view showing a state in which the honeycomb material and the air-permeable material are stacked. A part is cut from the whole and viewed from the direction of the honeycomb material (from the upper side in FIG. 7). The aluminum alloy expanded metal on the surface of the air-permeable material 13 can be seen on the other side of the honeycomb material 11 . In the acoustic double-sided honeycomb panel, the incident direction of the sound to be absorbed or blocked is the surface with the air-permeable material 13 (the back side of the paper surface in the figure).
本実施例で使用した通気性材１３（株式会社ユニックス製ポアルＣ１）の全体の厚さは１．６ｍｍで、エキスパンドメタルの厚さは０．４または０．６ｍｍで、開口率は４０％である。本実施例ではアルミニウム合金繊維不織布を通気性材として使用したが、他の金属、無機／有機系繊維材シートでも良い。 The overall thickness of the breathable material 13 (Poal C1 manufactured by Unix Co., Ltd.) used in this example is 1.6 mm, the thickness of the expanded metal is 0.4 or 0.6 mm, and the aperture ratio is 40%. be. In this embodiment, the aluminum alloy fiber nonwoven fabric is used as the air-permeable material, but other metal or inorganic/organic fiber material sheets may be used.
　図４はハニカム材の壁面の先端部のみに接着剤を付着させる工程の概念を示す断面図である。刷毛などでハニカム材の壁面の先端に均等に接着剤を付着させるのは難しい。本発明では図４（ａ）に示すように、水平に置いた定盤２の上に、図では全体は見えないが、周囲が閉じた形状で、所望の深さ設定できる設定プレート２１を配置する。定盤２と深さ設定プレート２１でプールを形成するので、ここに深さ設定プレート２１の上面近くまで接着剤１５を注ぐ。 Fig. 4 is a cross-sectional view showing the concept of the process of applying the adhesive only to the tip of the wall surface of the honeycomb material. It is difficult to evenly apply the adhesive to the tips of the honeycomb walls using a brush or the like. In the present invention, as shown in FIG. 4(a), a setting plate 21 with a closed periphery and capable of setting a desired depth is placed on a horizontally placed surface plate 2, although the whole is not visible in the drawing. do. Since the surface plate 2 and the depth setting plate 21 form a pool, the adhesive 15 is poured up to near the upper surface of the depth setting plate 21 .
図４（ｂ）に示すように、ハニカム材１１のセルを形成する壁面１１１の先端部分をこの接着材１５のプールの底に着くまで浸漬する。定盤２が水平であるので、全ての壁面１１１がほぼ同じ深さまで漬かる。 As shown in FIG. 4(b), the tip portions of the wall surfaces 111 forming the cells of the honeycomb material 11 are immersed in the adhesive material 15 until they reach the bottom of the pool. Since the surface plate 2 is horizontal, all the wall surfaces 111 are submerged to approximately the same depth.
図４（ｃ）に示すように、吸水性ハニカム材１１を接着材１５のプールから引き揚げると、ハニカム材１１のセルを形成する全ての壁面１１１の先端部分には接着材１５のプールの深さとほぼ同じ高さで接着剤１５が付着する。本実施例における浸漬深さ、すなわち接着剤付着高さは約２ｍｍである。 As shown in FIG. 4(c), when the water-absorbing honeycomb material 11 is pulled up from the pool of the adhesive 15, all the wall surfaces 111 forming the cells of the honeycomb material 11 have the depth and depth of the pool of the adhesive 15. The adhesive 15 adheres at substantially the same height. The immersion depth, ie, adhesive adhesion height, in this example is about 2 mm.
仮に、フォーム材をハニカム材に充填済みで、ハニカム材の先端を例えば２ｍｍを超えてフォーム材から突出させたものを使って同じ作業をした場合、浸漬深さより突出長さが大きいのでフォーム材は接着剤に触れないことが期待される。しかし、実際にはハニカム材とフォーム材自体の重さで撓むためフォーム材の表面まで接着剤で濡れてしまうことが往々にして生じる。フォーム材の表面が接着剤で濡れないことを保証するためには、例えば１０ｍｍ以上の突出長さが必要と思われる。 Hypothetically, if the honeycomb material is already filled with the foam material, and the tip of the honeycomb material protrudes from the foam material by more than 2 mm, for example, the same operation is performed. It is expected that the adhesive will not be touched. However, in practice, the honeycomb material and the foam material themselves bend due to the weight of the foam material, so that the surface of the foam material is often wetted with the adhesive. A projection length of, for example, 10 mm or more may be necessary to ensure that the surface of the foam material is not wetted by the adhesive.
　積層構造をなす音響両面ハニカムパネルにおいて通気性材１３とハニカム材１１を接着する接着剤は、水溶性のエマルジョン系接着剤（サイデン製ＰＺ－８０６またはコニシ株式会社製ボンドＣＸ５０、不揮発分４３．５～４６．５%）である。 The adhesive that bonds the air permeable material 13 and the honeycomb material 11 in the acoustic double-sided honeycomb panel having a laminated structure is a water-soluble emulsion adhesive (PZ-806 manufactured by Saiden or Bond CX50 manufactured by Konishi Co., Ltd., non-volatile content 43.5 ~46.5%).
図５はハニカム材の１つの壁面の先端部に接着剤を付着させた状況の概念を示す断面図である。ハニカム材の壁面１１１の先端に接着材１５が水滴状に付着している状況を見ることができる。 FIG. 5 is a cross-sectional view showing the concept of a state in which an adhesive is attached to the tip of one wall surface of the honeycomb material. It can be seen that the adhesive material 15 adheres to the tip of the wall surface 111 of the honeycomb material in the form of water droplets.
図６はハニカム材と通気性材を接着する工程の概念を示す断面図である。図６（ａ）に示すように、水平に置いた通気性材１３の上にハニカム材１１を対向させ、図示しないプレスを使って、図に矢印で示したように下降させ通気性材１３に圧力５トン／ｍ２で押し付ける。 FIG. 6 is a cross-sectional view showing the concept of the process of adhering the honeycomb material and the air-permeable material. As shown in FIG. 6(a), the honeycomb material 11 is placed on the horizontally placed air-permeable material 13, and is lowered using a press (not shown) in the direction indicated by the arrow in the drawing. Press with a pressure of 5 tons/m 2 .
図６（ｂ）に示すように、通気性材１３に強く押し付けられたハニカム材１１のセルを形成する壁面１１１の先端部分の断面は逆Ｔ字型に変形する。壁面１１１の先端部分に付着していた接着剤１５の一部は逆Ｔ字型の底に流動して、通気性材１３に浸透する。この時、接着剤１５が通気性材１３の表面を伝って隣り合うセルの壁面へ向かって流動してセルの開口を塞ぎ、吸音性能を損なうことがないように、限られた量の接着剤を壁面１１１の先端にのみ付着させている。なお、通気性材１３とハニカム材１１を接着する接着剤１５が完全に固化したときを芯材の完成とする。従って、芯材作成時間は、接着剤に関する時間Ａ（自然乾燥完全固化時間）が支配項であると言える。 As shown in FIG. 6B, the cross section of the tip portion of the wall surface 111 forming the cells of the honeycomb material 11 strongly pressed against the air-permeable material 13 is deformed into an inverted T shape. A part of the adhesive 15 adhering to the tip portion of the wall surface 111 flows to the bottom of the inverted T shape and permeates the air-permeable material 13 . At this time, the adhesive 15 flows along the surface of the air-permeable material 13 toward the wall surface of the adjacent cell, clogs the cell openings and impairs the sound absorption performance. is attached only to the tip of the wall surface 111 . The core material is completed when the adhesive 15 that bonds the air-permeable material 13 and the honeycomb material 11 is completely solidified. Therefore, it can be said that the core material preparation time is governed by the time A (natural drying and complete solidification time) related to the adhesive.
図７は第１の芯材の概念を示す断面図である。図６に示した工程によって、ハニカム材と通気性材を接着されたものを第１の芯材１０ａと呼ぶ。添え字の“ａ”は“第１”を示しており、これは次に説明する第２の芯材１０ｂと区別するためのものである。 FIG. 7 is a cross-sectional view showing the concept of the first core material. The honeycomb material and the air-permeable material bonded by the process shown in FIG. 6 are called a first core material 10a. The suffix "a" indicates "first" to distinguish it from the second core material 10b described below.
　図８は第１の芯材にフォーム材を充填する工程の概念を示す断面図である。フォーム材１２は硬質フェノールフォーム材である。フェノールフォーム材はフェノール樹脂を発泡させて製造されるもので、本実施例では、連通気泡率９５％以上を有し、密度１９ｋｇ／ｍ３の製品を使用した。（松村アクア株式会社製）気泡が連続している連通気泡により吸水性を示す。 FIG. 8 is a cross-sectional view showing the concept of the process of filling the first core material with the foam material. Foam material 12 is a rigid phenolic foam material. The phenolic foam material is produced by foaming phenolic resin, and in this example, a product having a continuous cell rate of 95% or more and a density of 19 kg/m 3 was used. (manufactured by Matsumura Aqua Co., Ltd.) Shows water absorption due to continuous air bubbles.
図８（ａ）は第１の芯材１０ａを構成している面材である通気性材１３ａがハニカム材と接着していない面を下にして、プレス下盤３１の上に置いて、その上方に対向してフォーム材１２を配置した状況である。フォーム材１２の厚さは６０ｍｍである。 FIG. 8(a) shows that the air-permeable material 13a, which is the surface material that constitutes the first core material 10a, is placed on the lower platen 31 of the press with the side not bonded to the honeycomb material facing down. This is a situation in which the foam material 12 is arranged facing upward. The foam material 12 has a thickness of 60 mm.
　ここで、図８（ｂ）に示すように、プレス上盤３２を図に示した矢印のように圧下すると、ハニカム材のセルの壁面１１１ａがフォーム材１２の第１の面（図で下側の面）から押し込まれ、最終的にフォーム材１２の第１の面が通気性材１３ａの上側の面に達して止まる。このとき、通気性材１３ａの上面とフォーム材１２の第１の面はお互いに接触している。従って、通気性材１３ａと接触しているフォーム材１２の表面の位置と、芯材１０ａの通気性材１３ａに接着されたハニカム材１２のセル壁１１１ａの端面の位置とは、ほぼ同一レベルにある。 Here, as shown in FIG. 8(b), when the press upper platen 32 is pushed down in the direction of the arrow shown in the figure, the wall surfaces 111a of the cells of the honeycomb material are pressed against the first surface of the foam material 12 (lower side in the figure). ), and finally the first surface of the foam material 12 reaches the upper surface of the air-permeable material 13a and stops. At this time, the upper surface of the air-permeable material 13a and the first surface of the foam material 12 are in contact with each other. Therefore, the position of the surface of the foam material 12 in contact with the air-permeable material 13a and the position of the end faces of the cell walls 111a of the honeycomb material 12 bonded to the air-permeable material 13a of the core material 10a are almost at the same level. be.
　図９は第２の芯材の概念を示す断面図である。第２の芯材の構造、材質、製作工程は第１の芯材と同じである。図９は図７の上下を逆にして添え字を“ａ”から“ｂ”に変えたものである。第２の芯材を製作するのに要する時間も、第１の芯材と同じく、接着剤の自然乾燥完全固化時間Ａが支配項である。 FIG. 9 is a cross-sectional view showing the concept of the second core material. The structure, material, and manufacturing process of the second core material are the same as those of the first core material. FIG. 9 is obtained by turning FIG. 7 upside down and changing the suffix "a" to "b". As with the first core material, the time required to manufacture the second core material is also governed by the natural drying and complete solidification time A of the adhesive.
図１０は第２の芯材にフォーム材を充填する工程を示す概念の断面図である。図１０（ａ）から見て取れるように、第２の芯材は図９に示した姿勢で、フォーム材１２の上に乗せるように配置される。ここで、図１０（ｂ）に示すように、プレス上盤３２を図に示した矢印の方向に圧下すると、ハニカム材のセルの壁面１１１ｂがフォーム材１２の第２の面（図で上の面）から押し込まれ、最終的に通気性材１３ｂの下側の面がフォーム材１２の第２の面（図で上側）に達し、互いに接触する。 FIG. 10 is a conceptual cross-sectional view showing the process of filling the second core material with the foam material. As can be seen from FIG. 10(a), the second core member is placed on top of the foam member 12 in the position shown in FIG. Here, as shown in FIG. 10(b), when the press upper platen 32 is pressed down in the direction of the arrow shown in the figure, the wall surfaces 111b of the cells of the honeycomb material move to the second surface of the foam material 12 (upper surface in the figure). Finally, the lower surface of the air-permeable material 13b reaches the second surface (upper side in the drawing) of the foam material 12 and contacts each other.
従って、通気性材１３ｂと接触しているフォーム材１２の面と、芯材１０ｂの通気性材１３ｂに接着されたハニカム材のセル壁面１１１ｂの端面とは、ほぼ同一レベルにある。 Therefore, the surface of the foam material 12 in contact with the air-permeable material 13b and the end surface of the cell wall surface 111b of the honeycomb material adhered to the air-permeable material 13b of the core material 10b are substantially at the same level.
　図１１は完成した両面通気性材の音響両面ハニカムパネルの断面図である。２つのハニカム材の先端がフォーム材の中で接していても良いのであるが、この実施例ではフォーム材１２の厚さは６０ｍｍであり、２つの芯材を構成しているハニカム材の厚さはそれぞれ２５ｍｍであるので、２つのハニカム材のセルの壁面１１１ａの先端と壁面１１１ｂの先端の間のフォーム材の厚さは１０ｍｍである。 Fig. 11 is a cross-sectional view of a completed acoustic double-sided honeycomb panel of double-sided breathable material. Although the ends of the two honeycomb materials may be in contact with each other in the foam material, in this embodiment, the thickness of the foam material 12 is 60 mm, and the thickness of the honeycomb material forming the two core materials is equal to that of the honeycomb material. are 25 mm each, so the thickness of the foam material between the tips of the walls 111a and 111b of the two honeycomb cells is 10 mm.
　こうして、第１の課題である、ハニカム材の先端に付着させた接着剤が通気性材１３ａ、通気性材１３ｂあるいはフォーム材１２の表面に拡がることなく、所定の通気性を保つ音響両面ハニカムパネルの構造が実現できた。 Thus, the acoustic double-sided honeycomb panel can maintain a predetermined air permeability without spreading the adhesive attached to the tip of the honeycomb material to the surface of the air-permeable material 13a, the air-permeable material 13b, or the foam material 12, which is the first problem. structure was realized.
本実施例１の場合であって、接着剤の固化を自然乾燥のみにより、かつ固化後に次工程に入る製作方法（以降「自然乾燥法」と呼ぶ）では、第１の芯材１０ａと第２の芯材１０ｂを完成させるのに、接着剤を自然乾燥させ、敢えてフォーム材の吸水性を利用しない方法とするので、接着材が固化する以前に、各芯材にフォーム材を充填する必要性はない。従って、それぞれの芯材にフォーム材を充填するタイミングを考える必要がなく、接着剤の固化した後に、フォーム材を二つの芯材に充填してやればよい。 In the case of the present embodiment 1, in the production method (hereinafter referred to as "natural drying method") in which the adhesive is solidified only by natural drying and the next step is performed after solidification (hereinafter referred to as "natural drying method"), the first core material 10a and the second core material 10a In order to complete the core material 10b, the adhesive is allowed to dry naturally and the water absorption of the foam material is intentionally not used. Therefore, it is necessary to fill each core material with the foam material before the adhesive solidifies. no. Therefore, it is not necessary to consider the timing of filling each core material with the foam material, and the two core materials can be filled with the foam material after the adhesive has solidified.
従って、二つの芯材製作を同時にスタートさせることができる。二つの芯材製作を同時にスタートさせ、それぞれの接着剤が完全に固化するのを待って、フォーム材１２を充填することになるので、全体としての接着剤固化時間を、ほぼ自然乾燥完全固化時間Ａとすることができる。実験によれば、自然乾燥完全固化時間Ａは、６０分である。 Therefore, two core productions can be started at the same time. The two core material production is started at the same time, and the foam material 12 is filled after waiting for each adhesive to completely harden. can be A. According to experiments, the natural drying and complete solidification time A is 60 minutes.
また、本実施例１の応用として、接着剤の固化を自然乾燥に頼らず、特許文献１に記載のフォーム材の吸水性を利用する方法（以降「フォーム材利用法」と呼ぶ）を採用して、次のような音響両面ハニカムパネルの製作方法が考えられる。この方法では、第１の芯材１０ａの組み立てで、図４の接着剤１５のプールから接着剤の塗布されたハニカム材が引き揚げられ、そのまま通気材に当接されると直ちにフォーム材を充填し、接着剤の水分を吸収させる。 In addition, as an application of the present Example 1, a method of utilizing the water absorption of the foam material described in Patent Document 1 without relying on natural drying for solidification of the adhesive (hereinafter referred to as "method of using foam material") is adopted. Therefore, the following method of manufacturing an acoustic double-sided honeycomb panel can be considered. In this method, in assembling the first core member 10a, the honeycomb material coated with the adhesive is pulled up from the pool of the adhesive 15 shown in FIG. , to absorb moisture in the adhesive.
フォーム材の吸水性により短縮された固化時間で、接着剤が完全に固化したのを見計らって、同じように図４の接着剤１５のプールより引き揚げ直後のハニカム材を通気性材に当接した第２の芯材１０ｂを準備し、同じように即座にフォーム材を充填して、接着剤の固化を促進させる。この方法によれば、それぞれの接着剤の固化時間はフォーム材利用完全固化時間Ｂであり、全体としての固化時間は、Ｂ＋Ｂ＝２Ｂとなる。実験による確認では、固化時間Ｂ＝２０分であるので、全体としての固化時間は２０分＋２０分＝４０分となる。 The honeycomb material immediately after being pulled up from the pool of the adhesive 15 in FIG. A second core 10b is prepared and similarly immediately filled with foam material to accelerate the setting of the adhesive. According to this method, the solidification time of each adhesive is the complete solidification time B using the foam material, and the total solidification time is B+B=2B. Experimental confirmation shows that the solidification time B=20 minutes, so the total solidification time is 20 minutes+20 minutes=40 minutes.
　なお、本実施例の説明では、２つの芯材は両方とも通気性材を面材とする例を図で説明したが、本実施例の変形として、２つの芯材が通気性材を面材とする芯材と非通気性材を面材とする芯材の任意の組み合わせであっても良い。 In the description of the present embodiment, an example in which both of the two core materials are made of a breathable material is explained in the drawings. and a core material with a non-breathable material as a face material may be combined arbitrarily.
　さらに、フォーム材１２の厚さ６０ｍｍに対して、２つのハニカム材１１の厚さ（セルの高さ）はそれぞれ２５ｍｍと薄くし、第２の課題であるハニカム材１１にフォーム材１２を充填する工程でハニカムセルをフォーム材に押し込めない、あるいはセルの壁面が変形してしまって充填が困難となるという問題を回避することができた。 Furthermore, the thickness (cell height) of the two honeycomb members 11 is reduced to 25 mm, respectively, while the thickness of the foam member 12 is 60 mm, and the honeycomb member 11, which is the second problem, is filled with the foam member 12. It was possible to avoid the problem that the honeycomb cells could not be pressed into the foam material in the process, or that the wall surfaces of the cells were deformed, making filling difficult.
　本実施例は、面材とハニカム材を接着して芯材を製作し、フォーム材を充填するところまでは、実施例１の応用と同じである。すなわち、ハニカム材の端部を図４の接着材１５のプールの底まで浸漬し、その先端部に接着剤１５が塗布されたハニカム材を該プールより引き揚げ、水平に置いた通気性材１３の上に素早く対向させ、直ちにフォーム材１２に押し込むことで、フォーム材１２の吸水性を利用して、接着剤の固化を促進し、製造に必要な全体工程の時間短縮を図るものである。 This example is the same as the application of Example 1 until the core material is manufactured by bonding the face material and the honeycomb material and the foam material is filled. That is, the end portion of the honeycomb material is immersed to the bottom of the pool of the adhesive 15 shown in FIG. By quickly facing upward and immediately pressing into the foam material 12, the water absorbency of the foam material 12 is used to accelerate the solidification of the adhesive and shorten the time required for the entire manufacturing process.
　図１２は、その様子を示したもので、まずプレス下盤３１の上に通気性材１３ａをしっかり据え置いて、第１の芯材１０ａを組み立てるために、ハニカム材壁１１１ａを図のように対向させる。図中、断面図で示しているハニカム材先端部の接着剤１５ａは、図４の接着剤１５のプールより、引き揚げられた直後であり、ちょっとした振動で流動し易い状態にある。 FIG. 12 shows how this is done. First, the air-permeable material 13a is firmly placed on the lower platen 31 of the press, and the honeycomb material walls 111a are opposed to each other as shown in the figure in order to assemble the first core material 10a. Let In the drawing, the adhesive 15a at the front end of the honeycomb material shown in the cross-sectional view has just been pulled up from the pool of the adhesive 15 in FIG.
　図１３は塗布された接着剤がまだ流動性を有している第１の芯材にフォーム材を充填する工程を示す概念の断面図である。この図１３は、基本的には、図８と同一である。実施例１の場合には、芯材の接着剤１５ａが流動性を失い、固化している状況でのフォーム材の充填を示し、実施例１の応用の場合と本実施例の場合は、接着剤が流動性を有している状態でのフォーム材の充填を示している点で相違するので、敢えて再掲したのである。 FIG. 13 is a conceptual cross-sectional view showing the process of filling the first core material, to which the applied adhesive still has fluidity, with the foam material. This FIG. 13 is basically the same as FIG. In the case of Example 1, the filling of the foam material is shown in a state in which the adhesive 15a of the core material has lost its fluidity and has solidified. The difference is that the filling of the foam material is shown in a state where the agent has fluidity, so it is intentionally shown again.
図１３（ａ）は、第１の芯材１０ａの上にフォーム材１２を配置した状況を示し、この通気性材１３ａとハニカム材１１ａの接着剤が流動性を保持している間に、図１３（ｂ）に示すようにハニカム材１１ａのセルにフォーム材１２を充填する。 FIG. 13(a) shows a state in which the foam material 12 is arranged on the first core material 10a. As shown in 13(b), the foam material 12 is filled into the cells of the honeycomb material 11a.
ここまでは、本実施例と実施例１の応用で示した芯材製作方法とは同一である。実施例１の応用では、その後、接着剤が完全に固化するまで待って、すなわちフォーム材利用完全固化時間Ｂの経過後に、第２の芯材にフォーム材の充填を行う。 Up to this point, the manufacturing method of the core material shown in the application of the present embodiment and the first embodiment is the same. In the application of Example 1, the second core is then filled with foam after waiting for the adhesive to fully set, ie after the foam-based complete set time B has elapsed.
それに対して、本実施例の製作方法では、第１の芯材にフォーム材を充填後、接着剤１５ａが流動性を失い半固化するまでのフォーム材利用半固化時間Ｃだけ待機して、次の工程に移行するのが特徴である。フォーム材が吸水性を利用する場合、実験によれば、流動性を失い半固化するまでの時間Ｃは概ね完全に固化する時間Ｂの１／４程度である。 On the other hand, in the manufacturing method of the present embodiment, after filling the first core material with the foam material, the adhesive 15a waits for the semi-solidification time C until the adhesive 15a loses fluidity and becomes semi-solidified. It is characterized by moving to the process of When the foam material utilizes water absorption, according to experiments, the time C until the foam material loses fluidity and becomes semi-solidified is about 1/4 of the time B required for complete solidification.
このフォーム材１２の充填後であって、接着剤１５ａを塗布して時間Ｃの経過後に、第１の芯材１０ａをプレスから定盤に移載して、図１４に示すように上下を反転した姿勢とする。反転しても接着剤１５ａは、完全な固化までには至っていないが、流動性は失われた状態なので、セルの壁面１１１ａ上を移動することは無い。 After the foam material 12 is filled and after the adhesive 15a is applied and time C has elapsed, the first core material 10a is transferred from the press to the surface plate and turned upside down as shown in FIG. posture. Although the adhesive 15a is not completely solidified even if it is turned over, it does not move on the wall surface 111a of the cell because it has lost its fluidity.
　次の工程で、図１２で示した第１の芯材１０ａと同様に、図示しない（図１２の符号の添え字をｂとした図と同一である）が、第２の芯材１０ｂを組み立てる。この場合もハニカム材先端部の接着剤１５ｂは、図4に示す接着剤１５のプールより、引き揚げられた直後であり、ちょっとした振動で流動し易い状態にある点は、フォーム材充填前の第１の芯材の場合と同一である。 In the next step, similarly to the first core member 10a shown in FIG. 12, the second core member 10b is assembled, though not shown (same as the drawing in FIG. 12 with the suffix b). . In this case as well, the adhesive 15b at the tip of the honeycomb material has just been pulled up from the pool of adhesive 15 shown in FIG. It is the same as the case of the core material of
次に、図１５はこの第２の芯材にフォーム材を充填する工程の概念を示す断面図である。図１５（ａ）に示すように、第１の芯材１０ａにその一部が充填されているフォーム材１２を第２の芯材１０ｂのハニカム材の上に置く。この時点で、第１芯材の接着剤は、フォーム材利用半固化時間Ｃを経過しているので、流動性を失い、半固化状態である。従って、流動して面材に付着して吸音性能を劣化させる恐れはない。 Next, FIG. 15 is a sectional view showing the concept of the process of filling the second core material with the foam material. As shown in FIG. 15(a), the foam material 12 partially filled in the first core material 10a is placed on the honeycomb material of the second core material 10b. At this point, the adhesive of the first core material has passed the semi-solidifying time C using the foam material, so it loses fluidity and is in a semi-solidified state. Therefore, there is no fear of flowing and adhering to the surface material to deteriorate the sound absorbing performance.
図１５（ｂ）に示すように、プレス上盤３２を矢印の方向に下降させて第２の芯材１０ｂのハニカム材のセルにフォーム材１２を充填する。本工程は、パネル製作の全体時間短縮の観点からは、第２の芯材の接着剤が接着剤プールから引き揚げられて、出来るだけ速やかに行うことが望ましい。 As shown in FIG. 15(b), the press upper platen 32 is lowered in the direction of the arrow to fill the cells of the honeycomb material of the second core material 10b with the foam material 12. As shown in FIG. From the viewpoint of shortening the overall panel manufacturing time, it is desirable to perform this step as soon as possible after the adhesive of the second core material is pulled up from the adhesive pool.
　プレスから第１の芯材１０ａ、第２の芯材１０ｂとフォーム材１２を組み立てたものを定盤の上に移載し、その状態で２つの芯材の接着剤が完全に固化するのを待つ。この製造法によって、両面通気性材である音響両面ハニカムパネルを完成できる。 The assembly of the first core material 10a, the second core material 10b, and the foam material 12 is transferred from the press onto a surface plate, and in this state, the adhesive between the two core materials is completely solidified. wait. This manufacturing method completes an acoustic double-sided honeycomb panel that is a double-sided breathable material.
　この製造方法を実験結果と照合すると、フォーム材の押し込まれた第１の芯材の接着剤が完全に固化する時間Ｂは２０分ほどであり、一方、第１の芯材１０ａの接着剤が流動性を失い半固化するまでの時間Ｃは５分ほどである。その時間後直ちに第２の芯材１０ｂの接着に取り掛かれるので、固化する時間がオーバラップする。従って、第１及び第２の芯材１０ｂの接着剤が完全に固化するまでの合計の時間は、Ｃ＋Ｂ＝５分＋２０分＝２５分となる。 Comparing this manufacturing method with experimental results, it takes about 20 minutes for the adhesive of the first core material into which the foam material is pressed to completely solidify, while the adhesive of the first core material 10a The time C until it loses fluidity and becomes semi-solidified is about 5 minutes. Since adhesion of the second core member 10b is started immediately after that time, the solidification times overlap. Therefore, the total time required for the adhesives of the first and second core members 10b to completely harden is C+B=5 minutes+20 minutes=25 minutes.
ここで、本実施例の固化時間と実施例１（自然乾燥法）及び実施例１の応用（フォーム材利用法）による接着剤のトータル固化時間とを対比すると、２５／６０＝５／１２及び２５／４０＝５／８とそれぞれ大幅な時間短縮が実現できた。 Here, when comparing the solidification time of this example with the total solidification time of the adhesive in Example 1 (natural drying method) and application of Example 1 (method using foam material), 25/60=5/12 and 25/40=5/8, and a significant reduction in time was achieved.
なお、実際は固化時間の他に、フォーム材の充填作業その他準備作業時間も必要ではあるが、この時間は固化時間に比べると十分に小さいので、除外して比較評価した。。 In practice, in addition to the solidification time, time for filling the foam material and other preparatory work is also required, but since this time is sufficiently shorter than the solidification time, it was excluded from the comparative evaluation. .
　また、本実施例の説明では、２つの芯材は両方とも通気性材を面材とする例を図で説明したが、本実施例の変形として、２つの芯材が通気性材を面材とする芯材と非通気性材を面材とする芯材の任意の組み合わせであっても良い。 In addition, in the description of the present embodiment, an example in which both the two core materials are made of a breathable material is explained with reference to the drawings. and a core material with a non-breathable material as a face material may be combined arbitrarily.
実施例１及び実施例２において用途・機能に応じた適宜材料からなる面材を有する芯材をその都度組み立て、音響両面ハニカムパネルを完成することができる事を説明した。本実施例では、各種の面材を備えた芯材を予め複数準備してストックしておき、要求に応じて必要な芯材を選択して製品を製造することを説明するものである。例として、図１６に第１の面材が通気性材、第２面材が非通気性材である音響両面ハニカムパネルの断面図を示した。 In Examples 1 and 2, it was explained that the acoustic double-sided honeycomb panel can be completed by assembling the core members having the face members made of suitable materials according to the purpose and function. In this embodiment, a plurality of core materials having various face materials are prepared in advance and stocked, and a necessary core material is selected according to a request to manufacture a product. As an example, FIG. 16 shows a cross-sectional view of an acoustic double-sided honeycomb panel in which the first face material is a breathable material and the second face material is a non-breathable material.
　実施例１で第１と第２の芯材の構造、材質、製作工程は同じであるが、本実施例では、用途・機能に応じた適宜異なる材料からなる面材を持った複数の芯材のストックからパネル製造に使う芯材を選ぶ。図１６の音響両面ハニカムパネル１ｂの第１の芯材を構成する面材は通気性材１３であり、第２の芯材を構成する面材は非通気性材１４である。 The structure, material, and manufacturing process of the first and second core members are the same as in Example 1, but in this example, a plurality of core members having face members made of appropriately different materials according to the application and function are used. Select the core material to be used for panel manufacturing from the stock of The face material constituting the first core material of the double-sided acoustic honeycomb panel 1b of FIG.
　図１７は、異なる面材を持つ２つの芯材を使って音響両面ハニカムパネルを製造する工程の概念を示す断面図である。通気性材１３は実施例１で説明したものと同じである。非通気性材１４は、音響の通過方向で見て、吸音層であるフォーム材の後ろに設置して遮音するための層として使われるもので、アルミニウム製の薄板である。本実施例では厚さ寸法１．２ｍｍのアルミニウム製の薄板を使用した。非通気性材はこれに限らず他の金属製の板などでも良い。 FIG. 17 is a cross-sectional view showing the concept of the process of manufacturing an acoustic double-sided honeycomb panel using two core materials having different face materials. The breathable material 13 is the same as that described in the first embodiment. The non-breathable material 14 is a thin aluminum plate that is placed behind the foam material that is the sound absorbing layer and used as a layer for sound insulation when viewed in the direction of passage of sound. In this example, an aluminum thin plate with a thickness of 1.2 mm was used. The impermeable material is not limited to this, and other metal plates or the like may be used.
　なお、本実施例の説明では、２つの芯材が通気性材を面材とする芯材と非通気性材を面材とする芯材の組み合わせである例を図で説明したが、本実施例の変形として、２つの芯材が両方とも通気性材又は非通気性材を面材としていても良い。 In the description of this embodiment, an example in which the two core materials are a combination of a core material having a breathable material as a face material and a core material having a non-breathable material as a face material has been described with reference to the drawings. As a variation of the example, the two cores may both have breathable or non-breathable facings.
　なお、図１０、図１５、図１７で、面材とハニカム材を予め接着し芯材として完成させておいてフォーム材に押し込む方法について示したが、非通気性面材の場合は、先にハニカム材のみを押し込んでおいて、その後に非通気性面材にエポキシ系接着剤を塗布し、裏返して非通気性面材を接着する方法もある。 10, 15, and 17 show a method in which a face material and a honeycomb material are bonded in advance to complete a core material and then pressed into a foam material. There is also a method in which only the honeycomb material is pressed in, and then an epoxy-based adhesive is applied to the non-breathable face material, turned inside out, and the non-breathable face material is adhered.
１ａ　　　音響両面ハニカムパネル
１ｂ　　　音響両面ハニカムパネル
１０ａ　　第１芯材
１０ｂ　　第２芯材
１１ａ　　ハニカム材
１１ｂ　　ハニカム材
１１１ａ　（セルの）壁面
１１１ｂ　（セルの）壁面
１２　　　フォーム材
１３ａ　　通気性材
１３ｂ　　通気性材
１３１　　アルミニウム合金繊維不織布
１３２　　アルミニウム合金製エキスパンドメタル
１４　　　非通気性材
１５ａ　　接着剤
１５ｂ　　接着剤
２　　　　定盤
２１　　　深さ設定プレート
３１　　　プレス下盤
３２　　　プレス上盤
  1a acoustic double-sided honeycomb panel 1b acoustic double-sided honeycomb panel 10a first core material 10b second core material 11a honeycomb material 11b honeycomb material 111a (cell) wall surface 111b (cell) wall surface 12 foam material 13a breathable material 13b breathable material 131 Aluminum alloy fiber non-woven fabric 132 Aluminum alloy expanded metal 14 Non-air-permeable material 15a Adhesive 15b Adhesive 2 Surface plate 21 Depth setting plate 31 Press lower plate 32 Press upper plate

Claims (7)

  1. 第１の面材、第１のハニカム材、フォーム材、第２のハニカム材、ならびに第２の面材を積層してあり、
    第１及び第２のハニカム材のそれぞれの端面は、第１及び第２の面材に接着剤によりそれぞれ接着されており、
    第１及び第２のハニカム材のそれぞれ他の端面は該フォーム材の内部に押し込まれており、
    該２つの面材と該フォーム材の表面はお互いに接触しており、
    該第１及び第２のハニカム材のそれぞれ第１及び第２の面材と接着された端面は、第１及び第２の面材にそれぞれ接触するフォーム材の表面とほぼ同一のレベルにあり、
    ２つの該ハニカム材の厚さの和が該フォーム材の厚さ以下であることを特徴とする音響両面ハニカムパネル。     A first face material, a first honeycomb material, a foam material, a second honeycomb material, and a second face material are laminated,
    The end surfaces of the first and second honeycomb materials are respectively bonded to the first and second face materials with an adhesive,
    the other end surfaces of the first and second honeycomb materials are pushed into the foam material;
    the two facings and the surface of the foam are in contact with each other;
    end surfaces of the first and second honeycomb materials bonded to the first and second face members, respectively, are on substantially the same level as surfaces of the foam material that contact the first and second face members, respectively;
    A double-sided acoustic honeycomb panel, wherein the sum of the thicknesses of the two honeycomb materials is less than or equal to the thickness of the foam material.
  2. 請求項１に示した音響両面ハニカムパネルにおいて、
    第１の芯材ならびに第２の芯材が通気性材を面材としていることを特徴とする音響両面ハニカムパネル。     In the acoustic double-sided honeycomb panel as set forth in claim 1,
    An acoustic double-sided honeycomb panel characterized in that the first core material and the second core material have air permeable material as the face material.
  3. 請求項１に示した音響両面ハニカムパネルにおいて、
    第１の芯材が通気性材を面材としており、
    第２の芯材が非通気性材を面材としていることを特徴とする音響両面ハニカムパネル。     In the acoustic double-sided honeycomb panel as set forth in claim 1,
    The first core material has a breathable material as a face material,
    A double-sided acoustic honeycomb panel characterized in that the second core material has a non-breathable material as a face material.
  4. 水平に配置された第１の面材の上に、接着剤がその端部に塗布された第１のハニカム材を当接し、該接着剤で接着して第１の芯材を組み立てる工程と、
    該第１の芯材の該接着剤が流動性を失う前に、該第１のハニカム材において該第１の面材が接着されていない側の端面よりフォーム材をその１の面から押し込む工程と、第１の芯材製作と同様の工程で、第２の面材と第２のハニカム材を接着剤で接着して第２の芯材を組み立てる工程と、
    第１の芯材の該接着剤が半固化した後に、該フォーム材の充填された第１の芯材の上下を反転し、第２の芯材の該第２の面材の接着されていない該第２のハニカム材の端面上に配置し、
    該第２の芯材の該接着剤が流動性を失う前に、該第２のハニカム材において該第２の面材が接着されていない側の端面より該フォーム材をその他の面から押し込む工程とからなることを特徴とする音響両面ハニカムパネルの製造方法。     a step of abutting a first honeycomb material having an end portion coated with an adhesive on a horizontally disposed first face material and bonding the first honeycomb material with the adhesive to assemble a first core material;
    A step of pressing a foam material from one face of the first honeycomb material from the end face of the first honeycomb material to which the first face material is not adhered before the adhesive of the first core material loses its fluidity. and a step of assembling the second core material by bonding the second face material and the second honeycomb material with an adhesive in the same process as the manufacturing of the first core material;
    After the adhesive of the first core material is semi-solidified, the first core material filled with the foam material is turned upside down, and the second face material of the second core material is not bonded. arranged on the end face of the second honeycomb material,
    Before the adhesive of the second core material loses fluidity, a step of pushing the foam material from the other surface of the second honeycomb material from the end surface of the side where the second face material is not adhered. A method for manufacturing an acoustic double-sided honeycomb panel, comprising:
  5. 面材とハニカム材を接着した芯材を複数まとめて製造しストックしておく工程と、
    ストックされた複数の芯材から所望の特性の面材を持つ２つの芯材を選定する工程と、
    選定した２つの該芯材のそれぞれ面材が接着されていない側の該ハニカム材の端面をフォーム材の両面からそれぞれ押し込む工程からなることを特徴とする音響両面ハニカムパネルの製造方法。     a step of collectively manufacturing and stocking a plurality of core materials obtained by adhering face materials and honeycomb materials;
    A step of selecting two core materials having face materials with desired characteristics from a plurality of stocked core materials;
    1. A method for manufacturing a double-sided acoustic honeycomb panel, comprising a step of pressing the end faces of the honeycomb members of the selected two core members to which the face members are not adhered from both sides of the foam member.
  6. 請求項４または請求項５に示した音響両面ハニカムパネルの製造方法において、
    第１の芯材ならびに第２の芯材が通気性材を面材としていることを特徴とする音響両面ハニカムパネルの製造方法。     In the method for manufacturing an acoustic double-sided honeycomb panel according to claim 4 or claim 5,
    A method for manufacturing an acoustic double-sided honeycomb panel, wherein the first core material and the second core material are made of a breathable material as a face material.
  7. 請求項４または請求項５に示した音響両面ハニカムパネルの製造方法において、
    第１の芯材として通気性材の面材を持つ芯材を選定し、
    第２の芯材として非通気性材を持つ面材を持つ芯材を選定することを特徴とする音響両面ハニカムパネルの製造方法。     In the method for manufacturing an acoustic double-sided honeycomb panel according to claim 4 or claim 5,
    Selecting a core material having an air-permeable surface material as the first core material,
    A method for manufacturing an acoustic double-sided honeycomb panel, characterized in that a core material having a face material having an air-impermeable material is selected as the second core material.
PCT/JP2022/005519 2021-03-29 2022-02-11 Structure and manufacturing method of acoustic double-faced honeycomb panel WO2022209348A1 (en)

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