JP3249941B2 - Aluminum soundproof structure and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an aluminum soundproof structure which is excellent in soundproof performance such as sound insulation, sound absorption and vibration suppression and is used as a structure such as a floor, an inner wall and an outer wall, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A soundproof structure has been used as a structure suitable for constructing a comfortable living environment. For example, in a house, a vehicle, or the like, a floor material or a wall material having excellent soundproof performance is used in order to create a quiet space in which external noise is blocked. As this kind of soundproofing structure, there is known a soundproofing structure in which an aluminum extruded hollow profile is used as a main frame and a soundproofing material is inserted into a hollow portion to enhance the soundproofing effect. For example, in Japanese Patent Application Laid-Open No. Hei 7-164584, a vibration damping resin is attached to a rib or the like of an extruded aluminum hollow member to improve soundproof performance. Also, Japanese Patent Application Laid-Open No.
In Japanese Patent No. 72305, the hollow portion of an aluminum extruded hollow profile is filled with a foamed rubber elastic body to improve the soundproofing performance.

[0003]

Although the soundproofing performance is improved by sticking the damping resin or filling the foamed rubber elastic body, the sticking and foaming of the damping resin when the extruded hollow aluminum material to be applied becomes long. It becomes difficult to fill the rubber elastic body. For example, when applying to an aluminum extruded hollow profile having a length of 20 to 30 m, the vibration damping resin cannot be uniformly applied to the inner wall surface of the rib over the entire length, and the inner surface of the hollow profile is not applicable. It is inevitable that a portion where the vibration damping resin does not adhere is generated. Even in the case of filling a foamed rubber elastic body, it has conventionally been considered impossible to fill a foamed rubber elastic body into a hollow portion in close contact. Therefore, as shown in Japanese Patent Application Laid-Open No. 7-172305, a foamable rubber sheet in which a rubber containing a foaming agent is formed in a sheet shape is inserted and arranged in a hollow portion, and then the foamable rubber sheet is heated. It is tightly packed in the hollow part. But,
Since it is difficult to form a foamable rubber sheet having a length of 20 to 30 m according to the cross-sectional shape of the hollow portion, the foamed rubber elastic body is not evenly filled and adhered to the hollow portion, and the foamed rubber elastic body is not formed. This results in voids without voids.

[0004] If there is a partial exfoliation of the vibration damping resin or a void portion without the foamed rubber elastic body, the original performance of the vibration damping resin or the foamed rubber elastic body is not exhibited, and the vibration damping ability of that portion is greatly changed. The soundproofing performance deteriorates. However, no practical method has been proposed so far, in particular, in which a vibration damping resin is uniformly applied to a long hollow material or a foam rubber elastic body is filled. Therefore, the present inventors put the soft foamed elastic body into a heat-fusible resin sheet molded into a bag shape, insert the soft foamed elastic body shrunk by suction into the hollow portion of the main frame, and then open it. It has been proposed in Japanese Patent Application No. 8-349848 that the soft foamed elastic body is pressed against the inner wall surface of the hollow portion by elastic recovery, and the heat-fusible resin sheet is heated and melted to adhere the soft foamed elastic body to the inner wall surface of the hollow portion. According to this method, the soft foamed elastic body can be easily charged and filled into a long hollow material. The present invention is a further improvement of the method of utilizing the shrinkage / restoration of the soft foamed elastic body proposed above, and the soft foamed elastic body is formed in the hollow portion of the extruded shape without using a heat-fusible sheet. It is an object to provide a soundproof structure that is densely and uniformly filled and has excellent soundproof performance.

[0005]

SUMMARY OF THE INVENTION In order to achieve the object, an aluminum soundproofing structure according to the present invention has a main frame made of an aluminum hollow extruded member having a hollow portion extending in a longitudinal direction; A flexible foamed elastic member inserted into the entire length and having a cross-sectional area similar to or larger than the cross-sectional area of the hollow portion in a free state similar to the cross-sectional shape of the hollow portion; and an inner wall surface of the hollow portion and the soft foamed elastic A synthetic resin layer positioned between the elastic member and a surface extending in the longitudinal direction of the body, wherein the soft foamed elastic body is pressed against the inner wall surface of the hollow portion via the synthetic resin layer. On the mainframe,
An extruded aluminum member having a structure composed of two face plates and a plurality of ribs connecting the face plates is used. The soft foamed elastic body can be inserted only into a hollow portion formed by one surface plate and a rib. JIS for flexible foamed elastic
A rebound resilience according to K6400 of 25% or less and / or
Alternatively, a rubber or synthetic resin foam such as a polyurethane foam having a Dow air permeability of 0.1 to 2.0 dm ³ / sec is used. Synthetic resin sheets include polyamide, polyolefin, polyester, polyvinyl alcohol,
Thermoplastic resin such as polyvinyl chloride, polyvinylidene chloride, and cellulose is molded in a bag shape.
A μm resin film is used.

The aluminum soundproof structure has a similar cross-section larger than a cross-section of the hollow portion of a main frame made of a long aluminum hollow extruded shape having a plurality of hollow portions penetrating in a longitudinal direction. A flexible foamed elastic body having an open-cell structure having substantially the same length as the length of the hollow portion is wrapped with a bag-shaped synthetic resin sheet, and the air inside the flexible foamed elastic body and the bag-shaped synthetic resin sheet is sucked to form the foam. After the soft foamed elastic body is contracted and the soft foamed elastic body in the contracted state is inserted into the hollow portion, the bag-like synthetic resin sheet is opened to restore the soft foamed elastic body, and the soft foamed elastic body is restored via the synthetic resin sheet. It is manufactured by pressing the soft foamed elastic body against the inner wall surface of the hollow part.

Before inserting the synthetic resin sheet filled with the soft foamed elastic body into the hollow portion of the main frame, an adhesive may be applied to the surface of the synthetic resin sheet or the inner wall surface of the hollow portion. Examples of the adhesive include a two-part reactive adhesive such as an epoxy resin, a urethane resin, an acrylic-modified epoxy resin, and a urethane-modified epoxy resin, an acrylic adhesive, a polyvinyl acetate resin-based adhesive, and polyvinyl acetate. There is a one-pack type emulsion such as an ethylene adhesive or an aqueous adhesive / adhesive adhesive. Further, a suction tube extending over the entire length of the soft foamed elastic body accommodated in the bag-shaped synthetic resin sheet is inserted into the bag-shaped synthetic resin sheet, and the soft foamed elastic body and the inside of the bag-shaped synthetic resin sheet are inserted through the suction tube. By sucking air, the soft foamed elastic body can be contracted in volume. The soft foamed elastic body that has contracted in volume is easily inserted into the hollow portion of the main frame. At the time of setting the suction tube, an insertion hole extending in the longitudinal direction and a slit extending from the insertion hole to one surface of the flexible foamed elastic body are formed at a substantially central portion of the flexible foamed elastic body, and the slit is opened to attach the suction tube to the insertion hole. The setting method is preferable. This suction tube is provided with suction holes penetrating through the tube wall at regular intervals, and may be left as it is inside the soft elastic foam.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A soundproof structure according to the present invention has a soft foamed elastic body 2 in a hollow portion of a main frame 10 made of an aluminum hollow extruded shape as shown in FIG.
0, and the soft foamed elastic body 2
0 is pressed against the inner wall of the main frame 10.
Since the extruded aluminum material, which is lighter than steel, is used as the main frame 10, the weight of the soundproof structure can be reduced. Extruded aluminum profiles are generally 6000
7000 series, etc., cut to a predetermined length, and given predetermined mechanical properties, corrosion resistance, surface color, etc. by heat treatment and surface treatment. For heat treatment, T
5 processing, T6 processing and the like are adopted.

As shown in FIG. 2, the required strength and strength can be obtained by adopting a hollow structure in which the upper wall portion 12 and the lower wall portion 13 are connected to each other by a plurality of oblique ribs 11, 11,. It can have rigidity. Rib 1
1, 11,... Are effective for intensity compensation, but from the viewpoint of soundproofing, the smaller the number, the better. Therefore, it is preferable to provide a minimum number of ribs 11, 11,... For compensating strength between the upper wall portion 12 and the lower wall portion 13. Further, in order to facilitate connection with another hollow extruded profile by welding or the like, it is preferable to provide a joint portion 15 having a step on one side. The joint portion 15 is inserted into a flat joint portion 16 provided on another main frame 10 connected side by side. The rib 1 is provided inside the main frame 10.
A plurality of hollow portions 14 are formed which are partitioned by 1, 11,..., An upper wall portion 12 and a lower wall portion 13. As shown, in the main frame 10 having the oblique ribs 11, 11,..., The hollow portion 14 has a triangular cylindrical shape.

Each hollow portion 14 is filled with a soft foamed elastic body 20 having a low coefficient of rebound resilience. Soft foam elastic body 2
0 has an effect of absorbing sound radiated from the outside and damping vibration transmitted to the structure. Soft foam elastic body 2
For 5, the lower the resilience coefficient of the material, the greater the sound absorbing effect. Specifically, rubber foams and the like can be used in addition to synthetic resin foams such as polyurethane foam, polyethylene foam, polypropylene foam, and polyvinyl chloride foam having a rebound resilience of 25% or less. Preferred soft foamed elastic bodies are polyurethane foam and foam rubber. In addition, the rebound resilience is based on JIS K6400, and a steel ball having a weight of 16.3 g and a diameter of 2.46 mm is 460.
The steel ball is dropped from a height of mm, the rebound distance of the steel ball is measured, and the rebound resilience (%) = rebound distance (mm) / drop distance (mm) × 100 is calculated.

The soft foamed elastic body 20 absorbs the transmitted vibration by the internal air layer and exhibits a large vibration damping ability. Therefore, the sound absorption performance also depends on the air permeability. Among them, those having a Dow air permeability in the range of 0.1 to 2.0 dm ³ / sec specified in the international standard exhibit excellent soundproof performance. When the air permeability is less than 0.1 dm ³ / sec, air is sucked when filling the soft foamed elastic body 20 into the hollow portion 14 of the main frame 10, and the soft foamed elastic body 2
0 is not preferable in terms of work because the volume shrinks 0. vice versa,
If the air permeability exceeds 2.0 dm ³ / sec, the sound absorbing performance is inferior.
Such a soft foamed elastic body 20 is prepared, for example, as follows. Average hydroxyl value 70-280, average molecular weight 6
100 to 100 parts by weight of a polyol having a NCO index (NCO / OH ratio ×
A large block-shaped slab foam is prepared by mixing a polyisocyanate, a foaming agent, a catalyst, and a foam stabilizer in an amount of 85 to 115 with a mixing head, discharging the mixture onto a bottom paper on a conveyor, and causing a foaming reaction. To manufacture. From this slab foam, a foam having a cross section similar to the cross section of the hollow portion 14 of the main frame 10 is cut out to obtain a soft foamed elastic body.

The polyol having an average hydroxyl value of 70 to 280 is composed of a polyol having a hydroxyl value of 20 to 160 and a hydroxyl value of 35.
It is prepared by mixing an appropriate amount of 0-1850 polyol. The polyol having an average molecular weight of 600 to 2400 is prepared by mixing an appropriate amount of a long-chain polyol having a molecular weight of 2000 to 6000 and a short-chain polyol having a molecular weight of 350 to 1000. Examples of the polyol include glycerin, trimethylolpropane, 1,2,6-hexanetriol,
Triethanolamine, pentaerythritol, ethylenediamine, methylglycoxide, tolylenediamine,
It is obtained by adding an alkylene oxide such as ethylene oxide, propylene oxide or butylene oxide alone to a compound having 3 to 4 active hydrogens such as tetramethylolcyclohexane, or by adding two or more of these alkylene compounds in a block or random manner. . The polyisocyanate is not particularly limited in its kind, but isocyanates generally used for the production of polyurethane foam, for example, 2,4-isomer, 2,6-isomer of tolylene diisocyanate or Mixtures thereof, diphenylmethane diisocyanate, hexamethylene diisocyanate, naphthalene diisocyanate and the like can be used. Among them, a 65:35 mixture of the 2,4-isomer and the 2,6-isomer of tolylene diisocyanate is preferred.

As the foaming agent, water or a low-boiling halogenated hydrocarbon such as CFC-11 or methylene chloride can be used alone or in combination of two or more. The catalyst includes
In addition to a metal-based catalyst such as a tin-based catalyst, a catalyst generally used in the production of polyurethane foam, such as an amine-based catalyst, is used. As the foam stabilizer, a generally used organosilicon-based foam stabilizer such as an organopolysiloxane-polyalkylene copolymer is used. Soft foam elastic body 20
Must have some open cells so that they can be contracted by air suction. Although it is related to the air permeability from the viewpoint of sound absorption, it is considered advantageous to use open cells. It should be noted that the volume of completely closed cell foamed resin cannot be reduced by air suction. In addition, when the main frame 10 is easily and securely inserted into the hollow portion 14, the size of the main frame 10 when contracted is 10% smaller than the cross section of the hollow portion 14.
It is adjusted to a small size. Incidentally, if the volume at the time of shrinkage is too small, the soft foamed elastic body 20 easily rotates in the hollow portion 14, and it becomes difficult to set the soft foamed elastic body 20 according to the cross-sectional shape of the hollow portion 14.

The flexible foamed elastic body 20 preferably has a size that is 5 to 30% larger on one side than the hollow portion 14. If the size is less than 5%, the hollow part 1
Even if the shrinkage is released in 4, the force that spreads to every corner of hollow portion 14 and adheres to main frame 10 is weakened. On the other hand, if the size exceeds 30%, a large amount of shrinkage remains even after the shrinkage is released, and the surface of the soft foamed elastic body 20 is
Does not fit nicely with the surface. In addition, the soft foamed elastic body 2
0 is set slightly longer than the main frame 10 because it is compressed when inserted into the hollow portion 14 of the main frame 10. At a substantially central portion of the soft foamed elastic body 20, an insertion hole 21 is cut out as shown in FIG. Further, a slit 23 extending from the insertion hole 21 to one side 22 is formed. Thus, when the insertion side surfaces 22 on both sides of the slit 23 are widened, the soft foamed elastic body 20
And the insertion hole 21 is opened to the outside.

The suction tube 25 is inserted into the insertion hole 21 in this state.
Set and release the force to expand the insertion side 22,
The insertion hole 21 is closed by the elastic restoring force of the soft foam elastic body 20, and the suction tube 25 is wrapped inside the soft foam elastic body 20. The slit 23 can be prevented from being opened again by bonding using an adhesive. Slit 2
When the opening of the flexible tube 3 is restricted, even when the flexible foamed elastic body 20 is bent when the flexible foamed elastic body 20 wrapped with the suction tube 23 is conveyed, the slit 23 is opened and the suction tube 23 is opened. Soft foam elastic body 2
Departure from zero is prevented. The suction tube 25
For example, it is made of flexible vinyl chloride or the like, and its length is set to be 20 to 30 cm longer than the length of the soft foam elastic body 20 in order to connect the tip of the tube 25 to an air suction device. 100-2000 for the suction tube 25
A plurality of suction holes 26 are formed at intervals of mm, preferably at intervals of 250 to 1000 mm. The suction port 26 is
It can be formed as a hole having an arbitrary shape such as a circle, a slit-like cut, or the like. The thickness and outer diameter of the suction tube 25 are not particularly limited, but are 0.5 to 2 mm in thickness and 5 mm in outer diameter.
It is generally about 10 to 10 mm. The diameter of the suction hole 26 is not particularly limited, but is preferably about 1 to 3 mm in diameter.

As shown in FIG. 4, the soft foamed elastic body 20 enclosing the suction tube 25 is a bag-shaped synthetic resin sheet 3.
1 As the synthetic resin sheet 31, a sheet having elongation and gas permeability is preferable,
Thermoplastic resin films of polyolefin, polyester, polyvinyl alcohol, polyvinyl chloride, polyvinylidene chloride, and cellulose are used. The synthetic resin sheet 31 does not break even when the inside is in a reduced pressure atmosphere.
It preferably has a thickness of 100 μm. 10μ thickness
If it is less than m, the synthetic resin sheet 31 is likely to be broken when the inside is brought into a reduced-pressure atmosphere, or during transportation or handling. Conversely, when the film thickness exceeds 100 μm, not only is the resin film unnecessarily consumed, but also the self-holding force of the shape is increased, and the contraction / expansion of the soft foamed elastic body 20 in response to pressure reduction or opening to the atmosphere tends to be restricted. Can be seen.

The soft foamed elastic body 20 is accommodated in a bag-shaped synthetic resin sheet 31. Alternatively, the synthetic resin sheet 31 accommodating the soft foamed elastic body 20 can also be obtained by winding the resin film around the soft foamed elastic body 20 and then bonding the overlapping portions of the resin films to each other. As shown in FIG. 4, the tip of the suction tube 25 is pulled out from one open end of the synthetic resin sheet 31 containing the soft foamed elastic body 20, and the open end of the synthetic resin sheet 31 is sealed using an appropriate adhesive. . Suction tube 2
When the distal end side 27 of 5 is connected to a suction device (not shown) and the bag-shaped space of the synthetic resin sheet 31 is exhausted through the suction holes 26, the soft foamed elastic body 20 contracts. When the vent hole 29 at the tip of the suction tube 25 is closed with the cap 28 in this state, air does not enter the soft foamed elastic body 20, and the contracted insertion body can be easily inserted into the hollow portion 14 of the main frame 10. Become.

The volume-reduced soft foamed elastic body 20 is inserted into the hollow portion 14 of the main frame 10. At this time,
As shown in FIG. 5, the use of the guide piece 41 allows the flexible foamed elastic body 20 to be easily inserted. The guide piece 41 is similar to the hollow portion 14 and has a slightly smaller shape, and is connected to the soft foamed elastic body 20 that has contracted in volume by a string 42. The string 42 is longer than the length of the main frame 10. When the guide piece 41 is inserted into one side of the hollow part 14 and compressed air is blown, the guide piece 41 protrudes from the other side of the hollow part 14 through the inside of the main frame 10, and the string 42 is passed through the hollow part 14. You. Hollow part 14
When the flexible foamed elastic body 20 is set at the entrance of the hollow portion 14 according to the shape of the above, and the string 42 attached to the guide piece 41 on the other end side is pulled, the soft foamed elastic body 20 is extended into the hollow portion 14. Let's go all in.

Next, the air holes 2 of the suction tube 25 wrapped by the soft foamed elastic body 20 in the hollow portion 14
When the cap 28 attached to the cover 9 is removed, the outside air is sucked into the contracted soft foamed elastic body 20 through the vent hole 29. At this time, pressurized air can be positively sent into the soft foamed elastic body 20 via the suction tube 25. Since the soft foamed elastic body 20 has an elastic restoring force, it expands due to invasion of air. Here, the cross-sectional shape of the soft foamed elastic body 20 is 5 to 5 times larger than the cross-sectional shape of the hollow portion 14.
Since the size is increased by 30%, the soft foamed elastic body 20 released from the contracted state fits into every corner of the hollow portion 14 and is pressed against the inner wall surface of the hollow portion 14. In Japanese Patent Application No. 8-349848 previously proposed, after the soft foamed elastic body 20 is charged, a heat treatment is applied to the soft foamed elastic body 2.
0 is thermally fused to the inner wall surface of the hollow portion 14. But,
According to subsequent studies by the present inventors, it has been found that a sufficient soundproofing effect can be obtained only by pressing the inserted soft foamed elastic body 20 against the inner wall surface of the hollow portion 14. That is, heat treatment for heat fusion is not required, and not only the manufacturing cost is reduced due to a reduction in man-hours, but also the deterioration of the soft foamed elastic body 20 due to heating is prevented. Therefore, excellent soundproof performance is maintained.

Since the soft foamed elastic body 20 is pressed against the inner wall surface of the hollow portion 14 by an elastic restoring force, it has a frictional resistance and does not fall off from the hollow portion 14. Further, the ribs 11, the upper wall 12, and the lower wall 13 of the main frame 10 are provided.
Absorbs sound wave vibrations that propagate through the sound, etc., and improves soundproofing performance. At this point, the soft foamed elastic body 20 is free-spaced in the hollow portion 14.
It is preferable to have a larger cross-sectional shape. The synthetic resin sheet 31 containing the soft foamed elastic body 20 can be bonded to the inner wall surface of the hollow portion 14 at room temperature using an adhesive. The adhesive is applied to the surface of the synthetic resin sheet 31 and / or the inner wall surface of the hollow portion 14. When an adhesive is used, the flexible foamed elastic body can be securely bonded and fixed to the inner wall surface of the hollow portion even when the working environment varies with the season. Above all, the water-based adhesive is easy to apply, and is applied in a state where moisture remains, thereby facilitating insertion of the soft foamed elastic body into the hollow portion. In this case, the water content of the water-soluble adhesive gradually evaporates, and adheres to the synthetic resin sheet 31 while forming a film on the inner wall surface of the hollow portion 14. The formed adhesive film is also effective in improving vibration damping performance. The evaporated water is released to the outside through the gas-permeable synthetic resin sheet 31.

As a method of applying the adhesive, for example, there is a method shown in FIG. In this case, the ring-shaped spray tube 50 is arranged on the entry side of the main frame 10 in which the soft foamed elastic body 20 is inserted into the hollow portion 14, and the ring-shaped spray tube is attached to the synthetic resin sheet 31 enclosing the soft foamed elastic body 20. Spray the adhesive 51 from 50. In this state, the soft foamed elastic body 20
Is drawn into the hollow portion 14, the adhesive 51 is applied over the entire length of the soft foamed elastic body 20. Alternatively, the adhesive can be applied by spraying the extruded profile from both ends into the interior. The adhesive 51 is a bag-shaped synthetic resin sheet 3
When the soft foamed elastic body 20 is restored by opening 1, it is filled between the soft foamed elastic body 20 and the inner wall surface of the hollow portion 14. When the soft foamed elastic body 20 is pressed against the inner wall surface of the hollow portion 14 via the adhesive 31, the positional relationship of the soft foamed elastic body 20 with respect to the inner wall surface of the hollow portion 14 is fixed. The elastic shrinkage and elastic restoration further improve the soundproofing function.

In this manner, the hollow portion 14 is uniformly filled with the soft foamed elastic body 20, and there is no gap between the inner wall surface of the hollow portion 14 and the soft foamed elastic body 20 (FIG. 1). Is obtained. Since the soft foamed elastic body 20 is elastically restored after being inserted into the hollow portion 14, even in the case of the long main frame 10, the hollow portion 1 is uniformly distributed in the longitudinal direction.
4 is pressed against the inner wall surface. Therefore, a soundproof structure having excellent soundproof performance and high reliability is obtained. In addition, since the air layer inside the soft foamed elastic body 20 exhibits a heat insulating effect, the structure has excellent heat insulating properties. The suction tube 25 inserted in the soft foam elastic body 20 can be removed, but may be inserted into the soft foam elastic body 20 as it is. If the suction tube 25 is left, the soundproof performance is further improved by the sound absorbing effect at this portion.

[0023]

EXAMPLE 1 A hollow extruded material having a sectional shape shown in FIG. 7A was extruded from a 6N01 aluminum alloy, forced air-cooled, straightened, and cut to a length of 25 m. Next, tempering was performed at 175 ° C. for 6 hours, and the strength was adjusted by furnace cooling. The hollow portion 14 of the main frame 10 made from the hollow extruded shape was in a triangular shape whose dimensions are shown in FIG. A polyol (average molecular weight 910, average hydroxyl group) obtained by mixing 19.0% by weight of polyether polyol (molecular weight 3000, hydroxyl value 56.1) and 44.5% by weight of polyether polyol (molecular weight 700, hydroxyl value 240.2). 185) 63.5% by weight, dioctyl phthalate 6.4% by weight, silicone foam stabilizer 1.0% by weight, water 1.1% by weight, amine catalyst 0.4% by weight, pigment 0.2% by weight And a quantity of tolylene diisocyanate (65:35 mixture of 2,4-isomer and 2,6-isomer of tolylene diisocyanate) in an amount to give an NCO index of 95, and apply the one-shot method to the bottom paper on the conveyor belt. After discharging and reaction foaming, the mixture was cured to obtain a continuous long body of polyurethane foam.
The base paper was peeled from the long polyurethane foam and cut into a length of about 2 m to produce a block of a flexible polyurethane foam.

The soft foamed elastic block had a rebound resilience of 7% and an air permeability of 0.83 dm ³ / sec. From this block, a soft foamed elastic body 20 having a triangular cross section having the dimensions shown in FIG. 8 and a length of 2 m was cut out. Thirteen of the obtained soft foamed elastic bodies 20 were prepared, and slits 23 were made over the entire length of the soft foamed elastic body 20 with a cutter, and an insertion hole 21 having a diameter of 6 mm was cut out at the center. Soft foamed elastic body 2 formed with slit 23 and insertion hole 21
No. 0 was bonded to each end face in the longitudinal direction with an adhesive to obtain a flexible foamed elastic body having a length of 25.02 m. The suction tube 25 has an outer diameter of 6 mm, a thickness of 1 mm, and a length of 25.2.
m vinyl chloride tube was prepared. .. Having a diameter of 1 mm were formed in the tube at intervals of 500 mm. The slit 23 of the soft foamed elastic body 20 was opened, the suction tube 25 was set in the insertion hole 21 over the entire length of the soft foamed elastic body 20, and the slit 23 was closed to enclose the suction tube 25 in the soft foamed elastic body 20.

In FIG. 8, a flexible foamed elastic body 20 having a slit 23 extending from one side of a triangular cross section to the insertion hole 21 is shown.
Are used, but slits 23, 23 as shown in FIG.
a can also be put in the soft foamed elastic body 20. That is, as shown in FIG. 9A, a slit 23 is formed parallel to the base from the oblique side of the triangular cross section, and further a slit 23 a that is orthogonal to the slit 23 and reaches the insertion hole 21 is formed. In this case, at the time of setting the suction tube 25, FIG.
As shown in (b), the portion above the slit 23 is opened, and the suction tube 25 is inserted into the insertion hole 21 from the second slit 23a. Next, the adhesive 23b is applied to the upper surface of the lower part of the opened flexible foamed elastic body 20, and then the upper part is returned to the original position and the upper part and the lower part of the flexible foamed elastic body 20 are bonded. This eliminates the troublesome work of applying the adhesive while pushing and expanding the slits 23, thereby facilitating the bonding work and enabling reliable bonding.

A synthetic resin sheet 31 was wrapped around the outer periphery of the soft foamed elastic body 20 on which the suction tube 25 was set, and was formed into a bag shape in which the overlapped portions and both ends of the sheet 31 were adhered as shown in FIG. The synthetic resin sheet 31
Used was a polyolefin-based resin film having a thickness of 50 μm. Further, at the time of bonding, the tip of the suction tube 25 was put out of the bag from one end of the synthetic resin sheet 31. Next, the tip of the suction tube 25 is connected to a vacuum pump (not shown), and the air in the bag made of the synthetic resin sheet 31 is sucked.
The volume of the entire flexible foamed elastic body 20 was reduced to about 10% of the cross-sectional shape of No. 4.

The ventilation tube 29 of the suction tube 25
(FIG. 4) was closed with a cap 28 to prevent air from entering, and the tip of the suction tube 25 was tied with a 28 m long string 42 attached to a guide piece 41 (FIG. 5). The string 42 was inserted into the hollow portion 14 over the entire length by disposing the guide piece 41 at one end of the hollow portion 14 and blowing it off to the other end with an air gun. The string 42 protruding from the other end of the hollow portion 14 was pulled, and the soft foamed elastic body 20 wrapped with the synthetic resin sheet 31 and in a contracted state was pulled into the hollow portion 14 and set. After setting the soft foam elastic body 20, the string 42 was removed from the tip of the suction tube 25, and the cap (not shown) was removed.
As a result, the outside air returned to the bubbles of the soft foamed elastic body 20 via the air holes 29 of the suction tube 25, and the soft foamed elastic body 20 expanded with the elastic restoring force. At this time, the hollow portion 14
Since the soft foamed elastic body 20 has a larger volume than the soft foamed elastic body 20, the soft foamed elastic body 20 uniformly adhered to the inner wall surface of the hollow portion 14 and penetrated into every corner of the triangle. The above operation was repeated three times, and the three hollow portions (a) and (b) shown in FIG.
(B) and (c) were filled with the soft foamed elastic body 20.

Example 2: Soft foam bullet as shown in FIG.
Adhesive 51 on synthetic resin sheet 31 wrapping
Except that the main frame 1 is applied in the same manner as in the first embodiment.
Insert and fill the soft elastic foam 20 into the hollow portion 14
Was. As the adhesive 31, a two-pack type acrylic epoxy
Use a water-based adhesive, and use a ring-shaped spray tube 50 to 1
00g / m ^Two Sprayed at the rate of In Examples 1 and 2
When observing the inside of the obtained soundproofing structure,
The flexible foamed elastic body 20 penetrates into every corner of 14 and has a hollow portion.
The flexible foamed elastic body 20 uniformly contacts the inner wall surface of 14
Was. A 1m long test specimen from each of the soundproof structures
Cut out the sample 60 and rubber at both ends as shown in FIG.
The measurement device shown in FIG.
To the point A (excitation point) located at one end of the sample 60
Enter the hit point with the impulse hammer 62, and
The acceleration is picked up by the sensor 63 at the point (pickup point).
Up. Hammer the excitation point A eight times and measure
Were averaged and analyzed with a frequency analyzer. XY analysis results
Process with a plotter, and plot the sound pressure spectrum (dB)
The transfer function is represented on a graph with the wave number (Hz) as the horizontal axis.
Was.

As shown in FIG. 13, in the sample (comparative example) containing only the shape member not filled with the soft foamed elastic body 20, as shown in FIG.
A high sound pressure spectrum was shown in a frequency band up to 000 Hz. This indicates that the energy of the sound applied at the excitation point A is propagated to the pickup point B without attenuation. Also, many sharp sound pressure peaks were detected. On the other hand, in the sample in which the hollow foam 14 was filled with the soft foamed elastic body 20, the sound pressure spectrum was lowered as a whole as shown in FIG. Moreover, the sharp sound pressure peak was reduced and the sound pressure spectrum was rounded. As is clear from this comparison, it was confirmed that the filling of the soft foamed elastic body 20 provided excellent soundproofing performance.

[0030]

As described above, in the soundproof structure of the present invention, the hollow portion of the aluminum hollow extruded profile is filled with the soft foamed elastic body without any gap, and the soft foamed elastic body is utilized by utilizing the elastic restoring force. Is pressed against the inner wall surface of the hollow part. Therefore, even when a long hollow extruded section is used as the main frame, excellent soundproof performance is exhibited. Moreover,
Since it can be manufactured by a simple method without the need for heat treatment that adversely affects the flexible foamed elastic body, it is lightweight and has a wide range of applications as flooring, side materials, roofing materials, etc. for buildings and vehicle structures. Used in.

[Brief description of the drawings]

FIG. 1 shows a soundproof structure in which a flexible foamed elastic material is filled in the hollow portion of a hollow extruded profile according to the present invention.

Fig. 2 Hollow extruded profile used as the main frame of the soundproof structure

Fig. 3 Flexible foamed elastic material filled in the hollow part of the extruded profile

FIG. 4 is a soft elastic foam housed in a bag-shaped synthetic resin sheet.

FIG. 5 shows an example of a method of inserting a contracted soft foamed elastic body into a hollow portion of a hollow extruded profile.

FIG. 6 shows a state in which an adhesive is applied to a soft foamed elastic body using a ring-shaped spray tube.

FIG. 7 shows an extruded aluminum member (a) used in Example 1.
And hollow shape (b)

FIG. 8 is a cross section of the soft foamed elastic body used in Example 1.

FIG. 9 shows another example of a soft foamed elastic body that facilitates insertion and adhesion of a suction tube.

FIG. 10: Synthetic resin sheet enclosing a soft foamed elastic body

FIG. 11 is a method for supporting a test sample whose soundproofing performance is measured.

FIG. 12: Soundproofing performance measurement system

FIG. 13 is a graph showing the propagation state of sound energy in a profile not filled with a soft elastic foam.

FIG. 14 is a graph showing the propagation state of sound energy in a soundproof structure filled with a soft elastic foam.

[Explanation of symbols]

10: Main frame 11: Rib 12: Upper wall part 13: Lower wall part 14: Hollow part 15: Joint part with a step 16: Flat joint part 20: Soft foam elastic body 21: Insertion hole 22: Insertion side 23: Slit 25: Hollow tube
26: Suction hole 27: Tip side of suction tube 28: Cap 29: Vent hole 30: Synthetic resin layer 31: Synthetic resin sheet 32:
Bonding part 41: Guide piece 42: String 50: Ring-shaped spray tube 51: Sprayed adhesive

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Takuo Kusano 2-2-2, Higashi-Shinagawa, Shinagawa-ku, Tokyo Inside Nihon Light Metal Co., Ltd. (72) Inventor Jun Hara 2-2-2, Higashi-Shinagawa, Shinagawa-ku, Tokyo No. Nippon Light Metal Co., Ltd. (72) Inventor Noboru Kashima 1-16-15 Uchikanda, Chiyoda-ku, Tokyo Inside Kyoritsu Chemical Industry Co., Ltd. (72) Inventor Takuyoshi Ishino 3756-20 Nakagawacho, Ashikaga City, Tochigi Prefecture (72) Inventor Shigeru Totsune 63-11 Tomioka-cho, Sano-shi, Tochigi (56) References JP-A-10-183806 (JP, A) JP-A-7-172305 (JP, A) JP-A-62-179925 ( JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) E04C 2/00-2/54 E04B 1/74-1/92 E04F 13/12

Claims (16)

(57) [Claims] 1. A main frame made of an aluminum hollow extruded shape having a hollow portion extending in a longitudinal direction, and a cross-sectional area of the hollow portion which is inserted into the entire length of the hollow portion and has a shape similar to the cross-sectional shape of the hollow portion and is in a free state. And a synthetic resin layer located between the inner wall surface of the hollow portion and a surface extending in the longitudinal direction of the flexible foamed elastic body. An aluminum soundproofing structure, wherein the soft foamed elastic body is pressed against the inner wall surface of the hollow portion via a resin layer. 2. The main frame has a structure including two surface plates and a plurality of ribs connecting the surface plates, and a soft foamed elastic body is inserted only into a hollow portion formed by one of the surface plates and the ribs. The aluminum soundproof structure according to claim 1, wherein 3. The aluminum soundproofing structure according to claim 1, wherein a rubber or synthetic resin foam having a rebound resilience of 25% or less according to JIS K6400 is used as the soft foam elastic. 4. A Dow type air permeability of 0.1 to 2.0 dm ³ /
The aluminum soundproofing structure according to any one of claims 1 to 3, wherein a rubber or synthetic resin foam of seconds is used as the soft foamed elastic body. 5. A rebound resilience according to JIS K6400 of 25% or less and a Dow type air permeability of 0.1 to 2.0 dm ^3.
The aluminum soundproofing structure according to any one of claims 1 to 4, wherein a polyurethane foam of 1 / sec is used as the soft foamed elastic body. 6. The aluminum soundproof structure according to claim 1, wherein the synthetic resin layer is made of a synthetic resin sheet having a thickness of 10 to 100 μm. 7. The aluminum soundproofing structure according to claim 1, wherein the synthetic resin layer is adhered to an inner wall surface of the hollow portion. 8. A main frame made of an elongated aluminum hollow extruded section having a plurality of hollow portions penetrating in a longitudinal direction, a similar cross section larger than a cross section of the hollow portion and substantially the same length as the length of the hollow portion. A flexible foamed elastic body having an open cell structure having a length is wrapped in a bag-shaped synthetic resin sheet, and the air inside the flexible foamed elastic body and the bag-shaped synthetic resin sheet is sucked to shrink the soft foamed elastic body. After inserting the soft foamed elastic body in the contracted state into the hollow portion, the bag-shaped synthetic resin sheet is opened to restore the soft foamed elastic body, thereby allowing the soft foamed elastic body to have the inner wall surface of the hollow portion. A method for manufacturing an aluminum sound-insulating structure, characterized in that the structure is pressed against the aluminum. 9. An adhesive is applied to a synthetic resin sheet enclosing the flexible foamed elastic body and / or an inner wall surface of the hollow section before inserting the contracted flexible foamed elastic body into the hollow portion of the main frame. A method for manufacturing an aluminum soundproof structure according to claim 8. 10. The method according to claim 8, wherein a rubber or synthetic resin foam having a rebound resilience of 25% or less according to JIS K6400 is used as the soft foam elastic. 11. A Dow type air permeability of 0.1 to 2.0 dm ³ /
The method for manufacturing an aluminum soundproof structure according to any one of claims 8 to 10, wherein a rubber or synthetic resin foam of seconds is used as the soft foamed elastic body. 12. A rebound resilience according to JIS K6400 of 25% or less and a Dow type air permeability of 0.1 to 2.0 dm.
^The method for producing an aluminum soundproof structure according to any one of claims 8 to 11, wherein a polyurethane foam of ³ / sec is used as the soft foamed elastic body. 13. A flexible foamed elastic body and a bag-shaped synthetic resin sheet are inserted into the bag-shaped synthetic resin sheet by inserting a suction tube extending over the entire length of the flexible foamed elastic body accommodated in the bag-shaped synthetic resin sheet through the suction tube. The method for manufacturing an aluminum soundproof structure according to any one of claims 8 to 12, wherein the air inside the space is sucked. 14. An insertion hole extending in the longitudinal direction is cut out at a substantially central portion of the flexible foamed elastic body, a slit is formed from the insertion hole to one surface of the flexible foamed elastic body, and the slit is opened to allow a suction tube to be inserted into the penetration hole. 14. The method for manufacturing an aluminum soundproof structure according to claim 13, wherein the aluminum soundproof structure is set at a distance from the outside. 15. The method for manufacturing an aluminum soundproof structure according to claim 13, wherein a suction tube having suction holes formed through the tube wall at regular intervals is used. 16. The method for manufacturing an aluminum soundproof structure according to claim 13, wherein the suction tube is left inside the soft foamed elastic body.