JPH0473960B2

JPH0473960B2 -

Info

Publication number: JPH0473960B2
Application number: JP60187494A
Authority: JP
Priority date: 1985-08-28
Filing date: 1985-08-28
Publication date: 1992-11-25
Also published as: JPS6248545A

Description

[Detailed description of the invention]

本発明は多層成形防音材に関し、更に詳細には
音源側に於て吸音性を有し総合的に遮音性を顕現
する壁材、天井材、間仕切り等に用いて有用なる
多層成形防音材に関する。従来より建築物、工場等に於て石膏ボード、石
綿スレート板等が防音材として用いられている
が、これら板材のみで有効な防音効果を求めるこ
とは困難である。また遮音構造として所定の空気
層を設けたコンクリート構造等が公知であり、か
かる構造は遮音性についてはそれなりの効果が認
められるが、構造の構築が煩雑であり、工期、経
費等に於て未だ満足するものでない。著しい騒音が公害としてとらえられる一方、社
会生活の向上に伴ない従来問題とならなかつた音
ですら社会問題へ発展する例があるごとく、一般
建築物、工場等を問わず防音、騒音対策は大きな
問題となつている。本出願人は、かかる問題を解消せんと、以前に
張り出し部頂部の空気流れ抵抗値及び高さの限定
した背後空気層を有する成形体を取り付ける騒音
処理法（特公昭54−19094）、張り出し部頂部の空
気流れ抵抗値を限定した背後空気層を有する成形
体の２枚を接合した吸音体（特公昭54−2008）及
び張り出し部頂部の空気流れ抵抗値を限定した背
後空気層を有する成形体を金属板等に取り付ける
防音板（特公昭54−8975）等を提案し、防音、騒
音対策に寄与した。しかしながら、例えば車両防
音材にあつては、省エネルギーのため車両の重量
を軽減する必要が生じ軽量化が要請されるに至つ
た。かかる現状に鑑み、本発明者らは防音効果を
全く下げることなく嵩高性不織布の目付量減によ
る成形体の重量軽減をなし得、更には、成形体の
重量をふやすことなく基材を嵩高くすることによ
り、一層優れた防音効果を顕現し得る防音材を鋭
意研究の結果、表皮層部分で特定の空気流れ抵抗
値のものを使用することにより可能となることを
見出だし本発明に至つたものであり、即ち、本発明の要旨は、少なくとも表皮層、樹脂フイルム及び嵩高性不
織布層とからなる成形防音材であつて、成形防音
材の張り出し部頂部の空気流れ抵抗値を表皮層と
樹脂フイルムの一体化物に於ては、20〜100c.g.s.
rayls、嵩高性不織布層に於ては、５〜200c.g.s.
raylsとし、成形防音材全体として、30〜300c.g.
s.raylsの張り出し部頂部の空気流れ抵抗値を有
する多層成形防音材にある。本発明に用いる嵩高性不織布は加熱成形に供す
るものであり、加熱成形後の形保持性等を要する
ため結合剤として熱硬化性合成樹脂を含有し、か
つ嵩高性不織布に未硬化の状態で散在しているこ
とを要するものである。この要件を満たすならば
主素材である不連続繊維材料としては、動物性、
植物性、鉱物性、合成樹脂性等より選ばれる１種
もしくは２種以上を組み合わせて用いて良く、ま
た結合剤として熱可塑性合成樹脂を併用すること
も何ら差し支えない。一般的には厚さ３〜50ｍ／ｍ、面密度400〜
4000ｇ／m²の嵩高性不織布であることが好まし
い。必要に応じて嵩高性不織布に不燃、難燃処理、
防水処理、撥水処理、毛羽立ち防止処理等を任意
に施すことが出来る。またこれらの処理は加熱成
形後に行なつても何ら差し支えない。例えばケイ
酸ソーダ水溶液、シリコン系、フツ素系等の撥水
剤、有機リン化合物、有機硫黄ハロゲン化合物、
無機アンチモン・アミド化合物、フツ化ケイ酸ソ
ーダ等の防炎処理剤等の散布などがあげられる。然るにかかる処理を施した場合に於ても処理後
の嵩高性不織布の成形体は、張り出し部頂部の空
気流れ抵抗値を５〜200c.g.s.raylsとする必要が
ある。かかる範囲内であれば成形後の張り出し部
頂部の表皮層部分での空気流れ抵抗値の調節によ
り、成形防音材として所望の空気流れ抵抗値を顕
現でき、併せて成形性、強度にも満足する。表皮層は、装飾性が必要であるが、吸音効果を
充分に考慮して材料を選択しなければならない。
即ち、樹脂フイルムと一体後の張り出し部頂部の
表皮層の空気流れ抵抗値が20〜100c.g.s.raylsで
あることを必要とし、この範囲にあらざれば成形
防音材として満足な防音性かつ重量軽減を同時に
なし得ず、従つて通気性のない材料、例えば比較
的厚い塩化ビニル樹脂シート（塩ビレザーと通称
される）等を用いる場合には開孔部を設けること
を必要とし、好ましくは薄葉状不織布やクロス等
の使用である。樹脂フイルムは、表皮層部分の空気流れ抵抗を
特定するために使用するものであり、ポリ塩化ビ
ニル系、ポリ酢酸ビニル系、ポリエチレン、ポリ
プロピレンもしくはこれらとアクリル酸、メタク
リル酸等の共重合体を使用する。樹脂フイルムの厚みは10〜50μ、好ましくは15
〜35μであり、かかる範囲にあることが本発明の
目的を満足するに好都合となる。かかる樹脂フイ
ルムは、加熱加圧成形に際して開孔してもよく、
所望の空気流れ抵抗を満足するのであれば全く差
し支えのないことである。樹脂フイルムは、嵩高性不織布上に載置する
か、嵩高性不織布または、表皮と一体化のものを
使用するかもしくはコーテイングの後フイルムと
なすかは適宜選択すればよい。表皮層、樹脂フイルム及び嵩高性不織布層から
なる成形防音材の張り出し部頂部の空気流れ抵抗
値は、30〜300c.g.s.raylsとなすことが必要であ
り、ここで頂部と限定しているのは、張り出し部
がその頂部に於て平面ないしは、なだらかな曲面
を想定しており、円錐、角錐等であつて頂部が鋭
角である場合には張り出し部の実質的に全域がか
かる空気流れ抵抗値を有すべきである。張り出し部頂部の空気流れ抵抗値が30c.g.s.
rayls未満では満足な吸音効果が得がたく、また
形保持性、剛性に不十分であり防音材として実用
に供しがたい。また300c.g.s.raylsを超えると多
孔質吸音材としての特性を失い防音材として実用
的でなくなるおそれがあり不都合である。平坦部については空気流れ抵抗値の範囲は特に
制限されず、防音材としての剛性、形保持性等よ
りして300c.g.s.raylsを超えることはなんら差し
支えない。形保持性、剛性等が実用に供しうる範
囲にあるならば平坦部の空気流れ抵抗値もまた30
〜300c.g.s.raylsとなすことが防音性の面で好ま
しい。本発明に用いる成形体の張り出し部の形状、配
置については任意であつてよく、本発明を実施す
るに用いる成形体として、該成形体を取り付ける
基壁の形状を個々に考慮することなく大量に生産
する場合等にあつては、半球状、角錐台状等の所
定形状の張り出し部を規則正しくもしくは不規則
に配置せしめることは好都合であり、また四角錐
台であつて四斜面を凹面状とした張り出し部や特
定の模様や絵画状に張り出し部を設けることは騒
音処理効果を低下せしめることなく内装材として
の装飾効果をも得ることが出来て実用上好ましい
ことである。本発明を実施するにあたつては、成形体をその
平坦部分で基壁に直接接触せしめて取り付けても
良く、また支柱等を介して基壁に取り付けること
によつても良い。取り付ける方法としては接着剤による方法、ビ
スやクリツプ止めによる方法等を任意に選択し得
る。基壁表面と該成形体の張り出し部の頂部内面ま
での距離、即ち基壁と成形体の間に形成される空
気層の厚さは、処理すべき騒音の周波数によつて
異なるが、５〜200ｍ／ｍの範囲が好ましい。５
ｍ／ｍ以下では背後空気層を形成しがたく、従つ
て吸音特性が著しく低下し騒音処理効果が得られ
ないおそれがあり、また200ｍ／ｍ以上の場合吸
音効果の増加が顕著でなくなる上に、空間の占有
率が大きくなり実用的でない。本発明になる多層成形防音材の一体化の１方法
としては、嵩高性不織布上に樹脂フイルム、表皮
を載置し、150〜250℃、２〜20Kg／cm²で加熱加圧
成形し、嵩高性不織布層の厚さを２〜15ｍ／ｍと
なせばよい。以下に実施例を挙げ本発明のより詳細な理解に
供する。当然のことながら本発明は以下の実施例
のみに限定されるものではない。実施例１落綿50重量部、皮毛20重量部及びガラス繊維10
重量部にフエノール樹脂粉末20重量部を散布混合
し、フリースを形成し、加熱炉で180℃に加熱し、
厚さ18ｍ／ｍ、面密度600ｇ／m²の嵩高性不織布
を得た。この嵩高性不織布に成形後の頂部空気流れ抵抗
が55c.g.s.raylsで面密度が40ｇ／m²の薄葉状不織
布と15μのポリエチレンフイルムの一体化物を貼
着し成形素材とした。比較例１落綿50重量部、反毛20重量部及びガラス繊維10
重量部にフエノール樹脂粉末20重量部を散布混合
し、フリースを形成し、加熱炉で180℃に加熱し、
厚さ33ｍ／ｍ、面密度1600ｇ／m²の嵩高性不織布
を得た。この嵩高性不織布上に成形後の頂部空気流れ抵
抗が実質的に０のサランクロスを貼着し成形素材
とした。実施例２実施例１と同様の成形素材を得た。比較例２落綿50重量部、反毛20重量部及びガラス繊維10
重量部にフエノール樹脂粉末20重量部を散布混合
し、フリースを形成し、加熱炉で180℃に加熱し、
実施例１と同様の嵩高性不織布上に頂部空気流れ
抵抗が10のクロスを貼着し成形素材とした。結果実施例１、比較例１になる成形素材成型後の
空気流れ抵抗はいずれも100c.g.s.raylsであつ
た（即ち防音効果は等しい）が1.2m²の成型品
であるフードインシユレーターの重量は各々
770ｇ、1920ｇであり1150ｇの軽減をなした。実施例２、比較例２になる成形素材成型後の
空気流れ抵抗は各々100c.g.s.rayls、35c.g.s.
raylsであつたが、1.2m²の成型品であるフード
インシユレーターの重量はいずれも770ｇであ
つた。以下に防音効果の比較をする（吸音率を
残響室法により測定）。 The present invention relates to a multilayer molded soundproofing material, and more particularly to a multilayered molded soundproofing material that has sound absorption properties on the sound source side and is useful for use in wall materials, ceiling materials, partitions, etc. that exhibits comprehensive sound insulation properties. Although gypsum boards, asbestos slate boards, and the like have been used as soundproofing materials in buildings, factories, and the like, it is difficult to obtain effective soundproofing effects using only these board materials. In addition, concrete structures with a predetermined air layer are known as sound insulation structures, and although such structures have a certain degree of sound insulation effect, construction of the structure is complicated and the construction period and costs are still low. It's not satisfying. While significant noise is regarded as pollution, there are examples where even noise that was not a problem in the past has developed into a social problem as social life improves, so soundproofing and noise countermeasures are important in general buildings, factories, etc. It's becoming a problem. In order to solve this problem, the present applicant previously proposed a noise treatment method (Japanese Patent Publication No. 54-19094) in which a molded body having a rear air layer with a limited air flow resistance and height at the top of the overhang was proposed. A sound absorbing body made by joining two pieces of a molded body having a rear air layer with a limited air flow resistance value at the top (Special Publication No. 1983-2008) and a molded body with a rear air layer with a limited air flow resistance value at the top of the overhanging part He contributed to soundproofing and noise countermeasures by proposing soundproofing plates (Special Publication No. 1989-8975) that were attached to metal plates, etc. However, in the case of soundproofing materials for vehicles, for example, it has become necessary to reduce the weight of vehicles in order to save energy, and weight reduction has come to be demanded. In view of the current situation, the present inventors were able to reduce the weight of the molded article by reducing the basis weight of the bulky nonwoven fabric without reducing the soundproofing effect at all, and further, to make the base material bulkier without increasing the weight of the molded article. As a result of intensive research into soundproofing materials that can achieve even better soundproofing effects, we discovered that this could be achieved by using a material with a specific air flow resistance value in the skin layer, which led to the present invention. That is, the gist of the present invention is to provide a molded soundproofing material consisting of at least a skin layer, a resin film, and a bulky nonwoven fabric layer, in which the air flow resistance value at the top of the overhanging part of the molded soundproofing material is calculated based on the skin layer and the resin. For integrated film, 20~100c.gs
rayls, bulky nonwoven fabric layer: 5~200c.gs
rayls and molded soundproofing material as a whole, 30 to 300 c.g.
S.rayls has a multi-layer molded soundproofing material with air flow resistance value at the top of the overhang. The bulky nonwoven fabric used in the present invention is subjected to heat molding, and since it requires shape retention after heat molding, it contains a thermosetting synthetic resin as a binder, and is scattered in an uncured state in the bulky nonwoven fabric. It requires that you do what you do. If this requirement is met, the main discontinuous fiber material is animal-based,
One type or a combination of two or more types selected from vegetable, mineral, synthetic resin, etc. may be used, and there is no problem in using a thermoplastic synthetic resin in combination as a binder. Generally, thickness is 3~50m/m, areal density is 400~
Preferably, it is a bulky nonwoven fabric of 4000 g/m ² . Non-flammable and flame retardant treatment is applied to bulky non-woven fabrics as necessary.
Waterproofing treatment, water repellent treatment, fuzz prevention treatment, etc. can be optionally applied. Moreover, there is no problem even if these treatments are performed after heat molding. For example, sodium silicate aqueous solution, silicone-based, fluorine-based water repellents, organic phosphorus compounds, organic sulfur halogen compounds,
Examples include spraying flame retardants such as inorganic antimony amide compounds and sodium fluorosilicate. However, even when such a treatment is applied, the treated bulky nonwoven fabric molded article must have an air flow resistance value of 5 to 200 c.gsrayls at the top of the overhanging portion. Within this range, by adjusting the air flow resistance value in the skin layer at the top of the overhang after molding, the desired air flow resistance value can be achieved as a molded soundproofing material, and the moldability and strength are also satisfied. . Although the skin layer needs to be decorative, the material must be selected with due consideration to the sound absorption effect.
In other words, it is necessary that the air flow resistance value of the skin layer at the top of the overhang after being integrated with the resin film is 20 to 100c.gsrayls, and if it is not within this range, it will not be possible to obtain satisfactory soundproofing and weight reduction as a molded soundproofing material. Therefore, when using a non-breathable material such as a relatively thick vinyl chloride resin sheet (commonly known as vinyl chloride leather), it is necessary to provide an opening, preferably a thin non-woven fabric. or cross. The resin film is used to determine the air flow resistance of the skin layer, and is made of polyvinyl chloride, polyvinyl acetate, polyethylene, polypropylene, or copolymers of these with acrylic acid, methacrylic acid, etc. do. The thickness of the resin film is 10 to 50 μ, preferably 15
~35μ, and being within this range is convenient for satisfying the purpose of the present invention. Such a resin film may be perforated during heating and pressure molding.
There is no problem as long as the desired air flow resistance is satisfied. It may be selected as appropriate whether the resin film is placed on a bulky nonwoven fabric, a bulky nonwoven fabric or one integrated with the skin, or a film is formed after coating. The air flow resistance value at the top of the overhanging part of the molded soundproof material consisting of the skin layer, resin film, and bulky nonwoven fabric layer must be 30 to 300c.gsrayls, and the top is limited to: The overhang is assumed to have a flat or gently curved surface at its top; in the case of a cone, pyramid, etc. with an acute angle at the top, substantially the entire area of the overhang has such an air flow resistance value. Should. Air flow resistance value at the top of the overhang is 30c.gs
rayls, it is difficult to obtain a satisfactory sound absorption effect, and the shape retention and rigidity are insufficient, making it difficult to use as a practical soundproofing material. Moreover, if it exceeds 300c.gsrayls, it is inconvenient because it may lose its properties as a porous sound absorbing material and become impractical as a sound insulating material. For flat areas, the range of air flow resistance is not particularly limited, and there is no problem in exceeding 300c.gsrayls in terms of rigidity as a soundproofing material, shape retention, etc. If the shape retention, rigidity, etc. are within a practical range, the air flow resistance value of the flat part should also be 30.
~300c.gsrayls are preferred in terms of soundproofing. The shape and arrangement of the overhanging portion of the molded body used in the present invention may be arbitrary, and the molded body used to carry out the present invention can be used in large quantities without considering the shape of the base wall to which the molded body is attached. In the case of production, etc., it is convenient to arrange protruding parts of a predetermined shape, such as a hemisphere or a truncated pyramid shape, regularly or irregularly. Providing an overhanging portion or an overhanging portion in a specific pattern or picture-like shape is practically preferable because it can also provide a decorative effect as an interior material without reducing the noise treatment effect. In carrying out the present invention, the molded body may be attached with its flat portion in direct contact with the base wall, or it may be attached to the base wall via a support or the like. The attachment method may be arbitrarily selected from adhesives, screws, clips, etc. The distance between the base wall surface and the top inner surface of the overhanging part of the molded body, that is, the thickness of the air layer formed between the base wall and the molded body, varies depending on the frequency of the noise to be treated, but is between 5 and A range of 200 m/m is preferred. 5
If it is less than 200 m/m, it is difficult to form a back air layer, so the sound absorption properties will be significantly reduced and the noise treatment effect may not be obtained.If it is more than 200 m/m, the increase in sound absorption effect will not be noticeable and , the space occupancy becomes large, making it impractical. One method for integrating the multilayer molded soundproofing material of the present invention is to place a resin film and a skin on a bulky nonwoven fabric, heat and pressure mold at 150 to 250°C and 2 to 20 kg/cm ² to form a bulky nonwoven fabric. The thickness of the nonwoven fabric layer may be 2 to 15 m/m. Examples are given below to provide a more detailed understanding of the present invention. Naturally, the present invention is not limited to the following examples. Example 1 50 parts by weight of fallen cotton, 20 parts by weight of leather hair, and 10 parts by weight of glass fiber
Sprinkle and mix 20 parts by weight of phenolic resin powder to form a fleece, heat it to 180°C in a heating furnace,
A bulky nonwoven fabric having a thickness of 18 m/m and an areal density of 600 g/m ² was obtained. To this bulky nonwoven fabric, an integrated product of a thin nonwoven fabric with a top air flow resistance of 55 c.gsrayls and an areal density of 40 g/m ² and a 15 μm polyethylene film was attached to the bulky nonwoven fabric to prepare a molded material. Comparative Example 1 50 parts by weight of fallen cotton, 20 parts by weight of recycled wool, and 10 parts by weight of glass fiber
Sprinkle and mix 20 parts by weight of phenolic resin powder to form a fleece, heat it to 180°C in a heating furnace,
A bulky nonwoven fabric having a thickness of 33 m/m and an areal density of 1600 g/m ² was obtained. Saran cloth having substantially zero air flow resistance at the top after molding was adhered onto this bulky nonwoven fabric to form a molding material. Example 2 A molding material similar to that in Example 1 was obtained. Comparative Example 2 50 parts by weight of fallen cotton, 20 parts by weight of recycled wool, and 10 parts by weight of glass fiber
Sprinkle and mix 20 parts by weight of phenolic resin powder to form a fleece, heat it to 180°C in a heating furnace,
A cloth having a top air flow resistance of 10 was adhered to the same bulky nonwoven fabric as in Example 1 to form a molding material. Results The air flow resistance after molding the molding materials used in Example 1 and Comparative Example 1 was 100c.gsrayls (that is, the soundproofing effect was the same), but the weight of the hood insulator, which was a molded product of 1.2 m ² are each
770g and 1920g, a reduction of 1150g. The air flow resistance after molding of the molding materials for Example 2 and Comparative Example 2 is 100c.gsrayls and 35c.gs, respectively.
rayls, the weight of each hood insulator, which is a 1.2 m ² molded product, was 770 g. Below is a comparison of the soundproofing effects (sound absorption coefficient measured using the reverberation room method).

【表】このように本発明になる多層成形防音材は重量
軽減及び防音効果の向上を顕現するものであつ
た。[Table] As described above, the multilayer molded soundproofing material of the present invention exhibited weight reduction and improved soundproofing effect.

Claims

[Claims]

1 In a molded soundproofing material consisting of at least a skin layer, a resin film, and a bulky nonwoven fabric layer, the air flow resistance value at the top of the overhanging part of the molded soundproofing material is 20 to 20. 100c.
gsrayls, bulky nonwoven fabric layer: 5 to 200 c.g.
s.rayls, molded soundproofing material as a whole, 30~300c.
A multilayer molded soundproofing material characterized by having the air flow resistance value of the top of the overhang of gsrayls.