JPH10183806A - Aluminum soundproof structure and method of manufacturing the same - Google Patents

Abstract

(57) [Problem] To provide a soundproof structure excellent in soundproof performance by filling a hollow portion of a main frame made of an extruded aluminum material with a flexible foamed elastic body. SOLUTION: Air is sucked from a bag-shaped heat-fusible sheet enclosing a soft foamed elastic body 20, and the soft foamed elastic body 20 is sucked.
Is shrunk, and inserted into the hollow portion 14 of the main frame 10 made of extruded aluminum. Next, when the bag-shaped heat-fusible sheet is opened, the soft foamed elastic body 20 swells by elastic restoring force and completely fills the hollow portion 14.
When the main frame 10 is heated in this state, the soft foamed elastic body 20 is uniformly adhered to the inner wall surface of the hollow portion 14 by the heat-fusing agent layer 30 generated by melting the heat-fusible sheet. It is preferable to use a suction tube 25 inserted into the soft foamed elastic body 20 for sucking air for contracting the volume of the soft foamed elastic body 20.

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. In addition, Japanese Patent Laid-Open No. 7-1
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 of the damping resin becomes difficult when the extruded aluminum hollow shape to be applied becomes long. Filling of the foamed rubber elastic body becomes difficult. 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. The present invention has been devised in order to solve such a problem, and the hollow portion of the extruded profile is densely filled with the soft foamed elastic body by utilizing the contraction and restoration of the foamed soft foamed elastic body. Accordingly, it is an object of the present invention to provide a soundproof structure having excellent soundproof performance by uniformly filling a soft foamed elastic body in a hollow portion regardless of the length of an extruded profile and the cross-sectional shape of the hollow portion.

[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 heat-sealing agent layer for bringing the surfaces extending in the longitudinal direction of the body into close contact with each other, wherein the heat-sealing agent layer is formed by melting the heat-sealing sheet. For the main frame, an extruded aluminum member having a structure including two surface plates and a plurality of ribs connecting the surface plates is used. The soft foamed elastic body can be inserted only into a hollow portion formed by one surface plate and a rib. Rubber or synthetic resin foam such as polyurethane foam having a rebound resilience according to JIS K6401 of 25% or less and / or a Dow type air permeability of 0.1 to 2.0 dm ³ / sec is used for the soft foam elasticity. Is done. A resin film having a melting point of 90 to 150 ° C. and a thickness of 20 to 70 μm is used for the heat sealing sheet.

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 a length substantially equal to the length of the hollow portion is wrapped with a bag-shaped heat-fusible sheet, and air inside the soft foamed elastic body and the bag-shaped heat-fusible sheet is removed. Suction to shrink the soft foamed elastic body, after inserting the soft foamed elastic body in a contracted state into the hollow portion, open the bag-shaped heat-fusible sheet to restore the soft foamed elastic body, Next, the heat-fusible sheet is heated and melted to adhere the soft foamed elastic body to the inner wall surface of the hollow portion, thereby producing the sheet.

Further, a suction tube extending over the entire length of the soft foamed elastic body accommodated in the bag-shaped heat-sealing sheet is inserted into the bag-shaped heat-sealing sheet, and the soft foamed elastic body and the bag-like heat-sealing material are inserted through the suction tube. By sucking the air inside the fusible sheet, the volume of the soft foamed elastic body can be contracted. 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 foam elastic body 20 is adhered to the inner wall of the main frame 10 by the heat-sealing agent layer 30. 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 materials are generally made of aluminum materials such as 6000 series and 7000 series, cut to a predetermined length,
Heat treatment, surface treatment, etc. impart predetermined mechanical properties, corrosion resistance, surface color, and the like. For the heat treatment, T5 treatment, T6 treatment or the like is employed.

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 K6401, 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 the soft foamed elastic body 20 is filled into the hollow portion 14 of the main frame 10, and the volume of the soft foamed elastic body 20 is contracted, which is preferable for work. Absent. Conversely, if the air permeability exceeds 2.0 dm ³ / sec, the sound absorption performance is poor.

[0011] Such a soft foamed elastic body 20 is prepared, for example, as follows. Average hydroxyl value 70-280,
100 parts by weight of a polyol having an average molecular weight of 600 to 2400 and an NCO index (NC
(O / OH ratio × 100) A polyisocyanate, a foaming agent, a catalyst, and a foam stabilizer in an amount of 85 to 115 are mixed by a mixing head, and the mixture is discharged onto a bottom paper on a conveyor to cause a foaming reaction. Manufacture block slab foam. 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 prepared by mixing an appropriate amount of a polyol having a hydroxyl value of 20 to 160 and a polyol having a hydroxyl value of 350 to 1850. In addition, the average molecular weight is 600-
The polyol of 2400 is prepared by mixing an appropriate amount of a long-chain polyol having a molecular weight of 2,000 to 6,000 and a short-chain polyol having a molecular weight of 350 to 1,000.

The polyols 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. From the viewpoint of sound absorption, there is a relationship in air permeability, but it is advantageous to use closed 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 suction tube 25 is made of, for example, flexible vinyl chloride or the like. In order to connect the tip of the tube 25 to an air suction device, the length thereof is set to be 20 to 30 cm longer than the length of the soft foam elastic body 20. deep. The suction tube 25 has a plurality of suction holes 26 at intervals of 100 to 2000 mm, preferably at intervals of 250 to 1000 mm.
Are drilled. The thickness and outer diameter of the suction tube 25 are not particularly limited, but may be 0.5 to 2 mm in thickness.
The outer diameter is generally about 5 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 flexible foamed elastic body 20 enclosing the suction tube 25 is a bag-shaped heat-fusible sheet 3.
1 As the heat-fusible sheet 31, a nylon, olefin, ester or the like thermoplastic resin film having a melting point in the range of 90 to 150 ° C. and a film thickness of 20 to 70 μm is used. When the melting point is lower than 90 ° C, the soundproof structure is irradiated with sunlight or the like at a temperature of 70 to 80 ° C during use.
There is a possibility that the temperature of the soundproof structure rises to a certain extent and the soft foamed elastic body 20 peels off from the inner wall surface of the main frame 10. Conversely, a resin film having a melting point exceeding 150 ° C. is not economical because the heating temperature during heat fusion is too high. Heat fusible sheet 31
In order to form the heat-fusing agent layer 30 having a required thickness, the film preferably has a film thickness of 20 to 70 [mu] m so as not to be broken even when the inside is in a reduced-pressure atmosphere. When the film thickness is less than 20 μm, not only the heat-fusing agent layer 30 necessary for bonding the soft foamed elastic body 20 to the inner wall surface of the main frame 10 is not formed, but also the heat-sealing property during transportation, handling, etc. The sheet 31 is easily broken. Conversely, when the film thickness exceeds 70 μm, not only is the resin film consumed more than necessary, but also the self-holding force of the shape is increased, and the tendency of restraining the contraction and expansion of the soft foamed elastic body 20 in response to decompression and opening to the atmosphere is increased. Can be seen.

The soft foamed elastic body 20 is accommodated in a heat-fusible sheet 31 formed in a bag shape. Alternatively, the heat-fusible sheet 31 accommodating the soft foamed elastic body 20 may be obtained by winding the resin film around the soft foamed elastic body 20 and then heat-sealing the overlapped portions of the resin film to each other. it can. As shown in FIG. 4, the tip of the suction tube 25 was pulled out from an open end of the heat-fusible sheet 31 containing the soft foamed elastic body 20, and the suction tube 25 was drawn out by hot pressing using an iron or the like. Later, the open end of the heat-fusible sheet 31 is sealed. When the distal end side 27 of the suction tube 25 is connected to a suction device (not shown) and the bag-shaped space of the heat-fusible sheet 31 is evacuated through the suction holes 26, the soft foamed elastic body 20 contracts. In this state, when the ventilation hole 29 at the tip of the suction tube 25 is closed with a suitable cap 28, air does not enter the flexible foamed elastic body 20, and the shrinkable insertion facilitates insertion into the hollow portion 14 of the main frame 10. Be a body.

The soft foamed elastic body 20 whose volume has shrunk is inserted into the hollow portion 14 of the main frame 10. At this time, FIG.
The use of the guide piece 41 makes it possible to easily insert the soft foamed elastic body 20 as shown in FIG. 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. When the flexible foamed elastic body 20 is set at the entrance of the hollow portion 14 according to the shape of the hollow portion 14 and the string 42 attached to the guide piece 41 at the other end is pulled, the flexible foamed elastic material 20 is 1
4 goes into the full length.

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 it is 30% larger, the soft foamed elastic body 20 released from the contracted state fits into every corner of the hollow portion 14 smoothly.

As described above, the soft foamed elastic body 20 is
90-150 ° C × on the main frame 10 inserted in
When the heat treatment is performed for 10 to 40 minutes, the soft foamed elastic body 20
The heat-fusible sheet 31 wrapping the heat-fusible sheet 31
It becomes 0, and the soft foamed elastic body 20 is adhered to the inner wall surface of the hollow portion 14 in a close contact state. If the heating temperature is less than 90 ° C. or the heating is performed for a short time of less than 10 minutes, the heat-fusible sheet 31 is not sufficiently melted, and the uniform heat fusion between the inner wall surface of the hollow portion 14 and the soft foamed elastic body 20 is performed. The adhesive layer 30 is not formed. Conversely 15
A heating temperature exceeding 0 ° C. or a long heating time exceeding 40 minutes is not only economically energies, but also may affect the material of the main frame 10 made of the soft foamed elastic body 20 or the extruded aluminum material. is there.

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 adhered to the inner wall surface of the hollow portion 14 through the heat-fusing agent layer 30 formed by melting the heat-fusible sheet 31, the long main frame 10 is particularly suitable. However, no adhesion failure occurs. Therefore, the soundproof structure has excellent soundproof performance and high reliability. 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.

[0022]

【Example】

Example 1: FIG. 6 shows an aluminum alloy material 6N01.
A hollow extruded profile having a cross-sectional shape having the dimensions shown in (a) was extruded, forced air-cooled, realigned, 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 this hollow extruded shape had a triangular shape whose dimensions are shown in FIG. 19.0% by weight of polyether polyol (molecular weight 3000, hydroxyl value 56.1), polyether polyol (molecular weight 700, hydroxyl value 240.
2) 63.5% by weight of a polyol obtained by mixing 44.5% by weight (average molecular weight: 910, average hydroxyl value: 185), 6.4% by weight of dioctyl phthalate, 1.0% by weight of silicone foam stabilizer, water 1.1% by weight, amine catalyst 0.4
Wt%, pigment 0.2 wt% and NCO index 95
Tolylene diisocyanate (65 of the 2,4- and 2,6-isomer of tolylene diisocyanate:
The mixture was discharged onto a bottom paper on a conveyor belt by a one-shot method, reacted and foamed, and then cured to obtain a continuous long body of polyurethane foam. The base paper is peeled off from the polyurethane foam strip and about 2
m and cut into a block of 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. 7 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 1 having slit 23 and insertion hole 21 formed
3 were bonded at their longitudinal end faces with an adhesive to obtain a 25.02 m long soft foamed elastic body. The suction tube 25 has an outer diameter of 6 mm, a thickness of 1 mm, and a length of 25.2.
mm vinyl chloride tube was prepared. .. Having a diameter of 1 mm were formed in the tube at intervals of 500 mm. Open the slit 23 of the soft foamed elastic body 20,
The suction tube 25 extends over the entire length of the soft foamed elastic body 20.
Was set in the insertion hole 21 and the slit 23 was closed to wrap the suction tube 25 in the soft foamed elastic body 20.

A heat fusible sheet 31 is wrapped around the outer periphery of the soft foam elastic body 20 on which the suction tube 25 is set in a tightly contacted state, and as shown in FIG. It was heat-sealed and formed into a bag at the heat-sealed part 32. As the heat-fusible sheet 31, an EVA copolymerized olefin-based resin film having a thickness of 40 μm and a melting point of 102 ° C. was used. In heat fusion, the tip of the suction tube 25 was put out of the bag from one end of the heat fusion 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 heat-fusible sheet 31 is sucked.
The volume of the entire soft foamed elastic body 20 was contracted to about 10% of the cross-sectional shape of the hollow portion 14 of No. 0.

The vent hole 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 in the heat-fusible 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), (b), and (c) shown in FIG. Then, the main frame 10 combined with the soft foamed elastic body 20 is held in a furnace at 130 ° C. for 30 minutes to melt the heat-fusible sheet 31 to form the hollow portion 14.
The soft foamed elastic body 20 was adhered to the inner wall surface of. Observation of the inside of the soundproof structure obtained in this manner shows that the hollow portion 1
4, the flexible foamed elastic body 20 penetrates into every corner, and the hollow portion 1
The flexible foamed elastic body 20 was evenly adhered to the inner wall surface of No. 4.

Example 2 The soundproofing structure manufactured in Example 1 was cut into a length of 2150 mm, and the end faces of the adjacent soundproofing structures were welded so as to have a width of about 1500 mm, and received as shown in FIG. A sample panel A for soundproof performance test in which a hollow portion on the sound side was filled with a soft foamed elastic body and a sample panel B in which all the hollow portions 14 were filled with urethane foam having a low resilience were produced. For comparison, a sample panel C in which the hollow portion 14 was not filled with anything was prepared. The sound source room and the sound receiving room were separated by a sample panel, and a sound level meter was arranged in each of the sound source room and the sound receiving room. Using the speaker as a sound source, to measure the average noise level of each sound source chamber and the receiving room to determine the sound transmission loss T _L according to equation (1) which is defined in JIS A1416. Generally, it can be said that the larger the sound transmission loss T _L is, the more excellent the soundproofing performance is.

T _L = L ₁ −L ₂ +10 log (S / A) (1) where L ₁ : average noise level of the sound source room L ₂ : average noise level of the sound receiving room S: sample Area A: Sound absorption power of sound receiving chamber Determined sound transmission loss _{TL is applied} to each sample panel A to C
FIG. 10 summarizes the acoustic frequencies added to. As can be seen from the investigation results in FIG. 10, the sample panel B in which the entire space is filled with the soft elastic foam exhibits the most excellent soundproof performance. However, the sample panel A in which only the sound-receiving-side hollow portion is filled with the soft elastic foam is inferior to the sample panel B in soundproofing effect, but it can be said that good results are obtained in consideration of cost. Sample panel C
Is a panel with only a mainframe, so its soundproof performance is inferior. As is clear from this comparison, the soundproofing structure according to the present invention has excellent soundproofing performance.

[0029]

As described above, in the soundproof structure of the present invention, the hollow portion of an aluminum hollow extruded profile is filled with a soft foamed elastic body without any gap, and the inner wall surface of the hollow portion is filled with a heat sealant. It has a bonded structure. 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, it is lightweight, and at the same time, is used for flooring of buildings, vehicle structures,
Used in a wide range of fields as side materials, roofing materials, etc.

[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-like heat-fusible sheet.

FIG. 5 is a guide piece used for inserting a contracted soft foamed elastic body into the hollow portion of a hollow extruded profile.

FIG. 6 shows a hollow extruded profile (a) and its hollow part (b) used in Example 1.

FIG. 7 is a cross section of the soft foamed elastic body used in Example 1.

FIG. 8 is a heat-fusible sheet enclosing a soft foamed elastic body.

FIG. 9 shows a soundproof panel in which a soundproof structure in which a hollow portion is filled with a soft foamed elastic body is connected sideways.

FIG. 10 shows sound transmission loss of each sample panel used in the examples.

[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: Heat fusing agent layer 31: Heat fusing sheet 32:
Heat fusion part 41: Guide piece 42: String

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[Procedure amendment]

[Submission date] January 21, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0013

[Correction method] Change

[Correction contents]

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.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Takuo Kusano 2-2-2, Higashi-Shinagawa, Shinagawa-ku, Tokyo Inside Japan Light Metal Co., Ltd. (72) Inventor Jun Hara 2-2-2, Higashi-Shinagawa, Shinagawa-ku, Tokyo Japan Light Metal Co., Ltd. (72) Inventor Noboru Kashima 1-16-15 Uchikanda, Chiyoda-ku, Tokyo Kyoritsu Chemical Industry Co., Ltd. (72) Inventor Takuyoshi Ishino 3756-20 Nakagawa-cho, Ashikaga-shi, Tochigi (72) Inventor: Shigeru Totsune 63-11 Tomiokacho, Sano City, Tochigi Prefecture

Claims (15)

[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. A flexible foamed elastic body having a cross-sectional area equal to or larger than the above, and a heat-fusing agent layer for bringing the inner wall surface of the hollow portion and the surface extending in the longitudinal direction of the flexible foamed elastic body into close contact with each other; An aluminum soundproofing structure, wherein the fusing agent layer is formed by melting a heat fusing sheet. 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 K6401 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 melting point of 90 to 150 ° C. and a film thickness of 20 to 70 μm.
The aluminum soundproofing structure according to any one of claims 1 to 4, wherein the resin film of m is used as a heat-sealing sheet. 6. A rebound resilience according to JIS K6401 of 25% or less and a Dow air permeability of 0.1 to 2.0 dm ^3.
An aluminum soundproofing structure according to any one of claims 1 to 5, wherein a polyurethane foam of 1 / sec is used as the soft foamed elastic body. 7. A main frame made of an elongated aluminum hollow extruded shape having a plurality of hollow portions penetrating in a longitudinal direction, a similar cross section larger than a cross section of the hollow portion of the main frame 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 with a bag-shaped heat-fusible sheet, and air inside the soft foamed elastic body and the bag-shaped heat-fusible sheet is sucked to form the soft foamed elastic body. After the body is contracted and the soft foamed elastic body in the contracted state is inserted into the hollow portion, the bag-shaped heat-fusible sheet is opened to restore the soft foamed elastic body, and then the heat-fusible sheet Wherein the soft foamed elastic body is adhered to the inner wall surface of the hollow part by heating and melting the aluminum foam. 8. The method for producing an aluminum soundproof structure according to claim 7, wherein a rubber or synthetic resin foam having a rebound resilience of 25% or less according to JIS K6401 is used as the soft foam elastic. 9. A Dow type air permeability of 0.1 to 2.0 dm ³ /
9. The method for producing an aluminum soundproof structure according to claim 7, wherein a rubber or synthetic resin foam of seconds is used as the soft foamed elastic body. 10. A rebound resilience according to JIS K6401 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 7 to 9, wherein a polyurethane foam of ³ / sec is used as the soft foamed elastic body. 11. A melting point of 90 to 150 ° C. and a film thickness of 20 to 70.
The method for producing an aluminum soundproof structure according to any one of claims 7 to 10, wherein a resin film of μm is used as the heat-sealing sheet. 12. A suction tube extending over the entire length of the soft foamed elastic body accommodated in the bag-shaped heat-sealing sheet is inserted into the bag-shaped heat-sealing sheet, and the soft foamed elastic body and the bag-shaped heat-sealing material are inserted through the suction tube. The method for manufacturing an aluminum soundproof structure according to any one of claims 7 to 11, wherein air inside the fusible sheet is sucked. 13. An opening extending in the longitudinal direction at substantially the center of the flexible foamed elastic body, and a slit is formed from the through hole to one surface of the flexible foamed elastic body. The method for manufacturing an aluminum soundproofing structure according to claim 12, wherein the soundproofing structure is set at: 14. The method for manufacturing an aluminum soundproof structure according to claim 12, wherein a suction tube having suction holes formed through the tube wall at regular intervals is used. 15. The method for producing an aluminum soundproof structure according to claim 12, wherein the suction tube is left inside the soft foamed elastic body.