JPH07227926A - Sound absorbing and heat insulating board, heat insulating panel using the same and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a sound absorbing and heat insulating board, which has sound absorbing qualities and heat insulating properties, though being lightweight, excellent in strength and reinforcing function and good productivity, and heat insulating panel made of the board and their manufacturing methods. CONSTITUTION:A sound absorbing and heat insulating board is prepared by integrating a reinforcing material 10 and a foamed resin 11. When the reinforcing material 10 is seen from its one side, a large number of independent projected parts 2 are regularly distributed over the whole surface of the board. Recessed part 3 is formed around each projected part 2. When the reinforcing material 10 is seen from the other side, the portion corresponding to the projected part 2 is formed to be a recessed part, while the portion corresponding to the recessed part 3 is formed to be a projected part. In addition, the apices of the projected parts on both the sides of the reinforcing material are set to be at the same height. Further, at least one side of the reinforcing material 10 is formed into flat surface by charging a foamed resin 11 in the recessed parts under the condition that the density of the whole board is set to be 10-200kg/m<3>. Heat insulating panel is obtained by bonding surface plate material 12 onto both the sides of the sound absorbing and heat insulating board.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound absorbing and heat insulating substrate having excellent sound absorbing properties and heat insulating properties and high strength, a heat insulating panel having the substrate as a core material, and a method for producing them. More specifically, for example, a sound-absorbing and heat-insulating substrate used as a sound-absorbing or heat-insulating interior material or the like can be obtained by laminating a design cloth, a film, a wallpaper material, etc. on the surface, and the substrate as a core material. For example, the present invention relates to a heat insulating panel used as a partitioning material, a ceiling material, a wall material, a floor material, etc. in a building, a freezing / refrigerating room and the like, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as a partition panel, a low density glass wool or rock wool flat plate is filled in the panel for the purpose of a heat insulating function, or a foamed resin such as polyurethane, urethane / phenolic resin, polyisocyanurate. Resin, phenol resin, urea resin, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene chloride, etc. are foamed and cured in the panel, and the foam is sandwiched between panel board materials, as well as paper, corrugated paper, asbestos paper, It is known that a non-combustible paper such as calcium silicate or magnesium silicate, an aluminum foil, a steel foil or the like having a honeycomb structure and sandwiched by panel plate materials.

In particular, the polyurethane foam resin has a good heat insulating property because it contains a CFC foaming agent having a low heat conductivity, and
It has been widely used as a core material for panels because it can be easily adhered to color steel plates, steel plates, aluminum plates, etc. as surface plate materials, but in recent years, foaming agents other than CFC foaming agents have been used from the standpoint of environmental protection. As a result, there is a problem that the heat insulating property is deteriorated and the use is regulated due to poor incombustibility.

On the other hand, glass wool or rock wool is used as a non-combustible heat insulating material. However, flat plates of low density glass wool or rock wool prevent deformation of the panel surface due to external pressure such as bending and compression. There was a problem that the strength reinforcement function was not obtained as much as it could be obtained. In addition, high-density glass wool and rock wool flat plates had the drawback of increasing weight and cost.

For example, a glass wool flat plate has a diameter of 4
Fine fibers of ~ 12μ are accumulated and laminated in a wool shape, but the lamination direction of the fibers is often in the direction along the plane of the flat plate, and is laminated in the thickness direction of the flat plate, that is, the direction perpendicular to the plane. It is known that there are few fiber bundles. For this reason, the resistance against surface pressure and bending pressure from a flat surface is weak.

In order to improve such a defect, flat plates of fibers are cut into strips, and the strips are arranged so that the cut surfaces face the flat sides, and the long axes of the fibers are perpendicular to the flat plates. Or a method of arranging a unit heat insulator in which a heat insulating material such as glass wool is wound around a core rod having a compressive strength as a core material of a panel so that the core rod is perpendicular to a flat plate (JP-A-57-253). No.) is proposed.

However, although the above-mentioned method can improve the bending strength and the compressive strength, it has a drawback that there are many problems in industrial productivity, cost and the like.

On the other hand, the honeycomb structure is applied to a large number of panel core materials by utilizing its excellent function as a lightweight reinforcing member. However, when only the honeycomb body is used as a panel core material, heat insulation and sound absorption are performed. The property is not sufficient because it is expressed only in the air layer of the honeycomb core.

In order to remedy this drawback, a method of combining a honeycomb structure and a heat insulating material such as glass wool in a plurality of layers to use as a core material for a panel is disclosed in Japanese Patent Publication No. Sho 63-3541.
4, Japanese Unexamined Patent Publication No. 63-239496, Japanese Utility Model Publication No. 6
3-151610, Japanese Utility Model Publication No. 59-120212, Japanese Utility Model Publication No. 62-30621, and a method of press-fitting a heat insulating material such as rock wool into the cells of the honeycomb structure is disclosed in JP-B-53-53. -4729 Publication and Japanese Patent Publication No. 5
The method proposed by JP-A-5-19174 and further filling glass wool or urethane foam in the cell is
It is disclosed in Japanese Patent Laid-Open No. 2-57791.

According to the method described above, a panel having heat insulation and sound absorption, light weight and high rigidity can be provided, but the manufacturing process becomes complicated, and there is a problem in terms of productivity and cost. ing.

Further, Japanese Unexamined Patent Publication No. 4-152115 discloses a method of molding a continuous corrugated molded product made of glass wool, rock wool or ceramic wool, in which corrugated plates are assembled to form a hollow portion. Honeycomb body,
It is described that a so-called corrugated honeycomb body or a corrugated plate is used as a core material (intermediate bone body) of an interior material.

[0012] However, according to the above-mentioned publication, in order to form the inorganic fiber into the corrugated shaped body, preforming according to the die forming is required, which causes a problem in productivity and cost. . Further, the continuous corrugated board has anisotropy in reinforcing effect when used as a panel core material, and in order to prevent this anisotropy, at least two corrugated boards are used so as to be orthogonal to each other. It has the drawback that it must be done.

[0013]

SUMMARY OF THE INVENTION The present invention has been made to solve the problems of the prior art as described above, and its purpose is to provide excellent incombustibility, sound absorption, heat insulation and high strength. It is an object of the present invention to provide a sound absorbing and heat insulating substrate having good industrial productivity, a heat insulating panel using the same, and a manufacturing method thereof.

[0014]

In order to achieve the above object, the sound-insulating and heat-insulating substrate of the present invention is a sound-insulating and heat-insulating substrate in which a reinforcing material and a foamed resin are integrated. When viewed from the surface, a large number of independent convex portions are aligned and distributed over the entire surface, and the periphery of these convex portions forms a concave portion, and when viewed from the other surface, the portion corresponding to the convex portion is a concave portion. None, the portion corresponding to the concave portion forms a convex portion, and the top portions of the convex portions on both sides have the same height, and at least one surface of the reinforcing material has a foamed resin in the concave portion. It is characterized by being filled and molded into a smooth surface and having an overall density of 10 to 200 kg / m ³ .

Further, the heat insulating panel of the present invention is characterized in that surface plate materials are adhered to both surfaces of the sound absorbing and heat insulating substrate.

On the other hand, in the method of manufacturing the sound-insulating and heat-insulating substrate of the present invention, when viewed from one side, a large number of independent convex portions are arranged and distributed over the entire surface, and concave portions are formed around these convex portions. When viewed from the other surface, the portion corresponding to the convex portion forms a concave portion, and the portion corresponding to the concave portion forms a convex portion, and the tops of the convex portions on both sides have the same height. After a plate material having releasability is brought into contact with at least one surface of the reinforcing material, the precursor of the foamed resin is placed in the gap between the plate material and the reinforcing material, and then the precursor of the foamed resin is foamed and cured. The plate material is peeled off.

Further, in the method for manufacturing the heat insulating panel of the present invention, when viewed from one surface, a large number of independent convex portions are aligned and distributed over the entire surface, and the concave portions are formed around these convex portions. When viewed from the surface of, the portion corresponding to the convex portion forms a concave portion, and the portion corresponding to the concave portion forms a convex portion, and the top portions of the convex portions on both sides have the same height. The surface plate is brought into contact with both sides of the reinforcing material, the precursor of the foamed resin is placed in the gap between the surface plate and the reinforcing material, and then the precursor of the foamed resin is foamed and cured to bond the surface plate together. It is characterized by

Hereinafter, the present invention will be described in more detail with reference to preferred embodiments.

As the reinforcing material used in the present invention, as long as it has the above-mentioned concavo-convex shape, inorganic fiber molded plate, cellulose fiber molded plate such as paper, metal molded plate, ceramic molded plate, plastic molded plate, FRP. A molded plate or the like can be used without any trouble. However, in terms of low thermal conductivity, adhesiveness with foamed resin, etc., it is preferable to use a porous molded plate made of organic or inorganic fibers, and in particular a non-flammable porous molded plate made of inorganic fibers is preferable. preferable. As the inorganic fiber, any material such as glass fiber, silica fiber, carbon fiber, rock wool, and ceramics fiber can be used without any problem, but in view of cost, productivity, etc., it is preferable to use glass fiber. preferable.

The reinforcing material composed of the above-mentioned inorganic fibers can be manufactured, for example, by the following method.

First, the fiber length of the inorganic fibers constituting the reinforcing material is preferably 20 mm or more. When the fiber length is less than 20 mm, the entanglement between the fibers is released by the tensile action during the concave or convex molding, and the molded product has a low density portion. The upper limit of the fiber length is not particularly limited, but when the fiber length is more than 500 mm when it is composed of linear fibers, the molding becomes insufficient at the time of concave or convex molding, or the fiber may be stretched by the tensile action at the time of molding. It may be torn off, and some parts of the molded product may have low density.
The range of 20 to 500 mm is more preferable. Further, when continuous fibers are used, it is preferable to use a fiber assembly that is annularly accumulated so as not to be linear.

These inorganic fibers are added in an amount of 50 to ⁵ per m ² .
000 g, preferably 200 to 2,000 g is accumulated and a binder is contained to form a mat. Known binders such as thermoplastic resins, thermosetting resins and inorganic adhesives can be used as the binder. For example, in addition to organic binders such as phenol resins, urea resins, melamine resins, polyolefin resins, polyester resins, epoxy resins, styrene resins and their copolymers, inorganic binders such as water glass and mixtures thereof can be used without any problems. Although used, a phenolic resin is particularly preferably used in terms of cost, heat resistance and nonflammability. 2 to 70 of binder to total weight
% By weight, preferably 5 to 30% by weight, particularly preferably 8 to
A mat containing 20% by weight is preferably used in terms of nonflammability, heat resistance and mechanical strength.

In the present invention, a glass wool mat obtained by a centrifugal method, a chopped strand mat having a fiber length of 20 mm or more, a continuous strand mat accumulated in an annular shape, etc. are particularly preferably used. For these glass fiber mats, we used 100 mm wide samples,
A tensile elongation of 50% or more, preferably 70% or more, when a tensile test is performed at a grip interval of 100 mm and a speed of 10 mm / min.
A mat having a large entanglement of fibers is preferably used.

Next, the above-mentioned inorganic fiber mat is, for example,
A first mold having a large number of independent convex portions of the same height, which are aligned and distributed over the entire surface, and concave portions of the same depth surrounding the convex portions, and so as to enter the concave portions of the first mold. By sandwiching it between a second mold having a projection of the same height formed and a recess of the same depth formed so as to receive the projection of the first mold, and by heating and compressing Mold. In this case, when a thermosetting resin is used as the binder, the mat can be molded simply by heating and compression. Further, when a thermoplastic resin is used as the binder, it is preferable to heat the mat once and then cool it in a compressed state. The heating and compression in the present invention is not limited to the case where the heating and the compression are performed at the same time as described above.
It is meant to include cases such as compression and further cooling.

In this case, the reinforcing material has a plate density of 0.08 to 0.8 g / c.
m ³ , so that the thickness of the inorganic fiber part is 0.1 to 10 mm,
It is preferable to heat-compress and shape. The density of the molded product is 0.
If it is less than 08g / cm ³ , the strength of the reinforcing material will be insufficient, and 0.8g
If it is larger than / cm ^3, not only the sound absorption and heat insulating properties are deteriorated, but also the adhesiveness with the foamed resin is deteriorated. The density of the reinforcing material is more preferably 0.1 to 0.6 g / cm ³ . Further, if the plate thickness of the inorganic fiber portion of the reinforcing material is thinner than 0.1 mm, sufficient strength cannot be obtained, and if it is thicker than 10 mm, the weight of the reinforcing material becomes too heavy. The plate thickness is 1
More preferably, it is set to -5 mm.

In the reinforcing material thus obtained, when viewed from one surface, a large number of independent convex portions are arranged and distributed over the entire surface,
Around these convex portions form a concave portion, and when viewed from the other surface, a portion corresponding to the convex portion forms a concave portion, and a portion corresponding to the concave portion forms a convex portion. The tops of the parts have the same height. Here, the independent convex portion means a convex portion surrounded by concave portions. The shape of the independent convex portion is not particularly limited, and various shapes such as a circle, a square, a triangle, a + character, and a Y shape can be adopted. Also, it is sufficient if a large number of independent convex portions are formed when viewed from at least one surface,
The convex portions may be continuous when viewed from the other surface.
However, in this case, it is preferable that the foamed resin described below is applied to at least the surface on which a large number of independent convex portions are formed. Further, in the present invention, it is most preferable that the convex portions and the concave portions are alternately formed and that there are a large number of independent convex portions when viewed from any surface.

The reinforcing material of the present invention has 100 to 10,000 convex portions or concave portions per m ² , and the total thickness from the convex portion on one surface to the convex portion on the other surface is an inorganic fiber material. Thickness of 2
It is preferable that the distance is more than double and the distance is 5 to 300 mm, and 10 to
More preferably, it is 150 mm. If the number of protrusions or recesses is 100 or less per 1 m ² , the effect as a reinforcing material is small. If the number of protrusions or recesses exceeds 10,000 per 1 ² , the height of irregularities cannot be ensured. It is more preferable that the number of projections or recesses is 200 to 2,500 per 1 m ² . Further, if the thickness of the entire reinforcing material is 5 mm or less, the reinforcing effect and heat insulation and sound absorbing properties are not sufficiently exhibited, and if the thickness is 300 mm or more, the reinforcing effect is reduced.

In the present invention, a foamed resin is filled in the concave portion of at least one surface of the reinforcing material and integrated to form a foamed molded plate having at least one smooth surface. In this case, if there are no particular restrictions on weight, cost, etc., it is preferable to fill the concave portions on both sides of the reinforcing material with the foamed resin from the viewpoint of the strength of the product, the heat insulating performance, and the like.

Further, two or more of the above reinforcing materials are arranged so that their convex portions are aligned with each other, and the voids between the concave portions of the reinforcing material and the concave portions of at least one surface facing the outside are filled with foamed resin,
It is also possible to obtain a foam molded plate having a large thickness.

In the present invention, a plate material having releasability is brought into contact with at least one side of the reinforcing material, a foamed resin precursor is placed in a gap between the plate material and the reinforcing material, and then the foamed resin precursor is heated. Or after foaming and curing by self-heating,
If the plate material is peeled off, a foamed resin is filled in at least one of the concave portions, and a sound absorbing and heat insulating substrate having a smooth surface is obtained.

On the other hand, a surface plate material is brought into contact with both surfaces of the reinforcing material, a precursor of a foamed resin is placed in a gap between the surface plate material and the reinforcing material, and then the precursor of the foamed resin is foam-cured to reinforce. A heat insulating panel can be obtained by filling the recessed portion of the material with the foamed resin and adhering the surface plate material integrally. In this case, as the surface plate material, it is preferable to use a metal plate such as a color steel plate, a steel plate or an aluminum plate.
Also, the thickness of the plate material is preferably 0.1 to 2 mm, 0.3 to 1 mm
Is more preferable.

Examples of the foamed resin include thermoplastic foamed resins such as polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride and polystyrene, polyurethane, polyisocyanurate, phenol resin, urea resin, urethane / phenol resin, epoxy resin and silicone. Thermosetting foamed resin such as can be used without any trouble. Further, a flame retardant such as aluminum hydroxide, antimony oxide, a halogenated flame retardant, or a phosphoric acid flame retardant may be used in combination with the foam resin to improve the flame retardancy of the foam.

In the foamed resin, the precursor before foaming is liquid,
From the viewpoint of workability, the shape of paste, powder, beads or the like is preferable. The foaming ratio of the foamed resin is 5
It is preferably from 200 to 200 times, more preferably from 10 to 100 times. A foamed resin having a foaming ratio of less than 5 times is not preferable because the heat transfer through the resin skeleton becomes large and the heat insulating property deteriorates. On the other hand, if the expansion ratio is more than 200 times, the air permeability is increased, the heat insulating property is deteriorated, and the strength is significantly decreased, which is not preferable.

The weight ratio of the reinforcing material to the foamed resin is
0.1 to 0.9: 0.9 to 0.1 is preferable and 0.
2 to 0.8: More preferably 0.8 to 0.2. When the proportion of the reinforcing material is smaller than the above range, the reinforcing effect by the reinforcing material is not expected, while when the proportion of the foamed resin is smaller than the above range, the heat insulating effect by the foamed resin is not sufficiently exhibited.

In order to arrange the foamed resin precursor in the gap between the plate and the reinforcing material, the precursor is preliminarily adhered to the reinforcing material or the plate material by a method such as spraying or coating, and then the reinforcing material and the plate material. It is sufficient to bring them into contact. In addition, when the precursor is liquid, the precursor may be pressed into the gap between the reinforcing material and the plate after the reinforcing material and the plate are brought into contact with each other.

The density of the foamed resin after foam hardening is 5
It is preferably in the range of ^{~100kg / m 3, 10~50kg / m} 3 and more preferably. Furthermore, the density of the entire molded plate that combines the reinforcing material and the foamed resin is in the range of 10 to 200 kg / m ³ , and especially 20
It is preferably about 100 kg / m ³ .

The sound-absorbing and heat-insulating substrate of the present invention thus obtained has the reinforcing material and the foamed resin integrated, and has excellent sound-absorbing property, heat insulating property and strength. This sound-absorbing and heat-insulating substrate can be used as an interior material by adhering it to a design surface material by an existing method, for example.

On the other hand, in the heat insulating panel of the present invention, the sound absorbing and heat insulating substrate is used as the core material, and the plate material is integrally bonded to both surfaces thereof, and thus has excellent heat insulating properties. This heat-insulating panel can be used as a partitioning material for a building, a refrigerated warehouse, a wall material, a floor material, a ceiling material, or the like.

[0039]

In the reinforcing material used in the present invention, when viewed from at least one surface, a large number of independent convex portions are aligned and distributed over the entire surface. This convex portion has a concave portion on the opposite surface side, and has a so-called cap-like protruding shape. When a force for crushing the convex portion having such a shape acts, the force acts as a tensile force or a pressing force on the peripheral wall of the convex portion. Therefore, it cannot be crushed unless the peripheral wall of the convex portion is destroyed, and an extremely high resistance force against such a force is exhibited.

The sound-insulating and heat-insulating substrate of the present invention is obtained by filling the concave portion of the high-strength reinforcing material with foamed resin, and has a very high compressive strength and bending strength while being lightweight. Further, since the surface filled with the foamed resin is a smooth surface, for example, in the case of making a panel, the adhesive area with the surface material is wide and the adhesiveness is good. Further, since the reinforcing material has the uneven shape, it is possible to fill a sufficient amount of foamed resin as the sound absorbing and heat insulating substrate. Furthermore, even foamed resins having a problem in strength, such as foamed phenolic resins and incombustible foamed resins, can be used without any problems.

In a preferred embodiment of the present invention, the fiber length is 20 mm or more, the density is 0.08 to 0.8 g / cm ³ , and the plate thickness is 0.1 to.
When a reinforcing material made of 10 mm inorganic fiber is used, the adhesiveness between the foamed resin and the reinforcing material is good, and therefore the strength is further improved. Further, since the reinforcing material itself has a heat insulating property and the heat transfer through the reinforcing material is small, the heat insulating property is further improved. Furthermore, when a reinforcing material made of an inorganic fiber and a non-combustible foamed resin are combined, a highly non-combustible substrate can be obtained.

On the other hand, according to the method of manufacturing a heat insulating panel of the present invention, a plate material is brought into contact with the reinforcing material, a precursor of the foamed resin is placed in a gap between the reinforcing material and the plate material, and foamed and cured. Since the molding of the core material having excellent strength and heat insulation and the bonding of the core material and the surface material can be performed at the same time, the productivity is greatly improved. In addition, the quality of the panel is improved with less uneven filling of the foamed resin and poor adhesion between the surface material and the core material.

In the above manufacturing method, if a plate material having releasability is used, a substrate excellent in strength, heat insulation and sound absorption can be manufactured with high productivity.

[0044]

2 and 3 show an embodiment of the reinforcing material used in the present invention. 2 is a perspective view of the reinforcing material, and FIG. 3 is a sectional view taken along the line AA of FIG.

This reinforcing material 10 is formed of a porous plate-like body 1 formed by compression molding a glass fiber mat, and when viewed from one side, a large number of independent convex portions 2 are arranged in an array. Around these convex portions 2, a concave portion 3 is formed. However, when viewed from the opposite surface, the portion corresponding to the convex portion 2 forms a concave portion, and the portion corresponding to the concave portion 3 forms an independent convex portion. In the case of this embodiment, the top surface of the convex portion 2 and the bottom wall of the concave portion 3 have a square shape.

In order to be integrated with the foamed resin and to obtain the desired bending strength and compressive strength as the sound absorbing and heat insulating substrate, the fiber length of the glass fiber constituting the porous plate-shaped body 1 is
The density is 20 mm or more and the density is 0.08 to 0.8 g / cm ³ . Also, FIG.
The plate thickness d in the above is 0.1 to 10 mm. Further, the total thickness H of the reinforcing member 10 from the convex portion on one surface to the convex portion on the other surface is not less than twice the plate thickness d and is in the range of 5 to 300 mm. Further, the pitch W of the unevenness is 10 to 100 mm, more preferably 20 to 60 mm. Then, when viewed from one surface, the number of the convex portions 2 is set to 100 to 10,000 per 1 m ² .

FIG. 4 shows an example of a method of molding the reinforcing material 10. That is, a mat 4 containing a binder formed by accumulating glass fibers having a fiber length of 20 mm or more.
A first mold 5 having a large number of independent convex portions 6 of the same height which are aligned and distributed on the entire surface, and concave portions 7 surrounding the convex portions and having the same depth; and the first mold 5. Second convex portion 7 ′ having the same height formed so as to enter the concave portion 7 of the first mold 5 and concave portion 6 ′ having the same depth formed so as to receive the convex portion 6 of the first mold 5. sandwiched between the mold 5 ', the density of the molded article 0.08~0.8g / cm ^3, the thickness of the inorganic fiber sections 0.1 to
Heat and compress to form 10 mm.

In FIG. 1, the reinforcing material 10 and the foamed resin 1 are shown.
1 and the surface plate materials 12 and 12 'are integrally molded, the heat insulation panel is shown. That is, on both surfaces of the reinforcing material 10, surface plate materials 12 and 1 made of a metal plate such as a color steel plate.
2'is bonded, and the foamed resin 11 is filled in the gap between the reinforcing material 10 and the surface plate materials 12, 12 '. In this case, the convex portions 2 of the reinforcing member 10 are in contact with the surface plate members 12 and 12 ', but since the convex portions 2 have the same height, all the convex portions 2 can be brought into contact with each other. The opposite side of the convex portion 2 forms a concave portion 3, and the inside of the concave portion 3 is filled with the foamed resin 11.

Therefore, when a pressing force as shown by an arrow F in FIG. 1 is applied to this panel, the force acts as a tensile force or a pressing force on the peripheral wall 9 and the foamed resin 11, and destroys the peripheral wall 9 and the foamed resin 11. If it is not crushed, it cannot be crushed, and extremely high resistance can be obtained as compared with the case of using the reinforcing material alone or the foamed resin alone. In this way, this insulation panel is lightweight yet has sufficient strength,
Further, excellent heat insulating property and sound absorbing property are provided by the reinforcing material 10 having the porous fiber structure and the foamed resin 11 filled in the concave portion 3.

Example 1 Short glass fibers produced by a centrifugal method were sprayed with a binder consisting of an aqueous solution of a resol type phenolic resin and accumulated on a perforated belt to have a fiber diameter of 6 to 8 μm and a fiber length.
800 g / m ² per unit area with 10% by weight of uncured binder consisting of 50-80 mm short glass fibers
To obtain a glass wool mat. The tensile elongation of this glass wool mat was 110%.

The glass wool mat thus obtained was
The first mold 5 is installed in a mold having a shape as shown in FIG.
And the second mold 5'is sandwiched and heat-compressed so that the total thickness H in FIG. 3 is 40 mm (projected thickness 0.04
m), the pitch W of the unevenness is 50 mm, the plate thickness d is 2 mm, and the bulk density is
A glass wool reinforcing material having a sheet density of 20 kg / m ³ and a plate density of 0.18 g / cm ³ was produced. Here, the bulk density is a value obtained by dividing the weight of the molded product by the projected area (m ² ) and the projected thickness (m), and the same applies to the following Examples and Comparative Examples.

This reinforcing material is applied to a color steel plate 2 having a thickness of 0.5 mm.
The novolac-type expanded phenolic resin powder having an expansion ratio of 50 was sprinkled at 400 g / m ^{2 on} each side in the gap between the colored steel plate and the reinforcing material. This colored steel plate / powdered phenolic resin / reinforcement material / powdered phenolic resin / colored steel plate assembly is pressed at a temperature of 160 ° C to
The resin is foamed and hardened by pinching and heating to a thickness of mm to obtain a bulk density.
40kg / m ³ , thickness 40mm, weight ratio of reinforcing material and foamed resin 0.
A panel using a 5: 0.5 molded plate as a core material was obtained.

A part of the panel thus obtained was cut into a 50 mm square and the cut cross section was observed. As a result, all the recesses of the reinforcing material were filled with the foamed phenol resin, and the reinforcing material and the color steel plate were integrally bonded. Was there.

Comparative Example 1 A glass wool mat having a weight per unit area of 1600 g / m ² was molded in the same manner as in Example 1, and the total thickness H was 40 mm (projected thickness 0.04 m) and the pitch W of the unevenness was 50 mm. , Plate thickness d is 2m
A glass wool reinforcing material having m, a bulk density of 40 kg / m ³ , and a plate density of 0.36 g / cm ³ was produced.

Epoxy adhesive was applied to the convex portions on both sides of this reinforcing material, and it was sandwiched between two colored steel plates to give a bulk density of 40 kg / m.
^3. A panel having a thickness of 40 mm and using only the above reinforcing material as a core material was produced.

Comparative Example 2 Novolak-type expanded phenolic resin powder having an expansion ratio of 25 times
Disperse 1600 g / m ² between two colored steel plates, press and heat at a pressure of 160 ° C to a thickness of 41 mm to foam and harden the resin, and use only the foamed resin with a bulk density of 40 kg / m ^{3 and a} thickness of 40 mm. A panel as a core material was produced.

Comparative Example 3 A glass wool mat having a weight per unit area of 1600 g / m ² was molded to a thickness of 40 mm to prepare a board having a density of 40 kg / m ³ . An epoxy adhesive was applied to both sides of this board and sandwiched between two colored steel plates to prepare a panel using only a glass wool board having a density of 40 kg / m ³ and a thickness of 40 mm as a core material.

Comparative Example 4 The glass wool mat used in Example 1 was placed in a corrugated metal mold having irregularities formed in only one direction and compressed under pressure to give an overall thickness of 40 mm (projected thickness 0.04 m), the pitch of unevenness was 50 mm, the plate thickness d was 2 mm, and the bulk density was 20 kg / m ^{3, and} a continuous wave type reinforcing material made of glass wool was produced. Using this reinforcing material, a panel of colored steel plate / foamed resin / corrugated reinforcing material / foamed resin / colored steel plate was produced in the same manner as in Example 1. A part of the panel thus obtained was cut into a 50 mm square, and the cut cross section was observed. As a result, some parts of the recess of the reinforcing material were not filled with the phenolic resin foam, and some were not bonded to the color steel plate.

Test Example For the panels of Example 1 and Comparative Examples 1 to 3, the compressive strength, bending fracture strength and thermal conductivity at a thickness deformation rate of 10% were measured. The results are shown in Table 1.

In the above, the compressive strength at a thickness deformation rate of 10% was obtained by cutting out a panel into a square of 305 mm × 305 mm, sandwiching both sides with an iron plate having a thickness that does not bend in the load range of this experiment, and cross head. It was subjected to a compression test at a speed of 10 mm / min, and the compression strength at a thickness deformation rate of 10% was calculated.
Converted to kg / m ² .

The bending fracture strength was in accordance with JIS A-1408, and the panel was cut into 300 × 250 mm No. 4 test pieces, and the width was 250 mm.
The bending strength was calculated at a span of 250 mm and converted to kg / cm ² .

The thermal conductivity of the panel is 300 mm x 300 m.
It was cut into a square of m, measured according to the flat plate direct method of JIS A-1412, and converted into Kcal / m ² · hr · ° C.

[0063]

[Table 1]

Example 2 The total thickness H produced in Comparative Example 1 was 40 mm (projected thickness was 0.1 mm).
04m), the pitch W of the unevenness is 50 mm, the plate thickness d is 2 mm, the bulk density is 40 kg / m ³ , and the plate density is 0.36 g / cm ³ . An aqueous solution of resol type phenolic resin mixed with 10% by weight of aluminum hydroxide and having a foaming ratio of 100 times was applied to the gap between the color steel plate and the reinforcing material in an amount of 200 g / m ^{2 on} each side as a solid content. Then, the resin is foamed and hardened by pressing it to a thickness of 41 mm with a press at 160 ° C to obtain a bulk density of 50 kg / m ³ and a thickness.
A panel having a molded plate of 40 mm and a weight ratio of the reinforcing material and the foamed resin of 0.8: 0.2 was obtained as a core material. The bending strength of the obtained panel material was 12.0 kg / cm ² , and the thermal conductivity was 0.65 Kcal / m ² · hr · ° C.

Example 3 A long glass fiber having a fiber diameter of 11 μm was deposited in a loop shape to obtain a mat in which the weight per unit area was 400 g / m ² . After dipping this mat in the resol type phenolic resin aqueous solution used in Example 1, the excess liquid was removed,
A mat having 10% of uncured resin attached was obtained. Using this mat, a reinforcing material having the same shape as in Example 1 and having a plate thickness d of 2 mm and a plate density of 0.1 g / cm ³ (bulk density 11 kg / m ³ ) was produced.

The reinforcing material was surrounded by a frame material having a height of 41 mm, sandwiched between two colored steel plates, and then foamed by mixing 20% by weight of aluminum hydroxide in the gap between the reinforcing material and the colored steel plate. 80x urethane foam stock solution with a magnification of 25
Press-fit by 0 g / m ² each, foam-cure, bulk density 51 kg / m ³ ,
A panel having a molded plate having a thickness of 40 mm and a weight ratio of the reinforcing material and the foamed resin of 0.22: 0.78 as a core material was obtained. The bending strength of the obtained panel material was 12.0 kg / cm ² , and the thermal conductivity was 0.50 kcal / m ² · hr · ° C.

[0067]

As described above, since the sound absorbing and heat insulating substrate of the present invention is molded into a smooth surface by filling the concave portion of the reinforcing material having a specific uneven shape with the foamed resin, it has excellent strength. It has heat insulation and sound absorption. Then, when the panel is formed, the strength of the panel becomes higher because it can be bonded to the surface plate material on a smooth surface. Furthermore, according to the manufacturing method of the present invention, since the heat insulating substrate can be molded and the surface plate material can be bonded at the same time, the panel can be manufactured with high productivity and at low cost.

[Brief description of drawings]

FIG. 1 is a partial sectional view showing an embodiment of a heat insulating panel of the present invention.

FIG. 2 is a perspective view showing an example of a reinforcing material used for the sound absorbing and heat insulating substrate and the heat insulating panel.

3 is a cross-sectional view taken along the line AA in FIG.

FIG. 4 is an explanatory view showing a method for forming the reinforcing material of FIGS.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Porous plate-like body 2 Convex part 3 Recessed part 4 Glass wool mat 5 1st type 5'Second type 6, 7'type convex part 7, 6'type concave part 8, 8'type sloped part 9 Peripheral wall portion of the convex portion 10 Reinforcement material 11 Foamed resin 12, 12 'Surface plate material

Claims (6)

[Claims] 1. A sound-absorbing and heat-insulating substrate in which a reinforcing material and a foamed resin are integrated with each other, wherein the reinforcing material has a large number of independent convex portions aligned and distributed when viewed from one side,
Around these protrusions forms a recess, and when viewed from the other surface, the portion corresponding to the protrusion forms a recess, and the portion corresponding to the recess forms a protrusion. The tops of the parts have the same height, and at least one surface of the reinforcing material is filled with foamed resin in the recesses to form a smooth surface having an overall density of 10 to 200 kg / m
Sound absorbing and heat insulating substrate characterized in that it is ³ . 2. The reinforcing material is made of an inorganic fiber having a fiber length of 20 mm or more, a density of 0.08 to 0.8 g / cm ³ , and a plate thickness of 0.1 to 10 mm, and the convex portion or the concave portion is 100 to 10,000 per 1 m ^2. The total thickness from the convex portion of one surface to the convex portion of the other surface is twice or more the plate thickness and is 5 to 300 mm.
The sound absorbing and heat insulating substrate according to claim 1, wherein 3. The weight ratio of the reinforcing material to the foamed resin is 0.1.
~ 0.9: 0.9 ~ 0.1, the density of the foamed resin is 5 ~ 100k
The sound absorbing and heat insulating substrate according to claim 1 or 2, which has g / m ³ . 4. A heat insulating panel comprising a sound absorbing and heat insulating substrate according to any one of claims 1 to 3 and a surface plate material adhered to both surfaces thereof. 5. When viewed from one surface, a large number of independent projections are arranged and distributed over the entire surface, and the circumferences of these projections form recesses, and when viewed from the other surface, the projections are formed. The portion corresponding to the above is a concave portion, and the portion corresponding to the concave portion is a convex portion, and the tops of the convex portions on both sides have a releasability on at least one surface of the reinforcing material having a shape with the same height. A sound-insulating thermal insulation characterized by abutting a plate material having the same, arranging a foamed resin precursor in a gap between the plate material and the reinforcing material, and then foam-curing the foamed resin precursor, and then peeling the plate material. For manufacturing flexible substrates. 6. When viewed from one surface, a large number of independent projections are aligned and distributed over the entire surface, and the circumferences of these projections form recesses, and when viewed from the other surface, the projections are formed. The portion corresponding to the above is a concave portion, and the portion corresponding to the concave portion is a convex portion, and the top surface of the convex portion on both sides is in contact with the surface plate material on both sides of the reinforcing material having the shape of the same height. A heat-insulating panel characterized in that a precursor of a foamed resin is arranged in a gap between the surface plate and the reinforcing material, and then the precursor of the foamed resin is foamed and cured to bond and integrate the surface plate. Manufacturing method.