JP7219019B2

JP7219019B2 - soundproof material

Info

Publication number: JP7219019B2
Application number: JP2018104291A
Authority: JP
Inventors: 弘和榊原
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 2018-05-31
Filing date: 2018-05-31
Publication date: 2023-02-07
Anticipated expiration: 2038-05-31
Also published as: JP2023025218A; JP7691968B2; JP2019211493A

Description

本発明は、防音材とその製造方法に関する。 The present invention relates to a soundproofing material and its manufacturing method.

従来、防音材として、フェルトとポリウレタンフォームとの積層体からなるものがある（特許文献１）。 Conventionally, as a soundproofing material, there is one made of a laminate of felt and polyurethane foam (Patent Document 1).

フェルトとポリウレタンフォームとの積層体からなる従来の防音材は、音がフェルトとポリウレタンフォームの両方によって遮音され、良好な防音効果が得られる。 A conventional soundproofing material composed of a laminate of felt and polyurethane foam provides good soundproofing because sound is insulated by both the felt and the polyurethane foam.

しかし、図７に示すように、フェルト１０１とポリウレタンフォーム１０３との積層体からなる従来の防音材１００は、フェルト１０１とポリウレタンフォーム１０３がそれぞれ防音材１００の端部外周１００Ａまで存在するため、例えばフェルト１０１側から入射した音の一部が、ポリウレタンフォーム１０３側に進入することなく、フェルト１０１内を通って防音材の端部１００Ａに至る場合、ポリウレタンフォーム１０３による遮音作用が得られず、充分な防音効果が得られなくなる。 However, as shown in FIG. 7, in the conventional soundproofing material 100 composed of a laminate of felt 101 and polyurethane foam 103, the felt 101 and the polyurethane foam 103 are each present up to the end outer periphery 100A of the soundproofing material 100. Therefore, for example, If part of the sound incident from the felt 101 side passes through the felt 101 and reaches the end portion 100A of the soundproof material without entering the polyurethane foam 103 side, the sound insulation effect of the polyurethane foam 103 cannot be obtained sufficiently. A good soundproofing effect cannot be obtained.

特開２００９－２２６６７５号公報JP 2009-226675 A

本発明は前記の点に鑑みなされたものであって、防音効果がより高い防音材とその製造方法の提供を目的とする。 SUMMARY OF THE INVENTION It is an object of the present invention to provide a soundproofing material having a higher soundproofing effect and a method for producing the same.

第１の態様は、繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材において、前記発泡樹脂層は、前記繊維層の片面と端部外周の少なくとも一部を覆って設けられていることを特徴とする。 A first aspect is a soundproofing material comprising a laminate of a fiber layer and a foamed resin layer foamed on one side of the fiber layer, wherein the foamed resin layer is formed on one side of the fiber layer and at least one of the ends of the outer periphery. It is characterized in that it is provided so as to cover the part.

第２の態様は、第１の態様において、前記繊維層には貫通孔が設けられ、前記発泡樹脂層は、前記繊維層の貫通孔の部分で該貫通孔の内周面を被覆しており、該内周面が被覆された貫通孔の両端が開口していることを特徴とする。 According to a second aspect, in the first aspect , the fiber layer is provided with through holes, and the foamed resin layer covers the inner peripheral surface of the through holes at the through holes of the fiber layer. , wherein both ends of the through-hole covered with the inner peripheral surface are open.

第３の態様は、第１または第２の態様において、前記発泡樹脂層は、ポリウレタンフォームからなることを特徴とする。 According to a third aspect, in the first or second aspect , the foamed resin layer is made of polyurethane foam.

第４の態様は、上型または下型の何れか一方の型の型面に取り付けた繊維層と他方の型の型面との間の発泡成形空間で、発泡樹脂原料を発泡させることにより、前記繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材を製造する方法において、前記繊維層を取り付けた一方の型の型面の端部外周は、少なくとも一部が前記繊維層の端部外周よりも大であり、前記繊維層と前記他方の型の型面との間の発泡成形空間は、前記繊維層の端部外周まで存在し、前記発泡樹脂原料の発泡により、前記発泡樹脂層を前記繊維層の片面と端部外周の少なくとも一部を覆って形成することを特徴とする。 In a fourth aspect , a foamed resin raw material is foamed in a foaming space between a fiber layer attached to the mold surface of either the upper mold or the lower mold and the mold surface of the other mold, In the method of manufacturing a soundproof material comprising a laminate of the fiber layer and a foamed resin layer foamed on one side of the fiber layer, the outer circumference of the end of the mold surface of one mold to which the fiber layer is attached is at least A portion of the foamed resin is larger than the outer circumference of the end of the fiber layer, and the foam molding space between the fiber layer and the mold surface of the other mold exists up to the outer circumference of the end of the fiber layer. It is characterized in that the foamed resin layer is formed by foaming the raw material so as to cover one side of the fiber layer and at least part of the periphery of the end portion.

第５の態様は、第４の態様において、前記繊維層は該繊維層の両面を貫通する貫通孔を有し、前記繊維層を取り付けた前記一方の型の型面には、前記繊維層の取り付け時に前記貫通孔に挿入される凸部を有し、前記貫通孔に挿入された前記凸部の側面と前記貫通孔の内周面との間に前記発泡成形空間に通じる隙間を形成し、前記凸部の先端を前記他方の型面と当接した状態にして前記発泡樹脂原料を発泡させることにより、前記繊維層の片面と端部外周の少なくとも一部を覆い、前記繊維層の貫通孔の部分では該貫通孔の内周面を被覆し、該内周面を覆った貫通孔の両端で開口した発泡樹脂層を形成することを特徴とする。 According to a fifth aspect, in the fourth aspect , the fiber layer has through holes penetrating through both sides of the fiber layer, and the mold surface of the one mold to which the fiber layer is attached has the fiber layer having a convex portion inserted into the through-hole at the time of attachment, forming a gap communicating with the foam molding space between a side surface of the convex portion inserted into the through-hole and an inner peripheral surface of the through-hole; By foaming the foamed resin raw material with the tip of the convex portion in contact with the other mold surface, one side of the fiber layer and at least a part of the periphery of the end portion are covered, and the through hole of the fiber layer is formed. A foamed resin layer covering the inner peripheral surface of the through-hole is formed in the portion (2), and openings are formed at both ends of the through-hole covering the inner peripheral surface.

本発明の防音材は、発泡樹脂層が繊維層の片面と端部外周を覆って設けられているため、防音材に入射する音が発泡樹脂層と繊維層を通過する毎にそれぞれの層で遮音され、良好な防音効果が得られる。また、繊維層側から入射した音の一部が繊維層内を通って防音材の端部に至る場合でも、防音材の端部外周の少なくとも一部を覆う発泡樹脂層を通過することにより、繊維層と発泡樹脂層の両方で遮音され、良好な防音効果が得られる。 In the soundproofing material of the present invention, the foamed resin layer covers one side of the fiber layer and the outer periphery of the end portion, so that the sound entering the soundproofing material passes through the foamed resin layer and the fiber layer. Sound is insulated and a good soundproofing effect is obtained. Further, even when part of the sound incident from the fiber layer side passes through the fiber layer and reaches the end of the soundproof material, the sound can Sound is insulated by both the fiber layer and the foamed resin layer, and a good sound insulation effect is obtained.

また、本発明の防音材は、繊維層の片面を覆う発泡樹脂層が、繊維層の貫通孔の部分で該貫通孔の内周面を被覆しており、該内周面が被覆された貫通孔の両端が開口している構成とされた場合、繊維層側から入射した音の一部が繊維層内を通って繊維層の貫通孔の内周面に至る場合であっても、貫通孔の内周面を被覆する発泡樹脂層を最終的に通過することになり、繊維層と発泡樹脂層の両方で遮音され、良好な防音効果が得られ、特に貫通孔の多い製品に対して有効である。 Further, in the soundproof material of the present invention, the foamed resin layer covering one side of the fiber layer covers the inner peripheral surface of the through hole at the portion of the through hole of the fiber layer, and the through hole covered with the inner peripheral surface When both ends of the hole are open, even if part of the sound incident from the fiber layer side passes through the fiber layer and reaches the inner peripheral surface of the through hole of the fiber layer, the through hole The sound is insulated by both the fiber layer and the foamed resin layer, resulting in a good soundproofing effect, which is especially effective for products with many through-holes. is.

本発明の防音材の製造方法は、良好な防音効果を有する防音材を容易に製造することができる。 The method for producing a soundproofing material of the present invention can easily produce a soundproofing material having a good soundproofing effect.

第１実施形態の防音材の平面図と１Ａ－１Ａ断面図である。1A and 1A are a plan view and a cross-sectional view of the soundproof material of the first embodiment. FIG. 第１実施形態の防音材について、その製造方法を示す断面図である。It is sectional drawing which shows the manufacturing method about the soundproofing material of 1st Embodiment. 第２実施形態の防音材の平面図と３Ａ－３Ａ断面図である。3A and 3A are a plan view and a cross-sectional view of the soundproof material of the second embodiment. FIG. 第２実施形態の繊維層の平面図と４Ａ－４Ａ断面図である。4A and 4A are a plan view and a cross-sectional view of the fiber layer of the second embodiment; FIG. 第２実施形態の防音材について、その製造方法を示す断面図である。It is sectional drawing which shows the manufacturing method about the soundproof material of 2nd Embodiment. 試料１－４の防音性の測定結果を示す表である。4 is a table showing measurement results of sound insulation properties of Samples 1-4. 従来の防音材を示す断面図である。FIG. 3 is a cross-sectional view showing a conventional soundproof material;

以下、本発明の実施形態について説明する。図１に示す第１実施形態の防音材１０は、繊維層１１と該繊維層１１の片面１２に発泡形成された発泡樹脂層１５との積層体からなる。発泡樹脂層１５は、繊維層１１の片面１２と端部外周１３を覆って設けられ、繊維層１１の他面１４は、露出した状態となっている。繊維層１１の端部外周１３は、繊維層１１の端部の側面に相当する。なお、発泡樹脂層１５は、繊維層１１の端部外周１３の全部ではなくても、少なくとも一部を覆っていればよい。勿論、発泡樹脂層１５が繊維層１１の端部外周１３の全部を覆うことは、遮音性の点からより好ましい。防音材１０の形状は、図示のような四角形の板状に限られず、多角形、楕円形、不規則形状の板状等でもよく、防音材１０が使用される製品や場所等に応じた形状とされる。また、防音材１０は、繊維層１１と発泡樹脂層１５の何れの側を音源側にしても使用することができる。 Embodiments of the present invention will be described below. A soundproof material 10 of the first embodiment shown in FIG. The foamed resin layer 15 is provided so as to cover one side 12 and the outer periphery 13 of the fiber layer 11, and the other side 14 of the fiber layer 11 is exposed. The end outer circumference 13 of the fiber layer 11 corresponds to the side surface of the end of the fiber layer 11 . In addition, the foamed resin layer 15 may cover at least a part of the outer circumference 13 of the end portion of the fiber layer 11, if not all of it. Of course, it is more preferable that the foamed resin layer 15 covers the entire outer periphery 13 of the fiber layer 11 in terms of sound insulation. The shape of the soundproofing material 10 is not limited to a rectangular plate shape as shown in the drawing, but may be a polygonal, elliptical, or irregular plate shape. It is said that Also, the soundproof material 10 can be used with either the fiber layer 11 or the foamed resin layer 15 facing toward the sound source.

繊維層１１は、不織布、フェルトなどの繊維集合体が挙げられ、特にフェルトが軽量性、防音性（吸音性）の点から好ましい。フェルトを構成する繊維の材質は限定されない。フェルトには、熱硬化性樹脂をバインダーとして繊維同士を結合させたレジンフェルト、バインダーを使用し、あるいは使用しないでプレスにより繊維相互を結合させたプレスフェルト、ニードルパンチ加工によって繊維相互を絡ませたニードルフェルト等があり、何れのフェルトも使用することができる。特にプレスフェルトは、プレスによって繊維が密になっているため、吸音性（遮音性）が高く、好ましいものである。繊維層１１の目付は１００～３０００ｇ／ｍ^２、厚みは２～４５ｍｍ程度が好ましい。繊維層１１の目付は、小さくなりすぎると遮音性（吸音性）が小になり、逆に目付が大になると防音材１０が重くなる。また、繊維層１１の厚みは、薄くなりすぎると遮音性（吸音性）が小さくなり、逆に厚くなると防音材１０が嵩張り、重くなる。 The fiber layer 11 may be a fiber assembly such as non-woven fabric or felt, and felt is particularly preferable from the viewpoint of lightness and soundproofing (sound absorbing). The material of the fibers that make up the felt is not limited. Felt includes resin felt that binds fibers together using a thermosetting resin as a binder, press felt that binds fibers together by pressing with or without a binder, and needles that intertwine fibers by needle punching. There are felt and the like, and any felt can be used. In particular, press felt is preferable because it has high sound absorption (sound insulation) because the fibers are made dense by pressing. The fiber layer 11 preferably has a basis weight of 100 to 3000 g/m ² and a thickness of about 2 to 45 mm. If the basis weight of the fiber layer 11 is too small, the sound insulation (sound absorption) is reduced, and conversely, if the basis weight is large, the soundproof material 10 becomes heavy. Also, if the thickness of the fiber layer 11 is too thin, the sound insulation (sound absorption) is reduced.

発泡樹脂層１５は、繊維層１１の片面１２に発泡樹脂原料から発泡形成されたものであり、発泡形成時に発泡樹脂原料の一部が繊維層１１の片面１２に含浸して硬化し、それにより繊維層１１と発泡樹脂層１５の接着が行われる。また、発泡樹脂層１５が接着した繊維層１１の片面１２には、前記発泡樹脂原料が含浸して硬化した含浸硬化層が形成され、その含浸硬化層によっても防音性（遮音性）が向上する。 The foamed resin layer 15 is formed by foaming a foamed resin material on one side 12 of the fiber layer 11. During foaming, part of the foamed resin material impregnates the one side 12 of the fiber layer 11 and hardens. The fiber layer 11 and the foamed resin layer 15 are bonded together. In addition, on one side 12 of the fiber layer 11 to which the foamed resin layer 15 is adhered, an impregnated hardened layer impregnated with the foamed resin raw material and hardened is formed, and the impregnated hardened layer also improves soundproofing (sound insulation). .

発泡樹脂層１５を構成する樹脂としては、ポリウレタンフォーム、ポリエチレンフォーム、ポリプロピレンフォーム等が挙げられる。特にポリウレタンフォームは、軽量で吸音性（遮音性）に優れるために好ましい発泡樹脂である。発泡樹脂層１５の密度（ＪＩＳＫ７２２２）は３０～１５０ｋｇ／ｍ^３、厚みは２～５０ｍｍが好ましい。発泡樹脂層１５の密度が小さ過ぎると遮音性が小さくなり、逆に密度が大になると重くなる。また発泡樹脂層１５が薄くなりすぎると遮音性が小さくなり、逆に厚くなると防音材１０が嵩張り、重くなる。 Examples of the resin forming the foamed resin layer 15 include polyurethane foam, polyethylene foam, polypropylene foam, and the like. In particular, polyurethane foam is a preferred foamed resin because it is lightweight and has excellent sound absorption (sound insulation) properties. The foamed resin layer 15 preferably has a density (JIS K7222) of 30 to 150 kg/m ³ and a thickness of 2 to 50 mm. If the density of the foamed resin layer 15 is too low, the sound insulation will be poor. Also, if the foamed resin layer 15 is too thin, the sound insulation will be reduced, and if it is too thick, the soundproof material 10 will be bulky and heavy.

防音材１０は、繊維層１１の片面に発泡樹脂層１５が設けられているため、防音材１０に入射した音が繊維層１１と発泡樹脂層１５の両方で吸音（遮音）され、良好な防音効果が得られる。また、繊維層１１の片面１２に設けられた発泡樹脂層１５が繊維層１１の端部外周１３を覆っているため、防音材１０の端部外周から漏れる音についても低減することができ、防音性がさらに良好になる。 Since the foamed resin layer 15 is provided on one side of the fiber layer 11 in the soundproofing material 10, the sound incident on the soundproofing material 10 is absorbed (sound-insulated) by both the fiber layer 11 and the foamed resin layer 15, resulting in good soundproofing. effect is obtained. In addition, since the foamed resin layer 15 provided on one side 12 of the fiber layer 11 covers the end outer periphery 13 of the fiber layer 11, the sound leaking from the end outer periphery of the soundproof material 10 can also be reduced. properties become even better.

前記防音材１０の製造方法について、図２を用いて説明する。防音材１０の製造は、金型２１を用いるモールド成形によって行われる。金型２１は、上型２２と下型３２とよりなり、上型２２または下型３２の何れか一方に繊維層１１が取り付けられる。図示の例では、図２の（２－１）のように、上型２２の型面２３に繊維層１１を取り付け、また、下型３２には発泡樹脂原料Ｐを注入し、図２の（２－２）のように上型２２を下型３２に被せて閉型し、繊維層１１と下型３２の型面３３間の発泡成形空間３５で発泡樹脂原料Ｐを発泡させる。符号Ｎは注入ノズルである。 A method of manufacturing the soundproof material 10 will be described with reference to FIG. The soundproof material 10 is manufactured by molding using a mold 21 . The mold 21 consists of an upper mold 22 and a lower mold 32 , and the fiber layer 11 is attached to either the upper mold 22 or the lower mold 32 . In the illustrated example, as shown in FIG. 2 (2-1), the fiber layer 11 is attached to the mold surface 23 of the upper mold 22, and the foamed resin raw material P is injected into the lower mold 32, and ( As in 2-2), the upper mold 22 is placed over the lower mold 32 and closed, and the foamed resin raw material P is foamed in the foam molding space 35 between the fiber layer 11 and the mold surface 33 of the lower mold 32 . Reference N is an injection nozzle.

繊維層１１が取り付けられる上型２２の型面２３には、図２の（２－１）のように、繊維層１１を取り外し可能に保持するための係止部２５が、繊維層１１の取り付け位置に設けられている。図示の係止部２５はピンで構成され、上型２２の型面２３の複数箇所に立設されている。 On the mold surface 23 of the upper mold 22 to which the fiber layer 11 is attached, as shown in (2-1) of FIG. placed in position. The locking portions 25 shown in the figure are composed of pins, and are erected at a plurality of locations on the mold surface 23 of the upper mold 22 .

また、上型２２の型面２３は、端部外周２４が繊維層１１の端部外周１３よりも大になっており、図２の（２－２）のように、型面２３に繊維層１１を取り付けた際に、繊維層１１の端部外周１３から型面２３の端部外周２４が所定量突出するように構成されている。なお、前記防音材１０の発泡樹脂層１５が、繊維層１１の端部外周１３の全部ではなく、少なくとも一部を覆う場合は、上型２２の型面２３の端部外周２４の少なくとも一部を繊維層１１の端部外周１３よりも大にして、型面２３に繊維層１１を取り付けた際に、繊維層１１の端部外周１３から型面２３の端部外周２４の少なくとも一部を所定量突出させる。 In addition, the mold surface 23 of the upper mold 22 has an end outer circumference 24 larger than the end outer circumference 13 of the fiber layer 11, and as shown in (2-2) of FIG. It is configured such that an end outer circumference 24 of the mold surface 23 protrudes by a predetermined amount from an end outer circumference 13 of the fiber layer 11 when the mold surface 11 is attached. In addition, when the foamed resin layer 15 of the soundproof material 10 covers at least a part of the end outer circumference 13 of the fiber layer 11 instead of the entire end outer circumference 13, at least a part of the end outer circumference 24 of the mold surface 23 of the upper mold 22 is covered. is larger than the end outer circumference 13 of the fiber layer 11, and when the fiber layer 11 is attached to the mold surface 23, at least part of the end outer circumference 24 of the mold surface 23 from the end outer circumference 13 of the fiber layer 11 Protrude by a specified amount.

下型３２は、型面３３が防音材１０の外形に応じて窪んだ凹形状となっており、上型２２を下型３２に被せて閉型した際に、上型２２の型面２３の繊維層１１の片面１２と下型３２の型面３３間に発泡成形空間３５が形成される。また、上型２２を下型３２に被せて閉型した際に、下型３２の型面３３の上部は、上型２２の型面２３の端部外周２４と当接して繊維層１１の端部外周１３から離れて位置し、前記発泡成形空間３３が繊維層１１の端部外周１３まで連続して形成される。 The lower mold 32 has a mold surface 33 that is recessed according to the outer shape of the soundproof material 10. When the upper mold 22 is placed over the lower mold 32 and closed, the mold surface 23 of the upper mold 22 is A foam molding space 35 is formed between one side 12 of the fiber layer 11 and the mold surface 33 of the lower mold 32 . Further, when the upper mold 22 is placed over the lower mold 32 to close the mold, the upper part of the mold surface 33 of the lower mold 32 abuts against the edge portion outer periphery 24 of the mold surface 23 of the upper mold 22 and the end of the fiber layer 11 . The foam molding space 33 is formed continuously up to the end outer periphery 13 of the fiber layer 11 .

発泡樹脂原料Ｐは、発泡によって、発泡成形空間３５に充満し、図２の（２－３）のように繊維層１１の片面１２と、該繊維層１１の端部外周１３を覆う発泡樹脂層１５を形成する。また、発泡樹脂原料Ｐの発泡時、発泡樹脂原料Ｐの一部が繊維層１１の片面１２と繊維層１１の端部外周（側面）１３とに含浸して硬化し、繊維層１１と発泡樹脂層１５を接着する。なお、発泡樹脂原料Ｐは、発泡樹脂がポリウレタンフォームの場合はポリウレタンフォーム原料である。
その後、上型２２を下型３２から離して金型２１を開き、図１に示した繊維層１１と発泡樹脂層１５とからなる防音材１０を取り出す。 The foamed resin raw material P fills the foamed molding space 35 by foaming, and the foamed resin layer covers the one side 12 of the fiber layer 11 and the outer periphery 13 of the end portion of the fiber layer 11 as shown in FIG. 2 (2-3). 15 is formed. Further, when the foamed resin raw material P is foamed, part of the foamed resin raw material P impregnates one side 12 of the fiber layer 11 and the end outer periphery (side surface) 13 of the fiber layer 11 and hardens, and the fiber layer 11 and the foamed resin are hardened. Layer 15 is glued. The foamed resin raw material P is a polyurethane foam raw material when the foamed resin is a polyurethane foam.
After that, the upper mold 22 is separated from the lower mold 32 to open the mold 21, and the soundproof material 10 composed of the fiber layer 11 and the foamed resin layer 15 shown in FIG. 1 is taken out.

図３に第２実施形態の防音材５０を示す。防音材５０は、所定位置に貫通孔５１、５２、５３を有する例である。貫通孔５１、５２、５３は、例えば車両におけるシャフトやケーブル等を通すのに使用される。防音材５０は、繊維層６１と、該繊維層６１の片面６２に発泡形成された発泡樹脂層７５との積層体からなり、前記発泡樹脂層７５が、前記繊維層６１の片面６２と端部外周６３を覆って設けられ、前記繊維層６１の他面６４は露出した状態となっている。繊維層６１の端部外周６３は、繊維層６１の端部の側面に相当する。図４に繊維層６１の平面図と、その４Ａ－４Ａ断面図を示す。なお、防音材５０の形状は、図示の形状に限られず、防音材５０が使用される場所に応じた形状とされる。 FIG. 3 shows the soundproof material 50 of the second embodiment. The soundproof material 50 is an example having through holes 51, 52, 53 at predetermined positions. The through holes 51, 52, 53 are used, for example, to pass shafts, cables, etc. in a vehicle. The soundproof material 50 is composed of a laminate of a fiber layer 61 and a foamed resin layer 75 foamed on one side 62 of the fiber layer 61. The foamed resin layer 75 is formed on one side 62 of the fiber layer 61 and an end portion. It is provided to cover the outer circumference 63, and the other surface 64 of the fiber layer 61 is exposed. An end outer circumference 63 of the fiber layer 61 corresponds to the side surface of the end of the fiber layer 61 . FIG. 4 shows a plan view of the fiber layer 61 and its 4A-4A sectional view. In addition, the shape of the soundproof material 50 is not limited to the illustrated shape, and may be a shape according to the place where the soundproof material 50 is used.

繊維層６１は、図４に示すように、所定位置に貫通孔６５、６７、６９が設けられている。図４に示した繊維層６１の貫通孔６５、６７、６９の部分で、図３に示すように発泡樹脂層７５は、該貫通孔の内周面６６、６８、７０を被覆する部分７６、７７、７８が形成され、該貫通孔の内周面６６、６８、７０を被覆する部分７６、７７、７８の両端が開口して防音材５０の貫通孔５１、５２、５３を構成している。 As shown in FIG. 4, the fiber layer 61 is provided with through holes 65, 67, 69 at predetermined positions. At the through holes 65, 67, 69 of the fiber layer 61 shown in FIG. 77, 78 are formed, and both ends of the portions 76, 77, 78 that cover the inner peripheral surfaces 66, 68, 70 of the through holes are open to form the through holes 51, 52, 53 of the soundproof material 50. .

第２実施形態の繊維層６１と発泡樹脂層７５は、第１実施形態の繊維層１１と発泡樹脂層１５と同様の材質、密度、厚み等からなり、繊維層６１はファブリックが好ましく、また発泡樹脂層７５はポリウレタンフォームが好ましい。 The fiber layer 61 and the foamed resin layer 75 of the second embodiment are made of the same material, density, thickness, etc. as the fiber layer 11 and the foamed resin layer 15 of the first embodiment. The resin layer 75 is preferably made of polyurethane foam.

図３に示した第２実施形態の防音材５０は、繊維層６１の片面６２に設けられた発泡樹脂層７５が、図４に示した繊維層６１の端部外周６３と貫通孔６５、６７、６９の内周面６６、６８、７０を覆っているため、防音材５０の端部外周及び貫通孔から漏れる音を低減することができ、防音性が良好になる。 In the soundproof material 50 according to the second embodiment shown in FIG. 3, the foamed resin layer 75 provided on one side 62 of the fiber layer 61 is formed so that the end outer periphery 63 and the through holes 65 and 67 of the fiber layer 61 shown in FIG. , 69, the sound leaking from the outer periphery of the end portion of the soundproof material 50 and the through-hole can be reduced, and soundproofing is improved.

前記防音材５０の製造方法について、図５を用いて説明する。防音材５０の製造は、金型８１を用いるモールド成形によって行われる。金型８１は、上型８２と下型９４とよりなり、上型８２と下型９４の何れか一方に繊維層６１が取り付けられる。図示の例では、図５の（５－１）のように、上型８２の型面８３に繊維層６１を取り付け、また、下型９４には発泡樹脂原料Ｐを注入し、図５の（５－２）のように上型８２を下型９４に被せて閉型し、繊維層６１と下型９４の型面９５間の発泡成形空間９７で発泡樹脂原料Ｐを発泡させる。 A method of manufacturing the soundproof material 50 will be described with reference to FIG. The soundproof material 50 is manufactured by molding using a mold 81 . The mold 81 consists of an upper mold 82 and a lower mold 94 , and the fiber layer 61 is attached to either the upper mold 82 or the lower mold 94 . In the illustrated example, as shown in (5-1) of FIG. 5, the fiber layer 61 is attached to the mold surface 83 of the upper mold 82, and the foamed resin raw material P is injected into the lower mold 94, and the ( As in 5-2), the upper mold 82 is placed over the lower mold 94 to close the mold, and the foamed resin raw material P is foamed in the foam molding space 97 between the fiber layer 61 and the mold surface 95 of the lower mold 94 .

繊維層６１が取り付けられる上型８２の型面８３は、型面８３の端部外周８４が繊維層６１の端部外周６３よりも大になっており、図５の（５－２）のように、型面８３に繊維層６１を取り付けた際に、繊維層６１の端部外周６３から型面の端部外周８４が所定量突出するように構成されている。なお、前記防音材５０の発泡樹脂層７５が、繊維層６１の端部外周６３の全部ではなく、少なくとも一部を覆う場合は、上型８２の型面８３の端部外周８４の少なくとも一部を繊維層６１の端部外周６３よりも大にして、型面８３に繊維層６１を取り付けた際に、繊維層６１の端部外周６３から型面８３の端部外周８４の少なくとも一部を所定量突出させる。 The mold surface 83 of the upper mold 82 to which the fiber layer 61 is attached has an end outer periphery 84 larger than the end outer periphery 63 of the fiber layer 61, as shown in FIG. 5 (5-2). In addition, when the fiber layer 61 is attached to the mold surface 83, the end outer circumference 84 of the mold surface protrudes from the end outer circumference 63 of the fiber layer 61 by a predetermined amount. When the foamed resin layer 75 of the soundproof material 50 covers at least part of the end outer circumference 63 of the fiber layer 61 instead of all of it, at least part of the end outer circumference 84 of the mold surface 83 of the upper mold 82 is covered. is larger than the end outer circumference 63 of the fiber layer 61, and when the fiber layer 61 is attached to the mold surface 83, at least part of the end outer circumference 84 of the mold surface 83 from the end outer circumference 63 of the fiber layer 61 Protrude by a specified amount.

図５の（５－１）のように、上型８２の型面８３には、繊維層６１を取り外し可能に保持するための係止部８５が、繊維層６１の取り付け位置に設けられている。図示の係止部８５はピンで構成され、上型８２の型面８３の複数箇所に立設されている。 As shown in (5-1) of FIG. 5, a locking portion 85 for detachably holding the fiber layer 61 is provided on the mold surface 83 of the upper mold 82 at the position where the fiber layer 61 is attached. . The locking portions 85 shown in the figure are composed of pins and erected at a plurality of locations on the mold surface 83 of the upper mold 82 .

また、上型８２の型面８３には、繊維層６１の取り付け時に繊維層６１の貫通孔６５、６７、６９に挿入される凸部８６、８８、９０が、繊維層６１の貫通孔６５、６７、６９の位置に合わせて形成されている。 In addition, on the mold surface 83 of the upper mold 82, protrusions 86, 88, and 90 which are inserted into the through holes 65, 67, and 69 of the fiber layer 61 when the fiber layer 61 is attached are formed in the through holes 65 and 69 of the fiber layer 61. It is formed according to the positions of 67 and 69 .

凸部８６、８８、９０は、外周が繊維層６１の貫通孔６５、６７、６９の内周よりも所定寸法小さくされ、繊維層６１の貫通孔６５、６７、６９に挿入された際に、凸部８６、８８、９０の側面８７、８９、９１と繊維層６１の貫通孔６５、６７、６９の内周面６６、６８、７０との間に、図５の（５－２）に示す隙間９２、９３、９４を形成するように構成されている。また凸部８６、８８、９０の高さは、上型８２を下型９４に被せて金型８１を閉じた際に、凸部８６、８８、９０の先端（下端）８６ａ、８８ａ、９０ａが下型９４の型面９５と当接する寸法とされている。 The projections 86, 88, 90 have outer peripheries smaller than the inner perimeters of the through holes 65, 67, 69 of the fiber layer 61 by a predetermined dimension, and when inserted into the through holes 65, 67, 69 of the fiber layer 61, Between the side surfaces 87, 89, 91 of the projections 86, 88, 90 and the inner peripheral surfaces 66, 68, 70 of the through holes 65, 67, 69 of the fiber layer 61, shown in (5-2) of FIG. It is configured to form gaps 92 , 93 , 94 . The heights of the protrusions 86, 88, and 90 are such that when the upper die 82 is placed over the lower die 94 and the die 81 is closed, the tips (lower ends) 86a, 88a, and 90a of the protrusions 86, 88, and 90 are It is sized to abut on the mold surface 95 of the lower mold 94 .

下型９４は、型面９５が防音材６０の外形に応じて窪んだ凹形状となっており、上型８２を下型９４に被せて閉型した際に、図５の（５－２）のように、上型８２の型面８３の繊維層６１の片面６２と下型９４の型面９５間に発泡成形空間９７が形成される。発泡成形空間９７は、前記上型８２の型面８３の凸部８６、８８、９０と繊維層６１の貫通孔６５、６７、６９の内周面６６、６８、７０との間の隙間９２、９３、９４と通じ、繊維層６１の端部外周６３まで連続して形成される。 The lower mold 94 has a mold surface 95 that is recessed in accordance with the outer shape of the soundproof material 60, and when the upper mold 82 is placed over the lower mold 94 and closed, (5-2) in FIG. , a foam molding space 97 is formed between one side 62 of the fiber layer 61 of the mold surface 83 of the upper mold 82 and the mold surface 95 of the lower mold 94 . The foam molding space 97 is a gap 92 between the protrusions 86, 88, 90 of the mold surface 83 of the upper mold 82 and the inner peripheral surfaces 66, 68, 70 of the through holes 65, 67, 69 of the fiber layer 61, It communicates with 93 and 94 and is formed continuously up to the end outer periphery 63 of the fiber layer 61 .

発泡樹脂原料Ｐは、発泡によって前記発泡成形空間９７に充満し、図５の（５－３）のように、繊維層６１の片面６２と繊維層６１の貫通孔内周面６６、６８、７０及び繊維層６１の端部外周６３を覆って発泡樹脂層７５を形成する。発泡樹脂層７５は、繊維層６１の貫通孔内周面６６、６８、７０を被覆する部分７６、７７、７８が形成され、貫通孔内周面６６、６８、７０を被覆する部分７６、７７、７８が貫通孔の両端で開口する。また、発泡樹脂原料Ｐの発泡時、発泡樹脂原料Ｐの一部が、繊維層６１の片面６２と、繊維層６１の貫通孔の内周面６６、６８、７０、及び繊維層６１の端部外周（側面）６３に含浸して硬化し、繊維層６１と発泡樹脂層７５を接着する。なお、発泡樹脂原料Ｐは、発泡樹脂がポリウレタンフォームの場合、ポリウレタンフォーム原料となる。
その後、上型８２を下型９４から離して、金型８１を開き、図３に示した繊維層６１と発泡樹脂層７５とからなる防音材６０を取り出す。 The foamed resin raw material P fills the foamed molding space 97 by foaming, and as shown in (5-3) of FIG. A foamed resin layer 75 is formed to cover the outer periphery 63 of the end portion of the fiber layer 61 . The foamed resin layer 75 has portions 76, 77, and 78 covering the through-hole inner peripheral surfaces 66, 68, and 70 of the fiber layer 61, and the portions 76, 77 covering the through-hole inner peripheral surfaces 66, 68, and 70. , 78 open at both ends of the through hole. Further, when the foamed resin material P is foamed, part of the foamed resin material P is transferred to the one surface 62 of the fiber layer 61, the inner peripheral surfaces 66, 68, and 70 of the through holes of the fiber layer 61, and the end portions of the fiber layer 61. The outer circumference (side surface) 63 is impregnated and cured to bond the fiber layer 61 and the foamed resin layer 75 together. In addition, the foaming resin raw material P turns into a polyurethane foam raw material, when foaming resin is a polyurethane foam.
After that, the upper mold 82 is separated from the lower mold 94, the mold 81 is opened, and the soundproof material 60 composed of the fiber layer 61 and the foamed resin layer 75 shown in FIG. 3 is taken out.

試料１、２、３、４の防音材を作製し、ＪＩＳＡ１４４１－１：２００７に基づいて透過損失（音響インテンシティ法による）を測定し、発泡樹脂層が繊維層の片面及び端部外周の両方を覆うことによる防音効果を評価した。各試料のサイズは、５００×５００×２０ｍｍである。音源残響室は３６ｍ^３、受音無響室は２０ｍ^３、測定面積は４００×４００ｍｍ（０．１６ｍ^２）である。試料の一側（試料１、２はフェルト側）に厚み０．８ｍｍの鉄板を重ね、試料の周囲を５０ｍｍ幅の枠で固定した状態で、鉄板側を音源とし、試料表面から１００ｍｍ離れた位置で中央分離散点４箇所（１００ｍｍピッチ）を測定した。 Soundproofing materials of samples 1, 2, 3, and 4 were produced, and the transmission loss (according to the sound intensity method) was measured based on JIS A1441-1:2007, and the foamed resin layer was on one side of the fiber layer and on the outer circumference of the end. The soundproof effect by covering both was evaluated. The size of each sample is 500 x 500 x 20 mm. The sound source reverberation chamber is 36 m ³ , the sound receiving anechoic chamber is 20 m ³ , and the measurement area is 400×400 mm (0.16 m ² ). A steel plate with a thickness of 0.8 mm was placed on one side of the sample (on the felt side for samples 1 and 2), and the periphery of the sample was fixed with a frame with a width of 50 mm. Measurement was performed at four centrally separated scattered points (100 mm pitch).

試料１は、図１の防音材１０と同様の構成からなり、厚み１０ｍｍのポリウレタンフォームで厚み１０ｍｍのフェルトの片面及び端部外周が覆われている。試料１は、フェルトとして、合成樹脂繊維からなる雑フェルト、目付５８０ｇ／ｍ^２、サイズ４８０×４８０×１０ｍｍのプレスフェルトを用い、図２に示したモールド成形に従い、上型の型面（５００×５００ｍｍ）にフェルトを取り付けた金型にポリウレタンフォーム原料を注入し、発泡させることにより作製した。ポリウレタンフォーム原料は、分子量５０００、官能基数３のポリエーテルポリオール１００重量部、アミン触媒１．５重量部、発泡剤としての水３．５重量部、ＭＤＩからなるイソシアネート６０重量部とからなる。試料１のポリウレタンフォームの密度は７０ｋｇ／ｍ^３、全体の目付量は１６４０ｇ／ｍ^２である。 The sample 1 has the same structure as the soundproof material 10 in FIG. 1, and is covered with a polyurethane foam having a thickness of 10 mm on one side and the periphery of the edge of a felt having a thickness of 10 mm. For sample 1, press felt made of synthetic resin fiber, basis weight of 580 g/m ² and size of 480 × 480 × 10 mm was used as the felt, and according to the molding shown in Fig. 2, the mold surface of the upper mold (500 × A polyurethane foam raw material was injected into a mold fitted with felt on a width of 500 mm and foamed. The raw materials for the polyurethane foam consist of 100 parts by weight of polyether polyol having a molecular weight of 5,000 and a functional group of 3, 1.5 parts by weight of an amine catalyst, 3.5 parts by weight of water as a foaming agent, and 60 parts by weight of isocyanate composed of MDI. The polyurethane foam of sample 1 has a density of 70 kg/m ³ and a total basis weight of 1640 g/m ² .

試料２は、図７に示した従来の防音材１００と同様の構成からなり、厚み１０ｍｍのポリウレタンフォームで厚み１０ｍｍのフェルトの片面のみ覆われている。試料２は、試料１のプレスフェルトと同じ材質のフェルトを５００ｍｍ×５００ｍｍ×１０ｍｍにしたものを用い、試料１の金型と同一構成の金型を用い、その上型の型面の全面にフェルトを取り付け、試料１のポリウレタンフォーム原料と同一配合のポリウレタンフォーム原料を注入し、発泡させることにより作製した。試料２のポリウレタンフォームの密度は７０ｋｇ／ｍ^３、全体の目付量は１６４０ｇ／ｍ^２である。 Sample 2 has the same structure as the conventional soundproof material 100 shown in FIG. 7, and only one side of 10 mm thick felt is covered with 10 mm thick polyurethane foam. For sample 2, a felt made of the same material as the press felt of sample 1 was used in a size of 500 mm x 500 mm x 10 mm, and a mold having the same configuration as that of sample 1 was used. was attached, and a polyurethane foam raw material having the same composition as that of the polyurethane foam raw material of Sample 1 was injected and foamed. The polyurethane foam of sample 2 has a density of 70 kg/m ³ and a total basis weight of 1640 g/m ² .

試料３は、フェルト単体（５００ｍｍ×５００ｍｍ×２０ｍｍ）からなり、試料１及び２のプレスフェルトと同じ材質のフェルトから作製した。試料３の全体の目付量は１１２０ｇ／ｍ^２である。 Sample 3 is composed of a single piece of felt (500 mm×500 mm×20 mm) and is made of the same material as the press felts of Samples 1 and 2. The total basis weight of sample 3 is 1120 g/m ² .

試料４は、ポリウレタンフォーム単体（５００×５００×２０ｍｍ）からなり、試料１及び２の金型と同一構成の金型を用い、試料１及び試料２のポリウレタンフォーム原料と同一配合のポリウレタンフォーム原料を金型に注入し、発泡させることにより作製した。試料４のポリウレタンフォームの密度は７０ｋｇ／ｍ^３、全体の目付量は１４００ｇ／ｍ^２である。 Sample 4 consists of a single polyurethane foam (500 x 500 x 20 mm). It was prepared by injecting into a mold and foaming. The polyurethane foam of sample 4 has a density of 70 kg/m ³ and a total basis weight of 1400 g/m ² .

透過損失の測定結果を図６に示す。
ポリウレタンフォームでフェルトの片面及び端部外周を覆った試料１は、フェルトの片面のみを覆った試料２と比べ、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても透過損失が大きく、防音性に優れていた。さらに、試料１と試料２の透過損失の差は、高周波側の４ｋＨｚ及と８ｋＨｚで一層大きくなっており、試料１の防音効果は高周波側でより高くなる。 FIG. 6 shows the measurement results of the transmission loss.
Sample 1, in which one side of the felt and the outer circumference of the edge are covered with polyurethane foam, has a larger transmission loss at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz than Sample 2, in which only one side of the felt is covered. was excellent. Furthermore, the difference in transmission loss between sample 1 and sample 2 is greater at 4 kHz and 8 kHz on the high frequency side, and the soundproofing effect of sample 1 is higher on the high frequency side.

フェルト単体からなる試料３は、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても試料１よりも透過損失が小さく、防音効果が劣っていた。 Sample 3 made of felt alone had a smaller transmission loss than Sample 1 at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and was inferior in soundproofing effect.

ポリウレタンフォーム単体からなる試料４は、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても試料１よりも透過損失が小さく、防音効果が劣っていた。 Sample 4 made of a single polyurethane foam had a smaller transmission loss than Sample 1 at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and was inferior in soundproofing effect.

これらのことから、本発明の防音材のように、繊維層の片面及び端部外周を発泡樹脂層で覆うことにより、高い防音性が得られることがわかる。
なお、本発明の防音材は、車両のフロアサイレンサやダッシュサイレンサなどの車両用防音材に限られず、例えば建物、産業機械、家電等の防音材として好適である。 From these results, it can be seen that high soundproofing properties can be obtained by covering one side of the fiber layer and the periphery of the ends with the foamed resin layer, as in the soundproofing material of the present invention.
The soundproofing material of the present invention is not limited to vehicle soundproofing materials such as vehicle floor silencers and dash silencers, but is suitable as soundproofing materials for buildings, industrial machinery, home appliances, and the like.

１０、５０防音材
１１、６１繊維層
１２、６２繊維層の片面
１３、６３繊維層の端部外周
１５、７５発泡樹脂層
２１、８１金型
２２、８２上型
３２、９４下型
２３、８３上型の型面
２４、８４上型の型面の端部外周
３３、９５下型の型面
３５、９７発泡成形空間
６５、６７、６９繊維層の貫通孔
６６、６８、７０繊維層の貫通孔の内周面
７６、７７、７８貫通孔の内周面を被覆する部分
８６、８８、９０上型の型面の凸部
８６ａ、８８ａ、９０ａ凸部の先端
８７、８９、９１凸部の側面
９２、９３、９４隙間
Ｐ発泡樹脂原料 REFERENCE SIGNS LIST 10, 50 Soundproof material 11, 61 Fiber layer 12, 62 One side of fiber layer 13, 63 Fiber layer end circumference 15, 75 Foamed resin layer 21, 81 Mold 22, 82 Upper mold 32, 94 Lower mold 23, 83 Mold surface of upper mold 24, 84 End outer periphery of mold surface of upper mold 33, 95 Mold surface of lower mold 35, 97 Foam molding space 65, 67, 69 Through hole of fiber layer 66, 68, 70 Penetration of fiber layer Inner peripheral surface of hole 76, 77, 78 Portion covering inner peripheral surface of through hole 86, 88, 90 Convex portion of mold surface of upper mold 86a, 88a, 90a Tip of convex portion 87, 89, 91 Side 92, 93, 94 Gap P Foaming resin raw material

Claims

A soundproofing material comprising a laminate of a fiber layer and a foamed resin layer foamed on one side of the fiber layer,
The foamed resin layer is provided to cover one side of the fiber layer and at least a part of the outer periphery of the end,
Through holes are provided in the fiber layer,
The foamed resin layer covers the inner peripheral surface of the through-hole at the portion of the through-hole of the fiber layer, and both ends of the through-hole covered with the inner peripheral surface are open. Sound deadening material.