JPH0794160B2 - Dash silencer manufacturing method using coating agent - Google Patents

Description

TECHNICAL FIELD The present invention relates to a soundproof material using a coating material as a sound insulating material and a method for producing the same.

[Conventional technology]

BACKGROUND ART Conventionally, a sheet-shaped sound insulation material used for sound insulation has been known. This sound-insulating sheet is mixed with rubber, synthetic resin, filler, and various additives as necessary, and mixed.
Kneaded, molded into a sheet by a known processing machine,
It is appropriately cut and molded into a required shape by die-cutting, three-dimensional molding or the like, and is widely used in industrial fields such as transportation machinery, industrial plants, and construction for the purpose of sound insulation.

[Problems to be Solved by the Invention]

By the way, although the sheet-shaped sound insulation material has a certain degree of sound insulation performance by itself, for example, when the sound insulation of the dash panel that separates the engine room and passenger compartment of the automobile is to be performed, the sound insulation of the sheet sound insulation material alone is not effective. It is hard to say that it is sufficient, but in addition to sheet-like sound insulation material, bulky felt, synthetic fiber, woven fiber such as natural fiber impregnated with phenolic resin, glass fiber, or various synthetic foam materials that have sound absorbing performance. Is molded and laminated, processed into an arbitrary shape, and provided as a soundproof material. In this case, the sheet-shaped sound insulation material is usually initially supplied in the form of a roll, or a square sheet of an appropriate size, and if this is molded according to the shape of the automobile dash panel of the above example,
There will always be unnecessary trim residue. In addition, since the sheet-shaped sound insulation material has a certain degree of rigidity, a sufficient shape cannot be obtained by one-time heat-processing and molding when trying to mold it to a shape with large irregularities. It is necessary to process the sheet-shaped sound insulation material alone by means such as heat molding or vacuum forming before laminating with the above. When stacking with a bulky felt without such pre-processing, preheat by a heat panel or the like to make the shape processability good just before placing the sheet-shaped sound insulation material on the molding die. There is a need. Also, if you want to apply soundproofing measures by partially sticking a sheet-shaped sound insulation material to the bulky felt, or if you want to place it after molding both separately, a step of bonding with an appropriate adhesive is required. is there.

Although the soundproof material for the dash panel is given as an example, it is not limited to automobiles, and when it is laminated with a sound absorbing material and processed into a required shape to make a soundproof material, the current sheet-shaped sound insulating material has the above-mentioned problems. The current situation is to have

[Means for Solving the Problems]

In view of the present situation, as a result of earnest research, the present inventors have succeeded in developing a soundproofing material using a coating agent and a manufacturing method thereof.

Therefore, the gist of the present invention is: 1. A vinyl chloride resin, a filler,
A characteristic is that a vinyl chloride plastisol consisting of a plasticizer, various additives, etc. is applied, and an unmolded or molded bulky felt is placed and laminated on it, and the molding die is closed for heat and pressure molding. A method for manufacturing a dash silencer using a coating agent.

2.Apply vinyl chloride plastisol consisting of vinyl chloride resin, filler, plasticizer, various additives, etc. to the molding die,
A method for producing a dash silencer using a coating agent, which comprises closing a molding die, injecting a reaction liquid for polyurethane foam, and heating.

Exist in.

Vinyl chloride plastisols are polyvinyl chloride resins, vinyl chloride resin polymers such as polyvinylidene chloride resins, copolymers with vinyl acetate, etc., dispersed with various plasticizers as binders, and as fillers, colorants, It is a mixture of solvents and additives.

As a plasticizer, phthalate-based DOP, DEP, DB
P, DMP, DINP, phosphoric ester type TEP, TCP, other aliphatic-basic acid esters, aliphatic dibasic acid esters, dihydric alcohol esters, oxyacid esters and the like can be used.

As the filler, in addition to conventionally known powdery fillers, various zinc powders, zinc dusts, lead powders, iron powders, copper powders, bronze powders, aluminum powders, and the like are used in order to particularly exhibit the performance as a sound insulating material. It is preferable to include metal powder. When a conventionally known powdery filler is used, it is preferable to select a pigment having a relatively high specific gravity such as barium sulfate.

As the colorant, a color pigment such as carbon black or titanium dioxide can be used. The solvent may be mixed in an amount of about several wt% mainly in order to improve the coating workability. As the additive, various dispersants, antifoaming agents, stabilizers, thixotropy imparting agents and the like can be used. If necessary, a catalyst can be used.

The method for manufacturing the soundproof material according to the present invention will be described below.

The vinyl chloride plastisol composition is applied to a molding die heated to about 130 ° C. to 200 ° C. by 1 to 10 kg / m ² by a conventionally known coating method such as airless spraying or brush coating. 1 kg
If it is less than / m ² , the desired sound insulation effect cannot be obtained and 10 kg / m ²
If it exceeds, the sound insulation effect does not improve in proportion to the coating amount, which is disadvantageous in terms of weight increase and cost increase. At this time,
The entire surface of the mold may be painted, or it is possible to paint only where it is needed.

Furthermore, pre-formed bulky felt or unformed bulky felt is stacked and placed on the coated surface of vinyl chloride plastisol, and the upper mold is lowered, and heated and pressed for an appropriate time and at an appropriate time. Mold. The pressing force and time are determined by the presence or absence of pre-processing for imparting the bulky felt shape, the thickness of the bulky felt, the degree of compression, the productivity, etc., but the applied vinyl chloride plastisol does not form a dry film. This is a mandatory condition.

When polyurethane foam is used for the sound absorbing layer, vinyl chloride plastisol is applied to the molding foam type. In the case of manufacturing by the injection molding method, the reaction liquid for polyurethane foam is injected after closing the mold. The reaction liquid is divided into two liquids of isocyanate and polyol, and the polyol further contains a foam stabilizer, a foaming agent, a catalyst, a colorant and the like. After the injection, heating necessary for forming the foam material is performed. In this case as well, in addition to the forming, it is an essential condition that the vinyl chloride plastisol forms a dry film.

[Action]

The vinyl chloride plastisol coated on the mold is adhesively laminated on a sound absorbing layer such as bulky felt or polyurethane foam material to form a sound insulating layer, and exhibits excellent sound insulating performance as a whole.

〔Example〕

Examples will be given below to provide a more detailed understanding of the present invention.
Naturally, the invention is not limited to the following examples.

Example 1 ZEON 121 (manufactured by Zeon Corporation) 50 parts by weight, plasticizer DOP (manufactured by Daicel Chemical Co., Ltd.) 35 parts by weight, precipitating barium sulfate (manufactured by Sakai Chemical Industry Co., Ltd.) 30 parts by weight, lead powder (Kikuchi Pigment Co., Ltd.) 5 parts by weight were mixed and dispersed in an open kneader to obtain vinyl chloride plastisol. An average of 2 kg / m ^{2 of the} plastisol was applied to the entire lower surface of the automobile dash silencer molding die heated to 140 ° C. with an airless spray coating machine, and the coated surface contained a phenol resin having a thickness of 30 mm. The bulky felt was placed on top of the other, the upper mold was lowered, and heat press molding was performed for 90 seconds at a pressure of 3 kg / m ² . An automobile dash silencer 1 was obtained in which a sound insulation layer made of vinyl chloride plastisol was laminated on one side of the felt sound absorption layer.

Example 2 A vinyl chloride plastisol having the same composition as in Example 1 was applied to the entire lower surface of the mold for injection molding of polyurethane worm on average 2 kg / m ² and the mold was closed. After that, 30 parts by weight of TDI / MDI mixed isocyanate (manufactured by Sanyo Chemical Industry Co., Ltd.), 100 parts by weight of polyether polyol (manufactured by Sanyo Chemical Co., Ltd.), 0.5 part by weight of foam stabilizer (silicon oil), foaming agent ( 0.5 parts by weight of water, 0.5 parts by weight of the reaction catalyst, and 2 parts by weight of the colorant were injected, and heating was performed at 120 ° C. for 15 minutes. An automobile dash silencer 2 was obtained in which a sound absorbing layer made of polyurethane worm material was laminated on one side with a sound insulating layer made of vinyl chloride plastisol.

Comparative Example 1 Styrene-butadiene rubber, recycled rubber, synthetic resin, and filler are mixed and dispersed and processed into a sheet shape, which has a conventionally known thickness of 3 m.
A m-type rubber sound-insulating sheet was formed by using a vacuum forming machine for an automobile dash part, and this was placed on the lower die of the forming die in the same manner as in Example 1, and a bulky felt containing a phenol resin having a thickness of 30 mm. Was placed in a layered manner, the upper mold was lowered, and hot press molding was performed for 90 seconds with a pressing force of 3 kg / cm ² . An automobile dash silencer 3 having a rubber sound insulating layer laminated on one side of the felt sound absorbing layer was obtained.

Comparative Example 2 Styrene-butadiene rubber, recycled rubber, synthetic resin, and filler are mixed and dispersed, and processed into a sheet shape, a conventionally known thickness of 3 m.
A rubber sound-insulating sheet of m was molded by a vacuum molding machine for automobile dash parts, and this was placed on the lower mold of the urethane molding mold as in Example 2, and the mold was closed and TDI / MDI was injected from the injection port. Mixed isocyanate (manufactured by Sanyo Chemical Industries) 30
Parts by weight, 100 parts by weight of polyether polyol (manufactured by Sanyo Kasei Co., Ltd.), 0.5 parts by weight of foam stabilizer (silicon oil),
0.5 parts by weight of foaming agent (water), 0.5 parts by weight of reaction catalyst, colorant 2
A polyol component consisting of parts by weight was injected, and heating at 120 ° C. for 15 minutes was applied. An automobile dash silencer 4 was obtained in which a sound insulation layer made of a rubber type sound insulation sheet was laminated on one side of a sound absorption layer made of a polyurethane foam material.

Test method Each silencer was attached to the dash of a small passenger car, engine sound was measured by a microphone attached to the occupant's ear position in the passenger compartment, and the sound insulation performance was evaluated in comparison with the state without a silencer.

result [Effects of the Invention] The soundproofing material using the coating agent according to the present invention has a soundproofing performance equal to or higher than that of a soundproofing material using a conventionally known soundproof sheet, and a method for producing the soundproofing material according to the present invention. According to the above, sound insulation sheet trim residue does not occur, which is useful for resource saving, and it is possible to omit the sound insulation sheet molding step or the preheating step for molding the sound insulation sheet when manufacturing the soundproofing material. Since it is coated with a coating agent, it can be automated by a coating robot, and by partially applying it, it can be used as a soundproofing material that has many excellent advantages such as intensive and rational soundproofing measures. A manufacturing method is provided.

[Brief description of drawings]

FIG. 1 is a sectional view of a part of the soundproof material manufactured according to claim 2. 1 is a sound insulation layer made of vinyl chloride plastisol, and 2 is a sound absorption layer made of bulky felt. FIG. 2 is a partial cross-sectional view of the soundproof material manufactured according to claim 3. 1 is a sound insulation layer made of vinyl chloride plastisol and 2'is a sound absorption layer made of polyurethane foam material.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B62D 25/20 7615-3D G10K 11/16 // B29K 27:06 B29L 9:00 (56) Reference Reference JP-A-57-181864 (JP, A) S.A. 58-122751 (JP, U)

Claims (2)

[Claims] 1. A heated molding die is coated with vinyl chloride plastisol comprising a vinyl chloride resin, a filler, a plasticizer, various additives and the like, which is unmolded or molded into a bulky felt. A method for manufacturing a dash silencer using a coating agent, which comprises stacking and stacking, and closing a molding die to perform heat and pressure molding. 2. A molding die, a vinyl chloride resin, a filler,
A method for producing a dash silencer using a coating agent, which comprises coating a vinyl chloride plastisol comprising a plasticizer, various additives, etc., closing a molding die, injecting a reaction liquid for polyurethane foam, and heating.