CN115071839A - 隔音缓冲材以及隔音缓冲材的制造方法 - Google Patents

隔音缓冲材以及隔音缓冲材的制造方法 Download PDF

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CN115071839A
CN115071839A CN202111313672.4A CN202111313672A CN115071839A CN 115071839 A CN115071839 A CN 115071839A CN 202111313672 A CN202111313672 A CN 202111313672A CN 115071839 A CN115071839 A CN 115071839A
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直井义秋
大冈庆一
二塚元忠
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Sanko Gosei Ltd
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Abstract

本发明的课题是提供一种耐冲击性及隔音性优异，并且耐结冰性、防水性优异的隔音缓冲材。本发明的解决方案是隔音缓冲材1的与轮胎侧的表面相反侧的表面也露出隔音缓冲区域2的具有相互缠绕的大量短纤维的无纺布4的表面，连续树脂区域3a的表面与此并排设置/邻接而实质上连续且露出。隔音缓冲区域2以此方式所形成的结果为，并无覆盖隔音缓冲区域2的正反面的构件，且不会因覆盖物而降低隔音缓冲区域2的吸音能力。此外通过树脂区域3抑制吸水性且谋求耐结冰性、防水性的提高。

Description

隔音缓冲材以及隔音缓冲材的制造方法
技术领域
本发明涉及一种隔音缓冲材以及隔音缓冲材的制造方法，所述隔音缓冲材装设于车体的车轮罩(wheel housing)内表面，吸收因在车辆行走时弹跳起的碎石等的异物与车体碰撞而产生的冲击，抑制冲击音并且抑制轮胎附近的车体的破损。
背景技术
例如在专利文献1中公开以下技术：具备大量短纤维相互缠绕而成的无纺布的隔音缓冲材(挡泥板衬垫)。如此，以无纺布所形成的隔音缓冲材由于形成在互相缠绕的纤维间的无数空隙会吸收因异物的碰撞而产生的冲击，因此耐冲击性及隔音性(特别是吸音性)优异。
然而，上述般仅以由短纤维所组成的无纺布而形成的隔音缓冲材，由于形成在短纤维间的空隙露出于表面而导致表面积变得非常大，因此容易吸收水分。因而在冬季时期，当被吸收于无纺布内的水分冻结，且于此无纺布表面结冰的冰往与轮胎靠近的方向成长，则会有冰与轮胎干涉而对车辆的操作性带来不良影响的疑虑。
相对于此，于专利文献2所公开的隔音缓冲材是通过以耐水性薄膜覆盖于以无纺布所形成的隔音缓冲材表面，而谋求提高耐水性及耐异物附着性。然而，若如此方式以耐水性薄膜完全覆盖无纺布的表面，则空气会被耐水性薄膜隔绝，因此无法完全发挥无纺布所带来的吸音效果。
为了解决此种问题，于专利文献3中，将提供一种耐冲击性及防音性优异，并且耐结冰性、防水性优异的隔音缓冲材作为课题，并公开了一种装设于车体的车轮罩内表面的隔音缓冲材，其特征在于，具备：基层，其由大量短纤维相互缠绕而成的无纺布所组成；及树脂表层，其覆盖基层的表面，其中树脂表层具有与基层及外部空气连通的无数空孔，并且克重为50～400g/m2的范围内，进一步还含有熔融树脂成分60％以上。
现有技术文献
专利文献
专利文献1：日本特开2000－264255号公报
专利文献2：日本特开2002－348767号公报
专利文献3：日本特开2008－132972号公报
发明内容
发明所欲解决的课题
专利文献3所公开的隔音缓冲材中，由于设置了覆盖无纺布的表面的树脂表层，所以吸音性能不足。具体而言，树脂表层即使具有与基层及外部空气连通的无数空孔，但吸气与吸音不同，波长大于空孔直径的声音会被树脂表层反射而不会被由大量短纤维相互缠绕而成的无纺布所组成的基层衰减(吸音)，且实际上在专利文献3中没有记载关于吸音性能的评价试验结果。
本发明鉴于关于以上现有技术的问题，目的在于提供一种耐冲击性及隔音性优异，并且耐结冰性、防水性优异的隔音缓冲材及隔音缓冲材的制造方法。
解决课题的技术方案
亦即本发明的隔音缓冲材是装设于车体的车轮罩内表面的隔音缓冲材，其特征在于，具备：隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；及连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面。
并且，本发明的隔音缓冲材是装设于车体的车轮罩内表面的隔音缓冲材，其特征在于，具备：隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；及肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成。
进一步本发明的隔音缓冲材是装设于车体的车轮罩内表面的隔音缓冲材，其特征在于，具备：隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面；及肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成。
除此之外，本发明的隔音缓冲材的制造方法中，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，所述隔音缓冲材具备：隔音缓冲区域，其由大量短纤维相互缠绕而成的无纺布所组成；及连续树脂区域，其通过所述隔音缓冲区域及边界部而形成连续面；所述隔音缓冲材的制造方法中，为了在无纺布侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与连续树脂区域的边界部稳定。
并且，本发明的隔音缓冲材的制造方法中，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，所述隔音缓冲材具备：隔音缓冲区域，其由大量短纤维相互缠绕而成的无纺布所组成；及肋状树脂区域，其通过所述隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成；所述隔音缓冲材的制造方法中，为了在隔音缓冲区域侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与肋状树脂区域的边界部稳定。
进一步，本发明的隔音缓冲材的制造方法中，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，所述隔音缓冲材具备：隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面；及肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成；所述隔音缓冲材的制造方法中，为了在隔音缓冲区域侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与连续树脂区域及╱或肋状树脂区域的边界部稳定。
如所述，因为本发明的隔音缓冲材具有由无纺布所组成的隔音缓冲区域，所述无纺布具有相互缠绕的大量纤维，所以可得到优异的吸音性及耐冲击性。并且，在此隔音缓冲材中，通过具备通过隔音缓冲区域及边界部而形成连续面的连续树脂区域及╱或通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成的肋状树脂区域，而谋求提高耐水性、并提高耐结冰性、防水性。特别是连续树脂区域及肋状树脂区域一体地形成，并以肋状树脂区域不仅具有从连续树脂区域延伸的突出部，且设为形成在两个隔音缓冲区域间，由此对通过隔音缓冲区域及边界部而形成连续面的连续树脂区域的两边皆赋予足够的合成。特别是通过形成一个肋状树脂区域与其他肋状树脂区域交叉的交叉部，而消除了关于刚性的各向异性，并对隔音缓冲材整体在全方向赋予刚性。
由于边界部为比隔音缓冲区域的无纺布更压缩的压缩无纺布区域，所以防止在射出成形时树脂从连续树脂区域及╱或肋状树脂区域往隔音缓冲区域的无纺布含浸，并高度维持来自隔音缓冲区域的无纺布的吸音性能。
具体而言，由于压缩无纺布区域具有相较于隔音缓冲区域三倍以上的密度，所以充分地防止在射出成形时树脂从连续树脂区域及╱或肋状树脂区域往隔音缓冲区域的无纺布含浸。在压缩无纺布区域相较于隔音缓冲区域未达三倍的密度的情况下，无法完全地防止在射出成形时树脂从连续树脂区域及╱或肋状树脂区域往隔音缓冲区域的无纺布含浸，而无法产生足够的吸音性能。要使压缩无纺布区域具有相较于隔音缓冲区域六倍以上的密度在工业上并非易事，也会产生不必要的生产成本。
通过在边界部的树脂区域侧设定隔音缓冲区域的无纺布所延伸的区域，而可确保树脂区域与隔音缓冲区域充足的一体性、连续性及接合性。
如所述，若根据本发明的隔音缓冲材，则发挥耐冲击性及吸音性优异、并且耐结冰性、防水性也优异的优良效果。
附图说明
图1为表示车体的车轮罩周边的局部侧视图。
图2为本发明一实施方式的隔音缓冲材的立体图。
图3为本发明一实施方式的隔音缓冲材的局部剖面示意图。
图4为本发明一实施方式的隔音缓冲材的其他的局部剖面示意图。
图5为本发明一实施方式的隔音缓冲材的其他的立体图。
图6为本发明一实施方式的隔音缓冲材的另一个局部剖面示意图。
图7为本发明一实施方式的隔音缓冲材的再另一个局部剖面示意图。
图8为本发明的实施例的隔音缓冲材的照片。
图9为本发明的实施例的隔音缓冲材的照片。
图10为本发明的实施例的隔音缓冲材的照片。
图11为本发明的实施例的隔音缓冲材的照片。
具体实施方式
以下根据附图说明本发明的实施方式。
图1为表示在已装设本发明的实施方式的隔音缓冲材1的汽车的轮胎102周边的局部侧视图。隔音缓冲材1形成沿着车体100的车轮罩101的内表面101a的形状，并装设于其内表面101a。
于图2、图5示意性地表示隔音缓冲材1的立体图。此隔音缓冲材1以下述构件构成：隔音缓冲区域2，其上表面被安装于车体；及树脂区域3，其与隔音缓冲区域2并排设置/邻接而实质上连续设置。
树脂区域3为将图5所示的连续树脂区域3a及图5所示的肋状树脂区域3b一体地射出成形而形成。
隔音缓冲区域2中，具有相互缠绕的大量短纤维的无纺布4通过边界部5而被树脂区域3保持，并以被张开设置于树脂区域3间的区域的形态设置。其结果为，树脂区域3与隔音缓冲区域2并排设置/邻接而实质上连续设置，并在隔音缓冲材1的轮胎侧的表面与隔音缓冲区域2并排设置/邻接而实质上连续且与其一起露出。并且，隔音缓冲区域2的具有相互缠绕的大量短纤维的无纺布4的表面也在隔音缓冲材1的与轮胎侧的表面相反侧的表面露出，且连续树脂区域3a的表面与隔音缓冲区域2的无纺布4的表面并排设置/邻接而实质上连续露出。隔音缓冲区域2以此方式所形成的结果为，并无覆盖隔音缓冲区域2的正反面的构件，且不会因覆盖物而降低隔音缓冲区域2的吸音能力。
隔音缓冲材1因在构成隔音缓冲区域2的无纺布4的内部形成无数微小的空隙，而具有优异的吸音性及耐冲击性。并且，此隔音缓冲材1因与隔音缓冲区域2并排设置/邻接而实质上连续地设置连续树脂区域3a而使吸水率下降，由此谋求耐水性的提高，并提高耐结冰性、防水性。特别是当以疏水性的树脂材料形成树脂区域3时，可进一步使耐水性提高。
肋状树脂区域3b通过隔音缓冲区域2及边界部5且比隔音缓冲区域2的表面突出而形成。此肋状树脂区域3b与连续树脂区域3a一体地射出成形而形成。并且，肋状树脂区域3b形成于两个隔音缓冲区域2之间。进一步形成有一个肋状树脂区域3b与其他的肋状树脂区域3b交叉的交叉部。
边界部5为压缩无纺布区域4a，所述压缩无纺布区域4a相较于由具有相互缠绕的大量短纤维的无纺布4所组成的隔音缓冲区域2的无纺布4更为压缩。此压缩无纺布区域4a与隔音缓冲区域2相比为具有三倍以上六倍以下的密度者。
在边界部5的树脂区域3侧设定有隔音缓冲区域2的无纺布4所延伸的延伸区域7。
接着，说明本发明一实施方式的隔音缓冲材1的制造方法。
首先，在模具8形成边界部形成凸部9的顶面的带状的推压面9a，所述边界部形成凸部9是用于形成边界部5。此推压面9a与模具8中对向面的间隔为通过射出成形所得的树脂板厚度的六～八成左右。设定在此模具8的推压面9a的位置，以可在树脂区域3设定隔音缓冲区域2的无纺布4所延伸的延伸区域7的程度，将其设定在比隔音缓冲区域2的外缘2a更内侧的位置。
进一步在模具8设定用于形成肋状树脂区域3b的肋状树脂形成区域8a。此肋状树脂形成区域8a以在两个隔音缓冲区域2之间形成肋状树脂区域3b的方式配置。并且，由于横竖地形成肋状树脂形成区域8a，其结果为形成一个肋状树脂形成区域8a与其他的肋状树脂形成区域8a交叉的肋状树脂形成区域交叉部8b。
在以上的模具8配置具有相互缠绕的大量短纤维的无纺布4。其配置的形态可为下述形态：于在树脂射出前将模具8以预定的方式设定完毕的状态下，无纺布4覆盖于带状的推压面9a上且无纺布4的外缘延伸至推压面9a外侧，并在树脂区域3设定隔音缓冲区域2的无纺布4所延伸的延伸区域7，所述带状的推压面9a是用以形成边界部5的边界部形成凸部9的顶面。
在此状态下对模具8内射出树脂，而可得到本发明的实施方式的隔音缓冲材1。亦即，对模具8内射出的树脂，被由带状的推压面9a所形成的边界部5阻隔而不会浸渍到隔音缓冲区域2下，形成连续树脂区域3a及肋状树脂区域3b，并防止因含浸树脂导致隔因缓冲区域2的吸音能力降低。因为在树脂区域3设定隔音缓冲区域2的无纺布4所延伸的延伸区域7，所以可保持隔音缓冲区域2与连续树脂区域3a及肋状树脂区域3b的连续性，并可得到具有一体性的隔音缓冲材1。
[实施例1]
为了确认本发明的可用性，于图8～图11显示本发明的隔音缓冲材1，亦即显示通过由无纺布4所组成的隔音缓冲区域2及边界部5而形成连续面的连续树脂区域3a以及肋状树脂区域3b所形成的隔音缓冲材1(实施例)的照片。
附图标记说明
1 隔音缓冲材
3 树脂区域
2 隔音缓冲区域
4 无纺布
7 延伸区域
3b 肋状树脂区域
5 边界部
9a 推压面
8 模具

Claims (16)

1.一种隔音缓冲材，装设于车体的车轮罩内表面，其特征在于，具备：
隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；及
连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面。
2.一种隔音缓冲材，装设于车体的车轮罩内表面，其特征在于，具备：
隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；及
肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成。
3.一种隔音缓冲材，装设于车体的车轮罩内表面，其特征在于，具备：
隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；
连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面；及
肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成。
4.根据权利要求1至3中任一项所述的隔音缓冲材，其特征在于，
所述隔音缓冲区域于轮胎侧的表面与连续树脂区域并排设置/邻接而实质上连续且与其一起露出，并且隔音缓冲区域的无纺布的表面也于隔音缓冲材的与轮胎侧的表面相反侧的表面露出，且连续树脂区域的表面与隔音缓冲区域的无纺布的表面一起并排设置/邻接而实质上连续露出。
5.根据权利要求3所述的隔音缓冲材，其特征在于，
所述连续树脂区域与所述肋状树脂区域一体地形成。
6.根据权利要求5所述的隔音缓冲材，其特征在于，
所述肋状树脂区域具有从所述连续树脂区域突出的突出部。
7.根据权利要求2或3所述的隔音缓冲材，其特征在于，
所述肋状树脂区域形成于两个所述隔音缓冲区域间。
8.根据权利要求2或3所述的隔音缓冲材，其特征在于，
形成有一个所述肋状树脂区域与其他所述肋状树脂区域交叉的交叉部。
9.根据权利要求1至3中任一项所述的隔音缓冲材，其特征在于，
所述边界部为比所述隔音缓冲区域的无纺布更压缩的压缩无纺布区域。
10.根据权利要求1至3中任一项所述的隔音缓冲材，其特征在于，
所述压缩无纺布区域与所述隔音缓冲区域相比，具有三倍以上的密度。
11.根据权利要求1至3中任一项所述的隔音缓冲材，其特征在于，
在所述边界部的所述树脂区域侧设定成所述隔音缓冲区域的无纺布所延伸的区域。
12.一种隔音缓冲材的制造方法，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，
所述隔音缓冲材具备：隔音缓冲区域，其由大量短纤维相互缠绕而成的无纺布所组成；及连续树脂区域，其通过所述隔音缓冲区域及边界部而形成连续面；
所述隔音缓冲材的制造方法中，为了在无纺布侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与连续树脂区域的边界部稳定。
13.一种隔音缓冲材的制造方法，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，
所述隔音缓冲材具备：隔音缓冲区域，其由大量短纤维相互缠绕而成的无纺布所组成；及肋状树脂区域，其通过所述隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成；
所述隔音缓冲材的制造方法中，为了在隔音缓冲区域侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与肋状树脂区域的边界部稳定。
14.一种隔音缓冲材的制造方法，所述隔音缓冲材装设于车体的车轮罩内表面，其特征在于，
所述隔音缓冲材具备：隔音缓冲区域，其配置大量短纤维相互缠绕而成的无纺布；连续树脂区域，其通过隔音缓冲区域及边界部而形成连续面；及肋状树脂区域，其通过隔音缓冲区域及边界部并比隔音缓冲区域表面突出而形成；
所述隔音缓冲材的制造方法中，为了在隔音缓冲区域侧限制边界部的边界而压缩无纺布并提高密度，由此抑制树脂流动且使隔音缓冲区域与连续树脂区域及╱或肋状树脂区域的边界部稳定。
15.根据权利要求12至14中任一项所述的隔音缓冲材的制造方法，其特征在于，
在所述边界部，将无纺布压缩至树脂板厚度的六至八成的带状推压面设定于模具。
16.根据权利要求12至14中任一项所述的隔音缓冲材的制造方法，其特征在于，
设定于模具的推压面的位置，以可在所述树脂区域设定所述隔音缓冲区域的无纺布所延伸的区域的程度，将其设置于比所述隔音缓冲区域的外缘更内侧的位置。
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