JP2002178349A - Method for producing soundproof material for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To surely prevent the scattering of dust components peculiar to cellulosic soundproof materials outside in a method for producing the inexpensive soundproof materials for vehicles based on a cellulosic defibrated or crushed material, can be recycled, and are excellent in sound absorption function. SOLUTION: The soundproof materials 11 and 12 comprises sound absorbing/ insulating components, and a resin binder as raw materials which are based on the cellulosic defibrated or crushed material. At least on one side of a cellulosic raw material mat M, a nonwoven fabric 21 with fine meshes or a barrier layer 41 comprising hot melt 51 or hydrogen bonds is formed so that the scattering of dust peculiar to a cellulose component after a molding process and fitting to a vehicle is prevented. When the sound absorbing/insulating components are mixed with the resin binder in a cotton mixing process, a dust fixing component 60 is added in a solution or solid state, and the dust components are fixed in the mat M to keep a good work environment.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an insulator dash mounted on a dash panel or a floor panel,
The present invention relates to a method for manufacturing a soundproofing material for vehicles suitable for floor carpets and the like, and in particular, can reliably prevent generation of dust from cellulosic defibrated materials having excellent sound absorbing performance at low cost and cellulosic components based on pulverized materials. The present invention relates to a method for manufacturing a soundproofing material for a vehicle, which can favorably maintain the environment and the environment in a vehicle compartment.

[0002]

2. Description of the Related Art Generally, vehicles are provided with various soundproofing materials in order to ensure quietness during running. For example, as shown in FIG. 9, an insulator dash 1 is mounted on the indoor side of a dash panel 1 a that partitions an engine room E and a passenger compartment R, and the interior surface of a floor panel 2 a in the passenger compartment R is installed. A floor carpet 2 is laid.

[0003] In the engine room E, a dash front insulator 3 mounted on the room side of the dash panel 1a and a hood insulator 4 mounted on the room side of the hood panel 4a are installed. The roof trim 5 is mounted on the interior surface of the roof panel 5a.
Although not shown, soundproof interior materials such as a trunk trim, a luggage trim, and a wheel house trim are installed in a trunk room or a luggage room.

As described above, the cabin R, the engine room E,
Alternatively, various soundproofing materials are installed in the trunk room and the luggage room. As a typical example, the configuration of the insulator dash 1 mounted on the interior surface of the dash panel 1a will be described with reference to FIG. As the insulator dash 1, a two-layer structure in which a sound insulating material 7 is integrated on the surface side of a sound insulating base material 6 having sound absorbing and sound insulating performance is conventionally known.

[0005] As the sound insulating material 7, a heavy sheet material such as a high-density recycled rubber sheet or a recycled PVC sheet is used. On the other hand, the material of the sound-insulating base material 6 is a polyester fiber such as polyethylene terephthalate (hereinafter referred to as PET) or other synthetic fibers, and a resin binder such as a low melting point heat-fusible fiber or a thermoplastic resin powder. To form a nonwoven fabric mat by performing a needling process or a press process while applying hot air. The nonwoven fabric mat is subjected to a heat softening treatment, and then subjected to cold press molding to conform to the shape of the dash panel 1a. The base material 6 is formed.

[0006] Another conventional example is to use anti-hair (wool and regenerated wool recovered by unraveling rags and debris of products made from wool) as a main fiber and adding a binder to the main fiber. In some cases, it may be possible to use felt with
This felt is similarly heat-softened and then cold-pressed into a required shape to form the soundproof substrate 6.

Further, there is a case where a urethane foam molded article obtained by foam molding after pouring a urethane resin liquid into a mold is used as the soundproof base material 6.

[0008]

As described above, when the above-mentioned sound absorbing base material 6 of the insulator dash 1 is made of synthetic fiber such as PET, the synthetic fiber is expensive. In the case of adjusting the rigidity and repulsion of the product, which leads to soaring, it can be dealt with only by increasing the compounding ratio of the binder, and the binder is expensive, which is also a major factor that leads to cost increase. ing.

[0009] On the other hand, when felt is used, since the bristles have thick fibers, there is a problem that the sound absorption performance is reduced and the weight of the product is increased. Furthermore, when a urethane foam is used, cost reduction can be expected, but harmful nitrogen oxides are generated during incineration, which is disadvantageous in terms of recycling.

The present invention has been made in view of such circumstances, and is a method of manufacturing a soundproofing material for vehicles such as an insulator dash, a floor carpet, and a hood insulator, which can be widely applied. It is another object of the present invention to provide a method for producing a soundproofing material for vehicles, which can maintain sound absorption and sound insulation performance satisfactorily and can form a cellulosic base material suitable for recycling without scattering of dust components to the outside.

[0011]

Means for Solving the Problems In order to achieve the above object, the invention described in claim 1 of the present application provides a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material, and the sound absorbing / sound insulating component. After mixing in a cotton blending process with a resin binder that binds the sound insulation component, a step of preparing a cellulose-based raw mat for preparing a cellulose-based raw mat by a mat forming step,
Alternatively, after the production of the cellulosic raw mat, a nonwoven fabric having a fine mesh is laminated on at least one of the front and back surfaces of the cellulosic raw mat, and after softening by heating, the cellulosic substrate is formed into a required shape by press molding. It is characterized by the following.

The soundproofing material can be applied to base materials such as an insulator dash, a floor carpet, and a roof trim provided in a vehicle cabin, and a base material such as a dash front insulator and a hood insulator in an engine room and a trunk room trim in a trunk room. Applicable as

Here, the sound absorbing / sound insulating component can exhibit both the sound insulating performance and the sound absorbing performance, such that the sound absorbing performance due to the porous property can be obtained and the sound insulating performance can be expected due to its rigidity and weight. Meaning.

As the sound-absorbing and sound-insulating components, natural fibers made of cellulose, recycled materials, and recycled materials are used. For example, pure pulp, recycled cellulose, and used paper (used newspapers, magazines, cardboard, etc.) are defibrated. Alternatively, a defibrated or crushed material obtained by crushing is used.

Next, the resin binder for binding the sound absorbing and sound insulating components is a heat-fusible fiber such as low melting point PET, a resin powder such as PE (polyethylene) resin, or a reactive adhesive (for example, a urethane resin-based adhesive). ) Etc. can be used.

The mixing ratio of the above sound absorbing / sound insulating component and the resin binder is as follows: sound absorbing / sound insulating component / resin binder =
Set between 90:10 and 20:80. And when soft feeling and sound absorption performance are required depending on the application,
The mixing ratio is adjusted to be rich in sound insulation components, and conversely, when rigidity and sound insulation performance are required, the mixing ratio is adjusted to be resin binder rich.

Further, a high melting point synthetic fiber may be added to the sound absorbing / insulating component.
P, PE, PA (polyamide resin), etc., with a fiber diameter of 0.1
A fiber having a denier of 2 to 30 and a fiber length of 2 to 80 mm, preferably 10 to 64 mm is preferable.

The fine nonwoven fabric laminated and laminated on the cellulosic raw material mat is, for example, P
A synthetic fiber non-woven fabric such as ET, PP, PE or the like, or a paper-like non-woven fabric made of natural fiber such as pulp, having an area density of 10 to 200 g / m ² and ²⁰ to 100 g / m ^{2
About two} are preferred.

The lamination of the cellulosic material mat and the nonwoven fabric may be carried out before or after the heating step in a hot air heating furnace after the cellulosic mixed material is deposited in a mat shape. After the preparation of the anti-mat, it may be performed before the heat softening treatment.

According to the first aspect of the present invention,
Natural fibers such as cellulose, recycled materials, and recycled materials are used as the main fibers.If the fibers with a small fiber diameter are selectively used, the sound absorption performance can be improved, and the fibrous defibrated material or pulverized material can be used. Since the sound absorbing and sound insulating components are used, the surface area is large, the sound absorbing and sound insulating performance can be improved, and the entanglement with the resin binder is strengthened, and the rigidity and strength can be increased.

In addition, since fine nonwoven fabric is laminated and laminated on at least one of the front and back surfaces of the cellulosic material mat, wind and hot air are discharged when the cellulosic material mat is heated with hot air. By setting the fine nonwoven fabric on the side, the dust component in the cellulosic raw material mat is prevented by the nonwoven fabric, and can be prevented from scattering into the heating furnace.

Further, a fine nonwoven fabric is laminated on one surface of the cellulosic raw mat, and it is possible to prevent dust components from scattering into the vehicle interior from the cellulose base material formed into a required shape by the nonwoven fabric.

Furthermore, when the binder component in the cellulosic raw mat is small, the dust component is very likely to be generated. Therefore, if fine nonwoven fabric is set on both sides of the cellulosic raw mat, the dust component can be reduced. It is more effective to prevent scattering to the outside.

Next, according to the invention described in claim 2 of the present application, the lamination of the cellulosic raw mat and the nonwoven fabric is performed by the fusing action of the resin binder in the cellulosic raw mat. And the nonwoven fabric are bonded and integrated.

According to the second aspect of the present invention,
Utilizing the fusing property of the resin binder in the cellulosic raw mat, simply heating with hot air or steam with a fine non-woven fabric on one side of the cellulosic raw mat, the binder component causes Are bonded, so that the adhesive for lamination can be eliminated or reduced.

The invention described in claim 3 of this application is characterized in that the lamination of the cellulosic raw mat and the nonwoven fabric is performed with an adhesive.

Here, when the amount of the resin binder in the cellulosic material mat is small, the cellulosic material mat and the fine nonwoven fabric are bonded and fixed via an adhesive.

As the adhesive, resin powder, powder-like, pellet-like, chip-like, mesh-like, web-like hot-melt-type adhesives, and liquid hot-melt are applied in the form of a thread to be applied randomly or in a mesh form. Further, a synthetic adhesive or an adhesive derived from a natural substance, for example, starch, gelatin, rosin and the like can be used.

According to the third aspect of the present invention,
The cellulosic web mat and the nonwoven fabric are fixed via an adhesive.The adhesive has a function of fixing the dust component on the surface of the cellulosic web mat in addition to the function of bonding the nonwoven fabric to the cellulosic web mat. Therefore, it is possible to more reliably prevent the dust component from scattering to the outside.

Next, the invention described in claim 4 of this application is characterized in that both lamination of the cellulosic raw material mat and the nonwoven fabric are performed by needle punching.

According to the invention described in claim 4,
Since the cellulosic raw mat and the nonwoven fabric are integrated by needle punching, both can be integrated without using an adhesive.

According to the invention described in claim 5 of the present application, the laminate of the cellulosic raw mat and the nonwoven fabric is adhered to each other by the stickiness of cellulose generated when water is sprayed or applied to the cellulosic raw mat. It is characterized by being fixed.

According to the fifth aspect of the present invention,
When water is sprayed or applied to the surface of the cellulosic raw mat, the nonwoven fabric can be attached due to the stickiness of the cellulose. At this time, the dust component on the surface of the cellulosic raw mat can also be fixed.

According to the invention described in claim 6 of this application, a sound absorbing / sound insulating component based on a cellulosic fibrillated or crushed material and a resin binder for binding the sound absorbing / sound insulating component are mixed in a cotton mixing step. Thereafter, water or a solution, a chemical or the like is sprayed or applied to at least one of the front and back surfaces of the cellulosic raw mat produced in the mat forming step, and the dust component is fixed. By pressing the raw mat into the required shape,
It is characterized in that a cellulose-based substrate is formed into a required shape.

Here, the timing of spraying or applying the water, solution, or chemical may be before or after hot air treatment in the production process of the raw material mat, and may be performed after the production of the cellulosic material mat and before the press molding. Is also good.

If a spraying or coating treatment of water, a solution, a chemical or the like is performed before the hot air treatment in the production process of the cellulosic material mat, the drying process can be performed simultaneously with the hot air treatment of the material mat.

If the spraying or application step of the above-mentioned water, solvent, chemicals or the like is performed after the hot air treatment of the cellulosic raw mat, the drying step can be abolished, but the blocking between the cellulosic raw mats can be prevented. It is preferable to perform a drying treatment.

Further, in the case where a step of spraying or applying water, a solution, a drug or the like is performed after the production of the raw mat and before the press molding,
Processing may be performed at the material setup point, or a processing device may be built in the molding machine (for example, in the conveying device). In this case, the cellulosic raw mat can be dried in the heating step before molding. There is no need to separately install

As the solvent or chemical to be sprayed or applied, various organic or synthetic adhesives such as aqueous adhesives, emulsions and emulsion adhesives, as well as adhesives and polysaccharides derived from natural substances can be used. . For example, agar, carrageenan, alginic acid, seaweed extracts such as sodium alginate and alginic acid compounds, starch, amylopectin, pectin, gum arabic, locust bean gum, plant extracts such as guar gum, gelatin, animal proteins such as casein, carboxymethyl cellulose , Methylcellulose and other celluloses chemically modified, as well as tackifiers (tackifier resin), rosin (pine resin) compounds, amylose, pectic acid, xylan, alginate fibers, protein fibers and the like.

According to the sixth aspect of the present invention,
Dust components can be reliably fixed by water, a solvent, a chemical, or the like sprayed or applied to at least one of the front and back surfaces of the cellulosic raw mat.

Further, by controlling the amount of water, solvent or chemical applied in accordance with the proportion of the defibrated material or pulverized material in the cellulosic material mat, effective dust prevention measures can be taken.

Next, the invention described in claim 7 of this application is a process for mixing a sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material and a resin binder for binding the sound absorbing / sound insulating component. After mixing in the above, a cellulosic raw mat is produced in a mat forming step, a hot melt is applied to at least one surface of the cellulosic raw mat, and the hot melt is stretched over a wide range of the cellulosic raw mat surface, After cooling and solidifying and fixing the dust component, a heat softening treatment is performed, and a press molding into a required shape is performed to form a cellulosic base material.

Here, as the hot melt, a powdery hot melt, a film-like hot melt, a film or a mesh-like or web-like hot melt may be used.
Alternatively, the liquid hot melt may be applied as a thin thread to the surface of the cellulosic raw mat at random or in a mesh.

The hot melt is sprayed or laminated on the raw material mat and passed through a heat belt or a hot roll, and then passed through a cooling belt or a cold roll, so that the hot melt is applied to the surface of the cellulosic raw mat. It spreads out and covers its surface.

According to the seventh aspect of the present invention,
By cooling and solidifying the hot melt in the molten state, the dust component of the cellulosic raw mat can be effectively fixed, and the dust component does not scatter outside. In addition, hot melt does not cause hydrogen bond in the cellulose component, and thus does not hinder the moldability of the cellulose-based raw mat.

Next, the invention described in claim 8 of this application is a process of mixing a sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material and a resin binder for binding the sound absorbing / sound insulating component. Then, a cellulosic raw material mat is prepared in a mat preparing step, and then, the cellulosic raw material mat is heated and softened, and then press-molded into a required shape to form a base material. The method is characterized in that the dust component of cellulose is fixed by mixing water or a liquid adhesive in the cotton mixing step of the cellulosic raw material mat.

Here, as the water or the adhesive to be added in the cotton mixing step, there are the following synthetic adhesives, adhesives derived from natural substances, and polysaccharides.

<Synthetic adhesives>-Various organic or aqueous adhesives-Emulsions and emulsion adhesives

<Adhesives and polysaccharides derived from natural substances> (seaweed extract) ex) agar, carrageenan ex) alginic acid, sodium alginate and alginic acid compound (plant extract) ex) starch, amylopectin, pectin, gum arabic ) Locust bean gum, guar gum (animal protein) Example) Gelatin, casein (cellulosic) Example) Carboxymethylcellulose Example) Methylcellulose or other chemically modified cellulose (Other) ・ Tackifier (Tackifier resin) ・ Rosin (Pine resin) compounds ・ Amylose, pectic acid, xylan, alginate fiber, protein fiber

According to the eighth aspect of the present invention,
Since water or liquid adhesive is added to the cellulosic raw mat, the dust components inside the raw mat can be fixed reliably with a small amount of addition, ensuring that the dust components scatter outside. Can be suppressed.

Next, the invention according to the ninth aspect of the present application is to provide a sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material and a resin binder for binding the sound absorbing / sound insulating component in a cotton mixing step. After mixing, a cellulosic raw fabric mat is produced in a mat producing process, and then, after heating and softening the cellulosic raw fabric mat, a method of manufacturing a soundproofing material for a vehicle is performed by press-molding to a required shape to form a base material. There, the polysaccharide is added in a solid state or a solution or a liquid state in a cotton blending process of the cellulosic raw mat, and in the heating and softening treatment of the cellulosic raw mat, the polysaccharide becomes a gel state to remove dust components of the cellulose. It is characterized by being fixed.

According to the ninth aspect of the present invention,
Polysaccharides added in the mixing process of cellulosic raw mat have a low melting point and a high viscosity in the molten state, so when subjected to hot air treatment or high-temperature treatment in a heating furnace, the polysaccharides etc. flow and dust components become effective. Fixed.

[0053]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a method for manufacturing a soundproof material for a vehicle according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view showing the structure of an automobile insulator dash and a dash front insulator as an embodiment of a vehicle soundproofing material according to the present invention, and FIG. 2 is a process of a first embodiment in a method of manufacturing the insulator dash. FIG. 3 is an explanatory diagram, FIG. 3 is a process chart diagram when a film-like hot melt is used in laminating a cellulosic substrate and a nonwoven fabric in the insulator dash, and FIG. 4 is a process showing a second embodiment in a method of manufacturing the insulator dash. FIGS. 5 and 6 are process explanatory diagrams showing a third embodiment of the method of manufacturing the insulator dash, FIG. 7 is a flowchart of a laminating process of a film-like hot melt and a cellulosic raw mat, and FIG. 8 is an insulator. Example showing a fourth embodiment in a method of manufacturing a dash It is an explanatory diagram.

First, referring to FIG. 1, an application example of the vehicle soundproofing material according to the present invention will be described.

In the drawing, an engine room E and a cabin R
A vehicle insulator dash 11 is attached to and fixed to the interior surface side of a dash panel 10 that separates the dash panel 10, and a dash front insulator 12 is mounted on an engine room side of the dash panel 10.

Then, the insulator dash 11 is
A fine nonwoven fabric 21 is formed on the surface side of the cellulosic base material 20 formed according to the surface shape of the dash panel 10.
Is laminated, and the problem of dust generation unique to the cellulosic base material 20 is reliably prevented by the fine nonwoven fabric 21 from scattering dust components into the vehicle compartment R.

Similarly, also in the dash front insulator 12, a fine nonwoven fabric 21 is laminated on the surface of the cellulosic base material 20 to prevent the dust component from scattering from the cellulosic base material 20 into the engine room E. Preventing.

The cellulosic base material 20 is composed of a sound absorbing / sound insulating component bound by a resin binder. The sound absorbing / sound insulating component is a cellulosic component, specifically, pure pulp, Recycled cellulose, waste paper (old newspapers, old magazines, cardboard, etc.), plants such as wood, chemically modified and processed celluloses, and industrial wastes derived from natural materials generated in the paper industry (sludge-like ,
(Which may be wet) may be dried as necessary, and these are fibrillated or pulverized by being defibrated and pulverized.

On the other hand, as the resin binder, low melting point PE is used.
A heat-fusible fiber made of T, a resin powder such as a polyethylene resin, or a reactive adhesive (for example, a urethane-based adhesive) can be used. In this embodiment, low-melting PET is used for the pulverized material obtained by pulverizing waste paper. The heat fusible fiber used as the material is used as the resin binder.

The mixing ratio of the sound absorbing / sound insulating component and the resin binder is as follows: sound absorbing / sound insulating component / resin binder = 90: 1.
The mixing ratio may be set in a range of 0 to 20:80. For example, in a case where a sound absorbing performance or a soft feeling is required, a sound absorbing / sound insulating component rich mixture is used. By appropriately selecting the resin binder-rich compounding ratio for the required application, the cellulose-based substrate 2
0 can be used in a wider range.

Incidentally, as the cellulosic base material 20 of the insulator dash 11, the sound insulating / sound absorbing component / resin binder = 80: 20, and the areal density and average thickness of the cellulosic base material 20 were 1,000 g / m ² , respectively. 20-30
mm.

Since the cellulosic substrate 20 is made of a natural material made of cellulose, a recycled material, or a recycled material, for example, if the fiber diameter is small, the sound absorbing performance is improved. Can be incinerated and recyclable, especially for scraps and used products.
The use of waste defibrated or crushed products such as waste paper is very advantageous in terms of cost.

Further, unlike the string shape obtained with a shredder or the like, the surface area is large, so that the sound absorption and sound insulation performance is high.
Entanglement with the resin binder is strengthened, and the strength of the product can be increased.

In addition, in order to enhance sound insulation and sound absorption performance,
It is also possible to add a high melting point fiber. In this case, the high melting point fiber can be appropriately selected from synthetic fibers such as PET, PP, PE, PA (polyamide resin), and has a fiber diameter of 0.2 to 30 denier. If a high melting point synthetic fiber having a fiber length of 2 to 80 mm (preferably 10 to 64 mm) is added, the sound absorbing performance can be enhanced.

In the present invention, when the cellulosic substrate 20 is formed in conformity with the shape of the dash panel 10, the dust component is scattered outside from the cellulosic substrate 20 even after being attached to the dash panel 10. In this case, the work environment or the environment in the vehicle interior is reliably prevented from deteriorating, and a fine nonwoven fabric 21 is laminated on one side (inside of the room) of the cellulose-based substrate 20.

The area density of the nonwoven fabric 21 is 10 to 200
g / m ² , preferably about 20 g / m ² , and the material is a synthetic fiber such as PET, PP, or PE, or a natural fiber such as pulp. .

Therefore, the dust component which is supposed to be scattered outside from the cellulosic base material 20 is prevented from being scattered to the vehicle cabin side by the barrier effect of the nonwoven fabric 21.
Good environmental hygiene in the passenger compartment can be maintained.

Similarly, the dash front insulator 1 mounted on the dash panel 10 in the engine room side
Also in 2, the fine nonwoven fabric 21 is formed on the engine room side of the cellulosic base material 20, and the nonwoven fabric 21 prevents the dust component in the cellulosic base material 20 from scattering into the engine room E. . The insulator dash 11 is composed of a laminated structure of a cellulosic base material 20 and a fine-grained nonwoven fabric 21 laminated on the surface thereof, and a recycled rubber sheet or a recycled PVC sheet or the like is provided on the surface side. , Sound insulation material with high areal density (not shown)
May be integrated.

Next, the insulator dash 11 obtained by laminating the nonwoven fabric 21 on the surface of the cellulosic base material 20 was used.
Will be described with reference to FIG.

First, the sound absorbing / sound insulating component and the resin binder are put into the mixer 30 and mixed in the mixer 30, and then the mixed material 32 is deposited on the belt conveyor 31. Fine nonwoven fabric supplied 2
1 is placed.

Next, hot air is passed through the mixed material 32 and the non-woven fabric 21 while applying a press pressure in a hot air heating furnace 33 to melt the resin binder in the mixed material 32 and to fuse the resin binder. The nonwoven fabric 21 is fused to one surface of the deposited mixed material 32.

In the hot air heating furnace 33, a belt 34 is circulated by driving a plurality of pulleys 34 a, and hot air flows through a plurality of holes formed in the belt 34 while being pressed by the belt 34. And the nonwoven fabric 21. The mixed material 32 and the nonwoven fabric 21
In the case where the mixing ratio of the resin binder in the mixed material 32 is relatively large, the material is compressed to a predetermined thickness by the belt 34, and then cut to a predetermined size by the cutting blade 35 to form a nonwoven fabric on one surface. Then, a cellulosic raw material mat M laminated with 21 is produced. The lamination of the nonwoven fabric 21 may be performed after the mixed material 32 is subjected to the hot air heating treatment or after the production of the cellulosic raw material mat M.

After the cellulosic raw material mat M is heated and softened in a hot air heating furnace 36, it is set in upper and lower dies 37, 38 for cold press molding.
By closing the mold 8, the molding of the automotive insulator dash 11 in which the nonwoven fabric 21 is integrated with one surface of the cellulosic base material 20 is completed.

When the amount of the resin binder in the cellulosic material mat M is small, dust is very likely to be generated. Therefore, it is preferable to set the nonwoven fabric 21 on both sides of the cellulosic material mat M. .

As the non-woven fabric 21, a synthetic fiber non-woven fabric such as PET, PP or PE, or a paper-like non-woven fabric made of natural fibers such as pulp is used. The surface density of the nonwoven fabric 21 is preferably of about 20 g / ^{m 2} at 10 to 200 g / ^{m 2.}

The process shown in FIG. 2 can be applied only when the resin binder is rich by blending the sound absorbing / sound insulating component, which is the material of the cellulosic base material, with the resin binder, but using steam heating instead of hot air heating. Alternatively, a heat laminating method may be used.

However, when the mixing ratio of the resin binder is small, the raw cellulose mat M and the nonwoven fabric 21 are integrated through the following bonding means. As this bonding means, the cellulosic mat M and the nonwoven fabric 21 are bonded via a resin powder, a powder, a pellet, a chip, a mist, a mesh, a web nest hot-melt adhesive.

Alternatively, the liquid hot melt may be applied in the form of a thread and applied in a random or mesh form to bond and integrate the two, and the two may be bonded using a synthetic adhesive or an adhesive derived from a natural substance. Can also.

As the synthetic adhesive, various organic or aqueous adhesives, emulsions and emulsion adhesives are used. In addition, the following adhesives and polysaccharides are derived from natural substances.

(Seaweed extract) Example) Agar, carrageenan Example) Alginic acid, sodium alginate and alginic acid compound (Plant extract) Example) Starch, amylopectin, pectin, gum arabic Example) Locust bean gum, guar gum (animal protein) Example ) Gelatin, casein (cellulosic) Example) Carboxymethylcellulose Example) Methylcellulose or other chemically modified cellulose (Others)-Tackifier (tackifier resin)-Rosin (pine resin) compound-Amylose, pectic acid, xylan, Alginate fiber, protein fiber

Further, the cellulose-based raw mat M and the nonwoven fabric 21 can be simultaneously fixed by needle punching without using an adhesive. Further, water is sprayed or applied to the cellulosic raw material mat M,
The nonwoven fabric 21 can also be attached to the cellulosic raw material mat M by the adhesiveness of the generated cellulose. Since the above method does not impair the air permeability of the cellulosic raw material mat M, a hot air heating method can be adopted for molding, which is useful for shortening the molding time and does not impair the sound absorbing performance.

FIG. 3 shows a film-like hot melt (having non-permeability) of a nonwoven fabric 21 on a cellulosic raw material mat M.
As shown in FIG. 3 (a), after laminating a film-like hot melt on a non-woven fabric 21, this is heated in an infrared heater or a thermostat, while the cellulosic material is melted. After heating the anti-mat M by hot air heating, the non-woven fabric 21 can be integrated with one surface of the cellulosic base material 20 by simultaneous press molding.

Further, as shown in FIG.
1, film hot melt, after the lamination or lamination temporary fixing treatment of the three members of the cellulosic raw mat M and heating with an infrared heater, simultaneous press molding may be performed,
As shown in FIG. 3 (c), after laminating the film-like hot melt on the nonwoven fabric 21 and further laminating or temporarily fixing the laminate on the cellulosic raw material mat M, heat-treat with an infrared heater and press-mold. Can also be performed. On the other hand, as shown in FIG. 3 (d), both the hot melt film and the nonwoven fabric 21 are laminated or temporarily fixed to the cellulosic raw material mat M, heated by an infrared heater, and then press-formed to form a cellulosic material. Substrate 20
Can also be formed.

As described above, according to the first embodiment of the present invention, at least one of the front and back surfaces of the raw material mat is prepared after the production of the raw material mat M or after the production of the raw material mat M. Since the nonwoven fabric 21 having a small thickness is laminated, dust in the cellulosic component does not scatter in the hot air heating furnaces 33 and 36,
Since the working environment can be favorably maintained and dust components do not scatter in the vehicle compartment R even after the insulator dash 11 is attached to the dash panel 10, it is also preferable from the viewpoint of environmental health in the vehicle compartment.

Next, FIG. 4 shows a second embodiment of the present invention. In order to prevent the dust component from scattering to the outside in the molding step of the cellulosic raw material mat M, water or an aqueous solution, or The medicine is sprayed or applied to fix the dust component.

That is, after the sound absorbing / sound insulating component and the resin binder are put into the mixer 30 and mixed, the mixed material 32 is dispersed and deposited on the belt conveyor 31, and the surface of the mixed material 32 is Is sprayed with water, a solution, or a chemical (water 41 in this embodiment).
The solution and the drug include various organic or aqueous adhesives, emulsions and emulsion adhesives.

Next, hot air is fed into the hot air heating furnace 33 while being pressurized by the belt 34, the thickness is adjusted by the belt 34, the cut air is cut to a predetermined size by the cutting blade 35, and the barrier layer 42 formed by hydrogen bonding is used. Cellulose-based raw mat M in which dust components are prevented from scattering to the outside can be obtained. Thereafter, after heating and softening treatment in a hot-air heating furnace 36, the upper and lower dies 37, 38 for cold press molding are press-molded into a desired shape, and the cellulosic base material 20 is formed.
Is molded.

In the embodiment shown in FIG. 4, the step of spraying the water 41 by the sprayer 40 is performed before the hot-air treatment, but may be performed after the hot-air treatment in the hot-air heating furnace 33. In this case, it is preferable to carry out a drying treatment in order to prevent blocking between the cellulosic material mats M.

This spraying step may be carried out after the preparation of the cellulosic raw material mat M and before the preheating step before molding by the hot air heating furnace 36. A processing device may be built in the molding machine (transport device portion). When a processing device is incorporated in the press molding device, the substrate can be dried in a heating step before molding, and thus a separate drying facility does not need to be provided.

Next, FIG. 5 shows a third embodiment of the method of the present invention, in which one side or both sides of a cellulosic raw material mat M are treated with hot melt to fix a dust component.

That is, the powdery hot melt 51 is sprayed from one side of the cellulosic raw material mat M from the container 50, or the hot melt 51 is transferred from the mesh-like or web-like hot melt raw roll 52 to the cellulosic raw material mat M. After being set on one surface of the raw material mat M and conveyed by upper and lower heat belts 54 circulated and driven by the hot rolls 53, the cellulosic raw material mat M and the hot melt 51 are subjected to heat lamination, and then circulated by the cooling roll 55 The hot melt 51 is spread in a plane by the driven cooling belt 56, and the entire surface of the cellulosic raw material mat M is covered with the hot melt 51.
Coated.

Thereafter, similarly to the above-described embodiment, after heating and softening treatment in a hot air heating furnace 36, it is formed into a required shape by upper and lower dies 37 and 38 for cold press molding, and hot melt 5
The cellulose-based base material 20 whose surface is coated with 1 can be formed.

Also in this method, the dust component of the cellulosic raw material mat M is fixed by the hot melt 51, so that a good working environment can be maintained. Further, when the cellulosic substrate 20 is attached to the dash panel 10, Alternatively, the dust component does not scatter into the vehicle compartment even after being attached. Since the hot melt 51 does not cause hydrogen bonding in the cellulose component, the surface does not harden, and the moldability of the cellulosic raw material mat M is not impaired.

FIG. 6 shows a modification of the above-described third embodiment, in which a liquid hot melt 51 from a coating device 57 is randomly or mesh-likely formed as a thin thread on one surface of a cellulosic material mat M. The liquid hot melt 51 can be spread on the product surface by applying the liquid and cooling roll 55. In this method, since the liquid hot melt 51 is molten at the time of application, the hot roll 53 or the heat belt 5
The step of melting in step 4 can be eliminated and the step can be shortened.

As the hot melt 51, in the case of a film-like hot melt, as shown in FIG. 7A, the film-like hot melt is subjected to a heat treatment with an infrared heater or a constant temperature bath, while a cellulosic material mat is used. M may be subjected to a hot air heat treatment to simultaneously press-mold both of them. Alternatively, as shown in FIG. 7 (b), after laminating the film-like hot melt and the cellulosic raw material mat M, an infrared heater is used. It is also possible to heat and press-mold.

FIG. 8 shows a fourth embodiment of the method of the present invention, in which the dust fixing component 60 is added in the step of preparing the cellulosic raw material mat M, particularly in the step of mixing the components in the mixer 30. By doing so, the dust in the cellulosic material mat M is fixed, and the working environment is prevented from deteriorating.

That is, in addition to the cellulose-based sound absorbing / sound insulating component and the resin binder, the dust fixing component 60 is mixed in the mixer 30, and the mixed material 32 is mixed with the belt conveyor 3.
1 and then produced in the same manner as in the above embodiment by a hot air heating step in which hot air is blown while applying pressure, followed by softening treatment in a hot air heating furnace 36, followed by cold press molding. The upper and lower dies 37 and 38 form the cellulose-based substrate 20 into a required shape.

The dust fixing component 60 is composed of water,
Adhesives can be used. As the adhesive, natural-based adhesives and polysaccharides can be used in addition to various organic or aqueous adhesives, synthetic adhesives such as emulsions and emulsion adhesives, and the like. For example, agar, carrageenan, alginic acid, seaweed extracts such as sodium alginate and alginic acid compounds, starch, amylopectin, pectin, gum arabic, locust bean gum, plant extracts such as guar gum, gelatin, animal proteins such as casein,
Cellulose-based materials such as carboxymethylcellulose, methylcellulose, and other celluloses chemically modified, tackifier (tackifier resin), rosin (pine resin) compounds, amylose, pectic acid, xylan, alginic acid fibers, and protein-based fibers. is there.

The dust-fixing component 60 can be applied in a solution state to fix dust, but when added in a solid state, for example, polysaccharides and the like have a low melting point and a high viscosity in a molten state. Utilizing this, the dust fixing component 60 is melted and flown by hot air treatment or high-temperature treatment in a heating furnace to fix the dust component.

[0101]

As described above, the method of the present invention can be used in the production process of a cellulosic raw mat and the molding process of the cellulosic raw mat when producing a soundproofing material for vehicles based on a cellulosic substrate. The problem that the dust component inside is scattered to the outside is caused by laminating a fine nonwoven fabric, water or an aqueous solution, or hot melt on the surface on at least one of the front and back surfaces of the cellulosic raw material mat. The problem of the generation of dust peculiar to the cellulosic base material is effectively solved by preventing the scattering of the base material to the outside or by adding a dust fixing component to the inside of the cellulosic raw material mat. Dust components do not scatter in the heating furnace during the production of the raw mat, and the working environment can be maintained well. Together, after the setting of the sound insulation in the vehicle even without dust components in the vehicle compartment or the engine room could scatter has the effect that the preferred environmental health of the vehicle.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a state in which an insulator dash and a dash front insulator as a vehicle soundproofing material manufactured by the method of the present invention are attached to a dash panel.

FIG. 2 is a process explanatory view showing a first embodiment of a method for manufacturing a vehicle soundproofing material according to the present invention.

FIG. 3 is a chart showing a laminating step and a forming step of a cellulosic raw mat and a nonwoven fabric in the first embodiment of the method for producing a vehicle soundproofing material according to the present invention.

FIG. 4 is a process explanatory view showing a second embodiment of the method for manufacturing the vehicle soundproofing material according to the present invention.

FIG. 5 is an explanatory view showing a production process of a raw mat in a third embodiment of the method for producing a vehicle soundproofing material according to the present invention.

FIG. 6 is an explanatory view showing a modification of the production process of the raw mat in the third embodiment of the method for producing a vehicle soundproofing material according to the present invention.

FIG. 7 is an explanatory view showing a modification of the third embodiment of the method for manufacturing a vehicle soundproofing material according to the present invention.

FIG. 8 is a process explanatory view showing a fourth embodiment of the method for manufacturing the vehicle soundproofing material according to the present invention.

FIG. 9 is an explanatory view showing the installation location of the vehicle soundproofing material.

FIG. 10 is a cross-sectional view showing a configuration of a conventional insulator dash.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Dash panel 11 Automotive insulator dash 12 Dash front insulator 20 Cellulose base material (sound absorbing layer) 21 Nonwoven fabric 30 Mixer 31 Belt conveyor 32 Mixing material 33 Hot air heating furnace 34 Belt 35 Cutting blade 36 Hot air heating furnace 37, 38 Cold press Upper and lower molds for molding 40 Sprayer 41 Water or solution, medicine, etc. 42 Barrier layer 50 Sprayer 51 Hot melt 52 Raw material roll 53 Heat roll 54 Heat belt 55 Cooling roll 56 Cooling belt 57 Coater 60 Dust fixing component

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) B29L 31:30 B29L 31:30 (72) Inventor Tsunamasa Shioya 3316 Miyayama, Samukawa-cho, Koza-gun, Kanagawa Pref. In-house F term (reference) 3D023 BA02 BA03 BB12 BB17 BD04 BD12 BE05 BE31 4F204 AA01 AA24 AA50 AG03 AH17 FA01 FA11 FB01 FB02 FG02 FH06 FJ10 FN15 FQ22

Claims (9)

[Claims] 1. A method of mixing a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material and a resin binder for binding the sound absorbing / sound insulating component in a cotton mixing step, and then forming a matte forming step to form a cellulosic material. The production stage of the cellulosic raw mat for preparing the mat, or after preparing the cellulosic raw mat, laminating a fine nonwoven fabric on at least one surface of the front and back surfaces of the cellulosic raw mat, after heat softening treatment, A method for producing a soundproofing material for vehicles, comprising forming a cellulosic base material into a required shape by press molding. 2. The laminate of the cellulosic web mat and the nonwoven fabric is characterized in that the cellulosic web mat and the nonwoven fabric are bonded and integrated by a fusion action of a resin binder in the cellulosic web mat. Item 2. The method for producing a vehicle soundproofing material according to Item 1. 3. The method according to claim 1, wherein the lamination of the cellulosic raw mat and the nonwoven fabric is performed with an adhesive. 4. The method according to claim 1, wherein the lamination of the cellulosic raw mat and the nonwoven fabric is performed by needle punching. 5. The lamination of a cellulosic raw mat and a non-woven fabric, wherein the two are adhered and fixed by the stickiness of cellulose generated when water is sprayed or applied to the cellulosic raw mat. The method for producing a soundproofing material for a vehicle according to Claim 1. 6. Cellulose produced by mixing a sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material and a resin binder for binding the sound absorbing / sound insulating component in a cotton mixing process, and then forming the mat by a mat forming process. After spraying or applying water or a solution, a chemical, or the like to at least one of the front and back surfaces of the raw material mat, and fixing the dust component, heat softening treatment is performed, and the cellulosic raw material mat is press-molded into a required shape. A method for producing a soundproofing material for vehicles, comprising forming a cellulosic base material by heating. 7. After mixing a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material and a resin binder for binding the sound absorbing / sound insulating component in a cotton mixing step, a cellulosic raw material is mixed in a mat forming step. A mat is prepared, hot melt is applied to at least one surface of the cellulosic raw mat, the hot melt is stretched over a wide area of the cellulosic raw mat, solidified by cooling, and after fixing the dust component, heat softening. A method for producing a soundproofing material for a vehicle, comprising performing a treatment and press-molding into a required shape to form a cellulosic base material. 8. After mixing a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material and a resin binder for binding the sound absorbing / sound insulating component in a cotton mixing step, a cellulosic raw material is mixed in a mat preparation step. A method for manufacturing a soundproofing material for a vehicle, in which a mat is produced, and then, after heating and softening the cellulosic raw mat, press-molding into a required shape to form a base material. A method for producing a soundproofing material for a vehicle, comprising fixing a dust component of cellulose by mixing water or a liquid adhesive. 9. A method in which a sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material and a resin binder for binding the sound absorbing / sound insulating component are mixed in a cotton blending step, and then a cellulosic material is produced in a mat making step. A method of manufacturing a soundproofing material for a vehicle, in which a mat is produced, and then, after heating and softening the cellulosic raw material mat, press-molding into a required shape to form a base material. Manufacturing of a soundproofing material for vehicles, wherein a polysaccharide is added in a solid state, a solution or a liquid state, and the polysaccharide becomes a gel state in a heating and softening treatment step of a cellulosic raw material mat to fix a dust component of cellulose. Method.