JP2002178848A - Soundproof material for vehicle and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a soundproof material for a vehicle at a low cost appropriate for recycle and made of opened fabric of cellulose having excellent sound absorbing performance and a crushed material as a base material. SOLUTION: This soundproof material is formed of a sound absorbing and cutting component based on the cellulose-based opened fabric material and the crushed material and a resin binder for connecting the sound absorbing and cutting component, and molded into the shape of a car body panel. A high melting point synthetic resin fiber, a natural fiber or a recycled material is added. The cellulose-based material 20 such as an insulator dash 10 or the like is directly molded in a mold, or a cellulose raw mat M is manufactured by a chip urethane manufacturing method or a non-woven fabric manufacturing method, and a thermal softening processing is performed, and thereafter, the soundproof material is formed into a required shape by pressing.

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 soundproofing material for vehicles suitable for floor carpets and the like and a method for producing the same, and in particular, a soundproofing material for vehicles based on a cellulose-based defibrated material or pulverized material which is inexpensive and has excellent sound absorbing performance, and which is suitable for recycling. It relates to a manufacturing method.

[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.

In the engine room E, a dash front insulator 3 is installed on the side of the engine room E of the dash panel 1a, and a hood insulator 4 is installed on the inner surface of the engine room E of the hood panel 4a. 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-described sound-insulating 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.

In addition, 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 soundproofing material for vehicles, such as an insulator dash, a floor carpet, and a hood insulator, which can be applied to a wide range, and a method of manufacturing the same. Regardless, it is an object of the present invention to provide a soundproofing material for vehicles that can maintain good sound absorption and sound insulation performance and is suitable for recycling, and a method for manufacturing the same.

[0012]

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. It consists of a resin binder that binds sound insulation components,
It is characterized by being press-formed according to the shape of the vehicle body panel.

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 thermoplastic type, such as a fusible fiber such as low melting point PET, a resin powder such as PE (polyethylene) resin, or a reactive adhesive (for example, urethane). Resin-based adhesive) can be used. In the thermosetting resin type, a thermosetting resin such as a phenol resin can be used.

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: 10
Set between 20:80. When the softness or sound absorption performance is required depending on the application, the compounding ratio is adjusted to rich sound absorbing and sound insulating components, and when the rigidity and sound insulating performance are required, the compounding ratio is adjusted to resin binder rich. I do.

Here, the soundproofing material for a vehicle can be applied to an insulator dash, a floor carpet, a hood insulator, a dash front insulator, a roof trim, a trunk trim and the like.

According to the first aspect of the present invention,
If natural fibers made of cellulose, recycled materials, or recycled materials are used as the main fibers, and those with small fiber diameters are selectively used, the sound absorption performance can be improved, and at the same time, fibrous defibrated or crushed materials Is a sound absorbing / sound insulating component, so that the surface area is large, so that sound absorbing / sound insulating performance can be enhanced. In addition, entanglement with the resin binder is strengthened, and rigidity and strength can be increased.

Furthermore, it is also possible to make incinerators and recyclable scrap materials and products after use, which is also preferable in terms of environmental measures.
Alternatively, the use of a pulverized material is advantageous in cost.

Further, when used as a base material for interior parts having soundproofing properties, a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material may be used depending on the sound absorbing / sound insulating performance required of the base material. By appropriately varying the mixing ratio of the resin and the binder or selecting the fiber diameter of the cellulosic defibrated material, a soundproofing material suitable for the intended use can be obtained.

Next, the invention according to claim 2 of the present application is characterized in that a high melting point synthetic fiber for improving sound absorption is added to the sound absorbing and sound insulating component.

Here, the high melting point synthetic fiber added to the sound absorbing / insulating component is 0.2 to 30 denier, 2 to 8 denier.
Synthetic fiber having a fiber length of 0 mm, preferably a fiber length of 10 to 64 mm, for example PET, PP, PE, P
Synthetic fibers such as A (polyamide resin) can be used.

According to the second aspect of the present invention,
Sound absorption based on cellulosic defibrated material or crushed material
When high melting point synthetic fiber is added to the sound insulation component,
Sound absorption performance and moldability can be improved.

Next, the invention according to claim 3 of the present application is characterized in that natural fibers are added to the sound absorbing and sound insulating components.

Here, as the natural fibers, bamboo, hemp, kenaf, banana, jute, coconut, etc. are used in the form of fibrillated fibers. To various properties and properties.

According to the third aspect of the present invention,
Sound absorption based on cellulosic defibrated material or crushed material
It is a configuration that natural fibers are added to the sound insulation component, and various properties and physical properties can be given to the sound absorbing material by the natural fiber material to be added.For example, if hard fibers such as bamboo fiber are added, the resin binder Even if the amount is reduced, sufficient rigidity can be secured, the recyclability is high, and the cost is advantageous.

Next, the invention described in claim 4 of this application is characterized in that a fibrillated or pulverized recycled material is added to the sound absorbing / sound insulating component.

Here, the recycled materials include industrial wastes such as offcuts generated in the interior material manufacturing process, used interior materials and exterior materials, and automobile-related waste materials, as well as carpets, fabrics, and synthetic resin moldings. Crushes general waste such as products,
A defibrated recycled material may be used.

According to the fourth aspect of the present invention,
Sound absorption based on cellulosic defibrated material or crushed material
Recycling material is added to the sound insulating component, which leads to a reduction in the amount of waste discharged, and various properties and physical properties can be imparted to the sound insulating material by selecting the property of the waste.

The invention according to claim 5 of the present application is to mix a sound absorbing / sound insulating component based on a cellulosic fibrillated or pulverized material with a resin binder, and then spray the mixed material into a mold. Then, the soundproof material for a vehicle is formed in accordance with the shape of the vehicle body panel by applying a press pressure and blowing hot air or steam into the forming die.

According to this method, a soundproof material for vehicles is directly formed without passing through a raw material mat. When the resin binder is a heat-fusible fiber or a thermoplastic resin powder, a mixed material is formed. The sound-absorbing material is obtained by combining the sound absorbing / sound insulating component and the resin binder by filling the mold and blowing hot air or high-temperature steam through a hole formed in the surface of the mold.

When a reactive adhesive (for example, urethane-based resin) is used as the resin binder, the mixed material is filled in a mold, and high-temperature steam is blown into the inside through a hole formed in the surface of the mold. To react the adhesive, thereby combining the sound absorbing / sound insulating component with the resin binder to obtain a soundproofing material.

Since the chemical structure of the sound-absorbing and sound-insulating components contains a hydroxyl group, hydrogen bonds are generated by water vapor between the polymer chains of cellulose, and a strong soundproofing material which is less likely to generate dust is obtained.

When a thermosetting resin such as a phenol resin is used as the resin binder, a mixed material is filled in a mold, and the phenol resin is cured by heat of a high-temperature mold to form a soundproof material. At this time, the dust component is solidified by the thermosetting resin, and a strong soundproofing material that is less likely to generate dust is obtained.

Next, the invention according to claim 6 of the present application is to mix a sound-absorbing / sound-insulating component based on a cellulosic defibrated material or a crushed material with a resin binder and then put the mixed material in a container. Filling, blowing hot air or steam while applying pressure, cutting and slicing as necessary to produce a cellulosic raw mat having a predetermined thickness. The sound-insulating material for a vehicle is press-formed in accordance with the shape of the vehicle.

Further, the invention according to claim 7 of the present application is to mix a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material with a resin binder and then form the mixed material into a mat shape. The cellulosic material mat is produced by depositing, blowing hot air, and performing compression processing, and after heating and softening the cellulosic material mat, press-molding the soundproofing material for vehicles according to the shape of the vehicle body panel. Features.

Here, in the case where a cellulosic raw mat is once formed from the mixed material and a soundproofing material is manufactured by press-molding the cellulosic raw mat, the following method is used for producing the raw mat. There is.

For example, a container is filled with the mixed material, and hot air or high-temperature steam is blown in a state where the mixed material is maintained at a desired thickness. The high temperature combines the sound absorbing / sound insulating component with the resin binder to form a cellulosic raw mat. Is prepared.

When water vapor is blown, sound absorption
Hydrogen bonds are generated by water vapor between the polymer chains of cellulose, which is a sound insulating component, and a strong cellulose-based raw mat that is less likely to generate dust is obtained.

It is also possible to form a raw mat by continuously depositing the mixed material on a belt conveyer, passing hot air through the belt while applying pressure, and combining the sound absorbing / sound insulating component with the resin binder by the high temperature. good.

Further, a method of filling a mixed material and passing hot air through the mixed material to form a cellulosic material mat without continuous deposition, a method of forming a cellulosic material mat in a high-temperature atmosphere of a constant temperature bath or a heating furnace, or the like. An anti-matting method is also conceivable.

In addition, a soundproofing material can be obtained by mixing a thermosetting resin with a sound absorbing / sound insulating component by a method such as spraying.

According to the invention as set forth in claim 6 or 7, a cellulosic raw material mat is once produced from the mixed material, and then a soundproofing material for a vehicle is formed by press working. When high-temperature steam is blown, hydrogen bonds are generated between the polymer chains of the cellulose as a sound-absorbing and sound-insulating component, and a strong raw mat that is less likely to generate dust is obtained. Therefore, the transporting process and the setting process can be performed smoothly in the actual molding equipment, and the rigidity of the obtained molded product is high.

Further, when producing a cellulosic raw material mat, if hydrogen bonds are not generated between polymer chains of cellulose which is a sound absorbing / sound insulating component, cellulose having good elongation at high temperature and good moldability can be obtained. A raw mat is obtained.

Next, the invention described in claim 8 of the present application is to provide a sound absorbing / sound insulating component, which is mixed with a liquid binder, then developed as required, and a powdery additive is sprayed, and each component is dispersed. Is characterized in that uniform mixing is enabled.

According to the eighth aspect of the present invention,
Since the sound-absorbing and sound-insulating components are moistened with a liquid binder, the powdery additives are well adsorbed by the sound-absorbing and sound-insulating components, which prevents the powdery additives from falling downward due to gravity. Can be prevented and uniform mixing can be achieved.

[0047]

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

FIG. 1 is a cross-sectional view showing a first embodiment in which the soundproofing material for a vehicle according to the present invention is applied to an insulator dash for a vehicle, and FIGS. 2 and 3 show a first embodiment (original) of a method for manufacturing the insulator dash. FIG. 4 and FIG. 5 are a chart diagram and a process explanatory diagram showing a method of directly molding a molded product without passing through an anti-mat, and FIGS. 4 and 5 show a second embodiment (molding via an original mat) of the same manufacturing method of the insulator dash. FIG. 6 to FIG. 8 show another embodiment of the vehicle soundproofing material according to the present invention, and FIG. 6 is a schematic diagram applied to an insulator dash. 7 is an example in which the waste material is pulverized and added to the substrate, and FIG. 8 is a correlation diagram of the cost and the mixing ratio of the substrate.

A first embodiment of the present invention will be described with reference to FIG. In the drawings, an automotive insulator dash 10 is mounted on the interior surface side of a dash panel 11 that partitions an engine room E and a vehicle compartment R, and is a cellulose-based base material that is an embodiment of a vehicle soundproofing material according to the present invention. It comprises a two-layer structure in which a sound insulating material 12 such as a high-density recycled rubber sheet or a recycled PVC sheet is laminated and integrated on the surface of a material 20.

The sound insulating material 12 has an area density of 2 to 8 kg.
/ M ² , and is press-integrated with the cellulosic substrate 20. Although the sound insulating material 12 exhibits good sound insulating properties due to the double-wall sound insulating function of the dash panel 11 and the sound insulating material 12, the sound insulating material 12 is eliminated and the insulator is formed of a single layer of the cellulosic base material 20. The dash 10 may be configured, and a high-density nonwoven fabric or film may be applied instead of the recycled rubber sheet.

On the other hand, the cellulosic base material 20 is configured based on a sound absorbing / sound insulating component combined with a resin binder. The sound-absorbing and sound-insulating components are components composed of cellulose. Specifically, pure pulp, regenerated cellulose, waste paper (old newspapers, old magazines, corrugated cardboard, etc.), plants such as wood, and chemically decorated and Processed celluloses,
Use industrial wastes (which may be sludge-like or wet) derived from natural materials generated in the paper industry, etc., if necessary, and use them as defibrated or crushed. To form a fibrous or powdery material.

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, a low melting point PET is added to a pulverized material obtained by defibrating 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 the range of 0 to 20:80. For example, in a case where the sound absorbing performance or the soft feeling is required, the mixing ratio is set to a rich sound absorbing and sound insulating component, and the rigidity and the sound insulating performance are set. For applications that require, the range of use of the cellulosic base material 20 can be greatly expanded by appropriately selecting a resin binder-rich compounding ratio.

The cellulosic base material 20 laminated on the back surface of the sound insulating material 12 of the insulator dash 10 has a sound absorbing / sound insulating component / resin binder = 80: 20 and a surface density and a thickness of the cellulosic base material 20 of 1 respectively. , 0
It is set to 00 g / m ² and 20 to 30 mm.

Therefore, since the cellulose-based substrate 20 has a structure in which a natural material made of cellulose, a recycled material, and a recycled material are used as a base, the use of a material having a small fiber diameter improves the sound absorbing performance. Can also
Scraps and used products can be incinerated and recyclable, and the use of defibrated or crushed waste materials such as waste paper is very advantageous in terms of cost.

Also, unlike the string shape obtained with a shredder or the like, since the surface area is large, the sound absorption and sound insulation performance is high.
Since the entanglement with the resin binder is increased, the strength of the product can be increased.

Further, in order to particularly enhance the sound absorbing performance of the sound absorbing / sound insulating component, it is possible to add a high melting point fiber.
In that case, as the high melting point fiber, high melting point PET, PP,
It can be appropriately selected from synthetic fibers such as PE and PA (polyamide resin), and if a high melting point synthetic fiber having a fiber diameter of 0.2 to 30 denier and a fiber length of 2 to 80 mm (preferably 10 to 64 mm) is added, Sound absorbing performance can be improved.

Next, a first embodiment of the method for producing the cellulosic base material 20 will be described with reference to FIGS.

In the first embodiment, as shown in the chart of FIG. 2, a sound absorbing / sound insulating component and a resin binder component are mixed and stirred in a mixer, and then dispersed in a molding die.
The molding of the cellulosic base material 20 is completed by blowing hot air or water vapor while pressing, and as shown in FIG. 3, a sound absorbing / sound insulating component and a resin binder are placed in the cavity of the lower molding die 30. Is sprayed in a mold, and then the upper mold 31 is lowered to blow hot air or steam into the mold,
Sound absorption and sound insulation components are entangled by the resin binder. At this time, as described above, the mixed material a mixed at a mixing ratio of sound absorbing / sound insulating component / resin binder = 80: 20 has a thickness of 5 to 30 m due to the clearance between the upper and lower molds 30 and 31.
It is molded so as to have an m average and an areal density of 1000 g / m ^2, and the cellulosic base material 20 is obtained.

Although the cellulosic base material 20 itself can be used as a sound insulating material, when the laminated structure shown in FIG. 1 is used, the sound insulating material 12 is laminated on the surface side of the cellulosic base material 20. The molding of the insulator dash 10 for a vehicle is completed by integration.

In the first embodiment, a pulverized waste paper is used as a sound absorbing / sound insulating component, and a heat-fusible fiber made of a low melting point PET resin is used as a resin binder. However, hot melt adhesive such as polyethylene resin powder is used. Even if an adhesive or a reactive adhesive such as a urethane-based adhesive is used, the cellulose-based substrate 20 can be formed into a desired shape by the same method.

Further, when water vapor is blown in as in the above-described method, since the chemical structure of cellulose contains hydroxyl groups, hydrogen bonds are generated between the polymer chains of cellulose by water vapor, and this hydrogen bond is formed. Strong cellulosic base material 20 that fixes dust components and is less likely to generate dust
And dust is not scattered in the vehicle interior, which is preferable from the viewpoint of environmental health in the vehicle interior.

Although not shown, when a thermosetting resin is used, the molding dies 30, 31 are heated to a high temperature.
What is necessary is just to cure the thermosetting resin to form the cellulosic base material 20.

Next, FIG. 4 and FIG.
FIG. 4 shows a second embodiment of the manufacturing method of FIG.
As shown in the chart diagram, after mixing the sound absorbing / sound insulating component and the resin binder, filling the container, blowing hot air or steam while applying pressure, and then performing slicing to obtain a raw material mat M having a predetermined thickness. After the softening treatment of the raw material mat M, the cellulosic base material 20 is formed by press molding.

That is, as shown in FIG. 5, a mixed material a in which a sound absorbing / sound insulating component and a resin binder were mixed was charged into a container 40, and a pressing plate 41 was lowered to apply a predetermined press pressure. Then, hot air or steam is blown into the inside through holes provided in the container 40 and the lid 42 to combine the sound absorbing / sound insulating component with the resin binder, and the cutting blade 4
Slice processing is performed to a predetermined thickness according to 3 to prepare a cellulosic raw material mat M.

When the resin binder is a thermoplastic resin, the cellulosic raw material mat M is heated and softened in a heating furnace 44, and then the cellulosic material mat M having the desired shape is formed by clamping the cold press molds 45 and 46. The substrate 20 is obtained.

Also in this case, the cellulosic substrate 2
If desired, the sound insulating material 12 may be laminated and integrated on the surface side of the surface 0. Particularly, if a thermoplastic raw mat is used, simultaneous heating and simultaneous molding become possible.

Further, also in this manufacturing method, by blowing water vapor, hydrogen bonds are generated between the polymer chains of the cellulose, which is a sound absorbing / sound insulating component, by the water vapor, so that a cellulosic raw material mat M which is less likely to generate dust is obtained. For,
A good working environment can be ensured without dust components scattered in the preheating equipment and the molding equipment.

In addition, since the cellulosic raw material mat M is strong, not only does it not hinder conveyance in actual molding equipment, but also the obtained insulator dash 10 itself has high product rigidity.

In place of the above-described manufacturing method, the mixed material is continuously deposited on a belt conveyor, and hot air is passed while applying a pressing pressure to the mixed material.
The sound absorbing / sound insulating component and the resin binder may be combined to produce the cellulosic raw material mat M. Even if the material is not continuously deposited, for example, a mixed material is filled and hot air is passed through the material. A method for preparing a cellulosic raw material mat M,
It is also conceivable to use a cellulosic raw material mat M in a high temperature atmosphere of a thermostat or a heating furnace.

The cellulose-based raw mat M
The advantage of this method is that strong bonds due to hydrogen bonds do not occur between polymer chains of cellulose, which is a sound absorbing and sound insulating component, so that moldability is good (elongation at high temperature is good).
There is an advantage that the cellulosic raw material mat M can be obtained.

Although the method for manufacturing the insulator dash 10 for a vehicle has been described in detail with reference to FIGS. 1 to 5, the soundproofing material for a vehicle according to the present invention is different from the insulator dash 10 described above in addition to the carpet material in a floor carpet. May be used as a sound-absorbing layer laminated on the back surface of the car. Good to do.

When used as a sound absorbing layer for a molded ceiling installed in a roof panel, a hood insulator in an engine room, a dash front insulator, or the like, the composition is made rich in a resin binder in order to obtain heat resistance and rigidity. Good to do.

In addition, it can be used as a sound absorbing layer for a trunk trim, a luggage trim, a wheel house trim, or the like, and can also be used by attaching a block-like cellulose-based mat to the back surface of an interior part.

FIGS. 6 to 8 show another embodiment of the vehicle soundproofing material according to the present invention. FIG.
FIG. 7 is a schematic diagram showing a state in which natural fibers are added to the sound insulation component.
FIG. 8 is a schematic diagram showing a state in which a recycled material is added to the sound absorbing and sound insulating components, and FIG. 8 is a correlation diagram of a cost-composition ratio showing a cost merit by adding the recycled material.

First, the insulator dash 10 shown in FIG.
Is composed of a laminate of a sound insulating material 12 and a cellulosic base material 20. The cellulosic base material 20 is composed of a sound absorbing / sound insulating component 21 bonded by a resin binder, and a sound absorbing / sound insulating component and a resin binder component. In addition to natural fiber 2
2 has been added. As the natural fiber, a fibrous fiber such as bamboo, hemp, kenaf, banana, jute, and palm is used.

Therefore, since natural fibers are inexpensive, adding natural fibers does not increase the cost.
Each type of the natural fiber 22 has various characteristics and can impart various properties and physical properties.

For example, if hard fibers such as bamboo fibers are added, rigidity can be secured, so that the amount of the resin binder can be reduced, which contributes to cost reduction and does not hinder recyclability at all. Absent.

The fiber length of the natural fiber 22 is 2
Although the moldability and rigidity increase as the fiber length increases, it is difficult to mix with a sound absorbing / sound insulating component or a resin binder.
A range of the order is practically preferable.

Next, FIG. 7 shows a sound absorbing / insulating component 21 to which a crushed product of a floor carpet 50 as a recycled material 23 is added. The resin backing layer 52 on the back of the carpet ground 51 is made of EVA (ethylene vinyl acetate). Copolymer),
The material is a thermoplastic resin such as PP (polypropylene) and PE (polyethylene).

Thus, as the recycled material 23,
Industrial waste such as offcuts generated in the interior material manufacturing process, interior materials after use, resin exterior materials such as bumpers, and the like can be used. The crushed material and the defibrated material are not limited to automobile-related waste materials, and general waste materials such as carpets, fabrics, and synthetic resin molded products can also be used.

If the recycled material 23 is added to the sound absorbing / sound insulating component 21, it becomes an inexpensive bulking material.
The amount of sound insulation components and resin binder can be reduced, which contributes to cost reduction and also reduces waste emissions.

Further, if the properties of the recycled material 23 are selected, various properties and physical properties can be imparted to the soundproofing material. For example,
As shown in FIG. 7, when a pulverized waste product containing a large amount of a fusing component, such as the resin backing layer 52, is added as in the case of the scraps of the floor carpet 50 shown in FIG. Is not reduced, so that the cost is further reduced.

As shown in FIG. 8, the relationship between the blending ratio of the recycled material 23 and the product cost is apparently increased as the blending ratio of the recycled material 23 is increased.

Next, when the recycled material 23 is added to the sound absorbing / sound insulating component and the resin binder, the following procedure is effective to uniformly mix the mixed materials. First, a liquid resin binder, for example, a reactive adhesive (urethane resin) or water is mixed with the sound absorbing and sound insulating components using a mixer or a sprayer. Then, the powdered recycled material 23 is sprayed while being mixed or in a developed state. Therefore, since the sound absorbing / sound insulating component is in a wet state, the powdered recycled material 23 is well adsorbed by the sound absorbing / sound insulating component. The inconvenience that proper mixing is not performed can be effectively solved, and uniform mixing can be achieved.

[0086]

As described above, the soundproofing material for a vehicle according to the present invention is a sound absorbing / sound insulating component based on a defibrated or crushed product made of cellulose and a resin binder for binding the sound absorbing / sound insulating component. In addition to the effects of using a sound absorbing and sound insulating component made of cellulose, which is inexpensive, high performance, and suitable for environmental measures, it also has a rich sound absorbing and sound insulating component and a resin binder depending on the application. Rich, etc., the mixing ratio can be selected as appropriate, and by selecting the fiber diameter of the defibrated material and the particle size of the pulverized material,
This has the effect of obtaining a useful vehicle soundproofing material in consideration of the required soundproofing performance and strength.

Further, as a method for producing a soundproofing material, if a base material is formed by adding hydrogen bonds to the cellulose component by steam heating to suppress the generation of dust, the working environment and the environmental hygiene in the vehicle compartment can be improved. It has the effect of being more favorable.

Further, if a cellulosic raw material mat is produced in a constant temperature bath or hot air heating without generating hydrogen bonds, and then a cellulosic base material is molded, it can be molded into a complicated shape because of its excellent elongation characteristics. It has the effect of being excellent in moldability.

Further, if natural fibers or recycled materials are added to the sound absorbing / sound insulating components, the sound absorbing / sound insulating components have strength,
Various properties and physical properties such as rigidity can be improved, and the cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an embodiment in which a soundproofing material for a vehicle according to the present invention is applied to a cellulosic base material of an insulator dash for a vehicle.

FIG. 2 shows a first method for producing the cellulose-based substrate shown in FIG.
It is an embodiment and is a flow chart showing a method of directly forming a substrate from a mixture without passing through a raw mat.

FIG. 3 is a process explanatory view of the construction method shown in FIG. 2;

FIG. 4 shows a second example of the method for producing the cellulosic substrate shown in FIG.
FIG. 3 is an embodiment, and is a chart showing a method of forming a base material from a mixture via a raw mat.

FIG. 5 is a process explanatory view of the chart shown in FIG. 4;

FIG. 6 is a cross-sectional view showing another embodiment in which the vehicle soundproofing material according to the present invention is applied as a cellulosic base material of an automotive insulator dash.

FIG. 7 is an explanatory view showing one embodiment of the vehicle soundproofing material according to the present invention, and showing a state in which a recycled material is added to the sound absorbing and sound insulating components.

8 is an explanatory diagram showing a correlation between a compounding ratio of recycled materials shown in FIG. 7 and a product cost.

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 Insulator dash for automobiles 11 Dash panel 12 Sound insulation material 20 Cellulosic base material 21 Sound absorption / sound insulation component combined with resin binder 22 Natural fiber (bamboo fiber) 23 Recycled material (floor carpet scrap) 30 Mold lower mold 31 Molding upper Mold 40 Container 41 Pressing plate 42 Lid 43 Cutting blade 44 Heating furnace 45, 46 Cold press mold a Mixed material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) G10K 11/162 G10K 11/16 A (72) Inventor Tsunamasa Shioya 3316 Miyayama, Samukawa-cho, Koza-gun, Kanagawa F term in Industrial Co., Ltd. (reference) 3D023 BA02 BB17 BC01 BD12 BE31 4L047 AA08 AA13 AA26 AA28 AA29 AB09 AB10 BA09 BA13 BA15 BB06 BC03 BC12 CA15 CB01 CB03 CB09 CC09 EA22 5D061 AA06 AA22 BB21

Claims (8)

[Claims] 1. A sound absorbing / sound insulating component based on a cellulosic defibrated or crushed material, and a resin binder that binds the sound absorbing / sound insulating component, and are press-formed according to the shape of a vehicle body panel. Soundproofing material for vehicles. 2. The vehicle soundproofing material according to claim 1, wherein a high melting point synthetic fiber for improving sound absorption is added to the sound absorbing / sound insulating component. 3. The soundproofing material for a vehicle according to claim 1, wherein a natural fiber is added to the sound absorbing / sound insulating component. 4. The soundproofing material for a vehicle according to claim 1, wherein a fibrillated or crushed recycled material is added to the sound absorbing / sound insulating component. 5. After mixing a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material and a resin binder, the mixed material is sprayed into a molding die, press-pressed and molded. A method for manufacturing a soundproofing material for a vehicle, characterized by forming a soundproofing material for a vehicle according to the shape of a vehicle body panel by blowing hot air or steam into a mold. 6. After mixing a sound absorbing / sound insulating component based on a cellulosic fibrillated or crushed material with a resin binder, the mixed material is filled in a container, and hot air or steam is blown while pressurizing. Cut as needed,
A vehicle characterized by producing a cellulosic raw mat having a predetermined thickness by slicing, heating and softening the cellulosic raw mat, and then press-molding a soundproofing material for a vehicle according to the shape of a vehicle body panel. Manufacturing method of soundproofing material. 7. After mixing a sound absorbing / sound insulating component based on a cellulosic defibrated material or a crushed material and a resin binder, the mixed material is deposited in a mat shape, and hot air is blown while pressurizing to form a cellulose. Make a raw material mat,
A method for producing a soundproofing material for a vehicle, comprising subjecting the cellulosic material mat to heat softening treatment and then press-molding the soundproofing material for a vehicle according to the shape of a vehicle body panel. 8. The method according to claim 1, wherein a liquid binder is mixed with the sound-absorbing and sound-insulating components, and then, if necessary, the developing agent is brought into a developed state, and a powdery additive is sprayed to enable uniform mixing of each component. A method for manufacturing the vehicle soundproofing material according to claim 4.