JP2006111256A - Sound absorbing mat and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a sound absorbing mat securing sufficient bonding strength, decreasing an environment load, and having excellent productivity and sound absorbing characteristics. <P>SOLUTION: The manufacturing method includes steps of: stretching melting hot-melt resin discharged from an application nozzle hole by making air flow jetted from an air flow forming nozzle hole contact with the melting hot-melt resin to form it into fibers, and forming a resin application layer by applying the curtain-shaped hot-melt resin 24 formed from these fiber elements on a nonwoven fabric 23; and superimposing the application surface of the nonwoven fabric 23 with a skin material 22 and pressurizing them. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a sound-absorbing mat that is suitably used as an automobile floor mat.

Conventionally, a floor mat for an automobile has a configuration in which a backing resin layer made of a soft resin material is laminated and integrated on the back side of a skin material such as a carpet base material in which a pile is planted on the front side. However, since this structure is heavy and hardly obtains a sound absorbing effect, in recent years, a structure in which a nonwoven fabric is bonded to the back side of the skin material with a latex emulsion (see Patent Document 1) is used. It is getting to be. In this configuration, since the nonwoven fabric is used, the weight can be reduced, and noise such as noise is absorbed when passing through the nonwoven fabric layer, so that a certain level of sound absorption effect can be obtained.
JP 2004-17882 A (Claim 1, paragraphs 0021 to 0023)

  However, in the configuration in which the latex emulsion is bonded and integrated by application and drying, there is a problem that the air permeability of the adhesive layer cannot be sufficiently secured, and thus sufficient sound absorption performance cannot be secured. On the other hand, if the coating amount of the latex emulsion is reduced to ensure air permeability, there arises a problem that sufficient adhesive strength cannot be obtained.

  Moreover, in order to dry a latex emulsion, the hot air drying process must be provided, and there also existed a problem that productivity fell for this reason. There is also a problem that the power consumption of the heat source during drying is large.

  Furthermore, when the latex emulsion is dried with hot air, for example, styrene monomer, ethylbenzene and the like are volatilized, which is not preferable in terms of environment.

  The present invention has been made in view of such a technical background, and is capable of ensuring sufficient adhesive strength, has a low environmental load, is excellent in productivity, and has a sound absorbing mat with excellent sound absorbing characteristics, and A manufacturing method thereof is provided.

  In order to achieve the above object, the present invention provides the following means.

  [1] In a sound-absorbing mat in which a skin material layer and a sound-absorbing layer are bonded and integrated through a gas-permeable adhesive resin layer, the gas-permeable adhesive resin layer is a fibrous material obtained by discharging from a coating nozzle hole. A sound-absorbing mat comprising a porous hot-melt resin layer formed by applying a molten hot-melt resin.

  [2] The sound absorbing mat according to item 1, wherein the sound absorbing layer is made of a nonwoven fabric.

[3] The sound-absorbing mat according to item 1 or 2, wherein the basis weight of the hot melt resin layer is 20 to 400 g / m ² .

  [4] The sound-absorbing mat according to any one of [1] to [3], wherein the hot-melt resin layer contains an olefin resin.

  [5] The sound absorbing mat according to any one of [1] to [3], wherein the hot melt resin layer is made of a resin composition containing an olefin resin and a rubber component.

  [6] The sound-absorbing mat according to item 4 or 5, wherein an amorphous polyα-olefin resin is used as the olefin resin.

  [7] The hot melt resin is formed into a fibrous form by bringing the molten hot melt resin discharged from the application nozzle hole into contact with the air stream ejected from the air stream forming nozzle hole and stretching it. A sound-absorbing method comprising a step of forming a resin-coated layer by applying a curtain-like hot melt resin on a nonwoven fabric, and a step of pressing a skin material on the coated surface of the nonwoven fabric. Manufacturing method of mat.

  [8] The hot melt resin discharged from the application nozzle hole is brought into contact with the molten hot melt resin discharged from the air flow forming nozzle hole and stretched to bring the hot melt resin into a fibrous form, and the adjacent fibrous bodies are brought into contact with each other. Including a step of forming a resin-coated layer by applying a curtain-like hot melt resin formed on the nonwoven fabric, and a step of pressing the skin material on the coated surface of the nonwoven fabric. A method for producing a sound-absorbing mat.

  [9] The method for producing a sound-absorbing mat according to the above item 7 or 8, wherein the hot-melt resin contains an olefin resin.

  [10] The method for producing a sound-absorbing mat as described in [7] or [8], wherein the hot melt resin contains an olefin resin and a rubber component.

  [11] The method for producing a sound-absorbing mat as described in 9 or 10 above, wherein an amorphous polyα-olefin resin is used as the olefin resin.

  In the invention of [1], the breathable adhesive resin layer is composed of a porous hot melt resin layer formed by applying a fibrous hot melt resin obtained by discharging from the application nozzle hole. The air flow rate of the layer can be controlled within a suitable air flow rate range in relation to the sound absorption characteristics, and the air flow rate of the adhesive resin layer can be set to a desired specific amount with high accuracy. (Adjustment is easy) Good sound absorption performance can be secured, and flexibility as a mat is not impaired. In addition, since the adhesive resin layer is formed by applying a fibrous hot melt resin obtained by discharging from the application nozzle hole, the resin constituting the adhesive layer is uniformly applied, thereby increasing the adhesive strength. Is obtained. In addition, application by discharging from the application nozzle hole can sufficiently be applied even in a small amount, and thus a high adhesive force can be secured even with a small amount of application. A quality sound-absorbing mat is provided. Furthermore, since an emulsion is not used as the adhesive, a hot air drying step is not required, the productivity is good, and the environment protection can be sufficiently handled.

  In the invention [2], since the sound absorbing layer is made of a nonwoven fabric, the sound absorbing performance can be further improved and the flexibility as a mat can be improved.

In the invention [3], since the basis weight of the hot melt resin layer is 20 to 400 g / m ^2, it is possible to further improve the sound absorbing performance while ensuring sufficient adhesive strength.

  In the invention of [4], since the hot melt resin layer contains an olefin resin, sufficient heat resistance and water resistance as a mat can be ensured.

  In the invention of [5], the hot melt resin layer employs a structure comprising a resin composition containing an olefin resin and a rubber component. Olefin-based resins tend to be relatively difficult to stretch even when brought into contact with the airflow ejected from the airflow forming nozzle holes when discharged from the application nozzle holes, and the application state tends to be slightly uneven. However, when the rubber component is contained, the resin is modified, and when the airflow is brought into contact, the resin is sufficiently stretched without being cut, and the coating state becomes uniform.

  In the invention of [6], since the amorphous poly-α-olefin resin is used as the olefin resin, the adhesive strength can be further improved.

  In the inventions of [7] and [8], the hot melt resin is made fibrous by bringing the melt hot melt resin discharged from the application nozzle hole into contact with the air stream ejected from the air stream forming nozzle hole and stretching it, Since a curtain-like hot melt resin formed of these fibrous bodies is applied onto the nonwoven fabric to form a resin coating layer, a very fine porous adhesive resin layer can be formed. Thus, a mat having good sound absorption performance can be manufactured. That is, it is possible to control the air flow rate of the adhesive resin layer within a suitable air flow rate range in relation to the sound absorption characteristics, and to set the air flow rate of the adhesive resin layer to a desired specific amount with high accuracy ( Fine adjustment of the air flow rate is easy) and good sound absorption performance can be ensured. Moreover, since this application | coating method can apply | coat resin which comprises an adhesive layer uniformly, high adhesive force is securable. Furthermore, this coating method can sufficiently apply even in a small amount, and thus can ensure a high adhesive force even in a small amount of application, and thereby a high-quality sound-absorbing mat with high adhesive strength at low cost. Can be manufactured. In addition, since an emulsion is not used as an adhesive, a hot air drying step is not required, the productivity is good, and the environment can be adequately protected. In the invention of [8], since the adjacent fibrous bodies are brought into contact with each other to form a curtain-like hot melt resin, there is an advantage that the adhesive force of the adhesive resin layer can be further improved.

  In the invention of [9], since the hot melt resin adopts a configuration containing an olefin resin, sufficient heat resistance and water resistance as a mat can be ensured.

  In the invention of [10], the hot melt resin adopts a configuration including an olefin resin and a rubber component. Olefin-based resins tend to be relatively difficult to stretch even when brought into contact with the airflow ejected from the airflow forming nozzle holes when discharged from the application nozzle holes, and the application state tends to be slightly uneven. However, when the rubber component is contained, the resin is modified, and when the airflow is brought into contact, the resin is sufficiently stretched without being cut, and the coating state becomes uniform.

  In the invention of [11], since the amorphous poly-α-olefin resin is used as the olefin resin, the adhesive strength can be further improved.

  As shown in FIG. 1, the sound-absorbing mat (1) of the present invention comprises a skin material layer (2) and a sound-absorbing layer (3) that are bonded and integrated through a breathable adhesive resin layer (4). The air-permeable adhesive resin layer (4) is composed of a porous hot melt resin layer formed by applying a fibrous molten hot melt resin obtained by discharging from the application nozzle hole. In the present embodiment, the sound absorbing layer (3) is composed of a nonwoven fabric.

  Examples of the fibrous hot melt resin obtained by discharging from the coating nozzle hole include, for example, an air flow (air flow, inert gas) ejected from the air flow forming nozzle hole to the molten hot melt resin discharged from the coating nozzle hole. For example, a hot melt resin made into a fibrous form (a fibrous body of a hot melt resin) by contacting and stretching a gas stream or the like. A porous hot melt resin layer is formed by applying the fibrous body to, for example, a skin material layer or a sound absorbing layer.

  According to the sound-absorbing mat (1) of the present invention, the breathable adhesive resin layer (4) is a porous hot melt formed by applying a fibrous hot melt resin obtained by discharging from a coating nozzle hole. Since it consists of a melt resin layer, sufficient air permeability can be obtained and good sound absorption performance can be secured, and flexibility as a mat is not impaired. Further, since the adhesive resin layer (4) is formed by applying a fibrous hot melt resin obtained by discharging from the application nozzle hole, the resin constituting the adhesive layer is uniformly applied, thereby High adhesive strength can be obtained. Furthermore, it is possible to apply even a small amount evenly by discharging from the application nozzle hole, so that a high adhesive force can be ensured even with a small amount of application, thereby reducing the cost and the high adhesive force. A quality sound-absorbing mat (1) is provided.

  The sound absorbing mat (1) of the present invention is manufactured, for example, as follows. First, the curtain spray coating device (21) will be described. As shown in FIG. 4, the coating device (21) includes a nozzle head portion (9) and a supply control valve (10) for controlling the supply of the adhesive. As shown in FIG. 5, a large number of application nozzle holes (11) are formed on the bottom surface of the nozzle head portion (9), and a large number of airflows are forward of the application nozzle holes (11) in the transport direction. The forming nozzle holes (12A) are formed, and a number of airflow forming nozzle holes (12B) are also formed on the rear side in the transport direction of the coating nozzle hole (11). The coating nozzle holes (11) are connected to the resin supply machine (15) via the supply control valve (10). The airflow forming nozzle holes (12A) (12B) are connected to a pressurized air supply machine (14) via a pressurized air hole (13). The nozzle head section (9) and the supply control valve (10) are provided with heaters (not shown) so that the hot melt resin being supplied can be maintained at a predetermined temperature. Yes.

  The supply control valve (10) includes an inlet (31) for introducing hot melt resin from the resin supply machine, a supply port (32) for supplying resin to the nozzle head section (9), and a hot melt resin to the resin supply machine. Return port (33) is provided, and these inlet (31), supply port (32) and return port (33) are all connected to the valve chamber (34) in the supply control valve (10). ing. In the valve chamber (34), a valve body (35) movable up and down is disposed. The valve body (35) is controlled to move up and down by the valve body operation mechanism (36), and the supply start, stop, and supply amount of the hot melt resin are controlled by these. ing.

  2 and 4, the nonwoven fabric (23) is conveyed at a constant speed from the right to the left in the drawing. Next, molten hot melt resin is discharged from the coating nozzle holes (11) of the curtain spray coating device (21) disposed above. The thread-like (or fibrous) hot-melt resin is lowered by the discharge, but is stretched by the contact of the air flow forming nozzle holes (12A) (12B) with the thread-like resin. Thus, the resin becomes fibrous, and a curtain-like hot melt resin (24) is formed by these fibrous bodies. At this time, as shown in FIG. 4, a wall is formed by the pressurized air flow injected from the airflow forming nozzle hole (12A) on the front side in the transport direction, and the hot melt resin moves forward in the transport direction. (Expansion) is prevented, and on the rear side in the transport direction, a wall is formed by the pressurized air flow injected from the airflow forming nozzle hole (12B), and the hot melt resin moves rearward in the transport direction. As a result of preventing (spreading), the nonwoven fabric (24) that spreads only in the left-right direction and that the adjacent fibrous bodies come into contact with each other to form a mesh-like curtain-like hot melt resin (24) is transported by being lowered. 23). In this manner, a porous resin coating layer (28) is formed on the nonwoven fabric (23) (see FIGS. 3 and 4). In addition, in FIG. 2, (27) is a support stand for supporting a nonwoven fabric.

  Next, as shown in FIG. 2, the skin material (22) is superposed on the coated surface of the nonwoven fabric (23) and pressed between a pair of pressure rolls (25) (25). Subsequently, it is cooled and solidified by passing through an air-cooling type cooling device (26). Thus, the sound-absorbing mat (1) of the present invention can be produced in a continuous process.

  In the above production method, the curtain-like hot melt resin (24) is applied on the nonwoven fabric (23). For example, the skin material layer (2) disposed with the overlapping surface (back surface) facing up is provided. A curtain-like hot melt resin (24) may be applied on the overlapping surface. However, when the hot melt resin (24) is applied to the back surface of the skin material layer (2), the coating amount tends to become unstable due to the unevenness of the tufts, making it difficult to ensure the uniformity of the coating amount. Therefore, it is preferable to apply a curtain-like hot melt resin (24) on the nonwoven fabric (23).

  The sound-absorbing mat (1) of the present invention is not particularly limited to that manufactured by the above-described exemplary manufacturing method. For example, a curtain spray coating method described in JP-A-6-198239 and JP-A-6-254446 may be used.

In the present invention, the basis weight of the hot melt resin layer (4) is preferably set to ²⁰ to 400 g / m ² . Less than 20 g / m ² is not preferable because sufficient adhesive strength cannot be secured. ^{On the other hand} , if it exceeds 400 g / m ² , the air permeability is lowered and it is difficult to obtain a sufficient sound absorbing performance. Among these, the basis weight of the hot melt resin layer (4) is more preferably set to 50 to 300 g / m ² .

  The hot melt resin is not particularly limited, and examples thereof include ethylene-vinyl acetate copolymer (EVA), styrene elastomer resin, polyester resin, olefin resin, polyamide resin and the like. . Among these, it is preferable to use an olefin resin, and in this case, sufficient heat resistance and water resistance as a mat can be ensured. Among these, it is more preferable to use a resin composition containing an olefin resin and a rubber component. When the composition does not contain a rubber component, it tends to be relatively difficult to stretch even when the airflow ejected from the airflow forming nozzle hole is in contact with the resin when discharged from the application nozzle hole, and the resin application state is slightly Although there is a tendency to be non-uniform, the resin is modified by containing a rubber component, and when the air current is brought into contact with the resin, the resin is sufficiently stretched without being cut, and the coating state becomes uniform.

  Although it does not specifically limit as said olefin resin, For example, polyethylene, a polypropylene, an amorphous poly alpha olefin resin (APAO) etc. are mentioned. Among these, it is preferable to use an amorphous polyα-olefin resin. In this case, the adhesive strength of the adhesive layer (4) can be further improved. Although it does not specifically limit as said amorphous poly alpha olefin resin, For example, an amorphous polypropylene, an amorphous ethylene-propylene copolymer, an amorphous propylene-butene-1 copolymer etc. are mentioned.

  The rubber component is not particularly limited, and examples thereof include polybutylene, SBR, NBR, SEBS (styrene-ethylene-butylene-styrene copolymer), SIS (styrene-isoprene-styrene copolymer) and the like. It is done. Among these, it is preferable to use polybutylene. In this case, when the airflow is brought into contact with the resin, the polybutylene is sufficiently stretched, and the uniformity of the coating state can be further improved.

  The hot melt resin preferably includes a tackifier (tackifier). Examples of the tackifier include rosin resins, terpene resins, petroleum resins (C5 to C9 fractions, etc.) and the like. Examples of the rosin resin include raw rosin, esterified rosin, polymerized rosin, hydrogenated rosin, and disproportionated rosin. Examples of the terpene resin include aromatic modified terpenes and phenol modified terpenes. Examples of the petroleum resin include aliphatic systems, aromatic systems, copolymerization systems thereof, and hydrogenation systems.

  The hot melt resin preferably contains a liquid component such as wax. Examples of the wax include paraffin wax and microcrystalline wax.

  As the hot melt resin, a foamed hot melt resin may be used.

  In the present invention, the skin material layer (2) is not particularly limited, and examples thereof include those in which a pile is planted on a base fabric, and needle punched nonwoven fabrics. In the case of the former configuration, a latex for preventing pile removal may be applied to the back surface of the base fabric. The kind of fiber which comprises this skin material layer (2) is not specifically limited, For example, a polypropylene fiber, a polyester fiber, a nylon fiber, an acrylic fiber etc. are mentioned.

  The pile is not particularly limited, and any configuration can be adopted, and examples thereof include a cut pile and a loop pile. The type of yarn constituting this pile is not particularly limited, and examples thereof include BCF yarn, spun yarn, monofilament yarn and the like, and the type of fiber is not particularly limited, for example, polyester, polypropylene, nylon, acrylic, cotton, Examples thereof include wool.

Further, the sound absorbing layer (3) is not particularly limited, but for example, using a nonwoven fabric such as a needle punched nonwoven fabric or a spunbonded nonwoven fabric provides sufficient sound absorbing performance while ensuring light weight. ,preferable. The type of fiber constituting the nonwoven fabric is not particularly limited, and examples thereof include polypropylene fiber, polyester fiber, nylon fiber, and acrylic fiber. In addition, from the viewpoint of ensuring sufficient sound absorption performance, it is preferable that the thickness of the nonwoven fabric is 3 to 30 mm and the basis weight of the nonwoven fabric is set to 200 to 1000 g / m ² .

  The sound-absorbing mat (1) of the present invention is suitably used as an automobile floor mat, but is not particularly limited to such applications.

  Next, specific examples of the present invention will be described.

<Example 1>
As shown in FIGS. 2 and 4, the needle spray nonwoven fabric (23) made of PET (polyethylene terephthalate) fiber having a thickness of 5 mm and a basis weight of 300 g / m ² is conveyed at a constant speed, and the curtain spray coating disposed above the needle punch nonwoven fabric (23). Hot melt resin was applied using an apparatus (21). That is, the hot melt resin is made fibrous by bringing the molten hot melt resin discharged from the application nozzle hole (11)... Into contact with the air stream ejected from the air flow forming nozzle holes (12A). A porous resin coating layer (28) is formed by applying a curtain-like hot melt resin (24) formed by bringing adjacent fibrous bodies into contact with each other on the nonwoven fabric (23). It was. The application basis weight was 100 g / m ² . As the hot melt resin, a resin composition was used in which 55 parts by mass of an amorphous polyα-olefin resin (APAO), 30 parts by mass of rosin, and 15 parts by mass of paraffin wax were mixed. The resin composition temperature at the time of discharge from the coating nozzle hole (11) was 190 ° C. Moreover, the hole size of the application nozzle hole (11) was 0.3 mm square (the spacing S between adjacent holes was 0.95 mm).

Next, as shown in FIG. 2, the skin material (22) is superposed on the hot melt resin-coated surface of the nonwoven fabric (23) and pressed between a pair of pressure rolls (25) (25), and then cooled. The sound absorbing mat (1) was obtained by passing through the device (26) and cooling and solidifying. As the skin material (22), a tuft carpet raw fabric in which a pile made of nylon BCF yarn is tufted with a basis weight of 610 g / m ² on a base fabric made of a spunbond nonwoven fabric made of PET fiber having a basis weight of 120 g / m ^2. Was used.

<Examples 2 to 6>
A sound-absorbing mat was obtained in the same manner as in Example 1 except that the resin composition having the composition shown in Table 1 was used as the hot melt resin.

<Example 7>
A sound-absorbing mat was obtained in the same manner as in Example 6 except that the basis weight of hot melt resin was 200 g / m ² .

<Comparative Example 1>
An SBR latex emulsion (polymer adhesive) was applied to the back surface of the same skin material (tuft carpet original fabric) as in Example 1 with a dry basis weight of 500 g / m ² , and then the coating layer had a thickness of 5 mm and a basis weight of 300 g. A sound absorbing mat was obtained by superposing needle punched nonwoven fabric made of PET (polyethylene terephthalate) fiber of / m ² and pressing with a roll.

  Various evaluations were performed on the respective sound-absorbing mats obtained as described above based on the following evaluation methods. These results are shown in Table 2.

<Peel strength measurement method>
Five samples each having a width of 25 mm and a length of 250 mm were collected from the mat in the vertical and horizontal directions. One end in the length direction of the skin material layer (2) of each sample is peeled off from the nonwoven fabric (3) in advance by about 50 mm, and the upper end chucks the one end portion where the skin material layer (2) is peeled off, while the lower side One end of the non-woven fabric (3) peeled off was chucked with a tensile tester and pulled at a pulling rate of 100 mm / min with a tensile tester, and the tensile strength (N) when peeling off 100 mm after starting the tension was measured. The environmental conditions during the test were a room temperature of 23 ± 2 ° C. and a humidity of 65 ± 20%. The average value of five samples in both the vertical and horizontal directions was taken as the peel strength (N).

<Sound absorption coefficient evaluation method>
The sound absorption coefficient at each frequency was measured in accordance with the normal incidence method of JIS A1405.

<Air permeability measurement method>
The air permeability (cm ³ / cm ² / sec) was measured according to JIS L1096 8.27.1 A method.

<Coating property evaluation method>
“◎” indicates that the resin is particularly excellent in the cohesive strength (easiness of elongation, fineness of the eyes) of the hot melt resin, and “×” indicates that the resin is inferior. .

<Heat resistance evaluation method>
The mat was cut into strips, and this was subjected to a creep test at an angle of 90 degrees with a load of 50 g / 50 mm width in an atmosphere of 50 ° C. and 95% RH for 1 hour. “◎”, “○” when there was almost no, “Δ” where there was some problem but no problem, and “×” where thermal deformation had occurred.

  As apparent from Table 2, the sound absorbing mats of Examples 1 to 7 according to the present invention had excellent sound absorbing performance, had sufficient adhesive strength, and were excellent in coatability. The sound absorbing mats of Examples 1, 6, and 7 were also excellent in heat resistance.

  On the other hand, the sound-absorbing mat of Comparative Example 1 had inadequate adhesive strength and a small air flow rate and was inferior in sound absorbing performance.

It is sectional drawing which shows the sound-absorbing mat concerning one Embodiment of this invention. It is a side view which shows roughly the manufacturing method of this invention. It is a typical perspective view which shows the state which discharges curtain-like hot-melt resin from the coating device, and has apply | coated to the nonwoven fabric. It is sectional drawing which shows a coating device. It is a bottom view of a coating device.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Sound absorption mat 2 ... Skin material layer 3 ... Nonwoven fabric layer 4 ... Breathable adhesive resin layer (hot melt resin layer)
DESCRIPTION OF SYMBOLS 11 ... Application | coating nozzle hole 12 ... Nozzle hole for airflow formation 22 ... Skin material 23 ... Nonwoven fabric 24 ... Curtain-like hot-melt resin 28 ... Resin application layer

Claims (11)

In the sound-absorbing mat in which the skin material layer and the sound-absorbing layer are bonded and integrated through a breathable adhesive resin layer,
The breathable adhesive resin layer is composed of a porous hot melt resin layer formed by applying a fibrous molten hot melt resin obtained by discharging from a coating nozzle hole. .   The sound absorbing mat according to claim 1, wherein the sound absorbing layer is made of a nonwoven fabric. Sound absorbing mat according to claim 1 or 2 basis weight of the hot melt resin layer is 20 to 400 g / m ^2.   The sound absorbing mat according to any one of claims 1 to 3, wherein the hot melt resin layer contains an olefin resin.   The sound absorbing mat according to any one of claims 1 to 3, wherein the hot melt resin layer is made of a resin composition containing an olefin resin and a rubber component.   The sound-absorbing mat according to claim 4 or 5, wherein an amorphous poly-α-olefin resin is used as the olefin resin. The molten hot melt resin discharged from the application nozzle hole is brought into contact with the air stream ejected from the air stream forming nozzle hole and stretched to make the hot melt resin into a fibrous form, and a curtain-like shape formed by these fibrous bodies. A step of forming a resin coating layer by applying a hot melt resin on the nonwoven fabric;
A method for producing a sound-absorbing mat, comprising a step of superposing and pressing a skin material on an application surface of the nonwoven fabric. Forming the hot melt resin into a fibrous form by bringing the melted hot melt resin discharged from the application nozzle hole into contact with the air stream ejected from the air stream forming nozzle hole and stretching it, and bringing the adjacent fibrous bodies into contact with each other A step of forming a resin coating layer by coating the curtain-like hot melt resin on the nonwoven fabric;
A method for producing a sound-absorbing mat, comprising a step of superposing and pressing a skin material on the coated surface of the nonwoven fabric.   The method for producing a sound-absorbing mat according to claim 7 or 8, wherein the hot melt resin contains an olefin resin.   The method for producing a sound-absorbing mat according to claim 7 or 8, wherein the hot-melt resin contains an olefin resin and a rubber component.   The method for producing a sound-absorbing mat according to claim 9 or 10, wherein an amorphous poly-α-olefin resin is used as the olefin resin.

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