JP2012096778A - Silencer for automobile, and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a silencer for automobile which favorably maintain sound absorption property to noise in a cabin while securing lightweight and to provide a method for manufacturing the same.SOLUTION: A front side film layer 50a includes: a front side fusion film 51; a rear side fusion film 53; and a barrier film 52 which is fused between front and rear both sides fusion films 51 and 53. A front side fusion layer 51 is fused to the central right hand side intermediate part 41 of the front side layer 40. A rear side film layer 50b comprises a front side fusion film 54, a rear side fusion film 56 and a barrier film 55 fused to between the front side fusion film 54 and the rear side fusion film 56 so as to have a plurality of cylindrical parts 50d which contain a flat film part 50c and air, and is fused to the central right-hand side intermediate part 61 of the rear side layer 60 at a corresponding part to a top part of each cylindrical part 50d out of rear side films 56.

Description

  The present invention relates to an automobile silencer suitable for reducing noise propagating into a vehicle cabin, noise generated in the vehicle cabin, and the like, and a method of manufacturing the same.

  Conventionally, as this type of automobile silencer, an ultra-lightweight soundproof material described in Patent Document 1 below has been proposed. This soundproofing material has a two-layer structure in which a non-breathable resonance layer is laminated on a sound absorbing layer.

  The soundproofing material configured as described above is arranged as a dash silencer along a dash panel that separates the engine room and the vehicle compartment of the vehicle. Here, in the dash silencer, the sound absorbing layer is formed of, for example, a thermoplastic felt so as to have air permeability, and the sound absorbing layer is disposed on the engine room side. On the other hand, the non-breathable resonance layer is formed of, for example, an olefin resin film so as to be non-breathable, and the non-breathable resonance layer is disposed so as to be located on the vehicle interior side. .

  Thus, in the dash silencer configured as described above, the sound absorbing layer mainly absorbs noise propagated from the engine room due to its air permeability. On the other hand, the non-breathable resonant layer mainly absorbs noise generated in the vehicle interior and absorbs noise in the vehicle interior by resonance with the sound absorbing layer based on the non-breathable property.

Japanese Patent No. 3498085

  By the way, in the dash silencer configured as described above, since the non-breathable resonance layer is a film as described above, the non-breathable resonance layer is considerably more than the sound absorbing layer made of thermoplastic felt. Thinly formed.

  Therefore, when the dash silencer is molded so as to have a concavo-convex shape in the plate thickness direction, the sound absorbing layer is inevitably formed so as to have a concavo-convex shape in the plate thickness direction, not the non-breathable resonance layer. Will be.

  For this reason, it is necessary to increase the weight of the thermoplastic felt in the portion of the dash silencer where the plate thickness is desired to be increased. However, when the weight of the thermoplastic felt is increased in this way, the weight as a dash silencer is increased even if the sound absorbing property can be secured satisfactorily. This goes against the demand for weight reduction of the dash silencer.

  Therefore, in order to cope with such a situation, the present invention effectively utilizes a film laminated structure including at least one bubble part, and the sound absorbing property against noise in the vehicle interior is favorable while ensuring weight reduction. An object of the present invention is to provide an automobile silencer and a method for manufacturing the same.

  In solving the above-described problems, the automotive silencer according to the present invention, according to claim 1,

  A porous layer (60) formed of a porous material, and a film laminate (70, 80) laminated on at least a part of the porous layer (61),

  The film laminate is

  A first barrier film (71, 81) formed of a resin having a melting point higher than that of the thermoplastic resin, and laminated on the first barrier film and melted at a temperature lower than the melting point. A first film layer (70a, 80a) having a first fused film (72, 82) made of the above-mentioned thermoplastic resin,

  A second barrier film formed of a resin having a melting point higher than that of the thermoplastic resin, the outer peripheral edge of the second barrier film being formed on the outer peripheral edge of the first fusion film from the side opposite to the first barrier film. The second barrier film (73, 83) fused at a temperature lower than the melting point, and the second barrier film laminated on the second barrier film and fused at a temperature lower than the melting point. A second film layer (70b, 80b) having a second fusion film (74, 84) made of the thermoplastic resin,

  The second film layer is

  At least a part of each of the inner peripheral side portion of the outer peripheral edge of the second barrier film and the corresponding fusion portion of the second fusion film corresponding thereto is opened toward the first fusion film. And at least one cylindrical portion (70d, 80d) that protrudes in a direction away from the first fusion film,

  A flat membrane portion (70c, 80c) composed of each portion other than the at least one cylindrical portion among both the inner peripheral side portion of the second barrier film and the corresponding fusion portion of the second fusion film. Have

  The at least one tube part is formed as a bubble part that encloses air between itself and at least a part of the flat film part and the first fusion film,

  The porous layer is fused at a temperature lower than the melting point to the corresponding portion of the second fusion film with respect to the top of the at least one cylindrical portion at the at least part thereof.

  Thus, the silencer has at least one cylindrical part formed as a bubble part independently between the porous layer and the first fusion film or together with at least a part of the flat membrane part. It is configured with a film laminate. Here, if at least a part of the porous layer is a portion where the thickness of the silencer is increased, the film laminate is maintained in a cylindrical shape by enclosing air in the cylindrical portion without causing deformation of the cylindrical portion. ing. For this reason, the thickness of at least a part of the porous layer can be appropriately ensured.

  Thus, since the thickness of at least a part of the porous layer is ensured by the height of the cylindrical portion of the film laminate, rather than increasing the material for forming the porous layer, Is not increased by the film laminate.

  In addition, since the porous layer is made of a porous material, it can exhibit good sound absorption under good air permeability. Furthermore, the film laminate is composed of a non-breathable film, but the film laminate ensures sound absorption by exhibiting a resonance phenomenon against noise based on the film configuration. Can do. As a result, the silencer can exhibit good sound absorption as well as light weight.

  Moreover, according to the description of Claim 2, this invention is the silencer for motor vehicles of Claim 1,

  The flat membrane portion is fused at a temperature lower than the melting point to the corresponding portion of the first fusion film with respect to the inner peripheral side portion of the second barrier film as a whole. And

  The at least one tube portion projects from the plurality of portions of the flat membrane portion toward the first fusion film as a closed cell portion in a direction away from the first fusion film. It is a cylinder part, It is characterized by the above-mentioned.

  Thus, even if at least one cylinder part is a plurality of cylinder parts which are each a closed cell part, the same operation effect as the invention of claim 1 can be achieved.

  According to a third aspect of the present invention, in the automobile silencer according to the first aspect,

  The at least one cylindrical part is formed as at least one communicating bubble part containing air between the first film and the first fusion film together with at least a part of the flat film part. .

  Thus, even if at least one cylindrical part is formed as at least one communicating bubble part including air between the first fusion film together with at least a part of the flat film part, The same effect as that of the first aspect of the invention can be achieved.

  Moreover, according to the description of Claim 4, the automotive silencer according to the present invention includes:

  A porous layer (40) formed of a porous material, and a film laminate (70) laminated on at least a part of the porous layer (41),

  The film laminate is

  A first fusion film (72a) formed of a thermoplastic resin, and the thermoplastic resin laminated on the first fusion film and fused to the first fusion film at a temperature lower than the melting point. A first film layer (70a) having a first barrier film (71a) made of a resin having a higher melting point,

  A second fusion film formed from the thermoplastic resin, wherein the second fusion film is fused at the outer peripheral edge of the first barrier film to the outer peripheral edge of the first barrier film at a temperature lower than the melting point. A second barrier comprising a film (74a) and a resin having a melting point higher than that of the thermoplastic resin laminated to the second fusion film and fused to the second fusion film at a temperature lower than the melting point. A second film layer (70b) having a film (73a),

  The second film layer is

  At least a part of both the inner peripheral side portion of the outer peripheral edge portion of the second fusion film and the corresponding fusion portion of the second barrier film corresponding to the outer peripheral edge portion is opened toward the first barrier film. At least one cylindrical portion (70d) protruding in a direction away from the first barrier film;

  A flat membrane portion (70c) composed of each portion other than the at least one cylindrical portion among both the inner peripheral portion of the second fusion film and the corresponding fusion portion of the second barrier film. And

  The at least one tube part is formed as a bubble part that encloses air between itself and at least a part of the flat film part and the first barrier film,

  The porous layer is fused at a temperature lower than the melting point to the first fusion film of the first film layer at least at a part of the porous layer.

  Thus, unlike the invention according to claim 1, even if the first film layer is fused with the at least part of the porous layer by the first fused film, the film laminate However, there is no change in having at least one tube part formed as a bubble part independently with the first barrier film or together with at least a part of the flat film part, and as a result, claim 1. The effect similar to that of the invention described in 1 can be achieved.

  Moreover, according to the description of Claim 5, this invention is the silencer for motor vehicles of Claim 4,

  The flat membrane portion is fused at a temperature lower than the melting point to the corresponding portion of the first barrier film with respect to the inner peripheral side portion of the second fusion film. And

  The at least one cylindrical portion is a plurality of cylindrical portions protruding as closed cell portions in a direction away from the first barrier film so as to open from the plurality of portions of the flat membrane portion toward the first barrier film, respectively. It is characterized by being.

  Thus, even if at least one cylinder part is a plurality of cylinder parts which are each a closed-cell part, the same operation effect as the invention of Claim 4 can be achieved.

  According to a sixth aspect of the present invention, in the automobile silencer of the fourth aspect,

  The at least one cylindrical part is formed as at least one communicating bubble part including air between the flat film part and the first barrier film together with at least a part of the flat film part.

  Thus, even if at least one cylindrical part is formed as at least one communicating bubble part including air between the first fusion film together with at least a part of the flat film part, The same effect as that of the invention of the fourth aspect can be achieved.

  Moreover, according to the description of Claim 7, the automobile silencer according to the present invention is provided.

  Both porous layers (40, 60) formed of a porous material, and a film laminate (50, 90) laminated between at least the opposing portions (41, 61) of the porous layers. prepare for,

  The film laminate is

  Between both first fusion films (51, 53, 91, 93) formed of a thermoplastic resin and between the first fusion films formed of a resin having a melting point higher than that of the thermoplastic resin. A first film layer (50a, 90a) having a first barrier film (52, 92) fused at a temperature lower than the melting point;

  One of the second fused films (54, 56, 94, 96) formed of the thermoplastic resin and one of the first fused films at the outer peripheral edge thereof. One second fused film (54, 94) fused to the outer peripheral edge of the first fused film (53, 93) at a temperature lower than the above melting point, and this one second fused film A second barrier film (55, 95) made of a resin having a melting point higher than that of the thermoplastic resin laminated on the film and fused to the one second fusion film at a temperature lower than the melting point; and A second film layer (50b, 90b) having the other second fused film (56, 96) laminated on the second barrier film and fused to the second barrier film at a temperature lower than the melting point; It has

  The second film layer corresponds to the inner peripheral portion of the outer peripheral edge of the one second fusion film (54, 94) and the corresponding second barrier film and the other second fusion film. At least one part formed by projecting at least one part of each fusion part in a direction away from the one first fusion film so as to open toward the one first fusion film (53, 93). A cylindrical portion (50d, 90d);

  Other than the at least one cylindrical portion among the inner peripheral portion of the one second fusion film, the corresponding fusion portion of the second barrier film, and the corresponding fusion portion of the other second fusion film. A flat membrane part (50c, 90c) consisting of each part of

  The at least one cylindrical part is formed as a bubble part that encloses air between itself and at least a part of the flat film part and the one first fusion film,

  One of the two porous layers is fused to the other first fusion film at a temperature lower than the melting point at the at least part of the porous layer, and the other porous layer is at least part of the porous layer. Then, it is fused at a temperature lower than the melting point to the corresponding portion of the other second fusion film with respect to the top of the at least one cylindrical portion.

  In such a configuration, unlike the invention according to claim 1 or claim 4, although the film laminate is laminated between the two porous layers, the film laminate is independently or a flat membrane portion. And having at least one cylindrical part formed as a bubble part enclosing air between at least a part of the first fused film and one of the first fusion films, and as a result, claim 1 or claim The effect similar to that of the invention described in item 4 can be achieved.

  Moreover, according to the description of claim 10, the manufacturing method of the silencer for automobiles according to the present invention,

  Resin having both melting layers made of thermoplastic resin material and having a melting point higher than the melting point of said thermoplastic resin material while preparing porous members for both porous layers and fusing film between these two fusion films Prepare first and second three-layer films respectively formed by barrier films made of materials,

  Vacuum forming the second three-layer film so that a plurality of cylindrical portions protrude from the flat membrane portion in the thickness direction,

  The first three-layer film layer is laminated on at least a part of one of the porous members for both porous layers, and the plurality of cylindrical portions are projected in a direction opposite to the first three-layer film layer. In addition, the second three-layer film layer is laminated on the first three-layer film layer, and the plurality of cylindrical portions are arranged as opposed portions to the other at least part of the other porous members for the two porous layers. Then, the structure laminated on the second three-layer film layer was heated so as to melt the respective fused films and then subjected to cold pressure molding.

  According to this, the manufacture of the silencer for motor vehicles which can achieve the effect similar to the invention of Claim 7 is attained. Here, in the manufacturing process of the silencer, one of the porous members for both porous layers, the first three-layer film, the second three-layer film formed with a plurality of cylindrical portions, and the other porous layer The porous member is subjected to cold pressure forming after heating so as to melt each fusion film under the above-described lamination.

  Along with this, molding of the porous members for both porous layers and adhesion by fusion between the porous members for both porous layers and the first and second three-layer films can be performed simultaneously. As a result, the manufacturing process of the silencer can be simplified without adopting an adhesive material separately.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows the correspondence with the specific means as described in embodiment mentioned later.

1 is a schematic partial cross-sectional view of an automobile to which a first embodiment of a dash silencer according to the present invention is applied. It is a perspective view of the dash silencer of FIG. FIG. 3 is an enlarged longitudinal sectional view of a dash silencer along line 3-3 in FIG. 2. It is a partial expanded longitudinal cross-sectional view of the film laminated body of FIG. It is a partial expanded sectional view of the film laminated body of FIG. It is a partially broken front view of the film laminated body of FIG. It is a manufacturing-process figure from the shaping | molding process of the film laminated body in the said 1st Embodiment to a dash silencer. It is a schematic perspective view of the metal mold | die used for vacuum forming in the vacuum forming process of FIG. It is a graph which shows the relationship between the sound absorption factor and frequency of the Example in the said 1st Embodiment, and a comparative example, respectively. It is a partial expanded sectional view which shows the principal part of the film laminated body of 2nd Embodiment of this invention. It is a partial expanded sectional view which shows the principal part of the film laminated body of 3rd Embodiment of this invention. It is a partial expanded sectional view of the film laminated body of FIG. It is a graph which shows the relationship between the sound absorption rate and frequency of the Example in the said 3rd Embodiment, and a comparative example, respectively. It is a partial expanded sectional view which shows the principal part of the film laminated body of 4th Embodiment of this invention. It is a partial expanded sectional view of the film laminated body of FIG. It is a partially broken front view of the film laminated body of 5th Embodiment of this invention. It is a partial expanded longitudinal cross-sectional view of the film laminated body of FIG. It is a partial expanded sectional view of the film laminated body of FIG. It is a graph which shows the relationship between the sound absorption factor and frequency of the Example in the said 5th Embodiment, and a comparative example, respectively. It is a partial expanded sectional view which shows the principal part of the film laminated body of 6th Embodiment of this invention. It is a partial expanded sectional view of the film laminated body of FIG.

Embodiments of the present invention will be described below with reference to the drawings.
(First embodiment)

  FIG. 1 shows a first embodiment of the present invention applied to a sedan type automobile. The automobile includes an engine room 10 and a passenger compartment 20, and the passenger compartment 20 is provided subsequent to the engine compartment 10 in the automobile. An engine E is disposed in the engine room 10. A front seat S is disposed in the passenger compartment 20.

  Further, the automobile is provided with a dashboard 30 (also referred to as a dash panel 30). As shown in the vertical cross-sectional shape of FIG. It is formed so as to be bent in an inclined shape. The dashboard 30 configured as described above is provided at the boundary between the engine room 10 and the vehicle compartment 20 and partitions the engine room 10 and the vehicle compartment 20 from each other. The dashboard 30 is connected to the lower edge of the front windshield of the passenger compartment 20 at the upper end of the extension. The lower end of the dashboard 30 is connected to the floor wall of the passenger compartment 20. Connected to the front edge.

  In addition, the vehicle includes a dash silencer DS. As shown in FIG. 1, the dash silencer DS is assembled along the dashboard 30 from the vehicle compartment 20 side. The dash silencer DS is arranged at the center in the vertical direction as shown in FIG. It is configured to have a concave and convex plate shape as illustrated in FIG. 3 so as to have a concave curved plate shape when viewed from the rear side of the automobile and from its upper edge portion to its lower edge portion.

  As shown in FIG. 3 or FIG. 4, the dash silencer DS includes a front layer 40, a film laminate 50, and a rear layer 60. The front layer 40, the film laminate 50, and the rear layer 60 are: They are sequentially stacked from the front side to the rear side of the automobile.

  As illustrated in the longitudinal cross-sectional shape of FIG. 3, the front layer 40 is made of a predetermined porous material for the front layer so that the upper and lower side portions are bent and extended backward and upward in an inclined manner from the center. The front layer 40 is formed and assembled to the dashboard 30 along its rear surface at the front surface thereof.

In the first embodiment, the thickness of the front layer 40 described above is set on the basis of 8 (mm). In addition, the predetermined porous material for the front layer described above is a felt made of polyethylene terephthalate (hereinafter referred to as PET) and having a predetermined weight per unit area (weight per unit area) (hereinafter referred to as front layer). Felt). Here, the predetermined weight per unit area of the front layer felt is 300 (g / m ² ).

  As can be seen from FIG. 2 or FIG. 3, the film laminate 50 is sandwiched between the central right intermediate portions 41 and 61 of the front layer 40 and the rear layer 60. In the first embodiment, the middle right intermediate portions 41 and 61 of the front layer 40 and the rear layer 60 respectively correspond to thickness increasing portions of the dash silencer DS (see reference symbol R in FIG. 2).

  As illustrated in FIG. 4, the film laminate 50 includes a front film layer 50a and a rear film layer 50b. The rear film layer 50b is formed on the front film layer 50a from the rear surface side as described later. Are stacked.

  As illustrated in FIG. 5, the front film layer 50 a is formed in a flat film shape by laminating a front fusion film 51, a barrier film 52, and a rear fusion film 53. The front side fusion film 51 is formed in a flat film shape with a predetermined thickness from a predetermined thermoplastic material for the front side fusion film, and the front side fusion film 51 is formed on the front layer 40 on the front surface thereof. Is fused to the central right intermediate portion 41 along the rear surface.

  In the first embodiment, the predetermined thickness of the above-mentioned front side fusion film 51 is set to 20 (μm). Moreover, polyethylene is employ | adopted as a thermoplastic material for the predetermined front side fusion | melting films mentioned above.

  The barrier film 52 is formed in a flat film shape with a predetermined thickness from a predetermined thermoplastic film for a barrier film, and this barrier film 52 is fused to the front-side fusion film 51 from the rear surface side. Yes.

  In the first embodiment, the predetermined thickness of the barrier film 52 described above is set to 15 (μm). Moreover, nylon is employ | adopted as the thermoplastic material for predetermined | prescribed barrier films mentioned above. In the first embodiment, as described above, nylon is used as the predetermined thermoplastic material for the barrier film because nylon has a higher melting point than polyethylene which is the material for forming the front-side fusion film 51 described above. It is for having.

  The rear side fusion film 53 is formed in a flat film shape from a predetermined thermoplastic material for the rear side fusion film, and this rear side fusion film 53 is fused to the barrier film 52 from the rear side. ing. In the first embodiment, polyethylene is adopted as the thermoplastic material for the predetermined rear side fusion film described above, similarly to the front side fusion film 51. The above-mentioned fusion of the barrier film 52 with the front fusion film 51 and the rear film 53 is performed at a temperature lower than the melting point of nylon.

  As illustrated in FIG. 5, the rear film layer 50 b is formed by laminating a front fusion film 54, a barrier film 55, and a rear fusion film 56. In the first embodiment, the front side fusion film 54, the barrier film 55, and the rear side fusion film 56 are formed of the front side fusion film 51, the barrier film 52, and the rear side fusion film of the front film layer 50a, respectively. It is the same as each forming material of the film 53.

  As illustrated in FIG. 4 or FIG. 5, the rear film layer 50b includes a flat film portion 50c and a large number of cylindrical portions 50d. The rear fusion film layer 50b includes a flat film portion. At 50c, the front film layer 50a is fused from the rear surface side, and a large number of cylindrical portions 50d protrude in the opposite direction to the front film layer 50a.

  Here, as illustrated in FIG. 5, the flat membrane portion 50 c corresponds to each corresponding portion of the front side fusion film 54, the barrier film 55, and the rear side fusion film 56 with respect to the flat membrane portion 50 c, and a large number of them. The cylindrical portion 50d corresponds to each corresponding portion of the front side fusion film 54, the barrier film 55, and the rear side fusion film 56 with respect to the multiple cylindrical portions 50d. Accordingly, the front-side fusion film 54 is fused to the rear-side fusion film 53 from the rear surface side, so that the flat film portion 50c is fused to the corresponding portion of the front-side film layer 50a with respect to the flat film portion 50c. ing. The fusion performed as described above in the rear film layer 50b is performed at a temperature lower than the melting point of nylon.

  As shown in FIG. 6, a large number of cylindrical portions 50d of the rear film layer 50b are arranged in a staggered manner along the surface direction of the front film layer 50a. Further, as illustrated in FIG. 5, each of the large number of cylindrical portions 50d protrudes in a cylindrical shape from the corresponding portion with respect to each cylindrical portion 50d in the front film layer 50a toward the thickness direction of the flat membrane portion 50c. Is formed. In other words, each cylindrical portion 50d is open to the front film layer 50a at the opening end.

  Thus, air is sealed in each of the numerous cylindrical portions 50d formed in this way. This means that each of the many cylindrical portions 50d is a cylindrical closed cell portion.

  In the first embodiment, the large number of cylindrical portions 50d are arranged in a staggered manner as described below. That is, when one cylindrical portion 50d is selected from among a large number of cylindrical portions 50d, the selected cylindrical portion 50d is surrounded by six cylindrical portions 50d arranged in a regular hexagon as shown in FIG. The center interval between the selected cylindrical portion 50d and each of the six cylindrical portions 50d and the center interval between the two adjacent cylindrical portions 50d among the six cylindrical portions 50d are the same predetermined intervals.

  Each cylindrical portion 50d has a predetermined outer diameter (for example, 20 (mm)) and a predetermined height (for example, 7 (mm)). Here, the predetermined outer diameter corresponds to the outer diameter of the peripheral wall of the cylindrical cylindrical portion 50d. The predetermined height corresponds to the distance from the rear surface of the front film layer 50a to the rear surface of the top wall portion of the cylindrical portion 50d. Further, the number of the cylindrical portions 50d is increased as much as possible so that the dash silencer DS can exhibit sound absorption. In addition, the thickness of the film laminated body 50 is 12 (mm).

  As shown in the vertical cross-sectional shape of FIG. 3, the rear layer 60 has a predetermined porous material for the rear layer so that the upper and lower side portions are bent and extended backward and upward in an inclined manner from the center. The rear layer 60 is directly thermocompression bonded from the rear surface side of the front layer 40 at a portion other than the corresponding portion with respect to the film laminate 50, and at the corresponding portion with respect to the film laminate 50. The film laminate 50 is pressure-bonded to the rear film layer 50b from the rear surface side.

In the first embodiment, unlike the front layer 40, the thickness of the rear layer 60 is set on the basis of 5 (mm). Further, as the predetermined porous material for the rear layer, a felt made of polyethylene terephthalate and having a predetermined basis weight (hereinafter referred to as a felt for the rear layer) is employed. Here, the predetermined basis weight of the felt for the rear layer is 800 (g / m ² ) unlike the felt for the front layer. The total basis weight of the dash silencer DS is 1,200 (g / m ² ).

  Next, the dash silencer DS configured as described above is manufactured as follows. First, the front layer felt described above is cut so as to have an outer dimension that matches the outer dimension of the dashboard 30 and is prepared as a front layer felt having a thickness of 8 (mm). Moreover, the felt for the back side layer described above is cut so as to have an outside dimension that matches the outside dimension of the dashboard 30 and is prepared as a felt for the back side layer having a thickness of 5 (mm).

  Next, in the inflation molding step S1 of FIG. 7, the three-layer film for the front film layer 50a and the three-layer film for the rear film layer 50b of the film laminate 50 are subjected to inflation molding with a multilayer inflation molding machine (not shown). .

  That is, in the multi-layer inflation molding machine, the front-side fused film molten polyethylene, the barrier film-fused nylon, and the rear-side fused film molten polyethylene each have a plurality of extruders (three extruders in the first embodiment). When these are extruded upward, the molten polyethylene for the front side fusion film, the molten nylon for the barrier film and the molten polyethylene for the rear side fusion film are both expanded and formed into a cylindrical film shape by the air flow.

  At this time, the cylindrical film made of the molten polyethylene for the front side fusion film encloses the cylindrical film made of the molten nylon for the barrier film, and the cylindrical film made of the molten nylon for the barrier film becomes the molten polyethylene for the rear side fused film. A three-layer cylindrical film body is formed so as to include a cylindrical film made of

  Thus, the three-layer cylindrical film body formed in this way is joined to each other as it is in a multi-layer inflation molding machine while being cooled, and the polyethylene film for the front side fusion film, the nylon film for the barrier film, and the rear side fusion film. It becomes the single cylinder film which consists of a polyethylene film for attachment films.

  After the single cylindrical film is formed in this way, the single cylindrical film is cut in the axial direction to form a three-layer film for the front film layer 50a.

  Next, the three-layer film for the rear film layer 50b is formed in the same manner as the three-layer film for the front film layer 50a.

  Thereafter, in the vacuum forming step S2, the three-layer film for the rear film layer 50b is heated and softened by a vacuum forming machine (not shown) using a vacuum mold K (see FIG. 8) to obtain a flat plate portion. A large number of cylindrical portions (corresponding to the cylindrical portion 50d) from the flat membrane portion 50c are vacuum-formed so as to protrude in a cylindrical shape toward the polyethylene film side for the rear fusion film.

  Here, the vacuum mold K is configured to project a cylindrical portion K2 corresponding to a large number of cylindrical portions 50d in a staggered manner from a flat plate portion K1 corresponding to the flat membrane portion 50c of the rear film layer 50b. In addition, since the heating temperature by a vacuum forming machine is lower than the melting point of nylon and higher than the melting point of polyethylene, the nylon film for barrier film does not melt.

  Next, in the heating step S3, the three-layer film for the rear film layer 50b is changed to the three-layer film for the front film layer 50a so that a large number of cylindrical portions protrude to the opposite side of the three-layer film for the front film layer 50a. Join from the back side. This joining is performed by joining the polyethylene film for the front side fusion film of the three-layer film for the rear film layer 50b to the polyethylene film for the rear side fusion film of the three-layer film for the front film layer 50a.

  After such joining, a press machine (not shown) is heated and pressed using a predetermined mold, and the three-layer film for the rear film layer 50b is formed into the three-layer film for the front film layer 50a from the rear side. Fuse. This fusing is performed by fusing the polyethylene film for the front fusing film of the three-layer film for the rear film layer 50b to the polyethylene film for the rear fusing film for the three-layer film for the front film layer 50a. In addition, since the heating temperature by a press machine is lower than the melting point of nylon and higher than the melting point of polyethylene, the nylon film for barrier film does not melt.

  Next, in the cold pressure forming step S4, the felt for the rear layer is laminated on the felt for the front layer through the three-layer film for the rear film layer 50b and the three-layer film for the front film layer 50a. This lamination is performed by laminating the corresponding portion of the rear layer felt with respect to the central right intermediate portion 61 of the rear layer 60 on the three-layer film for the rear film layer 50b from the rear side, and the front side of the front layer felt. The part corresponding to the middle right intermediate part 41 of the layer 40 is laminated on the three-layer film for the front film layer 50a from the front side. At this time, the three-layer film for the rear film layer 50b is laminated on the three-layer film for the front film layer 50a in a state where air is included in each cylindrical portion.

  And with the cold press molding apparatus (not shown), using the cold press mold, the felt for the front layer, the three-layer film for the front film layer 50a, the three-layer film for the rear film layer 50b And the laminated body which consists of felt for back side layers is cold press-molded after heating to predetermined heating temperature.

  Here, the cold pressing mold is formed so as not to deform each cylindrical portion of the three-layer film for the rear film layer 50b. The predetermined heating temperature is lower than the melting point of nylon and higher than the melting point of polyethylene. Therefore, both polyethylene films of the three-layer film for the front film layer 50a and both polyethylene films of the three-layer film for the rear film layer 50b are melted together.

  Therefore, the three-layer film for the front film layer 50a is fused to the felt for the front layer by melting the polyethylene film for the front-side fusion film, and the three-layer film for the rear film layer 50b is the front-side fusion. In the polyethylene film for film, the three-layer film for the rear film layer 50b is fused by fusion to the polyethylene film for the rear-side fusion film for the front-side film layer 50a. The polyethylene film is fused to the felt for the rear layer by melting.

  Thereby, the three-layer film for the front film layer 50a and the three-layer film for the rear film layer 50b become the front film layer 50a and the rear film layer 50b, respectively, and the front layer felt and the rear layer felt respectively The dash silencer DS described above is manufactured using the front layer 40 and the rear layer 60.

  In the dash silencer DS manufactured as described above, the film laminate 50 includes the front side layer 40, the rear side layer 60, and the thickness increase part R (see FIG. 3). Is sandwiched between. Here, the film laminate 50 is configured to include a large number of cylindrical portions containing bubbles, and the film laminate 50 does not cause deformation of each cylindrical portion 50d of the rear film layer 50b. The cylindrical portion 50d contains air and is maintained in a cylindrical shape. Accordingly, the center right intermediate portion 61 of the rear layer 60 is maintained away from the center right intermediate portion 41 of the front layer 40 rearward by the height of each cylindrical portion 50d. For this reason, the thickness increase site | part R of dash silencer DS can be ensured appropriately.

  Thus, the thickness of the thickness increasing portion R does not increase the felt that is a material for forming the front layer 40 and the rear layer 60, but is based on the height of each cylindrical portion 50d of the film laminate 50. Since it is ensured, the weight of the thickness increasing portion R is not increased by the film laminate 50.

  Further, in the dash silencer DS manufactured as described above, since the front layer 40 and the rear layer 60 are both made of felt, they can exhibit good sound absorption properties with good air permeability. Furthermore, although the film laminated body 50 is comprised with the film which has air permeability, the said film laminated body 50 exhibits sound absorption property by exhibiting the resonance phenomenon with respect to noise based on the film structure. Can be ensured.

  Therefore, the noise propagated from the engine room 10 through the front layer 40 to the film laminate 50 and the noise propagated from the vehicle compartment 20 through the rear layer 60 to the film laminate 50 are caused by the film laminate 50 by the front film layer 50a. The sound is absorbed well by the resonance of the rear film layer 50b.

  As a result, the dash silencer DS can exhibit good sound absorption as well as light weight.

  Further, in the manufacturing process of the dash silencer DS as described above, after the polyethylene films of the three-layer film for the front film layer 50a and the three-layer film for the rear film layer 50b are melted, Between the front felt and the three-layer film for the front film layer 50a, between the three-layer film for the front film layer 50a and the three-layer film for the rear film layer 50b, and the three-layer film for the rear film layer 50b and the rear felt Are adhered by fusion.

  Therefore, in the manufacture of the dash silencer DS, the above fusion can be performed simultaneously with the molding of the front layer 40, the film laminate 50, and the rear layer 60 without going through the step of applying an adhesive. This is because the dash silencer DS is formed by fusing between the front layer 40 and the front film layer 50a of the film laminate 50, and fusing between the front film layer 50a and the rear film layer 50b in the film laminate 50. And it is made simultaneously with the fusion | melting between the back side film layer 50b and the back side layer 60 of the film laminated body 50, and it means that it leads to the simplification of a manufacturing process.

  Incidentally, the dash silencer DS manufactured as described above was used as Example 1-1, and the sound absorption characteristics of Example 1-1 were measured by a so-called reverberation chamber method sound absorption coefficient test in comparison with Comparative Example 1-1. I tried to.

  Here, the said comparative example 1-1 has the structure which replaced with the film laminated body 50 of the said Example 1-1, and employ | adopted the single layer film. Therefore, the comparative example 1-1 is configured by a laminated structure of the front layer 40, the rear layer 60, and the single layer film of the example 1-1. The single-layer film is sandwiched between the central right intermediate portion 41 of the front layer 40 and the central right intermediate portion 61 of the rear layer 60.

  In addition, the reverberation room method sound absorption rate test is performed by calculating the sound absorption rate for the sound (that is, engine sound) and other sounds from the engine E according to Example 1-1 or Comparative Example 1-1 as the frequency of the engine sound and other sounds. It is a test to measure in the relationship.

  When the reverberation chamber method sound absorption coefficient test was performed on Example 1-1 and Comparative Example 1-1 based on the above assumptions, the results shown in FIG. 9 were obtained. In FIG. 9, the graphs 1 and 2 indicate the relationship between the sound absorption coefficient and the frequency in Example 1-1 and Comparative Example 1-1, respectively.

Here, when comparing the graphs 1 and 2, in both graphs 1 and 2, the sound absorption rate changes so as to have substantially the same increasing tendency as the frequency increases. In comparison with this, it can be seen that the sound absorption characteristics of Example 1-1 are substantially the same as those of Comparative Example 1-1. In other words, it can be seen that Example 1-1 can absorb the noise in the passenger compartment as well as the conventional product, although it is lighter than Comparative Example 1-1.
(Second Embodiment)

  FIG. 10 shows a main part of a second embodiment of the dash silencer according to the present invention. In the second embodiment, in the film laminate 50 described in the first embodiment, the rear film layer 50b is different from the first embodiment in that the front fusion film 54 is eliminated, and the barrier film 55 and the rear side fusion film 56 only.

  Accordingly, the fusion between the front film layer 50a and the rear film layer 50b is a fusion between the rear film 53 of the front film layer 50a and the barrier film 55 of the rear film layer 50b. It is made. Other configurations are the same as those in the first embodiment.

  In the second embodiment configured as described above, as described above, the rear film layer 50b is configured by only the barrier film 55 and the rear fusion film 56, and the rear side of the front film layer 50a. The fusion between the film layer 50b and the barrier film 55 of the rear film layer 50b is performed by the fusion between the rear fusion film 53 of the front film layer 50a and the barrier film 55 of the rear film layer 50b.

As a result, the same effect as the first embodiment can be achieved while simplifying the configuration of the rear film layer 50b of the film laminate 50.
(Third embodiment)

  FIG. 11 shows a main part of a third embodiment of the dash silencer according to the present invention. In the third embodiment, in the dash silencer DS described in the first embodiment, a film laminate 70 is employed instead of the front layer 40 and the film laminate 50.

  As shown in FIG. 11, the film laminate 70 includes a front film layer 70a and a rear film layer 70b formed by laminating the front film layer 70a.

  The front film layer 70a has a configuration in which the front fusion film layer 51 is excluded from the front film layer 50a of the film laminate 50 described in the first embodiment.

  That is, the front film layer 70a is constituted by the barrier film 71 and the rear fusion film 72 corresponding to the barrier film 52 and the rear fusion film 53 of the front film layer 50a (see FIG. 12). Here, the barrier film 71 and the rear side fusion film 72 are the same as those of the barrier film 52 and the rear side fusion film 53 of the front film layer 50a described in the first embodiment. It is the same as each structure and each forming material.

  Thus, in the front film layer 70a, the barrier film 71 is fused to the rear fused film 72 from the front side.

  On the other hand, the rear film layer 70b has a configuration in which the front fusion film layer 54 is removed from the rear film layer 50b of the film laminate 50 described in the first embodiment.

  That is, the rear film layer 70b is configured by a barrier film 73 and a rear fusion film 74 corresponding to the barrier film 55 and the rear fusion film 56 of the rear film layer 50b, respectively (see FIG. 12). . Here, the barrier film 73 and the rear side fusion film 74 are the same as the respective configurations and the formation materials of the barrier film 55 and the rear side fusion film 56 in the respective configurations and the respective formation materials.

  The rear film layer 70b includes a flat film part 70c and a large number of cylindrical parts 70d corresponding to the flat film part 50c and the large number of cylindrical parts 50d of the rear film layer 50b, respectively. Here, the flat film portion 70c corresponds to the corresponding portions of the barrier film 73 and the rear fusion film 74 with respect to the flat film portion 70c, and the large number of cylindrical portions 70d are the barrier film 73 and the rear fusion film. This corresponds to the corresponding portions of the 74 cylindrical portions 70d.

  Thus, the rear film layer 70b is fused from the rear surface side to the rear fusion film 72 of the front film layer 70a at the flat film portion 70c (corresponding portion of the barrier film 73 to the flat film portion 70c). Yes. This fusion is performed by fusing the corresponding portion of the barrier film 73 with respect to the flat film portion 70 c to the rear fusion film 72. As a result, a large number of cylindrical portions 70d open to the front film layer 70a at the respective opening ends, and in the opposite direction to the front film layer 70a (to the rear layer 60 side), respectively. It protrudes in a cylindrical shape as a closed cell part.

  In the third embodiment, the rear layer 60 described in the first embodiment is attached to the dash panel 30 from the rear surface side via the film laminate 70. Here, the rear layer 60 is fused from the rear surface side to the top wall portion of each cylindrical portion 70d of the rear film layer 70b at the central right intermediate portion 61, thereby the rear film layer 70b. Is fused. This fusion is performed by fusing each corresponding portion of the rear fusion film 74 with respect to the top wall portion of each cylindrical portion 70d to the central right intermediate portion 61 of the rear layer 60. Other configurations and the manufacturing method of the dash silencer are the same as those in the first embodiment.

  In the third embodiment configured as described above, as described above, the dash silencer differs from the first embodiment in that the front layer 40 described in the first embodiment is abolished and the film laminate 70 is removed. Unlike the first embodiment, the film laminate 70 is composed only of the rear layer 60, and the front film layer having a two-layer structure of the barrier film 71 and the rear fusion film 72 configured as described above. 70a and a laminated structure of a rear film layer 70b having a two-layer structure of a barrier film 73 and a rear fusion film 74.

  As a result, while simplifying the configuration of the film laminate 70 corresponding to the film laminate 50 described in the first embodiment and the configuration as the dash silencer, substantially the same effects as the first embodiment are achieved. Can be achieved.

Incidentally, the dash silencer in the third embodiment is defined as Example 3-1, and the sound absorption characteristics of Example 3-1 are measured by the reverberation chamber method sound absorption coefficient test in comparison with Comparative Example 3-1. I tried. Here, Comparative Example 3-1 has a single layer structure of felt having a thickness of 20 (mm) and a basis weight of 600 (g / m ² ).

  Based on the above assumption, a reverberation chamber method sound absorption coefficient test was performed on Example 3-1 and Comparative Example 3-1, and the results shown in FIG. 13 were obtained. In FIG. 13, each graph 3 and 4 shows the relationship between the sound absorption rate and the frequency in Example 3-1 and Comparative Example 3-1, respectively.

Thus, when comparing the graphs 3 and 4, in both graphs 3 and 4, the sound absorption rate changes so as to have substantially the same increasing tendency as the frequency increases. Here, in the range where the frequency is lower than about 1000 (Hz), the sound absorption rate according to the graph 3 tends to be somewhat lower than the sound absorption rate according to the graph 4, but in the range where the frequency is higher than about 1000 (Hz), It can be seen that the sound absorption rate by 3 tends to be somewhat higher than the sound absorption rate by graph 4 as the frequency increases.
(Fourth embodiment)

  FIG.14 and FIG.15 has shown the principal part of 4th Embodiment of the dash silencer which concerns on this invention. In the fourth embodiment, in the dash silencer described in the third embodiment, the rear layer 60 is eliminated and the front layer 40 described in the first embodiment is adopted.

  Accordingly, in the fourth embodiment, the front film layer 70a includes a front fusing film 72a that replaces the barrier film 71 described in the third embodiment, and a rear fusing described in the third embodiment. It is comprised by the barrier film 71a replaced with the adhesion film 72, and the barrier film 71a is melt | fused by the front side melt | fusion film 72a from the back surface side. Here, the front side fusion film 72a and the barrier film 71a are the respective configurations and formation materials, and the respective configurations and respective formations of the rear side fusion film 72 and the barrier film 71 described in the third embodiment, respectively. Same as material.

  The rear film layer 70b includes a front fusion film 74a that replaces the barrier film 73 described in the third embodiment, and a barrier film 73a that replaces the rear fusion film 74 described in the third embodiment. The rear film layer 70b is composed of a front fusion film 74a and a barrier film 73a, as in the rear film layer 70b described in the third embodiment. A plurality of cylindrical portions 70d are integrally formed.

  Thus, in the fourth embodiment, the front film layer 70a is fused from the rear surface side to the central right intermediate portion 41 of the front layer 40 by the front fusion film 72a. In addition, the rear film layer 70b is fused to the barrier film 71a of the front film layer 70a so as to enclose air in a large number of cylindrical parts 70d at a portion corresponding to the flat film part 70c in the front fuse film 74a. It is worn. Other configurations and the manufacturing method of the dash silencer are substantially the same as those in the first embodiment.

In the fourth embodiment configured as described above, as described above, the dash silencer is different from the third embodiment, except that the rear layer 60 is abolished and the front layer 40 is adopted. It has the same configuration as the embodiment. Even if comprised in this way, the effect substantially the same as the said 3rd Embodiment can be achieved.
(Fifth embodiment)

  FIG.16 and FIG.17 has shown the principal part of 5th Embodiment of the dash silencer which concerns on this invention. In the fifth embodiment, instead of the film laminate 70 described in the third embodiment (corresponding to the front layer 40 and the film laminate 50 described in the first embodiment), a film laminate 80 is provided. Is adopted.

  As shown in FIG. 16 or FIG. 17, the film laminate 80 includes a front film layer 80a and a rear film layer 80b formed by laminating the front film layer 80a.

  The front film layer 80a has the same configuration as the front film layer 70a (see FIGS. 11 and 12) of the film laminate 70 described in the third embodiment, and the front film layer 80a is a front film. It is comprised with the barrier film 81 and the back side melt | fusion film 82 corresponding to the barrier film 71 and the back side melt | fusion film 72 of the layer 70a, respectively (refer FIG. 18). Here, the barrier film 81 and the rear side fusion film 82 are the same as the respective configurations and the formation materials of the barrier film 71 and the rear side fusion film 72 in the respective configurations and the respective formation materials.

  Thus, in the front film layer 80a configured as described above, the barrier film 81 is fused to the rear fused film 82 from the front side.

  On the other hand, the rear film layer 80b includes a barrier film 83 and a rear melt film corresponding to the barrier film 73 and the rear fusion film 74 of the rear film layer 70b of the film laminate 70 described in the third embodiment. It is comprised with the film 84 (refer FIG. 18). Here, the barrier film 83 and the rear fusion film 84 are the same as the respective formation materials of the barrier film 73 and the rear fusion film 74 of the rear film layer 70b in the respective formation materials.

  The rear film layer 80b includes a flat film portion 80c and a plurality of flat film portions 80c corresponding to the flat film portion 70c and the many cylindrical portions 70d of the rear film layer 70b of the film laminate 70 described in the third embodiment. It is comprised by the cylindrical part 80d (refer FIGS. 16-18).

  Here, the flat film portion 80c corresponds to the corresponding portions of the barrier film 83 and the rear fusion film 84 with respect to the flat film portion 80c, and the many cylindrical portions 80d are formed of the barrier film 83 and the rear fusion film. This corresponds to the corresponding portions of the 84 cylindrical portions 80d.

  However, in the fifth embodiment, unlike the third embodiment, the rear film layer 80b is a front film layer at a central portion excluding the outer peripheral edge (the outer peripheral edge of the flat film portion 80c). 80a (in other words, the rear fusion film 82) is formed separately from the front film layer 80a so as to face the gap with a predetermined gap Ga, and the rear film layer 80b has an outer peripheral edge portion. At (the outer peripheral edge portion of the flat film portion 80c), it is fused from the rear surface side to the outer peripheral edge portion of the front film layer 80a. This fusion is performed by fusing the corresponding portion of the barrier film 83 with respect to the outer peripheral edge of the flat film portion 80 c to the outer peripheral edge of the rear side fusion film 82.

Thereby, the large number of cylindrical portions 80d correspond to the predetermined gap Ga between the front film layer 80a and the flat film portion 80c of the rear film layer 80b at each opening end portion 85 (see FIG. 17). The communication area 86 (see FIG. 17) is formed. In other words, the large number of cylindrical portions 80d communicate with the communication region 86 inside each of the cylindrical portions 80d.
Therefore, the air is filled over the inside of each cylindrical portion 80d and the communication area 86, unlike each cylindrical portion 70d as each closed cell portion as in the third embodiment. In the fifth embodiment, this is not a closed cell portion such as each cylindrical portion 70d described in the third embodiment, but a single open cell portion extending over each cylindrical portion 80d and the communication region 86. 88 is configured.

  However, in the fifth embodiment, the predetermined gap Ga described above is set as follows. That is, the predetermined gap Ga is a distance between the rear layer 60 and the front film layer 80a so that the sound absorption performance can be exhibited substantially in the same manner as the film laminate 70 described in the third embodiment. It is set to 25 (%), more preferably 10 (%).

  In the fifth embodiment, the rear layer 60 described in the first embodiment is attached to the dash panel 30 from the rear surface side via the film laminate 80. Here, the rear layer 60 is fused from the rear surface side to the top wall portion of each cylindrical portion 80d of the rear film layer 80b at the central right intermediate portion 61, thereby the rear film layer 80b. Is fused. This fusion is performed by fusing each corresponding portion of the rear side fusion film 84 with respect to the top wall portion of each cylindrical portion 70 d to the central right intermediate portion 61 of the rear layer 60.

The distance between the rear layer 60 and the front film layer 80a is the same as the distance between the rear layer 60 and the front film layer 70a described in the third embodiment. Further, the material for forming the rear layer 60 in the fifth embodiment is the same as the material for forming the rear layer 60 in the first or third embodiment. However, the thickness and basis weight of the rear layer 60 in the fifth embodiment are different from the rear layer 60 in the first or third embodiment, and are 10 (mm) and 600 (g / m ² ). Other configurations and the manufacturing method of the dash silencer are the same as those in the first embodiment.

  In the fifth embodiment configured as described above, as described above, the dash silencer abolishes the front layer 40 described in the first embodiment, similarly to the third embodiment, and the film laminate. The front film layer 80a, the barrier film 83, and the rear side are composed of the two-layer structure of the barrier film 81 and the rear side fusion film 82, which are configured only by the rear layer 60 and the rear layer 60. It is constituted by a laminated structure of a rear film layer 80b having a two-layer structure of the fusion film 84.

  Here, in the fifth embodiment, the rear film layer 80b is opposed to the front film layer 80a through the predetermined gap Ga as described above at a portion other than the outer peripheral edge portion thereof, so that a flat film portion is obtained. A single communicating bubble portion 88 is formed between the inside of each cylindrical portion 80b and the communication region 86 between 80c and the front film layer 80a.

  Moreover, the predetermined gap Ga is a distance between the rear layer 60 and the front film layer 80a so that the sound absorption performance can be exhibited substantially in the same manner as the film laminate 70 described in the third embodiment. It is set to 25 (%), more preferably 10 (%).

  As a result, unlike the fifth embodiment, the film laminate 80 is different from the many closed cell portions composed of the many cylindrical portions 70d of the film laminate 70 described in the third embodiment. Even if the single communication bubble part 88 is formed in the inside of the part 80b and the communication area 86, the dash silencer of the fifth embodiment is similar in sound absorption to the dash silencer described in the third embodiment. Can exhibit properties.

  Incidentally, the dash silencer in the fifth embodiment is set to Example 5-1, and the sound absorption characteristic of Example 4 is measured by the reverberation chamber method sound absorption coefficient test in comparison with Comparative Example 5-1. . Here, Comparative Example 5-1 has the same configuration as the dash silencer described in the third embodiment, but the rear layer of Comparative Example 5-1 is the rear layer of Example 5-1 Based on the premise of having the same forming material (felt), thickness and basis weight as the forming material (felt), thickness and basis weight of Example 5-1, and Comparative Example 5-1. When a reverberation chamber method sound absorption coefficient test was performed, results as shown in FIG. 19 were obtained. In FIG. 19, each graph 5 and 6 shows the relationship between the sound absorption coefficient and the frequency in Example 5-1 and Comparative Example 5-1, respectively.

Thus, when comparing the graphs 5 and 6, in both graphs 5 and 6, the sound absorption rate changes so as to have a substantially similar increasing tendency as the frequency increases. According to this, unlike the film laminated body 80 of this 5th Embodiment, unlike the many closed cell parts said to the film laminated body 70 of the said 3rd Embodiment, it comprises so that the communicating bubble part 88 may be provided. However, it can be seen that the sound absorption characteristics similar to those of the third embodiment can be ensured.
(Sixth embodiment)

  FIG. 20 shows a main part of a sixth embodiment of the dash silencer according to the present invention. The dash silencer referred to in the sixth embodiment has a configuration in which the film laminate 90 is employed instead of the film laminate 50 in the dash silencer described in the first embodiment. That is, the dash silencer referred to in the sixth embodiment is configured by the front layer 40, the film laminate 90 described in the first embodiment, and the rear layer 60 described in the first embodiment. .

  As shown in FIG. 20 or FIG. 21, the film laminate 90 is laminated between the front layer 40 and the rear layer 60. The film laminate 90 includes the front film layer 90a and the front side layer. And a rear film layer 90b formed by laminating the film layer 90a.

  The front film layer 90a has the same configuration as the front film layer 50a (see FIGS. 4 and 5) of the film laminate 50 described in the first embodiment, and the front layer 90a is the first film layer 50a. The front side film layer 50a described in the embodiment is configured with the front side fusion film 91, the barrier film 92, and the rear side fusion film 93 corresponding to the front side fusion film 51, the barrier film 52, and the rear side fusion film 53, respectively. Has been. Here, the front side fusion film 91, the barrier film 92, and the rear side fusion film 93 are respectively the front side fusion film 51, the barrier film 52, and the rear side fusion film 53 in each configuration and each forming material. The configuration and each forming material are the same.

  Thus, in the front film layer 90a configured as described above, the barrier film 92 is fused to the front fusion film 91 from the rear surface side, and is fused to the rear fusion film 93 from the front surface side. Has been.

  On the other hand, the rear film layer 90b includes a front fusion film 94 and a barrier respectively corresponding to the front fusion film 54, the barrier film 55, and the rear fusion film 56 of the film laminate 50 described in the first embodiment. The film 95 and the rear fusion film 96 are used (see FIG. 21). Here, the front side fusion film 94, the barrier film 95, and the rear side fusion film 96 are the respective formation materials of the front side fusion film 54, the barrier film 55, and the rear side fusion film 56, respectively. Are the same.

  The rear film layer 90b includes a flat film portion 90c and a plurality of flat film portions 90c corresponding to the flat film portion 50c and the many cylindrical portions 50d of the rear film layer 50b described in the first embodiment. The cylindrical portion 90d (see FIGS. 21 and 22).

  Here, the flat membrane portion 90c corresponds to the corresponding portions of the front side fusion film 94, the barrier film 95, and the rear side fusion film 96 with respect to the flat membrane portion 90c. The film 94, the barrier film 95, and the rear fusion film 96 correspond to the corresponding portions of the multiple cylindrical portions 90d.

  However, in the sixth embodiment, unlike the first embodiment, the rear film layer 90b is a front film layer at a central portion excluding the outer peripheral edge (the outer peripheral edge of the flat film portion 90c). 90a is formed separately from the front film layer 90a so as to face through a predetermined gap Gb, and the rear film layer 90b is formed at the outer peripheral edge (the outer peripheral edge of the flat film part 90c). The outer peripheral edge portion of the front film layer 90a is fused from the rear surface side. This fusion is performed by fusing a corresponding portion of the front side fusion film 94 with respect to the outer peripheral edge of the flat film portion 90c to the outer peripheral edge of the rear film layer 93 of the front film layer 90a.

As a result, a large number of cylindrical portions 90d correspond to the predetermined gap Gb between the front film layer 90a and the flat film portion 90c of the rear film layer 90b at each open end 97 (see FIG. 21). The communication region 98 (see FIGS. 20 and 21) formed in this way communicates. In other words, the multiple cylindrical portions 90d communicate with the communication region 98 inside each of the cylindrical portions 90d.
Therefore, the air is filled over the inside of each cylindrical portion 90d and the communication region 98, unlike each cylindrical portion 50d as each closed cell portion as in the first embodiment. In the sixth embodiment, this is not a closed cell portion like each cylindrical portion 50d described in the first embodiment, but a single open cell portion extending over each cylindrical portion 90d and the communication region 98. 99 is configured.

  However, in the sixth embodiment, the predetermined gap Gb described above is set as follows. That is, the predetermined gap Gb is a distance between the rear layer 60 and the front film layer 90a so that the sound absorption performance can be exhibited substantially in the same manner as the film laminate 50 described in the first embodiment. It is set to 25 (%), more preferably 10 (%). In the sixth embodiment, Gb = Ga.

  In the sixth embodiment, the rear layer 60 described in the first embodiment is attached to the front layer 40 from the rear surface side through the film laminate 90. Here, the front film layer 90 a is fused to the front layer 40 from the rear surface side by the front fused film layer 91. On the other hand, the rear layer 60 is fused to the rear film layer 90b by being fused from the rear surface side to the top wall portion of each cylindrical portion 90d of the rear film layer 90b at the middle right intermediate portion 61 thereof. It is worn. This fusion is performed by fusing each corresponding portion of the rear fusion film 96 with respect to the top wall portion of each cylindrical portion 90 d to the central right intermediate portion 61 of the rear layer 60. Other configurations and the manufacturing method of the dash silencer are the same as those in the first embodiment.

  In the sixth embodiment configured as described above, as described above, the dash silencer is configured by the front layer 40, the film laminate 90, and the rear layer 60 similarly to the first embodiment, and the film laminate. 90 is a front film layer 90a having a three-layer structure of the front side fusion film 91, the barrier film 92, and the rear side fusion film 93 configured as described above, and the front side fusion film 94, the barrier film 95, and the rear side fusion. The film 96 has a laminated structure of a rear film layer 90b having a three-layer structure.

  Here, in the sixth embodiment, the rear film layer 90b is opposed to the front film layer 90a via the predetermined gap Gb at a portion other than the outer peripheral edge portion as described above, so that the flat film portion A single communicating bubble portion 98 is formed between each of the cylindrical portions 90b and the communication region 98 between 90c and the front film layer 90a.

  Moreover, the predetermined gap Gb is a distance between the rear layer 60 and the front film layer 90a so that the sound absorbing performance can be exhibited substantially in the same manner as the film laminate 90 described in the first embodiment. It is set to 25 (%), more preferably 10 (%).

  As a result, unlike the sixth embodiment, the film laminate 90 is different from the many closed cell portions composed of the many cylindrical portions 50d of the film laminate 50 described in the first embodiment. The dash silencer of the sixth embodiment is similar in sound absorption to the dash silencer described in the first embodiment, even if the inside of the portion 90b and the communication region 98 form a single communication bubble 99. Can exhibit properties.

In carrying out the present invention, the following various modifications are possible without being limited to the above embodiments.
(1) In the film laminate 50, 70, 80 or 90, the barrier film forming material is not limited to nylon, and may be a resin such as a polyester film. Further, the material for forming each fusion film may be a thermoplastic resin having a lower melting point (melting point: 200 (° C.) or lower) than the material for forming the barrier film, such as polyethylene, polypropylene, polyethylene terephthalate, or unsaturated polyester. In addition, the molding of the cylindrical portion of the film laminate may be continuous or single molding.
(2) The material for forming the front layer 40 or the rear layer 60 is not limited to those described in the above embodiments, but is a structural material of organic fibers such as PET or wool, or an inorganic fiber structure material such as glass wool, or urethane foam. Any porous synthetic resin material may be used.
(3) In the film laminate 50, 70, 80 or 90, each of the forming materials of the front side fusion film 53, 71, 81, 91 or 93 and the rear side fusion film 53, 82, 93 or 96 is the barrier film 52. , 55, 72, 74, 82, 84, 92, or 95 as long as it has a lower melting point, and different thermoplastic resin materials may be used.
(4) In manufacturing the dash silencer DS described above, unlike the above embodiments, a sheet-like polyethylene for the front-side fused film, a sheet-like polyethylene for the barrier film, and a sheet-like polyethylene for the rear-side fused film are prepared in advance. Then, the sheet-like nylon for the barrier film is laminated so as to be sandwiched between the sheet-like polyethylene for the front-side fused film and the sheet-like polyethylene for the rear-side fused film to form the above-mentioned single sheet-like film. It may be.
(5) The noise for the dash silencer DS is not limited to the engine sound, and may include various noises that enter the engine room.
(6) In carrying out the present invention, the present invention may be applied to a floor silencer, a pillar silencer, a roof silencer, a room partition silencer, a hood silencer, an engine undercover silencer, etc., without being limited to a dash silencer.
(7) In carrying out the present invention, the film laminate 50 is not limited to a non-breathable one, but may be a breathable one. Specifically, a large number of small holes are penetrated over the entire surface of the film laminate 50 with a predetermined diameter (for example, 5 (mm)) and a predetermined opening pitch (for example, 30 (mm)). You may make it form.
(8) In carrying out the present invention, the film laminate is not limited to one location of the dash silencer, but may be applied to the entire product or each of a plurality of thickness increasing portions, unlike the above embodiment. .
(9) In carrying out the present invention, the film laminate may be applied to the thickness compression portion of the dash silencer without being limited to the thickness increase portion of the dash silencer. In this case, if the compression is performed to such an extent that the cylindrical portion of the film laminate is not completely crushed, it is possible to ensure good sound absorption.

In addition, the portion of the dash silencer where the plate thickness is desired to be reduced needs to compress the thermoplastic felt, but with this, even if the thinness can be secured, the density of the portion desired to be reduced increases. Sound absorption as a felt will be impaired.
(10) In carrying out the present invention, in the dash silencer described in the first embodiment, the film laminate 50 is different from the first embodiment in that the front film layer 50a is placed in the middle right middle of the rear layer 60. It is located on the part 61 side, and the rear film layer 50b is located on the middle right intermediate part 41 side of the front layer 40 so that it is laminated between the front film layer 50a and the rear film layer 50b. Good.
(11) In carrying out the present invention, the large number of cylindrical portions 50d in the rear film layer 50b of the film laminate 50 described in the first embodiment are not limited to a staggered pattern, but are dispersed in a grid pattern, for example. It may be formed as follows. Here, the cylindrical portion 50d may be a cylindrical portion having various shapes such as a rectangular cylindrical portion and a triangular cylindrical portion.
(12) In the manufacturing process of the dash silencer DS described in the above embodiment, an extrusion molding process may be employed instead of the inflation molding process.
(13) In the manufacturing process of the dash silencer DS described in the above embodiment, the heating step S3 and the cold pressure forming step S4 are not limited to the continuous steps with respect to the inflation forming step S1 and the vacuum forming step S2. A step different from the step S1 and the vacuum forming step S2 may be used.
(14) In the embodiment of the present invention, the cylindrical portion described in the fifth or sixth embodiment is not limited to a large number of cylindrical portions, and may be at least one cylindrical portion.
(14) In the embodiment of the present invention, the flat film portion described in the fifth or sixth embodiment is not limited to the whole, but at least a part thereof corresponds to the corresponding portion of the front film layer. It may be fused.

40 ... front layer, 41, 61 ... middle right middle part,
50, 70, 80, 90 ... film laminate, 50c, 70c, 80c, 90c ... flat membrane part,
50d, 70d, 80d, 90d ... cylindrical part,
50a, 70a, 80a, 90a ... front film layer,
50b, 70b, 80b, 90b ... rear film layer,
52, 55, 71, 73, 71a, 73a, 81, 83, 92, 95 ... barrier film,
51, 54, 56, 74a, 91, 94 ... front side fusion film,
53, 56, 72, 72a, 74a, 82, 84, 93, 96 ... rear fusion film,
60 ... rear layer, DS ... dash silencer.

Claims (10)

Comprising a porous layer formed of a porous material, and a film laminate laminated at least partially on the porous layer,
The film laminate is
A first barrier film formed of a resin having a melting point higher than that of the thermoplastic resin, and the thermoplastic layer laminated on the first barrier film and fused to the first barrier film at a temperature lower than the melting point. A first film layer having a first fusion film made of a resin;
A second barrier film formed of a resin having a melting point higher than that of the thermoplastic resin, and the outer peripheral edge of the second barrier film is formed on the outer peripheral edge of the first fusion film from the side opposite to the first barrier film. A second barrier film fused at a temperature lower than the melting point, and the thermoplastic resin laminated on the second barrier film and fused to the second barrier film at a temperature lower than the melting point. And a second film layer having a second fused film.
The second film layer is
At least a part of each of the inner peripheral side portion of the outer peripheral edge portion of the second barrier film and the corresponding fusion portion of the second fusion film corresponding thereto is opened toward the first fusion film. And at least one cylindrical portion that protrudes in a direction away from the first fusion film,
A flat membrane portion comprising each portion other than the at least one cylindrical portion of both the inner peripheral side portion of the second barrier film and the corresponding fusion portion of the second fusion film;
The at least one tube part is formed as a bubble part that encloses air between itself and at least a part of the flat film part and the first fusion film,
The automobile silencer, wherein the porous layer is fused at a temperature lower than the melting point to a corresponding portion of the second fusion film with respect to a top of the at least one cylindrical portion at the at least part thereof. The flat membrane portion is fused at a temperature lower than the melting point to the corresponding portion of the first fusion film with respect to the inner peripheral side portion of the second barrier film as a whole. And
The at least one cylindrical portion protrudes as a closed cell portion in a direction away from the first fusion film so as to open from the plurality of portions of the flat membrane portion toward the first fusion film, respectively. The automobile silencer according to claim 1, wherein the silencer is a cylindrical portion.   The at least one cylindrical part is formed as at least one communicating bubble part including air between the first film and the first fusion film together with at least a part of the flat film part. The automobile silencer according to claim 1. Comprising a porous layer formed of a porous material, and a film laminate laminated at least partially on the porous layer,
The film laminate is
A first fused film formed of a thermoplastic resin, and higher than the thermoplastic resin laminated on the first fused film and fused to the first fused film at a temperature lower than the melting point. A first film layer having a first barrier film made of a resin having a melting point;
A second fusion film formed of the thermoplastic resin, the second fusion film formed by fusion at the outer peripheral edge thereof to the outer peripheral edge of the first barrier film at a temperature lower than the melting point. A film and a second barrier film made of a resin having a higher melting point than the thermoplastic resin laminated to the second fused film and fused to the second fused film at a temperature lower than the melting point. A second film layer having
The second film layer is
At least a part of both the inner peripheral side portion of the outer peripheral edge portion of the second fusion film and the corresponding fusion portion of the second barrier film corresponding to the outer peripheral edge portion is opened toward the first barrier film. At least one tube portion protruding in a direction away from the first barrier film;
A flat membrane portion comprising each portion other than the at least one cylindrical portion among both the inner peripheral side portion of the second fusion film and the corresponding fusion portion of the second barrier film;
The at least one tube part is formed as a bubble part that encloses air between itself and at least a part of the flat film part and the first barrier film,
The porous silencer according to claim 1, wherein the porous layer is fused to the first fusion film of the first film layer at a temperature lower than the melting point in the at least part of the porous layer. The flat membrane portion is fused at a temperature lower than the melting point to the corresponding portion of the first barrier film with respect to the inner peripheral side portion of the second fusion film. And
The at least one tube portion is a plurality of tube portions protruding as closed cell portions in a direction away from the first barrier film so as to open from the plurality of portions of the flat membrane portion toward the first barrier film, respectively. The silencer for an automobile according to claim 4, wherein   The at least one cylindrical portion is formed as at least one communicating bubble portion that encloses air with the first barrier film together with at least a part of the flat membrane portion. Item 5. A silencer for automobile according to item 4. Both porous layers formed of a porous material, and a film laminate that is laminated between at least the opposing portions of the porous layers,
The film laminate is
Both first fused films formed of a thermoplastic resin and a resin having a melting point higher than that of the thermoplastic resin and fused between the first fused films at a temperature lower than the melting point. A first film layer having a first barrier film formed thereon;
One of the second fusion films formed of the thermoplastic resin and the outer peripheral edge of one of the first fusion films at the outer peripheral edge portion thereof One second fusion film fused to the part at a temperature lower than the melting point, and laminated on the one second fusion film and lower than the melting point to the one second fusion film A second barrier film made of a resin having a melting point higher than that of the thermoplastic resin fused at a temperature; and a second barrier film laminated on the second barrier film and fused to the second barrier film at a temperature lower than the melting point. A second film layer having the other second fused film,
The second film layer includes at least one of the inner peripheral portion of the outer peripheral edge of the one second fusion film and the corresponding fusion portion of the second barrier film and the other second fusion film. At least one cylindrical part formed by projecting each part in a direction away from the one first fusion film so as to open toward the one first fusion film;
Other than the at least one cylindrical portion among the inner peripheral side portion of the one second fusion film, the corresponding fusion portion of the second barrier film, and the corresponding fusion portion of the other second fusion film. And a flat membrane part consisting of each part of
The at least one tube part is formed as a bubble part that encloses air between itself and the first fusion film together with at least a part of the flat film part,
One of the porous layers is fused to the other first fusion film at a temperature lower than the melting point at the at least part of the porous layer, and the other porous layer is at least part of the porous layer. A silencer for an automobile, wherein the silencer is fused at a temperature lower than the melting point to a corresponding portion of the other second fusion film with respect to a top of the at least one cylindrical portion. The flat membrane portion is at a temperature lower than the melting point at the corresponding portion of the one first fusion film with respect to the inner circumferential portion of the one second fusion film. Are fused,
The at least one tube portion is formed as a closed cell portion in a direction away from the first fusion film so as to open from the plurality of portions of the flat membrane portion toward the first fusion film. The automobile silencer according to claim 7, wherein the silencer is a plurality of protruding cylindrical portions.   The at least one cylindrical portion is formed as a communicating bubble portion that encloses air between the flat film portion and at least a part of the flat membrane portion and the one first fusion film. Item 8. The automobile silencer according to Item 7. Resin having a porous member for both porous layers, a fused film made of a thermoplastic resin material, and a melting point higher than the melting point of the thermoplastic resin material fused between the fused films Prepare first and second three-layer films respectively formed by barrier films made of materials,
Vacuum forming the second three-layer film so that a plurality of cylindrical portions protrude from the flat membrane portion in the thickness direction,
The first three-layer film layer is laminated on at least a part of one of the porous members for both porous layers, and the plurality of cylindrical portions are protruded in a direction opposite to the first three-layer film layer. Further, the second three-layer film layer is laminated on the first three-layer film layer, and the plurality of tube portions are arranged at positions opposite to the other at least part of the porous members for both porous layers. A method of manufacturing an automotive silencer in which a structure laminated on the second three-layer film layer is subjected to cold pressure molding after heating so as to melt the respective fusion films.

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