JP2018171822A - Functional laminate and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a functional laminate having improved sound absorbency, heat insulation performance and vibration-damping performance.SOLUTION: In a functional laminate 100A, a porous surface layer 1 and a resin foam layer 2 are laminated. The porous surface layer 1 and the resin foam layer 2 are bonded together, partially at a boundary 4 therebetween, with a mixed layer part 11 of the porous surface layer and the resin foam layer.SELECTED DRAWING: Figure 1A

Description

  The present invention relates to a functional laminate and a method for producing the same.

  2. Description of the Related Art In recent years, many attempts have been made to absorb sound generated by an engine such as a vehicle (for example, an automobile, a truck, a bus, and a train) and an agricultural machine (for example, a mower and a tiller).

  In particular, in the field of automobiles, from the viewpoint of passenger comfort, attempts have been made to absorb engine noise by covering a powertrain member including an engine and a transmission with a sound absorbing material. As the cover material, for example, urethane foam and fiber nonwoven fabric are used alone.

  On the other hand, as an integrated foamed product such as a headrest, seat seat, seat back, and armrest, an integral foam consisting of a latex foam thin layer applied directly to the inner surface of the fabric and a body foam that is directly injected into the inner surface and foamed and cured A product has been reported (Patent Document 1). In such an integrally foamed product, the latex foam thin layer is mechanically bonded so as to embrace the fibers on the inner surface of the fabric in a region close to the fabric to form a bonded region, and the main body foam stock solution is substantially prevented from entering outside. It forms a breathable skin that prevents it.

  In addition, as a foam molded body such as a chair and a cushion, a foam molded body in which a sheet material is integrated on the outer surface of a foam molded body is reported (Patent Document 2). In such a foamed molded article, the sheet material is composed of a laminate of a stretched porous film and a non-woven fabric, and has a property of allowing gas to permeate but not liquid.

International Publication No. 93/03904 JP 2011-148204 A

  The inventor of the present invention has found a new problem that sound absorption is not sufficiently obtained when the technology related to the foamed product or the foamed molded body is applied to, for example, a cover material for a powertrain member.

  Therefore, the inventor of the present invention performs foam molding in a mold, for example, simply in the presence of a glass fiber nonwoven fabric, and forms the glass fiber nonwoven fabric and the foamed layer on the entire boundary (entire surface) of the glass fiber nonwoven fabric. It has also been found that sufficient sound absorption is not obtained even if they are bonded to each other by the mixed layer portion of the foam layer.

  An object of this invention is to provide the functional laminated body which is excellent by sound-absorbing property.

  Another object of the present invention is to provide a functional laminate that is superior not only in sound absorption but also in heat insulation.

The present invention
A porous surface layer and a resin foam layer are laminated,
The present invention relates to a functional laminate in which the porous surface layer and the resin foam layer are bonded to each other by a mixed layer portion of the porous surface layer and the resin foam layer at a part of their boundary.

The functional laminate of the present invention is superior in sound absorption.
The functional laminate of the present invention is also superior in heat insulation.
The functional laminate of the present invention is also superior in vibration damping properties.

The upper part shows a schematic plan view of the functional laminate according to Embodiment 1 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 1 of the present invention is produced, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 2 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 2 of the present invention is manufactured, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 3 of the present invention, and the lower part schematically shows the functional laminate when the PP cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 3 of the present invention is manufactured, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 4 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 4 of the present invention is manufactured, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 5 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 5 of the present invention is manufactured, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 6 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the base material for lamination in the mold when producing the functional laminate according to Embodiment 6 of the present invention, and the lower part shows P- of the base material for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 7 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 7 of the present invention is produced, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 8 of the present invention, and the lower part schematically shows the functional laminate when the P-P cross section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the substrate for lamination in the mold when the functional laminate according to Embodiment 8 of the present invention is manufactured, and the lower part shows P- of the substrate for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown. The upper part shows a schematic plan view of the functional laminate according to Embodiment 9 of the present invention, and the lower part schematically shows the functional laminate when the PP section of the upper functional laminate is viewed in the direction of the arrow. A cross-sectional view is shown. The upper part shows a schematic plan view of the base material for lamination in the mold when producing the functional laminate according to Embodiment 9 of the present invention, and the lower part shows P- of the base material for lamination in the upper mold. The typical cross section of a metal mold | die and the base material for lamination | stacking when a P cross section is seen in the arrow direction is shown.

[Functional laminate]
The functional laminate of the present invention relates to a laminate having at least sound absorbing properties, and the functionality includes at least one of the properties of sound absorbing properties, heat insulating properties, vibration damping properties, and the like.

  Hereinafter, the functional laminate of the present invention will be described in detail with reference to the drawings showing functional laminates according to various embodiments. In the present specification, various elements in the drawings are merely schematically and exemplarily shown for understanding of the present invention, and the appearance and size ratio may be different from the actual ones. The “vertical direction”, “left / right direction”, and “front / back direction” used directly or indirectly in this specification correspond to directions corresponding to the vertical direction, left / right direction, and front / back direction in the drawing, respectively. Unless otherwise specified, the same reference numerals or symbols indicate the same members or the same meaning contents except that the shapes are different.

  As shown in FIGS. 1A to 9A, the functional laminate of the present invention has a porous surface layer 1 and a resin foam layer 2 laminated thereon. In the present invention, the porous surface layer 1 and the resin foam layer 2 are bonded to each other by a mixed layer portion 11 of the porous surface layer 1 and the resin foam layer 2 at a part of the boundary 4 thereof. That is, the porous surface layer 1 and the resin foam layer 2 are bonded to each other by the mixed layer portion 11 only at a part of the boundary 4 thereof. When the porous surface layer 1 and the resin foam layer 2 are bonded or bonded together by the mixed layer at the entire boundary 4 (over the entire surface), the sound absorbing property, the heat insulating property, and the vibration absorbing property, particularly the sound absorbing property are sufficient. I can't get it. 1A-9A include FIGS. 1A, 2A, 3A, 4A, 5A, 6A, 7A, 8A and 9A. 1A to 9A, the upper part shows a schematic plan view of the functional laminate according to Embodiments 1 to 9 of the present invention, and the lower part shows a PP cross section of the upper functional laminate in the direction of the arrow. The typical sectional view of the functional layered product at the time of being damaged is shown.

  The mixed layer portion 11 includes the porous surface layer 1 formed by foaming and curing the foamable resin constituting the resin foam layer 2 when the resin foam layer 2 is foam-molded. It is a joint portion with the resin foam layer 2. The porous surface layer 1 has a mixed layer portion 11 only at a part of the boundary 4, and the mixed layer portion 11 provides adhesion and bonding between the porous surface layer 1 and the resin foam layer 2. In FIG. 1A to FIG. 9A, the mixed layer portion 11 is indicated by a hatched area by a solid line, and the hatched area by a broken line in the upper stage indicates the mixed layer portion 11 by fluoroscopy.

  The foamable resin constituting the resin foam layer 2 is a foamable resin (liquid raw material) used as a raw material for the resin foam layer 2. As will be described in detail later, when the resin foam layer 2 is, for example, a polyurethane foam layer, the foamable resin is a mixture of a polyol compound and an isocyanate compound. The foamable resin may contain additives such as a foaming agent and a foam stabilizer.

  The porous surface layer 1 does not have the mixed layer portion 11 in the portion 12 other than the part (portion having the mixed layer portion 11) in the boundary 4 with the resin foam layer 2. This is because in the method for producing a functional laminate described in detail later, the presence of the intermediate film 3 superimposed on the porous surface layer 1 inhibits the infiltration of the foamable resin into the porous surface layer 1. That is, when the intermediate film 3 is overlaid on the porous surface layer 1 and foam-molded on the intermediate film side, in the portion of the porous surface layer 1 where the intermediate film 3 is not laminated, the foamable resin permeates and the mixed layer portion 11 is formed. On the other hand, since the infiltration of the foamable resin into the porous surface layer 1 is inhibited by the intermediate film 3 in the portion 12 where the intermediate film 3 is laminated, the mixed layer portion 11 is not formed. As will be described in detail later, the intermediate film 3 disappears in the post-processing step. In FIGS. 1A to 9A, a portion where the intermediate film 3 is laminated is indicated by a broken line region 30. In FIG. 1A to FIG. 9A, the portion 30 where the intermediate film 3 was laminated theoretically has a space of the lost intermediate film, but the weight of the porous surface layer 1 and the intermediate film 3 The space does not substantially occur due to the thickness or the like.

The position (arrangement) of the mixed layer portion 11 of the porous surface layer 1 is particularly limited as long as the bonding between the porous surface layer 1 and the resin foam layer 2 is achieved at a part of the boundary 4 with the resin foam layer 2. Not. For example, the porous surface layer 1 is formed from at least one of the first main surface 15 mainly facing the resin foam layer 2, the second main surface 16 opposite to the first main surface, and the first main surface or the second main surface. In the case where the side surface 17 is erected, the mixed layer portion 11 is preferably positioned at a part of the boundary selected from the group consisting of the following portions.
(Part 1) A part (preferably an outer peripheral end part) of the first main surface 15; and (Part 2) a part or all of the side surface 17.

  The specific arrangement of the mixed layer portion 11 at the boundary 4 in the porous surface layer 1 may be determined according to the shapes of the porous surface layer 1 and the resin foam layer 2.

  Specifically, for example, in the functional laminates 100A and 100B according to Embodiments 1 and 2 shown in FIGS. 1A and 2A, both the porous surface layer 1 and the resin foam layer 2 have a flat plate shape. The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first major surface 15 (entire surface). In this case, the mixed layer portion 11 is preferably positioned on a part of the first main surface 15. In FIG. 1A, the mixed layer portion 11 is continuously positioned at the outer peripheral end portion of the first main surface 15. However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, as shown in FIG. 2A, the mixed layer portion 11 may be scattered in the outer peripheral end portion of the first main surface 15. In addition, the central portions of the first main surface 15 may be positioned in a scattered manner, or the central portions of the first main surface 15 may be continuously positioned. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, the mixed layer portion 11 is preferably positioned continuously or in a scattered manner at the outer peripheral end portion of the first main surface 15.

  Also, for example, in the functional laminate 100C according to Embodiment 3 shown in FIG. 3A, the porous surface layer 1 has a flat plate shape. The resin foam layer 2 has a surrounding portion 21 that surrounds the flat plate portion 20 and the porous surface layer 1 from the entire outer peripheral side surface 17 (entire surface). The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first major surface 15 (entire surface) and the entire outer peripheral side surface 17 (entire surface). In this case, the mixed layer portion 11 is preferably positioned at a part of the boundary 4 selected from the group consisting of a part of the first main surface 15 and a part or all of the outer peripheral side surface 17. In FIG. 3A, the mixed layer portion 11 is positioned on the entire outer peripheral side surface 17 (entire surface). However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be positioned continuously or interspersed with a part of the outer peripheral side surface 17 or the first main surface. The outer peripheral end portions and / or the central portions of the 15 outer peripheral ends may be continuously or scattered. From the viewpoint of further improving the functionality (especially sound absorption) of the laminate, it is preferable that the mixed layer portion 11 is positioned continuously or interspersed on all (entire surface) or part of the outer peripheral side surface 17.

  Moreover, for example, in the functional laminate 100D according to Embodiment 4 shown in FIG. 4A, the porous surface layer 1 has a flat plate shape. The resin foam layer 2 has an extending portion 22 that extends to the second main surface 16 while being in contact with a part of the outer peripheral side surface 17 of the flat plate portion 20 and the porous surface layer 1. The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first main surface 15 (entire surface), a part of the outer peripheral side surface 17 and a part of the second main surface 16. In this case, the mixed layer portion 11 is preferably positioned at a part of the boundary 4 selected from the group consisting of a part of the first main surface 15 and a part or all of the side surface 16. In FIG. 4A, the mixed layer portion 11 is positioned at the outer peripheral end portion of the first main surface 15, a part of the outer peripheral side surface 17, and a part of the second main surface 16. However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be positioned continuously or interspersed with a part of the outer peripheral side surface 17 or the first main surface. The outer peripheral end portions and / or the central portions of the 15 outer peripheral ends may be continuously or scattered. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, the mixed layer portion 11 is continuously or interspersed with all (entire surface) or part of the outer peripheral side surface 17 and the outer peripheral end portion of the first main surface 15. Preferably it is positioned.

  Further, for example, in the functional laminate 100E according to Embodiment 5 shown in FIG. 5A, the porous surface layer 1 has a flat plate shape having through holes 18 extending from the first main surface 15 to the second main surface 16. The resin foam layer 2 has a flat plate portion 20 and a through portion 23 formed inside the through hole 18. The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first main surface 15 (entire surface) and the entire side surface 17 constituting the through-hole 18 (entire surface). In this case, the mixed layer portion 11 is preferably positioned at a part of the boundary 4 selected from the group consisting of a part of the first main surface 15 and a part or all of the side surface 17 of the through hole 18. In FIG. 5A, the mixed layer portion 11 is positioned on the entire side surface 17 (entire surface) of the through hole 18. However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be positioned continuously or interspersed with a part or all of the side surface 17 of the through hole 18, Alternatively, the first main surface 15 may be continuously or dottedly positioned at the outer peripheral end portion and / or the central portion. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, it is preferable that the mixed layer portion 11 is continuously or dottedly positioned on all (entire surface) or part of the side surface 17 of the through hole 18.

  Further, for example, in the functional laminate 100F according to Embodiment 6 shown in FIG. 6A, the porous surface layer 1 has a ring shape having a hollow portion. The resin foam layer 2 has a flat plate portion 20 having a hollow portion 6a and a surrounding portion 21 that surrounds the entire outer peripheral side surface 17a and inner peripheral side surface 17b (entire surface). The porous surface layer 1 is adjacent to the resin foam layer 2 on the entire first major surface 15 (entire surface) and on the entire outer peripheral side surface 17a and inner peripheral side surface 17b (entire surface). In this case, the mixed layer portion 11 is preferably positioned at a part of the first main surface 15 and a part of the boundary 4 selected from the group consisting of a part or all of the outer peripheral side surface 17a and the inner peripheral side surface 17b. . In FIG. 6A, the mixed layer portion 11 is positioned on the entire outer peripheral side surface 17a and inner peripheral side surface 17b (entire surface). However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be continuously or dottedly positioned at a part of the outer peripheral side surface 17 a and / or the inner peripheral side surface 17 b. Alternatively, the first main surface 15 may be continuously or dottedly positioned on a part of the first main surface 15. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, the mixed layer portion 11 should be positioned continuously or interspersed on all (entire surface) or part of the outer peripheral side surface 17a and / or inner peripheral side surface 17b. Is preferred.

  Further, for example, the functional laminate 100G according to Embodiment 7 shown in FIG. 7A includes two porous surface layers 1 having a flat plate shape. The resin foam layer 2 has a flat plate portion 20 having a hollow portion 6 b and a connecting portion 24 that connects the two porous surface layers 1. The porous surface layer 1 is adjacent to the resin foam layer 2 on the entire first main surface 15 (entire surface) and on the entire inner side surface 17c (entire surface). In this case, the mixed layer portion 11 is preferably positioned at a part of the boundary 4 selected from the group consisting of a part of the first main surface 15 and a part or all of the inner side surface 17c. In FIG. 7A, the mixed layer portion 11 is positioned on the entire outer end portion of the first main surface 15 and the inner side surface 17 c (entire surface). However, as long as the mixed layer part 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer part 11 may be positioned continuously or scattered in a part of the inner side surface 17c, or the first main surface. A part of 15 may be continuously or scattered. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, the mixed layer portion 11 is continuously or interspersed with all (entire surface) or part of the outer end portion and the inner side surface 17c of the first main surface 15 Preferably it is positioned.

  Further, for example, in the functional laminate 100H according to Embodiment 8 shown in FIG. 8A, the porous surface layer 1 extends from the flat plate portion 10 and the flat plate portion 10 in the thickness direction of the porous surface layer 1. Part 19. The resin foam layer 2 has a flat plate portion 20 and an extending portion 25 extending from the flat plate portion 20 in the thickness direction of the resin foam layer 2. The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first main surface 15 (entire surface) and the entire inner side surface 17d of the flat portion 10 and the inner side surface 17e of the extending portion 19 (entire surface). In this case, the mixed layer portion 11 is preferably positioned at a part of the boundary 4 selected from the group consisting of a part of the first main surface 15 and a part or all of the inner side surfaces 17d and 17e. In the functional laminate 100H, the porous surface layer 1 and the resin foam layer 2 have complementary shapes in their cross sections (for example, the lower part of FIG. 8A). In FIG. 8A, the mixed layer portion 11 is positioned on all (entire surface) of the inner side surfaces 17d and 17e. However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be positioned continuously or interspersed on a part of the inner side surfaces 17 d and 17 e, or the first The main surface 15 may be positioned continuously or in a scattered manner. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, it is preferable that the mixed layer portion 11 is positioned continuously or interspersed on all (entire surface) or part of the inner side surfaces 17d and 17e.

  For example, in the functional laminate 100J according to Embodiment 9 shown in FIG. 9A, the porous surface layer 1 includes an annular portion 10a having a hollow portion 6c, an outer peripheral side surface 17f, and an inner peripheral side surface 17g, and the resin foam layer 2 Includes an enclosing portion 19a that surrounds the entire outer peripheral side surface 17f and the inner peripheral side surface 17g (entire surface). The resin foam layer 2 has a ring shape. The porous surface layer 1 is adjacent to the resin foam layer 2 over the entire first main surface 15 (entire surface) and the entire outer peripheral side surface 17f and inner peripheral side surface 17g (entire surface). In this case, it is preferable that the mixed layer portion 11 is positioned at a part of the first main surface 15 and a part of the boundary 4 selected from the group consisting of a part or all of the outer peripheral side surface 17f and the inner peripheral side surface 17g. . In FIG. 9A, the mixed layer portion 11 is positioned over the entire outer peripheral side surface 17f and inner peripheral side surface 17g (entire surface). However, as long as the mixed layer portion 11 is positioned at a part of the boundary 4 with the resin foam layer 2, the mixed layer portion 11 may be continuously or dottedly positioned at a part of the outer peripheral side surface 17f and / or the inner peripheral side surface 17g. Alternatively, the first main surface 15 may be continuously or dottedly positioned on a part of the first main surface 15. From the viewpoint of further improving the functionality (especially sound absorption) of the laminated body, the mixed layer portion 11 should be continuously or dottedly positioned on all (entire surface) or part of the outer peripheral side surface 17f and / or the inner peripheral side surface 17g. Is preferred.

  From the viewpoint of further improving the functionality (particularly sound absorption) of the functional laminate, the mixed layer portion 11 is formed on a part or all of the outer peripheral end of the first main surface 15 and / or the side surface 17 of the porous surface layer 1. Preferably it is positioned. As such a preferable specific example, functional laminated body 100A-100J which concerns on said Embodiments 1-9 is mentioned. The outer peripheral end portion of the first main surface 15 is a region having a width d from the outermost end in a plan view of the first main surface 15, and the total length of the first main surface 15 in the width direction is D. In some cases, the width d may be 0.1 × D to 0.25 × D. Therefore, for example, as shown in FIGS. 1A to 9A, when the first main surface 15 has a rectangular shape with dimensions of vertical D1 (mm) × horizontal D2 (mm), the width d of the outer peripheral end is the vertical and horizontal directions. In each case, d1 (mm) (= 0.1 × D1 to 0.25 × D1) and d2 (mm) (= 0.1 × D2 to 0.25 × D2). In particular, as shown in FIGS. 6A, 7A, and 9A, when the total length D is divided by the hollow portion, the widths d ′ and d ″ of the outer peripheral end are set for the lengths D ′ and D ″. It only has to be done. For example, d2 ′ (mm) = 0.1 × D2 ′ to 0.25 × D2 ′) and d2 ″ (mm) = 0.1 × D2 ″ to 0.25 × D2 ″. For example, when the 1st main surface 15 is circular shape of diameter D3 (mm) dimension, the width | variety d of an outer peripheral edge part is d3 (mm) (= 0.1 * D3-0.25 * D3). Here, the side surface 17 is the side surface 17 of the porous surface layer 1 of FIGS. 3A and 4A, the side surface 17 of the through hole 18 of FIG. 5A, the outer peripheral side surface 17a and the inner peripheral side surface 17b of the porous surface layer 1 of FIG. The inner side surface 17c of the porous surface layer 1 of 7A, the inner side surface 17d of the flat portion 10 and the inner side surface 17e of the extending portion 19 in the porous surface layer 1 of FIG. 8A, and the outer peripheral side surface of the porous surface layer 1 of FIG. 17f and inner peripheral side 17g.

  In the functional layered product (for example, 100A to 100J) of the present invention, the porous surface is formed in the portion (region) 12 other than the mixed layer portion 11 forming region in the boundary 4 between the porous surface layer 1 and the resin foam layer 2. The layer 1 and the resin foam layer 2 have one of the following forms 1 or 2, or a composite form thereof.

(Embodiment 1) The porous surface layer 1 and the resin foam layer 2 are adjacent to each other at the other portion 12 so as to be separable from each other. That is, the porous surface layer 1 and the resin foam layer 2 are adjacent to each other in the other portion 12, but are not integrated, and can be easily separated from each other or brought into contact with each other by an external force. Can do. As described in detail later, Form 1 is mainly brought about when a water-soluble film is used as the intermediate film 3 and this is eliminated in the post-treatment process.

(Form 2) The porous surface layer 1 and the resin foam layer 2 are integrated and adjacent to each other in the other portion 12. That is, the porous surface layer 1 and the resin foam layer 2 are integrated in the other portion 12, and cannot be easily separated from each other or brought into contact with each other by an external force. However, such integration is not achieved as strongly as integration based on adhesion and bonding by the mixed layer portion 11, and is such integration that can be broken by pulling by a human hand. Form 2 is mainly brought about when a hot melt film is used as the intermediate film 3 and disappears in a post-treatment step, as will be described in detail later.

  The ratio of the mixed layer portion 11 occupying the first major surface 15 of the porous surface layer 1 is preferably as small as possible so long as the bonding between the porous surface layer 1 and the resin foam layer 2 is achieved. The ratio of the mixed layer portion 11 occupying the first main surface 15 of the porous surface layer 1 is usually 90% or less, particularly 1 to 90%, and the bonding between the porous surface layer 1 and the resin foam layer 2 and the functionality. From the viewpoint of balance with further improvement in the functionality (particularly sound absorption) of the laminate, it is preferably 2 to 50%, more preferably 2 to 20%, and further preferably 2 to 10%.

  The ratio of the mixed layer portion 11 to the first main surface 15 of the porous surface layer 1 is the ratio of the area of the mixed layer portion 11 formation area to the area of the first main surface 15 of the porous surface layer 1.

(Porous surface layer)
The material which comprises the porous surface layer 1 is not specifically limited as long as it has porosity, For example, a fiber nonwoven fabric may be sufficient, or a polymer foam may be sufficient.

  Specific examples of the fiber nonwoven fabric of the porous surface layer include, for example, polyolefin fibers such as polyethylene fibers and polypropylene (PP) fibers; polyester fibers such as polyethylene terephthalate (PET) fibers and polybutylene terephthalate fibers; polyamide fibers such as aramid fibers; Polyvinyl alcohol fiber; Non-woven fabric of one or more organic fibers selected from the group consisting of cellulose fibers. The fiber nonwoven fabric of the porous surface layer may also be a nonwoven fabric of one or more inorganic fibers selected from the group consisting of glass fibers, silica fibers, rock wool, aluminum fibers, and alumina fibers. It may be a nonwoven fabric of mixed fibers of organic fibers and inorganic fibers.

  As the polymer foam of the porous surface layer, one having an open cell structure is used. As such a polymer foam, for example, selected from the group consisting of polyurethane foam layer; polyolefin foam layer such as polyethylene foam layer and polypropylene foam layer; polyester foam layer such as PET foam layer; silicone foam layer; Polymer foam layer.

  The porous surface layer is preferably a fiber non-woven fabric, more preferably a non-woven fabric of inorganic fiber or organic fiber, more preferably glass, from the viewpoint of further improving the sound absorption, heat insulation and vibration damping properties of the functional laminate. It is a nonwoven fabric of fibers.

  The average porosity Rs of the porous surface layer is usually 80 to 99.5%, and preferably 90 to 99% from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate. .

  The average porosity of the porous surface layer is the volume ratio of the voids formed between the fibers when the porous surface layer is a fiber nonwoven fabric, that is, the volume ratio of the voids between the fibers. Expressed as a percentage. The said nonwoven fabric of the porous surface layer part which is not impregnated with foamable resin is cut out from a functional laminated body. The volume ratio of the voids in the fiber nonwoven fabric is calculated, and this value is converted to the volume ratio of the voids when the thickness is the thickness of the porous surface layer described later in the functional laminate. The volume ratio of the voids can be calculated from physical properties such as the volume, weight, and specific gravity of the fiber nonwoven fabric. In this specification, the weight was measured using an electronic balance (AE160; manufactured by Mettler). Moreover, it can calculate from the volume of the said fiber nonwoven fabric, and the void volume of the said fiber nonwoven fabric measured by methods, such as a computer tomography method, a liquid immersion method, a water evaporation method, a suspension method, a mercury intrusion method, a gas adsorption method.

  When the porous surface layer is a polymer foam, the average porosity of the porous surface layer is the volume ratio of bubbles in the polymer inherently possessed by the polymer foam as the porous surface layer. Expressed as a percentage measured by the method. From the functional laminate, the polymer foam in the porous surface layer portion not impregnated with the foamable resin is cut out, and in the optical microscope or electron micrograph of the vertical cross section of the sample, bubbles with respect to the entire area at any 100 locations It can be calculated by measuring the ratio of the area and obtaining the average value.

  The average porosity of the porous surface layer uses the value measured from the functional laminate as described above, but even if measured from the material used for manufacturing (foam molding), the equivalent measured value is can get. That is, it can be calculated from physical properties such as the volume and weight of the porous surface layer material used for production (foam molding), the specific gravity of the fiber or polymer of the porous surface layer material. In this specification, the weight was measured using an electronic balance (AE160; manufactured by Mettler). Further, the volume of the porous surface layer material and the void volume of the porous surface layer material measured by a method such as a computer tomography method, a liquid immersion method, a water evaporation method, a suspension method, a mercury intrusion method, a gas adsorption method, etc. Can be calculated. Moreover, in the optical microscope and electron micrograph of the vertical cross section of the said porous surface layer material, it can calculate by measuring the ratio of the area of the bubble with respect to the whole area in arbitrary 100 places, and calculating | requiring an average value.

  The thickness of the porous surface layer is usually 1 to 50 mm, and preferably 2 to 30 mm from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate.

  The thickness of the porous surface layer is a thickness including a mixed layer portion to be described later, even if the porous surface layer is a fiber nonwoven fabric or a polymer foam. 1 is a thickness from the first main surface 15 to the second main surface 16 in 1 and is represented by a thickness measured by the following method. In the optical micrograph of the vertical cross section of the functional laminate, the thickness is measured at an arbitrary 100 locations to determine the average value.

  As for the thickness of the porous surface layer, the value measured from the functional laminate as described above is used, but even if measured from the material used for manufacturing (foam molding), the same measured value can be obtained. . That is, in the optical micrograph of the vertical cross section of the porous surface layer material used for production (foam molding), the thickness is measured at arbitrary 100 locations to obtain the average value. Further, the thickness of the porous surface layer material is measured with a gauge such as a film thickness meter, a displacement meter, or a caliper, and an average value is obtained.

  When the porous surface layer is a fiber nonwoven fabric in particular, the average fiber diameter and average fiber length of the fibers constituting the fiber nonwoven fabric are not particularly limited. The average fiber diameter is usually from 0.005 to 50 μm, preferably from 0.1 to 20 μm, more preferably from 1 to 20 μm, from the viewpoint of further improving the sound absorption, heat insulation and vibration damping properties of the functional laminate. 5 μm. The average fiber length is usually 2 mm or more, and preferably 20 mm or more from the viewpoint of further improving the sound-absorbing property, heat insulating property and vibration damping property of the functional laminate.

  The average fiber diameter of the fibers in the fiber nonwoven fabric of the porous surface layer is represented by the average diameter measured by the following method. Cut out the nonwoven fabric of the porous surface layer portion not impregnated with the foamable resin from the functional laminate, and measure the diameter of any 100 fibers in the optical microscope and electron micrographs of the vertical cross section of the sample. Find the average value.

  The average fiber length of the fibers in the fiber nonwoven fabric of the porous surface layer is represented by an average value measured by the following method. The said nonwoven fabric of the porous surface layer part which is not impregnated with foamable resin is cut out from a functional laminated body, the length of arbitrary 100 fibers is measured from the said nonwoven fabric, and an average value is calculated | required. Moreover, the inside of the nonwoven fabric is three-dimensionally imaged by a method such as CT, and the length of an arbitrary 100 fibers is measured to obtain an average value.

  The average fiber diameter and average fiber length of the fibers of the fiber nonwoven fabric use the values measured from the functional laminate as described above, but they are equivalent even if measured from the material used for manufacturing (foam molding) Is obtained. In other words, the average fiber diameter of the fibers of the fiber nonwoven fabric used for production (foam molding) is determined by measuring the diameter of any 100 fibers in an optical microscope or electron micrograph of a vertical cross section of the nonwoven fabric, and calculating the average value. Ask. The average fiber length of the fibers of the fiber nonwoven fabric used for production (foam molding) is obtained by measuring the length of any 100 fibers and determining the average value. Moreover, the inside of the said fiber nonwoven fabric is made into a three-dimensional image by methods, such as CT, and the length of arbitrary 100 fibers is measured and an average value is calculated | required.

When the porous surface layer is a fiber nonwoven fabric in particular, the basis weight of the fiber nonwoven fabric is not particularly limited, and is usually 50 to 6000 g / m ² , and further increases the sound absorbing property, heat insulating property, and vibration damping property of the functional laminate. From the viewpoint of improvement, it is preferably 100 to 3000 g / m ² .

  The basis weight in the fiber nonwoven fabric of the porous surface layer is represented by a value measured by the following method. The nonwoven fabric of the porous surface layer portion not impregnated with the foamable resin is cut out from the functional laminate, and the basis weight can be calculated from the area and weight of the nonwoven fabric. In this specification, the weight was measured using an electronic balance (AE160; manufactured by Mettler).

  As the basis weight of the fiber nonwoven fabric, the value measured from the functional laminate as described above is used. However, even when measured from the material used for production (foam molding), an equivalent measurement value is obtained. That is, the basis weight can be calculated from the area and weight of the fiber nonwoven fabric used for production (foam molding). In this specification, the weight was measured using an electronic balance (AE160; manufactured by Mettler).

(Resin foam layer)
The resin foam layer 2 is a polymer foam layer and has an open cell structure. The polymer constituting the resin foam layer may be any polymer known as a polymer capable of constituting a foam in the plastic field. Specific examples of the resin foam layer include, for example, a polyurethane foam layer; a polyolefin foam layer such as a polyethylene foam layer and a polypropylene foam layer; a polyester foam layer such as a PET foam layer; a silicone foam layer; and a polyvinyl chloride foam layer. Polymer foam layer.

  The resin foam layer is preferably a polyurethane foam layer from the viewpoint of further improving the sound absorption, heat insulation and vibration damping properties of the functional laminate.

  The average void diameter Df of the resin foam layer is not particularly limited, and may be, for example, in the range of 0.04 to 800 μm, particularly 10 to 600 μm, depending on the frequency of the sound to be absorbed. The greater the average void diameter Df of the resin foam layer is within the above range, the greater the frequency of the sound that is absorbed. On the other hand, the smaller the average void diameter Df of the resin foam layer is within the above range, the smaller the frequency of the sound that is absorbed.

  For example, when the average void diameter Df of the resin foam layer is 50 to 500 μm, particularly 100 to 300 μm, sound having a frequency of 1000 to 4000 Hz is effectively absorbed. Such sound absorption is suitable when the functional laminate is used for a cover member for a powertrain member of an automobile.

  The average void diameter Df of the resin foam layer is the diameter of bubbles in the polymer, and is represented by the average diameter measured by the following method. A resin foam layer is cut out from the functional laminate, and the diameter of an arbitrary 100 bubbles is measured in an optical microscope or an electron micrograph of a parallel section of the sample, and an average value is obtained.

  The average porosity Rf of the resin foam layer is usually 60 to 98%, and preferably 80 to 95% from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate.

  The average porosity of the resin foam layer is a volume ratio of bubbles in the polymer, and is expressed by a ratio measured by the following method. A resin foam layer is cut out from the functional laminate, and in the optical microscope and electron micrographs of the vertical cross section of the resin foam material, the ratio of the area of bubbles to the total area is measured at an arbitrary 100 locations, and the average value is obtained. Moreover, it can calculate from physical properties, such as the volume of the said resin foam material, weight, and specific gravity of a polymer. In this specification, the weight was measured using an electronic balance (AE160; manufactured by Mettler). Further, it can be calculated from the volume of the resin foam and the void volume of the resin foam measured by a method such as a computer tomography method, a liquid immersion method, a water evaporation method, a suspension method, a mercury intrusion method, a gas adsorption method.

  The thickness of the resin foam layer is usually 1 to 100 mm, and preferably 2 to 30 mm from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate.

  The thickness of the resin foam layer is a thickness in a direction substantially perpendicular to the second main surface 16 of the porous surface layer 1 and is a thickness up to the interface 22 with the intermediate film 3 in the resin foam layer 2. It is represented by the thickness measured by the method. In the optical micrograph of the vertical cross section of the functional laminate, the thickness is measured at an arbitrary 100 locations to determine the average value.

(Mixed layer)
The mixed layer portion 11 is a composite layer of a resin foam layer and a porous surface layer formed at the predetermined position (arrangement) at the interface 4 between the porous surface layer 1 and the resin foam layer 2. Specifically, the mixed layer portion 11 is a layer formed by the foamable resin constituting the resin foam layer 2 permeating into the porous surface layer 1 and foaming and curing. In other words, the configuration of the porous surface layer 1 It is a layer in which the material and the constituent material of the resin foam layer 2 coexist. In the mixed layer portion 11, bubbles of the foamable resin are formed in the voids of the porous surface layer 1 before the infiltration of the foamable resin. More specifically, a part of the porous surface layer 1 on the resin foam layer 2 side is converted to the mixed layer part 11, in other words, a part of the porous surface layer 1 on the resin foam layer 2 side in the mixed layer part 11. Is generated.

  The average gap diameter Dx of the mixed layer portion is not particularly limited, and may be, for example, in the range of 0.04 to 800 μm, particularly 10 to 500 μm, depending on the frequency of the sound to be absorbed. The larger the average gap diameter Dx of the mixed layer portion is within the above range, the greater the frequency of the sound that is absorbed. On the other hand, the smaller the average gap diameter Dx of the mixed layer portion is within the above range, the smaller the frequency of the sound that is absorbed.

  For example, when the average void diameter Dx of the mixed layer portion is 20 to 250 μm, preferably 42 to 250 μm, 47 to 250 μm, and 50 to 200 μm, sound having a frequency of 1000 to 4000 Hz is effectively absorbed. Such sound absorption is suitable when the functional laminate is used for a cover member for a powertrain member of an automobile.

  The average void diameter Dx of the mixed layer portion is the diameter of bubbles in the resin (polymer) formed in the voids of the porous surface layer before the infiltration of the foamable resin, and is measured by the following method. It is represented by In an optical microscope or electron micrograph of a parallel section of the mixed layer portion in the functional laminate, the diameter (longest diameter) of any 100 bubbles is measured, and the average value is obtained. Arbitrary 100 bubbles are arbitrary 100 bubbles formed by foaming of the foamable resin, and the bubbles and the bubbles inherently contained in the polymer foam as the porous surface layer are: It can be easily distinguished by the difference in brightness around the bubble. Moreover, a mixed layer part is cut out from a functional laminated body, the distribution of the diameter of the space | gap in this mixed layer part is measured by methods, such as a mercury intrusion method and a gas adsorption method, and an average diameter can be calculated.

  The average porosity Rx of the mixed layer portion is usually 30 to 95%, and preferably 50 to 90% from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate.

  The average porosity of the mixed layer portion is a volume ratio of bubbles in the resin (polymer) formed in the void of the porous surface layer before the infiltration of the foamable resin, and is a ratio measured by the following method. expressed. In an optical microscope or electron micrograph of a vertical cross section of the mixed layer portion in the functional laminate, the ratio of the area of bubbles to the total area is measured at an arbitrary 100 locations, and the average value is obtained. The area of bubbles is the area of bubbles in a resin (polymer) formed by foaming of a foamable resin in the voids of the porous surface layer. Further, it can be calculated from the volume of the mixed layer portion and the void volume of the mixed layer portion measured by a method such as a computer tomography method, a liquid immersion method, a water evaporation method, a suspension method, a mercury intrusion method, or a gas adsorption method.

  The thickness of the mixed layer portion is usually 0.05 to 5 mm, which is preferable from the viewpoint of further improving the sound absorbing property, heat insulating property, and vibration damping property (especially sound absorbing property) in a cover member application for an automobile powertrain member. Is 0.5 to 4 mm, more preferably 1 to 3 mm, and still more preferably 1 to 2.5 mm.

  The thickness of the mixed layer portion is a thickness in a direction substantially perpendicular to the second main surface 16 of the porous surface layer 1, and from the first main surface 15 in the porous surface layer 1 to the inside of the porous surface layer 1. Is the thickness until the foamable resin is not impregnated, and is represented by the thickness measured by the following method. In an optical microscope or electron micrograph of a vertical cross section in the vicinity of the mixed layer portion in the functional laminate, the thickness is measured at an arbitrary 100 locations to obtain an average value. In the optical microscope and the electron micrograph, the fact that the porous surface layer 1 is impregnated with the foamable resin and that the porous surface layer 1 is not impregnated are the presence / absence of the foamable resin in the voids of the porous surface layer 1 / Can be easily distinguished by the absence.

(Intermediate film)
The intermediate film 3 has no liquid permeability. The liquid impermeability of the intermediate film 3 is a characteristic that the intermediate film 3 cannot pass through its own foamable resin (liquid) when manufacturing the functional laminate.

  In the method for producing a functional laminate, the intermediate film 3 is a film that does not disappear in the foam molding step but disappears in the post-treatment step. Specific examples of such an intermediate film 3 include a hot melt film and a water-soluble film.

  A hot-melt film is a polymer film that disappears (melts) by heat treatment in a post-processing step described later and does not have a form as a film. The melting point of the hot melt film is particularly limited as long as it is a temperature at which the disappearance of the hot melt film is achieved while maintaining the form of the porous surface layer 1 and the resin foam layer 2 in the post-processing step described in detail later. Usually, it is 50-250 degreeC, Preferably it is 70-150 degreeC.

  Examples of the polymer constituting the hot melt film include polyurethane; polyester such as polyethylene terephthalate (PET) and polybutylene terephthalate; polyolefin such as polyethylene and polypropylene; polyamide such as aramid; and cellulose.

  The water-soluble film is a polymer film that disappears (dissolves) by an agitation treatment in water in a post-processing step described later, and does not have a film form. The water-soluble film may be water-soluble to such an extent that the film can be dissolved in water at 5 to 100 ° C., preferably 30 to 50 ° C. Dissolution may be achieved by stirring for 1 hour, preferably 40 minutes.

  Examples of the polymer constituting the water-soluble film include polyvinyl alcohol, polyacrylic acid, polyvinyl pyrrolidone, gelatin, pullulan, starch, alginic acid, and carrageenan.

  The thickness of the intermediate film is usually from 0.01 to 2 mm, and preferably from 0.02 to 0.5 mm from the viewpoint of further improving the sound absorbing property, heat insulating property and vibration damping property of the functional laminate.

The intermediate film 3 is available as a commercial product.
Hot melt films are, for example, SHE103-PUR, SHM104-PUR, etc. Ecelan series (NTW Co., Ltd.), Elfan series (Nihon Matai Co., Ltd.), Clan Better series (Kurashiki Spinning Co., Ltd.) Etc.).
Examples of the water-soluble film include C-200 high cellon series (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.), sorbon series (manufactured by Aicero Co., Ltd.), poval series (manufactured by Kuraray Co., Ltd.), etc. Is available as

[Method for producing functional laminate]
The functional laminate of the present invention can be produced by a production method including the following lamination base material forming step, foam molding step and post-treatment step. The manufacturing method of the functional laminated body of this invention is demonstrated in detail using FIG. 1B-FIG. 9B. 1B-9B include FIGS. 1B, 2B, 3B, 4B, 5B, 6B, 7B, 8B and 9B. In FIG. 1B to FIG. 9B, the upper part shows a schematic plan view of the base material for lamination in the mold when the functional laminates according to Embodiments 1 to 9 of the present invention are produced, respectively, and the lower part shows the upper part metal mold. A typical sectional view of a metallic mold and a substrate for lamination when a PP section of a substrate for lamination in a model is seen in the direction of an arrow is shown.

(Lamination substrate forming process)
In this step, the porous surface layer 1 and the intermediate film 3 are superposed to obtain a base material 40 for lamination. For the superposition, the other layer may be simply placed on one layer, but the porous surface layer 1 and the intermediate film 3 are preferably bonded from the viewpoint of the handling property of the substrate for lamination. .

  The adhesion method is not particularly limited as long as the movement of the intermediate film 3 on the porous surface layer 1 is prevented in the foam molding step. For example, a method using an adhesive may be adopted. Adhesion may be achieved on a part of the contact surface between the porous surface layer 1 and the intermediate film 3, or may be achieved on the entire surface. From the viewpoint of further improving sound absorption, heat insulation and vibration damping (particularly sound absorption) in the application of a cover member for a power train member of an automobile, adhesion is performed on the contact surface between the porous surface layer 1 and the intermediate film 3. It is preferably achieved in part.

  The porous surface layer 1 and the intermediate film 3 can be made of the materials described above, and are available as commercial products. In particular, when the porous surface layer 1 is a fiber nonwoven fabric, a material (sheet-like material) formed by adjusting predetermined fibers to have desired physical properties by a known molding method such as a hot press molding method or a needle punch molding method is used. be able to.

  The intermediate film 3 is cut into a predetermined size and shape. For this reason, in the foam molding process described later, in the portion where the intermediate film 3 is not laminated in the porous surface layer 1, the foamable resin permeates and the mixed layer portion 11 is formed. On the other hand, since the infiltration of the foamable resin into the porous surface layer 1 is inhibited by the intermediate film 3 in the portion 12 where the intermediate film 3 is laminated, the mixed layer portion 11 is not formed.

(Foam molding process)
In this step, foam molding is performed in the mold 50. The mold 50 is usually composed of an upper mold 51 and a lower mold 52.

  Foam molding is performed on the intermediate film 3 side of the substrate 40 for lamination using a foamable resin as a raw material constituting the resin foam layer 2. When foam molding is performed on the intermediate film 3 side of the substrate 40 for lamination, the foamable resin and the substrate 40 for lamination are formed so that the resin foam layer 2 is formed on the intermediate film 3 side of the substrate 40 for lamination. This means that it is placed and foam molding is performed. For example, as shown in the lower stage of FIG. 1B to FIG. 9B, the base material for lamination 40 is placed in the mold 50, and then a foamable resin is injected onto the intermediate film 3 in the mold 50. Thereafter, when the upper mold 51 is closed and foaming is started, the foamable resin expands, fills the cavity between the upper mold 51 and the lower mold 52, and the resin foam layer 2 is formed. After cooling, the molded body is demolded to obtain a functional laminate precursor in which the porous surface layer 1, the resin foam layer 2, and the intermediate film 3 are integrated.

  The foamable resin is a raw material for the resin foam layer. For example, when the resin foam layer is a polyurethane foam layer, a mixture of a polyol compound and an isocyanate compound is used as the foamable resin. The foamable resin may contain additives such as a foaming agent and a foam stabilizer.

  Foaming conditions are appropriately determined according to the type of foamable resin. For example, the mold 50 may be heated and / or the inside of the mold 50 may be pressurized or depressurized.

(Post-processing process)
In this step, the intermediate film 3 of the functional laminate precursor is eliminated.

The disappearance method is determined according to the intermediate film 3.
For example, when the intermediate film 3 is a hot melt film, this step is a heat treatment step, and the hot melt film is melted and disappears by heating. The heating temperature and the heating time may be determined according to the melting point and thickness of the intermediate film 3. When the melting point and thickness of the intermediate film 3 are within the above-mentioned ranges, the heating temperature is usually 50 to 250 ° C., preferably 70 to 150 ° C., and the heating time is usually 1 second to 10 hours, preferably Is from 10 seconds to 1 hour.

  When the intermediate film 3 is a hot melt film, the hot melt component remains if the hot melt film is eliminated by this step. As a result, in the region 12 where the intermediate film 3 was present at the interface 4 between the porous surface layer 1 and the resin foam layer 2, the porous surface layer 1 and the resin foam layer 2 are integrated (bonded) by the hot melt component. ) Is achieved (form 2 described above). The hot melt component is a component of the hot melt film, and may be a polymer component constituting the hot melt film, a decomposition product of the polymer component, or a mixture thereof. May be.

  Further, for example, when the intermediate film 3 is a water-soluble film, this step is an underwater stirring treatment step, and the water-soluble film is dissolved and lost by stirring in water. The temperature of water and the stirring time may be determined according to the material and thickness of the intermediate film 3. When the material and thickness of the intermediate film 3 are within the above ranges, the temperature of water is usually 5 to 100 ° C, preferably 30 to 50 ° C, and the stirring time is usually 1 second to 10 hours, Preferably, it is 1 minute to 1 hour.

  When the intermediate film 3 is a water-soluble film, if the water-soluble film is eliminated by this step, the water-soluble component usually remains on the inside and the surface of the porous surface layer 1 and the resin foam layer 2, but the porous film is porous. It does not contribute to the integration (bonding) of the surface layer 1 and the resin foam layer 2 (form 1 described above). The water-soluble component is a constituent component of the water-soluble film, and may be a polymer component constituting the water-soluble film.

[Usage]
The functional laminate 10 of the present invention is useful as a sound absorbing material, a heat insulating material and / or a vibration damping material (especially a sound absorbing material) because it has excellent sound absorbing properties, heat insulating properties and vibration damping properties (especially sound absorbing properties). .
Fields in which the functional laminate 10 of the present invention is useful include, for example, machines equipped with engines such as vehicles (for example, automobiles, trucks, buses and trains) and agricultural machines (for example, mowers and tillers). Fields.

  When the functional laminate 10 of the present invention is used as, for example, a sound-absorbing heat insulating material in a machine equipped with an engine, it is specifically used as a cover member for a powertrain member including an engine and a transmission. More specifically, the functional laminate 10 is used as a cover member that partially or entirely surrounds the powertrain member. The functional laminate 10 is disposed and used such that the resin foam layer 2 side contacts the power train member. Alternatively, it is used such that the porous surface layer 1 side faces the sound source and / or heat source in a non-contact manner, that is, the engine and transmission are arranged on the porous surface layer 1 side.

(Measuring method)
Various physical properties of each layer were measured by the methods described above.

(Evaluation method)
Sound absorption coefficient (α):
Normal acoustic absorption coefficient measurement system WinZacMTX, manufactured by Nippon Acoustic Engineering Co., Ltd., and measurement of vertical incident acoustic absorption coefficient using an acoustic tube with an inner diameter of 40 mm in a measurement frequency range of 200 to 4800 Hz (1/3 octave band) (JIS A 1405) -2, ISO 10534-2 compliant), and an average normal incidence sound absorption coefficient of 1000 to 4000 Hz was calculated. As the measurement sample, a functional laminate obtained in each example / comparative example was hollowed out into a columnar shape with a diameter of 40 mm. The functional laminate as a measurement sample was arranged so that sound was incident from the porous surface layer 1 side. It evaluated based on the increase width from the sound absorption rate in the comparative example using the same porous surface layer, without using an intermediate film.
◎◎: 8.0% ≤ increase width; (best)
A: 6.0% ≦ increased width <8.0%; (excellent)
○: 4.0% ≦ increased width <6.0%; (good)
Δ: 2.0% ≦ increased width <4.0%; (no practical problem)
X: Increase width <2.0%.

Thermal conductivity:
Based on JIS A1412-2 Part 2 heat flow meter method, the thermal conductivity in the thickness direction of the functional laminate is measured at 30 ° C using a steady-state thermal conductivity measuring device HFM436 / 3/1 Lambda manufactured by NETZSCH. Measured.

(Examples 1-2)
-Substrate forming process for lamination Glass wool A having an average fiber diameter of about 7.5 μm was hot press-molded so as to have the average porosity and thickness shown in Table 1 to obtain a porous surface layer 1. An intermediate film (hot melt film) 3 shown in Table 1 was adhered to the porous surface layer 1 to obtain a substrate 40 for lamination as shown in the lower part of FIG. 1B. Adhesion was achieved with an adhesive at part of the contact surface between the porous surface layer and the intermediate film.

-Foam molding process The raw material of the polyurethane foam of Table 1 as a foamable resin was mixed with the mixer, and it inject | poured on the molding surface of the lower mold | type 52 of FIG. 1B. Subsequently, the base material 40 for lamination | stacking was arrange | positioned so that the intermediate | middle film 3 may contact foamable resin to the upper mold | type 51 of FIG. 1B. Thereafter, the upper mold 51 in FIG. 1B is closed under an environment of 25 ° C. and normal pressure. When foaming is started, the foamable resin expands, and a cavity (dimension 100 mm) between the upper mold 51 and the lower mold 52 is obtained. The inside of (× 100 mm × 25 mm) was filled, and the resin foam layer 2 was formed. After cooling, the molded body was demolded to obtain a functional laminate precursor in which the porous surface layer 1, the resin foam layer 2, and the intermediate film 3 were integrated.

-Post-processing process The functional laminated body precursor was heated at 150 degreeC for 5 hours, the intermediate | middle film was lose | disappeared, and the functional laminated body was obtained.

(Example 3)
A functional laminate was obtained in the same manner as in Example 1 except that the water-soluble film shown in Table 1 was used as the intermediate film and the following post-treatment process was performed.

-Post-processing process The functional laminated body precursor was stirred in 40 degreeC warm water for 30 minutes, the intermediate | middle film was lose | disappeared, and the functional laminated body was obtained.

(Examples 4 to 6)
The same method as in Example 1 except that a glass wool B having an average fiber diameter of about 3.5 μm as the porous surface layer 1 was subjected to hot press molding so as to have the average porosity and thickness described in Table 1. Thus, a functional laminate was obtained.

(Example 7)
The same method as in Example 3 except that a glass wool B having an average fiber diameter of about 3.5 μm as the porous surface layer 1 was hot-press molded so as to have the average porosity and thickness shown in Table 1. Thus, a functional laminate was obtained.

(Example 8)
A porous surface layer 1 made of PET fiber having a fineness of 2.2 denier (average fiber diameter of about 16 μm) formed into a sheet shape with a needle punch and an adhesive so as to have the average porosity and thickness shown in Table 1. A functional laminate was obtained in the same manner as in Example 1 except that was used.

(Comparative Example 1)
A functional laminate was obtained in the same manner as in Example 1 except that the porous surface layer was used alone instead of the substrate for lamination without using an intermediate film.

(Comparative Example 2)
A functional laminate was obtained in the same manner as in Example 4 except that the porous surface layer was used alone instead of the substrate for lamination without using the intermediate film.

(Comparative Example 3)
A functional laminate was obtained in the same manner as in Example 8 except that the porous surface layer was used alone instead of the substrate for lamination without using the intermediate film.

(Comparative Example 4)
The functional laminate precursor obtained in the foam molding process of Example 5 was evaluated as a functional laminate.

Glass wool A: Glass fiber having an average fiber diameter of about 7.5 μm and an average fiber length of about 50 mm (weight per unit area of porous surface layer 1 by glass wool A Examples 1-3: 960 g / m ² , Comparative Example 1: 960 g / m ² )
Glass wool B: Glass fiber having an average fiber diameter of about 3.5 μm and an average fiber length of about 50 mm (weight of porous surface layer 1 by glass wool B Example 4: 1920 g / m ² , Example 5: 960 g / m ² , Example 6: 480 g / m ² , Example 7: 960 g / m ² , Comparative Example 2: 960 g / m ² , Comparative Example 4: 960 g / m ² )
PET wool: PET fiber having an average fiber length of 51 mm and a fineness of 2.2 denier (average fiber diameter of about 16 μm) (weight per unit area of the porous surface layer 1 of PET wool Example 8: 540 g / m ² , Comparative Example 3: 540 g / m) ² )
Hot melt film A: SHM103-PUR (manufactured by NTW Corporation)
Hot melt film B: SHM104-PUR (manufactured by NTW)
Water-soluble film A: C-200 (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.)
Raw material of polyurethane foam A: DK system (Daiichi Kogyo Seiyaku Co., Ltd.)

  The functional laminate of the present invention is a sound-absorbing material and a heat-insulating material in the field of machines including engines such as vehicles (for example, automobiles, trucks, buses, trains, etc.) and agricultural machines (for example, mowers and tillers). And / or useful as a damping material.

1: Porous surface layer 2: Resin foam layer 3: Intermediate film 11: Mixed layer portion 15: First main surface of porous surface layer 16: Second main surface of porous surface layer 4: Porous surface layer and resin foam Interface with layer 40: Substrate for lamination 50: Molding die 51: Upper die 52: Lower die 100: Functional laminate

Claims (24)

A porous surface layer and a resin foam layer are laminated,
The functional laminate in which the porous surface layer and the resin foam layer are bonded to each other by a mixed layer portion of the porous surface layer and the resin foam layer at a part of the boundary between them. In the mixed layer portion, the foamable resin constituting the resin foam layer penetrates into the porous surface layer,
Formed by foaming and curing, a joint between the porous surface layer and the resin foam layer;
The functional laminate according to claim 1, wherein the porous surface layer has the mixed layer portion only at a part of the boundary. The porous surface layer is erected from at least one of a first main surface mainly facing the resin foam layer, a second main surface opposite to the first main surface, and the first main surface or the second main surface. Have the sides that are
The functional layered product according to claim 1 or 2, wherein the mixed layer portion of the porous surface layer is positioned at a part of the boundary selected from the group consisting of the following portions:
(Part 1) An outer peripheral end of the first main surface; and (Part 2) a part or all of the side surface.   The functional laminate according to any one of claims 1 to 3, wherein the mixed layer portion has a thickness of 0.05 to 5 mm.   The functional laminate according to any one of claims 1 to 4, wherein the mixed layer portion has an average void diameter of 20 to 250 µm.   The functional laminate according to claim 1, wherein the mixed layer portion has an average porosity of 50 to 90%. The functional laminate according to any one of claims 1 to 6, wherein the porous surface layer and the resin foam layer have any one of the following forms in a portion other than the portion at the boundary:
(Mode 1) The porous surface layer and the resin foam layer are adjacent to each other in the other part so as to be separable from each other;
(Mode 2) The functional laminate according to claim 1, wherein the porous surface layer and the resin foam layer are integrated and adjacent to each other in the other portion.   The functional laminate according to any one of claims 1 to 7, wherein the porous surface layer and / or the resin foam layer contains a hot melt component or a water-soluble component.   The functional laminate according to any one of claims 1 to 8, wherein the porous surface layer has an average porosity of 80 to 99.5%.   The functional laminate according to any one of claims 1 to 9, wherein the porous surface layer has a thickness of 1 to 50 mm.   The functional laminated body in any one of Claims 1-10 whose said porous surface layer is a fiber nonwoven fabric.   The functional laminate according to claim 1, wherein the porous surface layer is an inorganic fiber nonwoven fabric.   The functional laminate according to claim 11 or 12, wherein the fibers constituting the fiber nonwoven fabric of the porous surface layer have an average fiber diameter of 0.005 to 50 µm.   The functional laminate according to claim 1, wherein the resin foam layer has an average void diameter of 0.04 to 800 μm.   15. The resin foam layer according to any one of claims 1 to 14, wherein the resin foam layer is a polymer foam layer selected from the group consisting of a polyurethane foam layer, a polyolefin foam layer, a polyester foam layer, a silicone foam layer, and a polyvinyl chloride foam layer. Functional laminate.   The functional laminate according to any one of claims 1 to 15, wherein the functional laminate is used as a sound absorbing material, a heat insulating material and / or a vibration damping material.   The functional laminate is used so that the resin foam layer side is in contact with a heat source and / or a sound source, or the porous surface layer side is arranged so as to face the heat source and / or the sound source without contact. The functional laminate according to claim 1, wherein the functional laminate is used.   The functional laminate according to any one of claims 1 to 17, wherein the functional laminate is used as a cover member for a powertrain member including an automobile engine and a transmission. A step of superposing a porous surface layer and an intermediate film to obtain a substrate for lamination;
Foam molding of foamable resin constituting the resin foam layer is performed on the intermediate film side of the substrate for lamination to obtain a functional laminate precursor; and an intermediate film of the functional laminate precursor The manufacturing method of a functional laminated body including the post-processing process to make it lose | disappear.   The said intermediate | middle film is a manufacturing method of the functional laminated body of Claim 19 which is a film | membrane which does not lose | disappear in a foam molding process, but lose | disappears in a post-processing process.   The method for producing a functional laminate according to claim 19 or 20, wherein the intermediate film is a hot-melt film or a water-soluble film. The intermediate film is a hot melt film;
The manufacturing method of the functional laminated body of Claim 21 whose said post-processing process is a heat processing process. The intermediate film is a water-soluble film;
The manufacturing method of the functional laminated body of Claim 21 whose said post-processing process is an underwater stirring process.   The method for producing a functional laminate according to any one of claims 19 to 23, wherein the intermediate film has a thickness of 0.02 to 0.5 mm.

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