JP2019211493A - Sound insulating material and manufacturing method of the same - Google Patents

Sound insulating material and manufacturing method of the same Download PDF

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JP2019211493A
JP2019211493A JP2018104291A JP2018104291A JP2019211493A JP 2019211493 A JP2019211493 A JP 2019211493A JP 2018104291 A JP2018104291 A JP 2018104291A JP 2018104291 A JP2018104291 A JP 2018104291A JP 2019211493 A JP2019211493 A JP 2019211493A
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fiber layer
foamed resin
mold
layer
outer periphery
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JP7219019B2 (en
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弘和 榊原
Hirokazu Sakakibara
弘和 榊原
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Inoac Corp
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Inoue MTP KK
Inoac Corp
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Abstract

To provide a sound insulating material which has a high sound insulating effect and which is suitable for a floor silencer, a dash silencer or the like for vehicle.SOLUTION: A sound insulating material 10 comprises a laminate of a fiber layer 11 made of felt and the like, and a foam resin layer 15 made of polyurethane foam or the like, which is foamed and formed from a foam resin raw material on a single-side surface 12 of the fiber layer 11. The foam resin layer 15 is provided by covering the single-side surface 12 of the fiber layer 11 and at least part of an end part outer periphery 13 of the fiber layer 11, and even for the sound leakage from the end part outer periphery of the sound insulating layer 10, a favorable sound insulating effect is exhibited by the foam resin layer 15 covering the end part outer periphery 13 of the fiber layer 11.SELECTED DRAWING: Figure 1

Description

本発明は、防音材とその製造方法に関する。   The present invention relates to a soundproof material and a method for manufacturing the same.

従来、防音材として、フェルトとポリウレタンフォームとの積層体からなるものがある（特許文献１）。   Conventionally, as a soundproofing material, there is one made of a laminate of felt and polyurethane foam (Patent Document 1).

フェルトとポリウレタンフォームとの積層体からなる従来の防音材は、音がフェルトとポリウレタンフォームの両方によって遮音され、良好な防音効果が得られる。   The conventional soundproofing material composed of a laminate of felt and polyurethane foam is sound-insulated by both felt and polyurethane foam, and a good soundproofing effect is obtained.

しかし、図７に示すように、フェルト１０１とポリウレタンフォーム１０３との積層体からなる従来の防音材１００は、フェルト１０１とポリウレタンフォーム１０３がそれぞれ防音材１００の端部外周１００Ａまで存在するため、例えばフェルト１０１側から入射した音の一部が、ポリウレタンフォーム１０３側に進入することなく、フェルト１０１内を通って防音材の端部１００Ａに至る場合、ポリウレタンフォーム１０３による遮音作用が得られず、充分な防音効果が得られなくなる。   However, as shown in FIG. 7, the conventional soundproofing material 100 made of a laminate of the felt 101 and the polyurethane foam 103 has the felt 101 and the polyurethane foam 103 up to the outer periphery 100 </ b> A of the end of the soundproofing material 100. When a part of the sound incident from the felt 101 side does not enter the polyurethane foam 103 side and reaches the end portion 100A of the soundproof material through the felt 101, the sound insulation action by the polyurethane foam 103 is not obtained, which is sufficient. No soundproofing effect can be obtained.

特開２００９−２２６６７５号公報JP 2009-226675 A

本発明は前記の点に鑑みなされたものであって、防音効果がより高い防音材とその製造方法の提供を目的とする。   This invention is made | formed in view of the said point, Comprising: It aims at provision of the soundproofing material with higher soundproofing effect, and its manufacturing method.

請求項１の発明は、繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材において、前記発泡樹脂層は、前記繊維層の片面と端部外周の少なくとも一部を覆って設けられていることを特徴とする。   The invention of claim 1 is a soundproofing material comprising a laminate of a fiber layer and a foamed resin layer foamed on one side of the fiber layer, wherein the foamed resin layer is at least on one side of the fiber layer and the outer periphery of the end. It is provided to cover a part.

請求項２の発明は、請求項１において、前記繊維層には貫通孔が設けられ、前発泡樹脂層は、前記繊維層の貫通孔の部分で該貫通孔の内周面を被覆しており、該内周面が被覆された貫通孔の両端が開口していることを特徴とする。   According to a second aspect of the present invention, in the first aspect, the fiber layer is provided with a through hole, and the pre-foamed resin layer covers the inner peripheral surface of the through hole at a portion of the through hole of the fiber layer. The both ends of the through hole covered with the inner peripheral surface are open.

請求項３の発明は、請求項１または２において、前記発泡樹脂層は、ポリウレタンフォームからなることを特徴とする。   According to a third aspect of the present invention, in the first or second aspect, the foamed resin layer is made of polyurethane foam.

請求項４の発明は、上型または下型の何れか一方の型の型面に取り付けた繊維層と他方の型の型面との間の発泡成形空間で、発泡樹脂原料を発泡させることにより、前記繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材を製造する方法において、前記繊維層を取り付けた一方の型の型面の端部外周は、少なくとも一部が前記繊維層の端部外周よりも大であり、前記繊維層と前記他方の型の型面との間の発泡成形空間は、前記繊維層の端部外周まで存在し、前記発泡樹脂原料の発泡により、前記発泡樹脂層を前記繊維層の片面と端部外周の少なくとも一部を覆って形成することを特徴とする。   According to the invention of claim 4, the foamed resin material is foamed in a foam molding space between the fiber layer attached to the mold surface of either the upper mold or the lower mold and the mold surface of the other mold. In the method for producing a soundproofing material comprising a laminate of the fiber layer and a foamed resin layer foamed on one side of the fiber layer, the outer periphery of the end of the mold surface of one mold to which the fiber layer is attached, At least a part is larger than the outer periphery of the end portion of the fiber layer, and the foam molding space between the fiber layer and the mold surface of the other mold exists up to the outer periphery of the end portion of the fiber layer, and the foaming The foamed resin layer is formed so as to cover at least a part of one side of the fiber layer and the outer periphery of the end portion by foaming a resin raw material.

請求項５の発明は、請求項４において、前記繊維層は該繊維層の両面を貫通する貫通孔を有し、前記繊維層を取り付けた前記一方の型の型面には、前記繊維層の取り付け時に前記貫通孔に挿入される凸部を有し、前記貫通孔に挿入された前記凸部の側面と前記貫通孔の内周面との間に前記発泡成形空間に通じる隙間を形成し、前記凸部の先端を前記他方の型面と当接した状態にして前記発泡樹脂原料を発泡させることにより、前記繊維層の片面と端部外周の少なくとも一部を覆い、前記繊維層の貫通孔の部分では該貫通孔の内周面を被覆し、該内周面を覆った貫通孔の両端で開口した発泡樹脂層を形成することを特徴とする。   According to a fifth aspect of the present invention, in the fourth aspect, the fiber layer has a through-hole penetrating both surfaces of the fiber layer, and the mold surface of the one mold to which the fiber layer is attached is provided with the fiber layer. Having a protrusion inserted into the through-hole at the time of attachment, forming a gap that leads to the foam molding space between the side surface of the protrusion inserted into the through-hole and the inner peripheral surface of the through-hole, The foamed resin material is foamed in a state where the tip of the convex part is in contact with the other mold surface, thereby covering at least a part of one side of the fiber layer and the outer periphery of the end, and the through hole of the fiber layer In this part, the inner peripheral surface of the through hole is covered, and a foamed resin layer opened at both ends of the through hole covering the inner peripheral surface is formed.

本発明の防音材は、発泡樹脂層が繊維層の片面と端部外周を覆って設けられているため、防音材に入射する音が発泡樹脂層と繊維層を通過する毎にそれぞれの層で遮音され、良好な防音効果が得られる。また、繊維層側から入射した音の一部が繊維層内を通って防音材の端部に至る場合でも、防音材の端部外周の少なくとも一部を覆う発泡樹脂層を通過することにより、繊維層と発泡樹脂層の両方で遮音され、良好な防音効果が得られる。   In the soundproofing material of the present invention, since the foamed resin layer is provided so as to cover one side and the outer periphery of the end of the fiber layer, each time the sound incident on the soundproofing material passes through the foamed resin layer and the fiber layer, Sound insulation is provided and a good soundproofing effect is obtained. Further, even when a part of the sound incident from the fiber layer side reaches the end of the soundproof material through the fiber layer, by passing through the foamed resin layer covering at least a part of the outer periphery of the end of the soundproof material, Sound insulation is provided by both the fiber layer and the foamed resin layer, and a good soundproofing effect is obtained.

また、本発明の防音材は、繊維層の片面を覆う発泡樹脂層が、繊維層の貫通孔の部分で該貫通孔の内周面を被覆しており、該内周面が被覆された貫通孔の両端が開口している構成とされた場合、繊維層側から入射した音の一部が繊維層内を通って繊維層の貫通孔の内周面に至る場合であっても、貫通孔の内周面を被覆する発泡樹脂層を最終的に通過することになり、繊維層と発泡樹脂層の両方で遮音され、良好な防音効果が得られ、特に貫通孔の多い製品に対して有効である。   In the soundproofing material of the present invention, the foamed resin layer covering one side of the fiber layer covers the inner peripheral surface of the through hole at the part of the through hole of the fiber layer, and the inner peripheral surface is covered. When both ends of the hole are configured to be open, even if a part of sound incident from the fiber layer side passes through the fiber layer and reaches the inner peripheral surface of the through hole of the fiber layer, the through hole Will eventually pass through the foamed resin layer covering the inner peripheral surface of the material, and will be sound-insulated by both the fiber layer and the foamed resin layer, providing a good soundproofing effect, especially effective for products with many through-holes It is.

本発明の防音材の製造方法は、良好な防音効果を有する防音材を容易に製造することができる。   The method for producing a soundproof material of the present invention can easily produce a soundproof material having a good soundproofing effect.

第１実施形態の防音材の平面図と１Ａ−１Ａ断面図である。It is a top view and 1A-1A sectional view of a soundproof material of a 1st embodiment. 第１実施形態の防音材について、その製造方法を示す断面図である。It is sectional drawing which shows the manufacturing method about the soundproof material of 1st Embodiment. 第２実施形態の防音材の平面図と３Ａ−３Ａ断面図である。It is the top view and 3A-3A sectional drawing of the soundproof material of 2nd Embodiment. 第２実施形態の繊維層の平面図と４Ａ−４Ａ断面図である。It is the top view and 4A-4A sectional view of the fiber layer of 2nd Embodiment. 第２実施形態の防音材について、その製造方法を示す断面図である。It is sectional drawing which shows the manufacturing method about the soundproof material of 2nd Embodiment. 試料１−４の防音性の測定結果を示す表である。It is a table | surface which shows the measurement result of the soundproofing property of the sample 1-4. 従来の防音材を示す断面図である。It is sectional drawing which shows the conventional soundproof material.

以下、本発明の実施形態について説明する。図１に示す第１実施形態の防音材１０は、繊維層１１と該繊維層１１の片面１２に発泡形成された発泡樹脂層１５との積層体からなる。発泡樹脂層１５は、繊維層１１の片面１２と端部外周１３を覆って設けられ、繊維層１１の他面１４は、露出した状態となっている。繊維層１１の端部外周１３は、繊維層１１の端部の側面に相当する。なお、発泡樹脂層１５は、繊維層１１の端部外周１３の全部ではなくても、少なくとも一部を覆っていればよい。勿論、発泡樹脂層１５が繊維層１１の端部外周１３の全部を覆うことは、遮音性の点からより好ましい。防音材１０の形状は、図示のような四角形の板状に限られず、多角形、楕円形、不規則形状の板状等でもよく、防音材１０が使用される製品や場所等に応じた形状とされる。また、防音材１０は、繊維層１１と発泡樹脂層１５の何れの側を音源側にしても使用することができる。   Hereinafter, embodiments of the present invention will be described. A soundproof material 10 according to the first embodiment shown in FIG. 1 is composed of a laminate of a fiber layer 11 and a foamed resin layer 15 formed by foaming on one surface 12 of the fiber layer 11. The foamed resin layer 15 is provided so as to cover one side 12 and the outer periphery 13 of the fiber layer 11, and the other surface 14 of the fiber layer 11 is exposed. The outer periphery 13 at the end of the fiber layer 11 corresponds to the side surface of the end of the fiber layer 11. In addition, the foamed resin layer 15 should just cover at least one part even if it is not the whole edge part outer periphery 13 of the fiber layer 11. FIG. Of course, it is more preferable that the foamed resin layer 15 covers the entire outer periphery 13 of the fiber layer 11 from the viewpoint of sound insulation. The shape of the soundproofing material 10 is not limited to a rectangular plate shape as shown in the figure, but may be a polygonal shape, an elliptical shape, an irregular shape, or the like, and a shape corresponding to a product or a place where the soundproofing material 10 is used. It is said. Further, the soundproofing material 10 can be used regardless of which side of the fiber layer 11 and the foamed resin layer 15 is the sound source side.

繊維層１１は、不織布、フェルトなどの繊維集合体が挙げられ、特にフェルトが軽量性、防音性（吸音性）の点から好ましい。フェルトを構成する繊維の材質は限定されない。フェルトには、熱硬化性樹脂をバインダーとして繊維同士を結合させたレジンフェルト、バインダーを使用し、あるいは使用しないでプレスにより繊維相互を結合させたプレスフェルト、ニードルパンチ加工によって繊維相互を絡ませたニードルフェルト等があり、何れのフェルトも使用することができる。特にプレスフェルトは、プレスによって繊維が密になっているため、吸音性（遮音性）が高く、好ましいものである。繊維層１１の目付は１００〜３０００ｇ／ｍ２、厚みは２〜４５ｍｍ程度が好ましい。繊維層１１の目付は、小さくなりすぎると遮音性（吸音性）が小になり、逆に目付が大になると防音材１０が重くなる。また、繊維層１１の厚みは、薄くなりすぎると遮音性（吸音性）が小さくなり、逆に厚くなると防音材１０が嵩張り、重くなる。 Examples of the fiber layer 11 include fiber aggregates such as nonwoven fabrics and felts, and felts are particularly preferable from the viewpoints of lightness and soundproofing (sound absorption). The material of the fibers constituting the felt is not limited. The felt includes a resin felt in which fibers are bonded using a thermosetting resin as a binder, a press felt in which fibers are bonded together by pressing without using a binder, or a needle in which fibers are entangled by needle punching. There are felts and the like, and any felt can be used. In particular, the press felt is preferable because the fibers are densely packed by pressing and have high sound absorption (sound insulation). The basis weight of the fiber layer 11 is preferably 100 to 3000 g / m 2 and the thickness is preferably about 2 to 45 mm. If the fabric weight of the fiber layer 11 becomes too small, the sound insulation (sound absorption) becomes small. Conversely, if the fabric weight becomes large, the soundproof material 10 becomes heavy. Moreover, if the thickness of the fiber layer 11 becomes too thin, the sound insulation (sound absorbing property) becomes small. Conversely, if the thickness becomes thick, the soundproof material 10 becomes bulky and heavy.

発泡樹脂層１５は、繊維層１１の片面１２に発泡樹脂原料から発泡形成されたものであり、発泡形成時に発泡樹脂原料の一部が繊維層１１の片面１２に含浸して硬化し、それにより繊維層１１と発泡樹脂層１５の接着が行われる。また、発泡樹脂層１５が接着した繊維層１１の片面１２には、前記発泡樹脂原料が含浸して硬化した含浸硬化層が形成され、その含浸硬化層によっても防音性（遮音性）が向上する。   The foamed resin layer 15 is formed by foaming from a foamed resin raw material on one side 12 of the fiber layer 11, and a part of the foamed resin raw material is impregnated and cured on one side 12 of the fiber layer 11 during foaming, thereby Bonding of the fiber layer 11 and the foamed resin layer 15 is performed. Moreover, an impregnated cured layer formed by impregnating and curing the foamed resin raw material is formed on one side 12 of the fiber layer 11 to which the foamed resin layer 15 is bonded, and the soundproofing (sound insulation) is also improved by the impregnated cured layer. .

発泡樹脂層１５を構成する樹脂としては、ポリウレタンフォーム、ポリエチレンフォーム、ポリプロピレンフォーム等が挙げられる。特にポリウレタンフォームは、軽量で吸音性（遮音性）に優れるために好ましい発泡樹脂である。発泡樹脂層１５の密度（ＪＩＳ Ｋ７２２２）は３０〜１５０ｋｇ／ｍ３、厚みは２〜５０ｍｍが好ましい。発泡樹脂層１５の密度が小さ過ぎると遮音性が小さくなり、逆に密度が大になると重くなる。また発泡樹脂層１５が薄くなりすぎると遮音性が小さくなり、逆に厚くなると防音材１０が嵩張り、重くなる。 Examples of the resin constituting the foamed resin layer 15 include polyurethane foam, polyethylene foam, and polypropylene foam. In particular, polyurethane foam is a preferred foamed resin because it is lightweight and excellent in sound absorption (sound insulation). The density (JIS K7222) of the foamed resin layer 15 is preferably 30 to 150 kg / m 3 and the thickness is preferably 2 to 50 mm. If the density of the foamed resin layer 15 is too small, the sound insulation is reduced. Further, if the foamed resin layer 15 is too thin, the sound insulating property is reduced. Conversely, if the foamed resin layer 15 is thick, the soundproof material 10 is bulky and heavy.

防音材１０は、繊維層１１の片面に発泡樹脂層１５が設けられているため、防音材１０に入射した音が繊維層１１と発泡樹脂層１５の両方で吸音（遮音）され、良好な防音効果が得られる。また、繊維層１１の片面１２に設けられた発泡樹脂層１５が繊維層１１の端部外周１３を覆っているため、防音材１０の端部外周から漏れる音についても低減することができ、防音性がさらに良好になる。   Since the soundproofing material 10 is provided with the foamed resin layer 15 on one side of the fiber layer 11, the sound incident on the soundproofing material 10 is absorbed (sound-insulated) by both the fiber layer 11 and the foamed resin layer 15, thereby providing good soundproofing. An effect is obtained. Moreover, since the foamed resin layer 15 provided on the one surface 12 of the fiber layer 11 covers the end outer periphery 13 of the fiber layer 11, it is possible to reduce sound leaking from the end outer periphery of the sound insulating material 10. The property becomes even better.

前記防音材１０の製造方法について、図２を用いて説明する。防音材１０の製造は、金型２１を用いるモールド成形によって行われる。金型２１は、上型２２と下型３２とよりなり、上型２２または下型３２の何れか一方に繊維層１１が取り付けられる。図示の例では、図２の（２−１）のように、上型２２の型面２３に繊維層１１を取り付け、また、下型３２には発泡樹脂原料Ｐを注入し、図２の（２−２）のように上型２２を下型３２に被せて閉型し、繊維層１１と下型３２の型面３３間の発泡成形空間３５で発泡樹脂原料Ｐを発泡させる。符号Ｎは注入ノズルである。   A method of manufacturing the soundproof material 10 will be described with reference to FIG. The soundproofing material 10 is manufactured by molding using a mold 21. The mold 21 includes an upper mold 22 and a lower mold 32, and the fiber layer 11 is attached to either the upper mold 22 or the lower mold 32. In the illustrated example, as shown in FIG. 2 (2-1), the fiber layer 11 is attached to the mold surface 23 of the upper mold 22, and the foamed resin raw material P is injected into the lower mold 32. The upper mold 22 is put on the lower mold 32 and closed as in 2-2), and the foamed resin material P is foamed in the foam molding space 35 between the fiber layer 11 and the mold surface 33 of the lower mold 32. Reference numeral N denotes an injection nozzle.

繊維層１１が取り付けられる上型２２の型面２３には、図２の（２−１）のように、繊維層１１を取り外し可能に保持するための係止部２５が、繊維層１１の取り付け位置に設けられている。図示の係止部２５はピンで構成され、上型２２の型面２３の複数箇所に立設されている。   On the mold surface 23 of the upper mold 22 to which the fiber layer 11 is attached, as shown in (2-1) of FIG. 2, a locking portion 25 for detachably holding the fiber layer 11 is attached to the fiber layer 11. In the position. The illustrated locking portion 25 is constituted by a pin and is erected at a plurality of locations on the mold surface 23 of the upper mold 22.

また、上型２２の型面２３は、端部外周２４が繊維層１１の端部外周１３よりも大になっており、図２の（２−２）のように、型面２３に繊維層１１を取り付けた際に、繊維層１１の端部外周１３から型面２３の端部外周２４が所定量突出するように構成されている。なお、前記防音材１０の発泡樹脂層１５が、繊維層１１の端部外周１３の全部ではなく、少なくとも一部を覆う場合は、上型２２の型面２３の端部外周２４の少なくとも一部を繊維層１１の端部外周１３よりも大にして、型面２３に繊維層１１を取り付けた際に、繊維層１１の端部外周１３から型面２３の端部外周２４の少なくとも一部を所定量突出させる。   Moreover, as for the mold surface 23 of the upper mold | type 22, the edge part outer periphery 24 is larger than the edge part outer periphery 13 of the fiber layer 11, and as shown to (2-2) of FIG. When 11 is attached, the end outer periphery 24 of the mold surface 23 protrudes from the end outer periphery 13 of the fiber layer 11 by a predetermined amount. In addition, when the foamed resin layer 15 of the soundproof material 10 covers at least a part of the end periphery 13 of the fiber layer 11, at least a part of the end periphery 24 of the mold surface 23 of the upper mold 22. Is larger than the outer periphery 13 of the end of the fiber layer 11, and when the fiber layer 11 is attached to the mold surface 23, at least part of the outer periphery 24 of the end of the mold surface 23 from the end outer periphery 13 of the fiber layer 11 Make a certain amount protrude.

下型３２は、型面３３が防音材１０の外形に応じて窪んだ凹形状となっており、上型２２を下型３２に被せて閉型した際に、上型２２の型面２３の繊維層１１の片面１２と下型３２の型面３３間に発泡成形空間３５が形成される。また、上型２２を下型３２に被せて閉型した際に、下型３２の型面３３の上部は、上型２２の型面２３の端部外周２４と当接して繊維層１１の端部外周１３から離れて位置し、前記発泡成形空間３３が繊維層１１の端部外周１３まで連続して形成される。   The lower mold 32 has a concave shape in which the mold surface 33 is recessed in accordance with the outer shape of the soundproof material 10, and when the upper mold 22 is put on the lower mold 32 and closed, the mold surface 23 of the upper mold 22 is formed. A foam molding space 35 is formed between one surface 12 of the fiber layer 11 and the mold surface 33 of the lower mold 32. When the upper mold 22 is put on the lower mold 32 and closed, the upper portion of the mold surface 33 of the lower mold 32 comes into contact with the outer periphery 24 of the end portion of the mold surface 23 of the upper mold 22 to end the fiber layer 11. The foam molding space 33 is located away from the outer periphery 13 of the part, and is continuously formed up to the outer periphery 13 of the end of the fiber layer 11.

発泡樹脂原料Ｐは、発泡によって、発泡成形空間３５に充満し、図２の（２−３）のように繊維層１１の片面１２と、該繊維層１１の端部外周１３を覆う発泡樹脂層１５を形成する。また、発泡樹脂原料Ｐの発泡時、発泡樹脂原料Ｐの一部が繊維層１１の片面１２と繊維層１１の端部外周（側面）１３とに含浸して硬化し、繊維層１１と発泡樹脂層１５を接着する。なお、発泡樹脂原料Ｐは、発泡樹脂がポリウレタンフォームの場合はポリウレタンフォーム原料である。
その後、上型２２を下型３２から離して金型２１を開き、図１に示した繊維層１１と発泡樹脂層１５とからなる防音材１０を取り出す。 The foamed resin raw material P fills the foam molding space 35 by foaming, and the foamed resin layer covers one side 12 of the fiber layer 11 and the outer periphery 13 of the end of the fiber layer 11 as shown in (2-3) in FIG. 15 is formed. Further, at the time of foaming of the foamed resin material P, a part of the foamed resin material P is impregnated and cured on one side 12 of the fiber layer 11 and the outer periphery (side surface) 13 of the end of the fiber layer 11, and the fiber layer 11 and the foamed resin are cured. Glue layer 15. The foamed resin raw material P is a polyurethane foam raw material when the foamed resin is polyurethane foam.
Thereafter, the upper mold 22 is separated from the lower mold 32, the mold 21 is opened, and the soundproofing material 10 composed of the fiber layer 11 and the foamed resin layer 15 shown in FIG.

図３に第２実施形態の防音材５０を示す。防音材５０は、所定位置に貫通孔５１、５２、５３を有する例である。貫通孔５１、５２、５３は、例えば車両におけるシャフトやケーブル等を通すのに使用される。防音材５０は、繊維層６１と、該繊維層６１の片面６２に発泡形成された発泡樹脂層７５との積層体からなり、前記発泡樹脂層７５が、前記繊維層６１の片面６２と端部外周６３を覆って設けられ、前記繊維層６１の他面６４は露出した状態となっている。繊維層６１の端部外周６３は、繊維層６１の端部の側面に相当する。図４に繊維層６１の平面図と、その４Ａ−４Ａ断面図を示す。なお、防音材５０の形状は、図示の形状に限られず、防音材５０が使用される場所に応じた形状とされる。   FIG. 3 shows a soundproof material 50 according to the second embodiment. The soundproof material 50 is an example having through holes 51, 52, 53 at predetermined positions. The through holes 51, 52, and 53 are used, for example, for passing a shaft or a cable in a vehicle. The soundproofing material 50 is composed of a laminate of a fiber layer 61 and a foamed resin layer 75 formed by foaming on one side 62 of the fiber layer 61, and the foamed resin layer 75 is connected to one side 62 of the fiber layer 61 and an end portion thereof. It is provided so as to cover the outer periphery 63, and the other surface 64 of the fiber layer 61 is exposed. An end outer periphery 63 of the fiber layer 61 corresponds to a side surface of the end of the fiber layer 61. FIG. 4 shows a plan view of the fiber layer 61 and its 4A-4A cross-sectional view. Note that the shape of the soundproofing material 50 is not limited to the shape shown in the figure, and is a shape according to the place where the soundproofing material 50 is used.

繊維層６１は、図４に示すように、所定位置に貫通孔６５、６７、６９が設けられている。図４に示した繊維層６１の貫通孔６５、６７、６９の部分で、図３に示すように発泡樹脂層７５は、該貫通孔の内周面６６、６８、７０を被覆する部分７６、７７、７８が形成され、該貫通孔の内周面６６、６８、７０を被覆する部分７６、７７、７８の両端が開口して防音材５０の貫通孔５１、５２、５３を構成している。   As shown in FIG. 4, the fiber layer 61 is provided with through holes 65, 67, and 69 at predetermined positions. In the portions of the through holes 65, 67, 69 of the fiber layer 61 shown in FIG. 4, as shown in FIG. 3, the foamed resin layer 75 has portions 76 covering the inner peripheral surfaces 66, 68, 70 of the through holes, 77, 78 are formed, and both ends of the portions 76, 77, 78 covering the inner peripheral surfaces 66, 68, 70 of the through holes are opened to form the through holes 51, 52, 53 of the soundproof material 50. .

第２実施形態の繊維層６１と発泡樹脂層７５は、第１実施形態の繊維層１１と発泡樹脂層１５と同様の材質、密度、厚み等からなり、繊維層６１はファブリックが好ましく、また発泡樹脂層７５はポリウレタンフォームが好ましい。   The fiber layer 61 and the foamed resin layer 75 of the second embodiment are made of the same material, density, thickness and the like as the fiber layer 11 and the foamed resin layer 15 of the first embodiment, and the fiber layer 61 is preferably a fabric and foamed. The resin layer 75 is preferably a polyurethane foam.

図３に示した第２実施形態の防音材５０は、繊維層６１の片面６２に設けられた発泡樹脂層７５が、図４に示した繊維層６１の端部外周６３と貫通孔６５、６７、６９の内周面６６、６８、７０を覆っているため、防音材５０の端部外周及び貫通孔から漏れる音を低減することができ、防音性が良好になる。   In the soundproof material 50 of the second embodiment shown in FIG. 3, the foamed resin layer 75 provided on one side 62 of the fiber layer 61 includes the end outer periphery 63 and the through holes 65 and 67 of the fiber layer 61 shown in FIG. 4. , 69 is covered, the sound leaking from the outer periphery of the end portion of the soundproof material 50 and the through hole can be reduced, and the soundproofing property is improved.

前記防音材５０の製造方法について、図５を用いて説明する。防音材５０の製造は、金型８１を用いるモールド成形によって行われる。金型８１は、上型８２と下型９４とよりなり、上型８２と下型９４の何れか一方に繊維層６１が取り付けられる。図示の例では、図５の（５−１）のように、上型８２の型面８３に繊維層６１を取り付け、また、下型９４には発泡樹脂原料Ｐを注入し、図５の（５−２）のように上型８２を下型９４に被せて閉型し、繊維層６１と下型９４の型面９５間の発泡成形空間９７で発泡樹脂原料Ｐを発泡させる。   A method for manufacturing the soundproof material 50 will be described with reference to FIG. The soundproof material 50 is manufactured by molding using a mold 81. The mold 81 includes an upper mold 82 and a lower mold 94, and the fiber layer 61 is attached to either the upper mold 82 or the lower mold 94. In the illustrated example, as shown in FIG. 5 (5-1), the fiber layer 61 is attached to the mold surface 83 of the upper mold 82, and the foamed resin raw material P is injected into the lower mold 94. As in 5-2), the upper mold 82 is put on the lower mold 94 and closed, and the foamed resin material P is foamed in the foam molding space 97 between the fiber layer 61 and the mold surface 95 of the lower mold 94.

繊維層６１が取り付けられる上型８２の型面８３は、型面８３の端部外周８４が繊維層６１の端部外周６３よりも大になっており、図５の（５−２）のように、型面８３に繊維層６１を取り付けた際に、繊維層６１の端部外周６３から型面の端部外周８４が所定量突出するように構成されている。なお、前記防音材５０の発泡樹脂層７５が、繊維層６１の端部外周６３の全部ではなく、少なくとも一部を覆う場合は、上型８２の型面８３の端部外周８４の少なくとも一部を繊維層６１の端部外周６３よりも大にして、型面８３に繊維層６１を取り付けた際に、繊維層６１の端部外周６３から型面８３の端部外周８４の少なくとも一部を所定量突出させる。   The mold surface 83 of the upper mold 82 to which the fiber layer 61 is attached has an end outer periphery 84 of the mold surface 83 larger than the end outer periphery 63 of the fiber layer 61, as shown in (5-2) of FIG. In addition, when the fiber layer 61 is attached to the mold surface 83, the end periphery 84 of the mold surface protrudes from the end periphery 63 of the fiber layer 61 by a predetermined amount. In addition, when the foamed resin layer 75 of the soundproof material 50 covers at least a part of the end part outer periphery 63 of the fiber layer 61, at least a part of the end part outer periphery 84 of the mold surface 83 of the upper mold 82. When the fiber layer 61 is attached to the mold surface 83 with at least a part of the end outer periphery 84 of the mold surface 83 from the end outer periphery 63 of the fiber layer 61. Make a certain amount protrude.

図５の（５−１）のように、上型８２の型面８３には、繊維層６１を取り外し可能に保持するための係止部８５が、繊維層６１の取り付け位置に設けられている。図示の係止部８５はピンで構成され、上型８２の型面８３の複数箇所に立設されている。   As shown in (5-1) of FIG. 5, the mold surface 83 of the upper mold 82 is provided with a locking portion 85 for detachably holding the fiber layer 61 at the attachment position of the fiber layer 61. . The illustrated locking portion 85 is formed of a pin and is erected at a plurality of locations on the mold surface 83 of the upper mold 82.

また、上型８２の型面８３には、繊維層６１の取り付け時に繊維層６１の貫通孔６５、６７、６９に挿入される凸部８６、８８、９０が、繊維層６１の貫通孔６５、６７、６９の位置に合わせて形成されている。   Further, on the mold surface 83 of the upper mold 82, convex portions 86, 88, 90 inserted into the through holes 65, 67, 69 of the fiber layer 61 when the fiber layer 61 is attached have the through holes 65, It is formed in accordance with positions 67 and 69.

凸部８６、８８、９０は、外周が繊維層６１の貫通孔６５、６７、６９の内周よりも所定寸法小さくされ、繊維層６１の貫通孔６５、６７、６９に挿入された際に、凸部８６、８８、９０の側面８７、８９、９１と繊維層６１の貫通孔６５、６７、６９の内周面６６、６８、７０との間に、図５の（５−２）に示す隙間９２、９３、９４を形成するように構成されている。また凸部８６、８８、９０の高さは、上型８２を下型９４に被せて金型８１を閉じた際に、凸部８６、８８、９０の先端（下端）８６ａ、８８ａ、９０ａが下型９４の型面９５と当接する寸法とされている。   When the protrusions 86, 88, 90 are inserted into the through holes 65, 67, 69 of the fiber layer 61, the outer periphery is made smaller than the inner circumference of the through holes 65, 67, 69 of the fiber layer 61, Between the side surfaces 87, 89, 91 of the convex portions 86, 88, 90 and the inner peripheral surfaces 66, 68, 70 of the through holes 65, 67, 69 of the fiber layer 61, shown in (5-2) of FIG. The gaps 92, 93 and 94 are formed. The heights of the convex portions 86, 88, 90 are such that when the upper die 82 is put on the lower die 94 and the die 81 is closed, the tips (lower ends) 86a, 88a, 90a of the convex portions 86, 88, 90 are The size of the lower mold 94 is in contact with the mold surface 95.

下型９４は、型面９５が防音材６０の外形に応じて窪んだ凹形状となっており、上型８２を下型９４に被せて閉型した際に、図５の（５−２）のように、上型８２の型面８３の繊維層６１の片面６２と下型９４の型面９５間に発泡成形空間９７が形成される。発泡成形空間９７は、前記上型８２の型面８３の凸部８６、８８、９０と繊維層６１の貫通孔６５、６７、６９の内周面６６、６８、７０との間の隙間９２、９３、９４と通じ、繊維層６１の端部外周６３まで連続して形成される。   The lower mold 94 has a concave shape in which the mold surface 95 is recessed according to the outer shape of the soundproof material 60. When the upper mold 82 is put on the lower mold 94 and closed, (5-2) in FIG. As described above, a foam molding space 97 is formed between the one surface 62 of the fiber layer 61 of the mold surface 83 of the upper mold 82 and the mold surface 95 of the lower mold 94. The foam molding space 97 includes a gap 92 between the convex portions 86, 88, 90 of the mold surface 83 of the upper mold 82 and the inner peripheral surfaces 66, 68, 70 of the through holes 65, 67, 69 of the fiber layer 61, 93 and 94 are continuously formed up to the outer periphery 63 at the end of the fiber layer 61.

発泡樹脂原料Ｐは、発泡によって前記発泡成形空間９７に充満し、図５の（５−３）のように、繊維層６１の片面６２と繊維層６１の貫通孔内周面６６、６８、７０及び繊維層６１の端部外周６３を覆って発泡樹脂層７５を形成する。発泡樹脂層７５は、繊維層６１の貫通孔内周面６６、６８、７０を被覆する部分７６、７７、７８が形成され、貫通孔内周面６６、６８、７０を被覆する部分７６、７７、７８が貫通孔の両端で開口する。また、発泡樹脂原料Ｐの発泡時、発泡樹脂原料Ｐの一部が、繊維層６１の片面６２と、繊維層６１の貫通孔の内周面６６、６８、７０、及び繊維層６１の端部外周（側面）６３に含浸して硬化し、繊維層６１と発泡樹脂層７５を接着する。なお、発泡樹脂原料Ｐは、発泡樹脂がポリウレタンフォームの場合、ポリウレタンフォーム原料となる。
その後、上型８２を下型９４から離して、金型８１を開き、図３に示した繊維層６１と発泡樹脂層７５とからなる防音材６０を取り出す。 The foamed resin raw material P fills the foam molding space 97 by foaming, and as shown in FIG. 5 (5-3), the one side 62 of the fiber layer 61 and the through hole inner peripheral surfaces 66, 68, 70 of the fiber layer 61. The foamed resin layer 75 is formed to cover the outer periphery 63 of the end of the fiber layer 61. The foamed resin layer 75 is formed with portions 76, 77, 78 covering the through hole inner peripheral surfaces 66, 68, 70 of the fiber layer 61, and the portions 76, 77 covering the through hole inner peripheral surfaces 66, 68, 70. 78 open at both ends of the through hole. Further, when the foamed resin raw material P is foamed, a part of the foamed resin raw material P includes one side 62 of the fiber layer 61, inner peripheral surfaces 66, 68, and 70 of the through holes of the fiber layer 61, and end portions of the fiber layer 61. The outer periphery (side surface) 63 is impregnated and cured, and the fiber layer 61 and the foamed resin layer 75 are bonded. The foamed resin material P is a polyurethane foam material when the foamed resin is polyurethane foam.
Thereafter, the upper mold 82 is separated from the lower mold 94, the mold 81 is opened, and the soundproofing material 60 composed of the fiber layer 61 and the foamed resin layer 75 shown in FIG.

試料１、２、３、４の防音材を作製し、ＪＩＳ Ａ１４４１−１：２００７に基づいて透過損失（音響インテンシティ法による）を測定し、発泡樹脂層が繊維層の片面及び端部外周の両方を覆うことによる防音効果を評価した。各試料のサイズは、５００×５００×２０ｍｍである。音源残響室は３６ｍ３、受音無響室は２０ｍ３、測定面積は４００×４００ｍｍ（０．１６ｍ２）である。試料の一側（試料１、２はフェルト側）に厚み０．８ｍｍの鉄板を重ね、試料の周囲を５０ｍｍ幅の枠で固定した状態で、鉄板側を音源とし、試料表面から１００ｍｍ離れた位置で中央分離散点４箇所（１００ｍｍピッチ）を測定した。 The soundproofing materials of Samples 1, 2, 3, and 4 were prepared, and transmission loss (according to the sound intensity method) was measured based on JIS A1441-1: 2007. The foamed resin layer was formed on one side and the outer periphery of the end of the fiber layer. The soundproofing effect by covering both was evaluated. The size of each sample is 500 × 500 × 20 mm. The sound source reverberation chamber is 36 m 3 , the receiving anechoic chamber is 20 m 3 , and the measurement area is 400 × 400 mm (0.16 m 2 ). A position where a steel plate of 0.8 mm thickness is stacked on one side of the sample (samples 1 and 2 are felt side), and the periphery of the sample is fixed with a 50 mm width frame, the iron plate side is used as a sound source and 100 mm away from the sample surface The four central separation points (100 mm pitch) were measured.

試料１は、図１の防音材１０と同様の構成からなり、厚み１０ｍｍのポリウレタンフォームで厚み１０ｍｍのフェルトの片面及び端部外周が覆われている。試料１は、フェルトとして、合成樹脂繊維からなる雑フェルト、目付５８０ｇ／ｍ２、サイズ４８０×４８０×１０ｍｍのプレスフェルトを用い、図２に示したモールド成形に従い、上型の型面（５００×５００ｍｍ）にフェルトを取り付けた金型にポリウレタンフォーム原料を注入し、発泡させることにより作製した。ポリウレタンフォーム原料は、分子量５０００、官能基数３のポリエーテルポリオール１００重量部、アミン触媒１．５重量部、発泡剤としての水３．５重量部、ＭＤＩからなるイソシアネート６０重量部とからなる。試料１のポリウレタンフォームの密度は７０ｋｇ／ｍ３、全体の目付量は１６４０ｇ／ｍ２である。 The sample 1 has the same configuration as that of the soundproofing material 10 of FIG. 1, and one side and an outer periphery of an end of a felt having a thickness of 10 mm are covered with a polyurethane foam having a thickness of 10 mm. Sample 1 uses a felt made of synthetic resin fibers, a press felt having a basis weight of 580 g / m 2 and a size of 480 × 480 × 10 mm as the felt, and according to the molding shown in FIG. A polyurethane foam raw material was injected into a mold having a felt attached to 500 mm) and foamed. The polyurethane foam raw material is composed of 100 parts by weight of a polyether polyol having a molecular weight of 5000 and 3 functional groups, 1.5 parts by weight of an amine catalyst, 3.5 parts by weight of water as a blowing agent, and 60 parts by weight of an isocyanate comprising MDI. The density of the polyurethane foam of Sample 1 is 70 kg / m 3 , and the overall basis weight is 1640 g / m 2 .

試料２は、図７に示した従来の防音材１００と同様の構成からなり、厚み１０ｍｍのポリウレタンフォームで厚み１０ｍｍのフェルトの片面のみ覆われている。試料２は、試料１のプレスフェルトと同じ材質のフェルトを５００ｍｍ×５００ｍｍ×１０ｍｍにしたものを用い、試料１の金型と同一構成の金型を用い、その上型の型面の全面にフェルトを取り付け、試料１のポリウレタンフォーム原料と同一配合のポリウレタンフォーム原料を注入し、発泡させることにより作製した。試料２のポリウレタンフォームの密度は７０ｋｇ／ｍ３、全体の目付量は１６４０ｇ／ｍ２である。 The sample 2 has the same configuration as that of the conventional soundproofing material 100 shown in FIG. 7, and is covered with only 10 mm of felt with a 10 mm thick polyurethane foam. Sample 2 is made of a felt made of the same material as the press felt of sample 1 and made of 500 mm × 500 mm × 10 mm. A mold having the same configuration as the mold of sample 1 is used, and the entire surface of the mold surface of the upper mold is felt. Was attached, and a polyurethane foam raw material having the same composition as the polyurethane foam raw material of Sample 1 was injected and foamed. The density of the polyurethane foam of Sample 2 is 70 kg / m 3 , and the overall basis weight is 1640 g / m 2 .

試料３は、フェルト単体（５００ｍｍ×５００ｍｍ×２０ｍｍ）からなり、試料１及び２のプレスフェルトと同じ材質のフェルトから作製した。試料３の全体の目付量は１１２０ｇ／ｍ２である。 Sample 3 was made of felt alone (500 mm × 500 mm × 20 mm), and was made of felt made of the same material as the press felts of Samples 1 and 2. The total basis weight of Sample 3 is 1120 g / m 2 .

試料４は、ポリウレタンフォーム単体（５００×５００×２０ｍｍ）からなり、試料１及び２の金型と同一構成の金型を用い、試料１及び試料２のポリウレタンフォーム原料と同一配合のポリウレタンフォーム原料を金型に注入し、発泡させることにより作製した。試料４のポリウレタンフォームの密度は７０ｋｇ／ｍ３、全体の目付量は１４００ｇ／ｍ２である。 Sample 4 is composed of a single polyurethane foam (500 × 500 × 20 mm), and uses a mold having the same configuration as the molds of Samples 1 and 2, and a polyurethane foam material having the same composition as the polyurethane foam materials of Sample 1 and Sample 2. It was prepared by pouring into a mold and foaming. The density of the polyurethane foam of Sample 4 is 70 kg / m 3 , and the overall basis weight is 1400 g / m 2 .

透過損失の測定結果を図６に示す。
ポリウレタンフォームでフェルトの片面及び端部外周を覆った試料１は、フェルトの片面のみを覆った試料２と比べ、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても透過損失が大きく、防音性に優れていた。さらに、試料１と試料２の透過損失の差は、高周波側の４ｋＨｚ及と８ｋＨｚで一層大きくなっており、試料１の防音効果は高周波側でより高くなる。 The measurement result of the transmission loss is shown in FIG.
Sample 1 with one side of the felt covered with polyurethane foam and the outer periphery of the end has a larger transmission loss at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz than the sample 2 with only one side of the felt covered. It was excellent. Further, the difference in transmission loss between the sample 1 and the sample 2 becomes larger at 4 kHz and 8 kHz on the high frequency side, and the soundproofing effect of the sample 1 becomes higher on the high frequency side.

フェルト単体からなる試料３は、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても試料１よりも透過損失が小さく、防音効果が劣っていた。   Sample 3 made of a simple felt had a transmission loss smaller than that of sample 1 at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and was inferior in soundproofing effect.

ポリウレタンフォーム単体からなる試料４は、５００Ｈｚ、１ｋＨｚ、２ｋＨｚ、４ｋＨｚ、８ｋＨｚの何れにおいても試料１よりも透過損失が小さく、防音効果が劣っていた。   Sample 4 made of a single polyurethane foam had a transmission loss smaller than that of sample 1 at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and was inferior in soundproofing effect.

これらのことから、本発明の防音材のように、繊維層の片面及び端部外周を発泡樹脂層で覆うことにより、高い防音性が得られることがわかる。
なお、本発明の防音材は、車両のフロアサイレンサやダッシュサイレンサなどの車両用防音材に限られず、例えば建物、産業機械、家電等の防音材として好適である。 From these facts, it can be seen that high soundproofing can be obtained by covering one side and the outer periphery of the end of the fiber layer with the foamed resin layer as in the soundproofing material of the present invention.
The soundproofing material of the present invention is not limited to a vehicle soundproofing material such as a vehicle floor silencer or a dash silencer, and is suitable as a soundproofing material for buildings, industrial machines, home appliances, and the like.

１０、５０ 防音材
１１、６１ 繊維層
１２、６２ 繊維層の片面
１３、６３ 繊維層の端部外周
１５、７５ 発泡樹脂層
２１、８１ 金型
２２、８２ 上型
３２、９４ 下型
２３、８３上型の型面
２４、８４ 上型の型面の端部外周
３３、９５ 下型の型面
３５、９７ 発泡成形空間
６５、６７、６９ 繊維層の貫通孔
６６、６８、７０ 繊維層の貫通孔の内周面
７６、７７、７８ 貫通孔の内周面を被覆する部分
８６、８８、９０ 上型の型面の凸部
８６ａ、８８ａ、９０ａ 凸部の先端
８７、８９、９１ 凸部の側面
９２、９３、９４ 隙間
Ｐ 発泡樹脂原料 10, 50 Soundproof material 11, 61 Fiber layer 12, 62 Single side of fiber layer 13, 63 Outer periphery of fiber layer 15, 75 Foamed resin layer 21, 81 Mold 22, 82 Upper mold 32, 94 Lower mold 23, 83 Upper mold surface 24, 84 Upper mold end surface outer periphery 33, 95 Lower mold surface 35, 97 Foam molding space 65, 67, 69 Through hole in fiber layer 66, 68, 70 Through fiber layer Hole inner peripheral surfaces 76, 77, 78 Portions covering inner peripheral surfaces of through-holes 86, 88, 90 Upper mold surface projections 86a, 88a, 90a Projection tips 87, 89, 91 Side surface 92, 93, 94 Clearance P Foamed resin material

Claims (5)

繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材において、
前記発泡樹脂層は、前記繊維層の片面と端部外周の少なくとも一部を覆って設けられていることを特徴とする防音材。 In a soundproof material consisting of a laminate of a fiber layer and a foamed resin layer formed on one side of the fiber layer,
The soundproof material, wherein the foamed resin layer is provided so as to cover at least a part of one side and an outer periphery of the end of the fiber layer. 前記繊維層には貫通孔が設けられ、
前発泡樹脂層は、前記繊維層の貫通孔の部分で該貫通孔の内周面を被覆しており、該内周面が被覆された貫通孔の両端が開口していることを特徴とする請求項１に記載の防音材。 The fiber layer is provided with a through hole,
The pre-foamed resin layer covers the inner peripheral surface of the through hole at a portion of the through hole of the fiber layer, and both ends of the through hole covered with the inner peripheral surface are open. The soundproof material according to claim 1. 前記発泡樹脂層は、ポリウレタンフォームからなることを特徴とする請求項１または２に記載の防音材。   The soundproofing material according to claim 1 or 2, wherein the foamed resin layer is made of polyurethane foam. 上型または下型の何れか一方の型の型面に取り付けた繊維層と他方の型の型面との間の発泡成形空間で、発泡樹脂原料を発泡させることにより、前記繊維層と該繊維層の片面に発泡形成された発泡樹脂層との積層体からなる防音材を製造する方法において、
前記繊維層を取り付けた一方の型の型面の端部外周は、少なくとも一部が前記繊維層の端部外周よりも大であり、
前記繊維層と前記他方の型の型面との間の発泡成形空間は、前記繊維層の端部外周まで存在し、
前記発泡樹脂原料の発泡により、前記繊維層の片面と端部外周の少なくとも一部を覆う発泡樹脂層を形成することを特徴とする防音材の製造方法。 By foaming a foamed resin raw material in a foam molding space between the fiber layer attached to the mold surface of either the upper mold or the lower mold and the mold surface of the other mold, the fiber layer and the fiber In a method for producing a soundproof material comprising a laminate with a foamed resin layer formed on one side of a layer,
The outer periphery of the end of the mold surface of one mold to which the fiber layer is attached is at least partially larger than the outer periphery of the end of the fiber layer,
The foam molding space between the fiber layer and the mold surface of the other mold exists up to the outer periphery of the end of the fiber layer,
A foamed resin layer that covers at least a part of one side of the fiber layer and the outer periphery of the end portion is formed by foaming of the foamed resin raw material. 前記繊維層は該繊維層の両面を貫通する貫通孔を有し、
前記繊維層を取り付けた前記一方の型の型面には、前記繊維層の取り付け時に前記貫通孔に挿入される凸部を有し、
前記貫通孔に挿入された前記凸部の側面と前記貫通孔の内周面との間に前記発泡成形空間に通じる隙間を形成し、前記凸部の先端を前記他方の型面と当接した状態にして前記発泡樹脂原料を発泡させることにより、
前記繊維層の片面と端部外周の少なくとも一部を覆い、前記繊維層の貫通孔の部分では該貫通孔の内周面を被覆し、該内周面を覆った貫通孔の両端で開口した発泡樹脂層を形成することを特徴とする請求項４に記載の防音材の製造方法。 The fiber layer has a through-hole penetrating both surfaces of the fiber layer;
The mold surface of the one mold to which the fiber layer is attached has a convex portion that is inserted into the through hole when the fiber layer is attached,
A gap communicating with the foam molding space is formed between the side surface of the convex portion inserted into the through hole and the inner peripheral surface of the through hole, and the tip of the convex portion is in contact with the other mold surface By foaming the foamed resin raw material in a state,
The fiber layer covers at least a part of one side and the outer periphery of the end, covers the inner peripheral surface of the through hole at the portion of the through hole of the fiber layer, and opens at both ends of the through hole that covers the inner peripheral surface The method for producing a soundproof material according to claim 4, wherein a foamed resin layer is formed.
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Citations (5)

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US4784902A (en) * 1985-09-19 1988-11-15 Geoffrey Crompton Components that can exhibit low smoke, toxic fume and burning characteristics, and their manufacture
JP2003027958A (en) * 2001-07-13 2003-01-29 Pacific Ind Co Ltd Engine cover, and method for manufacturing the same
JP2006150645A (en) * 2004-11-26 2006-06-15 Toray Pef Products Inc Sound arresting heat insulating cover material
JP2009226675A (en) * 2008-03-21 2009-10-08 Asahi Rubber Kk Sound-proofing material for vehicle
US20170240123A1 (en) * 2014-10-20 2017-08-24 Autoneum Management Ag Main floor part for a small utility vehicle

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4784902A (en) * 1985-09-19 1988-11-15 Geoffrey Crompton Components that can exhibit low smoke, toxic fume and burning characteristics, and their manufacture
JP2003027958A (en) * 2001-07-13 2003-01-29 Pacific Ind Co Ltd Engine cover, and method for manufacturing the same
JP2006150645A (en) * 2004-11-26 2006-06-15 Toray Pef Products Inc Sound arresting heat insulating cover material
JP2009226675A (en) * 2008-03-21 2009-10-08 Asahi Rubber Kk Sound-proofing material for vehicle
US20170240123A1 (en) * 2014-10-20 2017-08-24 Autoneum Management Ag Main floor part for a small utility vehicle

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