JP2020160311A - Soundproofing material - Google Patents

Abstract

To provide a soundproofing material which can obtain good soundproof properties (including vibration damping properties), by eliminating a state of being bent toward the polyurethane foam side opposite to the skin after the skin is integrally molded, when it is placed on the floor surface of a vehicle or the like so that the polyurethane foam can adhere to the floor surface.SOLUTION: In a soundproofing material 10 in which a skin material 30 is integrally molded on one side of a polyurethane foam 20, a sample of the soundproofing material 10 of 200 mm square and with thickness of 20 mm has compression hardness of 500 N or more with load at 50% compression when compressed to 80% of the sample thickness by a compression jig of φ80 mm at a test speed of 50 mm/min, as a measurement value. And in the polyurethane foam 20, slits 25 are formed which extend from a surface opposite to the skin material 30 to the skin material 30 side.SELECTED DRAWING: Figure 1

Description

The present invention relates to a soundproofing material.

Conventionally, as a soundproofing material used as a floor silencer or the like mounted on the floor of a vehicle, for example, there is one made of a polyurethane foam integrated with a skin in which polyurethane foam is foam-molded on the back surface of the skin material.

Patent Document 1 below describes a floor carpet for automobiles in which an impact material made of a skinless urethane resin foam is integrally molded on the back surface of the carpet.

Further, in Patent Document 2 below, a polyurethane foam having a breathability of 3.0 ft ³ / min or more and a foam layer hardness of 8 kg / 314 cm ² or less (25% ILD) was integrally molded on the back surface of the epidermis. A soundproofing material made of a polyurethane foam molded product with an integrated skin is described.

JP-A-10-71884 Japanese Unexamined Patent Publication No. 11-5499

However, in the soundproofing materials such as floor carpets for automobiles made of polyurethane foam with integrated skin shown in Patent Document 1 and Patent Document 2, the polyurethane foam integrally molded with the skin material shrinks due to natural cooling after the skin is integrally molded. To do. At that time, since one side of the polyurethane foam is fixed to the skin material, shrinkage is inhibited on the skin material side, and the polyurethane foam mainly shrinks on the side opposite to the skin material 30. Due to the shrinkage, the polyurethane foam 83 is bent toward the polyurethane foam 83, which is opposite to the skin material 81, like the conventional soundproofing material 80 shown in FIG. 10 (10-1). Reference numeral 84 is the surface of the polyurethane foam 83 opposite to the skin material 81.

When the surface 84 of the polyurethane foam 83 is placed on the floor surface 90 of an automobile or the like, the soundproofing material 80 bent toward the polyurethane foam 83 is the surface of the polyurethane foam 83 as shown in FIG. 10 (10-2). A gap 95 is generated between the 84 and the floor surface 90 due to the bending of the polyurethane foam 83, so that the polyurethane foam 83 cannot adhere to the floor surface 90, and should be obtained by the adhesion between the polyurethane foam 83 and the floor surface 90. There is a problem that soundproofing (including vibration damping) cannot be obtained.

The present invention has been made in view of the above points, and is a soundproofing material made of a polyurethane foam with an integral skin, and a state of being bent toward the polyurethane foam opposite to the skin material, which is generated after the integral molding of the epidermis, is a soundproofing material. The purpose is to provide a soundproofing material that eliminates the problem when it is placed on the floor of an automobile or the like, and that the floor surface of the automobile or the like and polyurethane foam are in close contact with each other to obtain good soundproofing (including vibration damping). To do.

The invention of claim 1 is a soundproofing material in which a skin material is integrally molded on one side of a polyurethane foam. The soundproofing material is a sample of 200 mm square x 20 mm thick with a compression jig of φ80 mm at a test speed of 50 mm / min. The compression hardness measured at 50% compression when compressed to 80% of the sample thickness is 500 N or more, and the polyurethane foam has a slit from the surface opposite to the skin material to the skin material side. Is formed.

The invention of claim 2 is characterized in that, in claim 1, the skin material is made of a fiber aggregate.

According to a third aspect of the present invention, in claim 1 or 2, the skin material has an impregnated cured layer of a polyurethane foam raw material formed at a boundary portion with the polyurethane foam, and the slit is a position of the impregnated cured layer. It is characterized in that it is formed up to.

In the invention of claim 4, in any one of claims 1 to 3, the air volume of the skin material containing the impregnated hardened layer based on the JIS K6400-7B method: 2012 is 5 to 80 cc / cm ² / sec. It is characterized by being.

In the invention of claim 5, in any one of claims 1 to 4, the loss coefficient ratio of the soundproofing material is the loss coefficient ratio = (loss coefficient without double-sided tape bonding) / (double-sided tape is bonded to the entire surface). The loss coefficient) is 0.6 or more.

The soundproofing material of the present invention bends to the polyurethane foam side opposite to the skin material due to shrinkage of the polyurethane foam after the skin is integrally molded.
However, since the soundproofing material of the present invention has a slit formed in the polyurethane foam from the surface opposite to the skin material to the skin material side, when the soundproofing material is placed on the floor surface of an automobile or the like, the soundproofing material is placed. The weight of the soundproofing material, or the weight of the mat placed on the soundproofing material and the weight of the soundproofing material press the soundproofing material against the floor surface, etc., thereby slitting on the surface side of the polyurethane foam opposite to the skin material. Expands and the surface side of the polyurethane foam opposite to the skin material expands outward and becomes flat. As a result, the polyurethane foam of the soundproofing material can be brought into close contact with the floor surface or the like, and a good soundproofing effect (including a vibration damping effect) can be obtained.

Further, in the soundproofing material of the present invention, the load at the time of 50% compression when a sample of 200 mm square × 20 mm in thickness is compressed to 80% of the sample thickness at a test speed of 50 mm / min by a compression jig of φ80 mm is used as a measured value. Since the compressed hardness is 500 N or more, it is relatively hard. Therefore, when the slit in the present invention is not formed in the polyurethane foam, the weight of the soundproofing material, or the weight of the mat placed on the soundproofing material and the weight of the soundproofing material do not flatten the polyurethane foam, and the polyurethane A gap is created between the foam and the floor surface, etc., and a good soundproofing effect cannot be obtained. Further, since the soundproofing material of the present invention has the above-mentioned hardness, the feet are not buried when an occupant or the like gets on the soundproofing material, and stable movement can be taken.

It is a back side perspective view of the soundproofing material of one embodiment of the present invention in a state where the slit is widened. It is sectional drawing of AA and BB of FIG. It is sectional drawing which shows the use example in the soundproofing material of FIG. It is a back side perspective view in the state where the slit is expanded about the soundproofing material of another embodiment. FIG. 4 is a sectional view taken along the line CC of FIG. It is sectional drawing which shows the process to the middle in the skin integral molding of a soundproofing material. It is sectional drawing which shows the remaining process in the skin integral molding of a soundproofing material. It is sectional drawing which shows the formation process of the slit in the manufacturing of a soundproof material. It is a table which shows the composition, composition, and the physical property value of an Example and a comparative example. It is sectional drawing which shows the problem of the conventional soundproof material.

Hereinafter, embodiments of the present invention will be described. The soundproofing material 10 of the embodiment shown in FIGS. 1 and 2 is made of a skin-integrated polyurethane foam in which a skin material 30 is integrally molded on one side of the polyurethane foam 20. The soundproofing material 10 is suitable as, for example, a carpet to be placed on the floor surface of an automobile or the like, and the surface 21 of the polyurethane foam 20 opposite to the skin material 30 is placed on the floor surface of the automobile or the like. Carpet.

The polyurethane foam 20 is a foam obtained from a polyurethane foam raw material, and slits 25 are formed by slitting from the surface 21 on the side opposite to the skin material 30 to the skin material 30 side.

The polyurethane foam 20 preferably has a density (JIS K7222: 2005) of 30 to 95 kg / m ³ and a thickness of 1 to 40 mm. If the density of the polyurethane foam 20 is too low, the hardness becomes too low, and conversely, if the density is high, the hardness becomes heavy. Further, if the polyurethane foam 20 becomes too thin, the space between the upper and lower surfaces in the molding space (cavity) of the mold used for integral skin molding becomes narrow and the polyurethane foam raw material cannot be filled, so that the urethane foam cannot be molded, and conversely, the urethane foam becomes thick. Then, the soundproofing material 10 becomes bulky and heavy.

The polyurethane foam raw material contains at least a polyol component, a catalyst, a foaming agent and an isocyanate.
The polyol component preferably contains a polyether polyol and a polymer polyol, or is composed of a polymer polyol alone.

Polyether polyols are polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, shoe cloth, or ethylene to the polyhydric alcohols. Examples thereof include polyether polyols to which alkylene oxides such as oxide and propylene oxide are added.

As the polyether polyol, a polyether polyol having 2 to 8 functional groups, a hydroxyl value of 20 to 168 mgKOH / g, and a number average molecular weight of 168 to 20000 is preferable. The ethylene oxide content (EO rate) of the polyether polyol is preferably 5 to 90%. The ethylene oxide content (EO rate) of the polyether polyol is the content of ethylene oxide units when the total amount of one raw material composition unit is 100% by weight.

The polymer polyol is obtained by polymerizing an ethylenically inert compound in a polyether polyol. By including the polymer polyol in the polyol component, the effects of improving air permeability and improving hardness can be obtained.
The polymer polyol preferably has a functional group number of 3 to 8, a hydroxyl value of 20 to 60 mgKOH / g, and a number average molecular weight of 2000 to 8000. The ethylene oxide content (EO rate) of the polymer polyol is preferably 3 to 50%. The ethylene oxide content (EO rate) of the polymer polyol is the content of ethylene oxide units when the total amount of one raw material composition unit is 100% by weight.
The weight ratio of the polymer polyol in the polyl component is preferably 20 to 100%, more preferably 50 to 100%, and the remaining ratio is the polyether polyol.

As the catalyst, those known for polyurethane foam can be used. For example, amine catalysts such as triethylamine, triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine, tetramethylguanidine, and imidazole compounds, tin catalysts such as stanas octoate and dibutyltin dilaurate, and phenylmercury propionate. Alternatively, a metal catalyst such as lead octate (also referred to as an organic metal catalyst) can be mentioned. A plurality of catalysts may be used in combination. The general amount of the catalyst is about 0.2 to 4 parts by weight with respect to 100 parts by weight of the polyol component.

The foaming agent is not particularly limited, but water is preferable. The amount of water as a foaming agent is preferably about 2 to 10 parts by weight with respect to 100 parts by weight of the polyol component. Further, 3 to 7 parts by weight is more preferable.

The isocyanate may be aromatic, alicyclic, or aliphatic, and may be a bifunctional isocyanate having two isocyanate groups in one molecule, or three or more isocyanates in one molecule. It may be a trifunctional or higher functional isocyanate having an isocyanate group, or they may be used alone or in combination of two or more.

For example, as bifunctional isocyanates, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylenedi isocyanate, p-phenylenedi isocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'- Fragrances such as diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylenediisonate, 3,3'-dimethoxy-4,4'-biphenylenediisocyanate Group type, cyclohexane-1,4-diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, methylcyclohexanediisocyanate and other alicyclic products, butane-1,4-diisocyanate, hexamethylene diisocyanate, isopropi Examples thereof include aliphatic ones such as range isocyanate, methylene diisocyanate and lysine isocyanate.

Examples of trifunctional or higher functional isocyanates include 1-methylbenzol-2,4,6-triisocyanate, 1,3,5-trimethylbenzol-2,4,6-triisocyanate, and biphenyl-2,4,4'. -Triisocyanate, diphenylmethane-2,4,4'-triisocyanate, methyldiphenylmethane-4,6,4'-triisocyanate, 4,4'-dimethyldiphenylmethane-2,2', 5,5'tetraisocyanate, triisocyanate Diphenylmethane-4,4', 4 "-triisocyanate, polypeptide MDI and the like can be mentioned. Other urethane prepolymers can also be used. Further, the isocyanate is not limited to one type, but one or more types. For example, one type of aliphatic isocyanate and two types of aromatic isocyanate may be used, two types of aromatic isocyanate and urethane prepolymer may be used, and three or more types of isocyanate may be used. The isocyanate index is preferably 90 to 130, more preferably 95 to 120. The isocyanate index is an index used in the field of polyurethane and is an active hydrogen group in a raw material (for example, a hydroxyl group of polyols). And the equivalent ratio of the isocyanate group of isocyanate to the active hydrogen group contained in the active hydrogen group such as water as a foaming agent) is a numerical value expressed as a percentage.

Examples of the components appropriately contained in the polyol component include a foam stabilizer and an additive.
The foam stabilizer may be any one used for polyurethane foam, and examples thereof include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants. The blending amount of the foam stabilizer is preferably 0 to 2 parts by weight with respect to 100 parts by weight of the polyol component.

Examples of the additive include a communicating agent, a cross-linking agent, a pigment, a filler, a flame retardant, an antioxidant, an ultraviolet absorber and the like.
Examples of the communicating agent include a polyether polyol having a high EO addition ratio, polyethylene glycol, a silicone foam stabilizer having high air permeability (having foam breaking property), and the like. When the communicating agent is blended, the amount of the communicating agent is preferably 0.5 to 20 parts by weight with respect to 100 parts by weight of the polyol. The communicating agent is not limited to one type, and two or more types may be used.
Examples of the cross-linking agent include glycerin, trimethylolpropane, 1,2,4-butanetriol, 2-methyl-2,3,4-butanetriol, triethanolamine, pentaerythritol and the like, and may be used alone or in combination of two or more. You may. Preferred cross-linking agents include glycerin, pentaerythritol, diethanolamine and the like as cross-linking agents having 2 to 4 functional groups, a molecular weight of 92 to 136, and a hydroxyl value of 1066 to 1826 mgKOH / g, and may be used alone or in combination of two or more.
When the cross-linking agent is blended, the amount of the cross-linking agent is preferably 1 to 6 parts by weight with respect to 100 parts by weight of the polyol component. The cross-linking agent may have an ethylene oxide content (EO rate) of more than 0%. For example, ethylenediamine type (number of functional groups: 4, molecular weight: 280, hydroxyl value 800 mgKOH / g, EO rate 40%), trimethylolpropane type (functional group: 3, molecular weight: 183, hydroxyl value 920 mgKOH / g, EO rate 50%). ) Etc.

Examples of the pigment include carbon black and titanium oxide.
Examples of the filler include graphite, alumina, melamine and the like.

Specific examples of the flame retardant include halogenated diphenyl ethers such as degabromdiphenyl ether and octabromdiphenyl ether, and halogen compounds such as halogenated polycarbonate, such as antimony trioxide, antimony tetroxide, and antimony pentoxide. Inorganic compounds such as sodium pyroantimonate, aluminum hydroxide, triazine ring-containing compounds, metal hydroxides, phosphoric acid ester flame retardants, condensed phosphoric acid ester flame retardants, phosphate flame retardants, inorganic phosphorus flame retardants, dialkyl Examples thereof include phosphinates, silicone flame retardants, metal oxides, boric acid compounds, and expansive graphite.

Examples of the antioxidant include naphthylamine-based, diphenylamine-based, p-phenyldiamine-based, quinoline-based, hydroquinone derivatives, monophenol-based, thiobisphenol-based, hindered phenol-based, and phosphite ester-based agents.

Examples of the ultraviolet absorber include 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, and 5,5'-methylenebis (2-hydroxy-4-methoxybenzophenone). 2-Hydroxybenzophenones such as 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, 2- (2'-hydroxy-3', 5'-ditertiary butylphenyl) -5-chlorobenzo Triazol, 2- (2'-hydroxy-3'-tertiary butyl-5'-methylphenyl) -5-chlorobenzotriazol, 2- (2'-hydroxy-5'-tertiary octyl) Phenyl) benzotriazol, 2- (2'-hydroxy-3', 5'-dicumylphenyl) benzotriazol, 2,2'-methylenebis (4-third octyl-6- (benzotriazolyl) phenol ), 2- (2'-Hydroxyphenyl) benzotriazoles such as 2- (2'-hydroxy-3'-tertiary butyl-5'-carboxyphenyl) benzotriazole; phenylsalicylate, resorcinol monobenzoate, 2,4 -Di-tertiary butylphenyl-3,5-di-tertiary butyl-4-hydroxybenzoate, 2,4-di-tertiary amylphenyl-3,5-di-tertiary butyl-4-hydroxybenzoate, hexadecyl-3.5 Phenylates such as −di-tertiary butyl-4-hydroxybenzoate; substituted oxanilides such as 2-ethyl-2'-ethoxyoxanilide, 2-ethoxy-4'-dodecyloxanilide; ethyl-α-cyano- Cyanoacrylates such as β, β-diphenyl acrylate, methyl-2-cyano-3-methyl-3- (p-methoxyphenyl) acrylate; 2- (2-hydroxy-4-octoxyphenyl) -4,6- Bis (2,4-ditertiary butylphenyl) -s-triazine, 2- (2-hydroxy-4-methoxyphenyl) -4,6-diphenyl-s-triazine, 2- (2-hydroxy-4-propoxy) Examples thereof include triaryltriazines such as −5-methylphenyl) -4,6-bis (2,4-ditertiary butylphenyl) -s-triazine.

The EO rate of the polyurethane foam 20 is preferably 7 to 15%, more preferably 8 to 13%. If the EO rate of the polyurethane foam is too low or too high, the quietness of the soundproofing material will decrease.

Here, the method for measuring the EO rate of the polyurethane foam 20 is to put only the polyurethane foam in a Soxhlet extractor [the weight of the charged polyurethane foam is A (g)] and wash it with a solvent (: acetone) at 68 to 72 ° C. for 8 hours. After drying, it decomposes with alkali. Then, only the polyol component is extracted [the weight that can be extracted is B (g)], and a part thereof is evaluated by matrix-assisted laser time-of-flight mass spectrometry <manufactured by JEOL Ltd.>. The EO rate at each molecular weight [EO rate at each molecular weight (= N number of EO (: theoretical value) x number of each molecular weight ÷ total number)] is calculated, and the total is C. The method for calculating the EO rate of polyurethane foam is as follows.
EO rate of polyurethane foam = [B × C] / [A] × 100
However, a molecular weight of 800 or more is calculated.

The slit 25 formed in the polyurethane foam 20 is provided to eliminate the state in which the polyurethane foam 20 integrally molded with the skin material 30 is bent to the opposite side to the skin material 30 due to natural cooling after the skin material is integrally molded. Has been done.

The bending of the soundproofing material 10 by the slit 25 is eliminated by the weight of the soundproofing material 10 when the soundproofing material 10 is placed on the floor surface 37 of an automobile or the like with the polyurethane foam 20 facing the side, as shown in FIG. Alternatively, the weight of the mat 39 placed on the soundproofing material 10 and the weight of the soundproofing material 10 press the soundproofing material 10 against the floor surface 37, so that the surface of the polyurethane foam 20 on the opposite side of the skin material 30 By expanding the slit 25 on the 21 side and flattening the polyurethane foam 20 from the bent state.

The elimination of bending will be described in more detail. Since the skin material 30 side of the polyurethane foam 20 is fixed to the skin material 30, the expansion of the slit 25 is prevented or slightly expanded on the skin material 30 side. On the other hand, since the surface 21 of the polyurethane foam 20 on the opposite side of the skin material 30 is open without being fixed to the skin material 30 or the like, the surface 21 side opposite to the skin material 30 is on the side opposite to the skin material 30 side. The expansion of the slit 25 becomes large. As a result, the surface 21 side of the polyurethane foam 20 opposite to the skin material 30 expands outward, and the bending of the polyurethane foam 20 is eliminated.

The slit 25 is formed from the surface 21 of the polyurethane foam 20 on the opposite side of the skin material 30 to the boundary portion with the skin material 30 through the polyurethane foam 20, which is considered to be good for the expansion of the slit 25. It is preferable to do so. If the slit 25 is formed only halfway through the polyurethane foam 20, there is a risk of tearing (breaking) from the end portion of the slit 25 inside the polyurethane foam 25 when the slit 25 is expanded.

The aspect of the slit may be a grid-like slit 25 in the soundproofing material 10 shown in FIGS. 1 and 2, a parallel slit 250 in the soundproofing material 100 shown in FIGS. 4 and 5, or another aspect. .. In particular, in the case of the lattice-shaped slits 25 shown in FIGS. 1 and 2, the bending of the soundproofing material 10 can be more effectively eliminated than in the case of the parallel slits 250 shown in FIGS. 4 and 5. .. In FIG. 4, reference numeral 200 is polyurethane foam, 300 is a skin material, 310 is a first layer in the skin material 30, 330 is a second layer in the skin material, and 340 is an impregnated hardened layer. Further, reference numeral 210 is the surface of the polyureta foam 200 on the opposite side of the skin material 300. The first layer, the second layer and the impregnated hardened layer will be described later.
The distance between the slit 25 and the slit 25 is appropriately determined, and examples thereof include 5 to 150 mm. More preferably, it is 10 to 100 mm.

The soundproofing material 10 exhibits good soundproofing (including vibration damping) because the polyurethane foam 20 is in close contact with the floor surface 37 by eliminating the bending of the polyurethane foam 20.

Examples of the skin material 30 include fiber aggregates such as non-woven fabric and felt, and felt is particularly preferable from the viewpoint of light weight and soundproofing (sound absorption). The skin material 30 is formed with an impregnated cured layer 34 made of a polyurethane foam raw material at a boundary portion with the polyurethane foam 20.

In the impregnation cured layer 34, when the polyurethane foam 20 and the skin material 30 are integrally molded with the skin, the polyurethane foam raw material for foaming and forming the polyurethane foam 20 impregnates the skin material 30 at the boundary portion with the polyurethane foam 20 and cures. Is formed by The impregnation hardened layer 34 suppresses the elongation of the polyurethane foam 20 on the skin material 30 side, and the slit 25 is expanded on the surface 21 side of the polyurethane foam 20 on the opposite side of the skin material 30 than on the skin material 30 side. The size can be increased, and the bending of the polyurethane foam 20 can be effectively eliminated.

The skin material 30 may be either one made of one layer or one made of a laminated body of a plurality of layers.
The skin material 30 of the embodiment is composed of a two-layer non-woven fabric sheet composed of a first layer 31 and a second layer 33. The first layer 31 is on the opposite side of the polyletan foam 20, while the second layer 33 is on the side facing the polyurethane foam 20.

The layer of either the first layer 31 or the second layer 33 has a basis weight of 90 g / m ² or more, preferably 90 g / m ² or more and 500 g / m ² or less, and has a fiber diameter of 2 to 4 d. The other layer has a basis weight of 100 g / m ² or more, preferably 100 g / m ² or more and 500 g / m ² or less. When the skin material 30 is formed in this way, since one layer is densely packed with fine fibers, the viscous polyurethane foam raw material impregnated in the skin material 30 is less likely to seep out from the skin material 30. One of the two layers is impregnated with an acrylic acid ester resin of 35 g / m ² or more, preferably 35 g / m ² or more and 100 g / m ² or less. In the layer impregnated with the acrylic acid ester resin, the fibers are filled with the acrylic ester resin, making it difficult for the polyurethane foam raw material to pass through the skin material 30, and making it even more difficult for the polyurethane foam raw material to seep out. To impregnate the skin material 30 of the acrylic acid ester resin, an emulsion of the acrylic ester resin is applied to the surface of the skin material 30, or powder of the acrylic ester resin is sprayed on the surface of the skin material 30. It can be done by applying hot rollers or hot air.

By adjusting the basis weight of the first layer 31 and the second layer 33 and the impregnation of the acrylic acid ester resin, the air volume of the skin material 30 including the impregnated hardened layer 34 based on the JIS K6400-7B method: 2012 can be adjusted. It can be 5 to 80 cc / cm ² / sec. By setting the air permeability of the skin material 30 including the impregnated hardened layer 34 based on the JIS K6400-7B method: 2012 to 5 to 80 cc / cm ² / sec, the soundproofing (sound absorbing) property of the soundproofing material 10 is improved. it can.

In a more preferable embodiment of the skin material 30, the second layer 33 on the polyurethane foam 20 side has a basis weight of 90 g / m ² or more having a fiber diameter of 2 to 4 d, and an acrylic acid ester resin is 35 g / m ^2. This is the impregnated mode. When the skin material 30 is configured in this embodiment, the second layer 33 in contact with the polyurethane foam raw material during the production of the soundproof material 10 is densely packed with fine fibers, and is further impregnated with 35 g / m ² or more of acrylic acid ester resin. Therefore, the amount of the polyurethane foam raw material impregnating (penetrating) into the second layer 33 can be limited so as not to be excessive. Further, the impregnated cured layer 34 formed at the portion of the second layer 33 in contact with the polyurethane foam 20 by impregnation / curing the polyurethane foam raw material has the air permeability of the second layer 33 depending on the amount of the EO rate of the polyurethane foam. Can be secured.

By setting the basis weight of the first layer 31 on the opposite side of the polyurethane foam 20 to 100 g / m ² or more, the impregnation of the urethane foam raw material into the first layer 31 is effectively prevented and the skin material 30 is ventilated. Sex can be ensured.
Further, it is preferable that the first layer 31 has a fiber diameter of 5d or more to improve the wear resistance of the surface. The first layer 31 and the second layer 33 are integrated by adhesion or needle punching.

The soundproofing material 10 has a compression hardness of 500 N, which is a measured value of a load at 50% compression when a sample of 200 mm square × 20 mm in thickness is compressed to 80% of the thickness in a compression jig of φ80 mm at a test speed of 50 mm / min. The above is preferable, and more preferably 650 to 2000N. If the compression hardness of the soundproofing material 10 is too low, for example, when the upper surface of the soundproofing material 10 is pressed by the feet of an occupant, the pressed portion may sink, making it difficult to walk or the posture may become unstable. ..

An example of using the two-layer skin material 30 will be described with reference to FIGS. 6 to 8 as to the method for producing the soundproofing material 10. The soundproofing material 10 can be manufactured by molding using a mold 40. The mold 40 includes a lower mold 41 and an upper mold 43, and the skin material 30 is attached to either the lower mold 41 or the upper mold 43. The skin material 30 is attached so that the first layer 31 faces the mold surface of one mold and the second layer 33 faces the inside of the mold. When the skin material 30 is attached to the upper mold 43, a locking means including a locking pin or the like for holding the skin material 30 detachably is provided on the mold surface of the upper mold 43.
In the illustrated example, as shown in FIG. 6 (6-1), the skin material 30 is attached to the mold surface of the upper mold 43.

Before attaching the skin material 30 to the mold surface of the mold 40, the mold release agent 38 is applied to the mold surface of the mold 40. The release agent 38 preferably contains a linear hydrocarbon wax so that the surface of the polyurethane foam 20 on the floor surface side (sound source side) can be easily opened. Soundproofing (sound absorption) can be further enhanced by making the surface of the polyurethane foam 20 on the floor surface side (sound source side) an open cell.
Examples of the linear hydrocarbon wax include paraffin wax, Fishertroph wax, sazole wax, etc., such as a solvent-based mold release agent dispersed in an organic solvent, a water-based mold release agent dispersed in water using an emulsifier, and the like. Can be used.

After applying the mold release agent 38 to the mold surface of the mold 40 and attaching the skin material 30, the polyurethane foam raw material 20a is mixed and injected into the mold 40 as shown in (6-2) of FIG. The polyurethane foam raw material 20a is foamed in the molding space between the second layer 33 of the skin material 30 and the mold surface of the lower mold 41 of the mold 40.

The polyurethane foam raw material 20a injected into the mold 40 fills the molding space between the second layer 33 of the skin material 30 and the mold surface of the lower mold of the mold 40 by foaming, and (6-3) in FIG. ), The polyurethane foam 20 is formed integrally with the skin material 30. At that time, a part of the polyurethane foam raw material 20a is impregnated into the second layer 33 of the skin material 30 and cured to form the impregnated cured layer 34 at the boundary portion with the polyurethane foam 20.

After that, as shown in FIG. 7, the upper mold 43 is separated from the lower mold 41 to open the mold 40, and the skin integrally molded body 10A in which the skin material 30 is integrally molded on one side of the polyurethane foam 20 shown in FIG. Take out.

After that, as shown in FIG. 8, the slit 25 is formed on the surface 21 of the polyurethane foam 20 on the side opposite to the skin material 30 with respect to the skin integrally molded body 10A by slit processing. Reference numeral 51 is a lower plate, 53 is a stamp, and 55 is a slit forming blade provided downward on the stamp 53. In the slit processing, the skin material 30 in the skin-integrated molded body 10A is directed to the lower plate 51, the surface 21 of the polyurethane foam 20 on the opposite side of the skin material 30 is directed to the stamp 55, and the polyurethane foam 20 is directed to the lower plate 51. The stamp 53 placed on the upper surface and located above the polyurethane foam 20 is lowered, and the slit forming blade 55 is inserted into the surface 21 of the polyurethane foam 20 to form the slit 25, whereby the soundproofing material 10 is formed. obtain.

Using the polyurethane foam raw material having the composition shown in FIG. 9, a skin-integrated molded body having a size of 500 mm square and a thickness of 20 mm was formed by a molding method using the mold 40 shown in FIGS. 6 to 7, and then shown in FIG. By slit processing, a lattice-shaped slit was penetrated through the polyurethane foam to form an impregnated hardened layer until it hits the solidified layer, and the soundproofing materials of Examples 1 to 10 were obtained. The distance between the slits is 100 mm. In Comparative Examples 1 to 4, no slit processing was performed and no slit was formed.

The numerical values of each component in the formulation of FIG. 9 indicate parts by weight. The mold was heated with warm water, and the lower mold 41 and the upper mold 43 were heated to 70 ° C. As the release agent, a linear hydrocarbon wax (product name: URH-520, manufactured by Konishi Co., Ltd.) was applied to the mold surface by spray coating at 10 to 30 g / m ² .

The components constituting the formulation of FIG. 9 are as follows.
-Polycarbonate-1: Polyether polyol, number of functional groups 3.6, number average molecular weight 5500, hydroxyl value 31.5 mgKOH / g, EO rate 15%
-Polycarbonate-2: Polyether polyol, number of functional groups 3, number average molecular weight 5000, hydroxyl value 34 mgKOH / g, EO rate 14%
-Polycarbonate-3: Polyether polyol, number of functional groups 3, number average molecular weight 7000, hydroxyl value 26 mgKOH / g, EO rate 14%
-Polycarbonate-4: Polyether polyol, number of functional groups 3, number average molecular weight 700, hydroxyl value 245 mgKOH / g, EO rate 0%
-Polypolymer-5: Polymer polyol, number of functional groups 3, number average molecular weight 5000, hydroxyl value 25 mgKOH / g, EO rate 0%, solid content concentration 32%
-Polypolymer-6: Polymer polyol, number of functional groups 3, number average molecular weight 3000, hydroxyl value 31 mgKOH / g, EO rate 40%, solid content concentration 32%
-Effervescent agent: water-Amine catalyst 1: Diethanolamine-Amine catalyst 2: Aliphatic tertiary amine composition [bis (2-dimethylaminoethyl) ether / dipropylene glycol]
・ Amine catalyst 3: DABCO 33LSI EVONIK ・ Foam regulator: organically modified siloxane, product name: B8715LF2, EVONIC ・ Additives: polyether polyol, molecular weight 5000, number of functional groups 3, hydroxyl value 34 mgKOH, EO rate 70%
-Isocyanate 1 (ISO-1): Polymeric MDI, NCO% 31.5%
-Isocyanate 2 (ISO-2): 4,4'-MDI / urethane prepolymer = 75 to 85/15 to 25, NCO% 26.5%
-Isocyanate 3 (ISO-3): Crude MDI, NCO%: 31.7%

For each example and each comparative example, the thickness of the impregnated hardened layer in the second layer, the hardness of the soundproofing material, the vibration damping property of the soundproofing material, the density of the polyurethane foam, the air permeability of the skin material including the impregnated hardened layer, and the reverberation. The room sound absorption coefficient, the reverberation room sound absorption coefficient of polyurethane foam, and the transmission loss of the soundproofing material were calculated or measured.

The thickness of the impregnated cured layer in the second layer is measured from a soundproof material of 500 mm square x 20 mm thickness with a scanning electron microscope (SEM: manufactured by JEOL Ltd.) at a magnification of 35 times, and 5 points (maximum and minimum). ) Was calculated from the average.

To measure the hardness of the soundproofing material, a sample of a soundproofing material of 500 mm square x 20 mm thick cut into 200 mm square x 20 mm thick is placed so that the skin material is on the upper surface, and the compression speed is 50 mm / with a compression jig of φ80 mm. In min, compress until the displacement amount becomes 80% of the thickness (displacement amount of sample 16 mm, remaining thickness of sample 4 mm), and measure the load at 25% compression, 50% compression, and 75% compression at that time. Read as a value.
The hardness of the soundproofing material is evaluated as "◎" when the compression hardness is 1000N or more, "○" when the compression hardness is 500N or more and less than 1000N, and "○" when the compression hardness is less than 500. × ”.

The vibration damping property (loss factor ratio) of the soundproof material is as follows: a metal plate (sound insulation material) with a thickness of 1 mm is layered under the polyurethane foam and a rubber sheet with a thickness of 1 mm is layered on the skin material with respect to the sample of the soundproof material of 30 x 300 mm. , The loss coefficient at about 650 Hz was measured based on JIS K 7391: 2008, and the vibration damping loss coefficient ratio was calculated by the following formula.
Loss count ratio = (loss coefficient without double-sided tape bonding) / (loss coefficient with double-sided tape bonded on the entire surface)
The evaluation of vibration damping property (loss coefficient ratio) is "◎" when it is 0.80 or more, "○" when it is 0.60 or more and less than 0.80, and "△" when it is 0.40 or more and less than 0.6. , When it was less than 0.40, it was evaluated as "x".

The density of the polyurethane foam is measured by cutting a soundproof material of 500 mm square × 20 mm in thickness into 100 mm square × 20 mm in thickness to obtain a skin material portion (if an impregnated hardened layer is present, the skin including the impregnated hardened layer). The material portion) was removed, and the sample consisting of the remaining polyurethane foam was subjected to JIS K7222: 2005.

The air flow rate of the skin material including the impregnated hardened layer is measured from the cut material obtained by cutting a soundproof material of 500 mm square × 20 mm thickness into 100 mm square × 20 mm thickness (if the impregnated hardened layer is present). The impregnated hardened layer is cut out, and the impregnated hardened layer is placed on the lower side of the sample consisting of the cut out skin material part (the skin material part including the impregnated hardened layer if the impregnated hardened layer is present). The measurement was performed based on the JIS K6400-7B method: 2012.

To measure the sound absorption coefficient of the reverberation room of the skin material including the impregnated hardened layer, four soundproof materials 10 of 500 mm square x 20 mm thickness are laid on the floor surface in the reverberation room (about 30 m ³ ), and the surface of the skin material (non-sound source side). For the surface), it was performed based on JIS A 1409. Here, all the gaps between the samples and between the samples and the jig were sealed with aluminum tape. The reverberation room sound absorption coefficient is an average sound absorption coefficient obtained by averaging the measured values of the sound absorption coefficient of each frequency (500, 630, 800, 1000, 1250, 1600, 2000, 2500, 3150, 4000, 5000, 6300 Hz). The sound absorption coefficient of the reverberation room was used. The reverberation room sound absorption coefficient of the soundproof material 10 corresponds to the average sound absorption coefficient for the surface of the skin material side including the impregnated hardened layer.
The evaluation of the reverberation room sound absorption coefficient of the skin material containing the impregnated hardened layer is "◎" when it is 65% or more, "○" when it is 50% or more and less than 65%, and "△" when it is 35% or more and less than 50%. , When it was less than 35%, it was evaluated as "x".

The measurement of the transmission loss of the soundproofing material was performed based on JIS A1441-1: 2007. The sound source reverberation room is 36 m ³ , the sound receiving and anechoic room is 20 m ³ , and the measurement area is 400 x 400 mm (0.16 m ² ). An iron plate (sound insulation material) with a thickness of 0.8 mm and a rubber sheet (sound insulation material) with a thickness of 1 mm (sound insulation material) (1700 g / m ² ) are laminated on the surface of the polyurethane foam, which is a soundproof material of 500 mm square x 20 mm in thickness. With the circumference of the soundproofing material fixed with a frame with a width of 50 mm, the gap is further sealed with clay, sound is incident from the iron plate side as a sound source, and four central separation scattering points (100 mm) are located 100 mm away from the surface of the rubber sheet. The value at 1600 Hz at (pitch) was measured.
"Structure A" of transmission loss is a configuration in which urethane foam is in close contact with a metal plate, that is, a skin material is in close contact with a rubber sheet, and "Structure B" is a structure in which a skin material is in close contact with a metal plate, that is, urethane foam is in close contact with a rubber sheet. Is.
The evaluation of the transmission loss was "⊚" when it was 44.2 dB or more, "○" when it was 42.2 dB or more and less than 44.2 dB, and "x" when it was less than 42.2 dB.

Comprehensive evaluation was performed for each example and each comparative example. The overall evaluation shall be the lowest of each evaluation. For example, if all of the evaluations are "◎", the overall evaluation is "◎", if at least one of the evaluations is "○" and the rest is "◎", the overall evaluation is "○", and at least one of the evaluations is "△". Comprehensive evaluation "△" when the rest is "○" or "◎", and overall evaluation "×" when at least one of the evaluations is "×" and the rest is "△" or "○" or "◎" ..

In Example 1, 30 parts by weight of polyol-1 (polyether polyol), 70 parts by weight of polyol 6 (polymer polyol), 5.10 parts by weight of foaming agent, 2.71 parts by weight of amine catalyst-1, and amine. A polyurethane foam raw material having a catalyst-2 of 0.39 parts by weight, a foaming agent of 0 parts by weight, an additive of 0 parts by weight, an isocyanate of ISO-1: ISO-2 = 22:78, and an isocyanate index of 105 was used. As a skin material, the first layer is 6d PET fiber with a grain size of 150 g / m ² , the second layer is a 3d PET fiber with a grain size of 100 g / m ² , and the acrylic acid ester resin is impregnated with 50 g / m ^2. A skin material having a total grain size of 300 g / m ² was used.

As a result of Example 1, the EO rate of the polyurethane foam was 9.20%, the thickness of the impregnated cured layer was 1 mm, the composition of the soundproofing material was integrated with the skin, there was a slit, and the hardness of the soundproofing material at 25% compression was 570N. The hardness at 50% compression is 1110N, the hardness at 75% compression is 3100N, the evaluation of the hardness of the soundproof material is "◎", the vibration damping property of the soundproof material (without rubber sheet) is 0.60, Evaluation of vibration damping property [○], density of polyurethane foam 55 kg / m ³ , air permeability of skin material including impregnated hardened layer is 20.8 cc / cm ² / sec, reverberation room sound absorption of skin material including impregnated hardened layer The rate is 71%, the evaluation of the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer is "◎", and the composition of the transmission loss of the soundproof material is [A] (urethane foam is adhered to the metal plate, and the skin material is made into a rubber sheet. The soundproofing material had a transmission loss of 49.2 dB, the soundproofing material's transmission loss was evaluated as "◎", and the overall evaluation was "○", and the soundproofing (vibration suppression, sound absorption) was good.

Example 2 is the same as that of Example 1 except that the soundproofing material of Example 1 is used and a rubber sheet having a thickness of 1 mm is placed on the surface of the skin material and the vibration damping property of the soundproofing material is measured. Is. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Example 2 is the same as that of Example 1 except for the result of the vibration damping property of the soundproofing material.
In the second embodiment, the vibration damping property of the soundproof material (with rubber sheet mounted) is 0.95, the vibration damping property is evaluated [⊚], and the comprehensive evaluation [⊚]. The result of the vibration damping property of the soundproof material is better in Example 2 with the rubber sheet mounted than in Example 1 without the rubber sheet mounted. From the result of this vibration damping property, in Example 2, the soundproofing material was pressed more strongly by the weight of the rubber sheet placed on the surface of the skin material than in Example 1 (without rubber sheet mounting), whereby polyurethane The slit of the foam is wider than in Example 1 (without rubber sheet) on the side opposite to the skin material, and the polyurethane foam is on the side opposite to the skin material in Example 1 (without rubber sheet). It is understood that the soundproofing material spreads outward more than the other, thereby eliminating the bending of the soundproofing material and more reliably adhering to the metal plate than in Example 1.

In Example 3, the foaming agent in Example 1 was 5.76 parts by weight, the amine catalyst-1 was 3.06 parts by weight, the amine catalyst-2 was 0.45 parts by weight, and the foam stabilizer was 0.31 parts by weight. The additive was 2.27 parts by weight, and the others were the same as in Example 1.

As a result of Example 3, the EO rate of the polyurethane foam was 9.65%, the thickness of the impregnated hardened layer was 1 mm, the composition of the soundproofing material was integrated with the skin, there was a slit, and the hardness of the soundproofing material at 25% compression was 700 N. The hardness at 50% compression is 1400N, the hardness at 75% compression is 3900N, the evaluation of the hardness of the soundproof material is "◎", the vibration damping property of the soundproof material (without rubber sheet) is 0.59, Evaluation of vibration damping property [○], density of polyurethane foam is 55 kg / m ³ , air permeability of skin material including impregnated hardened layer is 11.7 cc / cm ² / sec, reverberation room sound absorption of skin material including impregnated hardened layer The rate is 65%, the evaluation of the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer is "◎", and the composition of the transmission loss of the soundproof material is [A] (urethane foam is adhered to the metal plate, and the skin material is made into a rubber sheet. The soundproofing material had a transmission loss of 47.2 dB, the soundproofing material's transmission loss was evaluated as "◎", and the overall evaluation was "○", and the soundproofing (vibration suppression, sound absorption) was good.

Example 4 is the same as that of Example 3 except that the soundproofing material of Example 3 is used and a rubber sheet having a thickness of 1 mm is placed on the surface of the skin material and the vibration damping property of the soundproofing material is measured. Is. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Example 4 is the same as that of Example 3 except for the result of the vibration damping property of the soundproofing material.
In the fourth embodiment, the vibration damping property of the soundproofing material (with rubber sheet mounted) is 0.93, the vibration damping property is evaluated [⊚], and the comprehensive evaluation [⊚]. The result of the vibration damping property of the soundproof material is better in Example 4 with the rubber sheet mounted than in Example 3 without the rubber sheet mounted. From the result of this vibration damping property, in Example 4, the soundproofing material was pressed more strongly by the weight of the rubber sheet placed on the surface of the skin material than in Example 3 (without the rubber sheet placed), and thereby polyurethane. The slit of the foam is wider than in Example 3 (without rubber sheet) on the side opposite to the skin material, and the polyurethane foam is on the side opposite to the skin material in Example 3 (without rubber sheet). It is understood that the soundproofing material spreads outward more than the other, thereby eliminating the bending of the soundproofing material and more reliably adhering to the metal plate than in Example 3.

In Example 5, the foaming agent in Example 1, the foaming agent was 5.88 parts by weight, the amine catalyst-1 was 3.13 parts by weight, the amine catalyst-2 was 0.45 parts by weight, the foam stabilizer was 0 parts by weight, and the additive. Was 9.84 parts by weight, the isocyanate was ISO-1: ISO-2 = 0: 100, and the others were the same as in Example 1.

As a result of Example 5, the EO rate of the polyurethane foam was 12.56%, the thickness of the impregnated cured layer was 1 mm, the composition of the soundproofing material was integrated with the skin, there was a slit, and the hardness of the soundproofing material at 25% compression was 375N. The hardness at 50% compression is 650N, the hardness at 75% compression is 1500N, the evaluation of the hardness of the soundproofing material is "○", and the vibration damping property of the soundproofing material (without rubber sheet) is 0.64. Evaluation of vibration damping property [○], density of polyurethane foam is 55 kg / m ³ , air permeability of skin material including impregnated hardened layer is 72 cc / cm ² / sec, reverberation room sound absorption coefficient of skin material including impregnated hardened layer 73%, evaluation of the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer "◎", the composition of the transmission loss of the soundproof material is [A] (urethane foam adheres to the metal plate, and the epidermis adheres to the rubber sheet. (Structure), the transmission loss of the soundproof material was 50.2 dB, the evaluation of the transmission loss of the soundproof material was "⊚", and the overall evaluation was "〇", and the soundproofing (vibration suppression, sound absorption) was good.

Example 6 is the same as that of Example 5 except that the soundproofing material of Example 5 is used and a rubber sheet having a thickness of 1 mm is placed on the surface of the skin material and the vibration damping property of the soundproofing material is measured. Is. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Example 6 is the same as that of Example 5, except for the result of the vibration damping property of the soundproofing material. In the sixth embodiment, the vibration damping property of the soundproofing material (with rubber sheet mounted) is 0.96, the vibration damping property is evaluated [⊚], and the comprehensive evaluation [⊚]. The result of the vibration damping property of the soundproof material is better in Example 6 with the rubber sheet mounted than in Example 5 without the rubber sheet mounted. From the result of this vibration damping property, in Example 6, the soundproofing material was pressed harder than in Example 5 (without rubber sheet) due to the weight of the rubber sheet placed on the surface of the skin material, and thereby polyurethane. The slit of the foam is wider than in Example 5 (without rubber sheet) on the side opposite to the skin material, and the polyurethane foam is on the side opposite to the skin material in Example 5 (without rubber sheet). It is understood that the soundproofing material spreads outward more than the other, thereby eliminating the bending of the soundproofing material and more reliably adhering to the metal plate than in Example 5.

In Example 7, 100 parts by weight of polyol 6 (polymer polyol), 6.41 parts by weight of foaming agent, 3.33 parts by weight of amine catalyst-1, 0.37 parts by weight of amine catalyst-2, and foam stabilizer. A polyurethane foam raw material having 0 parts by weight, an additive of 2.47 parts by weight, an isocyanate of ISO-1: ISO-2 = 0: 100, and an isocyanate index of 105 was used, and the first layer was 6d as a skin material. It consists of PET fiber, a grain size of 150 g / m ² , a second layer of 3d PET fiber, a grain size of 100 g / m ² , and an acrylic acid ester resin impregnated with 50 g / m ² , and the total grain size is 300 g / m ^2. The skin material of was used.

As a result of Example 7, the EO rate of the polyurethane foam was 11.26%, the thickness of the impregnated cured layer was 1 mm, the composition of the soundproofing material was integrated with the skin, there was a slit, and the hardness of the soundproofing material at 25% compression was 529N. The hardness at 50% compression is 1024N, the hardness at 75% compression is 3933N, the evaluation of the hardness of the soundproofing material is "◎", the vibration damping property of the soundproofing material (without rubber sheet) is 0.62, Evaluation of vibration damping property [○], density of polyurethane foam 55 kg / m ³ , air permeability of skin material including impregnated hardened layer is 8.23 cc / cm ² / sec, reverberation room sound absorption of skin material including impregnated hardened layer The rate is 59%, the evaluation of the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer is "◎", and the composition of the transmission loss of the soundproof material is [A] (urethane foam is adhered to the metal plate, and the skin material is made into a rubber sheet. The soundproofing material had a transmission loss of 44.2 dB, the soundproofing material's transmission loss was evaluated as "◎", and the overall evaluation was "○", and the soundproofing (vibration suppression, sound absorption) was good.

Example 8 is the same as that of Example 7 except that the soundproofing material of Example 7 is used and a rubber sheet having a thickness of 1 mm is placed on the surface of the skin material and the vibration damping property of the soundproofing material is measured. Is. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Example 8 is the same as that of Example 7, except for the result of the vibration damping property of the soundproofing material. In the eighth embodiment, the vibration damping property of the soundproofing material (with rubber sheet mounted) is 0.95, the vibration damping property is evaluated [⊚], and the comprehensive evaluation [⊚]. The result of the vibration damping property of the soundproof material is better in Example 8 with the rubber sheet mounted than in Example 7 without the rubber sheet mounted. From the result of this vibration damping property, in Example 8, the soundproofing material was pressed more strongly by the weight of the rubber sheet placed on the surface of the skin material than in Example 7 (without rubber sheet placed), and thereby polyurethane. The slit of the foam is wider than in Example 7 (without rubber sheet) on the side opposite to the skin material, and the polyurethane foam is on the side opposite to the skin material in Example 7 (without rubber sheet). It is understood that the soundproofing material spreads outward more than the other, thereby eliminating the bending of the soundproofing material and more reliably adhering to the metal plate than in Example 7.

In Example 9, the soundproofing material of Example 1 was used, and the transmission loss of the soundproofing material was set to [B] (a structure in which the skin material was brought into close contact with the metal plate and the urethane foam was brought into close contact with the rubber sheet). , The same as in Example 1.

The results of Example 9 are the same as those of Example 1 except for the results of vibration damping and transmission loss of the soundproofing material. In Example 9, the vibration damping property of the soundproof material (without rubber sheet mounting) was 0.62, the evaluation of the vibration damping property [○], the transmission loss of the soundproof material was 47.2 dB, and the evaluation of the transmission loss of the soundproof material was " ◎ ”and overall evaluation“ ○ ”, and the soundproofing (vibration control, sound absorption) was good.

In Example 10, the soundproofing material of Example 9 (same as in Example 1) was used, and a rubber sheet having a thickness of 1 mm was placed on the surface of the skin material, and the vibration damping property of the soundproofing material was measured. Is the same as in Example 9. The structure of the transmission loss of the soundproofing material is [B] (a structure in which the skin material is brought into close contact with the metal plate and the urethane foam is brought into close contact with the rubber sheet).

The result of Example 10 is the same as that of Example 9, except for the result of the vibration damping property of the soundproofing material. In Example 10, the vibration damping property of the soundproofing material (with rubber sheet mounted) is 0.95, the vibration damping property is evaluated [⊚], and the comprehensive evaluation [⊚]. The result of the vibration damping property of the soundproof material is better in Example 10 with the rubber sheet mounted than in Example 9 without the rubber sheet mounted. From the result of this vibration damping property, in Example 10, the soundproofing material was pressed more strongly by the weight of the rubber sheet placed on the surface of the skin material than in Example 9 (without rubber sheet mounting), whereby polyurethane was used. The slit of the foam is wider than in Example 7 (without rubber sheet) on the side opposite to the skin material, and the polyurethane foam is on the side opposite to the skin material in Example 7 (without rubber sheet). It is understood that the soundproofing material spreads outward more than the other, thereby eliminating the bending of the soundproofing material and more reliably adhering to the metal plate than in Example 9.

Comparative Example 1 is the same as that of Example 1 except that a slit was not formed in the same polyurethane foam as in Example 1. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Comparative Example 1 is the same as that of Example 1 except for the result of the vibration damping property of the soundproofing material. In Comparative Example 1, the vibration damping property of the soundproof material (without rubber sheet mounting) was 0.29, the vibration damping property was evaluated [x], and the overall evaluation was [x]. The result of the vibration damping property of the soundproofing material was worse in Comparative Example 1 without slits than in Example 1 with slits. In Comparative Example 1, since the polyurethane foam had no slits formed, the soundproofing material was measured in a state of being bent toward the polyurethane foam due to the shrinkage of the polyurethane foam after the skin was integrally molded, and the polyurethane foam of the soundproofing material was a metal plate. The vibration damping property of Comparative Example 1 (without slits) is worse than the vibration damping property of Example 1 (with slits) because it does not adhere to.

In Comparative Example 2, the same soundproofing material (without slits) as in Comparative Example 1 was used, and a rubber sheet having a thickness of 1 mm was placed on the surface of the skin material, and the vibration damping property of the soundproofing material was measured. It is the same as Example 1. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

Comparative Example 2 is the same as Comparative Example 1 except for the result of the vibration damping property of the soundproofing material. In Comparative Example 2, the vibration damping property of the soundproof material (with rubber sheet mounted) is 0.57, the vibration damping property is evaluated [Δ], and the overall evaluation is [Δ]. The result of the vibration damping property of the soundproof material is better in Comparative Example 2 with the rubber sheet mounted than in Comparative Example 1 without the rubber sheet mounted. In Comparative Example 2, the weight of the rubber sheet placed on the surface of the skin material pushed the soundproofing material more strongly than in Comparative Example 1 (without the rubber sheet placed), whereby the contact area between the polyurethane foam and the device was increased. It became larger than Comparative Example 1 (without rubber sheet placed) and the damping property was better than that of Comparative Example 1, and the evaluation of the damping property was "Δ".

In Comparative Example 3, 65 parts by weight of polyol-2 (polyether polyol), 15 parts by weight of polyol 3 (polyether polyol), 10 parts by weight of polyol 4 (polyether polyol), and 10 parts by weight of polyol 5 (polymer polyol). Parts by weight, foaming agent 3.30 parts by weight, amine catalyst-1 0 parts by weight, amine catalyst-2 0.1 parts by weight, amine catalyst-3 0.6 parts by weight, foam stabilizer 0.25 parts by weight A polyurethane foam raw material having a weight of parts, an additive of 2 parts by weight, an isocyanate of 100 parts by weight of ISO-3, and an isocyanate index of 90 was used, and the same skin material as in Examples 1 and 2 was used as the skin material. ..

As a result of Comparative Example 3, the EO rate of the polyurethane foam was 6.90%, the thickness of the impregnated cured layer was 1 mm, the composition of the soundproofing material was integrated with the skin, there was no slit, and the hardness of the soundproofing material at 25% compression was 16N. The hardness at 50% compression is 30N, the hardness at 75% compression is 114N, the evaluation of hardness is "x", the vibration damping property of the soundproof material (without rubber sheet placement) is 0.70, and the vibration damping property. Evaluation [○], the density of polyurethane foam is 70 kg / m ³ , the air permeability of the skin material including the impregnated hardened layer is 3.10 cc / cm ² / sec, and the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer is 32%. , Evaluation of the reverberation room sound absorption coefficient of the skin material including the impregnated hardened layer "x", the composition of the transmission loss of the soundproof material is [A] (the structure in which the urethane foam is in close contact with the metal plate and the skin material is in close contact with the rubber sheet). The transmission loss of the soundproof material was 51.5 dB, the evaluation of the transmission loss of the soundproof material was "⊚", and the overall evaluation was "x". In Comparative Example 3, the hardness was low, the vibration damping property was slightly poor, and the reverberation chamber sound absorption coefficient of the skin material containing the impregnated hardened layer was poor.

In Comparative Example 3, since the hardness of the soundproofing material is low, even if the polyurethane foam is bent toward the polyurethane foam side due to shrinkage of the polyurethane foam after the skin is integrally molded, when the soundproofing material is placed on the device, the weight of the soundproofing material causes it. Even though the soundproofing material is pressed and the polyurethane foam does not have slits, the polyurethane foam spreads outward on the opposite side of the skin material, and the contact area between the polyurethane foam and the device is larger than in other comparative examples. The vibration damping material of the soundproofing material became larger than that of other comparative examples.

In Comparative Example 4, the same soundproofing material (without slits) as in Comparative Example 3 was used, and a rubber sheet having a thickness of 1 mm was placed on the surface of the skin material, and the vibration damping property of the soundproofing material was measured. This is the same as in Example 3. The structure of the transmission loss of the soundproofing material is [A] (a structure in which the urethane foam is brought into close contact with the metal plate and the skin material is brought into close contact with the rubber sheet).

The result of Comparative Example 4 is the same as that of Comparative Example 3 except for the result of the vibration damping property of the soundproofing material. In Comparative Example 4, the vibration damping property of the soundproof material (with rubber sheet mounted) was 0.97, the vibration damping property was evaluated [⊚], and the overall evaluation was [×]. The result of the vibration damping property of the soundproofing material was better in Comparative Example 4 with the rubber sheet mounted than in Comparative Example 3 without the rubber sheet mounted.

In the soundproofing material of Comparative Example 4, the soundproofing material was pressed more strongly than in Comparative Example 3 (without rubber sheet mounting) due to the weight of the rubber sheet placed on the surface of the skin material, whereby the polyurethane foam and the device were used. The contact area was larger than that of Comparative Example 3 (without rubber sheet mounting), and the vibration damping property was better than that of Comparative Example 3.

As described above, the soundproofing material of the present invention is made of polyurethane when the soundproofing material is placed on the floor surface of an automobile or the like in a state of being bent toward the polyurethane foam side opposite to the skin material, which is generated after the skin is integrally molded. Since this can be eliminated by expanding the slits formed in the foam, the polyurethane foam adheres to the floor surface and good soundproofing (including vibration damping) can be obtained.

10,100 Soundproofing material 20,200 Polyurethane foam 20a Polyurethane foam raw material 25,250 Slits 30,300 Skin material 31,310 First layer 33,330 Second layer 34,340 Impregnated hardened layer 40 Mold 41 Lower mold 43 Upper mold 38 release agent

Claims (5)

In a soundproof material in which a skin material is integrally molded on one side of polyurethane foam,
The soundproofing material has a compression hardness obtained by measuring a load at 50% compression when a sample of 200 mm square × 20 mm in thickness is compressed to 80% of the sample thickness at a test speed of 50 mm / min with a compression jig of φ80 mm. Is 500N or more,
The polyurethane foam is a soundproofing material characterized in that a slit is formed from a surface opposite to the skin material to the skin material side. The soundproofing material according to claim 1, wherein the skin material is made of an aggregate of fibers. The skin material has an impregnated cured layer of a polyurethane foam raw material formed at a boundary portion with the polyurethane foam.
The soundproofing material according to claim 1 or 2, wherein the slit is formed up to the position of the impregnated hardened layer. The invention according to any one of claims 1 to 3, wherein the air flow rate of the skin material containing the impregnated hardened layer based on the JIS K6400-7B method: 2012 is 5 to 80 cc / cm ² / sec. Soundproofing material. The feature is that the loss coefficient ratio of the soundproofing material is 0.6 or more when the loss coefficient ratio = (loss coefficient without double-sided tape bonding) / (loss coefficient with double-sided tape bonded on the entire surface). The soundproofing material according to any one of claims 1 to 4.

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