JP3472117B2 - Production method of soundproofing material - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a soundproofing material.
More specifically, it is mainly a chip-shaped solid material of lightweight material.
Of raw materials consisting of materials and thermoplastic fibrous binder
And melted by heating the mixed fibrous binder.
A method of binding solids to each other via a fibrous binder
A method for producing a soundproofing material. [0002] The present invention relates to raw materials, for example, a vehicle.
Non-metallic shredder dust made of waste materials
Soundproofing materials that are recycled by recycling
For example, vehicles such as dash silencers and floor silencers
It is particularly preferably applied to soundproofing materials used for applications. [0003] Dash silencers and floors for automobiles
Soundproofing materials for vehicles such as silencers or other various
For soundproofing materials for applications, shape retention and other necessary physical
Lightweight soundproofing material with low bulk density while having characteristics,
From the viewpoint of easy handling, soundproofing or anti-vibration performance
Is also considered desirable. [0004] As one of the leading technologies for that,
Raw material consisting of solid chips in the form of lightweight material and thermoplastic
Mixed with a fibrous binder,
The chip-shaped solid material is turned into a fibrous binder by thermal melting of the binder.
There is a soundproofing material of a type that is bonded to each other via a wire. This place
If you want to produce soundproofing materials,
Although it is OK to prepare using so-called new materials, for example
For example, non-metallic shredder dust made from vehicle waste
Is suitable for this application as a solid chip,
Costly and meaningful in terms of material recycling.
It is often used because of it. [0005] Japanese Patent Laid-Open Publication No.
Composite material and its manufacturing method "
Urethane, plastic, rubber, etc. derived from dust
Fiber-like heat can be used as a connecting material for chip-shaped solids
Mix with plastic resin, heat and solidify this mixture to form
Disclosed is a method for manufacturing a composite material secondary body to be a solid body
Have been. On the other hand, according to Japanese Patent Publication No.
In the "Method of manufacturing felt for automotive interior materials",
It is cut into a blended fiber cotton that has been
The cut flexible urethane foam is rotated with needle teeth
Feed into fleece making machine with built-in cylinder and mix
Fiber cotton and soft urethane foam are caught on rotating needles.
Hanging and lifting, fleece making machine by blowing air
A technique of scattering and mixing in the inside is disclosed. [0007] Incidentally, the chip-shaped solid
Binding raw materials consisting of shaped objects with thermoplastic fibrous binder
Of course, in soundproofing materials of the type
It is necessary that they are finely and evenly dispersed and mixed with each other.
Required. That is, if they are finely dispersed and mixed with each other,
If no, solid chips are bound in the soundproofing material.
Leaving a lot of adjacent parts without connecting by da
And these may cause unexpected material destruction like cracks.
With strength and shape retention as designed
Sound insulation material cannot be obtained. Also, if they are not uniformly dispersed and mixed with each other,
If the soundproofing material, the connection with the binder is high density
Certain parts and low density parts will be mixed,
Soundproof performance is not realized as designed, and strength and shape retention
In this case, the soundproofing material will vary in quality for each part.
This problem is caused, for example, by providing irregularities in the soundproofing material.
Strength differences for each part of the soundproofing material
In other words, the quality is different from that of the case where the quality is defective. Regarding such quality requirements,
For example, a technique described in Japanese Patent Application Laid-Open No. H08-112584
Rather, the gist of the invention is "support for various types of solid chips.
By controlling the size and bulk density within a certain range,
Processing operation on a variety of materials called レ ッ redder dust
Gives the above uniformity. "
In the description of the embodiment, the description "fibrous thermoplastic resin
Spray chip-like solids evenly on a delicate cotton sheet
After mixing and defibrating, heat and then adjust to the required thickness.
Compress and cool ". However
The specific content of the mixed defibration process is detailed in both text and drawings.
For the above request, this is
It cannot be determined whether or not it can be satisfied. On the other hand, it is described in Japanese Patent Publication No. 2-33484.
Technology is based on mixed fibers that have been transported in a free state on a transporter.
Rotating cylinders for cotton and soft urethane foam
Needles essentially act only as lifting means
And then scattered and mixed by blowing air
Therefore, the following two problems can be pointed out.
The first point is that the mixed fiber cotton is not
Because it is not forcibly opened, mixed fiber cotton
Do not finely disperse and mix with flexible urethane foam.
No. The second point is that flexible urethane foam is elongated and cut
However, the appearance of mixed fiber cotton is
It is obvious that the specific gravity of the cliff is quite small.
In accordance with the general principle of wind separation,
At the time of scattering, both produce a gradient of distribution density due to difference in specific gravity,
They are not uniformly dispersed and mixed with each other. Soft urethane like this technology
Normal tan foam etc. not cut into a special shape
When using chip-like solids, such a problem is further increased.
Become noticeable. Therefore, the present invention mainly relates to a chip made of a lightweight material.
Raw material consisting of solids and thermoplastic fibrous binder
And by mixing and heat-melting the mixed fibrous binder
Chip-like solids are bound together via a fibrous binder
In the method for producing a soundproofing material of the
The chip-like solid and the fibrous binder are finely
The problem to be solved is to disperse and mix uniformly
And [0013] The present inventor considers means for solving the above problems.
In the process, the solid chips and the thermoplastic fibrous
Disperse and mix finely and uniformly with each other
First, forcibly defibrate the fibrous binder
And when finely defibrated, mix with the solid chips
Must be used, and for the purpose of dispersion mixing.
Realize that air blowing should be avoided
Was. Further, a chip-like solid material and a fibrous
Aggregate (more preferably, both are roughly mixed)
Aggregate) is compressed by some means, and
For example, a rotary cylinder with needle-like projections
By using such a scraping projection member, it will scrape little by little.
Is effective in achieving the above task.
With this in mind, the present invention has been completed. [0015] In order to solve the above problems,
The structure of the present invention is mainly composed of a chip-shaped solid material of a lightweight material.
Of raw materials consisting of a thermoplastic fibrous binder
Mixing step, and heat mixing of the mixed fibrous binder.
By melting the chip-like solid through a fibrous binder
A method for manufacturing a soundproofing material including a binding step of binding to each other.
In the mixing step, the compressed
Scraping the aggregate of the chip-like solid and the fibrous binder
Includes defibration mixing process where small amounts are scraped by the projection members
This is a method for manufacturing a soundproofing material. Function / Effect of the Invention In the fibrillation mixing process during the mixing process
The chip-like solid constrained in a compressed state and the fiber
Prepare an assembly with a fibrous binder and attach a scraping projection
When scraping the aggregate little by little by using, every time that scraping,
A small amount of fibrous binder is forcibly shredded and finely defibrated
And a small amount of chip-shaped solid
Because individual shapes are scraped,
The fibrous binder that has been disintegrated
You. Therefore, an aggregate of scraped material (hereinafter referred to as
It is referred to as "fibrillated mixed processing material." )), Individual tips
The fibrous binder disintegrated into a solid
Are mixed finely and uniformly.
You. FIG. 1 shows an image of this operation. FIG.
(A) shows a chip-like solid material 1 and a fibrous
Shows the state of aggregate (coarsely mixed) with Indah 2
The fibrous binder 2 is not defibrated and has a chip-like
Form 1 and fibrous binder 2 are not finely dispersed and mixed.
No. FIG. 1 (b) shows the state of the defibrated and mixed processed material,
The binder 2 is forcibly broken up finely, and this
Attached to the chip-like solid 1, both are fine and even
They are dispersed and mixed. [0018] The mixture of the chip-like solid 1 and the fibrous binder 2
In the aggregate, the two are roughly mixed as shown in FIG.
It is preferable that the
Even if both are scraped at the same time little by little
If it is (for example, on an unfibrillated sheet of fibrous binder
An aggregate having a two-layer structure in which chip-like solids are sprayed)
It is considered that the same operation as described above is realized. The defibration / mixing material as described above is used in the binding step.
The soundproof performance, strength and shape retention as designed
Etc., and with variations in quality outside the design for each part
No soundproofing material can be manufactured. DETAILED DESCRIPTION OF THE INVENTION (Raw Materials) Raw materials are mainly light
It consists of a solid mass of chip material. Typical implementation form
One of the conditions is shredder dust made from vehicle scraps
Non-metals excluding metals, glass pieces, wire harnesses, etc.
Shredder dust.
Plastics such as urethane foam
Of foam forms make up the majority and plastic
Is mainly made of rubber or rubber fragments.
G. Textile fragments and fiber debris that make up the skin
In some cases. Some of the raw materials include the production process and
Metal, glass, etc. as long as the quality of the product is not impaired.
It is permissible that some small fragments are mixed. Non-metallic shredder derived from vehicle scrap
Waste material derived from other industrial fields other than dust
It may be recycled as raw material, and in some cases
Solid chips made from new materials such as plastic, rubber, and wood
A product may be prepared and used as a raw material. The shape and size of the chip-like solid are limited.
Absent. However, improvement of processing efficiency and formation of preferable soundproofing material
In order to achieve this, a shape with an extremely large aspect ratio (film shape,
Fibrous, etc.) and the average particle diameter of the chip is 20 mm
It is more preferable that it is not more than the degree. (Thermoplastic fibrous binder)
Usually, the fibrous binder is a fibrous thermoplastic resin.
Fat is used. Thermoplastic materials other than resin, such as heat
A fibrous binder made of plastic rubber etc. can also be used.
You. In addition, a low melting point sheath that melts during heat molding of the soundproofing material
And high melting point cores that do not melt during heat molding of soundproofing materials
Particularly preferred is a fibrous binder having a core-sheath structure comprising
it can. Form and Fiber of Fiber in Fibrous Binder
Meicho is not limited. As an example of a typical form of the fiber,
Fluffy fiber in which pills are formed by entanglement of relatively long fibers
And bundled fibers made up of relatively short fibers.
You. In addition, chip-like solid matter to which the fibrous binder should bind
In relation to the size of
The fiber length and the tip
It is more preferable that the average particle size of the
No. In the usual prior art, for example, for automobiles
When manufacturing dash silencers, make sure that
The amount of the fibrous binder Y used for the raw material X
X: Y = about 8: 2 by weight ratio or change the amount of Y used.
It is thought that it is necessary to increase
The fibrous binder is defibrated well and becomes
The amount of fibrous binder Y used because it is finely dispersed and mixed
However, it is sufficient that X: Y = about 9: 1 by weight ratio. However, fiber
The amount of the binder used is not limited. (Mixing step) The mixing step mainly consists of
Raw material consisting of high quality solid chips and thermoplastic fibers
This is a step of mixing with a binder. There is little
At least, a defibration mixing process described later is included. And defibration
As a pretreatment of the mixing process, use a normal stirring and mixing device or the like
Coarsely mix the chip-like solids with the fibrous binder
Preferably, such pretreatment is not essential. (Fibrillation / mixing process)
Of solid state chips and fibrous binder
A process in which the compound is scraped little by little by the scraping projection member.
You. The above-mentioned chip-shaped solid constrained in a compressed state
Implementation for preparing aggregates of shapes and fibrous binders
Although the type or content of the form is not limited, typical
The following are examples of the embodiment. As described above, the chip-like solid
It is preferable that the shape and the fibrous binder are roughly mixed.
That is not a requirement, for example, fibrous
The binder forms a sheet layer on which chip-like solids are
As in the case of a two-layered structure where
By scraping the compound little by little,
A small amount of fibrous binder is always scraped off at the same time
It is sufficient if it is an aggregate that is For constraining such an aggregate in a compressed state
The embodiments are not limited as long as the purpose is achieved.
No. A typical example is transported by appropriate transport means.
Is sent between the pair of rotating rollers and compressed.
Extrude. In this embodiment, the rotating rotor
The scrapes pushed out from between the rollers
Therefore, the defibration and mixing process can be performed continuously and efficiently.
Wear. In other embodiments, for example, at least one
A side feed mechanism is provided for the pair of pressing bodies that reciprocate up and down
With the assembly protruding partially between the pressing bodies.
An operation of constraining the part in the compressed state and scraping the protruding part
Aggregate again by releasing the restraint of the compound and traversing
Intermittent method that repeats the operation to protrude part of
Etc. are also possible. Embodiment of scraping by a scraping projection member
Is not limited as long as the purpose is achieved. That
A typical example is a rotating cylinder with needle-shaped protrusions on the peripheral surface.
The aggregate constrained in a compressed state toward
Therefore, it is a method of scraping little by little. This method was
Very excellent defibration when combined with the roller feed system
A mixing process can be performed. In other embodiments
Then, for example, reciprocating with a comb-like projection (so-called
Compression due to the reciprocating (scraping) projection
A method of sequentially scraping small pieces of confined and sent aggregates etc.
Is also possible. [0032] After the defibration and mixing process is completed,
In addition, finely divided fibers
Fine and uniformly dispersed and mixed with fiber binder
Is ready to be used as temporary stock.
May be used immediately in the next process for the production of soundproofing materials.
Good, and furthermore, due to the problem of the running conditions,
If it is determined that the mixture is not sufficient,
Can be fed back and used again for the defibration and mixing process.
Wear. (Other steps) In the present invention,
In addition to the steps / processes described above, any necessary or beneficial
Can be included. Usually, after the defibration and mixing process,
Conveying / filling to convey defibrated mixed processing material to mold and fill
Process and press the filling under heating to the specified soundproofing material shape
And a forming step of forming the same. The embodiment of the transport / filling step is not limited.
However, for example, the defibration mixed processing material is
Is preferable. When this method is adopted
However, the gas pumping process uses chip-like solids and fibers.
Do not scatter the binder in the free space.
That only feeds sequentially through the transfer path
A fibrous binder is applied to each chip-like solid.
Since it has arrived, it is blown into the mold
The fine and uniform mixed and dispersed state of both is maintained
It is. Therefore, in the molding process, the thermoplastic fibrous
Press the mold while heating above the melting temperature of the
Chip solids are well bound by the fibrous binder.
Can be used to obtain soundproofing material with no variation in quality.
You. [Explanation of Embodiment] An embodiment of the present invention will be described below.
FIG. 2 showing a process flow and a diagram showing details of a molding die.
3 will be described. In FIG. 2, each of the non-gold
Raw material 3 consisting of shredder dust and binder
4 is put into the hopper 5. Raw material 3
Plastic foam material, non-foam plastic
Chips with an average particle size of about 5 mm
And the binder 4 is made of the above-described thermoplastic material.
Fibrous binder 2 having an average fiber length of 10 mm
Polyester short fibers with a core-sheath structure (the melting point of the core is 235 °
C, the melting point of the sheath is 110 ° C.). Hopper
5 is provided with stirring means 6 provided with stirring blades.
Therefore, the solid chips 1 and the fibrous binder 2
Coarsely mixed and set as a set 7 from below the hopper 5
Is thrown onto the conveyor belt 8 with the accumulated thickness of. This collection
Compound 7 is in the state of FIG. Next, the aggregate 7 is conveyed by the conveyor belt 8.
It is sent between the pair of rotating rollers 9, which rotate in the same direction. Twin times
The clearance between the rollers 9 and 9 is
It is set to be considerably smaller than the accumulation thickness of the aggregate 7
The assembly 7 when passing between the rotating rollers 9 is rotated
The rollers 9 are constrained in a compressed state. Soshi
Immediately in the feeding direction by the rotating rollers 9, 9,
A large number of needle-like protrusions
A rotary cylinder 11 having a ridge 10 is installed,
It is rotating in the direction of mark A. Therefore, the aggregate 7 restrained in the compressed state
Immediately after passing between the rotating rollers 9 and 9
Is not released, the rotation cylinder 11
The needle-like protrusions 10 sequentially scrape off small amounts. Soshi
At this time, as described above, a small amount of the fibrous binder 2 is strong.
It is scraped in a finely crushed state
At the same time, a small amount of solid chips 1 is scraped off
In addition, fibrous defibrated for each chip-shaped solid 1
The binder 2 arrives. Therefore, it is scraped down
In the defibration and mixing processing material 12 to be accumulated,
(B) As shown in FIG.
The binder 2 is finely and uniformly dispersed and mixed. In the above steps, the collection on the conveyor belt 8 is performed.
Thickness of compound 7, feed speed of conveyor belt 8, rotation speed
The rotation speed of the rotary cylinder 9 or the rotation speed of the rotary cylinder 11
By adjusting the degree, in the defibration mixed processing material 12
The “fine and fine” of the chip-like solid 1 and the fibrous binder 2
Finely arbitrarily and variously adjust the "uniformly dispersed mixed state"
Can be The defibration-mixing material 12 enters the collecting tank 13.
Are temporarily accumulated, and then, for example,
Control by appropriate supply amount control means (not shown)
Then, the required amount is sent to the molding device 14 at a time,
/ Filling step followed by molding step. Defibration mixed processing material
Is sent directly to the molding equipment without temporary accumulation in the accumulation tank.
The forming device 14 may be connected to the collecting tank 13.
Blower 15, followed by main duct 16, main duct
The two branch ducts branched from the switch 16 via the switching valve 17
G, 18 and 19, provided at each end of branch ducts 18, 19
For the two molds 20, 21 and the switching valve 17
It consists of a cold / hot air delivery device 22 connected by a duct.
The molding dies 20 and 21 can control the mold temperature.
Or a cooling type, as shown in FIG.
The upper mold 23 and the lower mold 24
The periphery of the side is covered with a metal mesh 25 covering the mold opening space.
Surrounded, the defibration mixed processing material 12 is stopped in the mold and
It allows air to escape. The defibrated mixed material 12 is used for the function of the blower 15.
The pressure is sent to the molding die 20 via the switching valve 17.
Is blown into one of the molds 21. At that time, switch
The valve 17 is provided with a defibration / mixing material 12 which is connected to one branch duct 18.
The other branch duct 19
To the hot and cold air feeder 22 and the defibration and mixing processing material 12
When it is blown into the branch duct 19, the branch duct
Can be communicated with the cold / hot air delivery device 22. Therefore, the defibration mixed processing material 1
After completion of the blowing of 2, defibration and mixing into the other mold 21
The processing material 12 is blown, and at the same time,
Hot air (in the case of the present embodiment, for example,
(About 200 ° C) to blow the sheath of the fibrous binder 2
Can be melted. After that, on the mold 20
The mold 23 and the lower mold 24 are closed and press molding is performed.
Cold air (in the case of this embodiment, for example, 2
5 ° C or room temperature) to send the mold 21 itself.
By quickly performing mold cooling in conjunction with the mold cooling function,
The molded body of the soundproofing material can be taken out. Then switching valve
Activate 17 and defibrate and mix the empty mold 20
At the same time as the material 12 is blown, the defibration mixed material 12 is blown.
To the mold 21 for which the filling has been completed.
The hot air is sent to add the fibrous binder 2 similar to the above.
Heat melting, mold clamping, cooling and removal of molded products can be performed.
Wear. In this way, while using the switching valve 17 effectively,
Simultaneous process phases with different molds
Repeating the transport / filling process and molding process in progress
Reduces the play time of the mold and increases the molding cycle
Can be improved. [Performance evaluation test]
Of the soundproofing material used in comparison with the soundproofing material according to the conventional method.
The result of the performance evaluation test performed in the above will be described. According to the above embodiment, the non-metallic shredder
Dardust and a polyester staple fiber bag having a core-sheath structure.
Bulk density of 0.065 g / cm ^Three In
Soundproofing materials. And this is length 10.0c
m, cross section 10.0cm ^Two Cut out into a prismatic shape of
A test piece for strength evaluation was used. On the other hand, as a comparative example, a conventional soundproof material was used.
In the manufacturing method, that is, in FIG.
Rollers 9, 9 and a rotary cylinder 11 with needle-like projections are provided.
Do not place, instead scatter with blowing air while collecting tank
13 by the manufacturing system with the method of dropping to 13
A soundproofing material with the same bulk density is manufactured using the same raw materials as
A test piece for a comparative example was cut out in the same shape as described above. The tensile strength of these test pieces was
The tensile strength at break was measured using a testing machine. as a result
Are shown in Table 1. In Table 1, the “product of the present invention” refers to the present embodiment.
`` Comparative product '' is a test piece for a comparative example.
You. As is clear from Table 1, between the product of the present invention and the comparative product
Significant differences in tensile strength are observed. [Table 1] Further, the soundproofing material according to the present example and the soundproofing material according to the comparative example are described.
And evaluated the vibration damping performance by measuring the vibration transmissibility.
Was. That is, assuming use in vehicles,
On the body panel with a frame set in the box,
The soundproofing material according to the comparative example is processed into an appropriate shape and laminated,
A test piece was formed by laminating a vinyl chloride sheet thereon. Then, of the body panel of each specimen
Give the frame five types of vibration over 100-500Hz,
Vibration value transmitted to body panel and PVC sheet
Calculated the vibration transmissibility during that time. Table 2 shows the results.
Show. In Table 2, the "product of the present invention" refers to the test specimen according to the present example.
And the "comparative product" is a specimen for a comparative example. [Table 2] Needless to say, the larger the negative value of the vibration transmissibility,
It is evaluated that the damping performance is excellent. From Table 2,
As is apparent, the product of the present invention is 100 to 5 times smaller than the comparative product.
Excellent against vibration at any frequency over 00Hz
In addition to exhibiting vibration damping performance, especially in the relatively low frequency range
It has been found that the effect on is excellent. [Application Example of Embodiment] The application of this embodiment will be described below.
Here is an example. The defibration mixed material 12 to the molds 20 and 21
Is supplied to the collecting tank 13 as described above, for example.
Can be controlled by the supply amount control means.
The fibrillated mixed processing material 12 is gradually blown into 20, 21
Take advantage of the fact that the blowing resistance increases as
A sensor to detect the change in blowing resistance
At the time when the set resistance reaches a predetermined value,
Person who closes mouth automatically and finishes blowing
It may be an expression. After the blowing is completed, branch duct 1
Suction of the defibrated mixed material 12 remaining in 8 or 19
A mechanism that can be used may be used. When implemented as in the previous embodiment,
Has a single-layer structure. However, the molding
Without removing it for each molding cycle.
By repeating the cycle, a sound insulation material with a multilayer structure is obtained
be able to. In addition, defibration and mixing are performed every multiple cycles.
If the composition of the processing material 12 is changed, for example,
It is possible to obtain a soundproofing material with a multilayer structure with different characteristics such as
Arbitrarily emphasize desired characteristics such as sound absorption, sound insulation, vibration suppression, and vibration isolation
Soundproofing material can be manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram showing a state of an aggregate before and after a defibration and mixing process. FIG. 2 is a diagram showing a flow of steps in an example. FIG. 3 is a view showing details of a molding die in an example. [Description of Signs] 1 Chip-shaped solid material 2 Fibrous binder 9 Rotary roller 10 Needle-like projection 11 Rotary cylinder 12 Defibration and mixing treatment material 14 Molding device 17 Switching valve 20 Mold 21 Mold 23 Upper mold 24 Lower mold

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FIG10K 11/162 B29K 105: 26 // B29K 105: 26 B29L 31:58 B29L 31:58 G10K 11/16 A (72) Inventor Takashi Naka Aichi 1-1, Toyota-cho, Kariya, Japan Toyota Boshoku Co., Ltd. (72) Inventor Ikuji Tsujida 1, Toyota-cho, Toyota-shi, Aichi Prefecture Toyota Motor Co., Ltd. (72) Inventor Takuji Kajiwara 1, Toyota-cho, Toyota-shi, Aichi (56) References JP-A-2-106798 (JP, A) JP-A-6-299451 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/34 B27N 1/02 B27N 3/02 B60R 13/08 G10K 11/162

Claims (1)

(57) Claims: 1. A mixing step of mixing a raw material comprising a chip-like solid material occupying a majority amount of a plastic foam and a thermoplastic fibrous binder, and A bonding step of bonding the chip-shaped solids to each other via the fibrous binder by heat-melting the fibrous binder, wherein the mixing step is restrained in a compressed state. The aggregate of the chip-like solid and the fibrous binder is almost
Scraping portionwise with no adjacent scraping projection member,
The fibrous binder was forcibly cut into fine pieces and finely defibrated.
A method for producing a soundproofing material, characterized by including a fibrillation and mixing treatment for clinging to the solid chips .