JP4257818B2 - Soundproof material for vehicle and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle soundproofing material suitable for an insulator dash, a floor carpet, and the like mounted on a dash panel or a floor panel, and a manufacturing method thereof. In particular, the cellulose-based material is inexpensive, excellent in sound absorption performance, and suitable for recycling. Vehicle soundproofing material comprising a multilayer structure based on a base material And its manufacturing method About.
[0002]
[Prior art]
Usually, various soundproofing materials are installed in a vehicle in order to ensure quietness during traveling. For example, as shown in FIG. 16, an insulator dash 1 is mounted on the interior side of the dash panel 1a that partitions the engine room E and the vehicle interior R, and the interior surface of the floor panel 2a in the vehicle interior R is provided. A floor carpet 2 is laid on the floor.
[0003]
Further, in the engine room E, a dash front insulator 3 attached to the indoor side of the dash panel 1a, a hood insulator 4 attached to the indoor side of the hood panel 4a, and the like are installed, and the sound pressure in the engine room E is reduced. In addition, a roof trim 5 is mounted on the indoor surface of the roof panel 5a. Although not shown, interior materials having soundproofing properties such as a trunk trim, a luggage trim, and a wheel house trim are installed in the trunk room and the luggage room.
[0004]
As described above, various soundproofing materials are installed in the cabin R, the engine room E, the trunk room, and the luggage room. As a typical example, the insulator dash 1 mounted on the interior surface of the dash panel 1a. The configuration will be described with reference to FIG. As this insulator dash 1, one having a two-layer structure in which a sound insulating material 7 is integrated on the surface side of a sound insulating base material 6 having sound absorbing and sound insulating performance has been conventionally known.
[0005]
The sound insulating material 7 is made of a heavy sheet material such as a high density recycled rubber sheet or a recycled PVC sheet. On the other hand, as a material of the soundproofing substrate 6, a resin binder such as a low-melting-point heat-fusible fiber or a thermoplastic resin powder based on polyester fibers such as polyethylene terephthalate (hereinafter referred to as PET) or other synthetic fibers. The nonwoven fabric mat is produced by performing press processing while applying needling processing or hot air, and the nonwoven fabric mat is heat-softened and then cold-press-molded to match the shape of the dash panel 1a. The substrate 6 is molded.
[0006]
In addition, as another conventional example, the main fibers are anti-hairs (wool and regenerated hairs recovered by untangling rags and debris of products made from hairs), and a binder is added to this to give formability. The felt is also subjected to the heat softening treatment, and after that, the soundproof substrate 6 is molded by cold press molding to a required shape.
[0007]
Furthermore, a urethane foam molded body obtained by foam molding after injecting a urethane resin solution into the mold may be used as the soundproof substrate 6.
[0008]
[Problems to be solved by the invention]
Thus, in the soundproof base material 6 of the insulator dash 1 described above, in order to increase the sound absorption, the thickness of the base material 6 is increased, or the basis weight is set to be large. Increasing the basis weight leads to an increase in the cost of the product. In addition, if the product thickness is increased while keeping the basis weight constant, the density becomes low, so dust is likely to occur and the work environment is deteriorated. there were. Moreover, the moldability also deteriorated, and there was a problem that it was easy to tear at a portion with a high development rate.
[0009]
Furthermore, in the soundproofing substrate 6 using the conventional nonwoven fabric, increasing the blending amount of the thin fiber and the thin fusible fiber in order to increase the sound absorption, this also leads to an increase in cost, Since these fibers do not have a function of solidifying the base material, it has been pointed out that the rigidity of the base material is impaired.
[0010]
On the other hand, when felt is used, the fluff has thick fibers, so that there is a problem that the sound absorption performance is lowered and the weight of the product is increased. Further, when urethane foam is used, although cost reduction can be expected, there are problems that harmful nitrogen oxides are generated during incineration and disadvantageous in terms of recycling.
[0011]
The present invention was made in view of such circumstances, and is a vehicle soundproofing material applicable to a wide range, such as an insulator dash, floor carpet, hood insulator, and the like, and its manufacturing method. Excellent sound absorption and sound insulation performance, multilayer structure type vehicle soundproofing material suitable for recycling And its manufacturing method The purpose is to provide.
[0012]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 of the present application includes a sound absorption / sound insulation component based on a cellulosic defibrated material or a pulverized product, and a resin binder that binds the sound absorption / sound insulation component. The surface side of the cellulosic raw mat formed as a raw material is impregnated with a surface treatment agent and then dried to form a paper clay on the surface side of the cellulosic base material that is molded in accordance with the shape of the vehicle body panel. A high-density layer is provided. This high-density layer improves sound insulation performance and can fix dust components. It is characterized by that.
Furthermore, the invention described in claim 2 of this application compresses a mixed material obtained by mixing a sound absorption / sound insulation component based on a cellulosic defibrated material or a pulverized product and a resin binder that binds the sound absorption / sound insulation component. The cellulose base mat is formed through a heating process, and a surface treatment agent such as water, an aqueous solution or an adhesive is sprayed or applied on the surface side of the cellulose base mat, and the surface of the cellulose base mat After applying the surface treatment agent to the part, it is dried, and the cellulosic base material is formed into the required shape using the cellulose base mat as a raw material, and a paper clay-like high density layer is formed on the surface part of the base material. In addition, the sound insulation performance of the cellulosic substrate is controlled by adjusting the amount of the surface treatment agent impregnated.
[0013]
Applications of the present invention can be applied to insulator dash, floor carpet, hood insulator, dash front insulator, roof trim, trunk trim, and the like.
[0014]
Here, the sound-absorbing / sound-insulating component means that the sound-absorbing performance by the porous material can be obtained, and that both the sound-insulating performance and the sound-absorbing performance can be exhibited, such as the sound-insulating performance can be expected by its own rigidity and weight. .
[0015]
Then, natural fibers made of cellulose, recycled materials, and recycled materials are used as the sound absorption / sound insulation components, and for example, pure pulp, recycled cellulose, waste paper (old newspapers, old magazines, cardboard, etc.) are defibrated or crushed. A defibrated material or a pulverized material obtained by this method is used.
[0016]
Next, the resin binder that binds the sound absorbing and sound insulating components is a thermoplastic resin type, such as a low melting point PET or other fusible fiber, a PE (polyethylene) resin or other resin powder, or a reactive adhesive (for example, a urethane resin). Adhesives) can be used. In the thermosetting resin type, a thermosetting resin such as a phenol resin can be used.
[0017]
The blending ratio of the sound absorbing / sound insulating component and the resin binder is set between sound absorbing / sound insulating component / resin binder = 90: 10 to 20:80. Depending on the application, the blending ratio is adjusted to be rich in sound absorption and sound insulation components when softness and sound absorption performance are required, and the mixing ratio is adjusted to resin binder rich when rigidity and sound insulation performance are required. To do.
[0018]
Further, a high melting point synthetic fiber may be added to the sound absorbing and sound insulating component. Examples of the high melting point synthetic fiber include PET, PP, PE, and PA (polyamide resin), and the fiber diameter is 0.2 to 30 denier. The length is 2 to 80 mm, preferably 10 to 50 mm.
[0019]
Here, the high-density surface treatment layer formed on the surface of the cellulosic substrate is wetted by spraying a surface treatment agent such as water, an aqueous solution, an adhesive or the like on the mat surface when the cellulosic material mat is matted or by a ripping treatment. And then dried to form a paper clay-like high density layer.
[0020]
Further, by rubbing the mat surface with a roll rotating at a speed that does not synchronize with the transport roll, the treatment agent on the mat surface is well compatible with the cellulose component, and the density can be increased.
[0021]
As the surface treatment agent, water, an aqueous solution, and an adhesive can be used. Examples of the adhesive include synthetic adhesives, adhesives derived from natural substances, and polysaccharides.
[0022]
<Synthetic adhesive>
・ Various organic or water-based adhesives
・ Emulsion and emulsion adhesives
[0023]
<Natural substance-derived adhesives and polysaccharides>
(Seaweed extract)
Ex) Agar, Carrageenan
Example) Alginic acid, sodium alginate and alginic acid compounds
(Plant extract)
Example) starch, amylopectin, pectin, gum arabic
Eg) locust bean gum, guar gum
(Animal protein)
Example) Gelatin, casein
(Cellulose-based)
Example) Carboxymethylcellulose
Example) Methyl cellulose and other chemically modified cellulose
(Other)
・ Tack fire (tackifier resin)
・ Rosin (pine resin) compounds
・ Amylose, pectic acid, xylan, alginic acid fiber, protein fiber
[0024]
And according to invention of Claim 1, if a natural fiber, such as a cellulose, a recycled material, and a recycled material are employ | adopted as a main fiber and a fiber diameter is selectively used, sound absorption performance will be improved. In addition, because the fibrous defibrated material or pulverized material is a sound absorption / sound insulation component, it has a large surface area and can improve sound absorption / sound insulation performance, and the entanglement with the resin binder is strengthened, resulting in rigidity and strength. Can also be up.
[0025]
In addition, it is possible to incinerate and recycle scrap materials and used products, which is preferable for environmental measures, and costs can be reduced if waste defibrated material such as waste paper or pulverized materials are used as sound absorbing and sound insulating components. This is also advantageous.
[0026]
Also, when used as a base material for interior parts having soundproofing properties, depending on the sound absorption and sound insulation performance required for the base material, a sound absorption and sound insulation component based on cellulosic defibrated material or pulverized material and a resin binder The soundproofing material suitable for the application can be obtained by appropriately changing the blending ratio with the above or by selecting the fiber diameter of the cellulose-based defibrated material or the pulverized diameter of the pulverized product.
[0027]
And Claim 1 According to the invention described in the above, the surface treatment agent such as resin or adhesive impregnated on the surface layer portion of the cellulosic substrate is in a binder-rich state, and a single cellulosic raw mat is used to absorb sound. -Since the base material which consists of two layers from which sound insulation performance differs can be shape | molded, the sound-insulation material according to a use can be provided especially by distribution of a low density layer and a high density layer.
[0028]
Also, Claim 2 According to the invention described in, the thickness of the high-density layer in the cellulosic substrate can be controlled by adjusting the amount of the treatment agent impregnated on the surface side of the cellulosic raw mat.
[0029]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of a soundproofing material for a vehicle and a manufacturing method thereof according to the present invention will be described in detail with reference to the accompanying drawings.
[0030]
1 to 5 show the present invention. First reference example FIG. 1 shows Insulator dash for automobile FIG. 2 is a process chart showing a method for manufacturing the vehicle insulator dash, FIG. 3 is a process explanatory diagram of the method for manufacturing the vehicle insulator dash, and FIGS. 4 and 5 are insulators for the vehicle. It is each chart figure which shows the modification of the bonding process of the nonwoven fabric and original fabric mat in a dash.
[0031]
Next, FIGS. 6 to 10 show the present invention. Second reference example FIG. 6 shows Insulator dash for automobile FIG. 7 is an explanatory diagram showing a laminated state of a cellulose-based raw mat and a film, and FIGS. 8 and 9 are chart diagrams showing modifications of the laminating step of the raw fabric mat and the film. FIG. 10 is an explanatory view showing a molding process of the insulator dash shown in FIG. 6, and FIG. 11 is a time chart showing the vacuum / pneumatic action in the molding process.
[0032]
Next, FIGS. 12 and 13 show the present invention. One embodiment FIG. 12 is a cross-sectional view showing a configuration of an automotive insulator dash, and FIG. 13 is a process explanatory view showing a molding process of the insulator dash. 14 and 15 show the present invention. Another reference example FIG. 14 is a cross-sectional view showing a configuration applied to an automobile insulator dash, and FIG. 15 is a schematic view of a method for manufacturing the insulator dash.
[0033]
First, based on FIG. 1 to FIG. First reference example Will be described.
[0034]
In FIG. 1, an automotive insulator dash 10 is mounted on the interior surface side of a dash panel 11 that partitions an engine room E and a vehicle compartment R, and a high-density nonwoven fabric 21 is formed on the surface side of the cellulosic substrate 20. It is composed of a two-layer structure that is laminated and integrated.
[0035]
The cellulosic base material 20 is configured on the basis of a sound absorbing / sound insulating component bonded with a resin binder. The above sound absorbing and sound insulating components are cellulose-based components. Specifically, pure pulp, regenerated cellulose, waste paper (old newspapers, old magazines, cardboard, etc.), plants such as wood, and chemically modified and processed Cellulose, industrial waste derived from natural materials generated in the paper industry, etc. (which may be sludge-like or damp) are used as necessary, and these are defibrated, or By pulverizing, it is in the form of a fiber or powder.
[0036]
On the other hand, as the resin binder, heat-fusible fiber made of low melting point PET, resin powder such as polyethylene resin, and reactive adhesive (for example, urethane adhesive) can be used. In this embodiment, waste paper is defibrated. A heat-fusible fiber made of low melting point PET is used as a resin binder for the pulverized product.
[0037]
The mixing ratio between the sound absorbing / sound insulating component and the resin binder may be set within the range of the sound absorbing / sound insulating component / resin binder = 90: 10 to 20:80. Cellulosic base materials can be selected by selecting a rich mixture of sound absorption and sound insulation components for applications that require performance and softness, and by appropriately selecting a resin binder-rich formulation ratio for applications that require rigidity and sound insulation performance. The usage range of 20 can be greatly expanded.
[0038]
The cellulose base material 20 laminated on the back surface of the sound insulating material 12 of the insulator dash 10 has a sound absorption / sound insulation component / resin binder = 80: 20, and the surface density and average thickness of the cellulose base material 20 are 1,000 g / each. m ² , 20 mm.
[0039]
Accordingly, since the cellulose-based substrate 20 is configured to employ a natural material such as cellulose, a recycled material, and a recycled material as a base, if a fiber diameter or a pulverized product is used, the sound absorbing performance is improved. In addition, scraps and used products can be incinerated and recycled. In particular, if a defibrated product such as waste paper or a pulverized product is used, it is very advantageous in terms of cost.
[0040]
In addition, unlike a string obtained by a shredder or the like, since the surface area is large, the sound absorption and sound insulation performance is high, and the entanglement with the resin binder is strengthened, so that the strength of the product can be increased.
[0041]
Furthermore, in order to particularly improve the sound absorbing performance of the sound absorbing / sound insulating component, it is possible to add a high melting point fiber. In this case, as the high melting point fiber, high melting point PET, PP, PE, PA (polyamide resin), etc. If a high melting point synthetic fiber having a fiber diameter of 0.2 to 30 denier and a fiber length of 2 to 80 mm (preferably 10 to 64 mm) is added, the sound absorbing performance can be improved.
[0042]
On the other hand, the non-woven fabric 21 laminated on the surface of the cellulosic substrate 20 is a high-density synthetic fiber non-woven fabric such as PET, PP, PE, PA (polyamide resin), a binder-rich high-density paper-based non-woven fabric, a non-woven fabric of glass or natural fibers. Or what impregnated this with resin etc. can be used.
[0043]
And this nonwoven fabric 21 needs to be high density in order to strengthen sound insulation and rigidity, and as surface density, it is 50-300 g / m. ² Is suitable.
[0044]
Therefore, since the insulator dash 10 for automobiles shown in FIG. 1 is strengthened in sound insulation and rigidity by the high density nonwoven fabric 21, it is not necessary to set the basis weight and thickness of the cellulosic substrate 20 so much. The nonwoven fabric 21 prevents dust components from being scattered from the cellulosic base material 20 into the passenger compartment, which is preferable in terms of environmental sanitation in the passenger compartment.
[0045]
Next, the manufacturing method of the said insulator dash 10 for motor vehicles is demonstrated in detail based on FIG. 2 thru | or FIG.
[0046]
First, as shown in the chart of FIG. 2, it is formed into a mat shape through a process of heating while compressing a mixed material in which a sound absorbing / sound insulating component and a resin binder are mixed, and is cut into predetermined dimensions to obtain a cellulose-based material. When a raw fabric mat M is prepared and the resin binder in the cellulose-based raw mat M has a high blending ratio, the cellulose-based raw mat M and the nonwoven fabric 21 are overlapped and heat-softened, and then simultaneously press-molded. It ’s fine.
[0047]
That is, this process will be described in detail with reference to FIG. 3. A sound absorbing / sound insulating component and a resin binder are introduced into the mixer 30, and after mixing, the mixed material 32 is spread on the belt conveyor 31. Hot air is blown against the mixed material 32 while applying pressure to the mixed material 32 by the belt 34 that is circulated and driven by the pulley 34a in the heating furnace 33, and the resin binder is melted to combine the sound absorbing and sound insulating components. Then, a mat having a predetermined thickness is manufactured and cut by a predetermined dimension by the cutting blade 35, so that a cellulose-based raw mat M is manufactured.
[0048]
Then, the nonwoven fabric 21 and the cellulose-based raw mat M are overlapped and set in the hot-air heating furnace 36, and hot air is blown. The nonwoven fabric 21 is bonded, and the insulator dash 10 having the shape shown in FIG. 1 is formed by clamping the cold press forming dies 37 and 38. At this time, if the nonwoven fabric 21 is arranged on the hot air discharge side in the hot air heating furnace 36, dust components will not be scattered in the hot air heating furnace 36.
[0049]
Therefore, it is possible to integrally form the nonwoven fabric 21 using the air permeability of the nonwoven fabric 21 using conventional molding equipment. In particular, if the binder action of the resin binder in the cellulosic material mat M is utilized, the nonwoven fabric 21 is separately provided. It is not necessary to heat, and the insulator dash 10 shown in FIG. 1 can be easily formed.
[0050]
As shown in FIGS. 2 and 3, in addition to bonding them together with a binder component by hot air heating, both may be integrated by a hot laminating method and simultaneously press-molded.
[0051]
In addition, when the blending ratio of the resin binder in the cellulosic raw mat M is small, some bonding means may be taken. As this bonding means, for example, resin powder, powder form / pellet form / chip form / mist form / network form / spider web type hot melt adhesive is sprayed or set to bond them together, or liquid hot The melt may be formed into a thread shape and applied to the surface to be an adhesive surface in a random or mesh shape. Moreover, you may adhere | attach both with a synthetic adhesive or the adhesive agent derived from a natural substance.
[0052]
Furthermore, by utilizing the property that the cellulose component in the cellulose-based raw mat M has a hydrophilic group and is sticky, water or the like is sprayed on the surface of the mat M, or both are bonded by a film-like hot melt. You may do it.
[0053]
For reference, when a non-breathable rubber sheet or other skin is used in addition to the non-breathable nonwoven fabric 21, the cellulosic raw mat M and the skin are heated separately as shown in FIG. However, as shown in FIG. 5, the cellulosic raw mat M and the skin may be separately molded and bonded together by the hot melt or adhesive described above.
[0054]
Next, based on FIG. 6 to FIG. 10, the soundproofing material for vehicles according to the present invention and the manufacturing method thereof. Second reference example Will be described.
[0055]
this Second reference example However, as shown in FIG. 6, the automotive insulator dash 10 mounted on the indoor side of the dash panel 11 includes a cellulosic substrate 20 and a cellulosic substrate 20. It is composed of a two-layer structure in which the film 22 is integrated on the surface side.
[0056]
About the structure of the said cellulose-type base material 20, and its effect | action, First reference example Are omitted here. And the film 22 integrated with the surface side of this cellulose-type base material 20 uses a film or a hot-melt film of 20 micrometers or more.
[0057]
Therefore, also in the insulator dash 10 shown in FIG. 6, since the film 22 rich in sound insulation is integrated on the surface side of the cellulose-based substrate 20, without changing the blending or basis weight in the cellulose-based substrate 20. By avoiding cost increase, good sound insulation performance and sound absorption performance can be expected.
[0058]
Further, as with the high-density nonwoven fabric 21, the film 22 does not scatter dust components in the heating furnace 36 during the molding process or scatters in the vehicle interior, so that the working environment and the environmental sanitation in the vehicle interior are kept good. Can do.
[0059]
Next, as shown in FIG. 7, the film 22 that is integrally attached to the surface side of the cellulosic base material 20 is integrated with the nonwoven fabric 23 on the surface side so that the film 22 does not melt during heat softening. The nonwoven fabric 23 is preferably 10 g / m ² The above surface density is required.
[0060]
Further, in order to strengthen the adhesion between the cellulosic substrate 20 and the film 22, it is preferable to laminate a hot melt 24 on the side of the film 22 opposite to the cellulosic raw mat M. You may provide in the base material 20 side. In addition, the surface side of the cellulose-based raw mat M may be treated with an adhesive or an aqueous solution to increase the adhesive force with the film 22.
[0061]
Next, as shown in FIG. 8, the cellulosic base material 20 and the film 22 are integrated by laminating or temporarily fixing the cellulose base mat M and the film 22, and then heating and pressing. The cellulose-based substrate 20 and the film 22 shown in FIG. 6 may be integrated. In this case, the cellulose-based raw mat M and the film 22 may be laminated or temporarily fixed with a tucker or a tag pin. Simultaneous heating is possible in an infrared heating furnace or a thermostatic bath.
[0062]
Similarly, as shown in FIG. 9, while the cellulosic raw material mat M is heated with hot air, the film 22 is heated in an infrared heating furnace or a thermostatic bath, and both are molded and cooled to obtain FIG. The insulator dash 10 shown can also be molded.
[0063]
In addition, paying attention to the use of a non-breathable film 22, as shown in FIG. 10, molding is performed using a molding upper / lower mold (an upper mold 40 and a lower mold 41) provided with a vacuum / pneumatic mechanism. The cycle can also be shortened.
[0064]
That is, the upper and lower molds 40 and 41 are provided with both vacuum and pressure holes 40a and 41a, respectively. In order to improve the adhesion between the cellulosic substrate 20 and the film 22, the vacuum and pressure functions of the lower mold 41 are combined. The film 22 is evacuated from the holes 41a to apply a biasing force to the cellulose-based substrate 20 side. Further, in order to ensure a sufficient product thickness, vacuum suction is performed through the vacuum / compressed air hole 40a of the upper mold 40, and a thickness corresponding to the clearance between the upper and lower molds 40, 41 is ensured, so that the product plate thickness is faithfully maintained. Can be secured.
[0065]
Further, in order to shorten the molding (cooling) time, the upper and lower molds 40 and 41 are always kept at a low temperature with cooling water, or cooling air (room temperature or low temperature) through the vacuum / pressure air combined hole 41a of the lower mold 41. May be blown into the cellulosic substrate 20 to rapidly cool the cellulosic substrate 20 to increase the molding cycle.
[0066]
As shown in FIG. 11, a time chart of the vacuum suction mechanism and the pneumatic mechanism by the upper and lower molds 40 and 41, after the upper and lower molds 40 and 41 are clamped, first, a vacuum suction force is applied to the lower mold 41 to obtain a cellulose-based substrate. After increasing the adhesive force between the material 20 and the film 22, cooling air is supplied into the base material 20 from the vacuum / pressure air combined hole 41 a of the lower mold 41 to shorten the cooling cycle and to reduce the molding upper mold 40. The vacuum is also sucked from the vacuum / compressed air hole 40a to ensure the product plate thickness at the same time. Further, in order to improve the mold release property of the product, the mold release property may be enhanced by applying pressure air from the vacuum / pressure / air combination hole 40a of the molding upper die 40.
[0067]
Next, FIGS. 12 and 13 show the present invention. one As shown in FIG. 12, the cellulosic base material 20 in the automotive insulator dash 10 according to this embodiment includes a low-density layer 20a excellent in sound absorption performance and a high-density layer 20b excellent in sound insulation performance. It is characterized by being formed in a two-layer structure.
[0068]
And the material structure of the cellulose-type base material 20 was mentioned above. Reference example In particular, the characteristic part of the cellulosic substrate 20 is utilized in the low-density layer 20a. The high-density layer 20b is formed by the following procedure.
[0069]
That is, as shown in FIG. 13, a surface treatment agent 51 such as water, an aqueous solution, or an adhesive is sprayed or applied to one surface of the cellulose-based raw mat M by a sprayer 50, and the surface treatment agent 51 is applied by a transport roll 52. It is made to conform to the surface layer portion of the raw mat M, and then dried in a drying process to form a paper clay-like high-density layer 20b.
[0070]
In addition, although the conveyance roll 52 moves the original fabric mat M in the next drying process, the conveyance roll 52a rotates at a speed not synchronized with the moving speed of the original fabric mat M or reversely rotates between the conveyance roll 52a and the surface of the original fabric mat M. It is also possible to increase the frictional force so that the surface treatment agent 51 is well adapted to promote higher density.
[0071]
Examples of the adhesive for the surface treatment agent 51 include the following.
[0072]
<Synthetic adhesive>
・ Various organic or water-based adhesives
・ Emulsion and emulsion adhesives
[0073]
<Natural substance-derived adhesives and polysaccharides>
(Seaweed extract)
Ex) Agar, Carrageenan
Example) Alginic acid, sodium alginate and alginic acid compounds
(Plant extract)
Example) starch, amylopectin, pectin, gum arabic
Eg) locust bean gum, guar gum
(Animal protein)
Example) Gelatin, casein
(Cellulose-based)
Example) Carboxymethylcellulose
Example) Methyl cellulose and other chemically modified cellulose
(Other)
・ Tack fire (tackifier resin)
・ Rosin (pine resin) compounds
・ Amylose, pectic acid, xylan, alginic acid fiber, protein fiber
[0074]
So this Embodiment In the insulator dash 10, the cellulose-based substrate 20 is composed of a low-density layer 20 a and a high-density layer 20 b without changing the basis weight or thickness of the cellulose-based raw mat M that is a material. The low-density layer 20a can provide good sound absorption performance, the high-density layer 20b can provide good sound insulation performance, and the high-density layer 20b can prevent dust components from scattering to the outside. In addition, the balance between the sound absorption performance and the sound insulation performance can be appropriately adjusted by appropriately adjusting the amount of impregnation of the treatment agent 51.
[0075]
Next, FIGS. 14 and 15 show the present invention. Another reference example As shown in FIG. 14, the automotive insulator dash 10 mounted on the interior surface side of the dash panel 11 is First reference example In other words, in addition to the two-layer laminate in which the high-density nonwoven fabric 21 is integrated on the surface side of the cellulose-based substrate 20, a high-density material made from a recycled material as an intermediate layer inside the cellulose-based substrate 20 A layer 25 is provided.
[0076]
The recycled material used as the material of the high-density layer 25 is not limited to industrial waste such as scraps generated in the interior material manufacturing process, crushed material such as interior material and exterior material after use, and automobile-related waste material. General waste such as synthetic resin molded products may be used. However, low density products such as fabrics are not suitable because they have no effect of improving performance.
[0077]
Further, the recycled material is used after being pulverized into a regular shape or an irregular shape, and the pulverization size is preferably in the range of 1 to 20 mm.
[0078]
Furthermore, in order to reinforce the adhesiveness between the cellulosic substrate 20 and the high-density layer 25 made of a pulverized recycled material, the recycled material may be resin powder, hot melt (powder / pellet / chip) or the above-mentioned. A surface treating agent 51 may be added.
[0079]
Next, as a method of inserting the high-density layer 25 in the middle part of the cellulose-based substrate 20, a recycled material is used as a material between two cellulose-based raw mats M as shown in FIG. Cold press molding may be performed after the heat softening process with the high-density layer 25 interposed therebetween. The high density layer 25 is formed by spraying a pulverized product 61 of recycled material from the container 60.
[0080]
Further, as shown in FIG. 15 (b), after depositing a mixed material 32 mixed with a sound absorbing / sound insulating component and a resin binder from the mixer 30 on the belt conveyor 31 in the manufacturing process of the raw fabric mat M, the container 60 Then, the pulverized material 61 obtained by pulverizing the recycled material is sprayed, and then the mixed material 32 is sprayed from the upper side through the mixer 30 to deposit them continuously or stepwise to form one multilayer mat. Also good.
[0081]
Furthermore, the cellulose-based raw mat M may be set in the molding machine immediately before pressing, the recycled material may be sprayed, and another cellulose-based raw mat M may be stacked and press-molded. The high-density layer 25 may be provided at an intermediate position of the cellulosic base material 20 or biased on either side.
[0082]
And if the high-density layer 25 is arrange | positioned inside the cellulose-type base material 20 in this way, the triple-wall sound-insulation function by the three of the dash panel 11, the high-density layer 25, and the high-density nonwoven fabric 21 will be obtained, for example. A good sound insulation function can be obtained without changing the composition and basis weight of the base material 20.
[0083]
The sound insulation performance can be varied by appropriately changing the weight per unit area of the high-density layer 25. This also makes it possible to select fine sound absorption / sound insulation performance.
[0084]
Moreover, the structure which abolished the nonwoven fabric 21 may be sufficient, and it may replace with the nonwoven fabric 21 and the structure which formed the high-density layer 20b in the film 22 or the surface may be employ | adopted.
[0085]
【The invention's effect】
As described above, the vehicle soundproofing material according to the present invention is a cellulose based on a cellulose-based defibrated material or a sound absorbing / insulating component based on a pulverized material, and a resin binder that binds the sound absorbing / insulating component. In addition to the effects of being inexpensive, high-performance, and suitable for environmental measures by using a base material, On the surface side of this cellulosic substrate By forming a high-density surface treatment layer, sound insulation performance can be maintained while maintaining good sound absorption performance at a low price without increasing the grade of cellulosic base materials and without increasing the basis weight or plate thickness. It has the effect that it can be increased.
[0086]
And according to the method of forming a high-density layer by impregnating the surface treatment agent on the surface side of the cellulosic substrate, the necessary sound insulation performance is selected by appropriately selecting the treatment agent and adjusting the amount of impregnation. This is advantageous in that it is advantageous for fine soundproofing measures.
[Brief description of the drawings]
FIG. 1 shows a soundproof material for a vehicle according to the present invention. It is the first reference example It is sectional drawing which shows the structure of the insulator dash for motor vehicles.
FIG. 2 is a chart showing one embodiment of a method for manufacturing the automotive insulator dash shown in FIG.
3 is a process explanatory diagram of the chart shown in FIG. 2. FIG.
4 is a chart showing a modification of the laminating process in the chart shown in FIG. 2. FIG.
FIG. 5 is a chart showing a modification of the laminating step in the chart shown in FIG.
FIG. 6 shows a soundproof material for a vehicle according to the present invention. Second reference example It is sectional drawing which shows the structure of the insulator dash for motor vehicles.
7 is an explanatory view showing a configuration of a film used in the automobile insulator dash shown in FIG. 6. FIG.
FIG. 8 is a chart showing a modified example of integral molding of a raw fabric mat and a film in the automotive insulator dash shown in FIG. 6;
9 is a chart showing a modified example of integral molding of a raw fabric mat and a film in the automobile insulator dash shown in FIG. 6;
10 is an explanatory view showing a molding process of the automotive insulator dash shown in FIG. 6. FIG.
FIG. 11 is a time chart diagram of the molding upper and lower molds in the molding process shown in FIG. 10;
FIG. 12 shows a soundproof material for a vehicle according to the present invention. One embodiment It is sectional drawing which shows the structure of the insulator dash for motor vehicles.
13 is an explanatory diagram showing an outline of a method for manufacturing the automotive insulator dash shown in FIG. 12. FIG.
FIG. 14 shows a soundproof material for a vehicle according to the present invention. Another reference example It is sectional drawing which shows the structure of the insulator dash for motor vehicles.
15 is an explanatory view showing a laminating step between the raw fabric mat and the high-density layer in the automotive insulator dash shown in FIG. 14;
FIG. 16 is an explanatory view showing an installation location of a vehicle soundproofing material.
FIG. 17 is a cross-sectional view showing a configuration of a conventional automotive insulator dash.
[Explanation of symbols]
10 Insulator dash for automobiles
11 Dash panel
20 Cellulose base material
20a Low density layer
20b high density layer
21 Nonwoven fabric
22 films
23 Nonwoven fabric
24 Hot melt
25 High density layer (recycled pulverized product)
30 mixer
31 Belt conveyor
32 mixed materials
33 Hot air heating furnace
34 belt
35 cutting blade
36 Hot air heating furnace
37,38 Cold press mold
40, 41 Upper and lower molds for molding
40a, 41a Vacuum / Pneumatic hole
50 nebulizer
51 Surface treatment agent
52 Transport roll
60 containers
61 Pulverized material (recycled material)
M Cellulose base mat

Claims (2)

A surface treatment agent is impregnated on the surface side of a cellulose-based raw mat formed of a cellulose-based defibrated material or a pulverized material and a resin binder that binds the sound-absorbing / sound-insulating component. Then, by drying, a paper clay-like high-density layer is provided on the surface side of the cellulosic base material molded in accordance with the shape of the vehicle body panel . This high-density layer enhances sound insulation performance and dust. A soundproofing material for a vehicle characterized in that components can be fixed .   Cellulose base fabric mat is formed through a process of heating while compressing a mixed material that is a mixture of a sound absorption / sound insulation component based on cellulosic defibrated material or pulverized material and a resin binder that combines the sound absorption / sound insulation component Then, a surface treatment agent such as water, aqueous solution, adhesive or the like is sprayed or applied on the surface side of the cellulose-based raw mat, and after the surface treatment agent is applied to the surface portion of the cellulose-based raw mat, it is dried. By forming a cellulosic base material into a required shape using the cellulose base fabric mat as a raw material, forming a paper clay-like high density layer on the surface portion of the base material, and adjusting the amount of impregnation of the surface treatment agent And a method for producing a soundproof material for a vehicle, wherein the sound insulation performance of the cellulose-based substrate is controlled.

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