JP5008061B2 - Vehicle soundproof structure - Google Patents

Description

  The present invention relates to a soundproofing structure for a vehicle in which a soundproofing material is attached to the interior side of a vehicle body panel, and in particular, eliminates a heavy soundproofing layer to reduce the weight of the soundproofing material and to provide a wide frequency range. The present invention relates to a soundproof structure for a vehicle that can exhibit excellent soundproofing properties against noise.

  Usually, in order to enhance the quietness of the vehicle interior, various soundproof materials are attached to the interior side of the vehicle body panel as the soundproof structure of the vehicle. An example of this soundproof material is an insulator dash. Hereinafter, a conventional example of this insulator dash will be described with reference to FIG. An insulator dash 2 is attached to the interior surface of the dash panel 1 that divides the engine room E and the vehicle compartment R. The insulator dash 2 is a recycled rubber sheet as shown in an enlarged view in FIG. , A sound insulation layer 3 made of a high-density material such as a recycled PVC sheet, and a sound absorbing layer 4 made of a fiber assembly laminated and integrated on the back side thereof, and on the lower surface of the insulator dash 2, The floor carpet 5 is laid in a wrap shape, and the upper side of the insulator dash 2 is located in the instrument panel 6 (see, for example, Patent Document 1).

  By the way, as an insulator dash, in addition to the existing sound insulation type insulator dash 2, recently, a lightweight ventilation type insulator dash 2 'has been proposed. First, as shown in FIG. 10A, the existing sound insulation type insulator dash 2 uses a non-breathable heavy recycled rubber sheet, recycled PVC sheet, or the like as the sound insulation layer 3, and FIG. ), The noise transmitted through the dash panel 1 is absorbed in the high frequency range by the sound absorbing layer 4, but the low frequency range noise is bounced back by the sound insulating layer 3. The double wall sound insulation function between the two contributes greatly to the sound insulation function.

  Next, in the breathable insulator dash 2 ′, as shown in FIG. 11A, a high-density layer 7 having air permeability such as a high-density nonwoven fabric is integrated on the indoor surface side of the sound absorbing layer 4, As shown in FIG. 11 (b), the sound absorption mechanism in the ventilation type insulator dash 2 ′ is such that the noise transmitted through the dash panel 1 is mainly absorbed through the sound absorption layer 4 and the high density layer 7. Is done. Further, the remaining noise is transmitted to the indoor side, reflected by the instrument panel 6, and then absorbed again from the high-density layer 7 into the ventilation type insulator dash 2 ', which can greatly contribute to the improvement of the sound absorption in the vehicle interior ( For example, see Patent Document 2.)

Japanese Utility Model Publication No. 7-5966

JP 2003-216158 A

  Thus, conventionally, for example, as shown in FIG. 10, in the sound insulation type insulator dash 2, a heavy material such as a recycled rubber sheet and a recycled PVC sheet is used as the sound insulation layer 3. This is a factor that goes against the weight reduction of the product and reduces the fuel efficiency and installation workability. Further, in terms of sound absorption performance, the sound absorption effect of noise in the high frequency range is not sufficient, and noise transmitted through the room is reflected by the instrument panel 6 and re-reflected by the product surface, so that It has been pointed out that the sound pressure increases and the quietness in the passenger compartment is not satisfactory.

  On the other hand, the ventilation type insulator dash 2 ′ shown in FIG. 11 can contribute to weight reduction because it uses a high-density layer 7 made of a fibrous molded body instead of the sound-insulating layer 3 that is heavy in weight. Noise can be eliminated and sound absorption performance can be improved, but when forming the high-density layer 7, the fiber used is mainly recycled products, so the fiber specifications differ depending on the season, and the ventilation rate is adjusted. Is very difficult. In addition, considering the fact that there is a limit in the repulsive force when compressed in order to reduce the air permeability of the high-density layer 7, and there is also a limit in the lower limit when controlling the air flow rate, the desired sound absorption performance can be obtained. It is hard to say that it will be achieved.

  The present invention has been made in view of such circumstances, and is a soundproof structure for a vehicle in which a soundproofing material is attached to the interior side of a vehicle body panel. The soundproofing material is reduced in weight and has excellent soundproofing characteristics. An object of the present invention is to provide a soundproof structure for a vehicle that can exhibit the above.

In order to solve the above-described problems, the present invention provides a soundproof structure for a vehicle in which a soundproof material is attached to the interior side of a vehicle body panel. Layer, a low ventilation layer integrated on the vehicle interior side of the sound absorbing layer, and an adhesive layer that firmly integrates the sound absorbing layer and the low ventilation layer, the low ventilation layer being a molten layer And the base material layer, the molten layer faces the interior of the vehicle, and the synthetic fiber is melted and solidified by applying heat treatment to the surface of the fiber aggregate in which the synthetic fibers are accumulated in a mat shape. The base material layer is disposed so as to face the sound absorbing layer, and the air permeability of the low air permeability layer is set within a range of 0.1 to ³⁰ cm ³ / cm ² · sec. It is characterized by that.

  Here, the installation location of the soundproofing material can be applied to the interior side of the vehicle body panel, the interior side of the engine room, the interior side of the luggage room, and the interior side of the trunk room. Product forms include insulator dash, roof trim, engine room insulator, luggage trim, and trunk trim.

And as a low air permeability layer, the thing of air permeability of 0.1-30 cm < ³ > / cm < ² > / sec is said. In addition, as a numerical value of ventilation | gas_flowing quantity, the numerical value measured according to JISL1096 general textiles test method fragile A method is used. As a material for the low air permeability layer, a nonwoven fabric mat based on synthetic fibers such as polyester, polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6, nylon 66, and the like can be used. In particular, in the present invention, after the nonwoven fabric mat is heat-treated, a molten layer whose surface is melted by a thermal roller is partially formed, but by appropriately adjusting the roller temperature, roller speed, roller pressure, etc. A molten layer having a thickness can be formed, and the air flow rate can be set within the above-described range.

Further, the surface density of the low ventilation layer is 30 to 1600 g / m ² , preferably 50 to 500 g / m ² , and the thickness is 0.2 to 10 mm, preferably 0.5 to 3 mm. . Furthermore, the ratio of the molten layer to the base material layer is suitably 5 to 80% as the thickness ratio of the molten layer to the total thickness of the low air-permeable layer. Further, the amount of air flow can be adjusted by the arrangement of the molten layer (on the surface side or the sound absorbing layer side) and the thickness of the molten layer in the low air-permeable layer, and the sound absorbing performance and sound insulating performance can be controlled. In order to increase the sound absorption performance, the air flow rate may be increased. Conversely, in order to increase the sound insulation performance, the air flow rate may be adjusted to be decreased. Further, the molten layer can be formed on one side or both sides.

On the other hand, the sound absorbing layer is made of a fiber assembly made of felt, synthetic fibers such as PET (polyester) fibers, and paper (pulp etc.) in the form of fibers, and usually a raw fabric mat in which the fiber assemblies are accumulated in a mat shape. After the heat softening treatment, the film is press-molded by a cold press mold having a mold surface having a required shape. The physical properties of the sound absorbing layer are as follows: density 0.01 to 0.6 g / cm ³ , surface density 200 to 2400 g / m ² , and thickness 4 so that the average thickness of the entire soundproofing material is 5 to 60 mm. The range is 8 to 50 mm, preferably 5 to 10 mm, and the air flow rate is 0.1 to ³⁰ cm ³ / cm ² · sec, preferably 1 to 20 cm ³ / cm ² · sec.

  Next, as an adhesive layer for integrating the sound absorbing layer and the low air permeability layer, resin powder such as polyethylene powder, hot melt film (because a gap is formed when melted, air permeability is not impaired), Hot melt webs can be used. When resin powder is used, it is spread on the original fabric mat that is the material of the sound-absorbing layer and melted by heating with hot air, and then the original mat for forming the sound-absorbing layer and the original fabric mat for forming the low-air-permeable layer are stacked. In addition, it may be integrally formed into a required shape in a molding die. Further, when using a hot melt film or a hot melt web, it may be laminated on the raw mat on one side of either the low air-permeable layer or the sound absorbing layer.

  As apparent from the above configuration, according to the soundproof structure of the present invention, a conventional sound-insulating sheet such as a recycled rubber sheet or a recycled PVC sheet can be eliminated, which can contribute to weight reduction. In particular, in the low ventilation layer located on the surface side of the sound absorbing layer, a part of the fiber mat is melted by heat treatment to change the thickness of the molten layer, thereby adjusting the amount of ventilation. That is, the desired soundproofing performance can be achieved by adjusting the air flow rate to increase the sound absorption and to decrease the air flow rate to increase the sound insulation. Furthermore, since the sound absorbing layer and the low air-permeable layer are firmly bonded and integrated by the adhesive layer, there is no problem that the low air-permeable layer and the sound absorbing layer are peeled off even after long-term use, and good sound absorbing performance is maintained for a long time. be able to.

  As described above, the soundproof structure according to the present invention is provided by providing a low ventilation layer made of a fibrous molded body on the indoor surface side of the sound absorption layer, and this low ventilation layer is formed by appropriately forming a molten layer by heat treatment. The air flow rate is controlled appropriately, and the low ventilation layer and sound absorbing layer are firmly integrated by the adhesive layer, so the product weight of the soundproofing material can be significantly reduced and fuel efficiency can be improved. At the same time, there is an effect that the workability of attaching to the panel can be improved.

  Furthermore, since the air flow rate can be appropriately controlled in the low air permeability layer, an appropriate soundproofing function can be achieved by appropriately raising and lowering the air flow rate according to the target noise frequency level. In addition, since the peel strength between the sound absorbing layer and the low ventilation layer is set to 0.01 to 10.0 N / cm due to the presence of the adhesive layer, the sound absorbing layer and the low ventilation layer are peeled even after long-term use. In other words, the soundproof performance can be maintained well over a long period of time.

  DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a soundproof structure for a vehicle according to the present invention applied to an insulator dash mounted on the interior side of a dash panel will be described in detail with reference to the accompanying drawings. Note that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

1 to 6 show an embodiment of the present invention. FIG. 1 is a cross-sectional view showing a configuration of an insulator dash attached to a dash panel, and FIG. 2 is an explanatory diagram showing components of the insulator dash. 3 is an explanatory view showing a sound absorbing mechanism of the insulator dash, FIG. 4 is an explanatory view showing a manufacturing process of the low ventilation layer in the insulator dash, FIG. 5 is a sectional view showing a fracture surface of the low ventilation layer, and FIG. explanatory view showing a manufacturing process of the insulator dash, FIG. 7 is an explanatory diagram showing each configuration of which the insulator dash an exemplary embodiment of the present invention.

  In FIG. 1, a dash panel 10 that partitions an engine room E and a vehicle compartment R is partitioned into a dash upper portion 10a, a dash lower portion 10b, and a toe board portion 10c from the upper side. A dash 20 is attached. Further, a floor carpet 11 is laid in a wrap shape on the surface side of the insulator dash 20 to be mounted on the toe board portion 10c, and is further mounted on the upper half of the dash upper portion 10a and the dash lower portion 10b of the dash panel 10. The upper half of the insulator dash 20 is located in the instrument panel 12. A crash pad (not shown) is attached to the instrument panel 12.

  By the way, the insulator dash 20 according to the present invention is configured such that the product weight is significantly reduced in order to improve fuel efficiency and mounting workability, and further, sufficient soundproofing characteristics are provided even if the weight is reduced. ing. As is apparent from the configuration explanatory diagram of FIG. 2, the insulator dash 20 is disposed on the side facing the dash panel 10 and has a sound absorbing layer 30 that can effectively absorb high- and middle-frequency noises with a porous sound absorbing function. The low ventilation layer 40, which is disposed on the side facing the passenger compartment R, has a low air permeability, and has a soundproof performance that satisfies both sound absorption performance and sound insulation performance by appropriately controlling the air flow rate, The sound absorbing layer 30 and the adhesive layer 50 that firmly integrates the low air-permeable layer 40 are roughly configured.

More specifically, the sound absorbing layer 30 is made of felt, polyester fiber typified by polyethylene terephthalate, synthetic fiber nonwoven fabric such as polypropylene fiber, fiber aggregate made of paper (pulp or the like), or polypropylene, polyurethane, polyethylene, A foamed resin material in which a foaming agent selected from an inorganic foaming agent such as sodium bicarbonate or an organic foaming agent such as azodicarbonamide is mixed in a synthetic resin material such as polyester can be used. The sound absorbing layer 30 only needs to have a porous sound absorbing function capable of absorbing noise in a high frequency range. The surface density is 200 to 2400 g / m ² , and the thickness of the insulator dash 20 is 5 to 60 mm. Thus, it is set between 4.8 and 50 mm.

Next, the low ventilation layer 40 uses synthetic fibers such as polyester, polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6 and nylon 66 as the material. In this embodiment, the melt layer 41 and the sound absorbing layer are formed on the surface side. 4 is a two-layer structure having a base layer 42 on the surface facing the layer 30, and a heat treatment described later with reference to FIG. The thickness of the molten layer 41 is adjusted at a ratio of 5 to 80% of the entire thickness of the low air-permeable layer 40, and the ratio is appropriately selected in consideration of the required sound absorption performance and sound insulation performance. Moreover, the range of 0.1-30 cm < ³ > / cm < ² > / sec (by a fragile type air flow measuring device) is appropriate for the air flow rate of the low air permeability layer 40. The surface density of the low air layer 40 is 30~1600g / m ^2, preferably from 50 to 500 g / m ^2. Furthermore, the thickness of the low ventilation layer 40 is set to 0.2 to 10 mm.

  Next, the adhesive layer 50 uses a resin powder such as polyethylene powder as a hot melt, or a thermoplastic resin material such as a hot melt film or a hot melt web. And in this invention, the sound absorption layer 30 and the low air permeability layer 40 are firmly integrated through the adhesive layer 50, and the peeling strength in that case is set to 0.01-10.0 N / cm Is a feature. The peel strength is a numerical value measured according to JIS K 6854-2 adhesive-peeling bond strength test method-second part: 180 degree peel [ISO8510-2: 1990 (IDT)].

  As described above, when the structure of the soundproofing material according to the present invention is applied to the insulator dash 20, the sound absorbing layer 30 and the low ventilation layer 40 are composed of the co-fibrous molded body. Since PVC sheets can be eliminated, it can greatly contribute to weight reduction. Therefore, improvement in fuel efficiency and improvement in workability on the vehicle body panel can be expected.

  Moreover, the low air permeability layer 40 can control the air flow rate of the low air permeability layer 40 appropriately by forming the melt layer 41 in an appropriate ratio by heat treatment. As a result, for example, the soundproofing mechanism shown in FIG. 3 will be described. The noise F1 from the engine room E is rebounded into the engine room E by the dash panel 10, but part of it is propagated inside the vehicle compartment R. The noise level of the transmitted noise F2 that passes through the sound absorbing layer 30 is particularly reduced in the high and medium frequency regions due to the porous sound absorbing function in the sound absorbing layer 30. Further, since the transmission noise F3 transmitted through the low ventilation layer 40 is controlled in the amount of ventilation in the low ventilation layer 40, for example, when the ventilation rate is increased, the sound absorption performance is improved, particularly in the high / medium frequency range. Can effectively absorb the noise. On the contrary, when the air flow rate is lowered, the sound insulation is improved, and the noise in the low frequency range can be effectively attenuated. Then, the transmitted noise F4 which has been subjected to considerable energy attenuation by the transmitted noise F2 transmitted through the sound absorbing layer 30 and the transmitted noise F3 transmitted through the low air-permeable layer 40 is reflected by the instrument panel 12, and the reflected noise F5 is further reduced by low ventilation. The sound absorption process is performed again by entering the inside from the layer 40 and can greatly contribute to the quietness of the passenger compartment without increasing the sound pressure in the instrument panel 12.

  As described above, in the present invention, the sound absorbing layer 30 can effectively perform a soundproofing treatment on a wide frequency range of high and medium frequency noises by the porous sound absorbing function, and the low air permeability layer 40 has an intrusion. Effective noise absorption and sound insulation processing for the noise level by determining whether the noise level to be performed is low frequency range or high / medium frequency range and effectively controlling the air flow rate by increasing / decreasing the ratio of the molten layer 41 it can.

  Next, the manufacturing process of the low ventilation layer 40 will be described based on FIG. 4, and the manufacturing process of the insulator dash 20 by integrating the sound absorbing layer 30 and the low ventilation layer 40 will be described based on FIG. As shown in FIG. 4, material fibers such as felt and polyester are opened by a spreader 60 and supplied to a feeder 61. Then, the fibers sent from the feeder 61 to the cross layer 62 are formed as a raw mat by appropriately adjusting the mat thickness from the cross layer 62, subjected to hot air treatment by the heat treatment machine 63, and then subjected to pressure bonding by the thermal roller 64. The low ventilation layer 40 having an appropriate thickness is wound and accommodated in the winding roll 65. Here, when the low ventilation layer 40 has a two-layer structure of the molten layer 41 and the base material layer 42 as in the embodiment, as shown in FIG. 4, the thermal roller 64 is set only on the upper side, for example, When the molten layer 41 is disposed on the upper and lower surfaces of the base material layer 42, the thermal roller 64 may be disposed vertically, and when the thickness of the molten layer 41 is adjusted, the roller temperature of the thermal roller 64, the roller The ratio of the molten layer 41 can be adjusted by appropriately changing the speed and the roller pressure.

  Furthermore, the structure of the low ventilation layer 40 in the insulator dash 20 will be described with reference to FIG. FIG. 5 is a cross-sectional view of the fracture surface of the low air permeability layer 40 taken by an electron micrograph. As is apparent from FIG. 5, the melt layer 41 is set to a thickness of 158 μm and is almost solid, whereas the base material layer 42 is set to a thickness of 1612 μm and the fiber voids are extremely It is easy to understand that this is a conspicuous configuration. Therefore, with respect to the molten layer 41 and the base material layer 42 constituting the low air-permeable layer 40, the above-described soundproofing mechanism is achieved due to the difference in the physical properties and the thickness ratio thereof.

  Next, a process of manufacturing the insulator dash 20 by integrating the sound absorbing layer 30 and the low ventilation layer 40 via the adhesive layer 50 will be described with reference to FIG. First, the raw fabric mat M1 which is a material of the sound absorbing layer 30 is cut to a predetermined size, and then placed on the transfer table 70. The transfer table 70 is transferred to a spraying area of the resin powder P, which is the next process, and a powder spreader. From 71, resin powder P such as polyethylene powder, which is a material of the adhesive layer 50, is sprayed. Next, the transfer table 70 is further sent to the next step, and the raw fabric mat M1 is heated and softened to a predetermined temperature in the hot air heating furnace 72. At this time, the resin powder P adhering to the original fabric mat M1 is in a molten state that effectively functions as an adhesive. Then, in this state, the product is put into a cold press molding die 73 in which the mold surface shape is set to the product shape of the insulator dash 20.

  On the other hand, the raw fabric mat M2, which is the material of the low air-permeable layer 40, is also cut to a certain size, held at the periphery with a clamp device 74, heated and softened to a predetermined temperature with an infrared heater device 75, and then cold-press-molded gold By inserting the mold 73 into the mold 73 and clamping the cold press molding mold 73, the molding of the insulator dash 20 shaped into the shape shown in FIG. 1 is completed. In this embodiment, the sound absorbing layer 30 and the low air permeability layer 40 are integrated through the adhesive layer 50 using the resin powder P such as polyethylene powder as an adhesive medium. A hot melt film or a hot melt web can be used. When a hot melt film is used, it breaks during heating, so air permeability is not impaired. In order to use a hot melt film or a hot melt web, it may be laminated on one side of the raw fabric mat M1 of the sound absorbing layer 30 or the raw fabric mat M2 of the low air-permeable layer 40.

FIG. 7 shows a reference example of the low ventilation layer 40. As shown in FIG. 7A, the low ventilation layer 40 is composed of a two-layer structure of a molten layer 41 and a base material layer. In this reference example , the molten layer 41 is opposed to the sound absorbing layer 30 side, and is a reference example in which the front and back of the molten layer 41 and the base material layer 42 in the above-described embodiment are reversed. Moreover, as shown in FIG.7 (b), the low ventilation layer 40 of the 3 layer structure which has arrange | positioned the molten layer 41 to the front and back of the base material layer 42 is also employable. Furthermore, as shown in FIG. 7C, the low air permeability layer 40 may be substantially occupied by the molten layer 41. In this way, considering whether the required sound insulation performance is sound absorption performance (especially for high and medium frequency range noise) or sound insulation (particularly for low and medium frequency range noise), Effective soundproofing measures can be taken by selecting the occupation ratio of the molten layer 41 in the low ventilation layer 40 and appropriately adjusting the ventilation rate.

  In the embodiment described above, the present invention is applied to the insulator dash 20 attached to the interior side of the dash panel 10, but the soundproofing material attached to the engine room or the trunk room as well as the roof trim attached to the interior of the vehicle interior. It can be applied in general. Further, as the adhesive layer, a hot melt film, a hot melt web, or the like can be used in addition to a resin powder type such as polyethylene powder.

It is sectional drawing which shows one Example applied to the insulator dash as a vehicle soundproofing material used for this invention. It is explanatory drawing which shows the structure of the insulator dash shown in FIG. It is explanatory drawing which shows the soundproofing mechanism of the insulator dash shown in FIG. It is explanatory drawing which shows the manufacturing process of the low ventilation layer in the insulator dash shown in FIG. It is sectional drawing by the electron micrograph photograph which shows the fracture surface of the low ventilation layer in the insulator dash shown in FIG. It is explanatory drawing which shows the manufacturing process of the insulator dash shown in FIG. It is composition explanatory drawing which shows the modification of the low ventilation layer in the insulator dash shown in FIG. It is explanatory drawing which shows the installation location of an insulator dash. It is sectional drawing which shows the structure of the conventional insulator dash. It is explanatory drawing which shows the structure and soundproofing mechanism of the conventional sound insulation type insulator dash. It is explanatory drawing which shows the structure and soundproofing mechanism of the conventional ventilation type | mold insulator dash.

Explanation of symbols

10 Dash panel 20 Insulator dash (soundproof material)
DESCRIPTION OF SYMBOLS 30 Sound absorption layer 40 Low ventilation layer 41 Molten layer 42 Base material layer 50 Adhesive layer 60 Opening machine 61 Feeder 62 Cross layer 63 Heat processing machine 64 Thermal roller 65 Winding roll 70 Transfer table 71 Powder spreader 72 Hot air heating furnace 73 Cold press molding Mold 74 Clamping device 75 Infrared heater device M1 Original fabric mat (for sound absorption layer formation)
M2 raw fabric mat (for forming a low air-permeable layer)
P resin powder

Claims (3)

In a vehicle soundproof structure in which a soundproof material (20) is attached to the interior side of the vehicle body panel (10),
The soundproofing material (20) includes a sound absorbing layer (30) formed in accordance with the shape of the interior surface of the vehicle body panel (10), and a low ventilation layer integrated on the interior side of the sound absorbing layer (30). (40) and an adhesive layer (50) that firmly integrates the sound absorbing layer (30) and the low air permeability layer (40). The low air permeability layer (40) includes a molten layer (41). It consists of a laminated body with a base material layer (42), the said fusion | melting layer (41) faces the interior of a vehicle, and the said synthetic | combination is performed by heat-treating the surface of the fiber integration body which accumulated the synthetic fiber in mat shape. The base layer (42) is disposed so as to face the sound absorbing layer (30), and the air permeability of the low ventilation layer (40) is 0.1. A soundproof structure for a vehicle, which is set within a range of ˜30 cm ³ / cm ² · sec.   The peel strength between the low air-permeable layer (40) and the sound absorbing layer (30) is set to 0.01 to 10.0 N / cm by the adhesive layer (50). Vehicle soundproof structure.   The low ventilation layer (40) includes a molten layer (41) formed on a surface of a fiber aggregate obtained by collecting synthetic fibers in a mat shape, and a non-melted base material layer (42). The thickness of the molten layer (41) with respect to the thickness of the low ventilation layer (40) is set in the range of 5 to 80%. Vehicle soundproof structure.

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