JPH0247002A - Manufacture of pad for insulator of automobile - Google Patents

Abstract

PURPOSE:To improve the insulation for vibration by a method in which raw material to be defibrated with which a binder is mixed, is thrown into a making box, and after forming a fleecelike mat, it is hot-formed. CONSTITUTION:Material to be defibrated and the raw material of thermosetting resin are thrown downward by a making drum 7 provided on the upper-most stream of a duct 9, while it is re-defibrated. On one hand, a making box 10 fittable to the duct 9 which has an opening directed up has air permeable bot tom, and the raw material flowing down in the duct 9 is regulated by straightening plates 12a, 12b, whereby the raw material is dropped on the whole area of the bottom of the making box 10. The bottom surface of the making box 10 is preliminarily formed so as to fit to the shape of a pad, and after the elaspe of a prescribed time, the material is accumulated in the shape of the mat M. After the coating amount of the fleecelike mat M has been set freely variably according to the portions, a scraper roll 13 is retracted to the outside of the making box 10, and the top die 14 for per-forming is alternately advanced. The performed mat M is hot-pressed, whereby a desired pad is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a pad material for a dash insulator for an automobile or the like.

(Prior Art) In order to prevent vibrations or transmitted sound from the engine room of an automobile, a member called an insulator is usually attached to the dash panel. This insulator consists of a pad material that is pasted on the panel side and a skin material that is laminated on the conductor side.
(see figure).

■Raw material is about 20-100mm! A recycled wool product 1, such as coarse wool, having IM binding is used.

■Defibration process The waste product 1 mentioned above is defibrated by a defibrator 2, and a blower 3
It is transported by air to the hopper 4.

■Mixing process The defibrated material is discharged in fixed quantities from the small brim 4 and supplied to the feed conveyor 5F. Mainly, 1-nol resin) is used as a binder material, and a defibrated material is mixed therein.

(2) Papermaking process The paper is then dropped onto a papermaking conveyor 20 via a papermaking drum 7 (a rotatable roller with a large number of needles on its circumferential surface). That is, the defibrated material is re-defibrated in the papermaking drum 7 and is then flown onto the conveyor 20 according to the rotational direction of the drum 7. In this way, a fleece-like mat M having a substantially constant basis weight (1.0 to 2.0 g/Td) is obtained on the conveyor 20.

■ Baking process If the above fleece-like mat M is used as it is, it lacks portability (handling ability) and does not interfere with transportation to the subsequent molding process. Therefore, in order to apply this, the fleece-like mat M is first led to the baking oven 21. Here, hot air is blown onto the fleece-like mat M, which is then pressed by a large number of press rollers 22. Next, cold air is immediately blown in the cooling furnace 23. That is, in this baking process, the fleece-like mat M
The fibers are connected to each other by the mixed binder resin, and the leg mat 24 is made of a base with easy handling.
It is said that

(2) Cutting process The baking mat 24 is then cut at regular intervals to form an original fabric 25 of a predetermined size.

■Molding process Therefore, the original fabric 25 is formed into a pair of upper and lower molds 26a.

26b, where it is hot pressed into a predetermined shape. In this case, the mold temperature is 180-230℃, the pressure is 1
−． It is molded under the conditions of 10 g/cIi and a pressing time of 20 to 40 seconds.

(Problems to be Solved by the Invention) In the conventional case, the following problems occurred due to the process of manufacturing the baking mat 24.

■The upper edges of the four parts are less likely to have a sharp shape.

Since hot forming is performed after passing through baking 7t 24, in other words, the fibers are molded together with a binder material, the entire recess is pulled toward the bottom side during molding, and as a result, the upper edge The shape becomes arcuate, resulting in a rounded shape.

■Easy to cause springback.

Springback refers to a phenomenon in which the original fabric 25 is bent and formed and returns to its flat shape before forming. Similarly to the above, this is also a phenomenon in which the original fabric 25 is formed after being hardened into a flat shape by a binder material. Due to this, it has a strong ability to return to its original shape.

■Variation occurs in insulation properties for vehicle photography.

Since various parts such as an air conditioner are installed around the dash panel where the insulator f1 is installed, it is necessary to avoid interference with these parts. Conventionally, this has been dealt with by changing the thickness of the pad material depending on the location.

However, if the baking 7-piece 24, which has been molded to a fairly uniform thickness, is molded with different thicknesses for each part, the thicker parts will have a lower degree of compression, while the thinner parts will have a higher degree of compression. For example, thinner parts become harder as the density increases, resulting in significantly lower vibration insulation.

The present invention aims to solve these problems.

(Means for Solving the Problems) In order to achieve the object described in (1), the present invention involves adding a thermoplastic or thermosetting resin binder material at a predetermined mixing ratio to a defibrated raw material such as coarse wool, and then These are put into a paper-making box with a molding surface formed on the bottom to form fleece-like bits, and then predetermined according to the part 7. The upper surface of the fleece-like mat was scraped off by -ffi, and then the mat was placed in a mold [1] and hot-formed.

(Function) In the present invention, the defibrated raw material mixed with the binder material is first put into a papermaking box, where a C fleece-like mat is formed. In this case, the fleece-like mat is deposited following the pattern formed on the bottom of the papermaking box. The top surface of the fleece-like mat is then scraped off to fit the intended shape of the pad.

As a result, the fleece-like mat takes on the intended shape of the pad in advance, and when it is then hot-formed, the fibers are connected to each other by the binder material and solidified into the predetermined shape.

(Example) Examples embodying the method of the present invention will be described in detail with reference to the drawings.

■Raw materials A recycled wool product 1 such as coarse wool is used in the same manner as in the past.

In this example, 50-60% coarse wool, 20-30% synthetic fibers,
It is a recycled product made of 10-20% palm fiber,
A lano with a length of 0 mm and a length of m was used.

■The steps from defibration and mixing to the papermaking process are the same as conventional ones. The same reference numerals are given to the same members as in the prior art, and the description thereof will be omitted.

■ Papermaking process The feed conveyor 5 in the mixing process is connected to the papermaking duct 9 in the papermaking machine F3, and the defibrated material and thermosetting resin raw material transported by this are installed at the most downstream part of this duct 9. The rotatable papermaking drum 7 rotates the paper and sends it back to the hand.

On the other hand, a paper box 10 having a frontage of 17 J is arranged at the lower end of the duct 9 and can be aligned with the duct. Further, this paper box 10 can be carried out and carried into the duct 9 using means such as rails. Further, the papermaking box 10 has a breathable bottom and a suction duct 1 connected to a suction device it (not shown) at the loading position.
The upper end of 1 can be matched. Furthermore, inside the papermaking duct 9, there are a plurality of flow regulating roots 1 at two positions, upper and lower.
2a and 12b are provided, and these allow the raw material flowing along the suction wind flowing in the duct 9 to be rectified and fall onto almost the entire bottom surface of the papermaking box 10. The bottom surface of the papermaking box 10 is formed in advance to almost match the shape of the padding material, and after a predetermined time has elapsed, the fleece-like pine i-M is accumulated.In this example, this pine)-M The basis weight is 1 to 2 kg/butt, and the density is 0.005 to 0.0100/cm3.

(2) Scraping process When the paper-forming T-culm is completed, the paper-forming box 10 is separated from the duct 11 and transferred to the main process. Here, the raw material is scraped off by moving the scraping roller 13 over the top surface of the mat M. In this case, the scraping roller 13 is moved up and down depending on the part of the mat M. J, the amount is controlled. As a result, the basis weight of the fleece-like mat M can be freely set according to the hanging area.

■Brief forming process When the scraping process is completed, the scraping roller 13 is retracted to the outside of the papermaking box 10, and replaced by the upper die 1 for forming the brim.
4 enters. The reason for preforming before the hot molding process is that the fibers of the fleece mat M have not yet been bound to each other by resin, so if hot molding is performed without temporary tightening, it will cause problems, especially when closing the mold. This is because steep surfaces (standing wall surfaces) may be scraped off.

The molding surface of the upper mold 14 for yellow molding has a number of suction passages 15, each of which is connected to a suction device (not shown), with a gap between the ends. 1
Adhesion to the molding surface of the ~-shaped mat M on the upper die 14 side is ensured.

①Hot forming process The mat M taken out after completion of the bridle forming is set behind the pair of upper and lower forming molds 16a, 16b, on the lower mold 16b side, and is hot pressed here. The molding conditions in this case (type, pressure, pressing time, etc.) were the same as those of the conventional method, and the desired pad material could be taken out after a predetermined period of time had elapsed.

Now, in the hot forming process, hot forming is performed from the fleece-like mat M, and the fibers are not fixed to each other by the binder material, so the followability when closing the mold is poor. In good condition. Therefore, for example, if the occurrence of underfilling in the deep drawing part is prevented, a product with a tight shape can be obtained.

Furthermore, since the molding is performed without the shape being fixed by a binder material, springback does not occur after molding is completed, unlike in the past.

In addition, in the scraping process performed prior to this process, the basis weight m is controlled according to the planned finishing density, so parts that are thinly molded (parts where interference with other parts is planned to be avoided) are controlled. ), excessive hardening can be avoided by increasing the density. This maintains good vibration absorption properties of the finished pad product.

(Effect of the invention) The effects of the present invention are as follows.

■Because it is hot-formed while remaining as a fleece-like mat,
It has excellent followability during molding, avoids underfilling, and can produce products with sharp shapes.

■Also, for the same reason, the shape when molded is maintained due to springback.

■Prior to hot-press molding, the basis weight is controlled depending on the area, so it is possible to avoid excessive hardening locally. Therefore, when installed as an insulator, good insulation against vehicle vibrations is ensured.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing a manufacturing process according to the present invention, and FIG. 2 is an explanatory diagram showing a conventional manufacturing process. 1... Recycled wool product 10... Paper making box 13... Scraping rollers 16a, b... Molding mold applicant Ne1 Co., Ltd. Takuhiro

Claims (1)

[Claims] After adding a thermoplastic or thermosetting resin binder material at a predetermined mixing ratio to defibrated raw materials such as coarse wool, these are put into a paper-making box with a molding surface formed on the bottom to form a fleece-like mat. A method for manufacturing a pad material for a vehicle insulator, characterized in that the upper surface of the fleece-like mat is scraped off by a predetermined amount depending on the region, and then the mat is placed in a mold and hot-formed.