JPH04223148A - Deep drawable light soundproof material - Google Patents

Abstract

PURPOSE:To provide light soundproof material, while sufficient soundproof effect is kept. CONSTITUTION:A resin cotton 3 impregnated with thermosetting resin such as phenol resin and the object formed integrally with a skin layer 4 are provided on both surfaces of a honeycomb plate 1 through a sound-absorbing layer 2, and such a structure can be used as soundproof material by pressing.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight soundproofing material, and more particularly to a lightweight soundproofing material that reduces the weight of the soundproofing material itself, can follow severe unevenness, and has excellent deep drawability.

0002

2. Description of the Related Art Conventionally, for example, molded ceiling materials have been used as ceiling materials for automobiles, in which felt is press-molded either alone or integrally with a non-woven skin material. Also, recently, a molded ceiling material has been manufactured by sandwiching the honeycomb board 1 between felts 6 and integrating the honeycomb board 1 with a nonwoven fabric skin material 7 and molding the honeycomb board under heat and pressure.

However, although molded ceiling materials made of felt alone have excellent deep drawability, satisfactory performance in both sound absorption and rigidity has not been achieved. Furthermore, a molded ceiling material in which the honeycomb board 1 is sandwiched between felts 6 and integrated with the nonwoven skin material 7 has excellent sound absorption and rigidity, but has the disadvantage that the weight of the soundproofing material itself increases.

0004

[Problems to be Solved by the Invention] An object of the present invention is to reduce the weight of a soundproofing material while also achieving excellent soundabsorption and rigidity, in order to further reduce the weight of automobiles. The point is that it achieves deep drawing formability.

[0005]

[Means for Solving the Problem] In order to solve the problem, the present inventors have conducted extensive research and have replaced the felt 6 that holds the honeycomb board 1 in place with resin cotton 3 and a skin layer 4. However, the gist of the present invention resides in the following items.

[0006] A deep-drawn lightweight sound insulating material comprising a honeycomb board 1, which is integrated with resin cotton 3 impregnated with a thermosetting resin on both sides of a honeycomb board 1 via a sound absorbing layer 2, and a skin layer 4.

[0007] A deep-drawn lightweight soundproofing material characterized in that it is made by integrating resin cotton 3 and skin layer 4, impregnating them in a thermosetting resin, and drying them before use.

[0008] A deep-drawn lightweight soundproofing material characterized in that the skin layer 4 is made of paper, glass mat, or glass paper.

[0009] A deep-drawn lightweight soundproofing material characterized in that an adhesive 5 is applied in advance to at least one side of a honeycomb board 1.

The resin cotton 3, which is an essential component of the present invention, is made by lightly compression molding resin fibers, and examples thereof include polyester fibers, polyamide fibers, polyvinyl alcohol fibers, and polyvinyl chloride fibers.

As the skin layer 4, it is essential that the weight can be reduced compared to when the felt 6 is used, and it is preferable to use a material that also has shape retention and surface reinforcement functions, such as glass paper, glass mat, paper, etc. I can give an example.

It is essential that the resin cotton 3 and the skin layer 4 be impregnated with a thermosetting resin in advance. The thermosetting resin is a phenol resin, a polyester resin, a urethane resin, a melamine resin, a paraffin resin, etc., and the preferred impregnation method is dipping or coating. The amount of thermosetting resin impregnated in the resin cotton 3 needs to be sufficient to ensure adhesion with the honeycomb plate 1, and is preferably about 1 to 100% of the weight of the resin cotton. The amount of impregnation may be selected depending on whether adhesive is applied or not.

The honeycomb board 1 is preferably made of a paper material such as kraft paper, K-liner paper, or cardboard, or a plastic material having a honeycomb structure from the viewpoint of moldability.

The sound absorbing layer 2 interposed between the resin cotton 3 and the honeycomb plate 1 is made of a foam material such as polystyrene, polypropylene, polyurethane, etc., which is about half the thickness of conventionally used felt.

The areal density of each constituent material is 30 to 150 g/m2 for the skin layer 4, 30 to 100 g/m2 for the resin cotton 3, and 5 to 100 g/m2 for the sound absorbing layer 2 when impregnated with thermosetting resin.
The weight of the conventionally used felt 6 is about 350 to 1000 g/m2.

[0016] The honeycomb plate 1 and the sound absorbing layer 2 may be bonded by simply heating and press-forming without applying any adhesive, but it is preferable to use hot melt or spreadable adhesive 5 on the cells of the honeycomb plate 1 in advance. is preferred in terms of making the adhesion stronger.

As a method of integrally molding each of the constituent materials, for example, when the resin cotton 3 and the skin layer 4 are integrally provided on both sides of the honeycomb plate 1 with the sound absorbing layer 2 interposed therebetween, 140~ 30 seconds to 2 minutes at 250℃, 1 to 200 kg
/cm2 is preferable.

[0018]

EXAMPLES Examples will be given below to provide a more detailed understanding of the present invention. Naturally, the present invention is not limited to the following examples.

[0019]

[Example 1] Resin cotton made of polyester fibers and a skin layer made of glass paper were integrated, impregnated in phenol resin, and dried to form an integrated product. The above-mentioned integrated product was provided on both sides of a cardboard honeycomb board through a 230 g/m2 urethane foam material, and
Pressure molding was carried out for 5 seconds under the conditions of 5 kg/cm 2 and the sound insulating material 1 was obtained.

[0020]

[Example 2] Resin cotton made of polyvinyl chloride fibers and a skin layer made of glass mat were integrated, impregnated in melamine resin, and dried to form an integrated product. The above integrated product was applied to both sides of a plastic honeycomb plate through a 250 g/m2 bulky nonwoven fabric at 200°C for 45 seconds for 5k.
The soundproofing material 2 was obtained by pressure molding under the conditions of g/cm2 and integrating them.

[0021]

[Comparative Example] Bulky felt was pressure-molded on both sides of a cardboard honeycomb board at 200° C. for 45 seconds at a pressure of 5 kg/cm 2 and integrated to obtain soundproofing material 3.

[0022]

[Test Method] The weight per 1 m2 of Sound Insulating Materials 1 to 3 was measured, and the sound absorption coefficient was measured by the reverberation chamber method.

[0023]

[Results] The weight of the soundproof material 1 was 900 g/m2, and the sound absorption coefficient was 0.5 (250 Hz). The weight of the soundproofing material 2 is 915g/m2, and the sound absorption coefficient is 0.
．． 5 (250Hz). The weight of the soundproofing material 3 is 1200g/m2, and the sound absorption coefficient is:
It was 0.5 (250Hz).

[0024]

[Effects of the Invention] The soundproofing material of the present invention is lightweight while maintaining a satisfactory soundproofing effect.

[0025]

[Brief explanation of the drawing]

FIG. 1 is a sectional view of a soundproofing material according to the present invention.

FIG. 2 is a cross-sectional view of a conventional soundproofing material.

[Explanation of symbols]

1 Honeycomb board 2 Sound absorption layer 3 Resin cotton 4 Epidermal layer 5 Adhesive 6 Felt 7 Non-woven skin material

Claims (1)

[Scope of Claims] [Claim 1] A lightweight, deep-drawn material characterized by being made of resin cotton impregnated with a thermosetting resin on both sides of a honeycomb board through sound absorbing layers, and integrated with a skin layer. Soundproofing material. [
2. The deep drawable lightweight sound insulating material according to claim 1, which is used after integrating the resin cotton and the skin layer, impregnating it in a thermosetting resin, and drying it. 3. The deep-drawn lightweight soundproofing material according to claim 1, wherein the skin layer is made of paper, glass mat, or glass paper. 4. The deep-drawn lightweight soundproofing material according to claim 1, wherein an adhesive is applied in advance to at least one side of the honeycomb plate.