JPH04288225A - Deep drawable lightweight soundproofing material - Google Patents

Abstract

PURPOSE:To provide a soundproofing material which can be made lightweight while sufficient soundproofing effect is kept. CONSTITUTION:A resin bulk fiber made of a polyester fiber and a skin layer made of a glass paper are integrated and after they are impregnated with a phenol resin, they are dried to make an integrated product. A bulky non- woven fabric and a non-woven fabric skin layer are provided on one face of a honeycomb plate 1 made of a paper board and the integrated product consisting of the resin bulk fiber 2 and the skin layer 3 is provided on another face and they are press-molded and integrated to obtain a soundproofing material.

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 4, integrating the honeycomb board 1 with a nonwoven fabric skin material 6, 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. Further, a molded ceiling material in which the honeycomb board 1 is sandwiched between felts 4 and integrated with the nonwoven skin material 6 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 Problems] In order to solve the above problems, the inventors of the present invention have conducted intensive research and found that one side of the felt 4 on which the honeycomb board 1 is interposed is replaced with a resin cotton 2 and a skin layer 3. However, the gist of the present invention resides in the following items.

[0006] One surface of the honeycomb board 1 is integrated with felt 4 and a nonwoven skin material 6, and the other surface is integrated with resin cotton 2 impregnated with a thermosetting resin and a skin layer 3. A lightweight soundproofing material that can be deep drawn.

[0007] A lightweight, deep-drawn soundproofing material characterized in that it is made by integrating resin cotton 2 and skin layer 3, impregnating them in a thermosetting resin, drying them, and then using them.

[0008] A deep-drawn lightweight soundproofing material characterized in that the skin layer 3 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 2, 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.

[0011] As the skin layer 3, it is essential that the weight can be reduced compared to when felt is used, and that it has shape retention,
It is preferable to use a material that also has a surface reinforcing function, such as glass paper, glass mat, paper, etc.

It is essential that the resin cotton 2 and the skin layer 3 be impregnated with a thermosetting resin in advance. The thermosetting resin is a phenol resin, a polyether 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 into the resin cotton 2 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 felt 4 integrated on one side of the honeycomb plate 1 is mainly made of one or more discontinuous fiber materials of animal origin, vegetable origin, or synthetic resin and a binder such as thermosetting resin. It is what it is.

As the nonwoven skin material 7, it is preferable to use a thin nonwoven fabric made of the same material as the felt 4.

It is preferable to interpose a sound absorbing layer between the resin cotton 2 and the honeycomb plate 1 from the viewpoint of improving the sound absorbing performance, and it is preferable to interpose a sound absorbing layer between the resin cotton 2 and the honeycomb plate 1, and a sound absorbing layer having a thickness about half that of the conventionally used felt 4, polystyrene, polypropylene, Use foam material such as polyurethane.

The areal density of each constituent material is 30 to 150 g/m2 for the skin layer 3 and 30 to 100 g/m2 for the resin cotton 2 when impregnated with thermosetting resin. 4 is about 350 to 1000 g/m2.

Honeycomb board 1 and resin cotton 2 or felt 4
Adhesion to the honeycomb plate 1 may be achieved by simply heating and pressurizing the honeycomb plate 1 without applying any adhesive, but using hot melt or spreadable adhesive 5 on the cells of the honeycomb plate 1 in advance makes the adhesion stronger. It is preferable.

As a method for integrally molding each of the constituent materials, for example, an integrated product of the felt 4 and the nonwoven fabric skin material 7 is provided on one surface of the honeycomb plate 1, and the resin cotton 2 and the skin layer 3 are formed on the other surface. When the honeycomb plate 1 is placed between the
Conditions of 1 to 200 kg/cm2 for 2 minutes are preferable.

[0020]

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.

[0021]

[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 obtain integrated product A. After providing an integrated product of 500 g/m2 of bulky nonwoven fabric and 50 g/m2 of nonwoven skin material on one side of a cardboard honeycomb board, and providing integrated product A of resin cotton and skin layer on the other side,
Pressure molding was carried out at 200° C. for 45 seconds at a pressure of 5 kg/cm 2 to form a single piece, thereby obtaining soundproofing material 1.

[0022]

[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 obtain integrated product B. An integrated product of 500 g/m2 of bulky nonwoven fabric and 50 g/m2 of nonwoven skin material was provided on one side of a plastic honeycomb board, and an integrated product B of resin cotton and skin layer was provided on the other side, and then They were pressure-molded at 5 kg/cm2 for 45 seconds at 0.degree. C. and integrated to obtain soundproofing material 2.

[0023]

[Comparative Example] Bulky felt was pressure-molded on both sides of a cardboard honeycomb board at 200° C. for 1 minute at a pressure of 5 kg/cm 2 and integrated to obtain soundproofing material 3.

[0024]

[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.

[0025]

[Results] The weight of the soundproof material 1 was 1050 g/m2, and the sound absorption coefficient was 0.5 (250 Hz). The weight of the soundproofing material 2 is 1055g/m2, and the sound absorption coefficient is 0.5 (
250Hz). The weight of soundproofing material 3 is 1200g
/m2, and the sound absorption coefficient was 0.5 (250Hz).

[0026]

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

[0027]

[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 Resin cotton 3 Epidermal layer 4 Felt 5 Adhesive 6　Nonwoven fabric skin material

Claims (4)

[Claims] Claim 1: A deep honeycomb board characterized by having one surface of a honeycomb board integrated with a felt or non-woven skin material, and the other surface being integrated with a skin layer of resin cotton impregnated with a thermosetting resin. Lightweight soundproofing material that can be squeezed. 2. The deep drawable lightweight soundproofing material according to claim 1, wherein the resin cotton and the skin layer are integrated, then impregnated into a thermosetting resin and dried before use. . 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.