JPH06903A - Deep drawable lightweight soundproofing material - Google Patents

Abstract

PURPOSE:To provide soundproofing material, with which lightening can be done while satisfactory soundproofing effect is maintained. CONSTITUTION:Resin cotton 4 made of polyester-based film and glass paper surfacing layer 5 are made into an integral body and, after that, impregnated with phenolic resin and dried so as to produce an integral matter. After bulky non-woven fabric or non-woven fabric surfacing material 7 is provided on one side of corrugated board paper honeycomb panel 1, on the other side of which the integral matter is provided through urethane foam material, the resultant assembly is formed under pressure so as to integrate it in order to obtain 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 which is excellent in deep drawability and which can reduce the weight of the soundproofing material itself and can follow severe irregularities.

[0002]

2. Description of the Related Art Conventionally, as a ceiling material for automobiles, for example, a molded ceiling material has been used in which a felt is singly or integrally molded with a non-woven fabric skin material and pressure-molded. In addition, recently, a molded ceiling material has been manufactured in which the honeycomb plate 1 is placed with the felt 2 and is integrated with the non-woven fabric skin material 7 to be heated and pressed.

However, although the molded ceiling material made of only felt is excellent in deep-drawing formability, satisfactory performance in sound absorption and rigidity cannot be obtained. Further, the molded ceiling material in which the honeycomb plate 1 is sandwiched by the felt 2 and integrated with the non-woven fabric skin material 7 has the drawback that the weight of the soundproof material itself is increased although it has excellent sound absorption and rigidity.

[0004]

The object of the present invention is to reduce the weight of the soundproofing material in order to further reduce the weight of the vehicle, and at the same time, the soundproofing material is excellent in sound absorbing property and rigidity. The point is to achieve deep drawability.

[0005]

In order to solve the above problems, the inventors of the present invention have conducted intensive studies and found that one side of the felt 2 on which the honeycomb plate 1 is placed is replaced with a resin cotton 4 and a skin layer 5. Therefore, the gist of the present invention lies in the following items.

One side of the honeycomb plate 1 is integrated with the felt 2 and the non-woven skin material 7, and the other side is integrated with the resin cotton 4 and the skin layer 5 impregnated with the thermosetting resin through the sound absorbing layer 3. A lightweight soundproof material that can be deep-drawn because it is made into a material.

A lightweight soundproof material capable of deep drawing, characterized in that it is used after the resin cotton 4 and the skin layer 5 are integrated, impregnated in a thermosetting resin and dried.

A lightweight soundproof material capable of deep drawing, characterized in that paper, glass mat, and glass paper are used as the skin layer 5.

A light-weight soundproofing material capable of deep drawing, characterized in that at least one surface of the honeycomb plate 1 is coated with an adhesive in advance.

The resin cotton 4, which is an essential constituent of the present invention, is a resin fiber lightly compression-molded, and examples thereof include polyester fibers, polyamide fibers, polyvinyl alcohol fibers, and polyvinyl chloride fibers.

As the skin layer 5, it is indispensable that the weight can be reduced as compared with the case where the felt is used.
It is preferable that it also has a surface reinforcing function, and examples thereof include glass paper, glass mat, and paper.

It is essential that the resin cotton 4 and the skin layer 5 are 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 or the like, and the impregnation method is preferably dipping or coating. The thermosetting resin impregnation amount of the resin cotton needs to be an amount that ensures the adhesion with the honeycomb plate 1, and is preferably about 1 to 100% of the weight of the resin cotton, and the adhesion of the honeycomb plate 1 to the cells. The amount of impregnation may be selected depending on whether or not the agent is applied.

The honeycomb plate 1 is preferably made of a paper material such as kraft paper, K-liner paper, cardboard or the like or a plastic material having a honeycomb structure in terms of formability.

The felt 2 integrated with one surface of the honeycomb plate 1 is mainly composed of one or more discontinuous fiber materials of animal, vegetable and synthetic resin and a binder such as thermosetting resin. It will be.

As the non-woven fabric skin material 7, it is preferable to use a thin leaf-like non-woven fabric made of the same material as the felt 4.

The sound absorbing layer 3 placed between the resin cotton 4 and the honeycomb plate 1 is made of a material having a thickness of about half that of a conventionally used felt or a foam material such as polystyrene, polypropylene or polyurethane.

The surface density of each constituent material is 30 to 150 g / m ² for the skin layer 5 in the impregnated state of the thermosetting resin, and the resin cotton 4
Is 30 to 100 g / m ² , and the sound absorbing layer 3 is 50 to
500 g / m ^2, felt 2 that has been conventionally used is about 350~1000g / m ^2.

Honeycomb plate 1 and sound absorbing layer 3 or felt 2
Bonding with the adhesive may be performed only by heating and pressurizing without applying an adhesive, but using hot melt or the application adhesive 6 in advance in the cells of the honeycomb plate 1 makes the adhesion stronger. Is preferred.

As a method of integrally molding each of the constituent materials, for example, an integrated product of the felt 2 and the non-woven fabric skin material 7 is provided on one surface of the honeycomb plate 1, and the resin cotton 4 and the skin layer 5 on the other surface. In the case where the honeycomb plate 1 is placed with the sound absorbing layer 3 being integrated with the
Conditions of 1 to 200 kg / cm ² at 50 ° C. for 30 seconds to 2 minutes are preferable.

[0020]

EXAMPLES The following examples are provided for a more detailed understanding of the present invention. Naturally, the invention is not limited to the following examples.

[0021]

Example 1 A resin cotton made of polyester fiber and a skin layer made of glass paper were integrated, impregnated in a phenol resin, and then dried to obtain an integrated product A. On one side of the cardboard of the honeycomb plate, the integrated product of the bulky nonwoven fabric and 50 g / m ² nonwoven surface material of 500 g / m ^2, the other surface through a urethane foam material 250 g / m ² above The integrated product A was pressure-molded at 200 ° C. for 45 seconds under the condition of 5 kg / cm ² and integrated to obtain a soundproofing material 1.

[0022]

Example 2 A resin cotton made of polyvinyl chloride fiber and a skin layer made of glass paper were integrated, impregnated in a phenol resin and then dried to obtain an integrated product B. On one side of the cardboard of the honeycomb plate, the integrated product of the bulky nonwoven fabric and 50 g / m ² nonwoven surface material of 500 g / m ^2, the other surface through a urethane foam material 250 g / m ² above The integrated product B was pressure-molded at 200 ° C. for 45 seconds under the condition of 5 kg / cm ² and integrated to obtain a soundproofing material 2.

[0023]

Comparative Example A soundproof material 3 was obtained by press-molding bulky felt on both sides of a cardboard honeycomb plate at 200 ° C. for 45 seconds under the condition of 5 kg / cm ² and integrating them.

[0024]

[Test method] The weight per 1 m ^{2 of the} soundproof material 1 to the soundproof material 3 was measured, and the sound absorption coefficient was measured by the reverberation chamber method.

[0025]

Results: The weight of the soundproofing material 1 was 1080 g / m ² , and the sound absorption coefficient was 0.5 (250 Hz). The weight of the soundproof material 2 is 1085 g / m ² , and the sound absorption coefficient is 0.5 (250H
z). The weight of the soundproofing material 3 is 1200 g / m ²
The sound absorption coefficient was 0.5 (250 Hz).

[0026]

EFFECTS OF THE INVENTION The soundproof material according to the present invention can achieve a light weight while maintaining a satisfactory soundproof effect.

[0027]

[Brief description of drawings]

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

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

[Explanation of symbols]

 1 Honeycomb Plate 2 Felt 3 Sound Absorption Layer 4 Resin Cotton 5 Skin Layer 6 Adhesive 7 Nonwoven Fabric Skin Material

Claims (4)

[Claims] 1. One side of a honeycomb plate is integrated with felt and a non-woven fabric skin material, and the other side is integrated with resin cotton and skin layer impregnated with a thermosetting resin through a sound absorbing layer. A lightweight soundproof material that allows deep drawing. 2. The light-weight soundproofing material capable of deep drawing according to claim 1, wherein the resin cotton and the skin layer are integrated and then impregnated in a thermosetting resin and dried. . 3. The deep-soundable lightweight soundproof material according to claim 1, wherein paper, glass mat, or glass paper is used as the skin layer. 4. The lightweight soundproofing material capable of deep drawing according to claim 1, wherein an adhesive is applied in advance to at least one surface of the honeycomb plate.