JPS588649A - Manufacture of molding sound insulating material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a molded soundproofing material. More specifically, the present invention relates to a manufacturing method that can easily form a molded soundproofing material having a complicated deep-drawn shape in one step by simultaneously performing heating compression and vacuum suction.

A sheet-like material made of a thermoplastic resin and/or rubber component and a filler (hereinafter referred to as a "sound insulation sheet"), and a bulky nonwoven fabric containing a thermosetting synthetic resin (hereinafter referred to as a "bulky nonwoven fabric")
A device is used for sound insulation by pasting a bulky non-woven fabric on a vehicle panel or the like.

A soundproofing material made of a combination of a soundproofing sheet and a bulky nonwoven fabric is mounted as a molded body having a tongue-and-groove shape by compression molding in a caloric state. However, in compression molding using a simple force O heat mold, the rigidity of the sound insulating sheet is strong, and the bulky nonwoven fabric serves as a cushion, and the distance between the lower surface of the recess and the top of the convex part, that is, the overhang distance of the convex part, is reduced by 10%. It was possible to mold only the shape of . Therefore, in the case of a molded soundproofing material in which the height of the overhanging part of the convex part is 10% or more, the sound insulation sort and the bulky nonwoven fabric must be molded individually and then bonded together, which is a very complicated process, and there is no improvement. desired.

Conventionally, it has been known to use vacuum forming to compression mold sound insulating sheet-like materials, bulky nonwoven fabrics, thermoplastic tree fertilizer films, and the like.

For example, according to Japanese Patent Publication No. 4B-38'783, the first step is to heat press a breathable felt-like sheet impregnated with a synthetic resin, and after curing, it is molded into a vacuum suctionable male mold of the same type as the heat press. A 72nd step of moving and fitting, a 3rd step of laminating a 0.3% thermoplastic synthetic resin sheet fully lined with cushioning material on the outer surface, and a 4th step of vacuum forming and bonding. A new manufacturing method has been proposed.

However, in this proposal, the breathability of the felt-like sheet was utilized and the outer surface was lined with a cushioning material.
The only recommended method is to form a thermoplastic sheet as thin as 3%, and it is possible to mold a laminate of 2 to 5% stiff and thick sound-insulating notebook and bulky nonwoven fabric into any shape and height. No mention is made at all of a method of forming a molded body having an overhanging portion on the sound-insulating sort side, and this cannot be achieved by using the proposed method. Furthermore, the process is complicated and cannot be put to practical use.

According to Japanese Patent Application Laid-Open No. 53-136061, the first step is to vacuum-form a sound-insulating sheet-like material using a vacuum forming mold, and then add a bulky material onto the vacuum-formed sound-insulating sheet-like material. A manufacturing method has been proposed that includes a second step of laminating a nonwoven fabric, a thermoplastic tree manure film, and a thermoplastic resin film lined with the nonwoven fabric in all 111 layers, and then a fifth step of η0 thermopressure molding. In this proposal, since the thermoplastic tree fertilizer sheet such as PVO with a thickness of 15 to 3% is vacuum-formed into an uneven shape by a conventionally known normal vacuum forming method, it is possible to form a complex uneven shape. Although this is a step forward in that it can be molded using the same mold without changing the mold, it is possible to form a laminate of 2 to 5% stiff and thick sound insulating sheet and bulky nonwoven fabric into any shape and shape. There is no mention of a method for easily molding a molded body with a tall overhang in one step, and it has the same drawbacks as conventional manufacturing methods in terms of process complexity. ing.

The inventor of the present invention has taken into account such circumstances and has conducted extensive research to find out whether the failures a, s
Therefore, the object of the present invention is to form a laminate of a thick and rigid sound insulating sheet and a bulky nonwoven fabric into a molded body having an overhang of an arbitrary height. The object of the present invention is to provide a manufacturing method that allows easy molding.

In other words, the gist of the present invention is to sequentially apply a sheet-like material made of a thermoplastic resin and/or rubber component and a filler, and a bulky nonwoven fabric containing a thermosetting synthetic resin to a lower mold having vacuum degassing holes. Method 1 for producing a molded soundproofing material, in which lamination is performed, followed by vacuum suction through the vacuum degassing hole and molding under heat and pressure at the same time.

The sound insulating sort constituting the molded sound insulating material of the present invention can be made of any rubber selected from natural rubber, synthetic rubber, keratinized rubber, etc. and/or thermoplastic synthetic material such as vinyl chloride resin, bituminous material, etc. Fillers freely selected from conventionally known fillers such as calcium carbonate, asbestos, talc, and magnesium carbonate are mixed in, and after kneading, a flat or patterned sheet is formed using a calendar roll or embossing roll. There is no problem in adding other conventionally known additives such as anti-aging agents.If the 7th layer is desired to have decorative properties, the surface may be embossed or painted. The thickness of these sheet layers (l−jL
Approximately 5 to 5% is preferable.

Bulky nonwoven fabric that can be used in the present invention (1) mainly consisting of a binder consisting of one or more animal, vegetable, mineral, or synthetic resin discontinuous fiber materials and a thermosetting synthetic resin; It can be obtained by a known manufacturing method of bulky nonwoven fabric, but before heating and molding, the amount of binder made of thermosetting resin is 5 to 40% based on the total weight of bulky nonwoven fabric.
% is in an uncured state, and it is important to make it possible to handle it as a bulky nonwoven fabric by other means such as melting the thermosetting synthetic resin or using a thermoplastic resin in combination.

If the amount of uncured thermosetting resin is less than 5% of the total weight of the bulky nonwoven fabric, the mold retention property and strength of the molded article will be poor;
% or more, the resin is not mixed uniformly in the nonwoven fabric, resulting in variations in strength and excessive rigidity, which is undesirable. The proportion of synthetic fibers in the mixed discontinuous fiber material depends on the location where the soundproofing material is used, for example, when it is used in an engine room, or when it is used close to the road surface, where it is exposed to rainwater and sand.

The bulky nonwoven fabric in this state generally has a thickness of 8 to 50% and an areal density in the range of 400 to 4000 no/-.

The present inventor has disclosed a method for obtaining a molded soundproofing material by laminating a bulky nonwoven fabric containing an uncured thermosetting resin, which is covered with a sheet-like material made of a thermoplastic resin and/or a rubber component and a filler, and then molding under heat and pressure. are the application agents first, but in the present invention, 1 is applied by simultaneously performing vacuum suction and heating power p pressure.
This method has been improved so that only two molds are used and the shape of the projecting portion of the convex portion can be formed higher and sharper in one step.

The lower mold used in the production of the present invention must be capable of heating at least to a temperature that can thermally soften the sound insulating sheet, and must have vacuum degassing holes. In the present invention, vacuum suction is performed auxiliary at the same time during heating and pressure molding, and it is necessary to provide one vacuum degassing hole on the entire surface (without d, the protrusion of the convex part extends from the lower surface of the concave part to the top of the convex part). If the distance already at the top is 8 to 60%, the four lower surfaces of the lower mold corresponding to the convex part, especially one part of the corner (corresponding to the top of the convex part of the molded product) K, with an appropriate gap of 05 to 27 W It is sufficient if a vacuum degassing hole of about .

The upper mold of the invention is a 11F pressure mold having a shape corresponding to the desired shape of the molded product, which can be heated to a temperature of about 150 to 250°C, and has a pressure of about 1 to 1ooF (re/
It belongs to crl.

In addition, a clamp device having a T-shaped cross section and having a certain amount of weight is attached so as to be able to freely slide up and down. When the upper mold is raised, the clamp device is suspended from the protrusion of the KTT mold part of the upper mold, and as the upper mold gradually descends, the mold part is placed on the surface of the lower mold. When the laminate of the bulky nonwoven fabric and the sound insulating sheet is lightly pressed, the clamp presses the outside of the outer periphery of the desired shape with its own weight.4 In this state, the vacuum suction becomes an air-cut state and the protruding part of the convex part is in an air cut state. Pulled to the vacuum degassing hole. Next, the molded soundproofing material of the present invention is obtained by being strongly pressed by the mold surface of the heated upper mold that continues to descend without stopping. Since the upper mold and the clamp device exist in a slidable state, even if the upper mold is completely lowered and reaches the zero press state, the clamp device portion will not be subjected to a load greater than its own weight.

Conventionally, when vacuum forming thermoplastic sheets, the outer periphery of the material is completely crimped to form a vacuum chamber, so the material is stretched by vacuum suction, making it difficult to create a uniform thickness surface. By using a 1F mold equipped with a slideable lamp device as in the present invention, a vacuum chamber can be formed, and the material can be moved and molded with a sound insulating sheet of uniform thickness so that it is not dragged into the mold by the unevenness. It also has an 11th point from which soundproofing material can be obtained.

According to the present invention, there is nothing wrong with laminating a skin material and/or a waterproofing material layer on the bulky nonwoven fabric 11ri on which the slender sheet is not laminated and simultaneously molding them in one piece.

The method for manufacturing the molded soundproofing material of the present invention will be explained in more detail.

A sound insulating sheet and a bulky nonwoven fabric are placed in this order on a lower mold that has a vacuum degassing hole in a part of the lower corner of the mold recess that corresponds to the shape of the convex part of the molded article, and if necessary, a skin material and/or After laminating the waterproof material layer, turn on the operation switch of the vacuum pump. In this state, a vacuum chamber is not formed and the sound insulation sheet is not vacuum suctioned.) Lower the upper mold with the slideable lamp device attached as described above. . When the mold surface of the upper mold lightly presses the laminate into the recess of the lower mold, a vacuum chamber is formed by the clamping device and the sound insulation sheet is pulled toward the vacuum degassing hole, at the same time the upper mold continues to descend without stopping. It is strongly pressed by the molding surface of the mold and easily formed into the desired uneven shape.
It can be molded during the process.

At this time, it goes without saying that the lower mold should be heated to such an extent that the sound insulation sheet can be thermally softened, and the upper mold should be heated to a temperature higher than the reaction temperature of the thermosetting tree fertilizer contained in the bulky nonwoven fabric. That's true.

Also, it is recommended that the vacuum pump switch be linked to the vertical movement of the upper mold.

The present invention can be used without going through the complicated process of vacuum forming a sound insulation sheet If-bearing material, laminating other laminates, and applying heat and pressure forming as in the conventional method. Naturally, the present invention is not limited to the following examples.

Example: 40 parts by weight of recycled tire rubber, 60 parts by weight of blown asphalt (Mexphalt 95/15 manufactured by Shell Oil Co., Ltd.), 150 parts by weight of calcium carbonate, 50 parts by weight of asbestos After kneading with a mixing roll, the mixture was kneaded with a calender roll to a thickness of 2. I got a sound insulation sheet for ¥n.

30 parts by weight of recycled hair and 50 parts by weight of fallen M were mixed fully opened, melting point 1
Phenolic resin powder 25 with a reaction temperature of 170″C at 40°C
Parts by weight were mixed by scattering, formed into a fleece in a fleece forming machine, and then heated at 150°C [through a heat oven to a thickness of 2'/F areal density 100 containing approximately 11% of uncured 7 enol resin.
A bulky nonwoven fabric of 0y-/ze was obtained.

This is a lower mold made to correspond to the shape of the dash outer (dash surface on the engine room side) of the automatic car.
The height from the bottom of the recess to the top of the molded body is approximately 25fi.
A vacuum degassing hole with a gap of about 1.571151 mm and a diameter of about 1 mm was provided at a part of the bottom corner of the concave part of the mold corresponding to the protruding part of the convex part whose plan view shape was 40 mm x 9071 Lm. The sound insulating sheet and bulky nonwoven fabric obtained above were sequentially laminated on the lower mold. Next, the upper mold, which had a T-shaped cross section around the four peripheries of the mold and had a continuous clamping device that was suspended from a bulge at the top and that was slidable up and down, was lowered. At the stage when the upper mold began to descend, the vacuum pump was activated by the limit switch, but at that point the sound insulation sheet was not sucked. As it descends further, when the upper mold pushes the laminate to a certain extent into the recess of the lower mold, the clamping device presses all four peripheries of the laminate due to its own weight and cuts the air, causing the S-sound sheet to be pulled toward the vacuum vent and almost At the same time (after approximately 0.5 seconds), the molded material was heated and strongly pressurized by the upper mold, which continued to descend without stopping, and the molded soundproofing material of the present invention was obtained.

The molded soundproofing material obtained had sharp convex shapes and was of excellent quality.

Patent applicant: Japan Special Paint Co., Ltd.

Claims (1)

[Claims] A sheet-like material made of a thermoplastic resin and/or rubber component and a filler, and a bulky nonwoven fabric containing a thermosetting synthetic resin are laminated on a lower mold having vacuum degassing holes,
Next, a method for manufacturing a molded soundproofing material, characterized in that heating and pressure molding is performed simultaneously while vacuum suction is applied through the vacuum degassing hole.