JPS60115991A - Molded soundproof 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] Regarding the molded soundproofing material obtained by molding the bulky nonwoven fabric obtained by mixing into an arbitrary uneven shape under heating conditions, the molded soundproofing material has water resistance, heat resistance, impact resistance, The present invention relates to a molded soundproofing material that has excellent strength, excellent shape retention of molded products after heat history, and improved deep drawability.

For example, on the back of the hood of a car, animal-based, vegetable-based,
One or two types of mineral and synthetic resin discontinuous fibers
A molded article of a bulky nonwoven fabric mainly composed of a thermosetting synthetic resin powder and a thermosetting synthetic resin powder is attached as a sound absorbing material. These molded sound absorbing materials were previously proposed by the present inventor, and have a flat high-density portion with a thickness of approximately 2 to 5% and a thickness of approximately 3 to 1%.
It consists of an arbitrarily shaped protruding part that has an air flow resistance value in a specific range at 0%, and the flat high-density part gives rigidity and strength to the molded sound absorption board, and also acts as a base when attached to the back of the bonnet. The arbitrarily shaped overhang forms an intermediate layer between the bonnet and the bonnet and acts as a sound absorbing section with a so-called rear air layer.

One example of the fiber components of these molded sound-absorbing fibers installed in the engine room is discontinuous fiber material, which is made by opening animal and vegetable fibers such as fallen cotton and wool, and/or synthetic resin fiber materials. A mixture of thermosetting synthetic resin powder and thermoplastic synthetic resin powder in an appropriate ratio is mixed with the ingredients, a fleece is formed using a fleece forming machine, and then an appropriate amount of heat is applied to heat-fuse the resin powder to a ready-to-handle state. A molded article is used in which a bulky non-woven fabric is produced and molded under heat and pressure into a desired shape.Another example is a fabric made mainly of glass fiber discontinuous fiber material and thermosetting synthetic resin. BACKGROUND ART A molded article made of a bulky nonwoven fabric (glass wool mat) that is heated and press-molded into a desired shape is known.

On the other hand, with the advancement of turbocharging in automobile engines, the heat resistance of soundproofing and sound absorbing materials installed in engine compartments in higher temperature ranges (i.e., the combustibility and strength caused by exposure to high temperatures) has increased. In addition to demands for improvements in water resistance and deep drawing formability, there have been increasing demands for improvements in water resistance and deep drawability.

When looking at the above-mentioned molded products in light of these demands, we find that the former molded products made of animal/vegetable and/or synthetic resin fiber materials are superior in terms of moldability, flexibility, impact resistance, and economic efficiency. The latter type of molded product made of glass wool satisfies these demands due to its water resistance and heat resistance, but although it has water resistance, strength, and combustibility, it is easy to break, has impact resistance, and is a molded product that is susceptible to high heat deterioration. The above requirements were not satisfied in terms of shape retention.

In view of these circumstances, the inventors of the present invention have arrived at the present invention as a result of intensive research, and the object of the present invention is to provide a material with excellent water resistance, heat resistance, surface/impact resistance, and strength. Another object of the present invention is to provide a method for producing a molded soundproofing material that has excellent shape retention properties during high-temperature deterioration and is further improved in deep drawing molded products.

However, the gist of the present invention is that the softening point is 80~80~
Discontinuous fiber material 100 weights: 11 weights of one or more types of synthetic σI fat-filled fiber materials and glass fiber fibers mixed and defibrated at a ratio of 9:1 to 1:9 at 250°C. The molded soundproofing material is obtained by compression-molding a bulky nonwoven fabric made by adding 5 to 40 layers of a thermosetting synthetic resin to 1 part and 1 part of a thermosetting synthetic resin in an arbitrary uneven shape under heating.

The present inventor first discovered organic fiber materials such as animal/plant and/or synthetic resin fiber materials and inorganic fibers such as glass wool, rock wool, and slag wool. Although we have proposed a molded soundproofing material in which a bulky nonwoven fabric consisting of a mixed fiber material and a binder component is heated and pressed, the present invention further provides the following features:
Water resistance; ■ Heat resistance that can withstand high temperature conditions of 200°C or higher, especially shape retention and impact resistance of molded products after high heat history; and ■ Forming with significantly improved deep drawability. This is a proposal regarding soundproofing materials.

Materials for the synthetic resin fiber material used in the present invention include:
May be polyester fibers, acrylic fibers, polyamide fibers, nylon, polycrystalline fibers, polyurethane fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, vinylon, acetate fibers, fluorine fibers, polypropylene fibers, polyethylene fibers, etc. , one or a mixture of two or more of these may be used.

It is essential to use these synthetic resin fiber materials with a softening point of 80 to 250°C, and if a synthetic resin fiber material with a softening point of less than 80°C is used, the shape of the molded product is likely to change, Synthetic resin fibers with significantly reduced strength and a softening point exceeding 250° C. are very expensive and have the disadvantage of poor molding workability.

The diameter of these fibers may be 100 μm or less, but more preferably 15 μm or less, which provides excellent sound absorbing properties as a soundproofing material and is also advantageous for weight reduction.

Along with the above synthetic resin fiber phase, discontinuous fibers &! Glass wool, glass fiber, etc. are suitable as the essential glass fiber material constituting the i-rate. Such glass wool or glass fiber may be of conventionally known type.
Molten glass may be drawn and spun at high speed to form fibers or fluff. Ai fiber Q11 made with Rondo style and pot style. Alternatively, a cotton-like material made by steam spraying may be used.

The ratio of one or more synthetic resin fiber IJ materials and glass fiber material is 9:1 to 1:9, preferably 7:1.
It is essential to mix at a ratio of 3 to 3 Nia. When looking at the molded product, if there is too much synthetic resin fiber material, the heat resistance will be unsatisfactory, and if too much glass fiber material is used, it will break easily and have problems in terms of impact resistance and shape retention of the molded product. There are drawbacks to not being able to satisfy requests.

It is essential to add 5 to 40 parts by weight of a thermosetting synthetic resin to 100 parts by weight of a discontinuous fiber material obtained by mixing and defibrating a synthetic resin fiber material and a glass fiber material. The thermosetting synthetic resin may be a phenol resin, a thermosetting acrylic resin, a melamine resin, or the like.

The manufacturing method of the present invention will be explained in more detail below.

Polyester fiber, acrylic fiber, polyamide fiber kIF
Synthetic resin fiber materials such as and the required amount of glass fiber materials such as Glass Unope glass fibers are put into a bale feeder, the fiber materials are first opened, and a web with a similar thickness is formed using a wrapper. Thermosetting resin powder is spread on the formed web soil using a resin spreader, the 17i-1 fibers and the resin powder are mixed again using the beater in the homing machine, and the fleece is made into a desired thickness using a wrapper again and transferred to the net conveyor of the heating furnace. Pour it on top one by one. To make the obtained fleece easier to handle, heat may be applied to it in a heating furnace, and the mixed resin powder may be partially cured and taken out in a semi-cured state and molded under heat and pressure. Alternatively, the mixed resin powder may be sufficiently removed. It may be cured and taken out as a felt-like material with excellent elasticity and cushioning properties.

Next, the bulky nonwoven fabric is taken out in a semi-cured state and compressed into an uneven shape using a mold heated at 180°C to 250°C at a pressure of 1 to 100 mm/c to form soundproofing. It is used to obtain wood.

In the present invention, by using synthetic resin fibers and a specific proportion of glass wool together with glass fiber sidewalls, the synergistic effect of the combination is moldability, flexibility, impact resistance, economic efficiency, water resistance, strength, and combustibility. It is possible to obtain a molded soundproofing material that has excellent shape retention properties of molded products after heat history, and depending on the degree of compression, the molded soundproofing material obtained can also be used as a breathable soundabsorbing material. It can also be used as a sound insulating side that has substantially no air permeability, such as an engine undercover. The molded soundproofing material of the present invention has excellent water resistance and heat resistance of nearly 250° C., and is therefore suitable for the underside of the engine, side walls, part of the outer dash, etc., rather than the back of the bonnet.

There is no problem in attaching a sheet-like material made of rubber, vinyl chloride, or the like with a heavy specific gravity as a binder to the molded soundproofing material obtained in the present invention, or attaching a plastic film or the like to impart water-retaining properties, or integrally molding the material.

Examples are given below along with comparative examples to provide a more detailed understanding of the present invention. Naturally, the present invention is not limited to the following examples.

Example 1 40 parts by weight of acrylic fiber with a softening point of 105°C and 60 mQ parts of glass wool were spread and mixed, and the reaction temperature was 1 at a melting point of 150°C.
Sprinkle and mix 20 parts of phenolic resin powder at 80°C,
After forming a fleece with a fleece forming machine, it is passed through a heating furnace at 160°C to a thickness of 26%, and the surface 'J? Hff94A! iI/η
A semi-cured type 'w: foveal nonwoven fabric of 72 was obtained.

The obtained bulky nonwoven fabric was divided into 2 squares of 300 x 300%.
15 Kg/cnl using a mold heated to 00℃
The peripheral part 20'Xn'l: 2'Xn thickness was compression molded with other sound absorbing parts at 6%.

Example 2 50 parts of polyester fiber with a softening point of 146°C, 5 parts of glass wool (1:tt part) were opened and mixed, 20 parts by weight of phenolic resin powder with a melting point of 150°C and a reaction temperature of 180°C was sprinkled and mixed, and a fleece forming machine was used. 160 after making it with IJ-su
℃ heating furnace to a thickness of 27% and an areal density of 955 f/
n? A semi-cured type bulky nonwoven fabric was obtained. 200 pieces of bulky nonwoven fabric obtained in a 300 x 300% square
Using a mold heated to 15° C., 20% of the peripheral portion was compression molded to a thickness of 2%, and the other sound absorbing portions were compression molded to a thickness of 6%.

Example 3 50 Ichikawabe polyamide fibers with a softening point of 178°C and 50 parts by weight of glass wool were spread and mixed, 20 N-Wc parts of a phenolic resin powder with a melting point of 150°C and a reaction temperature of 180°C was sprinkled and mixed, and a fleece forming machine was used. 16 after making a face IJ-S
Passed through a heating furnace at 0°C to a thickness of 25% and an areal density of 937?
A semi-cured type bulky nonwoven fabric of /gl was obtained. The obtained bulky nonwoven fabric was placed into a 300x300% square.
Example 4 Polyester fiber 25 with a softening point of 146°C was compression-molded using a mold heated to 0°C at 15 kg/cut to have a thickness of 2% in the peripheral part and 6 thicknesses in other sound-absorbing parts. 25 parts by weight of acrylic fiber with a softening point of 105°C, 50 parts by weight of glass wool
The parts by weight were opened and mixed, and the melting point was 150°C and the reaction temperature was 180°C.
20 parts by weight of phenolic resin powder was scattered and mixed, formed into a fleece using a fleece forming machine, and passed through a heating furnace at 160°C to a thickness of 26% and an areal density of 942? /tr? A semi-cured type bulky nonwoven fabric was obtained. The obtained bulky nonwoven fabric was compressed into a 300 x 300% square using a mold heated to 200°C at 15 Kq/crit to a thickness of 2% in the peripheral area and a thickness of 6% in the other sound absorbing parts. Molded.

Comparative Example 1 30 parts by weight of acrylic resin fiber, 20 parts by weight of recycled wool, and 50 parts by weight of fallen cotton were fully opened and mixed at a melting point of 150°C and a reaction temperature of 18°C.
20 parts by weight of phenolic resin powder at 0°C was completely dispersed and mixed, formed into a fleece using a fleece forming machine, and passed through a heating furnace at 160°C to form a semi-cured bulky nonwoven fabric with a thickness of 25% and an areal density of 930 ii'/m''. The obtained bulky woven fabric was molded into a 300 x 300% square in a mold heated to 200°C, and the entire layer was heated to 15 mm/arf to form a peripheral area 2.
The 0% part was compression molded to a 2% thickness, and the other sound absorbing parts were compression molded to a 6% thickness.

Comparative Example 2 20 parts by weight of acrylic resin fiber, 15 parts by weight of recycled wool, 30 parts by weight of fallen cotton, and 2 parts of 35 suspended glass wool were opened and mixed,
20 parts by weight of phenolic resin powder with a melting point of 150°C and a reaction temperature of 180°C was sprinkled and mixed, formed into a fleece using a fleece forming machine, and then passed through a heating furnace at 160°C to a thickness of 26% and an areal density of 94.0? / tri” semi-cured type bulky nonwoven fabric was obtained.
×300% square using a mold heated to 200℃
5/C7I'L, 20% of the peripheral part was compression molded to 2% thickness, and the other sound absorption iτ was compression molded to 6 thicknesses.

Comparative Example 3 Molten glass was spun at high speed, made into a cotton-like fiber, and 15 parts by weight of water-soluble phenol resin liquid was sprayed on the FC Kura,
A glass wool mat of '/m2 was obtained. The obtained glass wool pine) e300x300% square was made using a mold heated to 200℃, and the peripheral part 2o was made at 97c71 in 15 minutes.
'

Comparative Example 4 40 Mt parts of synthetic resin fiber (polyolefin fiber) with a softening point of 70°C and 6 oM glass wool were spread and mixed, and 20 parts of phenolic resin powder with a melting point of 150°C and a reaction temperature of 180°C was sprinkled and mixed. , made into fleece with a fleece forming machine and then passed through a heating oven at 160'C to a thickness of 24%,
Semi-cure type bulky nonwoven fabric with surface density tK 925 F /i (i-obtained. Obtained bulky nonwoven fabric '15
Using a mold heated to 200℃ in a 300x300% square, 20% of the peripheral area is 2% at 15 Kq/crl.
The other sound absorbing parts were compression molded to a thickness of 6%.

Test method 1, high temperature deterioration The maximum bending stress of the test piece was previously measured according to JIS K7203. After holding the test piece at a total temperature of 60°C and 95% humidity for 100 hours, it was taken out and the maximum bending stress was measured again.
I observed the appearance.

:? Water immersion deterioration test In a test in which the maximum bending stress was measured in advance according to JIS K7203, the test piece was immersed in water and held for 100 hours, then taken out, the maximum bending stress was measured again, and the appearance was observed.

3. Cycle deterioration After 6 cycles of a test piece whose maximum bending stress was previously measured according to JIS K7203 (water immersion, 1 hour) = (-40°C, 4 hours) → (150°C, 4 hours), The maximum bending stress during ladle was measured, and the entire appearance was observed.

4. Thermal deterioration A test piece whose maximum bending stress was previously measured according to J I SK7203 was kept at a temperature of 200°C for 100 hours, then taken out, the maximum bending stress was again measured, and the appearance was observed.

The evaluation by the above test methods 1 to 4 is a relative evaluation with the result before the test as 100, and the appearance is observed by observing the shape, size, state of damage, etc.

5. Impact Resistance The test pieces of Examples and Comparative Examples were set in a stepping stone tester, and a No. 6 crushed stone was applied 500 ft = 15 times from a distance of 30 cm at a pressure of 4 Kg/azl to the surface of the molded product. Assess the condition.

For impact resistance evaluation, ◎: No change △: There are scratches ×: The original model is damaged.

6. Sound absorption coefficient 250-40000 after thermal deterioration test using reverberation chamber method...
All sound absorption coefficients were measured.

As described above, the molded soundproofing material of the present invention has superior water resistance, heat resistance, impact resistance, and strength compared to conventional materials, and has been known to have excellent shape retention and properties of molded products. It became clear that.

Patent Applicant Nippon Tokushu Toyo Co., Ltd. Procedural Amendment (formula) March 13, 1980 Director General of the Patent Office 1, Indication of the case 1982 Patent Application No. 223079 2, Title of the invention 3, Person making the amendment Case Relationship with Patent applicant address: 5-16-7 Oji, Kita-ku, Tokyo Postal code: 11
4 February 8, 1980 (Delivery port: February 28, 1980) 5. Number of inventions increased by the amendment 0 6. Full text of the specification subject to the amendment 7. Engraving of the description of the contents of the amendment (changes to the contents) none)

Claims (1)

[Claims] One or more synthetic resin fiber materials having a softening point of 80 to 250°C and a glass fiber material are 9=1 to 1:
A bulky nonwoven fabric made by adding 5 to 40 parts by weight of a thermosetting synthetic resin to 100 parts by weight of a discontinuous fiber material mixed and defibrated at a ratio of 9 to 100 parts by weight is compression-molded into an arbitrary uneven shape under heating. molded soundproofing material