JPWO2019004432A1 - Sealing member manufacturing method and member joining method - Google Patents

Abstract

Provided are a method for manufacturing a seal member, which has high heat resistance, weather resistance, and sound insulation, is easy to manufacture, and can suppress an increase in weight, and a method for joining members. For the first member 6 made of crosslinked rubber, a material having a melting peak temperature of 100 ° C or higher and 200 ° C or lower measured in accordance with the differential scanning calorimetry of the transition temperature measuring method for plastics specified in JIS K 7121 The second member 7 made of the non-woven fabric containing the two is joined by ultrasonic welding.

Description

  The present invention relates to a method of manufacturing a seal member used for a vehicle or a door of a building, and a method of joining members.

  2. Description of the Related Art A door provided in a vehicle such as an automobile or a building usually has a configuration in which a seal member (packing) for improving sealing is attached to an outer peripheral edge of a door body made of a rigid body such as metal. The seal member desirably has a high sound insulation property for keeping the room quiet in addition to heat and weather resistance in addition to suppressing intrusion of water and dust. The normal seal member is attached to the outer peripheral edge of the door main body, and exhibits excellent sealing properties in a state where it is sandwiched between the door main body and the door frame and compressed. Therefore, the seal member is often in the form of a hollow tube made of an elastomer that can be easily elastically deformed so as to be sandwiched and compressed between the door body and the door frame.

  Patent Document 1 discloses a configuration in which a hard core material and a soft filler are inserted into a hollow tube (hollow seal portion) to prevent excessive deformation. In the configuration described in Patent Literature 2, a column-shaped cushion portion made of rubber or synthetic resin made of a highly foamed sponge is provided inside a hollow tube (hollow seal portion). The inside of the tube is not completely closed by the columnar cushion portion, and two air holding spaces (sealed spaces) are left inside the tube. In the configuration described in Patent Document 3, a highly foamed sponge material made of rubber or synthetic resin is provided inside a hollow tube (hollow seal portion). The inside of the tube is not completely closed by the highly foamed sponge material, and an air holding space (air layer) is left inside the tube. In the configuration described in Patent Document 4, a waterproof tube filled with a porous sound absorbing material is inserted into a hollow tube (hollow seal portion). These hollow tubes can be formed of, for example, a material described in Patent Document 5. Patent Document 6 discloses a method for producing an open-cell foam.

  Patent Literature 7 discloses a technique in which a rubber member having a rubber-bonded rough surface having a predetermined roughness and a resin member having a resin-bonded rough surface having a predetermined roughness are ultrasonically welded. Patent Document 8 discloses a wafer having a configuration in which a non-woven fabric (decorative layer) is provided via a resin adhesive layer on a trim portion having a substantially U-shaped cross section provided to protrude from a part of a tube (hollow seal portion). The strip is disclosed.

JP-A-9-286239 JP 2003-81026 A JP 2001-206166 A Japanese Utility Model Publication No. 2-75316 International Publication No. 2009/072503 JP 2013-234289 A JP-A-2006-305878 JP 2009-120006 A

  In recent years, vehicles (electric vehicles and hybrid vehicles) using an electric motor as a driving source have become widespread. Electric motors generate higher frequency noise (about 2000 Hz to about 16000 Hz) than gasoline engines. Since this high frequency noise is extremely harsh, there is a demand for improved sound insulation of a door seal member of a vehicle equipped with an electric motor as compared with the related art. Also, there is a tendency that doors of buildings are required to have as high a sound insulation as possible in accordance with environmental changes.

  When the inside of the hollow tube is completely closed with resin or the like as in the configuration described in Patent Document 1, the attenuation of vibration is small and the sound insulation is poor. Patent Documents 2 and 3 disclose a weather strip having a configuration in which a highly foamed sponge is disposed inside a hollow tube. Further, it discloses that the weather strip has not only a soundproof function but also a waterproof function. It is well known to those skilled in the art that the weather strip exhibits expected performance by being deformed, and is provided with an air vent hole to facilitate deformation. In the configuration in which the air vent holes are provided as described above, it is general to use a material having a relatively low water absorption among the highly foamed materials in order to suppress as much as possible water from entering and being held therein. Therefore, there is no idea that a material having high water absorption is dared to be used for the weather strip. In the inventions described in Patent Literatures 2 and 3, the hollow seal portion and the high-foaming sponge are integrally formed by extrusion, and are basically made of the same material (foaming sponge made of rubber or synthetic resin). ). That is, for the purpose of improving the sound insulation, it is not assumed that the member provided inside the hollow tube is arbitrarily selected from various materials regardless of the material of the tube.

The configuration described in Patent Literature 4 has a double tube structure in which a sound absorbing material such as glass wool is inserted into a waterproof tube and then inserted into a hollow tube (hollow seal portion). Therefore, it is necessary to manufacture an insertion member by filling a sound absorbing material such as glass wool into a thin waterproof tube, and then insert the insertion member into a hollow tube. It is complicated. Further, the waterproof tube needs to have a thin film thickness so that the sound absorbing property of the sound absorbing material does not deteriorate, and the thinner the waterproof tube, the more complicated the process of filling the sound absorbing material. Therefore, in the invention described in Patent Document 4, it is difficult to maintain both the sound absorbing effect of the sound absorbing material and reduce the complexity of the manufacturing process.
In addition, none of Patent Documents 1 to 4 mentions the frequency selectivity of sound insulation.

  In addition, for vehicle doors and building doors that are considered as applications for seal members, weight reduction is desired in addition to heat resistance, weather resistance, and sound insulation. In vehicle doors, weight reduction of the entire vehicle is an important factor for improving running performance and maneuverability and reducing fuel consumption, and the weight of the sealing member cannot be ignored. Also, in addition to installation work, building doors need to be transported to the installation location, so it is desirable to reduce the weight of these doors, especially when they are installed on the higher floors of the building, in order to facilitate these operations. ing. However, in Patent Literatures 1 to 4, an increase in weight due to an insertion member (a hard core material and a soft filler, a columnar cushion portion, a high foam sponge material, a sound absorbing material, and a waterproof tube) for improving sound insulation is completely considered. Not.

  Patent Documents 5 and 6 disclose compositions that can be used as a part of a seal member, but do not consider characteristics of the seal member such as sound insulation at all. Patent Literatures 7 and 8 propose a special method invented for joining resin members with high reliability. This indicates that in order to join the members with high reliability, there are great restrictions on the selection of the material, the joining method, and the like.

  Therefore, an object of the present invention is to provide a method of manufacturing a seal member, which has high heat resistance, weather resistance, and sound insulation, is easy to manufacture, and can suppress an increase in weight, and a method of joining members. .

  In the method for joining members of the present invention, the first member made of crosslinked rubber has a melting peak temperature of 100 ° C. measured according to the differential scanning calorimetry of the plastic transition temperature measuring method specified in JIS K 7121. A second member made of a nonwoven fabric containing a material having a temperature of 200 ° C. or lower is joined by ultrasonic welding.

  In the method for manufacturing an elastically deformable seal member according to the present invention, the first resin member is a hollow tube, and the nonwoven fabric is fixed inside the tube by the above-described member joining method.

  Advantageous Effects of Invention According to the present invention, it is possible to provide a method of manufacturing a seal member that has high heat resistance, weather resistance, and sound insulation, is easy to manufacture, and can suppress an increase in weight, and a method of joining members.

1 is a front view of a vehicle door having a seal member manufactured by a method according to the present invention. 1 is a front view of a building door having a sealing member manufactured by a method according to the present invention. It is a front view showing an example of the seal member manufactured by the method concerning the present invention. FIG. 4 is a cross-sectional view of a seal member of Reference Example 1. It is a schematic diagram which shows an example of an acoustic characteristic measuring system. FIG. 5B is an enlarged view showing an acoustic characteristic measurement state by the acoustic characteristic measurement system shown in FIG. 5A. It is a graph which shows an example of the acoustic characteristic measurement result by the acoustic characteristic measurement system shown in FIG. 5A. It is a graph which shows the sound insulation volume calculated | required based on the acoustic characteristic measurement result shown in FIG. 6A. It is sectional drawing of the conventional sealing member of the non-compression state. FIG. 7B is a cross-sectional view of the conventional seal member shown in FIG. 7A in a compressed state. 9 is a graph showing the sound insulation of the seal members of Reference Examples 1 to 3 and a conventional example. FIG. 9 is a cross-sectional view of a seal member of Reference Example 2. FIG. 9 is a cross-sectional view of a seal member of Reference Example 3. 13 is a cross-sectional view of a seal member of Reference Example 4. FIG. 9 is a graph showing the sound insulation of a seal member of Reference Example 4 and a conventional example. FIG. 2 is a sectional view of the seal member according to the first embodiment of the present invention. 6 is a graph showing the sound insulation of the seal members of Examples 1 to 3 of the present invention and a conventional example. FIG. 6 is a cross-sectional view of a seal member according to a second embodiment of the present invention. FIG. 9 is a sectional view of a seal member according to a third embodiment of the present invention. 13 is a cross-sectional view of a seal member of Reference Example 5. FIG. 9 is a graph showing the sound insulation of the seal members of Reference Examples 5 and 6 and a conventional example. 13 is a cross-sectional view of a seal member of Reference Example 6. FIG. FIG. 9 is a sectional view of a seal member of Comparative Example 1. 9 is a graph showing the sound insulation of seal members of Comparative Examples 1 and 2 and a conventional example. FIG. 9 is a cross-sectional view of a seal member of Comparative Example 2. 13 is a cross-sectional view of a seal member of Comparative Example 3. FIG. 9 is a graph showing the sound insulation of the seal members of Comparative Examples 3 to 5 and a conventional example. 14 is a cross-sectional view of a seal member of Comparative Example 4. FIG. 13 is a cross-sectional view of a seal member of Comparative Example 5. FIG. It is a perspective view which shows typically the schematic structure of the sealing member of Examples 1-3 of this invention, the reference examples 1-6, and the comparative examples 1-3. It is a perspective view which shows typically the schematic structure of the seal member of Examples 4, 6-8 of this invention, and the reference example 7. It is a perspective view showing typically the schematic structure of the seal member of Example 9 of the present invention. It is a perspective view which shows typically the schematic structure of the seal member of Example 10, 12 of this invention. It is a perspective view which shows typically the schematic structure of the sealing member of the conventional example. FIG. 28 is a front view of a seal member that is a composite member including the seal members shown in FIGS. 27A to 27E. It is explanatory drawing which shows the step of inserting a porous body into a tube member of the manufacturing method of the seal member of this invention. It is a perspective view which shows the tube member in the state where the porous body was inserted in the step shown in FIG. 29A. It is a top view of a core used in the manufacturing method of the seal member of the present invention. It is a top view showing the state where tube members were attached to both ends of a core in a manufacturing method of a seal member of the present invention. It is a top view showing the state where the core where the tube member was attached to both ends and the oil sheet was wound was arranged in the cavity of the metallic mold of the manufacturing method of the seal member of the present invention. It is a front view which shows typically the heating and pressurized state by the press machine of the manufacturing method of the sealing member of this invention. It is a top view showing the state where the joint was formed in the perimeter of the core in the manufacturing method of the seal member of the present invention. It is a perspective view which shows typically the step which takes out a core of the manufacturing method of the sealing member of this invention. It is a top view showing the seal member manufactured by the manufacturing method of the seal member of the present invention. It is a top view showing the state where the core which attached the tube member to both ends of another example of the manufacturing method of the seal member of the present invention was arranged in the cavity of the metallic mold. FIG. 37 is a sectional view of a main part of the seal member shown in FIG. 36. It is a perspective view showing the ultrasonic welding process of the present invention. FIG. 39B is a perspective view showing a step that follows the step shown in FIG. 39A. It is a top view showing an example of the manufacturing method of the seal member of the present invention. FIG. 40B is a plan view showing a step that follows the step shown in FIG. 40A. FIG. 40B is a plan view showing a step that follows the step shown in FIG. 40B. FIG. 40C is a plan view showing a step that follows the step shown in FIG. 40C. FIG. 40D is a plan view showing a state where the step shown in FIG. 40D is completed. FIG. 40 is a plan view showing a step that follows the step shown in FIGS. 40D to 40E. It is a top view showing other examples of the manufacturing method of the seal member of the present invention. FIG. 42B is a plan view showing a step that follows the step shown in FIG. 42A. FIG. 42B is a plan view showing a step that follows the step shown in FIG. 42B. FIG. 42C is a plan view showing a step that follows the step shown in FIG. 42C.

Hereinafter, embodiments of the present invention will be described.
The seal member 1 is mainly used in the vehicle door 2 shown in FIG. 1 and the building door 4 shown in FIG. Specifically, for example, the seal member 1 is attached to the outer peripheral edge of the vehicle door body 2a of the vehicle door 2 shown in FIG. It is used in a compressed state while being sandwiched between the door frame 3a of the vehicle body 3 and the door frame 3a. The seal member 1 is attached to the outer peripheral edge of the building door main body 4a of the building door 4 shown in FIG. 2, and the building door main body 4a and a vehicle schematically showing a main part by a two-dot chain line. 5 may be used in a compressed state while being sandwiched between the door frame 5a and the door frame 5a. Hereinafter, the seal member 1 mainly used for the vehicle door 2 shown in FIG. 1 will be described as an example, but the following description is also substantially applicable to the seal member 1 used for the building door 4.

The seal member 1 shown in FIGS. 3 and 4 has a hollow tube 6 and a porous body 7 arranged inside the tube 6. The tube 6 is made of an elastically deformable elastomer, and is attached so as to be in close contact with the outer peripheral edge of the vehicle door main body 2a shown in FIG. The tube 6 has a hollow portion having a substantially circular cross section with an inner diameter of about 5 to 25 mm in an initial state (non-compressed state). FIGS. 3 and 4 show the tube 6 having a relatively simple shape. However, the tube 6 may have a shape further provided with an engaging portion and a mounting portion for mounting to the vehicle door body 2a. An example of the elastomer constituting the tube 6 is an ethylene / α-olefin / non-conjugated polyene copolymer, which has a specific gravity of 0.3 or more and 1.0 or less and a water absorption of less than 50% in an uncompressed state. However, the present invention is not limited to this example, and a tube 6 of another material may be used, and its specific gravity and water absorption may be different from those in the above-described example. The measurement of the water absorption is performed as follows. That is, a test piece of 20 mm × 20 mm was punched out of a tube-shaped processed product, and the test piece was depressurized to −635 mmHg at a position 50 mm below the water surface and held for 3 minutes. Subsequently, after returning to atmospheric pressure and elapse of 3 minutes, the weight of the test piece that has absorbed water is measured, and the water absorption of the test piece is calculated from the following equation.
Water absorption [%] = {(W2−W1) / W1} × 100
W1: Weight of test specimen before immersion (g)
W2: Weight of test piece after immersion (g)

  In the seal member 1 shown in FIG. 4, a porous body 7 is inserted inside a tube 6 (hollow portion). However, the inside of the tube 6 is not completely closed by the porous body 7, and an air holding space 8 is provided between a part of the inner wall of the tube 6 and a part of the outer surface of the porous body 7. I have. That is, the air holding space 8 in the present application is surrounded by the inner wall of the hollow tube 6 (the surface constituting the inner space) and the outer surface of the porous body 7 (but not including the pores on the surface of the porous body 7). Pointed space. Specifically, as clearly shown in FIG. 9, the air holding space 8 is a space wider than at least the pores of the porous body 7. For example, the maximum width of the air holding space 8 (the maximum value of the distance between the inner wall of the tube 6 and the outer surface of the porous body 7 in a direction orthogonal to each part of the outer surface of the porous body 7) is 1 mm or more, more preferably. Is 5 mm or more, more preferably 8 mm or more. The proportion of the portion occupied by the air holding space 8 in the tube 6 can be represented by the proportion of the area of the porous body 7. This numerical value indicates an area occupied by a portion corresponding to the porous body 7 by observing a cross section of a portion including the hollow tube 6 and the porous body 7. The ratio of the area of the porous body 7 in the tube 6 is preferably in the range of 5% or more and 95% or less. For example, in the configuration shown in FIG. % Or more and 95% or less. The more preferable lower limit of the ratio of the area of the porous body 7 in the tube 6 is 8%, and the more preferable lower limit is 15%. On the other hand, a more preferred upper limit is 90%, and a still more preferred upper limit is 85%. FIG. 4 shows a porous body 7 made of a foam (polyurethane foam) as a reference example. The porous body 7 of the present invention is a nonwoven fabric, that is, an aggregate of fibers containing a certain minute space. It is. The porous body 7 has a configuration capable of measuring the water absorption.

  The air holding space 8 is maintained without being lost even in a state where the air holding space 8 is compressed by being sandwiched between the door body 2a and the door frame 4 when the seal member 1 is used. In a state in which the seal member 1 is used (for example, in a state of being compressed by 30%, that is, in a state where the dimension in the compression direction is reduced by 30%), a cross section of the compressed porous body 7 orthogonal to the longitudinal direction of the tube 6 The cross-sectional area is 5% or more and 90% or less of the cross-sectional area of the hollow portion (including the portion occupied by the porous body 7 in the tube 6) which is a portion surrounded by the inner wall of the tube 6. In other words, the area of the air holding space 8 in the use state of the seal member 1 is 10% or more and 95% or less of the sectional area of the portion surrounded by the inner wall of the tube 6. When the porous body 7 is inserted over the entire length of the tube 6, if the ratio of the cross-sectional area of the porous body 7 to the cross-sectional area of the hollow portion of the tube 6 is 5% or more and 90% or less, the tube 6 The volume occupancy of the porous body 7 in the hollow portion is 5% or more and 90% or less. However, the porous body 7 does not necessarily need to be inserted over the entire length of the tube 6, and even if the porous body 7 is arranged only in a part of the hollow portion of the tube 6 in the longitudinal direction, the effect of improving the sound insulation can be obtained. . The volume occupancy and the sound insulation in that case will be described later.

As described above, the material of the porous body 7 of the present invention is a nonwoven fabric, and the water absorption in the non-compressed state is 10% or more and 3000% or less. The upper limit of the water absorption is more preferably 2800%, further preferably 2500%, further preferably 2000%, and particularly preferably 1600%. On the other hand, the lower limit of the water absorption is more preferably 12%, and still more preferably 13%. The water absorption of the nonwoven fabric forming the porous body 7 was measured in the same manner as the elastomer material forming the tube 6 described above. At this time, even if each test piece had a different shape, the water absorption was measured under substantially the same conditions by using a test piece formed so that each surface area was 4000 mm ² . The bulk density of the nonwoven fabric constituting the porous body 7 in a non-compressed state is 10 kg / m ³ or more and 150 kg / m ³ or less. Further, the compressive stress (25% compressive stress) for compressing the nonwoven fabric constituting the porous body 7 until the dimension in the compression direction is reduced by 25% is 1 N / cm ² or less, and the dimension in the compression direction is reduced by 50%. Compressive stress (50% compressive stress) for compressing to ^2.5 N / cm ² or less.

The sound insulation of the seal member 1 and the like can be measured by, for example, the acoustic characteristic measurement system shown in FIGS. 5A and 5B. This acoustic characteristic measurement system has two rooms, that is, a reverberation room 9 which is a first room, and a semi-anechoic room 10 or an anechoic room which is a second room. The reverberation room 9 and the semi-anechoic room 10 are adjacent to each other, and share a part of the wall (the partition 11). The reverberation room 9 has an inner wall made of a reverberation plate such as a metal plate. The semi-anechoic chamber 10 has a sound absorbing structure on the inner wall except for the floor (a structure in which a not-shown absorbing member is provided on substantially the entire inner wall). A room in which all inner walls including the floor have a sound absorbing structure is called an anechoic room. The second room of the present invention may be a semi-anechoic room 10 or an anechoic room. The partition 11 is provided with an opening 12 for communicating the reverberation chamber 9 and the semi-anechoic chamber 10. Opposite to this opening 12, as shown in FIG. A holding mechanism 13 for holding the member 1) while compressing it is provided. The speaker 14 in the reverberation room 9 emits sound while the seal member 1 is held in a compressed state. One example of a generated sound has a constant sound pressure level (about 100 dB) over almost all frequencies above 400 Hz, as shown in FIG. 6A. Then, based on the sound pressure level SPL0 of the sound when the sealing member 1 recorded by the microphone 15 of the semi-anechoic room 2 is not installed and the sound pressure level SPL1 of the sound when the sealing member 1 is installed, (FIG. 6B).
Sound insulation volume [dB] = SPL0 [dB] -SPL1 [dB]
In FIG. 6A, the presence of the seal member 1 is indicated by a conventional seal member described later, that is, a seal member having a configuration in which nothing is inserted into the hollow tube 6 by the holding mechanism 13. It is the result of having performed sound insulation measurement in the state where it was held.
Here, the sound insulation performance of the seal member 1 can be represented by a decibel average value of the sound insulation volume in a specific frequency range (for example, 4000 Hz to 10000 Hz). An average value of decibels of the sound insulation of a specific frequency range of the seal member 1 of the present invention is calculated, and the sound insulation of the conventional seal member having a structure in which nothing is inserted into the hollow tube 6 has the same frequency range. By comparing with the average value of the decibels of the present invention, it is possible to show the improvement amount of the sound insulation according to the present invention. The sound insulation effect of each seal member was determined in the following four stages based on the amount of improvement with respect to the sound insulation of the reference seal member, and is shown in Tables 1 to 3 described below. ◎: 6 dB or more, ：: 2 dB or more and less than 6 dB, Δ: 1 dB or more and less than 2 dB, ×: less than 1 dB.

  The results of measuring the sound insulation effect of the seal member 1 of the present invention using the porous body 7 made of various materials and the seal members of the conventional example, the reference example, and the comparative example will be described below. In all of the following examples, the tube 6 manufactured according to Patent Document 5 is made of an ethylene / α-olefin / non-conjugated polyene copolymer, has a water absorption of 0.49% in an uncompressed state, and has an uncompressed state. The specific gravity in the state is 0.62. The tube has an outer diameter of 19 to 22 mm and an inner diameter of about 15 to 16 mm in a non-compressed state, and is provided with a mounting portion. The total length of the tube is 840 mm. At the time of measurement, the seal member is kept in a 30% compressed state as described above using, for example, the acoustic characteristic measurement system shown in FIGS. 5A and 5B.

[Conventional example]
Before describing the seal member 1 of the present invention, the sound insulation effect of the conventional seal member having only the tube 6 without the porous body 7 shown in FIGS. 7A and 7B will be described. FIG. 7A shows a non-compressed state, and FIG. 7B shows a 30% compressed state (used state). Tables 1 and 2 and FIGS. 8, 12, 14, 18, 21, and 24 show the sound insulation of various frequencies by the seal member having no porous body. According to the results, in the conventional example, the sound insulation at a high frequency of 2000 Hz or more was not sufficient, and the average value of the sound insulation at 4000 Hz to 10000 Hz was 50.7 dB.

[Reference Example 1]
The seal member 1 of Reference Example 1 will be described. This sealing member 1 is shown in FIG. 4, and a porous body 7 having a square cross section of 10 mm × 10 mm is inserted into a tube 6. The material constituting the porous body 7 is a polyurethane foam (trade name: Sealflex ESH (manufactured by INOAC CORPORATION)), the water absorption in an uncompressed state is 1400%, and the bulk density in an uncompressed state is 45 kg /. m is ^3. The material has a 25% compressive stress of 0.52 N / cm ² and a 50% compressive stress of 0.72 N / cm ² . The cross-sectional area of the porous body 7 in the cross section orthogonal to the longitudinal direction of the tube 6 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion (inner space) of the tube 6, and extends over the entire length of the tube 6. Since the porous body 7 was arranged, the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 60%. Table 1 and FIG. 8 show the sound insulation volume against sounds of various frequencies when the sealing member 1 in which the porous body 7 made of this material is inserted into the tube 6 is used. The sound insulation of the sealing member 1 is good, and the sound insulation at high frequencies of 2000 Hz or more is significantly improved as compared with the conventional example. The sound insulation at 4000 Hz to 10000 Hz has a decibel average value higher than that of the conventional example. 12.7 dB has been improved.

[Reference Example 2]
In the seal member 1 of Reference Example 2 shown in FIG. 9, a porous body 7 having a square cross section of 10 mm × 10 mm is inserted into a tube 6. The material constituting the porous body 7 is a polyurethane foam (trade name: Color Form ECS (manufactured by INOAC CORPORATION)), the water absorption in an uncompressed state is 2742%, and the bulk density in an uncompressed state is 22 kg /. m is ^3. Further, 25% compressive stress is 0.33 N / cm ^2, 50% compression stress is a material of 0.35 N / cm ^2. The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupancy of the porous body 7 with respect to the product was 60%. Table 1 and FIG. 8 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. The sound insulation of the seal member 1 was better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz was 9.8 dB higher than that of the conventional example.

[Reference Example 3]
In the seal member 1 of Reference Example 3 shown in FIG. 10, a porous body 7 having a square cross section of 10 mm × 10 mm is inserted into a tube 6. The material constituting the porous body 7 is a polyurethane foam (trade name: Calmflex F-2 (manufactured by Inoac Corporation)), the water absorption in an uncompressed state is 2310%, and the bulk density in the uncompressed state is It is 25 kg / m ³ . Further, 25% compressive stress is 0.48 N / cm ^2, 50% compression stress is a material of 0.5 N / cm ^2. The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupancy of the porous body 7 with respect to the product was 60%. Table 1 and FIG. 8 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. The sound insulation of the seal member 1 was better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz in decibels was improved by 9.9 dB as compared with the conventional example.

[Reference Example 4]
In the seal member 1 of the reference example 4 shown in FIG. 11, the inside of the tube 6 is filled with a porous body 7 made of a flexible polyurethane foam. The porous body 7 is formed as a non-flowable solid polyurethane foam by injecting a fluid state material before foaming into the tube 6 and then foaming. The inside of the tube 6 is not completely closed by the porous body 7, and an air holding space 8 exists between a part of the inner wall of the tube 6 and a part of the outer surface of the porous body 7. The water absorption of the polyurethane foam constituting the porous body 7 in the uncompressed state after foaming is 665%, and the bulk density in the uncompressed state is 60 kg / m ³ . The material has a 25% compressive stress of 0.12 N / cm ² and a 50% compressive stress of 0.18 / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 89% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupancy of the porous body 7 with respect to the product was 89%. Table 1 and FIG. 12 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. According to the seal member 1, better sound insulation was obtained as compared with the conventional example, and the decibel average value of the sound insulation at 4000 Hz to 10000 Hz was improved by 10.7 dB as compared with the conventional example.

[Example 1]
In the seal member 1 according to the first embodiment of the present invention illustrated in FIG. 13, a porous body 7 having a cross-sectional shape of 2 mm × 20 mm is inserted into a tube 6. The material constituting the porous body 7 is a non-woven fabric made by processing polypropylene by a melt blown method, and has a water absorption of 16% in an uncompressed state and a bulk density of 31 kg / m ³ in an uncompressed state. The material has a 25% compressive stress equal to or less than the lower limit of measurement (measurable) and a 50% compressive stress of 0.09 N / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 40% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupation ratio of the porous body 7 to the product was 40%. Table 1 and FIG. 14 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. The sound insulation of the sealing member 1 is good, and the sound insulation at high frequencies of 2000 Hz or more is significantly improved as compared with the conventional example. The sound insulation at 4000 Hz to 10000 Hz has a decibel average value higher than that of the conventional example. It has improved by 12.4 dB. In each embodiment of the present invention, after the porous body 7 is arranged on the inner surface of the tube 6, the porous body 7 is joined to the inside of the tube 6 by a method using ultrasonic vibration described later (see FIGS. 39A to 39B). ing. The frequency of the ultrasonic wave used in this method is usually 20 kHz or more and 3000 kHz or less, preferably 25 kHz or more and 1000 kHz or less. When welding the tube 6 and the porous body 7 using ultrasonic waves having such a preferable frequency range, the amount of energy applied to the tube 6 and the porous body 7 is appropriate, and the tube 6 at the time of welding and after the welding is welded. And the handling of the porous body 7 is easy.

[Example 2]
In the seal member 1 according to the second embodiment of the present invention illustrated in FIG. 15, a porous body 7 having a cross-sectional shape of 2 mm × 6.5 mm is inserted into a tube 6. The material constituting the porous body 7 is the same nonwoven fabric as in the first embodiment. The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 9% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupation ratio of the porous body 7 to the product was 9%. Table 1 and FIG. 14 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. The sound insulation of the seal member 1 is better than that of the conventional example, and the average value of the sound insulation at 4000 Hz to 10000 Hz is 9.1 dB higher than that of the conventional example.

[Example 3]
In the seal member 1 according to the third embodiment of the present invention illustrated in FIG. 16, a porous body 7 having a cross-sectional shape of 8 mm × 13 mm is inserted into a tube 6. The material constituting the porous body 7 is a non-woven fabric (trade name: Tafnel oil blotter AR-65 (manufactured by Mitsui Chemicals, Inc.)), the water absorption in the non-compressed state is 203%, and the bulk density in the non-compressed state is 70 kg / m ³ . The material has a 25% compressive stress of 0.16 N / cm ² and a 50% compressive stress of 2.2 N / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 55% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupancy of the porous body 7 with respect to the product was 55%. Table 1 and FIG. 14 show the sound insulation volume against sounds of various frequencies when the seal member 1 is used. The sound insulation of the seal member 1 was better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz was 9.8 dB higher than that of the conventional example.

[Reference Example 5]
In the seal member 1 of Reference Example 5 shown in FIG. 17, a porous body 7 having a square cross section of 10 mm × 10 mm is inserted into a tube 6. The material constituting the porous body 7 is a foamed rubber (trade name: Epto Sealer No. 685 (manufactured by Nitto Denko Corporation)), the water absorption in an uncompressed state is 169%, and the bulk density in an uncompressed state is 140 kg. / m ^3. The material has a 25% compressive stress of 0.26 N / cm ² and a 50% compressive stress of 0.54 N / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube, and since the porous body 7 is arranged over the entire length of the tube 6, the internal volume of the tube 6 Was 60% by volume. Table 1 and FIG. 18 show the sound insulation volume against sounds of various frequencies in the use state of the seal member 1. The sound insulation of the seal member 1 was better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz in decibels was improved by 12.0 dB as compared with the conventional example.

[Reference Example 6]
In the seal member 1 of the reference example 6 shown in FIG. 19, a rectangular porous body 7 having a cross section of 10 mm × 15 mm is inserted inside the tube 6. The material constituting the porous body 7 is adjusted to the amount of the foaming agent in accordance with Patent Document 6 so that the water absorption in the uncompressed state is 46.8% and the bulk density in the uncompressed state is 73 kg / m ³ . It is a foamed rubber (EPT sponge (EPDM sponge)) produced as described above. Further, 25% compressive stress is 0.06 N / cm ^2, 50% compression stress is a material of 0.1 N / cm ^2. The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 80% of the cross-sectional area of the hollow portion of the tube 6, and the porous body 7 is disposed over the entire length of the tube 6. The volume occupancy of the porous body 7 with respect to the product was 80%. Table 1 and FIG. 18 show the sound insulation volume against sounds of various frequencies in the use state of the seal member 1. The sound insulation of the sealing member 1 is good, and the sound insulation at high frequencies of 2000 Hz or more is significantly improved as compared with the conventional example. The sound insulation at 4000 Hz to 10000 Hz has a decibel average value higher than that of the conventional example. It improved by 14.4 dB.

Next, comparative examples for comparison with Examples 1 to 3 and Reference Examples 1 to 6 of the present invention will be described.
[Comparative Example 1]
In the seal member of Comparative Example 1 shown in FIG. 20, a porous body 7 having a circular cross section with a diameter of 10 mm is inserted into a tube 6. The material constituting the porous body 7 is adjusted to the water absorption in the non-compressed state of 0.8% and the bulk density in the non-compressed state to 290 kg / m ³ by adjusting the amount of the foaming agent according to Patent Document 6. It is a foamed rubber (EPT sponge (EPDM sponge)) produced as described above. Further, 25% compressive stress is 4.4 N / cm ^2, 50% compression stress is a material of 13.1N / cm ^2. The cross-sectional area of the porous body 7 in the use state of the sealing member is 65% of the cross-sectional area of the hollow portion of the tube 6, and since the porous body 7 is disposed over the entire length of the tube 6, the internal volume of the tube 6 Was 65% by volume. Table 1 and FIG. 21 show the sound insulation volume against sounds of various frequencies when the seal member is used. According to this seal member, only the same level of sound insulation as the conventional seal member can be obtained, and in comparison with the seal members 1 of Examples 1 to 3 and Reference Examples 1 to 6, the sound insulation volume particularly for high frequencies of 2000 Hz or more is low. It is insufficient, and the decibel average value of the sound insulation volume from 4000 Hz to 10000 Hz is improved only by 0.5 dB as compared with the conventional example.

[Comparative Example 2]
In the seal member of Comparative Example 2 shown in FIG. 22, a porous body 7 having a square cross section of 10 mm × 10 mm is inserted into a tube 6. The material constituting the porous body 7 is foamed rubber (CR (chloroprene rubber) sponge square cord), the water absorption in the non-compressed state is 1.6%, and the bulk density in the non-compressed state is 310 kg / m ^3. It is. The material has a 25% compressive stress of 5.19 N / cm ² and a 50% compressive stress of 13.2 N / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member is 66% of the cross-sectional area of the hollow portion of the tube 6, and since the porous body 7 is disposed over the entire length of the tube 6, the internal volume of the tube 6 The volume occupancy of the porous body 7 was 66%. Table 1 and FIG. 21 show the sound insulation volume against sounds of various frequencies when the seal member is used. According to this seal member, only the same level of sound insulation as the conventional seal member can be obtained, and in comparison with the seal members 1 of Examples 1 to 3 and Reference Examples 1 to 6, the sound insulation volume particularly for high frequencies of 2000 Hz or more is low. This is insufficient, and the average value of the decibel of the sound insulation from 4000 Hz to 10000 Hz is lower than the conventional example by 2.0 dB.

[Comparative Example 3]
In the sealing member 1 of Comparative Example 3 shown in FIG. 23, the inside of the tube 6 is filled with a porous body 7 made of a soft polyurethane foam without any gap. That is, the porous body 7 is formed by injecting a material in a fluid state before foaming into the inside of the tube 6 and then foaming it to form a non-flowable solid polyurethane foam. The inside of the tube 6 is completely closed by the porous body 7, and there is no air holding space 8 between the inner wall of the tube 6 and the outer surface of the porous body 7. The water absorption of the polyurethane foam constituting the porous body 7 in the uncompressed state after foaming is 1268%, and the bulk density in the uncompressed state is 56 kg / m ³ . The material has a 25% compressive stress of 0.54 N / cm ² and a 50% compressive stress of 0.8 / cm ² . The cross-sectional area of the porous body 7 in the use state of the sealing member is 100% of the cross-sectional area of the hollow portion of the tube, and the porous body 7 is arranged over the entire length of the tube 6. The volume occupancy of the porous body 7 was 100%. Table 1 and FIG. 24 show the sound insulation of the sealing member 1 against sounds of various frequencies in the use state. The sound insulation is insufficient, and the average value of the sound insulation between 4000 Hz and 10000 Hz is the same as the conventional example. 3.9 dB lower than the above.

[Comparative Example 4]
In the seal member 1 of Comparative Example 4 schematically shown in FIG. 25, a rectangular porous body 7 having a cross-sectional shape of 10 mm × 10 mm is arranged outside the tube 6 side by side with the tube 6. The material constituting the porous body 7 is the same polyurethane foam (trade name: Calmflex F-2 (manufactured by INOAC CORPORATION)) as the porous body 7 of Reference Example 3. The bulk density, 25% compressive stress and 50% compressive stress in the state are all the same as those of the porous body 7 of Reference Example 3. The seal member 1 was compressed by 30% in a state where the porous body 7 was disposed so as to be located on the sounding portion side, and the sound insulation volume for sounds of various frequencies was measured. Since the porous body 7 was disposed outside the tube 6, the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 0%. Table 1 and FIG. 24 show the measurement results of the sound insulation volume. According to the sealing member 1, similarly to the conventional example, the sound insulation particularly at a high frequency of 2,000 Hz or more is insufficient, and the average value of the sound insulation between 4000 Hz and 10000 Hz is only 0.4 dB higher than that of the conventional example. Not.

[Comparative Example 5]
In Comparative Example 5 schematically shown in FIG. 26, the seal member 1 of Comparative Example 4 is compressed by 30% in a state where the porous body 7 is arranged so as to be located on the opposite side of the sound generating portion, and is capable of compressing sounds of various frequencies. The sound insulation volume was measured. Since the porous body 7 was disposed outside the tube 6, the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 0%. Table 1 and FIG. 24 show the measurement results of the sound insulation volume. According to the sealing member 1, similarly to the conventional example, the sound insulation particularly at a high frequency of 2,000 Hz or more is insufficient, and the average value of the sound insulation between 4000 Hz and 10000 Hz is only 0.4 dB higher than that of the conventional example. Not.

  The sealing members of Examples 1 to 3, Reference Examples 1 to 6, and Comparative Examples 1 to 3 described above have a configuration in which the porous body 7 is arranged over the entire length of the tube 6. However, the present inventor does not dispose the porous body 7 over the entire length of the tube 6, but arranges the porous body 7 only partially in the longitudinal direction of the tube 6. It has been found that there is a case where a superior sound insulation effect can be obtained as compared with the seal member (FIGS. 7A and 7B). The tubes 6 of Examples 4 to 13 described below, Reference Examples 7 to 13 and Comparative Examples 6 and 7 are not closed loops but hollow at both ends as schematically shown in FIGS. 27B to 27D. Having the same cross-sectional dimensions and properties as those of the sealing member tubes 6 of Examples 1 to 3, Reference Examples 1 to 6, and Comparative Examples 1 to 5 except for that point. It is made of material. Examples 4 to 13, Reference Examples 7 to 13, and Comparative Example 6 in which the porous body 7 is inserted into both ends or one end (one end) of such a straight or curved tube 6. , 7 will be described below in detail.

[Example 4]
In the seal member 1 according to the fourth embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 relative to the inner volume of the tube 6 was 13.3%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz is 8.6 dB higher than that of the conventional example. Table 2 shows the results.

[Example 5]
In the seal member 1 according to the fifth embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, one end (one end) of the tube 6 having a total length of 840 mm. The porous body 7 was arranged only in a portion within 280 mm from the inside, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 6.7%. The sound-insulating property of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the decibel average value of the sound insulation of 4000 Hz to 10000 Hz is improved by 2.6 dB as compared with the conventional example. Table 2 shows the results.

[Example 6]
In the seal member 1 according to the sixth embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 20 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 40% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 26.7%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz in decibels is improved by 10.9 dB as compared with the conventional example. Table 2 shows the results.

[Example 7]
In the seal member 1 according to the seventh embodiment of the present invention, a porous body 7 having a cross-sectional shape of 2 mm × 5 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 10% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 6.7%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz is improved by 2.5 dB as compared with the conventional example. Table 2 shows the results.

Example 8
In the seal member 1 according to the eighth embodiment of the present invention, a porous body 7 having a cross-sectional shape of 2 mm × 2.5 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 5% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 3.3%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation at 4000 Hz to 10000 Hz is 1.8 dB higher than that of the conventional example. Table 2 shows the results.

[Example 9]
In the seal member 1 according to the ninth embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 10%. The sound insulation of the seal member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 5.4 dB higher than that of the conventional example. Table 2 shows the results.

[Example 10]
In the seal member 1 according to the tenth embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 5%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is improved by 4.3 dB as compared with the conventional example. Table 2 shows the results.

[Example 11]
In the seal member 1 according to the eleventh embodiment of the present invention, a porous body 7 having a cross section of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 relative to the inner volume of the tube 6 was 2.5%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the decibel average value of the sound insulation of 4000 Hz to 10000 Hz is improved by 1.6 dB as compared with the conventional example. Table 2 shows the results.

[Example 12]
In the seal member 1 according to the twelfth embodiment of the present invention, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 15%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 7.7 dB higher than that of the conventional example. Table 2 shows the results.

Example 13
In the seal member 1 according to the thirteenth embodiment of the present invention, a porous body 7 having a cross section of 8 mm × 13 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 3 (FIG. 15). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 55% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 6.9%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is improved by 1.7 dB compared to the conventional example. Table 2 shows the results.

[Reference Example 7]
In the seal member 1 of Reference Example 7, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 1 (FIG. 4). The cross-sectional area of the porous body 7 in the use state of the seal member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and as shown in FIG. The porous body 7 was arranged only in the inner part, and the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 40%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 12.0 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 8]
In the seal member 1 of Reference Example 8, a porous body 7 having a cross-sectional shape of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 1 (FIG. 4). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 140 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 20%. The sound-insulating property of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 9.3 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 9]
In the seal member 1 of Reference Example 9, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having both ends opened. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 1 (FIG. 4). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 7.5%. The sound insulation of the seal member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 8.4 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 10]
In the seal member 1 of Reference Example 10, a porous body 7 having a cross-sectional shape of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 1 (FIG. 4). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 18 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 relative to the inner volume of the tube 6 was 2.5%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz is 2.1 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 11]
In the seal member 1 of Reference Example 11, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having both ends opened. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 3 (FIG. 10). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 7.5%. The sound insulation of the seal member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of the sound insulation between 4000 Hz and 10000 Hz is 4.0 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 12]
In the seal member 1 of Reference Example 12, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having both ends opened. The material constituting the porous body 7 is the same polyurethane foam as in Reference Example 2 (FIG. 9). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 7.5%. The sound insulation of the sealing member 1 against sounds of various frequencies in the use state is better than that of the conventional example, and the average value of decibel of the sound insulation at 4000 Hz to 10000 Hz is 2.8 dB higher than that of the conventional example. Table 2 shows the results.

[Reference Example 13]
In the seal member 1 of Reference Example 13, a porous body 7 having a cross section of 10 mm × 10 mm is inserted into a hollow linear or curved tube 6 having both ends opened. The material constituting the porous body 7 is the same foamed rubber as that of Reference Example 5 (FIG. 17). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 60% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 53 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 7.5%. The sound insulation of the sealing member 1 against sounds of various frequencies in the used state is better than that of the conventional example, and the average value of the sound insulation of 4000 Hz to 10000 Hz is 6.6 dB higher than that of the conventional example. Table 2 shows the results.

Next, comparative examples for comparison with Examples 4 to 13 and Reference Examples 7 to 13 of the present invention will be described.
[Comparative Example 6]
In the seal member 1 of Comparative Example 6, a porous body 7 having a cross-sectional shape of 2 mm x 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, one end (one end) of the tube 6 having a total length of 840 mm. The porous body 7 was arranged only in a portion within 53 mm from the inside, and the volume occupation ratio of the porous body 7 to the inner volume of the tube 6 was 1.3%. As in the conventional example, the sound insulation of the sealing member 1 against sounds of various frequencies in the use state is insufficient, especially for high frequencies of 2000 Hz or higher, and the average sound insulation of 4000 Hz to 10000 Hz is in decibels. Is only 0.4 dB better than the conventional example. Table 2 shows the results.

[Comparative Example 7]
In the seal member 1 of Comparative Example 7, a porous body 7 having a cross-sectional shape of 2 mm × 10 mm is inserted into a hollow linear or curved tube 6 having openings at both ends. The material constituting the porous body 7 is the same nonwoven fabric as in Example 1 (FIG. 13). The cross-sectional area of the porous body 7 in the use state of the sealing member 1 is 20% of the cross-sectional area of the hollow portion of the tube 6, and although not shown, a portion within 26 mm from both ends of the tube 6 having a total length of 840 mm. And the volume occupancy of the porous body 7 with respect to the inner volume of the tube 6 was 1.3%. As in the conventional example, the sound insulation of the sealing member 1 against sounds of various frequencies in the use state is insufficient, especially for high frequencies of 2000 Hz or higher, and the average sound insulation of 4000 Hz to 10000 Hz is in decibels. Is improved only by 0.7 dB over the conventional example. Table 2 shows the results.

  As described above, according to Examples 1 to 13 and Reference Examples 1 to 13 of the present invention, particularly in the range of the frequency (about 2000 Hz to about 16000 Hz) of the high-frequency noise generated by the electric motor used for the electric vehicle or the hybrid vehicle. Demonstrate excellent sound insulation. As described above, excellent sound insulation is obtained by Examples 1 to 13 and Reference Examples 1 to 13 because the sound absorbing effect of the porous body 7 and the vibration attenuation by the air in the air holding space 8 work together. is there. On the other hand, in the conventional example in which the porous body is not provided, the air inside the tube 6 has a vibration damping effect, but the porous body 7 does not have a sound absorbing effect, so that sufficient sound insulation cannot be obtained. In Comparative Example 3 in which the air holding space does not exist in the tube 6, although the porous body 7 has a sound absorbing effect, there is no vibration damping effect by the air in the tube 6, so that sufficient sound insulation cannot be obtained. In Comparative Examples 4 and 5 in which the porous body 7 is located outside the tube 6, the vibration of the air is transmitted through the side of the porous body 7 located in the open space. The sound absorbing effect of the porous body 7 does not reach only a small part, and sufficient sound insulation cannot be obtained.

Further, among the seal members in which the porous body 7 and the air holding space are provided in the tube 6, Comparative Examples 1 and 2 in which sufficient sound insulation properties cannot be obtained, it is considered that the material of the porous body was not appropriate. . That is, when the materials of Comparative Examples 1 and 2 are examined again, it is found that the bulk density is higher than those of Examples 1 to 13 and Reference Examples 1 to 13. This means that the high density of the porous body 7 means that the total amount of holes in a given cross-sectional area of the porous body 7 is small, and that the smaller the number of holes, the smaller the sound absorbing effect. Therefore, in order to realize high sound insulation, it is preferable that the density of the porous body 7 is small. Considering that the sound insulation of Comparative Examples 1 and 2 is small and the sound insulation of Reference Example 5 is within an allowable range, it can be said that the bulk density is preferably 150 kg / m ³ or less. However, if the bulk density is too low, the material strength of the porous body 7 is reduced, and there is a possibility that processing and mounting are difficult. Therefore, the bulk density is preferably 10 kg / m ³ or more.

  Focusing on the water absorption of the material constituting the porous body 7, it is considered that the higher the water absorption, the larger the number of continuous pores. Comparing the water absorption of Examples 1 to 13 and Reference Examples 1 to 13 with Comparative Examples 1 and 2, it is considered that sufficient sound insulation may not be obtained if the water absorption is 1.6% or less. Furthermore, in order to more reliably obtain sufficient sound insulation, it is preferable that the water absorption is preferably about 10% or more. However, if the water absorption is too high, the weight may become heavy due to the absorption of water that has entered through the gap, or the continuous pores may be closed, and the original sound insulation of the seal member of the present invention may not be obtained. The water absorption is preferably 3000% or less.

Focusing on the compressive stress, which is one of the properties of the material constituting the porous body 7, the 25% compressive stress of the porous body 7 of the seal member 1 from which excellent sound insulation was obtained was approximately 1 N / cm ² or less. . The 50% compressive stress of the porous body 7 of the seal member 1 from which excellent sound insulation was obtained was approximately ^2.5 N / cm ² or less.

As described above, in order to obtain excellent sound insulation in the sealing member 1 of the present invention, it is preferable that the bulk density is 10 kg / m ³ or more and 150 kg / m ³ or less, the water absorption is 10% or more and 3000% or less, and 25% or less. % compression stress 1N / cm ² or less, satisfies the condition of 50% compression stress 2.5 N / cm ² or less. However, even if all of these conditions are not satisfied, if at least one of these conditions is satisfied, a certain effect can be obtained for improving the sound insulation, and thus is included in the scope of the present invention.

The sound insulation of the seal member 1 according to the present invention has been described above. Characteristics other than the sound insulation will be described below. As described above, weight reduction is required for vehicle doors and building doors, which are the main applications of the seal member 1 of the present invention. The tube 6 of the seal member 1 of the present invention is the same as that of the conventional example, and the weight of the seal member 1 is increased by the amount of the porous body 7 inserted into the tube 6. Therefore, it is preferable that the porous body 7 is as light as possible. In most of Examples 1 to 3, Reference Examples 1 to 6, and Comparative Examples 1 to 5, there is no significant difference in the cross-sectional area of the porous body 7; Leads to the suppression of an increase in the weight. That is, as described above, setting the bulk density to 150 kg / m ³ or less is also effective in suppressing an increase in the weight of the seal member 1. By setting the bulk density to a small value as described above, a very excellent effect of improving the sound insulation without increasing the weight is obtained. In general, conventional seal members tend to be heavy for seal members having high sound insulation. However, it can be seen from Table 1 that the seal member of the present invention has good sound insulation even though it is clearly lighter than Comparative Examples 1 to 3, which have low sound insulation. That is, it has achieved a special effect that was difficult in the past.

  Further, in the seal member 1 of the present invention, since the porous body 7 to be inserted into the tube 6 does not need to be inserted in advance into a waterproof tube or the like, the manufacturing process of the seal member 1 is not complicated, and the number of parts can be increased. Absent. When the porous body 7 is formed of a material having a small compressive stress as described above, the porous body 7 can be easily attached and the seal member 1 can be easily compressed at the time of use. The seals can be easily adhered to the outer peripheral edges of the doors 2a and 4a and the door frames 3a and 5a with a small force, so that the reliability (heat resistance and weather resistance) of the seal is good.

  In Examples 4 to 13 and Reference Examples 7 to 13 of the present invention, instead of arranging the porous body 7 over the entire length of the tube 6 as shown in FIG. 27A, as shown in FIGS. 27E shows that even with a configuration in which the porous body 7 is inserted only partially in the longitudinal direction, an effect of improving sound insulation can be obtained as compared with a conventional sealing member having no porous body as shown in FIG. 27E. . In Examples 4 to 13 and Reference Examples 7 to 13, sound insulation comparable to the sealing members 1 of Examples 1 to 3 and Reference Examples 1 to 6 in which the porous body 7 is disposed over the entire length of the tube 6 is realized. In addition, the required amount of the porous body 7 is small and the insertion operation of the porous body 7 is easy, so that the manufacturing cost can be kept low, and the overall weight of the sealing member 1 can be kept low, and the weight can be reduced. It contributes to various effects. However, in Comparative Examples 6 and 7, since the ratio (volume occupancy) of the porous body 7 to the internal volume of the tube 6 is too small, the sound absorbing effect of the porous body 7 does not reach and sufficient sound insulation is obtained. Absent. Looking at the amount of improvement in sound insulation of Examples 1 to 13, Reference Examples 1 to 13, and Comparative Examples 1 to 7 shown in Table 2, the volume occupancy of the porous body 7 is about 2.5 to 89%. Is preferable. In addition, according to the results of Examples 4 to 13, Reference Examples 7 to 13, and Comparative Examples 6 and 7, in order to obtain the effect of improving the sound insulation, at least the porous body 7 is required to be in the longitudinal direction of the tube 6. It can be seen that the tube 6 is preferably arranged so as to occupy a range of 4% or more of the entire length.

  In Examples 4 to 13 and Reference Examples 7 to 13, hollow linear or curved tubes 6 having both ends opened as shown in FIGS. 27A to 27E are used. It may constitute a part of the looped tube body 6X. In the example shown in FIG. 28, a pair of tubes (one tube 6a and another tube 6b) are joined via a corner joint 6c to form a loop-shaped tube body 6X that is a composite member. . In this case, as described above, one or both of the pair of tubes 6a and 6b are partially inserted with the porous body 7 in the length direction as described above, as in Examples 4 to 13 and Reference Examples 7 to 13. A straight or curved seal member 1 can be formed. In the case of the seal member 1 used for the vehicle door 2 as shown in FIG. 1, the upper tube 6a located on the upper side (ceiling side) and the lower tube 6b located on the lower side (floor side) are attached when mounted. It is general that a loop-shaped tube body 6X is configured. In the upper tube 6a arranged near the occupant's ear, the porous body 7 is at least partially arranged as in Examples 10 to 26. It is particularly preferable to improve the sound insulation. In this case, the lower tube 6b may be at least partially provided with the porous body 7 to improve the sound insulation, or the lower tube 6b far from the occupant's ear may not be provided with the porous body 7 to reduce the manufacturing cost. May be further suppressed and weight may be reduced.

  Generally, both ends of a tube (for example, the upper tube 6a) joined to another tube (for example, the lower tube 6b) via the corner joint 6c are open for convenience of a molding and joining process. Conventionally, it has been difficult for a seal member including such a tube to achieve high sound insulation because of sound leakage from the open end of the tube. On the other hand, in Examples 4 to 13 and Reference Examples 7 to 13 described above, sound leakage from the opening end is suppressed by the porous body 7. Referring to Table 2, when at least a part of the porous body 7 is present within a distance of 33% of the entire length of the tube from the opening end, the effect of improving the sound insulation is obtained. I understand.

  Inserting the porous body 7 into the hollow tube 6 in this manner can be achieved by using the loop-shaped tube, which is a composite member as shown in FIG. 28, even in the closed loop-shaped seal member 1 as shown in FIG. The present invention is also effective for the sealing member 1 which is a part of the body 6X and is formed of a hollow linear or curved tube 6a having openings at both ends.

  The seal member 1 of the present invention described above is not limited to the structure attached to the outer peripheral edge of the vehicle door body or the building door body, but may be attached inside the door frame. Further, the seal member 1 of the present invention is attached to an outer peripheral edge of a storage portion of a vehicle drive device, for example, a gasoline engine or an electric motor of an automobile, and is sandwiched between a housing frame and compressed. May be sealed. Further, the present invention can be used for various members requiring a seal such as an electric product, and the application range is not limited.

[Seal member manufacturing method]
Next, a method for manufacturing the seal member 1 of the present invention will be described. This method has a configuration in which the porous body 7 is disposed inside a hollow tube body 6X which is a composite member formed by joining a plurality of tubes 6a and 6b (parts) via a joint 6c as described above. This is a method for manufacturing the sealing member 1 described above.

  Usually, when forming the hollow tube body 6X which is a composite member, a plurality of tubes which are hollow parts are joined via a joint. As an example, one tube is fitted into one end of a rod-shaped (columnar) core for forming the hollow portion of the joint, and the other tube is fitted into the other end of the core. Then, an unvulcanized rubber layer or a resin layer is formed so as to cover the outer periphery of the core, and the rubber layer is vulcanized and bonded by heating and pressing, or the resin layer is heated and pressed and then cooled and pressed. By solidifying, a joint made of an elastically deformable vulcanized rubber layer or resin layer is formed.

  In one embodiment of the present invention, before forming the joint 6c and joining the tubes 6a and 6b, as shown in FIG. 29A, the aforementioned porous body 7 is inserted in advance into the tubes 6a and 6b, and FIG. As shown, the porous body 7 is fixed to the inner surface of the tube. Then, the tubes 6a and 6b into which the porous bodies 7 are inserted are fitted and attached to both ends of the curved rod-shaped (cylindrical) core 16 shown in Fig. 30 (Fig. 31). At this time, it is preferable that the porous body 7 is not in contact with the core 16. Then, for example, an unvulcanized rubber sheet or a thermoplastic resin sheet is wound around the outer periphery of the core 16 to which the tubes 6a and 6b into which the porous body 7 is inserted and fixed are attached. Then, as shown in FIG. 32, the core 16 to which the tubes 6a and 6b are attached and the unvulcanized rubber sheet or the resin sheet is wound is arranged in the cavity 17a of the mold 17. As schematically shown in FIG. 33, the mold 17 is set on a press machine 18 and the rubber is vulcanized by heating and pressing, or by heating and pressing, followed by cooling and pressing. The resin sheet is thermally welded to form a joint 6c made of a vulcanized rubber layer or a resin layer. The heating conditions for forming the joint 6c by vulcanizing the rubber include, for example, heating at 170 ° C. for 15 minutes, heating at 180 ° C. for 8 minutes, or heating at 190 ° C. for 4 minutes. The heating conditions for solidifying the thermoplastic resin to form the joint 6c include preheating at 200 ° C. for 10 minutes, heating and pressurizing for 5 minutes, and cooling and pressurizing for 5 minutes. When the joint 6c is completed, it is removed from the mold 17 as shown in FIG. Then, as shown in FIG. 35, while the joint 6c is elastically deformed, the slit 6 is formed in advance from the slit 19 of the joint 6c formed in advance by a projection (not shown) or the like provided on the mold. If it is not formed, a part of the joint 6c is cut out to form a slit portion 19, and then the core 16 is taken out from the slit portion 19. Thus, a tube body 6X having a configuration in which the tubes 6a and 6b are joined via the joint 6c as shown in FIG. 36 is completed.

  In another example, the core 16 to which the tubes 6a and 6b in which the porous body 7 has been previously inserted and fixed as described above is mounted in the cavity 20a of the mold 20 of the injection molding apparatus shown in FIG. Then, the molten unvulcanized rubber or resin is injected into the cavity 20a, and the inside of the cavity 20a and the outside of the core 16 is filled with the molten unvulcanized rubber or resin. Then, the injected unvulcanized rubber or resin is vulcanized or solidified to form a joint 6c formed of a vulcanized rubber layer or a resin layer that can be elastically deformed. Thereafter, in the same manner as in the above-described process, the cores 16 are removed from the mold as shown in FIGS. 34 to 35 and the core 16 is taken out from the slit portion 19 of the joint 6c, so that the tubes 6a and 6b are joined as shown in FIG. The tube body 6 </ b> X having the configuration joined through the via 6 c is completed.

  According to the manufacturing method described above, before the tubes 6a and 6b are joined to each other by the joint 6c, the porous body 7 is joined and fixed to the inner surface of the tube 6 as shown in FIG. When the porous body 7 is fixed inside the tube 6 in this manner, the sound insulation is further improved. One of the reasons is that the vibration absorbing effect of the porous body 7 is enhanced by the fact that the porous body 7 is fixed and does not easily move or vibrate. Further, it is considered that the slit 19 of the joint 6 c for taking out the core 16 hinders sound insulation (contributes to sound transmission), but the porous body 7 is fixed in the vicinity of the slit 19. Since the porous body 7 is reliably located at a position where the sound absorbing function is particularly desired, the sound insulating effect of the seal member can be efficiently obtained.

  As exemplified in each of the above-described Examples and Reference Examples, examples of the material of the porous body 7 that can realize good sound insulation under appropriate conditions include polyurethane foam, foamed rubber, and nonwoven fabric. However, depending on the material of the tube 6 and the porous body 7, the bonding strength is weak, and the effect of improving the sound insulation property by fixing the porous body 7 inside the tube 6 described above cannot be obtained. May melt and lose porosity and sound insulation. Specifically, when the material of the porous body 7 is the same or similar to the material of the tube 6, the bonding can be easily performed with high reliability by a method such as heat fusion. That is, the resin members made of the same or similar resin materials have close melting temperatures, and strong heat fusion is realized by heating to a temperature near the melting temperature. Further, as disclosed in Patent Literature 7, it is conceivable to increase the bonding strength by defining the surface roughness of the bonding surface of members (rubber member and resin member) bonded to each other. However, when the member to be joined is made of a nonwoven fabric, the material is not the same or similar to the material of the tube 6 (for example, crosslinked rubber), so that the reliability of joining by heat welding is not high. In addition, since it is difficult to adjust the surface roughness of the nonwoven fabric to a predetermined roughness, it is difficult to perform good bonding by applying the method of Patent Document 7. Therefore, Patent Document 8 discloses that a resin adhesive layer is interposed between a resin material (weather strip) and a nonwoven fabric, the weatherstrip is joined to the resin adhesive layer, and the nonwoven fabric is joined to the resin adhesive layer. It has been proposed that the weather strip and the nonwoven fabric be strongly bonded indirectly. However, this method requires a resin adhesive layer, which causes problems such as manufacturing cost, complicated manufacturing steps, and an increase in the size of the joint.

  As described above, a method of easily and reliably joining two members, for example, a first member made of a crosslinked rubber or the like and a second member made of a resin nonwoven fabric at low cost and without intervening an adhesive layer. It has been demanded. Therefore, in the present invention, a method has been newly found in which a resin member and a nonwoven fabric can be favorably joined by ultrasonic welding. That is, the first member (for example, the tube 6) made of crosslinked rubber has a melting peak temperature of 100 ° C. or higher measured in accordance with the differential scanning calorimetry of the plastic transition temperature measuring method specified in JIS K 7121. When joining a second member (porous body 7) made of a nonwoven fabric containing a material having a temperature of 200 ° C. or less by ultrasonic welding, it can be easily and reliably joined at low cost without an intervening adhesive layer. I found it. That is, when ultrasonic vibration is applied to the non-woven fabric using a general ultrasonic welding machine, the material having a melting peak temperature of 100 ° C. or more and 200 ° C. or less is melted or softened, and entangled with the surface of the crosslinked rubber and strongly bonded. Is done. When the nonwoven fabric is composed of a plurality of materials, the melting peak temperature of at least one material is 100 ° C or more and 200 ° C or less, preferably 110 ° C or more and 190 ° C or less, more preferably 120 ° or more and 180 ° C or less. Often, the melting peak temperatures of other materials need not be within this temperature range. As a preferred example, the non-woven fabric is made of a material including polyethylene or polypropylene. Specifically, Krypton's Mystic White (trade name, material: polyethylene, melting peak temperature: 148 ° C.), polypropylene produced by the melt blown method of Mitsui Chemicals, Inc. used in Examples 1-2, 4-12. Non-woven fabric (material: polypropylene, melting peak temperature: 162 ° C), Tafnel oil blotter AR-65 of Mitsui Chemicals, Inc. used in Examples 3 and 13 (trade name, material: polypropylene, melting peak temperature: 169 ° C), Thinsulate (trade name, material: polypropylene (melting peak temperature: 166 ° C.) + Polyester (melting peak temperature:> 230 ° C.), etc.) of 3M Japan Ltd. is suitably used as the material of the nonwoven fabric. The measurement is based on the method of measuring the transition temperature of plastics specified in JIS K 7121. By scanning calorimetry (DSC), weighing was carried out by heating at a heating rate of about 10 ° C. / sec Samples of 5mg in a range of 30 to 230 ° C..

  The tube 6 bonded to the nonwoven fabric is preferably made of a material containing foamed ethylene / propylene / diene rubber, foamed chloroprene rubber, and foamed EVA (ethylene / vinyl acetate copolymer resin). More specifically, as a material of the tubes 6a and 6b, a synthetic rubber such as the above-described EPDM (ethylene-propylene-diene rubber) is generally used, but is not limited thereto. The tubes 6a, 6b and the joint 6c may be formed of the same material, or may be formed of different materials. The material of the joint 6c may be the above-mentioned EPDM (ethylene-propylene-diene rubber) or the like. Synthetic rubber, olefin-based thermoplastic elastomer (for example, Mirastomer (trade name) of Mitsui Chemicals, Inc.) or the like can be used.

  An example of ultrasonic welding in the method according to the present invention is shown in FIGS. 39A and 39B. For example, as shown in FIG. 39A, using an ultrasonic welding machine 21 such as an ultrasonic stapler Haru SUH-30 (trade name) (oscillation frequency 60 kHz) of Suzuki Corporation, the inside of the tube 6 is opened from the open end of the tube 6. The horn 21a is made to enter and is brought into contact with the porous body (nonwoven fabric) 7, and the chip 21b is brought into contact with the outer surface of the tube 6 at a position overlapping with the porous body 7. Then, as shown in FIG. 39B, ultrasonic vibration is applied to the nonwoven fabric 7 from the horn 21a while the tube 6 and the nonwoven fabric 7 are heated while being pressed by the horn 21a and the tip 21b. As a result, as described above, the material whose non-woven fabric 7 has a melting peak temperature of 100 ° C. or higher and 200 ° C. or lower melts or softens, and is firmly joined to the tube 6 made of crosslinked rubber. As described above, in the method according to the present invention, after the porous body (nonwoven fabric) 7 is arranged on the inner surface of the tube 6, the porous body 7 is bonded to the inside of the tube 6 using ultrasonic vibration. The frequency of the ultrasonic wave used in this method is generally 20 kHz or more and 3000 kHz or less, preferably 25 kHz or more and 1000 kHz or less. When welding the tube 6 and the porous body 7 using ultrasonic waves having such a preferable frequency range, the amount of energy applied to the tube 6 and the porous body 7 is appropriate, and the tube 6 at the time of welding and after the welding is welded. And the handling of the porous body 7 is easy.

The present inventor performed joining using the same material as in Example 1 while changing the conditions of ultrasonic welding, and the results are shown in Table 3. From this table, it can be seen that the non-woven fabric 7 is preferably applied by applying ultrasonic vibration while applying a pressure of 1.0 MPa or more for 0.7 seconds or more. In particular, it can be seen that good bonding can be achieved by applying ultrasonic vibration while pressing the nonwoven fabric 7 under the condition that the product of the pressure and the pressing time is larger than 1.75 [MPa · sec]. In Table 3 below, the product of the pressure and the pressurizing time when the pressure is 2.5 MPa and the pressurizing time is 0.7 seconds is 1.75. As an example, a force gauge (not shown) (for example, Force Gauge AD-4932A-50N of A & D Co., Ltd.) is brought into contact with the horn 21a of the ultrasonic welding machine 21, and the tube 6 is connected with the horn 21a and the tip 21b. The force applied when bonding the nonwoven fabric 7 was measured with a force gauge, and the pressure was determined by dividing the force by the area of the portion sandwiched between the horn 21a and the tip 21b. The area of the portion sandwiched between the horn 21a and the chip 21b is substantially the same as the area of the terminal portion of the chip 21b (14.45 mm ^{2 in} one example).

A method of manufacturing the sealing member 1 as shown in FIG. 28 using the joining method of the members described above (the first member made of foamed rubber and the second member made of nonwoven fabric) will be described.
As shown in FIG. 40A, a nonwoven fabric 7 which is a porous body is inserted into a tube 6a made of crosslinked rubber and having an air vent hole 23 as shown in FIG. 40B. Then, as shown in FIG. 40C, the nonwoven fabric 7 is arranged at a predetermined position away from the open end of the tube 6a. As shown in FIG. 40D, a small ultrasonic welding machine 21 is prepared, and the horn of the ultrasonic welding machine 21 abuts or faces the nonwoven fabric 7 inserted into the tube 6a through the air vent hole 23, The ultrasonic welding machine 21 is arranged so that the tip facing the horn supports the surface (outer surface) of the tube 6a opposite to the surface (inner surface) on which the nonwoven fabric 7 is placed. Thus, similarly to the step shown in FIG. 39B, ultrasonic vibration is applied while pressing the nonwoven fabric 7 against the inner surface of the tube 6 with a horn and a tip. Thereby, as shown in FIG. 40E, the nonwoven fabric 7 is ultrasonically welded to the inner surface of the tube 6 and is firmly fixed to such a degree that it does not come off even when pulled. Then, similarly to the process shown in FIG. 31 to FIG. 37 or FIG. 38, the tube is joined to another tube 6b via the joint 6c (see FIG. 41).

  42A to 42D show a modification of the method of manufacturing the seal member 1. In this modification, the tubes 6a and 6b in which the porous body (nonwoven fabric) 7 is not inserted are joined to each other via the joint 6c in the same manner as in the steps shown in FIGS. 31 to 37 or 38 (see FIG. 42A). ). After that, as shown in FIG. 42B, the nonwoven fabric 7 is inserted from the slit 19 of the joint 6c and enters the inside of the tube 6a. At this time, the joint 6c made of an elastic material such as a crosslinked rubber is bent and deformed so that a part of the width of the slit 19 is temporarily widened so that the nonwoven fabric 7 can be inserted. Then, as shown in FIG. 42C, the nonwoven fabric 7 is arranged at a predetermined position away from the open end of the tube 6a. As shown in FIG. 42D, using a small ultrasonic welding machine 21, similarly to the process shown in FIG. 39B, ultrasonic vibration is applied while pressing the nonwoven fabric 7 against the inner surface of the tube 6 with a horn and a tip. It is firmly joined to the inner surface of the tube 6. Thus, a seal member 1 similar to the configuration shown in FIG. 41 is completed.

  According to these methods, the nonwoven fabric 7 can be firmly joined to the inner surface of the tube 6a by ultrasonic welding, and the sound insulation effect can be enhanced. Since the joining can be performed in a very short time (in the example shown in Table 3 at a minimum of less than 1 second) using a general ultrasonic welding machine 21, the working efficiency is very good. The operation is very simple only by bringing the horn of the ultrasonic welding machine 21 into contact with the nonwoven fabric 7 through the well-known air vent hole 23 generally provided in the tube 6a. Furthermore, even if the horn does not directly contact the non-woven fabric 7, ultrasonic welding can be performed if ultrasonic vibration and pressure can be applied to the non-woven fabric 7 through a part of the tube 6a. Since the manufacturing process is simple, the working time is short, and there is no need to use an adhesive layer or the like, the manufacturing cost of the seal member 1 can be extremely reduced.

DESCRIPTION OF SYMBOLS 1 Seal member 2 Vehicle door 2a Vehicle door main body 3 Body 3a Door frame 4 Building door 4a Building door main body 5 Vehicle body 5a Door frames 6, 6a, 6b Tube (first member)
6c joint 7 porous body (nonwoven fabric, second member)
Reference Signs List 8 air holding space 9 reverberation room 10 semi-anechoic room 11 partition wall 12 opening 13 holding mechanism 14 speaker 15 microphone 16 core 17, 20 mold 17a, 20a cavity 18 press machine 19 slit unit 21 ultrasonic welding machine 21a horn 21b chip

Claims (23)

  The first member made of a crosslinked rubber includes a material having a melting peak temperature of 100 ° C or more and 200 ° C or less measured in accordance with the differential scanning calorimetry of the plastic transition temperature measurement method specified in JIS K 7121. A method for joining members, wherein the second member made of a nonwoven fabric is joined by ultrasonic welding.   The member joining method according to claim 1, wherein the ultrasonic welding is performed using ultrasonic waves having a frequency of 20 kHz or more and 3000 kHz or less.   The method for joining members according to claim 1, wherein the nonwoven fabric is made of a material containing polyethylene or polypropylene.   The member according to any one of claims 1 to 3, wherein the first member is made of a material including foamed ethylene / propylene / diene rubber, foamed chloroprene rubber, and foamed EVA (ethylene / vinyl acetate copolymer resin). Joining method. In a method of manufacturing an elastically deformable seal member,
The first resin member is a hollow tube,
A method for manufacturing a seal member, comprising fixing the nonwoven fabric inside the tube by the method for joining members according to any one of claims 1 to 4.   The inside of the tube is not completely closed by the nonwoven fabric, and an air holding space is provided between a part of the inner wall of the tube and a part of the outer surface of the nonwoven fabric, and the nonwoven fabric occupies the inside of the tube The method for manufacturing a seal member according to claim 5, wherein the nonwoven fabric is arranged so that a volume to be occupied occupies 2.5% or more of an inner volume of the tube.   The method for producing a seal member according to claim 6, wherein the nonwoven fabric has a water absorption in an uncompressed state of 10% or more and 3000% or less. The method for producing a seal member according to claim 6, wherein the nonwoven fabric has a bulk density of 10 kg / m ³ or more and 150 kg / m ³ or less in a non-compressed state. The non-woven fabric, compressive stress of the dimensions of the compression direction is compressed to reduce 25% is 1N / cm ² or less, the manufacturing method of the sealing member according to any one of claims 6 to 8. The method for manufacturing a seal member according to any one of claims 6 to 9, wherein the nonwoven fabric has a compressive stress of ^2.5 N / cm2 or less for compressing until the dimension in the compression direction is reduced by 50%.   The manufacturing of the seal member according to any one of claims 6 to 10, wherein the nonwoven fabric is arranged such that a volume occupied by the nonwoven fabric inside the tube is 89% or less of an inner volume of the tube. Method.   The method for manufacturing a seal member according to any one of claims 6 to 11, wherein the nonwoven fabric is arranged in a range of 4% or more of the entire length of the tube in the longitudinal direction of the tube.   13. The non-woven fabric according to claim 6, wherein the tube has a straight or curved shape with openings at both ends, and at least a part of the nonwoven fabric is arranged within a range in which a distance from an opening end is 33% or less of the entire length of the tube. The method for producing a seal member according to any one of the above.   14. The method for manufacturing a seal member according to claim 13, wherein the tube is joined to another tube via a joint to form a closed loop. After fixing the nonwoven fabric inside the tube, attaching the tube and the other tube to both ends of a rod-shaped core for forming a joint, respectively,
Forming a joint made of a vulcanized rubber layer or a resin layer that is elastically deformable on the outer periphery of the core in which the tube and the other tube are respectively attached to both ends,
After the step of forming the joint composed of a vulcanized rubber layer or a resin layer that can be elastically deformed on the outer periphery of the core, a step of taking out the core from a slit portion of the joint,
The method for manufacturing a seal member according to any one of claims 6 to 14, comprising:   From the opening end of the tube before being attached to the end of the core, insert the nonwoven fabric into the tube, and place the horn of the ultrasonic welding machine on at least a part of the nonwoven fabric through the opening. The method for manufacturing a seal member according to claim 15, wherein ultrasonic vibration is applied from the horn to the nonwoven fabric in a state of being in contact with or facing the nonwoven fabric. Before fixing the nonwoven fabric inside the tube, attaching the tube and the other tube to both ends of a rod-shaped core for forming a joint, respectively,
Forming a joint made of a vulcanized rubber layer or a resin layer that is elastically deformable on the outer periphery of the core in which the tube and the other tube are respectively attached to both ends,
After the step of forming the joint made of a vulcanized rubber layer or a resin layer that can be elastically deformed on the outer periphery of the core, a step of taking out the core from a slit portion of the joint,
The method for manufacturing a seal member according to any one of claims 6 to 14, wherein the nonwoven fabric is fixed inside the tube after the step of removing the core.   From a hole provided in the tube or a slit provided in the joint connected to the other tube via the joint, insert the nonwoven fabric into the tube, and insert a horn of an ultrasonic welding machine, From the horn to the non-woven fabric, in contact with at least a part of the non-woven fabric through the hole, or opposed to at least a part of the non-woven fabric with a part of the tube covering the non-woven fabric sandwiched therebetween The method for manufacturing a seal member according to claim 17, wherein ultrasonic vibration is applied.   The method according to any one of claims 6 to 18, wherein the tube is made of an elastomer having a specific gravity of 0.3 or more and 1 or less and a water absorption of less than 50%.   The method for manufacturing a seal member according to claim 19, wherein the elastomer includes ethylene / α-olefin / non-conjugated polyene.   The method according to any one of claims 6 to 20, wherein the tube has an inner diameter of 5 mm or more and 40 mm or less in a non-compressed state.   22. The cross-sectional area of the porous body in a use state of the seal member is 5% or more and 90% or less of a cross-sectional area of a portion surrounded by the inner wall of the tube. A manufacturing method of the seal member according to the above.   23. The cross-sectional area of the air holding space in a use state of the seal member is 10% or more and 95% or less of a cross-sectional area of a portion surrounded by the inner wall of the tube. 3. The method for manufacturing a seal member according to item 1.

Images