Sound insulation material and method for producing sound insulation material

Abstract

The invention relates to a sound insulation material and a manufacturing method of the sound insulation material. This sound insulation material (1) is provided with: a first layer (10) that is formed from a polyurethane foam; a second layer (20) which is laminated on the surface of the first side of the first layer and is composed of a sheet-like member made of a material other than polyurethane; and a third layer (30) that is laminated on the first-side surface of the second layer, is formed from a polyurethane foam, and has a higher density over the entire layer than the density of at least a portion of the first layer.

Description

[0001] This application is a divisional application of an application filed on October 15, 2019, with application number 201980078884.3, and invention name “Sound insulation material and method for manufacturing sound insulation material”. Technical Field

[0002] The invention relates to a sound insulation material and a method for manufacturing the sound insulation material.

[0003] This application claims priority based on Japanese Patent Application No. 2018-222665 filed on November 28, 2018, the contents of which are incorporated herein in their entirety. Background Art

[0004] There has been a conventional sound insulating material composed of a single-layer structure of polyurethane foam (for example, PTL 1).

[0005] Reference List

[0006] Patent Literature

[0007] PTL 1: Japanese Patent Laid-Open No. 2006-316788 Summary of the invention

[0008] Problem that the invention aims to solve

[0009] However, such conventional sound insulation materials have room for improvement in sound insulation performance.

[0010] An object of the present invention is to provide a soundproofing material capable of allowing the soundproofing performance to be improved, and a method for producing a soundproofing material by which the soundproofing material capable of allowing the soundproofing performance to be improved can be obtained.

[0011] Solutions for solving problems

[0012] The sound insulation material of the present invention comprises

[0013] a first layer, the first layer being composed of polyurethane foam,

[0014] a second layer, the second layer being laminated on the first side surface of the first layer and being composed of a sheet-like member made of a material other than polyurethane, and

[0015] A third layer is laminated on the surface of the second layer on the first side, the third layer is made of polyurethane foam, and has a density higher than that of at least a portion of the first layer over the entire layer.

[0016] The method for producing the sound insulation material of the present invention comprises:

[0017] The first layer manufacturing step is to obtain the first layer composed of polyurethane foam.

[0018] a second layer preparation step of preparing a second layer composed of a sheet-like member made of a material other than polyurethane,

[0019] a third layer manufacturing process of thermally compressing the polyurethane foam that has not been thermally compressed, thereby obtaining a third layer having a density higher than the density of any part of the first layer obtained in the first layer manufacturing process over the entire layer, and

[0020] A stacking process is performed by stacking the second layer prepared in the second layer preparation process on the surface of the first side of the first layer obtained in the first layer preparation process, and stacking the third layer obtained in the third layer preparation process on the surface of the first side of the second layer, thereby obtaining a stacked body.

[0021] Effects of the Invention

[0022] According to the present invention, it is possible to provide a soundproof material capable of allowing the soundproof performance to be improved, and a method for producing a soundproof material capable of obtaining the soundproof material capable of allowing the soundproof performance to be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In the attached picture:

[0024] Figure 1 A cross-sectional view schematically showing a sound insulating material according to a first embodiment of the present invention;

[0025] Figure 2 A view for describing a third layer manufacturing process in the method for manufacturing a sound insulating material according to the first embodiment of the present invention;

[0026] Figure 3 For description Figure 1 A view of the effect of sound insulation materials;

[0027] Figure 4 A cross-sectional view schematically showing a sound insulating material according to a second embodiment of the present invention;

[0028] Figure 5 A view for describing a laminate forming process in a method for producing a sound insulating material according to a second embodiment of the present invention;

[0029] Figure 6 is a graph showing the sound pressure test results in Example 1 and Comparative Example 1 of the sound insulation material of the present invention; and

[0030] Figure 7 To schematically illustrate Figure 6A cross-sectional view of a sound insulating material according to Comparative Example 1 used in a sound pressure test. DETAILED DESCRIPTION

[0031] The soundproofing material of the present invention may be used in any location and / or article, and is preferably used in a vehicle.

[0032] Hereinafter, embodiments of a soundproofing material and a method of manufacturing the soundproofing material according to the present invention will be illustrated and described with reference to the accompanying drawings.

[0033] In the drawings, the same reference numerals are given to common components.

[0034] [First embodiment]

[0035] Figure 1 to Figure 3 Each is a view for describing a soundproof material 1 according to a first embodiment of the present invention and a method for producing the same.

[0036] Figure 1 A cross section of a soundproof material 1 according to a first embodiment of the present invention is shown. The soundproof material 1 of the present embodiment is composed of a laminated structure in which a plurality of layers (specifically, 4 layers in the present example) are laminated.

[0037] Here, for convenience, one side ( Figure 1 The upper side in the stacking direction is referred to as the "first side (S1)", and the other side in the stacking direction ( Figure 1 The lower side in (S2) is called "side 2 (S2)". Figure 1 In the example of , when the soundproof material 1 is used, its stacking direction corresponds to the vertical direction, its first side S1 corresponds to the upper side in the vertical direction, and its second side S2 corresponds to the lower side in the vertical direction. However, when the soundproof material 1 is used, its stacking direction, and its respective directions and orientations at the first side S1 and the second side S2 may be different from Figure 1 Those in the examples.

[0038] like Figure 1 As shown in the example of , the soundproof material 1 is configured so that its surface located on the second side S2 is opposite to the sound source generator G when in use. The soundproof material 1 is constructed so that when thus configured, any sound generated from the sound source generator G is suppressed from being transmitted to the first side S1 instead of to the soundproof material 1. This performance exhibited by the soundproof material 1 is referred to herein as "soundproof performance", which allows any sound from the sound source generator G to be suppressed from being transmitted to the first side S1 instead of to the soundproof material 1.

[0039] From the perspective of improving sound insulation performance, such as Figure 1As shown in the example of , the sound insulating material 1 is preferably configured so that its surface located on the second side S2 is in contact with the sound source generator G when in use.

[0040] The sound source generator G may be any product, and is preferably a component constituting a vehicle. In this example, the sound source generator G is disposed in the engine room of the vehicle. In this example, the sound insulation material 1 is placed on the sound source generator G and in contact therewith.

[0041] The sound insulating material 1 of the present embodiment includes a first layer 10 as a surface layer closest to the second side S2, a second layer 20 laminated on the surface of the first layer 10 located on the first side S1, a third layer 30 laminated on the surface of the second layer 20 located on the first side S1, and a fourth layer 40 laminated on the surface of the third layer 30 located on the first side S1, and the fourth layer 40 is the surface layer closest to the first side S1.

[0042] exist Figure 1 In the example of , the first layer 10, the second layer 20, the third layer 30 and the fourth layer 40 are each formed in a flat plate-like manner, in other words, each has a substantially constant thickness and is flat over the entire layer. The surface of the soundproof material 1 located on the second side S2 (the surface of the first layer 10 located on the second side S2) is therefore flat. This configuration is particularly preferred because the surface ( Figure 1 The upper surface of Figure 1 When it is flat as in the example, the contact area between the sound insulation material 1 and the sound source generator G can be increased, thereby improving the sound insulation performance.

[0043] The first layer 10, the second layer 20, the third layer 30, and the fourth layer 40 are preferably fixed to each other (e.g., bonded or welded) at least at their respective portions (e.g., only the outer peripheral ends of each layer) between these layers. Therefore, when the sound insulating material 1 is transported and / or used, for example, the individual layers 10 to 40 of the sound insulating material 1 can be prevented from being separated from each other.

[0044] However, the first layer 10 to the fourth layer 40 may not be fixed to each other.

[0045] The first layer 10 is made of polyurethane foam. The polyurethane foam constituting the first layer 10 is referred to herein as "first polyurethane foam".

[0046] In this embodiment, the density (kg / m 3 ) are basically uniform.

[0047] The first polyurethane foam constituting the first layer 10 is a general polyurethane foam that has not been thermally compressed.

[0048] The first layer 10 (and therefore the first polyurethane foam) has a structure in which a large number of cells are arranged (not collapsed), and is therefore high in performance of absorbing any incoming sound (hereinafter referred to as "sound absorbing performance").

[0049] The third layer 30 is made of polyurethane foam. The polyurethane foam constituting the third layer 30 is referred to herein as "third polyurethane foam".

[0050] In this embodiment, the density (kg / m 3 The third layer 30 has a density (kg / m2) higher than that of any part of the first layer 10 in its entirety. 3 ).

[0051] In this example, the third layer 30 (third polyurethane foam) is composed of thermally compressed polyurethane foam (thermally compressed polyurethane foam). Figure 2 Schematically shown in FIG. 1 , the third layer 30 is obtained by thermally compressing a block 130 composed of ordinary polyurethane foam that has not been thermally compressed. Hereinafter, the polyurethane foam that has not been thermally compressed constituting the block 130 is referred to as "the fourth polyurethane foam". In this example, the third layer 30 is obtained by thermal compression in its thickness direction.

[0052] As described above, the density (kg / m 3 ) is high. Therefore, when compared at the same volume, the amount of voids in the third layer 30 is less than that in the first layer 10, so the sound absorption performance is lower, but the rebound performance (hereinafter, referred to as sound shielding performance) of any sound trying to enter is higher. In this example, the third layer 30 is composed of heat-compressed polyurethane foam, so collapsed cells are provided and there are almost no voids or no voids therein, so there is almost no sound absorption performance, but the sound shielding performance is high. The vibration damping performance of the third layer 30 is higher than that of the first layer 10.

[0053] The second layer 20 is made of a material other than polyurethane, and is composed of a sheet-like member arranged in a sheet form.

[0054] The second layer 20 is made of a material other than polyurethane, in other words, a material different from that of the first layer 10 and the third layer 30, and thus the sound insulation performance of the soundproof material 1 can be allowed to be improved compared to the case where the second layer 20 is not between the first layer 10 and the third layer 30 and the first layer 10 and the third layer 30 are in direct contact with each other. More specifically, the inventors of the present invention have recently paid attention to the following: in the case where the second layer 20 is not between the first layer 10 and the third layer 30, in the case where the force of any sound is inputted from the sound source generator G to the soundproof material 1 at a specific frequency, the sound insulation performance is deteriorated compared to the case where the force of any sound is inputted at other frequencies. The reason for this is considered to be because such sound of a specific frequency is amplified due to the resonance of each polyurethane foam (the first polyurethane foam and the third polyurethane foam) constituting the first layer 10 and the third layer 30. The inventors of the present invention have recently discovered that the second layer 20 composed of a material other than polyurethane can be provided between the first layer 10 and the third layer 30, thereby allowing the sound insulation performance to be improved in the case where the force of such sound is input at a specific frequency. The reason for this is considered to be because the second layer 20 is interposed between the first layer 10 and the third layer 30, thereby suppressing the resonance of each polyurethane foam (the first polyurethane foam and the third polyurethane foam) constituting the first layer 10 and the third layer 30 in the case where the force of such sound is input at a specific frequency.

[0055] From the viewpoint of improving the sound insulation performance, the material constituting the second layer 20 (and therefore the sheet-like member) is, for example, preferably a resin other than polyurethane (for example, a synthetic resin such as polyester), a plant fiber (for example, cotton), rubber, or metal, and from the viewpoint of reducing the weight, it is particularly preferably a resin other than polyurethane (for example, a synthetic resin such as polyester), a plant fiber (for example, cotton), or rubber. The structure of the second layer 20 (and therefore the sheet-like member) may be any structure as long as it is sheet-like, and is preferably, for example, a fabric (textile, knitted fabric, or nonwoven fabric), a mesh sheet having a large number of through holes, or a seamless sheet having no through holes, and is particularly preferably a nonwoven fabric.

[0056] In the example shown in the drawings, the second layer 20 is made of polyester nonwoven fabric.

[0057] The fourth layer 40 is composed of nonwoven fabric. The material constituting the nonwoven fabric may be any material, and examples thereof include polyester.

[0058] The nonwoven fabric constituting the fourth layer 40 has higher oil resistance and heat resistance than the first layer 10 and the third layer 30 each consisting of polyurethane foam.

[0059] The effects of this embodiment are described here.

[0060] First, as described above, in this embodiment, the third layer 30 having high sound shielding performance is arranged closer to the first side S1 than the first layer 10 having high sound absorbing performance. In this example, the soundproof material 1 of this embodiment is arranged so that the surface of the soundproof material 1 located on the second side S2 is opposite to (more specifically, in contact with) the sound source generator G. Therefore, as Figure 3 As schematically shown, any sound that enters the sound insulating material 1 vertically (in other words, in the stacking direction) from the sound source generator G to the first side S1 is partially absorbed by the first layer 10, and any sound that is not absorbed by the first layer 10 is shielded (rebounds to the second side S2) by the third layer 30. Therefore, any sound generated from the sound source generator G can be effectively suppressed from propagating to the first side S1 instead of the sound insulating material 1.

[0061] Generally, as the weight of the soundproofing material increases, the sound shielding performance of the soundproofing material tends to be higher, and thus the soundproofing performance is higher. In this embodiment, the density (kg / m 3 ) is lower than the third layer 30 (therefore the third polyurethane foam). Therefore, in general, if compared at the same volume, the first layer 10 has an advantage of being lighter in weight, while it has a disadvantage of having lower sound insulation performance than the third layer 30. Therefore, if the first layer 10 (therefore the first polyurethane foam) constitutes the entire portion having a thickness corresponding to the total thickness of the first layer 10 and the third layer 30, the weight of the sound insulation material 1 can be reduced, but it is difficult to sufficiently suppress any sound from the sound source generator G to propagate to the first side S1 instead of the sound insulation material 1 (in other words, it is difficult to obtain sufficient sound insulation performance). On the other hand, if the third layer 30 (therefore the third polyurethane foam) constitutes the entire portion having a thickness corresponding to the total thickness of the first layer 10 and the third layer 30, any sound from the sound source generator G can be effectively shielded (rebounded) and any sound from the sound source generator G can be effectively suppressed from propagating to the first side S1 instead of the sound insulation material 1 (high sound insulation performance is obtained), while the weight of the sound insulation material 1 tends to increase significantly. In particular, as shown in this example, in the case where the soundproof material 1 is used for a vehicle, the weight of the soundproof material 1 is preferably light from the viewpoint of low fuel consumption. The soundproof material 1 of the present embodiment includes both the first layer 10 having high sound absorbing performance and the third layer 30 having high sound shielding performance, and therefore the soundproof material 1 can not only suppress an increase in its weight but also obtain good soundproof performance.

[0062] The soundproof material 1 of the present embodiment can also allow any vibration generated from the sound source generator G to be effectively attenuated because the third layer 30 composed of the third polyurethane foam has a high vibration damping performance.

[0063] In the present example, the sound insulation material 1 of the present embodiment, wherein the third layer 30 composed of the third polyurethane foam is arranged at the first side S1 relative to the first layer 10 composed of the first polyurethane foam, allows more of any sound generated from the sound source generator G to enter the first layer 10 vertically (in the stacking direction) and be absorbed, compared with the opposite case, in other words, the case wherein the first layer 10 composed of the first polyurethane foam is arranged at the first side S1 relative to the third layer 30 composed of the third polyurethane foam, thereby allowing the sound absorption performance of the first layer 10 to be more effectively exhibited. As a result, the sound insulation performance of the sound insulation material 1 can be improved.

[0064] As described above, the second layer 20 composed of a material other than polyurethane is provided between the first layer 10 and the third layer 30 in the soundproof material 1 of the present embodiment. Therefore, when the force of any sound is input at a specific frequency from the sound source generator G, any resonance between the first layer 10 and the third layer 30 can be suppressed, and the soundproof performance can be improved, compared with the case where the second layer 20 does not temporarily exist between the first layer 10 and the third layer 30. Therefore, the soundproof material 1 of the present embodiment can obtain high soundproof performance with respect to any sound in a wider frequency range.

[0065] Since the second layer 20 is formed of a sheet-like member, it is possible to suppress an increase in thickness and weight of the sound insulating material 1 .

[0066] In the case where the second layer 20 is composed of a nonwoven fabric as in the present example, the function of improving the sound insulation performance of the second layer 20 is particularly advantageously exhibited.

[0067] The soundproof material 1 of the present embodiment, in which the surface layer closest to the first side S1 is composed of the fourth layer 40, which is composed of a nonwoven fabric having high oil resistance and heat resistance, can effectively protect the layers (the first layer 10, the second layer 20, and the third layer 30) on the second side S2 relative to the fourth layer 40 in the soundproof material 1 from oil and high heat by the fourth layer 40. Therefore, the oil resistance and heat resistance of the soundproof material 1 can be improved. This configuration is particularly preferred in the case where the soundproof material 1 is arranged at a location such as the inside of an engine room of a vehicle, and in particular, the soundproof material 1 is arranged at a location that is likely to be exposed to oil and / or high heat, as in the present example.

[0068] Here, the sound insulating material 1 may have different Figure 1 The sound insulating material 1 may be any structure of the example as long as it includes at least the above-mentioned first layer 10 to third layer 30. For example, the sound insulating material 1 may include the fourth layer 40 or may not include the fourth layer 40, and / or may have the third layer 30 as the surface layer closest to the first side S1. Alternatively, the sound insulating material 1 may include the fourth layer 40 composed of a material other than non-woven fabric.

[0069] Next, a method for producing a soundproof material according to the first embodiment of the present invention is described. When used to produce the soundproof material 1 according to the first embodiment, the method for producing a soundproof material according to this embodiment is preferred. Figure 1 An example of a sound insulation material 1 is shown in FIG.

[0070] The first layer 10, the second layer 20, the third layer 30, and the fourth layer 40 are obtained respectively (the first layer manufacturing process, the second layer manufacturing process, the third layer manufacturing process, and the fourth layer manufacturing process, respectively).

[0071] In the first layer manufacturing process, first a first polyurethane foam is manufactured, and then the obtained first polyurethane foam is cut into a predetermined shape and size to obtain the first layer 10. The first layer 10 (and therefore the first polyurethane foam) obtained in the first layer manufacturing process has a substantially uniform density throughout the entire layer.

[0072] In the second layer preparation step, a sheet-like member ( Figure 1 The polyester nonwoven fabric in the example is cut into a predetermined shape and size to prepare the second layer 20.

[0073] In the third layer manufacturing process, first, the fourth polyurethane foam which is not heat-compressed is manufactured. Then, the obtained fourth polyurethane foam is cut into a predetermined shape and size, thereby obtaining a block 130 including the fourth polyurethane foam. Next, the block 130 is heat-compressed in one direction and thus thinned, thereby obtaining the third layer 30 ( Figure 2 ). The third layer 30 (and therefore the third polyurethane foam) obtained in the third layer manufacturing process has a substantially uniform density throughout the layer, and has a higher density throughout the layer than any portion of the first layer 10 (and therefore the first polyurethane foam) obtained in the first layer manufacturing process.

[0074] In the fourth layer preparation process, the nonwoven fabric manufactured in advance is cut into a predetermined shape and size, thereby preparing the fourth layer 40 .

[0075] After the first layer manufacturing process, the second layer manufacturing process, the third layer manufacturing process, and the fourth layer manufacturing process are completed, the second layer 20 manufactured in the second layer manufacturing process is laminated on the surface of the first layer 10 obtained in the first layer manufacturing process, which surface is located on the first side S1, the third layer 30 obtained in the third layer manufacturing process is laminated on the surface of the second layer 20, which surface is located on the first side S1, and the fourth layer 40 manufactured in the fourth layer manufacturing process is laminated on the surface of the third layer 30, which surface is located on the first side S1, thereby obtaining the sound insulating material 1 composed of the laminate of the first layer 10 to the fourth layer 40 (laminating process). The laminating process preferably allows the first layer 10, the second layer 20, the third layer 30, and the fourth layer 40 to be mutually fixed (for example, bonded or welded) at least at their respective portions (for example, only the outer peripheral ends of each layer) between these layers. In the case where the first layer 10 to the fourth layer 40 are fused to each other, the second layer 20 and the fourth layer 40 are each preferably made of a material that can be heat-fused (in other words, can be dissolved or softened by heating to be bonded to an adjacent layer). Therefore, the first layer 10 to the fourth layer 40 can be fused to each other without using any other member such as an adhesive. Here, in the lamination process, the first layer 10 to the fourth layer 40 are not optionally fixed to each other.

[0076] The sound insulating material 1 may be produced by a method different from the above-mentioned production method.

[0077] Although the above description Figure 1 However, the soundproof material 1 according to the first embodiment is not limited to Figure 1 For example, in the first embodiment, the thickness of each of the first layer 10 to the fourth layer 40 may be non-uniform. That is, each of the first layer 10 to the fourth layer 40 may be non-flat.

[0078] [Second embodiment]

[0079] Figure 4 and Figure 5 2 are views for describing a soundproof material 1 and a method for producing the same according to a second embodiment of the present invention.

[0080] Figure 4 1 shows a cross section of a soundproofing material 1 according to a second embodiment of the present invention. The soundproofing material 1 of this embodiment corresponds to the soundproofing material 1 according to the first embodiment which is formed by thermocompression molding ( Figure 5 ) and obtained sound insulation material. Figure 5 It is a view for describing a laminated body forming process in the method for producing a sound insulating material according to the second embodiment of the present invention.

[0081] like Figure 5As shown, in the method for producing a soundproof material according to the second embodiment of the present invention, the processes up to the above-mentioned lamination process can be performed in the same manner as in the first embodiment. Figure 5 In the example of the lamination process, the laminate (soundproof material 1) obtained has Figure 1 The structure in .

[0082] In the method for producing a soundproof material according to the present embodiment, the laminate (soundproof material 1) obtained in the lamination process is subjected to thermocompression molding in the laminate molding process after the lamination process. The thermocompression molding can be performed by, for example, using a pressing mold P including a first mold part P1 and a second mold part P2, and compressing the laminate (soundproof material 1) between the first mold part P1 and the second mold part P2 under heating, wherein the first mold part P1 has a molding surface configured to form a surface located on the first side S1 of the laminate (soundproof material 1), and the second mold part P2 has a molding surface configured to form a surface located on the second side S2 of the laminate (soundproof material 1). Therefore, the first layer 10 is thermocompressed in at least a portion thereof, and not only the thickness is reduced, but also the density is higher. Although the second layer 20 to the fourth layer 40 can be thermocompressed and thus the thickness is slightly reduced, the degree of such reduction of each of the second layer 20 to the fourth layer 40 is slight compared with the thickness of the first layer 10.

[0083] After the laminate forming step, the laminate (soundproof material 1, Figure 4 ) is at least partially thermally compressed, and as described above, the thickness and density of the first layer 10 are non-uniform. In the present embodiment, the third layer 30 has a density higher than the density of at least a portion (preferably the entirety) of the first layer 10 after the laminate forming process over its entire layer. In other words, after the laminate forming process, the first layer 10 has a portion having a lower density than the density of the third layer 30 (more specifically, the minimum value of the density). Therefore, it is possible to suppress the deterioration of the sound absorbing performance of the first layer 10 obtained in the first layer manufacturing process due to such a subsequent laminate forming process.

[0084] From the same viewpoint, in the laminate (sound insulating material 1 ) after the laminate forming step, it is preferable that the average density of the first layer 10 is lower than the average density of the third layer 30 .

[0085] From the same viewpoint, it is also preferable that the first layer 10 has a portion that has not been thermally compressed in the laminate (soundproof material 1) after the laminate forming step.

[0086] According to the second embodiment, the soundproofing material 1 (laminated body) can be formed into a desired shape by subjecting the laminated body (soundproofing material 1) to thermocompression molding in the laminated body molding step. Figure 4 As shown, in the case where the surface of the sound source generator G facing the sound insulation material 1 (located on the first side S1) is non-flat (has an uneven shape), the shape of the surface of the sound insulation material 1 (laminated body) located on the second side S2 can be formed along the shape of the surface of the sound source generator G facing the sound insulation material 1 (located on the first side S1), resulting in an increase in the contact area between the sound insulation material 1 and the sound source generator G. Therefore, the sound insulation performance of the sound insulation material 1 can be improved. The sound insulation material 1 can also be placed on the sound source generator G more stably.

[0087] The third layer 30 in the laminate (the sound insulation material 1 of the second embodiment) after the laminate forming process can be made to have a higher density than the density of at least a portion (preferably the entirety) of the first layer 10 over its entire layer, resulting in the sound insulation performance of the sound insulation material 1 being improved as in the first embodiment, although there is any difference in the degree of such improvement.

[0088] In the manufacturing method according to the second embodiment, it is preferred that the first layer 10 to the fourth layer 40 are not fixed (joined or fused) to each other in the lamination process, but the first layer 10 to the fourth layer 40 are at least partially fused to each other by heat in the subsequent laminate forming process. Therefore, the thermocompression forming and mutual fusion of each layer can be performed in one process, so that productivity can be improved.

[0089] In the case where the first layer 10 to the fourth layer 40 are fused to each other, the second layer 20 and the fourth layer 40 are each preferably made of a material that can be heat-fused (in other words, can be dissolved or softened by heating to join with the adjacent layer). Therefore, the first layer 10 to the fourth layer 40 can be fused to each other without using any other member such as an adhesive.

[0090] In the case where the first layer 10 to the fourth layer 40 are mutually fused, the laminate (soundproof material 1) is greatly compressed on a portion of such fusion to cause a reduction in thickness, thereby allowing heat to be easily transferred to each layer 10 to 40 and easily allowing such fusion, but the thickness of the first layer 10 is reduced mainly corresponding to the thickness reduction caused by such thermal compression, and the sound absorption performance of the first layer 10 and even the sound insulation performance of the soundproof material 1 are deteriorated. Therefore, the first layer 10 to the fourth layer 40 are more preferably mutually fused only on a portion of each layer (for example, only on the outer peripheral end of each layer). Therefore, it can be ensured that any portion in which the first layer 10 to the fourth layer 40 are not mutually fused is in the soundproof material 1, the amount of thermal compression of the first layer 10 can be reduced by that amount relative to that portion, and the sound absorption performance of the first layer 10 and even the sound insulation performance of the soundproof material 1 can be improved.

[0091] Hereinafter, preferred numerical ranges of the dimensions and physical properties of each layer of the soundproof material 1 in the above-mentioned first and second embodiments will be described. This numerical range is particularly preferred in the case where the soundproof material 1 is used for a vehicle as in the present example.

[0092] In each of the above examples, from the viewpoint of improving the sound insulation performance, the thickness T1 ( Figure 1 , Figure 4 ) is preferably greater than 10 mm, more preferably greater than 15 mm.

[0093] From the viewpoint of suppressing an increase in the weight and thickness of the sound insulating material 1 , the maximum value of the thickness T1 of the sound insulating material 1 is preferably 30 mm or less, more preferably 25 mm or less.

[0094] In each of the above examples, from the viewpoint of not only suppressing the weight increase of the sound insulating material 1 but also improving the sound insulating performance, the thickness T10 ( Figure 1 , Figure 4 ) is preferably higher than the thickness T30 of the third layer 30 composed of the third polyurethane foam ( Figure 1 , Figure 4 ) is the maximum value of .

[0095] From the same viewpoint, the thickness T10 of at least a portion (preferably the entirety) of the first layer 10 is preferably 10 to 50 times the maximum value of the thickness T30 of the third layer 30 .

[0096] In each of the above examples, from the viewpoint of improving the sound absorbing performance of the first layer 10 and thus improving the sound insulating performance of the sound insulating material 1, the thickness T10 ( Figure 1 , Figure 4 ) is preferably the thickness T1 of the sound insulation material 1 ( Figure 1 , Figure 4 ) is 0.50 times or more, more preferably 0.70 times or more of the maximum value. From the same viewpoint, the thickness T10 of at least a portion (preferably the entirety) of the first layer 10 is preferably 8 mm or more, more preferably 12 mm or more.

[0097] From the viewpoint of suppressing the increase in weight and thickness of the first layer 10 and thus the sound insulating material 1, the maximum value of the thickness T10 of the first layer 10 is preferably 0.90 times or less of the maximum value of the thickness T1 of the sound insulating material 1, and more preferably 0.86 times or less of the maximum value of the thickness T1 of the sound insulating material 1. From the same viewpoint, the maximum value of the thickness T10 of the first layer 10 is preferably 25 mm or less, and more preferably 20 mm or less.

[0098] In each of the above examples, from the viewpoint of improving the sound shielding performance of the third layer 30 and thus improving the sound insulation performance of the sound insulation material 1, the thickness T30 ( Figure 1 , Figure 4 ) is preferably the thickness T1 of the sound insulation material 1 ( Figure 1 , Figure 4 ) is at least 0.025 times the maximum value of the thickness T1 of the sound insulating material 1, and more preferably at least 0.045 times the maximum value of the thickness T1 of the sound insulating material 1. From the same viewpoint, the minimum value of the thickness T30 of the third layer 30 is preferably at least 0.5 mm, and more preferably at least 0.8 mm.

[0099] From the viewpoint of suppressing the increase in weight and thickness of the third layer 30 and thus the sound insulating material 1, the maximum value of the thickness T30 of the third layer 30 is preferably 0.15 times or less of the maximum value of the thickness T1 of the sound insulating material 1, and more preferably 0.075 times or less of the maximum value of the thickness T1 of the sound insulating material 1. From the same viewpoint of weight reduction, the maximum value of the thickness T20 of the third layer 30 is preferably 5 mm or less, more preferably 3 mm or less, and further preferably 1.5 mm or less.

[0100] The sound insulation material 1 includes Figure 1 and Figure 4 In each example of the fourth layer 40 (the surface layer located on the first side S1) composed of non-woven fabric, from the viewpoint of improving the oil resistance and heat resistance of the fourth layer 40 and even the sound insulation material 1, the thickness T40 of the fourth layer 40 is preferably greater than 0.5 mm, and more preferably greater than 1 mm.

[0101] From the viewpoint of suppressing an increase in the weight and thickness of the fourth layer 40 and thus the sound insulating material 1 , the thickness T40 of the fourth layer 40 is preferably 5 mm or less, and more preferably 3 mm or less.

[0102] In each of the above examples, from the viewpoint of improving the sound absorption performance of the first layer 10 and reducing the weight of the first layer 10, the density of at least a portion (preferably the entirety) of the first layer 10 (and therefore the first polyurethane foam) is preferably 20 kg / m 3 Below, more preferably 15kg / m 3 In which at least a portion (preferably the entirety) of the first layer 10 (and therefore the first polyurethane foam) has a density of 20 kg / m 3 In the following case, the sound absorbing performance of any sound at a high frequency of about 5000 to 10000 Hz is improved. This improvement is particularly preferred when the sound insulating material 1 is used in a vehicle.

[0103] From the viewpoint of ease of production of the first layer 10, the overall density of the first layer 10 (and therefore the first polyurethane foam) is preferably 6 kg / m 3 More preferably 10kg / m 3 above.

[0104] The "density" of the polyurethane foam herein refers to the density (apparent density) measured in accordance with JIS K 6400-1:2004.

[0105] From the viewpoint of improving the sound absorbing performance of the first layer 10 and reducing the weight of the first layer 10 , the first layer 10 (and therefore the first polyurethane foam) is preferably composed of a soft polyurethane foam having an open-cell structure in which cells communicate with each other.

[0106] In each of the above examples, from the viewpoint of improving the sound absorption performance of the first layer 10 and reducing the weight of the first layer 10, the air permeability of at least a portion (preferably the entirety) of the first layer 10 (and therefore the first polyurethane foam) is preferably 0.1 to 40 ml / cm 2 / sec, more preferably 5 to 30 ml / cm 2 / sec.

[0107] The “air permeability” (air permeability) of each polyurethane foam is measured herein in accordance with JIS K 6400-7:2012 in a fragile type at a thickness of 10 mm.

[0108] Figure 1 and Figure 4 In each example, the block 130 ( Figure 2 ) has a composition (and therefore a density and an air permeability) different from that of the first polyurethane foam constituting the first layer 10 obtained in the first layer manufacturing process. However, the fourth polyurethane foam may have the same composition (and therefore a density and an air permeability) as that of the first polyurethane foam constituting the first layer 10 obtained in the first layer manufacturing process.

[0109] In each of the above examples, from the viewpoint of improving the sound shielding performance of the third layer 30, the density of the fourth polyurethane foam is preferably 6 kg / m 3 More than 10 kg / m 3 From the same viewpoint, the density of the fourth polyurethane foam is preferably higher than the density of the first polyurethane foam constituting the first layer 10 obtained in the first layer production step.

[0110] From the viewpoint of suppressing the increase in weight of the third layer 30, the density of the fourth polyurethane foam is preferably 100 kg / m 3 Below, more preferably 90kg / m 3 the following.

[0111] In each of the above examples, the air permeability of the fourth polyurethane foam is preferably lower than the air permeability of the first polyurethane foam constituting the first layer 10 obtained in the first layer manufacturing process from the viewpoint of improving the sound shielding performance of the third layer 30 and reducing the weight of the third layer 30. From the same viewpoint, the air permeability of the fourth polyurethane foam is preferably 0.05 to 30 ml / cm 2 / sec, more preferably 3 to 20 ml / cm 2 / sec.

[0112] The fourth polyurethane foam may be a soft polyurethane foam having an open cell structure in which cells communicate with each other, or may be a hard polyurethane foam having a closed cell structure in which cells do not communicate with each other but are independent of each other.

[0113] In each of the above examples, from the viewpoint of improving the sound shielding performance of the third layer 30, the third polyurethane foam constituting the third layer 30 is preferably formed by placing a block 130 ( Figure 2 ) is a polyurethane foam obtained by heat-compressing a block to 0.3 times or less of the volume of the block, and more preferably is a polyurethane foam obtained by heat-compressing a block to 0.15 times or less of the volume of the block.

[0114] From the viewpoint of time and cost required for the heat compression operation of the third layer 30, the third polyurethane foam constituting the third layer 30 is preferably formed by combining a block 130 ( Figure 2 ) is a polyurethane foam obtained by heat-compressing a block to 0.05 times or more of the volume of the block, and more preferably a polyurethane foam obtained by heat-compressing a block to 0.10 times or more of the volume of the block.

[0115] In each of the above examples, from the viewpoint of improving the sound shielding performance of the third layer 30, the minimum value of the density of the third layer 30 (and therefore the third polyurethane foam) (the density of the portion with the lowest density; the same applies below) is preferably 100 kg / m3 More than 300 kg / m 3 From the same viewpoint, the minimum value of the density of the third layer 30 (thus the third polyurethane foam) is preferably 8 times or more, more preferably 17 times or more, the minimum value of the density of the first layer 10 (thus the first polyurethane foam).

[0116] From the viewpoint of suppressing an increase in the weight of the third layer 30, the maximum value of the density (density of the portion having the highest density; the same applies below) of the third layer 30 (and therefore the third polyurethane foam) is preferably 1000 kg / m 3 Below, more preferably 500kg / m 3 From the same viewpoint, the maximum value of the density of the third polyurethane foam constituting the third layer 30 is preferably 50 times or less, and more preferably 33 times or less, the minimum value of the density of the first layer 10 (and therefore the first polyurethane foam).

[0117] In the case where the third polyurethane foam constituting the third layer 30 satisfies the aforementioned numerical range, the third layer 30 can preferably achieve both the sound shielding performance and the reduction in weight at the same time.

[0118] In each of the above examples, the air permeability of the third layer 30 (and therefore the third polyurethane foam) is preferably lower than the air permeability of at least a portion of the first layer 10 (and therefore the first polyurethane foam) from the viewpoint of improving the sound shielding performance of the third layer 30. From the same viewpoint, the third layer 30 (and therefore the third polyurethane foam) preferably has little or no air permeability.

[0119] The third polyurethane foam constituting the third layer 30 may be a general polyurethane foam that is not heat-compressed, and is advantageously a heat-compressed polyurethane foam because the density of the third polyurethane foam can be easily and surely increased during production.

[0120] The first polyurethane foam constituting the first layer 10 is preferably a polyurethane foam obtained by reacting and foaming a polyurethane foam-producing composition containing a liquid halogenated olefin in the first layer production step. This makes it possible to improve the sound absorbing effect of the first layer 10 and reduce the weight of the first layer 10.

[0121] The fourth polyurethane foam before the heat compression of the third layer 30 in the third layer production step may be a polyurethane foam obtained by reacting and foaming a composition for producing a polyurethane foam containing a liquid halogenated olefin.

[0122] Hereinafter, the composition for producing polyurethane foam will be described in detail.

[0123] [Polyurethane foam production composition]

[0124] The composition for producing polyurethane foam is preferably a polyurethane foam comprising a polyol, a polyisocyanate, a catalyst, a blowing agent, a foam stabilizer and an auxiliary blowing agent (hereinafter referred to as "the composition A for producing polyurethane foam"), wherein the polyurethane foam contains water as a blowing agent, the content of water is 4 to 11 parts by mass relative to 100 parts by mass of the polyol, and the polyurethane foam contains a liquid halogenated olefin as an auxiliary blowing agent, the content of the liquid halogenated olefin is 10 to 30 parts by mass relative to 100 parts by mass of the polyol.

[0125] The provided composition A for producing polyurethane foam allows the production of polyurethane foam which is not only low in density and light in weight but also high in sound absorbing ability, and is also excellent in production suitability.

[0126] Although the mechanism of exerting this effect is not clear, it is partially speculated as follows. That is, it is speculated that a specific amount of water is included as a foaming agent to provide a polyurethane foam with excellent foamability, low density and light weight. It is also speculated that a specific amount of liquid halogenated olefin is included as a foaming aid to impart high sound absorption ability.

[0127] <Polyol>

[0128] The polyurethane foam-producing composition A contains a polyol. The polyol is not particularly limited as long as it is a compound having two or more hydroxyl groups in one molecule.

[0129] The polyol used here is, for example, a polyether polyol or a polyester polyol. In particular, polyether polyol is preferred because it can improve the sound absorption ability. Unlike polyester polyol, polyether polyol further has the advantages of excellent reactivity with polyisocyanate and no hydrolysis.

[0130] The polyether polyol used here is, for example, polypropylene glycol, polybutylene glycol, a polyether polyol made of a polymer obtained by addition polymerization of propylene oxide and ethylene oxide to a polyol, or a modified product thereof. Examples of polyols include glycerol and dipropylene glycol. Examples of polyether polyols specifically include triols obtained by addition polymerization of propylene oxide to glycerol and further addition polymerization of ethylene oxide thereto, and diols obtained by addition polymerization of propylene oxide to dipropylene glycol and further addition polymerization of ethylene oxide thereto.

[0131] Polyether polyols include polyether ester polyols. Such polyether ester polyols are obtained by reacting a polycarboxylic acid anhydride and a compound having a cyclic ether group with a polyoxyalkylene polyol. Examples of polyoxyalkylene polyols include polyethylene glycol, polypropylene glycol, and propylene oxide adducts of glycerol. Examples of polycarboxylic acid anhydrides include anhydrides of succinic acid, adipic acid, and phthalic acid. Examples of compounds (alkylene oxides) having a cyclic ether group include ethylene oxide and propylene oxide.

[0132] The polyester polyol used here is any condensation polyester polyol obtained by reacting a polycarboxylic acid such as adipic acid or phthalic acid with a polyol such as ethylene glycol, diethylene glycol, propylene glycol or glycerol, as well as a lactone polyester polyol and a polycarbonate polyol. Such polyols can each change the number of hydroxyl functional groups and the hydroxyl value by adjusting the type, molecular weight, and / or degree of condensation of the raw material components.

[0133] Among them, the polyol is preferably a polyether polyol, and particularly preferably a polypropylene glycol polyether polyol produced by adding a propylene oxide group to a higher alcohol. The number average molecular weight of the polypropylene glycol polyether polyol is preferably 500 or more, more preferably 1,000 or more, further preferably 2,000 or more, and preferably 15,000 or less, more preferably 8,000 or less, further preferably 4,000 or less.

[0134] The number average molecular weight and the weight average molecular weight are measured by a GPC (gel permeation chromatography) method, and are determined in terms of standard polystyrene.

[0135] <Polyisocyanate>

[0136] The polyurethane foam production composition A contains a polyisocyanate. The polyisocyanate is not particularly limited as long as it is a compound having two or more isocyanate groups (also referred to as "isocyanate groups") in one molecule.

[0137] Specifically, for example, toluene diisocyanate (TDI), 4,4-diphenylmethane diisocyanate (MDI), 1,5-naphthalene diisocyanate (NDI), triphenylmethane triisocyanate, xylylenediisocyanate (XDI), hexamethylene diisocyanate (HDI), dicyclohexylmethane diisocyanate, isophorone diisocyanate (IPDI), or any modified product thereof such as an adduct, isocyanurate compound, or biuret compound is used.

[0138] In particular, the polyisocyanate preferably contains 70% by mass or more, more preferably 80% by mass or more, further preferably 90% by mass or more of tolylene diisocyanate compounds relative to the entire polyisocyanate, and the entire amount of the polyisocyanate particularly preferably corresponds to the tolylene diisocyanate compounds.

[0139] The toluene diisocyanate compound may be 2,4-toluene diisocyanate, 2,6-toluene diisocyanate or a mixture thereof. The toluene diisocyanate compound may also be an isocyanurate compound of toluene diisocyanate or an adduct of toluene diisocyanate (e.g., a trifunctional compound), and is particularly preferably 2,4-toluene diisocyanate, 2,6-toluene diisocyanate or a mixture thereof.

[0140] The isocyanate index of the polyisocyanate may be 100 or less or greater than 100, and is preferably 80 or more, and is preferably 130 or less, more preferably 110 or less. In the case where the isocyanate index is 80 or more, the hardness of the resulting foam is appropriate, and mechanical properties such as compression residual strain are excellent. On the other hand, the isocyanate index is preferably 130 or less, because the heat generation when making such a foam is suppressed, and the coloring of such a foam is suppressed. The isocyanate index here is the equivalent ratio of the isocyanate group of the polyisocyanate relative to the active hydrogen group of polyol and / or water as a foaming agent, expressed as a percentage. Therefore, an isocyanate index greater than 100 means an excess of polyisocyanate compared to polyols, etc.

[0141] <Catalyst>

[0142] The polyurethane foam-producing composition A contains a catalyst. The catalyst promotes a urethanization reaction of a polyol and a polyisocyanate, a foaming reaction of water as a blowing agent and a polyisocyanate, and / or the like, and can be appropriately selected from conventionally known compounds.

[0143] Specifically, for example, a tertiary amine such as triethylenediamine, dimethylethanolamine, or N,N',N'-trimethylaminoethylpiperazine, an organic metal compound (metal catalyst) such as tin octylate or dibutyltin dilaurate, an acetate, or an alkali metal alkoxide is used.

[0144] The catalyst is preferably used in combination with an amine catalyst and a metal catalyst to enhance its effect. The content of the amine catalyst is preferably 0.01 parts by mass or more, more preferably 0.2 parts by mass or more, and preferably 0.7 parts by mass or less, more preferably 0.6 parts by mass or less, relative to 100 parts by mass of the polyol. In the case where the content of the amine catalyst is within this range, the urethanization reaction and the foaming reaction can be sufficiently promoted in a well-balanced manner.

[0145] The content of the metal catalyst is preferably 0.05 parts by mass or more, more preferably 0.1 parts by mass or more, and is preferably 0.5 parts by mass or less, more preferably 0.4 parts by mass or less, relative to 100 parts by mass of the polyol. In the case where the content of the metal catalyst is within this range, the urethanization reaction and the foaming reaction proceed in a well-balanced manner, foaming can be favorably performed, and the strain characteristics of the foam are excellent.

[0146] <Foaming agent>

[0147] The polyurethane foam-producing composition A contains a blowing agent, and contains water as the blowing agent. The blowing agent is used to foam the polyurethane resin to provide a polyurethane foam.

[0148] The content of water is 4 to 11 parts by mass relative to 100 parts by mass of the polyol. In the case where the content of water is less than 4 parts by mass relative to 100 parts by mass of the polyol, foaming by the foaming reaction is insufficient, and the density of the foam increases. In the case where the content of water is more than 11 parts by mass relative to 100 parts by mass of the polyol, the heat of reaction of water and polyisocyanate increases, the temperature during foaming rises, it is difficult to control, and burning (scorching) in the foam is easily caused.

[0149] The water content is preferably 4.5 parts by mass or more, more preferably 5.0 parts by mass or more, further preferably 5.5 parts by mass or more, and is preferably 10.0 parts by mass or less, more preferably 9.0 parts by mass or less, further preferably 8.0 parts by mass or less, based on 100 parts by mass of the polyol.

[0150] The composition A for producing polyurethane foam may further contain any foaming agent other than water, and preferably contains only water as the foaming agent. In the case where a foaming agent other than water is contained therein, the content of such foaming agent other than water is preferably 50% by mass or less, more preferably 30% by mass or less, further preferably 10% by mass or less relative to the content of water, and it is particularly preferred that no foaming agent other than water is contained.

[0151] <Foam Stabilizer>

[0152] The composition A for producing polyurethane foam contains a foam stabilizer. The foam stabilizer is used to smoothly carry out the foaming by the foaming agent. The foam stabilizer used here can be a foam stabilizer commonly used for producing soft polyurethane foam. Specifically, the foam stabilizer used here is, for example, an organosilicon compound, an anionic surfactant such as sodium dodecylbenzene sulfonate or sodium dodecyl sulfate, a polyether siloxane or a phenolic compound.

[0153] The content of the foam stabilizer is preferably 1.0 to 8.0 parts by mass relative to 100 parts by mass of the polyol. When the content is 1.0 parts by mass or more, the foam stabilizing effect when the raw material of the foam is foamed is fully exhibited, and a good foam can be obtained. When the content is 8.0 parts by mass or less, the foam stabilizing effect is appropriately exhibited, and the connectivity of the cells is maintained within an appropriate range.

[0154] The foam stabilizer preferably contains non-reactive silicone and reactive silicone. The two silicones are used in combination to provide excellent foaming properties. The reactive silicone here refers to an organosilicon compound (polysiloxane compound) having at least one reactive group selected from the group consisting of amino, epoxy, hydroxyl, mercapto and carboxyl groups at the main chain end or side chain.

[0155] The reactive silicone is a compound obtained by introducing a reactive group selected from the group consisting of an amino group, an epoxy group, a hydroxyl group, a mercapto group, and a carboxyl group, or a group having a reactive group, into a side chain or a main chain terminal of an organosilicon compound such as dimethyl silicone, methylphenyl silicone, or methylhydrogen silicone. In particular, a reactive silicone having a hydroxyl group or a carboxyl group as a reactive group is preferred, and a reactive silicone having a carboxyl group as a reactive group is more preferred.

[0156] Commercially available products can be used as the reactive silicone, and examples thereof include various corresponding reactive silicones manufactured by, for example, Shin-Etsu Chemical Co., Ltd., Dow Toray Co., Ltd., and Momentive Performance Materials, and specific examples of the reactive silicone having a carboxyl group include CF1218 (manufactured by Dow Toray Co., Ltd.) and X22-3701 (manufactured by Shin-Etsu Chemical Co., Ltd.). Examples of the reactive silicone having a hydroxyl group include SF 8427, BY 16-201, and SF 8428 (these are manufactured by Dow Toray Co., Ltd.), and X-22-4039 and X-22-4015 (these are manufactured by Shin-Etsu Chemical Co., Ltd.).

[0157] The non-reactive silicone is not particularly limited as long as it does not have any reactive group, and may be any modified non-reactive silicone, such as polyether-modified, aralkyl-modified, or long-chain alkyl-modified non-reactive silicone. Commercially available products may be used as the non-reactive silicone, and may be appropriately selected from various corresponding products commercially available from, for example, Shin-Etsu Chemical Co., Ltd., Dow Toray Co., Ltd., and Momentive Performance Materials.

[0158] The content of the non-reactive silicone is preferably 2.0 parts by mass or more, more preferably 2.5 parts by mass or more, further preferably 3.0 parts by mass or more, and further preferably 3.5 parts by mass or more, and is preferably 5.0 parts by mass or less, and more preferably 4.5 parts by mass or less, relative to 100 parts by mass of the polyol. The content of the non-reactive silicone is preferably within this range because a polyurethane foam having excellent sound absorbing ability is obtained.

[0159] The content of the reactive silicone is preferably 1.0 parts by mass or more, more preferably 1.5 parts by mass or more, further preferably 2.0 parts by mass or more, and preferably 3.0 parts by mass or less relative to 100 parts by mass of the polyol. The content of the reactive silicone is preferably within this range because a polyurethane foam having excellent sound absorbing ability is obtained.

[0160] <Auxiliary foaming agent>

[0161] The polyurethane foam production composition A contains an auxiliary foaming agent. The auxiliary foaming agent is also called a "foaming aid" and assists foaming by the foaming agent, thereby adjusting the density of the foam. The polyurethane foam production composition A contains a liquid halogenated olefin as the auxiliary foaming agent.

[0162] Here, "liquid halogenated olefin" means a halogenated olefin that is liquid at 10° C., in other words, its boiling point is higher than 10° C. Any olefin to be halogenated is preferably an α-olefin having 2 to 10 carbon atoms, more preferably an α-olefin having 2 to 6 carbon atoms, further preferably an α-olefin having 3 to 5 carbon atoms, particularly preferably an α-olefin having 3 or 4 carbon atoms, and most preferably propylene.

[0163] The liquid halogenated olefin is preferably a compound represented by Formula 1 below.

[0164] [Formula 1]

[0165] C 3 H g F h X i (1)

[0166] In Formula 1, each X independently represents a chlorine atom, a bromine atom or an iodine atom, g represents an integer of 0 to 5, h represents an integer of 1 to 6, i represents an integer of 0 to 5, and g+h+i=6 is satisfied.

[0167] In Formula 1, each X independently represents a chlorine atom, a bromine atom or an iodine atom, preferably represents a chlorine atom or a bromine atom, and more preferably represents a chlorine atom.

[0168] g represents an integer of 0 to 5, preferably 1 to 4, and more preferably 1 to 3. h represents an integer of 1 to 6, preferably 2 to 5, and more preferably 2 to 4. i represents an integer of 0 to 5, preferably 0 to 4, and more preferably 0 to 2.

[0169] The compound represented by Formula 1 is not particularly limited and may be cis or trans or a mixture thereof. Specific examples include 3-chloropentafluoropropylene, 2-chloropentafluoropropylene, 1-chloropentafluoropropylene, 1,1-dichlorotetrafluoropropylene, 1,2-dichlorotetrafluoropropylene, 1,3-dichlorotetrafluoropropylene, hexafluoropropylene, 1-chloro-2,3,3,3-tetrafluoropropylene, 1,3-dichloro-2,3,3-trifluoropropylene, 1,2-dichloro-3,3,3-trifluoropropylene, 1,1,3,3,3-pentafluoropropylene, 1,2,3,3,3-pentafluoropropylene, 2-chloro-3,3,3-trifluoropropylene, 2,3,3,3-tetrafluoropropylene, 1,2,3,3-tetrafluoropropylene, 1,1,2-trifluoropropylene, and any halogenated propylene with vinylene group listed below.

[0170] The compound represented by Formula 1 is preferably a compound having a vinylene group (-CH=CH-). Specifically, the compound is 3,3,3-trifluoropropene, 3-bromo-3,3-difluoropropene, 3-chloro-3,3-difluoropropene, 3-fluoropropene, or the compounds listed below.

[0171] Specifically, the compound is preferably composed of CF 3-m Cl m A compound represented by CH=CY (m represents an integer of 0 to 3, Y represents a fluorine atom or a chlorine atom), wherein the halogen other than fluorine is chlorine, and the fluorinated propane obtained here is composed of CF 3- n Cl n CH 2 CfY n represents (n represents an integer of 0 to 3, and Y represents a fluorine atom or a chlorine atom) and has a methylene group (-CH 2 -).

[0172] The compound represented by Formula 1 is more preferably 1 -CH=CH-R 2 (Among them, R 1Represents trihalomethyl, R 2 Represents halogen) represented by fluorinated propylene. Specific examples may include 3,3,3-trichloro-1-fluoropropylene, 1,3,3-trichloro-3-fluoropropylene, 3,3-dichloro-1,3-difluoropropylene, 1,3-dichloro-3,3-difluoropropylene, 3-chloro-1,3,3-trifluoropropylene, 3-bromo-1,3,3-trifluoropropylene, 1-iodo-3,3,3-trifluoropropylene, 1-chloro-3,3,3-trifluoropropylene and 1,3,3,3-tetrafluoropropylene. Among these fluorinated propylenes, preferably 1-chloro-3,3,3-trifluoropropylene (trans or cis) and 1,3,3,3-tetrafluoropropylene (trans or cis), more preferably 1-chloro-3,3,3-trifluoropropylene (trans or cis), and further preferably trans-1-chloro-3,3,3-trifluoropropylene (boiling point 19 ° C).

[0173] Commercially available products can be used as the liquid halogenated olefin, and examples include Solstice LBA (trans-1-chloro-3,3,3-trifluoropropene, manufactured by Honeywell International, Inc.) The liquid halogenated olefin can also be synthesized according to a known method, for example, the method described in Japanese Patent Laid-Open No. 2000-7591.

[0174] The content of the liquid halogenated olefin is 10 to 30 parts by mass relative to 100 parts by mass of the polyol. In the case where the content of the liquid halogenated olefin is less than 10 parts by mass relative to 100 parts by mass of the polyol, not only the effect of the auxiliary foaming agent cannot be fully exerted to increase the apparent density of the foam, but also the obtained polyurethane foam is harder. In the case where the content is greater than 30 parts by mass, due to excessive foaming, the apparent density of the foam is reduced, the strength of the resin skeleton is reduced, and the mechanical strength of the foam is reduced.

[0175] The content of the liquid halogenated olefin is preferably 11 parts by mass or more, more preferably 12 parts by mass or more, further preferably 13 parts by mass or more, and is preferably 25 parts by mass or less, more preferably 20 parts by mass or less, further preferably 18 parts by mass or less, based on 100 parts by mass of the polyol.

[0176] The liquid halogenated olefin may be used alone or in combination of two or more thereof, and in the case where two or more thereof are used in combination, the total amount of such liquid halogenated olefin is preferably within the above range.

[0177] The composition A for the manufacture of polyurethane foam may include an auxiliary blowing agent other than liquid halogenated olefins. Examples of such auxiliary blowing agents other than liquid halogenated olefins include liquefied carbon dioxide and alkyl halides, and examples of alkyl halides include difluoromethane, pentafluoroethane, 1,1,2,2-tetrafluoroethane, 1,1,1,2-tetrafluoroethane, difluoroethane, 1,1,1,2,3,3,3-heptafluoropropane, 1,1,1,3,3,3-hexafluoropropane, 1,1,1,3,3-pentafluoropropane, and 1,1,1,3,3-pentafluorobutane.

[0178] The content of the liquid halogenated olefin in the auxiliary foaming agent is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, particularly preferably 95% by mass or more, relative to the total mass of the auxiliary foaming agent, and most preferably, only the liquid halogenated olefin is contained as the auxiliary foaming agent.

[0179] <Other raw material components>

[0180] The polyurethane foam composition A for manufacturing, if necessary, comprises, for example, a crosslinking agent, a flame retardant, a filler, a stabilizer, a colorant, and / or a plasticizer compounded according to a conventional method. Examples of crosslinking agents include polyols such as ethylene glycol, glycerine, trimethylolpropane and pentaerythritol, amines such as ethylenediamine and hexamethylenediamine, and amino alcohols such as diethanolamine and triethanolamine. Examples of flame retardants include tris-dichloropropyl phosphate, tris-chloroethyl phosphate, dibromoneopentyl alcohol and tribromoneopentyl alcohol.

[0181] [Production of polyurethane foam using polyurethane foam producing composition A]

[0182] Each polyurethane foam (the 1st polyurethane foam and the 3rd polyurethane foam) is manufactured according to a conventional method by reacting and foaming each component (raw material) of the polyurethane foam manufacturing composition A. In the case of manufacturing each polyurethane foam therein, any method of a prepolymer method involving a one-step method for directly reacting a polyol and a polyisocyanate or involving a prepolymer method for reacting a polyol and a polyisocyanate in advance to provide a prepolymer having an isocyanate group at the end and reacting it with a polyol is adopted. A slab foaming method involving a reaction and foaming at normal temperature and atmospheric pressure and any method of a mold foaming method involving a raw material (reaction mixture) of a polyurethane foam body injected into a forming mold and clamped (clamping), and a reaction in a mold and foaming can be adopted, and a slab foaming method is more preferred, because it is easy to achieve the lightweight of this polyurethane foam.

[0183] The reaction of the raw materials of such polyurethane foam is complicated and mainly includes urethanization reaction by addition polymerization of polyol and polyisocyanate, crosslinking reaction of the reaction product and the like and polyisocyanates, and foaming reaction of polyisocyanates and a foaming agent.

[0184] Example

[0185] Experiments and evaluations were conducted in Comparative Example 1 and Example 1 of the soundproofing material of the present invention. These will be referred to below. Figure 6-7 to describe.

[0186] The sound insulation material 1 of Example 1 is composed of Figure 1 More specifically, the sound insulating material 1 of Example 1 includes the first layer 10 to the fourth layer 40 each having a flat plate shape. The first layer 10 is composed of polyurethane foam that has not been thermally compressed and has a density of 12 kg / m 3 The second layer 20 and the fourth layer 40 are each made of polyester nonwoven fabric. The third layer 30 is formed by 3 The block of the uncompressed polyurethane foam was obtained by heat-compressing it in the thickness direction to 0.1 times the thickness (and therefore the volume) and having a density of 350 kg / m 3 The overall thickness T1 of the sound insulating material 1 of Example 1 is 22 mm.

[0187] The sound insulation material 1' of Comparative Example 1 is composed of Figure 7 More specifically, the sound insulation material 1' of Comparative Example 1 is composed of the first layer 10' to the fourth layer 40' each having a flat plate shape. The first layer 10' and the third layer 30' are each composed of polyurethane foam that has not been thermally compressed and has a density of 12 kg / m 3 The second layer 20' is formed by making the density of 35 kg / m 3 The block of the uncompressed polyurethane foam was obtained by heat-compressing it in the thickness direction to 0.1 times the thickness (and therefore the volume) and having a density of 350 kg / m 3 The fourth layer 40' is made of polyester nonwoven fabric. The entire thickness of the sound insulating material 1' of Comparative Example 1 is 22 mm.

[0188] The sound pressure test was performed by using the sound insulating materials of Example 1 and Comparative Example 1.

[0189] The sound pressure test was performed in an anechoic chamber by using a test device. The test device was constructed to generate any sound in an aluminum box, and a microphone was arranged on the upper side away from the aluminum box. In the sound pressure test of each of the sound insulating materials 1 and 1' in the example, in a state in which the sound insulating materials 1 and 1' were each arranged on the upper part of the aluminum box, any sound was generated in the aluminum box, and the sound pressure (dB) was measured by the microphone.

[0190] The results of the sound pressure test are shown in Figure 6 .exist Figure 6 In the figure, the horizontal axis represents frequency (Hz) and the vertical axis represents sound pressure (dB). Sound pressure is an index of sound insulation performance, which is a combination of sound absorption performance and sound shielding performance of a sound insulation material. The lower the sound pressure value, the higher the sound insulation performance, which is a combination of sound absorption performance and sound shielding performance of a sound insulation material.

[0191] from Figure 6 As can be clearly seen from the results, Example 1 shows lower sound pressure in a wide frequency range compared to Comparative Example 1, resulting in higher sound insulation performance. Comparative Example 1 shows increased sound pressure relative to any sound around 1600 Hz. The reason for this is believed to be that the various polyurethane foams constituting the first layer 10' to the third layer 30' in Comparative Example 1 resonate, thereby amplifying the sound. Compared to Comparative Example 1, Example 1 also shows lower sound pressure relative to any sound around 1600 Hz. The reason for this is believed to be that the resonance between the various polyurethane foams constituting the first layer 10 and the third layer 30 is suppressed by the second layer 20 composed of polyester non-woven fabric arranged between the first layer 10 and the third layer 30.

[0192] Industrial Applicability

[0193] The soundproofing material of the present invention may be used in any location and / or article, and is preferably used in a vehicle.

[0194] Description of Reference Numerals

[0195] 1. 1' sound insulation material

[0196] 10, 10' 1st layer (on the surface of the 2nd side)

[0197] 20, 20' 2nd floor

[0198] 30, 30' 3rd floor

[0199] 40, 40' 4th layer (on the surface of the 1st side)

[0200] 130 Block composed of 4th polyurethane foam

[0201] P Pressing Die

[0202] P1 First mold part

[0203] P2 Second mold part

Claims

1. A sound insulation material comprising A first layer, wherein the first layer is composed of polyurethane foam; a second layer laminated on the surface of the first side of the first layer, the second layer being composed of a sheet-like member made of a material other than polyurethane; and a third layer, the third layer being laminated on the surface of the first side of the second layer, the third layer being composed of polyurethane foam and having a density higher than that of at least a portion of the first layer over the entire layer, The minimum value of the density of the third layer is more than 8 times the minimum value of the density of the first layer, The minimum density of the third layer is 300 kg / m 3 above, The minimum value of the thickness of the third layer is greater than or equal to 0.5 mm, and the maximum value of the thickness of the third layer is less than or equal to 1.5 mm. The third layer has uniform density throughout. The second layer is made of non-woven fabric. The thickness of at least a portion of the first layer is 10 to 50 times the maximum value of the thickness of the third layer.

2. The sound insulating material according to claim 1, wherein the third layer is composed of heat-compressed polyurethane foam.

3. The sound insulating material according to claim 2, wherein the heat-compressed polyurethane foam constituting the third layer is obtained by heat-compressing a polyurethane foam that has not been heat-compressed to 0.1 to 0.3 times its volume. 4 . The sound insulating material according to claim 1 , further comprising a surface layer on the first side, wherein the surface layer on the first side is located closest to the first side and is composed of a nonwoven fabric.

5. A method for manufacturing a sound insulation material, comprising: The first layer manufacturing step is to obtain the first layer composed of polyurethane foam. a second layer preparation step of preparing a second layer composed of a sheet-like member made of a material other than polyurethane, a third layer manufacturing process of thermally compressing the polyurethane foam that has not been thermally compressed, thereby obtaining a third layer having a density higher than the density of any part of the first layer obtained in the first layer manufacturing process over the entire layer, and a lamination step of laminating the second layer prepared in the second layer preparation step on the surface of the first side of the first layer obtained in the first layer preparation step, and laminating the third layer obtained in the third layer preparation step on the surface of the first side of the second layer, thereby obtaining a laminated body, wherein the minimum value of the density of the third layer is more than 8 times the minimum value of the density of the first layer, The minimum density of the third layer is 300 kg / m 3 above, The minimum value of the thickness of the third layer is greater than or equal to 0.5 mm, and the maximum value of the thickness of the third layer is less than or equal to 1.5 mm. The third layer has uniform density throughout. The second layer is made of non-woven fabric. The thickness of at least a portion of the first layer is 10 to 50 times the maximum value of the thickness of the third layer. 6 . The method for producing a sound insulating material according to claim 5 , wherein in the first layer producing step, the first layer is obtained by reacting and foaming a composition for producing a polyurethane foam containing a liquid halogenated olefin.

7. The method for producing a sound insulation material according to claim 5 or 6, further comprising: A laminate forming step of forming the laminate obtained in the lamination step by thermal compression, wherein The third layer in the laminate after the laminate forming step has a density higher than a density of at least a portion of the first layer over the entire layer.

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