Sound insulation sheet member, sound insulation structure using same, and method for manufacturing sound insulation sheet member

Abstract

The purpose of the present invention is to provide a sound-insulating sheet member which has excellent manufacturability and durability, while having high sound-insulating performance beyond the mass law, although the sound-insulating sheet member is relatively lightweight. The resonator includes at least a sheet and a plurality of resonating portions. The resonance part is provided so as to be in contact with the sheet surface of the sheet, and is provided with a weight part and a base part. The weight portion is supported by the base portion and has a larger mass than the base portion, and the weight portion has a through portion. The base portion covers the weight portion so as to be in contact with a surface of the weight portion on the front end side of the resonance portion.

Description

[0001] This application is a divisional application; the application number of the parent case is "2019800576229", and the name of the invention is "Soundproof sheet component, soundproof structure using the component, and method for manufacturing soundproof sheet component". Technical Field

[0002] The present invention relates to a soundproofing sheet member, a soundproofing structure using the soundproofing sheet member, and a method for producing the soundproofing sheet member.

[0003] This application claims priority based on Japanese Patent Application No. 2018-166867 filed on September 6, 2018 and Japanese Patent Application No. 2019-148471 filed on August 13, 2019, and the contents of which are cited herein. Background Art

[0004] In buildings such as residential buildings, office buildings, and hotels, it is required to isolate outdoor noise from cars, railways, airplanes, ships, etc., equipment noise generated inside the building, and human voices to achieve quietness suitable for the purpose of the room. In addition, in vehicles such as cars, railways, airplanes, and ships, in order to isolate wind noise and engine sounds to provide a quiet and comfortable space for passengers, it is necessary to reduce indoor noise. Therefore, the research and development of solutions to isolate the propagation of noise and vibration from the outdoors to the indoors or from the outdoors to the indoors of vehicles, that is, vibration-proof and sound-proof solutions, has been promoted. In recent years, in buildings, with the increase in high-rise buildings, lightweight vibration-proof and sound-proof components have been required, and in vehicles, lightweight vibration-proof and sound-proof components have also been required to improve energy efficiency. In addition, in order to increase the design freedom of buildings, vehicles, and the above-mentioned equipment, vibration-proof and sound-proof components that can also correspond to complex shapes are required.

[0005] Generally speaking, the characteristics of vibration-proof and sound-insulating materials follow the so-called mass law. That is, the transmission loss, which is an indicator of the amount of noise reduction, is determined by the logarithm of the product of the mass of the vibration-proof and sound-insulating material and the frequency of the elastic wave and the sound wave. Therefore, in order to further increase the amount of noise reduction of a certain frequency, the mass of the vibration-proof and sound-insulating material must be increased. However, in the method of increasing the mass of the vibration-proof and sound-insulating material, the amount of noise reduction is limited due to the mass of buildings, vehicles, etc.

[0006] In order to solve the problem of increased mass of vibration-proof and sound-proof components, improvements have been made to the component structure. For example, there are known methods of combining a plurality of rigid flat materials such as gypsum boards, concrete, steel plates, glass plates, and resin plates, and methods of forming a hollow two-layer wall structure or a hollow three-layer wall structure using gypsum boards, etc.

[0007] Furthermore, in recent years, in order to achieve sound insulation performance that exceeds the mass law, a sound insulation board formed of a flat acoustic metamaterial using a combination of a high-rigidity flat plate material and a resonator has been proposed. Specifically, a sound insulation board having a plurality of independent pile-shaped protrusions (resonators) composed of silicone rubber and tungsten or a plurality of independent pile-shaped protrusions (resonators) composed of rubber on an aluminum substrate (see non-patent documents 1 and 2), and a sound insulation board having a plurality of independent pile-shaped protrusions (resonators) composed of silicone rubber or silicone rubber and lead caps on an epoxy substrate (see non-patent document 3) have been proposed.

[0008] Furthermore, a sound insulating sheet member including a sheet having rubber elasticity and a resonance portion having a base portion and a weight portion has been proposed (Patent Document 1).

[0009] Prior art literature

[0010] Patent Literature

[0011] Patent Document 1: International Publication No. 2017 / 135409

[0012] Patent Document 2: Japanese Patent Application Publication No. 2000-265593

[0013] Non-patent literature

[0014] Non-patent literature 1: MBAssouar, M. Senesi, M. Oudich, M. Ruzzene and Z. Hou, Broadband plate-type acoustic metamaterial for low-frequency soundattenuation, Applied Physics Letters, 2012, volume 101, pp 173505.

[0015] Non-patent literature 2: M.Oudich, B.Djafari-Rouhani, Y.Pennec, MBAssouar, andB.Bonello, Negative effective mass density of acoustic metamaterial platedecorated with low frequency resonant pillars, Journal of Applied Physics, 2014, volume 116, pp 184504.

[0016] Non-patent literature 3: M.Oudich, Y.Li, MBAssouar, and Z.Hou, A sonic band gapbased on the locally resonant phononic plates with stubs, New Journal of Physics, 2010, volume 12, pp 083049. Summary of the invention

[0017] Problems to be solved by the invention

[0018] Non-patent documents 1 to 3 have studied the shielding performance after changing the material and size of the pile-shaped protrusions (resonators). However, there is a limit to the degree of freedom in design in improving the sound insulation performance by simply changing the material and size of the pile-shaped protrusions (resonators).

[0019] Furthermore, since the sound insulation boards described in Non-Patent Documents 1 to 3 use adhesives to place the resonators on the substrate, the manufacturing process is complicated and the productivity and economic efficiency are poor. Furthermore, since the sound insulation boards described in Non-Patent Documents 1 to 3 use relatively rigid aluminum substrates or epoxy substrates, it is difficult to deform them, and for example, they cannot be placed along non-flat surfaces such as curved surfaces.

[0020] In order to solve this problem, it is also considered to use a pre-bent aluminum substrate or epoxy substrate and set a plurality of resonators on the curved surface of these substrates. However, in this case, it is necessary to set each resonator on the curved surface, which further increases the difficulty of the manufacturing process and further deteriorates the productivity and economy. In addition, it is lack of versatility to prepare a substrate corresponding to the curved shape of the setting part each time. Therefore, in order to expand industrial utilization, especially from the viewpoints of design freedom, versatility, productivity, cost, etc., a sound insulation sheet component based on a new design concept is desired.

[0021] The sound-insulating sheet member described in Patent Document 1 has a high degree of freedom in design and excellent versatility. However, sufficient studies have not yet been conducted in terms of ease of manufacture, productivity, and durability.

[0022] As described in Patent Document 1, in the case of a manufacturing method in which a counterweight is provided in a hole of a metal mold and resin is poured in, there is a problem that the resin is difficult to spread under the counterweight and bubbles are difficult to escape. Since the resin cannot reach under the counterweight and bubbles remain, the front end side of the counterweight may not be fully covered with the resin. Since the counterweight is not covered with the resin, the counterweight is exposed, which may cause the counterweight to fall off.

[0023] On the other hand, Patent Documents 1 and 2 disclose sound insulating sheets provided with weights on the front end side of the protrusions. By providing the weights, low-frequency sounds that are difficult to soundproof are blocked.

[0024] However, a method for manufacturing a sound-insulating sheet having such a weight has not yet been fully established.

[0025] For example, as described in Patent Document 2, when the weight portion is provided on the front end side of the protrusion, there is a concern that the weight may be easily separated from the protrusion.

[0026] Furthermore, as described in Patent Document 1, in a metal mold for forming a sound insulation sheet, a weight is inserted into a recess of a metal mold for forming a protrusion, and resin is flowed into the recess. In this process, there is a concern that the position of the weight may be deviated due to the flow of resin. If the position of the weight is greatly deviated, the sound insulation performance may be affected, or the exposed weight may be separated from the protrusion or rusted due to the deviation.

[0027] The present invention has been made in view of the above background technology, and its object is to provide a soundproofing sheet member which has high soundproofing performance exceeding the law of mass despite being relatively lightweight, and has excellent manufacturability and durability, and a soundproofing structure using the soundproofing sheet member.

[0028] Furthermore, another object of the present invention is to provide a soundproofing sheet member and a method for manufacturing the soundproofing sheet member, which can suppress a large deviation of the position of a weight portion relative to a protrusion.

[0029] In addition, the present invention is not limited to the purpose described here, and the purpose of achieving the effects derived from each structure shown in the following mode for implementing the invention and the effects that cannot be obtained by the conventional technology can also be defined as other purposes of the present invention.

[0030] Solutions to Solve Problems

[0031] The inventors have conducted intensive studies to solve the above problems and have found that the above problems can be solved by using a sheet member having rubber elasticity and provided with a specific resonance portion, thereby completing the present invention.

[0032] Furthermore, as a result of in-depth research conducted by the inventors to solve the above-mentioned problems, they found that a protrusion is provided on one of the bottoms of multiple cavities for forming the protrusions and the front end side of the counterweight portion, and a recess is provided on the other side, and the cavity inserts the protrusion into the recess to limit the position of the sheet portion of the counterweight portion in the surface direction relative to the bottom. By allowing the resin to flow into the above-mentioned cavity, the above-mentioned problems can be solved, thereby completing the present invention.

[0033] That is, the present invention provides various specific aspects shown below.

[0034] [1] A soundproof sheet component comprising at least a sheet material and a plurality of resonance portions, wherein the resonance portions are provided in contact with a sheet surface of the sheet material,

[0035] The resonance part includes a weight part and a base part.

[0036] The counterweight is supported by the base and has a greater mass than the base,

[0037] The counterweight portion has a through portion,

[0038] The base portion covers the weight portion so as to be in contact with a surface of the weight portion on the front end side of the resonance portion.

[0039] [2] According to the sound insulation sheet member described in [1], the base portion is filled in the outer peripheral portion of the weight portion and the through portion.

[0040] [3] The sound insulating sheet member according to [1] or [2], wherein the weight portion is arranged on the front end side relative to the center in the height direction of the resonance portion.

[0041] [4] The soundproofing sheet member according to any one of [1] to [3], wherein the maximum height from the opposite surface of the sheet to the front end of the resonance portion is 30 mm or less.

[0042] [5] The soundproofing sheet member according to [4], wherein the maximum height from the opposite surface of the sheet surface to which the resonance portion is provided to the front end of the resonance portion is 20 mm or less.

[0043] [6] The soundproof sheet member according to any one of [1] to [5], wherein the resonance portion has a cavity formed by a recessed surface on the front end side of the resonance portion, and the cavity is formed in the through portion.

[0044] [7] The soundproof sheet member according to any one of [1] to [6], wherein the through portion is a through hole.

[0045] [8] A soundproof structure using the soundproof sheet member described in any one of [1] to [7].

[0046] [9] A soundproof sheet component comprising at least a sheet material and a plurality of resonance portions, wherein the resonance portions are provided in contact with a sheet surface of the sheet material,

[0047] The resonance part includes a weight part and a base part.

[0048] The counterweight is supported by the base and has a greater mass than the base,

[0049] The weight portion has a through portion.

[0050]

[10] According to the sound insulation sheet member described in [9], the base portion is filled in the outer peripheral portion of the weight portion and the through portion.

[0051]

[11] The soundproof sheet member according to

[10] , wherein the maximum height from the surface opposite to the sheet surface on which the resonance portion is provided to the front end of the resonance portion is 30 mm or less.

[0052]

[12] The soundproofing sheet member according to

[11] , wherein the maximum height from the opposite surface of the sheet surface to which the resonance portion is provided to the front end of the resonance portion is 20 mm or less.

[0053]

[13] A soundproof structure using the soundproof sheet member described in any one of [9] to

[12] .

[0054]

[14] A method for manufacturing a soundproof sheet component, the soundproof sheet component comprising a sheet portion, a plurality of protrusions provided in a surface direction of the sheet portion, and a weight portion provided at a front end side of each of the plurality of protrusions, the method comprising:

[0055] a weight inserting step of inserting the weight into the bottoms of the plurality of cavities of a metal mold including the plurality of cavities for forming the protrusions; and

[0056] a resin insertion step in which resin is introduced into the plurality of cavities;

[0057] A protrusion is provided on one of the bottom and the front end side of the weight portion, and a recess or a through portion for inserting the protrusion is provided on the other side.

[0058] In the weight insertion step, the protrusion is inserted into the recess or the through-hole.

[0059] In the resin inserting step, the resin is flowed into the cavity in a state where the protrusion is inserted into the recess or the through portion and the position of the weight portion relative to the bottom portion in the surface direction is restricted.

[0060]

[15] The method for manufacturing a sound insulation sheet member according to

[14] ,

[0061] The weight portion includes the through portion.

[0062]

[16] The method for manufacturing a sound insulation sheet component according to

[15] ,

[0063] The bottom portion is provided with the protrusion and a step portion that protrudes at a height lower than the protrusion and contacts a portion of the surface on the front end side of the weight portion.

[0064]

[17] The method for manufacturing a sound insulation sheet component according to

[16] ,

[0065] The step portion is provided so as to be in contact with a side surface of the protrusion.

[0066]

[18] The method for manufacturing a sound insulation sheet component according to

[16] ,

[0067] The step portion is provided to be separated from a side surface of the protrusion.

[0068]

[19] The method for manufacturing a sound insulation sheet member according to

[17] or

[18] ,

[0069] The step portion is inclined in a direction in which the height decreases from the radial center side of the protrusion toward the radial outer side.

[0070] The maximum diameter of the step portion at the highest position is smaller than the hole diameter of the through portion provided in the weight portion, and the maximum diameter of the step portion at the lowest position is larger than the hole diameter of the through portion.

[0071]

[20] The method for manufacturing a soundproofing sheet member according to any one of

[14] to

[19] ,

[0072] The metal mold comprises a lower mold and an upper mold.

[0073] The lower mold is provided with the cavity in an opening on the upper surface.

[0074] The upper mold is movable between a position abutting against the upper surface of the lower mold and a position separated upward, and has a recess provided on the upper surface and a through-flow path opening in the recess.

[0075] In the resin inserting step, the dissolved resin is caused to flow from the recess into the cavity through the through flow path in a state where the lower mold is in contact with the upper mold.

[0076]

[21] The method for manufacturing a sound insulation sheet member according to

[20] ,

[0077] Prior to the resin inserting step, there is a step of extruding the solid material of the resin disposed in the recess by using a press die inserted in the recess.

[0078]

[22] The method for manufacturing a soundproof sheet member according to any one of

[14] to

[16] ,

[0079] The protrusion is provided on the bottom portion in a manner that inclines in a direction in which the height decreases from the radial center side of the protrusion toward the radial outer side.

[0080] The maximum diameter of the protrusion at the highest position is smaller than the hole diameter of the through-portion provided in the weight portion, and the maximum diameter at the lowest position is larger than the hole diameter of the through-portion.

[0081]

[23] The method for manufacturing a soundproof sheet member according to any one of

[14] to

[22] ,

[0082] The resin inserting step may include a step of moving the protrusion provided at the bottom toward the bottom before the resin flowing into the cavity is cured.

[0083]

[24] The method for manufacturing a sound insulation sheet component according to

[23] ,

[0084] The method includes the step of moving the protrusion toward the cavity to release the sound insulating sheet member from the metal mold after the resin is cured.

[0085]

[25] The method for manufacturing a soundproofing sheet member according to any one of

[14] to

[24] ,

[0086] A maximum value of a gap between the protrusion and the recess or between the protrusion and the through-hole is smaller than a minimum value of a gap between the weight inserted in the cavity and the cavity.

[0087]

[26] A sound insulation sheet component, comprising:

[0088] Sheet Department;

[0089] a plurality of protrusions provided in the surface direction of the sheet portion and comprising a resin material; and

[0090] a weight portion provided inside the front end side of each of the plurality of protrusions and having a recess or a through portion on the front end side,

[0091] A gap is formed on the inner side of the end surface of the front end side of the weight portion.

[0092]

[27] The sound insulation sheet component according to

[26] ,

[0093] The above-mentioned counterweight part has the above-mentioned through part,

[0094] The through portion is filled with the resin material further inside the space.

[0095]

[28] The sound insulation sheet component according to

[27] ,

[0096] The resin material is filled between the surface of the through-portion and the space.

[0097]

[29] The sound insulation sheet component according to

[27] ,

[0098] The protrusion has:

[0099] a covering portion that covers a portion of a surface of the weight portion on the front end side with the resin material; and

[0100] A through portion is provided in the radially outer side of the gap along the circumferential direction with the radial center of the protrusion as an axis, and penetrates the covering portion so as to expose a portion of the surface on the front end side of the weight portion.

[0101]

[30] The sound insulation sheet component according to

[29] ,

[0102] The penetration portion has an inclined portion that is inclined in a direction approaching the surface of the covering portion as it moves from the radial center side of the protrusion toward the radial outside.

[0103] The maximum diameter of the inclined portion at the innermost side is smaller than the hole diameter of the through portion, and the maximum diameter of the inclined portion at the outermost side is larger than the hole diameter of the through portion.

[0104] A portion of the surface on the front end side of the weight portion is exposed in the middle of the inclined portion.

[0105]

[31] The sound insulation sheet component according to

[27] ,

[0106] The protrusion has:

[0107] a covering portion that covers a portion of a surface of the weight portion on the front end side with the resin material; and

[0108] a recessed portion provided in such a manner that a portion of the covering portion is missing and a portion of the surface on the front end side of the weight portion is exposed at the bottom surface,

[0109] The gap opens at the bottom surface of the recessed portion.

[0110]

[32] The sound insulation sheet component according to

[27] ,

[0111] The protrusion has a covering portion that covers a portion of the surface on the front end side of the weight portion with the resin material.

[0112] The gap has a through portion which is circumferentially arranged on the radially outer side of the gap with the radial center of the protrusion as an axis and penetrates the covering portion in a manner that a portion of the surface on the front end side of the weight portion is exposed.

[0113] The penetration portion has an inclined portion that is inclined in a direction approaching the surface of the covering portion as it moves from the radial center side of the protrusion toward the radial outside.

[0114] The maximum diameter of the inclined portion at the innermost side is smaller than the hole diameter of the through portion, and the maximum diameter of the inclined portion at the outermost side is larger than the hole diameter of the through portion.

[0115] A portion of the surface on the front end side of the weight portion is exposed in the middle of the inclined portion.

[0116] The effects of the invention are as follows.

[0117] According to the present invention, it is possible to provide a soundproofing sheet member which has high soundproofing performance that exceeds the law of mass despite being relatively lightweight and is excellent in manufacturability and durability, and a soundproofing structure using the soundproofing sheet member.

[0118] Furthermore, the present invention can provide a soundproofing sheet member and a method for manufacturing the soundproofing sheet member capable of suppressing a large deviation of the position of the weight portion relative to the protrusion. BRIEF DESCRIPTION OF THE DRAWINGS

[0119] Figure 1 It is a schematic perspective view showing the sound insulating sheet member and the sound insulating structure according to the first embodiment.

[0120] Figure 2A 1 is a schematic perspective view showing a resonance portion including a base portion 22 and a weight portion 23 .

[0121] Figure 2B It is a schematic perspective view showing the weight portion 23 .

[0122] Figure 3 yes Figure 1 Cross-sectional view taken along arrow II-II.

[0123] Figure 4 It is a figure which shows an example of the manufacturing process of a sound-insulating sheet member.

[0124] Figure 5 It is a figure which shows an example of the manufacturing process of a sound-insulating sheet member.

[0125] Figure 6 It is a figure which shows an example of the manufacturing process of a sound-insulating sheet member.

[0126] Figure 7 It is a figure which shows an example of the manufacturing process of a sound-insulating sheet member.

[0127] Figure 8 It is a schematic perspective view showing a soundproofing sheet member and a soundproofing structure according to a second embodiment.

[0128] Fig. 9 This is a diagram showing an example of the use of the sound insulation structure.

[0129] Fig. 10A This is a simplified structural diagram of a unit cell used for estimating the acoustic band gap.

[0130] Fig. 10B This is a simplified structural diagram of a unit cell used for estimating the acoustic band gap.

[0131] Fig.11 It is a schematic perspective view showing a structural example of the soundproof sheet member 100 and the soundproof structure 200 according to the first embodiment of the present invention.

[0132] Fig.12 yes Fig.11 Sectional view viewed in the direction II-II.

[0133] Fig.13 It is an external perspective view of the weight portion 23 according to one embodiment of the present invention.

[0134] Fig.14 This is an external perspective view of a resonance portion 21 in which a weight portion 23 is buried in a base portion 22 according to one embodiment of the present invention.

[0135] Fig.15 This is a partial cross-sectional view of a resonance portion 21 in which a weight portion 23 is buried in a base portion 22 according to one embodiment of the present invention.

[0136] Fig.16 It is a cross-sectional view showing the metal mold MD according to one embodiment of the present invention.

[0137] Fig.17 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0138] Fig.18 It is a figure which shows the process of manufacturing the sound-proofing sheet member 100 which concerns on one embodiment of this invention.

[0139] Fig.19 It is a figure which shows the process of manufacturing the sound-proofing sheet member 100 which concerns on one embodiment of this invention.

[0140] Fig. 20 It is a figure which shows the process of manufacturing the sound-proofing sheet member 100 which concerns on one embodiment of this invention.

[0141] Fig.21 This is a partial cross-sectional view of a resonance portion 21 in which a weight portion 23 is buried in a base portion 22 according to one embodiment of the present invention.

[0142] Fig. 22 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0143] Fig.23 It is a cross-sectional view showing the metal mold MD according to one embodiment of the present invention.

[0144] Fig.24 It is a cross-sectional view showing the metal mold MD according to one embodiment of the present invention.

[0145] Fig.25 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0146] Fig.26 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0147] Fig. 27 It is a cross-sectional view showing the metal mold MD according to one embodiment of the present invention.

[0148] Fig.28 It is a top view of the resonance part 21 which concerns on one Embodiment of this invention.

[0149] Fig.29 yes Fig.28 AA line section view in.

[0150] Fig.30 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0151] Fig.31 It is a top view of the resonance part 21 which concerns on one Embodiment of this invention.

[0152] Fig.32 yes Fig.31 BB line section view in.

[0153] Fig.33 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0154] Fig.34 It is a top view of the resonance part 21 which concerns on one Embodiment of this invention.

[0155] Fig.35 yes Fig.34 CC line section view in.

[0156] Fig.36 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0157] Fig.37 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0158] Fig.38 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0159] Fig.39 It is shown Fig.38 28M is a top view of a modified example of the core portion 28M shown.

[0160] Fig.40 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0161] Fig.41 It is a top view of the resonance part 21 which concerns on one Embodiment of this invention.

[0162] Fig.42 This is a partial cross-sectional view of a resonance portion 21 in which a weight portion 23 is buried in a base portion 22 according to one embodiment of the present invention.

[0163] Fig.43 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention.

[0164] Fig.44 This is a partial detailed view of a cavity CV as a space for shaping the resonance portion 21 according to one embodiment of the present invention. DETAILED DESCRIPTION

[0165] The soundproof sheet member of the present invention comprises at least a sheet having rubber elasticity and a plurality of resonance parts. The resonance parts are provided in contact with the sheet surface of the sheet, the weight part is supported by the base part and has a greater mass than the base part, and the weight part has a through part.

[0166] The sound insulation sheet of the present invention is obtained by placing a counterweight in a plurality of cavities provided in a metal mold, and allowing a resin material or the like to flow into the cavity, and then allowing the resin material or the like to harden (solidify). In this case, when the resin material or the like is allowed to flow into the cavity, since the counterweight has a through portion, the resin material or the like is also filled from the through portion. Therefore, the filling speed of the resin material or the like becomes faster, and the manufacturability can be improved compared to the case where the counterweight is a cylinder. In addition, the air remaining in the lower part of the cavity during filling can be allowed to escape from the through portion, so that the cavity can be fully filled. Therefore, the molding defect of the resonance part can be suppressed, and the manufacturing stability is excellent compared to the case where the counterweight is a cylinder.

[0167] When the molded sound insulation sheet is demolded from the above-mentioned cavity, a shear force is applied to the resonance part, and there is a possibility that the cylindrical weight or the like falls off from the resonance part or the resonance part breaks from the weight part. In addition, when used as a sound insulation sheet, there is a possibility that the weight falls off or the resonance part breaks from the weight part due to vibration. On the other hand, the weight with a through-portion of the present invention is also filled with a resin material or the like in the through-portion, and this part also functions as a fixed end fixed to the resonance part, and there is a tendency to suppress falling off or breaking.

[0168] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the following embodiments are examples for illustrating the present invention, and the present invention is not limited to the embodiments. Furthermore, in the following description, unless otherwise specified, the positional relationships such as up, down, left, and right are based on the positional relationships shown in the accompanying drawings. Furthermore, the dimensional ratios of the accompanying drawings are not limited to the ratios shown in the drawings. In addition, in this specification, the expression of a numerical range such as "1 to 100" includes both its lower limit "1" and upper limit "100". Furthermore, the expression of other numerical ranges is also the same.

[0169] (First Embodiment)

[0170] Figure 1 and Figure 3 1 is a schematic perspective view and a cross-sectional view taken along the arrow II-II showing a soundproof sheet member 100 and a soundproof structure 200 according to the present embodiment. The soundproof sheet member 100 includes: a sheet 11 having rubber elasticity; a plurality of resonance portions 21 provided on the sheet surface 11a of the sheet 11 in contact with the sheet surface 11a; and at least one rib-shaped protrusion 31 provided on the sheet surface 11a. The soundproof sheet member 100 is supported by a support body 51 provided on the sheet surface 11b side of the sheet 11, thereby constituting the soundproof structure 200.

[0171] In the soundproof sheet component 100 and the soundproof structure 200, for example, after a sound wave is irradiated from a noise source located on the side of the support body 51, resonance of the sheet 11 and / or the resonant portion 21 is generated. At this time, there may be a frequency region where the direction of the force acting on the support body 51 is opposite to the direction of the acceleration generated by the sheet 11 and / or the resonant portion 21, and part or all of the vibration of a specific frequency is offset, thereby generating a complete acoustic band gap in which vibration of a specific frequency is almost completely absent. Therefore, near the resonant frequency of the sheet 11 and / or the resonant portion 21, part or all of the vibration is stationary, and as a result, high soundproofing performance that exceeds the mass law can be obtained. Soundproof components that utilize such a principle are called acoustic metamaterials. Below, each component of the soundproof sheet component 100 and the soundproof structure 200 of this embodiment is described in detail.

[0172] In the present invention, the maximum height from the opposite side of the sheet surface with the resonance portion to the front end of the resonance portion is not particularly limited and can be appropriately adjusted according to the purpose, but is preferably 30 mm or less. In addition, the maximum height from the opposite side of the sheet surface with the resonance portion to the front end of the resonance portion is preferably 20 mm or less. It is more preferably 15 mm or less, further preferably 10 mm or less, further preferably 8 mm or less, further preferably 5 mm or less, and particularly preferably 3 mm or less. And, in the case of being used to block high frequencies, it is preferably 1.0 mm or less. If it is within the above range, it has a sound insulation function, and the space required for the installation of the sound insulation sheet component can be reduced, so that the overall size of small electronic devices can be kept as small as possible.

[0173] The lower limit is not particularly limited, but is, for example, 0.01 mm or more from the viewpoint of ease of manufacture. Figure 1 The height in the middle is indicated by H, which indicates the height from the sheet surface 11 b of the sheet 11 to the maximum height of the resonance portion 21 in the normal direction of the sheet 11 .

[0174] [Sheet]

[0175] The sheet 11 is a sheet having rubber elasticity. Although not particularly limited, the sheet 11 may have rubber elasticity due to the molecular motion of a resin (organic polymer), etc. The sheet 11 may also function as a vibrator (resonator) that vibrates at a certain frequency when sound waves are injected from a noise source.

[0176] The material constituting the sheet 11 preferably contains at least one selected from the group consisting of a heat- or light-curing elastomer and a thermoplastic elastomer.

[0177] When a metal mold is used for injection, the cavity on the surface of the metal mold needs to be filled with the elastomer. However, the photocurable elastomer can be filled in the cavity in the state of a liquid with a low viscosity before curing, which can increase the filling rate and is therefore preferred.

[0178] As the material constituting the sheet 11, specifically, there can be mentioned: thermosetting resin elastomers such as chemically cross-linked natural rubber or synthetic rubber, vulcanized thermosetting resin elastomers, polyurethane thermosetting resin elastomers, silicone thermosetting resin elastomers, fluorine thermosetting resin elastomers, acrylic thermosetting resin elastomers, etc.;

[0179] Photocurable elastomers such as acrylic photocurable elastomers, silicone photocurable elastomers, epoxy photocurable elastomers, etc.

[0180] Thermoplastic elastomers such as olefin-based thermoplastic elastomers, styrene-based thermoplastic elastomers, polyvinyl chloride-based thermoplastic elastomers, polyurethane-based thermoplastic elastomers, ester-based thermoplastic elastomers, amide-based thermoplastic elastomers, silicone-based thermoplastic elastomers, and acrylic-based thermoplastic elastomers.

[0181] As further specific examples of the above-mentioned heat or light curing elastomer and thermoplastic elastomer, rubber can be cited. Specifically, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and their modified bodies can be cited, but it is not particularly limited to these. These can be used alone or in combination of two or more.

[0182] In addition, among them, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and their modified bodies are preferred, and silicone rubber, acrylic rubber and their modified bodies are more preferred. By using these materials, there is a tendency to have excellent heat resistance and cold resistance.

[0183] The sheet 11 may be any sheet having so-called rubber elasticity, and may contain various additives such as a flame retardant, an antioxidant, a plasticizer, and a colorant.

[0184] Flame retardants are additives added to make combustible raw materials difficult to burn or prevent them from igniting. Specific examples thereof include: bromine compounds such as pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, hexabromocyclododecane, hexabromobenzene; phosphorus compounds such as triphenyl phosphate; chlorine compounds such as chlorinated paraffin; antimony compounds such as antimony trioxide; metal hydroxides such as aluminum hydroxide; nitrogen compounds such as melamine cyanurate; boron compounds such as sodium borate, etc., but are not particularly limited to these.

[0185] Furthermore, an antioxidant is an additive added to prevent oxidative degradation, and specific examples thereof include phenolic antioxidants, sulfur-based antioxidants, phosphorus-based antioxidants, and the like, but are not particularly limited thereto.

[0186] In addition, plasticizers are additives for improving flexibility and weather resistance. Specific examples thereof include phthalates, adipates, trimellitates, polyesters, phosphates, citrates, sebacates, azelates, maleates, silicone oils, mineral oils, vegetable oils, and modified forms thereof, but are not particularly limited thereto.

[0187] Furthermore, examples of the coloring agent include coloring matter and pigments.

[0188] These can be used alone or in combination of two or more.

[0189] In this embodiment, the sheet 11 is formed into a square when viewed from above, but its shape is not particularly limited to this. Any shape in view from above, such as a triangle, rectangle, rectangle, trapezoid, rhombus, pentagon, hexagon or other polygon, circle, ellipse, or an indefinite shape not classified into the above shapes, can be adopted. In addition, the sheet 11 can have a cutout, a punching, etc. at any position from the viewpoint of improving the stretching performance and reducing weight, as long as it does not lose its characteristics as an acoustic metamaterial.

[0190] The thickness of the sheet 11 is not particularly limited as long as the maximum height of the sound insulation sheet component is within the scope of the present invention. Since the frequency band (acoustic band gap width, frequency position) showing high sound insulation performance can also be controlled according to the thickness of the sheet 11, the thickness of the sheet 11 can be appropriately set in a manner that makes the acoustic band gap consistent with the desired sound insulation frequency region. If the thickness of the sheet 11 is thicker, the acoustic band gap width becomes narrower and tends to shift to the low frequency side. In addition, if the thickness of the sheet 11 is thinner, the acoustic band gap width becomes wider and tends to shift to the high frequency side.

[0191] From the viewpoints of sound insulation performance, mechanical strength, flexibility, and operability, the thickness of the sheet 11 is preferably 10 μm or more, more preferably 50 μm or more, and further preferably 100 μm or more. Furthermore, the thickness of the sheet 11 is preferably 2 mm or less, more preferably 1 mm or less, and further preferably 500 μm or less.

[0192] From the viewpoints of sound insulation performance, mechanical strength, flexibility, operability, productivity, etc., the sheet 11 preferably has a Young's modulus of 0.01 MPa or more, more preferably 0.1 MPa or more, and preferably has a Young's modulus of 100 MPa or less, more preferably 10 MPa or less.

[0193] Here, the Young's modulus in this specification refers to the ratio of the force (stress) acting on the unit cross-sectional area of ​​the sample when an external force is applied in one axial direction to the deformation rate (strain), and refers to the value of the storage longitudinal elastic modulus at 25°C and 10 Hz measured by the forced vibration non-resonance method according to JIS K 6394:2007 "Vulcanized rubber and thermoplastic rubber-Method of determining dynamic properties-".

[0194] Furthermore, from the viewpoint of reducing the temperature dependence of the sound insulation at low temperatures, the sheet 11 preferably has a glass transition temperature below 0°C. The lower the glass transition temperature of the sheet 11, the higher the cold resistance, the smaller the temperature dependence of the elastic modulus at around 0°C, and thus there is a tendency that the sound insulation performance is less likely to depend on the ambient temperature. It is more preferably below -10°C, further preferably below -20°C, and particularly preferably below -30°C. In addition, in this specification, the glass transition temperature of the sheet 11 refers to the peak temperature of the loss tangent in the dynamic viscoelasticity measurement at the above-mentioned frequency of 10 Hz, especially the temperature dependence measurement.

[0195] [Resonance section]

[0196] The resonance part 21 functions as a vibrator (resonator) that vibrates at a certain frequency after a sound wave is injected from a noise source. The resonance part 21 of the present embodiment is composed of a composite structure having a base 22 and a weight part 23 supported on the base 22 and having a mass greater than that of the base 22. The resonance part 21 effectively functions as a resonator having a resonance frequency, and the resonance frequency is determined by the mass of the weight part 23 acting as a weight and the spring constant of the base 22 acting as a spring.

[0197] The arrangement, number of settings, size, etc. of the resonance part 21 can be appropriately set according to the desired performance and are not particularly limited. The resonance part 21 is arranged to contact the sheet surface of at least one side of the sheet. For example, in the present embodiment, a plurality of resonance parts 21 are arranged in a lattice shape and at equal intervals, but the arrangement of the resonance part 21 is not particularly limited thereto. For example, the plurality of resonance parts 21 may be arranged in a staggered manner or randomly. Since the sound insulation mechanism using the present sheet does not utilize Bragg scattering like the so-called phononic crystal, the intervals of the resonance parts 21 may not be regularly and periodically arranged.

[0198] Furthermore, the number of the resonance parts 21 provided per unit area is not particularly limited as long as the resonance parts 21 can be arranged so as not to interfere with each other due to contact or the like.

[0199] The maximum number of resonance parts 21 per unit area varies depending on the shape of the resonance part 21, but for example, when the resonance part 21 is cylindrical, the height direction of the cylinder is parallel to the normal direction of the sheet, and the diameter of the cylinder cross section is 1 cm, it is preferable to have 100 resonance parts per unit area. 2 The number is less than 100.

[0200] The minimum number of resonance parts 21 per unit area is preferably 10 cm, for example, when the resonance part 21 is cylindrical, the height direction of the cylinder is parallel to the normal direction of the sheet, and the cross-sectional diameter is 1 cm. 2The number of the resonant parts 21 is preferably 2 or more, more preferably 10 or more, and further preferably 50 or more. By setting the number of the resonant parts 21 to be greater than the above-mentioned preferred lower limit, there is a tendency to obtain higher sound insulation performance. Furthermore, by setting the number to be less than the above-mentioned preferred upper limit, it is easy to achieve overall lightweighting of the sheet.

[0201] The maximum height H1 of the resonance portion 21 in the normal direction of the sheet 11 can be appropriately set according to the desired performance and is not particularly limited. From the viewpoint of ease of forming and improvement of productivity, the maximum height H1 is preferably greater than 10 μm, more preferably greater than 100 μm, and further preferably greater than 1 mm. Furthermore, it is preferably less than 20 mm, more preferably less than 15 mm, further preferably less than 10 mm, further preferably less than 8 mm, further preferably less than 5 mm, and particularly preferably less than 3 mm. By setting it within the above-mentioned preferred numerical range, the sheet 11 (i.e., the sound insulation sheet component 100) provided with the resonance portion 21 becomes easy to wind and overlap, and the so-called roll-to-roll manufacturing and roll-shaped storage can be carried out, which tends to improve productivity and economy.

[0202] Furthermore, the height of the resonance part 21 in the normal direction of the sheet 11 may be the same or different in all the resonance parts. By making the height of the resonance part different, there may be an effect of expanding the frequency range in which the sound insulation performance is exhibited.

[0203] [Base]

[0204] In the present embodiment, a plurality of bases 22 having a substantially cylindrical outer shape are arranged on the sheet surface 11a of the sheet 11 in such a manner as to contact the sheet surface 11a, and a counterweight 23 is respectively embedded in the base 22. The outer shape of the base 22 is not particularly limited, and any shape such as a triangular prism, a rectangular prism, a trapezoidal prism, a polyhedral prism such as a pentagonal prism or a hexagonal prism, a cylindrical shape, an elliptical prism, a truncated cone, a truncated cone, a pyramid, a cone, a hollow cylinder, a branched shape, an indefinite shape not classified into the above shapes, etc. can be adopted. In addition, it is also possible to form a column having a cross-sectional area and / or a cross-sectional shape that is different depending on the height position of the base 22.

[0205] Furthermore, the shapes and heights of the plurality of bases provided on the sheet surface 11 a so as to be in contact with the sheet surface 11 a may be the same or different.

[0206] The material of the base 22 is not particularly limited as long as it satisfies the above-mentioned required properties. For example, a resin material may be mentioned, and at least one selected from the group consisting of a heat- or light-curing elastomer, a thermoplastic elastomer, a heat- or light-curing resin, and a thermoplastic resin may be mentioned.

[0207] Examples of the heat- or light-curing elastomer and the thermoplastic elastomer include those described in the description of the sheet.

[0208] Examples of heat- or light-curing resins include acrylic thermosetting resins, polyurethane thermosetting resins, silicone thermosetting resins, epoxy thermosetting resins, etc. Examples of thermoplastic resins include polyolefin thermoplastic resins, polyester thermoplastic resins, acrylic thermoplastic resins, polyurethane thermoplastic resins, polycarbonate thermoplastic resins, etc.

[0209] As specific examples, there can be mentioned: chemically cross-linked natural rubber or synthetic rubber such as vulcanized rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and their modified rubbers; polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride, polychlorotrifluoroethylene, polyethylene, polypropylene, polynorbornene, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polystyrene, epoxy resin, oxazine resin and other polymers, but are not particularly limited thereto. They can be used alone or in combination of two or more.

[0210] Furthermore, the base 22 may be a porous body containing pores (gas such as air) in the above-mentioned resin material. In addition, the base 22 may also contain a liquid material such as mineral oil, vegetable oil, silicone oil, etc. Furthermore, when the base 22 contains a liquid material, it is preferably sealed in the resin material in advance from the viewpoint of suppressing the liquid material from flowing out to the outside.

[0211] The material of the base 22 is preferably the same material as the sheet 11, and is particularly preferably an elastomer. If the sheet 11 and the base 22 contain the same elastomer, the sheet 11 and the base 22 are easily formed into one piece, and the productivity is greatly improved. That is, the sheet 11 and the resonance part 21 (base 22) are an integrally formed product containing at least one selected from the group consisting of a heat- or light-curing elastomer and a thermoplastic elastomer, but this is only one of the particularly preferred modes.

[0212] Specific examples of elastomers include vulcanized rubber such as chemically crosslinked natural rubber or synthetic rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and modified products thereof, polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride, polychlorotrifluoroethylene, polyethylene, polypropylene, polynorbornene, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polystyrene, epoxy resin, oxazine resin, etc., but are not particularly limited thereto.

[0213] Among them, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and modified bodies thereof are preferred, and silicone rubber, acrylic rubber and modified bodies thereof are more preferred from the viewpoint of excellent heat resistance and cold resistance.

[0214] It should be noted that the base 22 can also be a two-color molded body or a multi-color molded body composed of two or more resin materials. In this case, by making the base 22 on the side in contact with the sheet 11 adopt the same elastomer as the sheet 11, the sheet 11 and the base 22 can be easily integrally molded.

[0215] In addition, when a resonance portion 21 (base 22) having a circular cross-section is provided as in the present embodiment, in a cross section parallel to the sheet surface 11a of the sheet 11 at a height position of the resonance portion 21 (base 22) where the sum of the cross-sectional areas of the plurality of resonance portions 21 (base 22) is the largest, the diameter of the circle with the largest diameter among the circles (circular cross section) included in the cross section is preferably 100 mm or less, more preferably 50 mm or less, and further preferably 20 mm or less. Furthermore, the diameter of the circle with the smallest diameter is preferably 10 μm or more, more preferably 100 μm or more, and further preferably 1 mm or more. By setting within the above-mentioned preferred numerical range, it is possible to ensure that the resonance portion 21 (base 22) provided to the sheet surface 11a of the sheet 11 is a predetermined number or more, thereby being able to further obtain good sound insulation performance, and there is a tendency that the ease of forming and productivity are also further improved.

[0216] [Counterweight]

[0217] The weight portion 23 is covered by the base 22 in a manner that the weight portion 23 is in close contact with and adhered to (contacted with) the base 22, which is a resin material. As described below, the sound insulation sheet component 100 is formed by placing the weight portion 23 in the cavity of a metal mold, allowing the resin material to flow in and harden. Therefore, the weight portion 23 has a structure in which the surface on the sheet side, the surface on the peripheral side, the surface in the through-portion, and the surface on the front end side of the resonance portion of the weight portion 23 are covered by the base in a manner that they are adhered to the base. In other words, the base 22 is a molded body that is formed in contact with the surface on the front end side of the resonance portion of the weight portion 23 and covers the weight portion 23. By covering the surface on the front end side of the resonance portion of the weight portion with the base, the weight portion can be made difficult to fall off by utilizing the anchoring effect. The coverage rate of the surface on the front end side of the resonance portion of the weight portion covered by the base (the ratio of the area covered by the base in a bonding manner to the area of ​​the surface on the front end side of the resonance portion) is preferably 80% or more, and particularly preferably 100% coverage.

[0218] The weight portion 23 is not particularly limited as long as it has a through portion and has a greater mass than the above-mentioned base portion 22. A weight having a through portion will be described with reference to the drawings.

[0219] Figure 2A denoting the resonance part including the base 22 and the weight part 23, Figure 2B Represents the weight portion 23. Figure 2A As shown, the resin is filled in the outer periphery and the through-portion of the weight portion 23. Since the weight portion 23 has the through-portion, the resin passes not only through the outer periphery of the weight portion but also through the through-portion and then reaches the surface of the front end side of the resonance portion of the weight portion, thereby making it easy to fill the resin, and even if bubbles are generated, the bubbles can be released, and the coverage rate can be improved.

[0220] In the present invention, the counterweight having a through portion refers to, for example, Figure 2B As shown, the parts having the through-portion include rings, washers, nuts, etc. Since washers and nuts are general-purpose products widely used for other purposes, the cost can be greatly reduced by using them as the counterweight 23. In addition, since the nut has a groove formed on the inner wall of the through hole to engage with the screw, the counterweight is difficult to fall off by filling the groove with resin.

[0221] Although the shape of the counterweight is not particularly limited, it is preferably in the shape of a plate from the viewpoint of adjusting the sound insulation performance and reducing the thickness. Since the counterweight portion is in the shape of a plate, the center of gravity of the counterweight can be located farther away from the substrate than in the case where the counterweight is in the shape of a sphere, thereby tending to increase the vibration torque of the resonance portion. For example, while keeping the acoustic band gap width constant, the plate-shaped counterweight of the present invention can be thinner than in the case where the counterweight is in the shape of a sphere. On the other hand, while keeping the height of the counterweight constant, the plate-shaped counterweight of the present invention can obtain a wider band gap width than in the case where the counterweight is in the shape of a sphere. As a through portion, it can be Figure 2B The through hole shown may not be a hole. As a case where it is not a hole, for example, a "C-shaped" member having a circular ring portion separated in a circumferential direction, such as a spring washer, can be cited.

[0222] also, Figure 1 , Figure 3 to Figure 8 The through portion of the counterweight portion 23 is omitted, but the counterweight portion 23 is as shown in FIG. Figure 3 Thus, there is a through portion.

[0223] In the present embodiment, the outer diameter of the counterweight is formed into a substantially circular shape smaller than the base 22, and is buried in the base 22 at the front end side of the resonance part 21. In this way, since the counterweight part 23 that functions as the counterweight of the resonator adopts a structure supported by the base 22 that determines the spring constant, the resonance frequency of the resonance part 21 can be easily controlled by, for example, adjusting the spring constant by changing the shape of the base 22 or the raw material (elastic modulus, mass), and changing the mass of the counterweight part 23. In general, if the elastic modulus of the base 22 becomes smaller, the acoustic band gap tends to shift to the low frequency side. In addition, if the mass of the counterweight part 23 becomes larger, the acoustic band gap tends to shift to the low frequency side.

[0224] Figure 2B In FIG. 8 , hx represents the height of the weight, r1 represents the outer diameter of the weight, and r2 represents the diameter (inner diameter) of the through portion.

[0225] The height (hx) of the weight is not particularly limited, but when the height of the resonance part is set to 1, the height of the weight is preferably 0.95 or less, more preferably 0.9 or less. Also, it is preferably 0.2 or more, more preferably 0.3 or more. By setting it to such a range, there is a tendency to obtain a wider band gap width while suppressing the height of the sound insulation sheet component.

[0226] The outer diameter (r1) of the counterweight is not particularly limited. In the case where the cross-section of the resonance portion is circular, if the outer diameter of the counterweight is approximately the diameter of the circular cross-section, there is a tendency for excellent sound insulation performance. Although not particularly limited, the maximum value of r1 is preferably less than 100 mm, more preferably less than 50 mm, and further preferably less than 20 mm. Furthermore, the minimum value of r1 is preferably greater than 10 μm, more preferably greater than 100 μm, and further preferably greater than 1 mm. By setting it within the above-mentioned preferred numerical range, good sound insulation performance can be obtained, and there is a tendency for the ease of forming and productivity to be further improved.

[0227] The counterweight with a through portion of the present invention is also filled with a resin material or the like in the through portion of the counterweight, which also functions as a fixed end fixed to the resonance portion, thereby preventing the counterweight from falling off or breaking even if exposed.

[0228] The inner diameter (r2) of the counterweight is not particularly limited. As long as it is smaller than the outer diameter (r1), it is not particularly limited, but the maximum value of r2 is preferably 90 mm or less, more preferably 40 mm or less, further preferably 20 mm or less, and particularly preferably 10 mm or less. In addition, the minimum value of r2 is preferably 2 μm or more, more preferably 50 μm or more, and further preferably 80 μm or more. By setting it within the above-mentioned preferred numerical range, there is a tendency for the resin material, etc., to be easily filled into the through-portion.

[0229] Furthermore, the ratio between the outer diameter and the inner diameter of the weight is not particularly limited.

[0230] The material constituting the weight portion 23 may be appropriately selected in consideration of quality, cost, etc., and its type is not particularly limited. From the viewpoint of miniaturization of the soundproof sheet member 100 and the soundproof structure 200 and improvement of soundproofing performance, the material constituting the weight portion 23 is preferably a material having a high specific gravity.

[0231] Specifically, examples include: metals or alloys such as aluminum, stainless steel, iron, tungsten, gold, silver, copper, lead, zinc, and brass; inorganic glasses such as soda glass, quartz glass, and lead glass; and composite materials such as the above-mentioned metal or alloy powders or the above-mentioned inorganic glass contained in the resin material of the above-mentioned base 22, but are not particularly limited thereto. The material, mass, and specific gravity of the weight portion 23 may be determined so that the acoustic band gap of the sound insulation sheet member 100 and the sound insulation structure 200 coincides with the desired sound insulation frequency region.

[0232] Among them, from the viewpoints of low cost and high specific gravity, at least one selected from the group consisting of metals, alloys and inorganic glasses is preferred. In addition, specific gravity refers to the ratio of the mass of a material to the mass of pure water at 4°C under a pressure of 1013.25 hPa of the same volume, and in this specification, the value measured according to JIS K 0061 "Determination of density and specific gravity of chemical products" is used.

[0233] In order to improve process adaptability and component strength, the surface of the weight portion 23 (including the through portion) may be subjected to surface treatment.

[0234] For example, chemical treatment using a solvent or the like for improving adhesion to the base 22 or physical treatment for improving component strength by providing irregularities on the surface may be considered, but the surface treatment method is not particularly limited.

[0235] In the present embodiment, the weight portion 23 is embedded in the base portion 22 at the front end side of the resonance portion 21, but the position of the weight portion 23 is not particularly limited. Although the shapes, masses, elastic moduli, etc. of the base portion 22 and the weight portion 23 are different, from the viewpoint of reducing the thickness and weight of the sound insulation sheet component and improving the sound insulation performance, it is preferred to arrange the base portion 22 and the weight portion 23 so that the center of gravity (center of mass) of the resonance portion 21 is at least located closer to the front end side than the center in the height direction of the resonance portion 21. Typically, the weight portion 23 is offset and arranged closer to the front end side than the center in the height direction of the resonance portion 21.

[0236] Furthermore, the weight portion 23 may be completely buried in the base 22, only a part of it may be buried in the base 22, or it may be provided on the base 22 instead of being buried in the base 22. Furthermore, when the base 22 adopts a branch structure, from the viewpoint of reducing the weight of the sound insulation sheet component or improving the sound insulation performance, when the weight portion is provided in the branch portion provided from the branch point, it is preferable to arrange the weight portion 23 so as to be located closer to the front end side than the center of the branch portion.

[0237] Furthermore, the shapes and heights of the plurality of weights 23 included in the soundproofing sheet member may be the same or different.

[0238] In addition, a plurality of resonance parts 21 are provided on the sheet surface 11a of the sheet 11, and the material constituting the resonance part 21, the arrangement, shape, size, and setting direction of the resonance part 21 are not necessarily the same in all the plurality of resonance parts 21. By providing a plurality of resonance parts 21 in which at least one of the resonance parts is different, the frequency region exhibiting high sound insulation performance can be expanded.

[0239] [Protrusion]

[0240] In addition to the above-mentioned resonance part, the sound-insulating sheet member of the present invention may have other protrusions, for example, rib-shaped protrusions.

[0241] In the present embodiment, the rib-like protrusions 31 are formed into a generally plate-like shape in a manner extending along the length direction (sheet flow direction, MD direction) of the sheet 11. The rib-like protrusions 31 are provided on the sheet surface 11a of the sheet 11, more specifically, at two locations of the edge of the sheet 11 in the width direction (direction perpendicular to the sheet flow direction, TD direction).

[0242] The rib-shaped protrusion 31 has a maximum height H2 higher than the maximum height H1 of the resonance part 21 in the normal direction of the sheet 11. Therefore, even if the soundproof sheet member 100 is rolled into a sheet or a plurality of soundproof sheet members 100 are overlapped, the rib-shaped protrusion 31 functions as a spacer to suppress the resonance part 21 from contacting the back surface of the sheet 11. Therefore, by providing the rib-shaped protrusion 31, manufacturing failures such as deformation, variation, cracking, falling off, and damage of the resonance part 21 do not occur, and the soundproof sheet member 100 can be easily manufactured and stored by so-called roll-to-roll. In addition, the rib-shaped protrusion can also function as a vibrator (resonator) that vibrates at a certain frequency after a sound wave is incident from a noise source.

[0243] The shape of the protrusion is not particularly limited, and when functioning as a spacer, it only needs to be higher than the maximum height H1 of the resonance part 21. When functioning as a vibrator, the position, number and height of the protrusion can be adjusted according to the frequency range to be adjusted.

[0244] The maximum height H2 of the rib-like protrusion 31 is not particularly limited as long as it is higher than the maximum height H1 of the resonance portion 21. From the viewpoint of ease of forming and improvement of productivity, it is preferably 50 μm or more, more preferably 100 μm or more, and further preferably 1 mm or more. Furthermore, it is preferably 20 mm or less, more preferably 15 mm or less, further preferably 10 mm or less, further preferably 5 mm or less, and particularly preferably 3 mm or less.

[0245] The shape and setting position of the rib-like protrusion 31 are not particularly limited as long as they are set so as not to interfere with the resonance part 21 that functions as a resonator. For example, the outer shape of the rib-like protrusion 31 is not particularly limited, and any shape such as a triangular prism, a rectangular prism, a trapezoidal prism, a pentagonal prism, a hexagonal prism, a cylindrical prism, an elliptical prism, a truncated cone, a truncated cone, a pyramid, a cone, a hollow cylinder, an indefinite shape not classified into the above shapes, etc. can be adopted. In addition, it can also be formed into a columnar shape having a cross-sectional area and / or a cross-sectional shape (at least one of the cross-sectional area and the cross-sectional shape) that is different depending on the height position of the rib-like protrusion 31. Furthermore, the maximum length of the rib-like protrusion 31 in the length direction of the sheet 11 can be less than the maximum length in the MD direction of the sheet, and is not particularly limited.

[0246] In addition, in the present embodiment, a pair of rib-like protrusions 31 extending in the length direction of the sheet 11 is used, but a plurality of rib-like protrusions 31 having a shorter maximum length may be separately arranged in the length direction of the sheet 11. In this case, the arrangement intervals of the rib-like protrusions 31 may be periodic or random. In the case where the plurality of rib-like protrusions 31 are separately arranged like this, the distance between the rib-like protrusions 31 is not particularly limited, but is preferably 100 mm or less, more preferably 50 mm or less, and further preferably 20 mm or less.

[0247] The raw material constituting the rib-shaped protrusion 31 is not particularly limited, but is preferably the same resin material as the sheet 11 and / or the resonance portion 21 (base 22), and more preferably the same elastomer as the sheet 11 and the resonance portion 21 (base 22). If the same resin material as the sheet 11 and / or the base 22 is used, it becomes easy to form an integral part with the sheet 11 and / or the resonance portion 21 (base 22), and productivity is greatly improved.

[0248] [Support]

[0249] The sound insulation sheet component of the present invention can be appropriately set according to the environment in which the sound insulation performance is required. For example, the sound insulation sheet component can be directly set on a device, a structure, etc. An adhesive layer or the like can also be provided between the sound insulation sheet component and the device, the structure, etc. Furthermore, the sound insulation sheet component can also be used in a form supported by a support. When the sound insulation sheet component of the present invention is used for sound insulation, the support can support the sound insulation sheet component, or it can be not supported by the support during manufacturing, storage, etc.

[0250] The support body only needs to be provided in contact with at least one surface of the sheet of the soundproof sheet member, and may be provided on the sheet surface provided in contact with the resonance portion and / or on the other surface of the sheet surface provided in contact with the resonance portion.

[0251] In the present embodiment, a support body 51 is provided on the sheet surface 11b side of the back side of the sheet 11. The raw material constituting the support body 51 is not particularly limited as long as it can support the sheet 11, but from the viewpoint of improving the sound insulation performance, a material having a higher rigidity than the sheet 11 is preferred. Specifically, the support body 51 preferably has a Young's modulus of 1 GPa or more, more preferably 1.5 GPa or more. The upper limit is not particularly limited, and for example, 1000 GPa or less can be cited.

[0252] Furthermore, when the soundproof sheet member is directly provided on a device, a structure, etc., the surface on which the soundproof sheet member is provided preferably has the same rigidity as the supporting body from the viewpoint of supporting the sheet material and improving the soundproofing performance.

[0253] The raw material constituting the support 51 is not particularly limited. For example, a photocurable resin sheet, a thermosetting resin sheet, a thermoplastic resin sheet, a metal plate, an alloy plate, etc. can be cited. As the photocurable resin sheet, the thermosetting resin sheet, and the thermoplastic resin sheet, sheets of the photocurable resin, the thermosetting resin, and the thermoplastic resin cited in the description of the above base can be cited.

[0254] Specific examples of raw materials constituting the support body 51 include: polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene succinate; poly(meth)acrylate resins such as polymethyl methacrylate; polycarbonate resins such as polycarbonate with isosorbide as the main raw material; polyolefin resins such as polyethylene, polypropylene, and polynorbornene; organic materials such as vinyl chloride resin, polyacrylonitrile, polyvinylidene chloride, polyether sulfone, polyphenylene sulfide, polyarylate, polyamide, polyimide, triacetyl cellulose, polystyrene, epoxy resin, and oxazine resin; composite materials containing metals such as aluminum, stainless steel, iron, copper, zinc, and brass, inorganic glass, inorganic particles, and fibers in the above-mentioned organic materials, etc.

[0255] Among them, from the viewpoints of sound insulation, rigidity, formability, cost, etc., the support is preferably at least one selected from the group consisting of a photocurable resin sheet, a thermosetting resin sheet, a thermoplastic resin sheet, a metal plate, and an alloy plate. Here, the thickness of the support 51 is not particularly limited, but from the viewpoints of sound insulation performance, rigidity, formability, lightness, cost, etc., it is usually preferably 0.05 mm or more and 0.5 mm or less.

[0256] In addition, from the viewpoints of light transmittance, adhesion with the sound insulating sheet member, and the like, the support 51 may be provided with a coating on the surface of the support 51 .

[0257] In addition, the shape of the support body 51 can be appropriately set according to the installation surface of the sound insulation structure 200, and is not particularly limited. For example, it can be a flat sheet, a curved sheet, or a special shape processed to have a curved surface, a bent portion, etc. In addition, from the viewpoint of weight reduction, a cutout, a punched portion, etc. can be set at any position of the support body 51.

[0258] Furthermore, the surface density (mass per unit area) of the support body 51 can also be appropriately set according to the desired performance and is not particularly limited. From the viewpoint of improving the effect of the present invention, the surface density of the support body 51 is preferably 80% or less of the surface density of the sound insulation sheet member 100, more preferably 30% or less, and further preferably 10% or less.

[0259] (Second Embodiment)

[0260] Figure 8 1 is a schematic perspective view and a cross-sectional view thereof showing a soundproof sheet member 101 and a soundproof structure 201 of the present embodiment. In the present embodiment, except for the number of resonance parts, the shapes of the base and the weight part, and the shape and number of rib-like protrusions, the structure is the same as that of the soundproof sheet member 100 and the soundproof structure 200 of the first embodiment described above, and thus repeated description is omitted here.

[0261] The resonance part 21 of the present embodiment is composed of a composite structure including a base 24 and a weight part 25 supported by the base 24 and having a greater mass than the base 24. In the present embodiment, a plurality of bases 24 having a substantially cylindrical outer shape are also provided on the sheet surface 11a of the sheet 11 in a manner of contacting the sheet surface 11a.

[0262] The rib-like protrusions 32 of this embodiment are formed into a roughly cylindrical shape, and each rib-like protrusion 32 is separately arranged at the edge of the width direction (the direction perpendicular to the sheet flow direction, TD direction) of the sheet 11 in a row along the length direction of the sheet 11 (the sheet flow direction, MD direction).

[0263] In this embodiment, the same effects as those of the first embodiment are achieved. In addition, in this embodiment, since the plurality of rib-shaped protrusions 32 are arranged separately in a row, the conformability (flexibility) of the soundproof sheet member 101 is further improved. Therefore, even for an adhesive surface with a more complex shape, the flexible sheet 11 that can stretch and contract can conform to the surface shape, and as a result, the sheet 11 can be stably mounted on the support 51.

[0264] [Manufacturing method]

[0265] The method for producing the soundproof sheet member and the soundproof structure of the present invention is not particularly limited. For example, the following production methods 1 to 4 may be mentioned.

[0266] The shape of the chamber used in each manufacturing method is not particularly limited, and for example, the shape of the bottom can be appropriately selected from a hemispherical shape, a flat shape, a convex shape, a concave shape, or the like.

[0267] (Manufacturing method 1)

[0268] The production method 1 may include the following steps (1) to (3).

[0269] (1) A step of preparing a metal mold having a plurality of cavities and pouring a resin material into the cavities.

[0270] (2) A step of hardening the poured resin material.

[0271] (3) A step of peeling the obtained hardened product from the metal mold.

[0272] In the production method 1, after the step (2) or (3), a step of providing a support body on the obtained cured product may be further included.

[0273] (Manufacturing method 2)

[0274] The manufacturing method 2 may include the following steps (4) to (7).

[0275] (4) A step of preparing a metal mold having a plurality of cavities and arranging weights in the plurality of cavities provided in the metal mold.

[0276] (5) A step of flowing the resin material into the cavity.

[0277] (6) A step of hardening the poured resin material.

[0278] (7) A step of peeling the obtained hardened product from the metal mold.

[0279] In the production method 2, after the step (6) or (7), a step of providing a support body on the obtained cured product may be further included.

[0280] (Manufacturing method 3)

[0281] The manufacturing method 3 may include the following steps (8) to (11).

[0282] (8) A step of applying a photocurable elastomer precursor or a photocurable resin precursor to a metal mold having a plurality of cavities.

[0283] (9) A step of laminating a substrate on the elastomer precursor or resin precursor formed in a flat surface on a metal mold.

[0284] (10) A step of pressing the stack of the support and the metal mold from the substrate side with a press roller to fill the cavity with the elastomer precursor or the resin precursor.

[0285] (11) A step of curing the elastomer precursor or resin precursor having the cavity shape of the metal mold transferred thereto by irradiating light from the substrate side, and overlapping and bonding the cured product of the elastomer precursor or resin precursor to the substrate.

[0286] (12) (11) A step of peeling off, from the metal mold, a member formed by bonding the cured product of the elastomer precursor or resin precursor to the substrate.

[0287] (Manufacturing method 4)

[0288] The manufacturing method 4 may include the following steps (13) to (15).

[0289] (13) A process of rotating a roller mold having an outer peripheral surface on which a plurality of cavities are arranged, applying a photocurable elastomer precursor or a photocurable resin precursor to the outer peripheral surface of the roller mold while moving a substrate along the outer peripheral surface of the roller mold in the rotation direction of the roller mold, and filling the cavities with the elastomer precursor or the resin precursor.

[0290] (14) A step of irradiating light onto a region between the outer peripheral surface of the roll mold and the substrate in a state where the elastomer precursor or the resin precursor is sandwiched between the outer peripheral surface of the roll mold and the substrate.

[0291] (15) A step of peeling off the member formed by bonding the cured product of the elastomer precursor or resin precursor obtained in the step (14) to the substrate from the roll mold.

[0293] In steps (10) and (11) of manufacturing method 3 and steps (13) and (14) of manufacturing method 4, a sound insulating sheet member having a resonance portion and a sheet material can be formed.

[0294] There is no particular limitation on the substrate used in the manufacturing methods 3 and 4. The sound insulating sheet member formed on the substrate may be used as it is, or the substrate may be peeled off and used.

[0295] After step (11) or (12) of the manufacturing method 3 or step (14) or (15) of the manufacturing method 4, a step of providing a support may be further included. Furthermore, the substrate may be a support.

[0296] Steps (10) and (11) of the manufacturing method 3 and steps (13) and (14) of the manufacturing method 4 may be performed multiple times. For example, in the manufacturing method 4, steps (13), (14), (13), (14), (15) may be performed in the order of steps (13), (14), (13), (14), (15).

[0297] Furthermore, when the process is repeated multiple times, the photocurable elastomer precursor or photocurable resin precursor used may be different. For example, in the manufacturing method 4, the photocurable elastomer precursor or photocurable resin precursor used in the first step (13) and the second step (13) may be different. Metal powder or the like may be mixed in the second photocurable elastomer precursor or photocurable resin precursor so that the hardened product (resonance part) obtained in the step (15) becomes the base part and the weight part.

[0298] For the production methods 3 and 4, reference can be made to the production methods described in International Publication No. 2010 / 3080794 and the like.

[0299] In such manufacturing methods 1 to 4, for example, the following method can also be used. Fig.44 A metal mold having a protrusion in the cavity as described above. In this case, it is possible to form Fig.42 The resonant portion 21 is shown. Fig.42 The resonance portion has a cavity formed by a recessed surface on the front end side, and the cavity is formed in the through-portion.

[0300] (One aspect of the method for manufacturing the sound insulating sheet member using the first embodiment)

[0301] One aspect of the method for producing a soundproof sheet member is described using the first embodiment described above. The method for producing a soundproof sheet member and a soundproof structure of the present invention is not limited thereto, and can also be appropriately applied to other embodiments.

[0302] The soundproof sheet component 100 can be obtained by providing the above-mentioned resonance part 21 and rib-like protrusion 31 on the sheet surface 11a of the sheet 11. The method of providing the resonance part 21 and the rib-like protrusion 31 is not particularly limited. For example, examples are shown of a method of pressing and bonding the components formed separately by heating and pressing or applying pressure, a method of bonding using various known adhesives, and a method of joining by heat welding, ultrasonic welding, laser welding, etc. As adhesives, epoxy resin adhesives, acrylic resin adhesives, polyurethane resin adhesives, silicone resin adhesives, polyolefin resin adhesives, polyvinyl butyral resin adhesives, and mixtures thereof, etc. can be cited, but are not particularly limited thereto. In addition, a part or the whole of the resonance part 21 and the rib-like protrusion 31 can also be formed by punching out the rubber sheet obtained by the above-mentioned molding method. And, in the case where a part of the resonance part 21 is metal or alloy, it can be formed by cutting the metal or alloy.

[0303] In addition, a method of manufacturing using a 3D printer or the like can also be mentioned.

[0304] From the viewpoint of improving productivity and economy, it is preferred to form the sound insulation sheet component 100 in one piece by metal mold forming, casting molding, etc. As an example, there can be cited a method of using a metal mold or casting mold having a cavity with a shape corresponding to the one-piece formed product of the sheet 11, the resonance part 21, and the rib-like protrusion 31 to form an integrally formed product of the resonance part 21, the sheet 11, the resonance part 21, and the rib-like protrusion 31. As such an integral forming method, various well-known methods such as stamping forming, compression forming, casting forming, extrusion forming, and injection molding are known, and their types are not particularly limited. In addition, if the raw material of each component is, for example, a resin material having rubber elasticity, it can be flowed into the cavity in the form of a liquid precursor or a heated melt. In addition, if it is a metal, an alloy, or an inorganic glass, it can be pre-configured (embedded) in a predetermined position in the cavity.

[0305] The resin material is not particularly limited, and examples thereof include the materials described in the description of the sheet material, the base, etc. as the sound-insulating sheet member of the present invention, and raw materials and intermediates thereof.

[0306] Figure 4 to Figure 7 1 is a diagram showing an example of a manufacturing process of the soundproof sheet member 100. Here, a metal mold 61 having a cavity 61a having a shape corresponding to the resonance portion 21 and a cavity 61b having a shape corresponding to the rib-shaped protrusion 31 is used (see FIG. Figure 4 ), a weight portion 23 is arranged in the cavity 61a of the metal mold 61 (refer to Figure 5), then, a resin material having rubber elasticity is flowed into the chambers 61a and 61b, and after heating or pressurizing as required (see Figure 6 ), the integrally molded product of the sheet material 11, the resonance part 21 and the rib-like protrusions 31 is demolded to obtain the soundproof sheet member 100. According to such an integral molding method, there is a tendency that not only the productivity and economic efficiency are improved, but also even a complex shape can be easily molded, and the adhesion of each member is improved, so that the soundproof sheet member 100 with excellent mechanical strength is easily obtained. From the above viewpoints, the sheet material 11, the resonance part 21 and the rib-like protrusions 31 are also preferably an integrally molded product containing a thermosetting elastomer or a thermoplastic elastomer.

[0307] [Effects]

[0308] In the soundproof sheet components 100-101 and the soundproof structures 200-201 of the present embodiment, a plurality of resonance parts 21 are arranged on the sheet surface 11a of the sheet 11 having rubber elasticity in a manner of contacting the sheet surface 11a. Therefore, after the sound wave is incident from the noise source, a high sound insulation performance that exceeds the mass law can be obtained. In addition, the resonance frequency of the resonance part 21 can be easily controlled by adjusting the spring constant by changing the shape, density distribution or raw material (elastic modulus, mass) of the resonance part 21 and the base 22, changing the mass of the weight part 23, etc. In addition, the frequency band (acoustic band gap width, frequency position) can also be controlled by the material, thickness, etc. of the sheet 11. Therefore, the soundproof sheet components 100-101 and the soundproof structures 200-201 of the present embodiment have a higher degree of freedom in sound insulation frequency selection and design freedom than the prior art.

[0309] Furthermore, in the soundproof sheet members 100-101 and the soundproof structures 200-201 of the present embodiment, the resonance portion 21 and the rib-shaped protrusion 31 are provided in contact with the sheet surface 11a of one side of the sheet 11 having rubber elasticity, and are not provided on the other side of the sheet surface 11b. Therefore, even if the support 51 is a non-flat surface such as a curved surface, the stretchable and flexible sheet 11 can follow the surface shape, and as a result, the sheet 11 can be stably attached to the support 51. Therefore, the soundproof sheet members 100-101 and the soundproof structures 200-201 of the present embodiment are superior in operability and versatility compared to the prior art.

[0310] Furthermore, when the sheet 11 and the resonance portion 21 are integrally molded, a plurality of resonance portions 21 (resonators) can be provided collectively, and thus productivity and operability are extremely high.

[0311] Since the rib-shaped protrusions 31 to 32 having a maximum height H2 higher than the maximum height H1 of the resonance part 21 are provided, even if the soundproofing sheet members 100 to 101 are rolled into a sheet or a plurality of soundproofing sheet members 100 to 101 are overlapped, the rib-shaped protrusions 31 to 32 function as spacers, thereby suppressing the resonance part 21 from contacting the back surface of the sheet 11. Therefore, manufacturing failures such as deformation, variation, cracking, falling off, and damage of the resonance part 21 do not occur, and the soundproofing sheet members 100 to 101 can be easily produced and stored continuously by so-called roll-to-roll, and the production speed is improved compared with batch production of individual sheets, and the productivity and economic efficiency are improved.

[0312] [Sound insulation structure]

[0313] The soundproof sheet member of the present invention can be used as a soundproof structure. As shown in the above-mentioned embodiment, the soundproof structure may also have a support body, a rib-shaped protrusion, and the like.

[0314] As an example of a method of utilizing the sound insulating sheet member of the present invention, it is conceivable to utilize the sound insulating sheet member by installing it inside or outside a small electronic device for the purpose of reducing the noise of a motor of the small electronic device or the noise of switching in an electronic circuit.

[0315] The soundproof structure may also be a laminated body including the soundproof sheet component of the present invention. For example, the soundproof sheet component 101 may be provided on both sides of the support 51. In addition, a plurality of soundproof structures each having a soundproof sheet component provided on a support may be laminated for use. By combining a plurality of soundproof sheet components, the acoustic band gap width, frequency position, etc. may be controlled.

[0316] Furthermore, even in the case of a laminate having soundproof sheet members on both sides of a support, if the box including the support and the laminate is flexible, it can follow a non-flat surface such as a curved surface, and the soundproof structure can be stably installed.

[0317] When used as a soundproof structure, the positional relationship between the resonance portion and the sheet material of the soundproof sheet member is not particularly limited, and can be, for example, Fig. 9 The cross-sectional view of the structure shown is used as shown.

[0318] Fig. 9 The soundproof structure 203 has a sheet 11, a resonance part 21, a rib-shaped protrusion 32, and a sheet 70. The soundproof structure 203 is provided on a soundproof structure setting object (e.g., a window 300). In the case where the weight of the soundproof structure setting object 300 is greater than that of the support body, such as Fig.16 As shown, the sheet is not directly provided on the sound insulation structure, so that an acoustic band gap is easily formed and high sound insulation performance is sometimes obtained.

[0319] Example

[0320] The present invention will be described in more detail below with reference to Examples, but the present invention is not limited thereto. The present invention can adopt various conditions as long as the object of the present invention is achieved within the scope of the gist of the present invention.

[0321] [Calculation of the acoustic band gap]

[0322] Respectively with respect to each part i to iv of the sheet, the physical properties (specific gravity, Young's modulus, Poisson's ratio) and material dimensions r1, r2, h, a recorded in the Example 1 column of Table 1 are substituted into the equations of the solid mechanics module of the multi-physics analysis software COMSOL Multiphysics (COMSOL), and the finite element method is used to calculate the acoustic band gap.

[0323] In order to compare the sizes of the acoustic band gaps, the normalized acoustic band gap width is [((acoustic band gap maximum frequency)−(acoustic band gap minimum frequency))÷(acoustic band gap center frequency)].

[0324] [Example 1]

[0325] Embodiment 1 includes Fig. 10A The unit cell including the soundproof sheet member shown in Table 1 shows the dimensions, materials, and physical properties of the components of the unit cell. The acoustic band gap in the unit cell was calculated based on the above calculation method.

[0326] As a result of the calculation, in Example 1, the acoustic band gap was 3461-4551 Hz and the normalized acoustic band gap width was 0.27, confirming that there was a sufficient sound insulation bandwidth.

[0327] Comparative Example 1

[0328] Comparative Example 1 includes Fig. 10A Table 1 shows the dimensions, materials, and physical properties of the components of the unit including the sound insulating sheet member shown.

[0329] The result of calculating the acoustic band gap using the same method as in Example 1 confirmed that the acoustic band gap was 7185-7804 Hz and the normalized acoustic band gap width was 0.08, which failed to sufficiently expand the sound insulation band width. Comparison between Example 1 and Comparative Example 1 confirmed that the normalized acoustic band gap width was widened by using a weight.

[0330] [Comparative Example 2]

[0331] Comparative Example 2 includes Fig. 10A The unit body including the soundproof sheet member shown is an example of using a weight portion having no through-hole. Table 1 shows the dimensions, materials, and physical properties of the components of the unit body.

[0332] As a result of calculating the acoustic band gap using the same method as in Example 1, it was confirmed that the acoustic band gap was 3345-4467 Hz and the normalized acoustic band gap width was 0.29, indicating that the sound insulation band had a sufficient sound insulation bandwidth.

[0333] [Comparative Example 3]

[0334] Comparative Example 3 includes Fig. 10B Table 1 shows the dimensions, materials, and physical properties of the components of the unit including the sound insulating sheet member shown.

[0335] The acoustic band gap was calculated using the same method as in Example 1. As a result, it was confirmed that the acoustic band gap was 4157-4733 Hz and the normalized acoustic band gap width was 0.13, and the sound insulation bandwidth could not be sufficiently expanded.

[0336] From the comparison between Example 1 and Comparative Example 3, it was confirmed that, when the thickness of the sound insulating material was set to the same level, the acoustic band gap width could be increased by using a plate-shaped weight.

[0337] [Determination of coverage]

[0338] The weight is placed in the center of a petri dish with an inner dimension of 16 mm × an outer dimension of 19 mm × a height of 12 mm, and Sylgard 184 (Toray Dow Corning Co., Ltd.) is dripped on it. The flow of Sylgard 184 to the bottom surface of the weight after dripping is observed, and the coverage rate of the front side is measured. The coverage rate is expressed by the ratio of the area covered by the resin in a close and adhesive manner to the area of ​​the front side of the resonance portion of the weight.

[0339] [Component Strength Evaluation]

[0340] Table 1

[0341]

[0342] When the weight is pulled with a constant force in the plane direction of the sheet surface, the strength is obtained from the stress at the portion of the weight where the stress is most concentrated.

[0343] Next, the coverage was measured and the component strength was evaluated for Example 1 and Comparative Example 2. The results are shown in Table 2. The strength values ​​in Table 2 are normalized values ​​when the stress of Example 1 is set to 1.

[0344] Table 2

[0345] Coverage rate (%) strength Example 1 100 1.0 Comparative Example 2 70.5 0.7

[0346] According to the results, it was confirmed that the coverage rate can be improved by providing the counterweight with through holes. In Comparative Example 2, bubbles were generated when the resin was filled from the outer periphery of the counterweight, and the bubbles were not discharged to the outside, so the coverage rate was 70.5%. On the other hand, in Example 1, although bubbles were generated, the bubbles were discharged through the through holes, so the coverage rate was 100%. The high coverage rate is considered to be able to suppress the fall-off of the counterweight and improve durability.

[0347] Next, a production method other than the above-mentioned production methods 1 to 4 and a sound insulating sheet member produced by the production method will be described.

[0348] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the following embodiments are examples for describing the present invention, and the present invention is not limited to the embodiments. Furthermore, in the following description, unless otherwise specified, the positional relationships such as up, down, left, and right are based on the positional relationships shown in the accompanying drawings. Furthermore, the dimensional ratios of the accompanying drawings are not limited to the ratios shown in the drawings.

[0349] In addition, the following Figure 11 to Figure 1 0 are denoted by the same reference numerals, and description thereof is omitted. In the fourth embodiment, the structure related to the resonance part is different from that of the third embodiment, so the resonance part will be described below.

[0350] [Third Embodiment of Sound Insulating Sheet Member and Method of Manufacturing the Same]

[0351] Fig.11 It is a schematic perspective view showing a structural example of a soundproofing sheet member 100 and a soundproofing structure 200 according to the third embodiment. Fig.12 yes Fig.11 Sectional view viewed in the direction II-II.

[0352] The soundproof sheet member 100 includes a sheet portion 11 having rubber elasticity and a plurality of resonance portions (protrusions) 21 provided on the sheet surface 11a of the sheet portion 11 so as to be in contact with the sheet surface 11a of the sheet portion 11. The soundproof sheet member 100 is supported by a support body 51 provided on the sheet surface 11b side of the sheet portion 11 opposite to the sheet surface 11a, thereby constituting a soundproof structure 200.

[0353] In the soundproof sheet component 100 and the soundproof structure 200, for example, after a sound wave is injected from a noise source located on the side of the support body 51, at least one of the sheet portion 11 and the resonance portion 21 resonates. At this time, there may be a frequency region where the direction of the force acting on the support body 51 is opposite to the direction of the acceleration generated by at least one of the sheet portion 11 and the resonance portion 21, and part or all of the vibration of a specific frequency is offset, thereby generating a complete acoustic band gap in which almost no vibration of a specific frequency exists. Therefore, near the resonant frequency of at least one of the sheet portion 11 and the resonance portion 21, part or all of the vibration is stationary, and as a result, high sound insulation performance that exceeds the mass law can be obtained. Soundproof components that use such a principle are called acoustic metamaterials. Below, each component of the soundproof sheet component 100 and the soundproof structure 200 of this embodiment is described in detail.

[0354] The maximum height from the sheet surface 11b of the sheet surface 11a having the resonance portion 21 to the front end of the resonance portion 21 is not particularly limited and can be appropriately adjusted according to the intended use, but is preferably 20 mm or less. It is more preferably 15 mm or less, further preferably 10 mm or less, further preferably 8 mm or less, further preferably 5 mm or less, and particularly preferably 3 mm or less. Furthermore, in the case of being used to block high frequencies, it is preferably 1.0 mm or less. If it is within the above range, it has a sound insulation function and can reduce the installation space required for the sound insulation sheet component 100, so that the overall size of small electronic devices and the like can be kept as small as possible.

[0355] The lower limit is not particularly limited, but is, for example, 0.01 mm or more from the viewpoint of ease of manufacture. Fig.11 The height in the middle is indicated by H, which indicates the height from the sheet surface 11 b of the sheet portion 11 to the maximum height of the resonance portion 21 in the normal direction of the sheet portion 11 .

[0356] [Sheet Department]

[0357] The sheet portion 11 is a sheet having rubber elasticity. Although not particularly limited, the sheet portion 11 may have rubber elasticity due to the molecular motion of a resin (organic polymer), etc. The sheet portion 11 may also function as a vibrator (resonator) that vibrates at a certain frequency after sound waves are injected from a noise source.

[0358] The material constituting the sheet portion 11 preferably contains at least one selected from the group consisting of a heat- or light-curing elastomer and a thermoplastic elastomer.

[0359] Specific examples of the material constituting the sheet portion 11 include: thermosetting resin elastomers such as vulcanized thermosetting resin elastomers such as chemically cross-linked natural rubber or synthetic rubber, polyurethane thermosetting resin elastomers, silicone thermosetting resin elastomers, fluorine thermosetting resin elastomers, and acrylic thermosetting resin elastomers; thermoplastic elastomers such as olefin thermoplastic elastomers, styrene thermoplastic elastomers, polyvinyl chloride thermoplastic elastomers, polyurethane thermoplastic elastomers, ester thermoplastic elastomers, amide thermoplastic elastomers, silicone thermoplastic elastomers, and acrylic thermoplastic elastomers; and the like.

[0360] As further specific examples of the thermosetting elastomer and the thermoplastic elastomer, rubber can be cited. Specifically, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and modified forms thereof can be cited, but are not particularly limited thereto. These can be used alone or in combination of two or more.

[0361] In addition, among them, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and their modified bodies are preferred, and silicone rubber, acrylic rubber and their modified bodies are more preferred. By using these materials, there is a tendency to have excellent heat resistance and cold resistance.

[0362] The sheet portion 11 may be any sheet having so-called rubber elasticity, and may contain various additives such as a flame retardant, an antioxidant, a plasticizer, and a colorant.

[0363] Flame retardants are additives added to make combustible raw materials difficult to burn or prevent them from igniting. Specific examples thereof include: bromine compounds such as pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, hexabromocyclododecane, hexabromobenzene; phosphorus compounds such as triphenyl phosphate; chlorine compounds such as chlorinated paraffin; antimony compounds such as antimony trioxide; metal hydroxides such as aluminum hydroxide; nitrogen compounds such as melamine cyanurate; boron compounds such as sodium borate, etc., but are not particularly limited to these.

[0364] Furthermore, an antioxidant is an additive added to prevent oxidative degradation, and specific examples thereof include phenolic antioxidants, sulfur-based antioxidants, phosphorus-based antioxidants, and the like, but are not particularly limited thereto.

[0365] In addition, plasticizers are additives for improving flexibility and weather resistance. Specific examples thereof include phthalates, adipates, trimellitates, polyesters, phosphates, citrates, sebacates, azelates, maleates, silicone oils, mineral oils, vegetable oils, and modified forms thereof, but are not particularly limited thereto.

[0366] Furthermore, examples of the coloring agent include coloring matter and pigments.

[0367] These can be used alone or in combination of two or more.

[0368] The sheet portion 11 is formed in a square shape when viewed from above, but its shape is not particularly limited to this. It can be any shape when viewed from above, such as a triangle, rectangle, rectangle, trapezoid, rhombus, pentagon, hexagon or other polygon, circle, ellipse, or an indefinite shape not classified into the above shapes. In addition, the sheet portion 11 can have a cutout portion, a punching hole, etc. at any position as long as it does not lose the characteristics of the acoustic metamaterial, from the viewpoint of improving the stretching performance and reducing the weight.

[0369] The thickness of the sheet portion 11 is not particularly limited as long as the maximum height of the sound insulation sheet component is within the scope of the present invention. Since the frequency band (acoustic band gap width, frequency position) that exhibits high sound insulation performance can also be controlled according to the thickness of the sheet portion 11, the thickness of the sheet portion 11 can be appropriately set in a manner that makes the acoustic band gap consistent with the desired sound insulation frequency region. If the thickness of the sheet portion 11 is thicker, the acoustic band gap width becomes narrower and tends to shift to the low frequency side. In addition, if the thickness of the sheet portion 11 is thinner, the acoustic band gap width becomes wider and tends to shift to the high frequency side.

[0370] From the viewpoints of sound insulation performance, mechanical strength, flexibility, and operability, the thickness of the sheet portion 11 is preferably 10 μm or more, more preferably 50 μm or more, and further preferably 100 μm or more. Furthermore, the thickness of the sheet portion 11 is preferably 2 mm or less, more preferably 1 mm or less, and further preferably 500 μm or less.

[0371] From the viewpoints of sound insulation performance, mechanical strength, flexibility, operability, productivity, etc., the sheet portion 11 preferably has a Young's modulus of 0.01 MPa or more, more preferably a Young's modulus of 0.1 MPa or more, and preferably has a Young's modulus of 100 MPa or less, more preferably a Young's modulus of 10 MPa or less.

[0372] Here, the Young's modulus in this specification refers to the ratio of the force (stress) acting on the unit cross-sectional area of ​​the sample after an external force is applied in one axial direction to the deformation rate (strain), and refers to the value of the storage longitudinal elastic modulus at 25°C and 10 Hz measured by the forced vibration non-resonance method according to JIS K 6394:2007 "Vulcanized rubber and thermoplastic rubber-Method for determining dynamic properties-".

[0373] Furthermore, from the viewpoint of reducing the temperature dependence of the sound insulation at low temperatures, the sheet portion 11 preferably has a glass transition temperature below 0°C. The lower the glass transition temperature of the sheet portion 11, the higher the cold resistance, and the smaller the temperature dependence of the elastic modulus at around 0°C, so that the sound insulation performance tends to be less dependent on the ambient temperature. It is more preferably below -10°C, further preferably below -20°C, and particularly preferably below -30°C. In addition, in the present specification, the glass transition temperature of the sheet portion 11 refers to the peak temperature of the loss tangent in the dynamic viscoelasticity measurement at the above-mentioned frequency of 10 Hz, especially the temperature dependence measurement.

[0374] [Resonance section]

[0375] The resonance part 21 functions as a vibrator (resonator) that vibrates at a certain frequency after a sound wave is injected from a noise source. The resonance part 21 of the present embodiment is composed of a composite structure having a base 22 and a weight part 23 supported on the base 22 and having a mass greater than that of the base 22. The resonance part 21 effectively functions as a resonator having a resonance frequency, and the resonance frequency is determined by the mass of the weight part 23 acting as a weight and the spring constant of the base 22 acting as a spring.

[0376] The arrangement, number of settings, size, etc. of the resonance portion 21 can be appropriately set according to the desired performance and are not particularly limited. The resonance portion 21 is arranged along the surface direction of the sheet surface 11a of at least one side of the sheet portion 11. For example, in the present embodiment, a plurality of resonance portions 21 are arranged in a lattice shape and at equal intervals, but the arrangement of the resonance portion 21 is not particularly limited thereto. For example, the plurality of resonance portions 21 may be arranged in a staggered manner or randomly. Since the sound insulation mechanism utilizing the sound insulation sheet component 100 does not utilize Bragg scattering like the so-called phononic crystal, the intervals of the resonance portions 21 may not be regularly and periodically arranged.

[0377] The number of the resonance parts 21 to be provided per unit area is not particularly limited as long as the resonance parts 21 can be arranged so as not to interfere with each other due to contact or the like.

[0378] The maximum number of resonance parts 21 per unit area varies depending on the shape of the resonance part 21, but for example, when the resonance part 21 is cylindrical, the height direction of the cylinder is parallel to the normal direction of the sheet, and the diameter of the cylinder cross section is 1 cm, it is preferable to have 100 resonance parts per unit area. 2 The number is less than 100.

[0379] The minimum number of resonance parts 21 per unit area is preferably 10 cm, for example, when the resonance part 21 is cylindrical, the height direction of the cylinder is parallel to the normal direction of the sheet, and the cross-sectional diameter is 1 cm. 2 The number of the resonant parts 21 is preferably 2 or more, more preferably 10 or more, and further preferably 50 or more. By setting the number of the resonant parts 21 to be greater than the above-mentioned preferred lower limit, there is a tendency to obtain higher sound insulation performance. Furthermore, by setting the number to be less than the above-mentioned preferred upper limit, it is easy to achieve overall lightweighting of the sheet.

[0380] The maximum height of the resonance portion 21 in the normal direction from the sheet surface 11a of the sheet portion 11 can be appropriately set according to the desired performance, and is not particularly limited. From the viewpoint of the ease of forming and the improvement of productivity, the maximum height is preferably 10 μm or more, more preferably 100 μm or more, and further preferably 1 mm or more. Furthermore, it is preferably 20 mm or less, more preferably 15 mm or less, further preferably 10 mm or less, further preferably 8 mm or less, further preferably 5 mm or less, and particularly preferably 3 mm or less. By setting it within this range, there is an advantage from the viewpoint of productivity, such as the ease of peeling the sheet portion 11 from the metal mold MD.

[0381] Furthermore, the height of the resonance part 21 in the normal direction of the sheet part 11 may be the same or different in all the resonance parts. By making the height of the resonance part different, there may be an effect of expanding the frequency range in which the sound insulation performance is exhibited.

[0382] [Base]

[0383] The base 22 has a generally cylindrical outer shape. A plurality of bases 22 are arranged on the sheet surface 11a of the sheet portion 11 in such a manner as to contact the sheet surface 11a, and a counterweight portion 23 is respectively buried inside the base 22. The outer shape of the base 22 is not particularly limited, and may be a triangular prism, a rectangular prism, a trapezoidal prism, a pentagonal prism, a hexagonal prism or other polyhedral prism, a cylindrical shape, an elliptical prism, a truncated cone, a truncated cone, a pyramid, a cone, a hollow cylinder, a branched shape, an indefinite shape not classified into the above shapes, or any other shape. Furthermore, it may also be formed into a columnar shape having at least one of a cross-sectional area and a cross-sectional shape that is different depending on the height position of the base 22.

[0384] Furthermore, the shapes and heights of the plurality of bases 22 provided on the sheet surface 11 a so as to be in contact with the sheet surface 11 a may be the same or different.

[0385] The material of the base 22 is not particularly limited as long as it satisfies the above-mentioned required properties. For example, a resin material may be used, and at least one selected from the group consisting of a thermosetting elastomer, a thermoplastic elastomer, a thermosetting resin, and a thermoplastic resin may be used.

[0386] Examples of the thermosetting elastomer and the thermoplastic elastomer include those described in the description of the sheet.

[0387] Examples of thermosetting resins include acrylic thermosetting resins, polyurethane thermosetting resins, silicone thermosetting resins, epoxy thermosetting resins, etc. Examples of thermoplastic resins include polyolefin thermoplastic resins, polyester thermoplastic resins, acrylic thermoplastic resins, polyurethane thermoplastic resins, polycarbonate thermoplastic resins, etc.

[0388] As specific examples, there can be mentioned: chemically cross-linked natural rubber or synthetic rubber such as vulcanized rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and their modified rubbers; polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride, polychlorotrifluoroethylene, polyethylene, polypropylene, polynorbornene, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polystyrene, epoxy resin, oxazine resin and other polymers, but are not particularly limited thereto. They can be used alone or in combination of two or more.

[0389] Furthermore, the base 22 may be a porous body containing pores (gas such as air) in the above-mentioned resin material. In addition, the base 22 may also contain a liquid material such as mineral oil, vegetable oil, silicone oil, etc. Furthermore, when the base 22 contains a liquid material, it is preferably sealed in the resin material in advance from the viewpoint of suppressing the liquid material from flowing out to the outside.

[0390] The material of the base 22 is preferably the same material as the sheet 11, and is particularly preferably an elastomer. If the sheet 11 and the base 22 contain the same elastomer, the sheet 11 and the base 22 can be easily formed into one piece, and the productivity is greatly improved. That is, the sheet 11 and the resonance part 21 (base 22) are one-piece products simultaneously containing at least one selected from the group consisting of a thermosetting elastomer and a thermoplastic elastomer, but this is only one of the particularly preferred methods.

[0391] Specific examples of elastomers include vulcanized rubber such as chemically crosslinked natural rubber or synthetic rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and modified products thereof, polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride, polychlorotrifluoroethylene, polyethylene, polypropylene, polynorbornene, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polystyrene, epoxy resin, oxazine resin, etc., but are not particularly limited thereto.

[0392] Among them, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, polyurethane rubber, silicone rubber and modified bodies thereof are preferred, and silicone rubber, acrylic rubber and modified bodies thereof are more preferred from the viewpoint of excellent heat resistance and cold resistance.

[0393] It should be noted that the base 22 can also be a two-color molded body or a multi-color molded body composed of two or more resin materials. In this case, by making the base 22 on the side in contact with the sheet portion 11 adopt the same elastomer as the sheet portion 11 described above, the sheet portion 11 and the base 22 can be easily integrally molded.

[0394] In addition, when a resonance portion 21 (base 22) having a circular cross-section is provided as in the present embodiment, in a cross section parallel to the sheet surface 11a of the sheet portion 11 at a height position of the resonance portion 21 (base 22) where the sum of the cross-sectional areas of the plurality of resonance portions 21 (base 22) is the largest, the diameter of the circle with the largest diameter among the circles (circular cross section) included in the cross section is preferably 100 mm or less, more preferably 50 mm or less, and further preferably 20 mm or less. Furthermore, the diameter of the circle with the smallest diameter is preferably 10 μm or more, more preferably 100 μm or more, and further preferably 1 mm or more. By setting within the above-mentioned preferred numerical range, it is possible to ensure that the resonance portion 21 (base 22) provided to the sheet surface 11a of the sheet portion 11 is a predetermined number or more, thereby being able to further obtain good sound insulation performance, and there is a tendency that the ease of forming and productivity are also further improved.

[0395] [Counterweight]

[0396] Fig.13 It is a perspective view of the appearance of the weight portion 23 .

[0397] The weight portion 23 of this embodiment has a through hole (through portion) 124 having a circular cross section. The through hole 124 penetrates the weight portion 23 in the vertical direction. The weight portion 23 is not particularly limited as long as it has a greater mass than the base portion 22 described above. Fig.13 As shown, the weight portion 23 is, for example, in the shape of a ring (annular shape), but may also be in the shape of a disk such as a washer or in the shape of a hexagonal column such as a nut.

[0398] Although the shape of the counterweight portion 23 is not particularly limited, it is preferably in a plate shape from the viewpoint of adjusting the sound insulation performance and thinning. Since the counterweight portion 23 is in a plate shape, the center of gravity of the counterweight can be located at a position away from the substrate compared to the case where the counterweight portion 23 is in a sphere, etc., so that there is a tendency to increase the vibration moment of the resonance portion 21. For example, when the width of the acoustic band gap is constant, the plate-shaped counterweight can be thinner than when the counterweight portion 23 is in a sphere. On the other hand, when the height of the counterweight portion 23 is constant, the plate-shaped counterweight can obtain a wider band gap width than when the counterweight portion 23 is in a sphere.

[0399] In the present embodiment, the weight portion 23 is formed into a substantially circular shape having an outer diameter smaller than that of the base portion 22 , and is embedded in the base portion 22 at the front end side (hereinafter referred to as the front end side) of the resonance portion 21 . Fig.14 This is a perspective view of the appearance of the resonance part 21 in which the weight part 23 is buried in the base part 22. Fig.15 It is a partial cross-sectional view.

[0400] like Fig.14 and Fig.15 As shown in FIG. 1 , in the resonance part 21, the weight part 23 is arranged on the front end side of the base part 22. The base part 22 has a covering part 125 covering a part of the surface on the front end side of the weight part 23, and a recessed part 26 provided in a manner that a part of the covering part 125 is missing (penetrated). The recessed part 26 is circular in a plan view and is provided coaxially with the through hole 124. The diameter of the recessed part 26 is larger than the diameter of the through hole 124 and smaller than the outer diameter of the weight part 23. Therefore, a part of the surface on the front end side of the weight part 23 is exposed at the bottom surface of the recessed part 26.

[0401] In addition, the resonance part 21 is provided with a cavity 27 having a circular cross section, which is opened at the bottom surface of the recessed part 26 and extends in the axial direction. The cavity 27 is formed in the resin material of the base 22 loaded in the through hole 124 of the weight part 23. The cavity 27 is coaxial with the recessed part 26. In the present embodiment, the resin material is filled between the surface of the through hole 124 and the cavity 27. The depth of the cavity 27 is set to a length that does not reach the surface on the rear end side of the weight part 23.

[0402] In this way, since the weight portion 23 that functions as a weight of the resonance portion 21 adopts a structure supported by the base portion 22 that determines the spring constant, the resonance frequency of the resonance portion 21 can be easily controlled by adjusting the spring constant by changing the shape of the base portion 22 or the raw material (elastic modulus, mass), or changing the mass of the weight portion 23. Generally speaking, if the elastic modulus of the base portion 22 becomes smaller, the acoustic band gap tends to shift to the low frequency side. In addition, if the mass of the weight portion 23 becomes larger, the acoustic band gap tends to shift to the low frequency side.

[0403] Fig.13 The height hx of the weight portion 23 is not particularly limited, but when the height of the resonance portion is set to 1, it is preferably 0.95 or less, and more preferably 0.9 or less. Also, it is preferably 0.2 or more, and more preferably 0.3 or more. By setting it to such a range, there is a tendency to obtain a wider band gap width while suppressing the height of the sound insulation sheet component.

[0404] The outer diameter r1 of the counterweight portion 23 is not particularly limited. In the case where the cross-section of the resonance portion 21 is circular, if the outer diameter of the counterweight is approximately the diameter of the circular cross-section, there is a tendency for excellent sound insulation performance. Although not particularly limited, the maximum value of the radius r1 is preferably less than 100 mm, more preferably less than 50 mm, and further preferably less than 20 mm. In addition, the minimum value of the radius r1 is preferably greater than 10 μm, more preferably greater than 100 μm, and further preferably greater than 1 mm. By setting it within the above-mentioned preferred numerical range, good sound insulation performance can be obtained, and there is a tendency for the ease of forming and productivity to be further improved. The counterweight portion 23 of the present embodiment is also filled with a resin material or the like in a portion of the through hole 124, and a portion of the front end side is covered by the covering portion 125, so that even if a portion is exposed, it can be prevented from falling off or breaking from the base 22. The inner peripheral surface of the through hole 124 of the weight portion 23 may have corrugated convexo-concave or spiral notched grooves. In this case, the weight portion 23 can be further suppressed from falling off by allowing the resin to enter the grooves.

[0405] The inner diameter r2 of the counterweight portion 23 is not particularly limited. It can be smaller than the outer diameter r1 without particular limitation, but the maximum value of the inner diameter r2 is preferably 90 mm or less, more preferably 40 mm or less, further preferably 20 mm or less, and particularly preferably 10 mm or less. In addition, the minimum value of the inner diameter r2 is preferably 2 μm or more, more preferably 50 μm or more, and further preferably 80 μm or more. By setting it within the above preferred numerical range, there is a tendency that the filling of the resin material or the like into the through hole 124 becomes easier.

[0406] Furthermore, the ratio between the outer diameter r1 and the inner diameter r2 of the weight portion 23 is not particularly limited.

[0407] The material constituting the weight portion 23 may be appropriately selected in consideration of quality, cost, etc., and its type is not particularly limited. From the viewpoint of miniaturization of the soundproof sheet member 100 and the soundproof structure 200 and improvement of soundproofing performance, the material constituting the weight portion 23 is preferably a material having a high specific gravity.

[0408] Specifically, examples include: metals or alloys such as aluminum, stainless steel, iron, tungsten, gold, silver, copper, lead, zinc, and brass; inorganic glasses such as soda glass, quartz glass, and lead glass; and composite materials such as the above-mentioned metal or alloy powders or the above-mentioned inorganic glass contained in the resin material of the above-mentioned base 22, but are not particularly limited thereto. The material, mass, and specific gravity of the weight portion 23 may be determined so that the acoustic band gap of the sound insulation sheet member 100 and the sound insulation structure 200 coincides with the desired sound insulation frequency region.

[0409] Among them, from the viewpoints of low cost and high specific gravity, at least one selected from the group consisting of metals, alloys and inorganic glasses is preferred. In addition, specific gravity refers to the ratio of the mass of a material to the mass of pure water at 4°C under a pressure of 1013.25 hPa of the same volume, and in this specification, the value measured according to JIS K 0061 "Determination of density and specific gravity of chemical products" is used.

[0410] In order to improve process adaptability and component strength, the surface of the weight portion 23 (including the through hole) may be subjected to surface treatment. For example, chemical treatment using a solvent or the like for improving adhesion with the base portion 22 or physical treatment for improving component strength by providing concavities and convexities on the surface may be considered, but the surface treatment method is not particularly limited.

[0411] In the present embodiment, the weight portion 23 is embedded in the base portion 22 at the front end side of the resonance portion 21, but the position of the weight portion 23 is not particularly limited. Although the shapes, masses, elastic moduli, etc. of the base portion 22 and the weight portion 23 are different, from the viewpoint of reducing the thickness and weight of the sound insulation sheet member 100 and improving the sound insulation performance, it is preferred to arrange the base portion 22 and the weight portion 23 so that the center of gravity (center of mass) of the resonance portion 21 is at least located closer to the front end side than the center in the height direction of the resonance portion 21. Typically, the weight portion 23 is offset and arranged closer to the front end side than the center in the height direction of the resonance portion 21.

[0412] In addition, the weight portion 23 may be completely buried in the base 22, or only a part thereof may be buried, or it may be provided on the base 22 instead of being buried in the base 22. (Details will be described below) Furthermore, in the case where the base 22 adopts a branch structure, from the viewpoint of reducing the weight of the sound insulation sheet component or improving the sound insulation performance, when the weight portion is provided in the branch portion provided from the branch point, it is preferred to configure the weight portion 23 in a manner that it is located closer to the front end side than the center of the branch portion.

[0413] Furthermore, the shapes and heights of the plurality of weights 23 included in the soundproofing sheet member may be the same or different.

[0414] In addition, a plurality of resonance parts 21 are provided on the sheet surface 11a of the sheet 11, and the material constituting the resonance part 21, the arrangement, shape, size, and setting direction of the resonance part 21 are not necessarily the same in all the plurality of resonance parts 21. By providing a plurality of resonance parts 21 in which at least one of the resonance parts is different, the frequency region exhibiting high sound insulation performance can be expanded.

[0415] [Support]

[0416] The soundproof sheet component 100 of the present invention can be appropriately set according to the environment in which the soundproofing performance is required. For example, the soundproof sheet component 100 can be directly set on a device, a structure, etc. An adhesive layer or the like can also be provided between the soundproof sheet component 100 and the device, the structure, etc. In addition, the soundproof sheet component 100 can also be used in a form supported by a support body 51. When the soundproof sheet component 100 of the present invention is used for soundproofing, the support body 51 can support the soundproof sheet component 100, and it can also be not supported by the support body during manufacturing, storage, etc.

[0417] The support body 51 only needs to be provided in contact with at least one surface of the sheet portion 11 of the soundproof sheet member 100 , and may be provided on at least one of the sheet surface 11 a provided in contact with the resonance portion 21 and the other sheet surface 11 b .

[0418] In the present embodiment, a support body 51 is provided on the sheet surface 11b side of the back side of the sheet portion 11. The raw material constituting the support body 51 is not particularly limited as long as it can support the sheet portion 11, but from the viewpoint of improving the sound insulation performance, a material having a higher rigidity than the sheet portion 11 is preferred. Specifically, the support body 51 preferably has a Young's modulus of 1 GPa or more, more preferably 1.5 GPa or more. The upper limit is not particularly limited, and for example, 1000 GPa or less can be cited.

[0419] Furthermore, when the soundproof sheet member 100 is directly provided on a device or a structure, the surface on which the soundproof sheet member 100 is provided preferably has the same rigidity as the support 51 from the viewpoint of supporting the sheet portion 11 and improving the soundproofing performance.

[0420] The raw material constituting the support 51 is not particularly limited. For example, a photocurable resin sheet, a thermosetting resin sheet, a thermoplastic resin sheet, a metal plate, an alloy plate, etc. can be cited. As the photocurable resin sheet, the thermosetting resin sheet, and the thermoplastic resin sheet, sheets of the photocurable resin, the thermosetting resin, and the thermoplastic resin cited in the description of the above base can be cited.

[0421] Specific examples of raw materials constituting the support body 51 include: polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene succinate; poly(meth)acrylate resins such as polymethyl methacrylate; polycarbonate resins such as polycarbonate with isosorbide as the main raw material; polyolefin resins such as polyethylene, polypropylene, and polynorbornene; organic materials such as vinyl chloride resin, polyacrylonitrile, polyvinylidene chloride, polyether sulfone, polyphenylene sulfide, polyarylate, polyamide, polyimide, triacetyl cellulose, polystyrene, epoxy resin, and oxazine resin; composite materials containing metals such as aluminum, stainless steel, iron, copper, zinc, and brass, inorganic glass, inorganic particles, and fibers in these organic materials, etc.

[0422] Among them, from the viewpoints of sound insulation, rigidity, formability, cost, etc., the support is preferably at least one selected from the group consisting of a photocurable resin sheet, a thermosetting resin sheet, a thermoplastic resin sheet, a metal plate, and an alloy plate. Here, the thickness of the support 51 is not particularly limited, but from the viewpoints of sound insulation performance, rigidity, formability, lightness, cost, etc., it is usually preferably 0.05 mm or more and 0.5 mm or less.

[0423] In addition, from the viewpoints of light transmittance, adhesion with the sound insulating sheet member, and the like, the support 51 may be provided with a coating on the surface of the support 51 .

[0424] In addition, the shape of the support body 51 can be appropriately set according to the installation surface of the sound insulation structure 200, and is not particularly limited. For example, it can be a flat sheet, a curved sheet, or a special shape processed to have a curved surface, a bent portion, etc. In addition, from the viewpoint of weight reduction, a cutout, a punched portion, etc. can be set at any position of the support body 51.

[0425] Furthermore, the surface density (mass per unit area) of the support body 51 can also be appropriately set according to the desired performance and is not particularly limited. From the viewpoint of improving the effect of the present invention, the surface density of the support body 51 is preferably 80% or less of the surface density of the sound insulation sheet member 100, more preferably 30% or less, and further preferably 10% or less.

[0426] [Manufacturing method]

[0427] The method for producing the soundproofing sheet member and the soundproofing structure of the present invention may include the following steps (1) to (4).

[0428] (1) A step of preparing a metal mold having a plurality of cavities.

[0429] (2) A step of arranging weights in a plurality of cavities provided in a metal mold.

[0430] (3) A step of causing the resin material to flow into the cavity.

[0431] (4) A step of hardening the poured resin material.

[0432] (5) A step of peeling the obtained hardened product from the metal mold.

[0433] After step (4) or step (5), a step of providing a support on the obtained hardened product may be further included. The shape of the chamber used in each manufacturing method is not particularly limited, and for example, the shape of the bottom can be appropriately selected to be hemispherical, flat, convex or concave.

[0434] From the viewpoint of improving productivity and economy, it is preferred to form the sound insulation sheet component 100 in one piece by metal mold forming, casting molding, etc. As an example, there can be cited a method of forming the one-piece formed product of the sheet portion 11 and the resonance portion 21 using a metal mold or a casting mold having a cavity with a shape corresponding to the one-piece formed product of the sheet portion 11 and the resonance portion 21. As such an one-piece forming method, various well-known methods such as stamping forming, compression forming, transfer forming, casting forming, extrusion forming, and injection molding are known, and their types are not particularly limited. In addition, if the raw material of each component is, for example, a resin material having rubber elasticity, it can be flowed into the cavity in the form of a liquid precursor or a heated melt. In addition, if it is a metal, an alloy, or an inorganic glass, it can be pre-configured (embedded) in a predetermined position in the cavity.

[0435] The resin material is not particularly limited, and examples thereof include the materials described in the description of the sheet material, the base, etc. as the sound-insulating sheet member of the present invention, and raw materials and intermediates thereof.

[0436] Next, refer to Figures 16 to 20The method for manufacturing the soundproofing sheet member 100 will be described. Here, an example of a structure in which the soundproofing sheet member 100 is manufactured by transfer molding using a metal mold will be described.

[0437] Fig.16 It is a cross-sectional view showing the metal mold MD.

[0438] The metal mold MD includes upper molds M11 and M12 and lower molds M21 and M22. A press heating plate 161 is integrally fixed to the upper side of the upper mold M12. A press heating plate 62 is integrally fixed to the lower side of the lower mold M22. When the upper mold M11 and the lower mold M21 are joined, a space for molding the sound insulation sheet component 100 is formed.

[0439] In addition, regarding Fig.16 In the figures thereafter, for ease of understanding, six resonance parts 21 are shown to be formed in a row, but the number of resonance parts 21 is not limited to six in a row, and any number can be set. In addition, the dimensions of the components of the soundproof sheet member 100 including the resonance part 21 and the dimensions of the metal mold MD corresponding to the components are associated with, for example, dimensional changes caused by temperature changes of the resin material, so that the soundproof sheet member 100 of the desired size can be formed after the above steps (3) to (5), but the description of the corresponding dimensions is omitted in the following description.

[0440] The lower mold M21 and the lower mold M22 can move relative to each other in the vertical direction so as to be separable and approachable with respect to the lower mold M22 in a state where the lower mold M21 is arranged on the upper side. The lower mold M21 has a recess 11M corresponding to the sheet portion 11 formed on the upper surface M21a. Fig.17 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0441] like Fig.17 As shown, the lower mold M21 has a recess 22M formed vertically through the lower mold M21 to form the base 22. The lower mold M22 has an upper surface 22Ma forming the bottom of the cavity CV, a core portion (step portion) 26M protruding from the upper surface 22Ma toward the recess 22M, and a core portion (protrusion) 27M.

[0442] The core portion 26M is a portion forming the recessed portion 26 in the resonance portion 21, and is formed in a cylindrical shape. The diameter of the core portion 26M is formed to be larger than the through hole 124 of the counterweight portion 23. The height of the core portion 26M corresponds to the thickness of the covering portion 125 in the base 22. The core portion 26M protrudes at a height lower than the core portion 27M. The core portion 27M is a portion forming the gap 27 in the resonance portion 21, and is formed in a cylindrical shape. The diameter of the core portion 27M is formed to be smaller than the through hole 124 of the counterweight portion 23. The height of the core portion 27M is formed to be smaller than the thickness of the counterweight portion 23.

[0443] In addition, in addition to the definition that the core portion 26M having an outer diameter larger than that of the core portion 27M protrudes from the upper surface 22Ma and the core portion 27M having an outer diameter smaller than that of the core portion 26M protrudes from the front end surface of the core portion 26M, it can also be defined as follows: the core portion 27M having an outer diameter smaller than that of the core portion 26M protrudes from the upper surface 22Ma, and the annular core portion 26M having an outer diameter larger than that of the core portion 27M protrudes from the upper surface 22Ma in a state of contact with the outer peripheral surface of the core portion 27M.

[0444] The maximum value of the radial gap between the core portion 27M and the through hole 124 (the surface direction of the recess 22M, the recess 11M of the arranged core portions 26M and 27M; the surface direction of the sheet portion 11 (the direction with the radial center of the resonance portion 21 as the axis and perpendicular to the axis) is formed to be smaller than the minimum value of the radial gap between the recess 22M and the counterweight portion 23.

[0445] The cavity CV for forming the resonance portion 21 is composed of the upper surface 22Ma, the core portion 26M, the core portion 27M, and the lower surface M11a of the upper mold M11 (see Fig.16 and Fig.17 ) surrounds the space of the recess 22M.

[0446] The upper mold M11 and the upper mold M12 can be relatively moved in the up-down direction in a state where the upper mold M11 is arranged on the upper side and can be separated from or approached to the upper mold M12 (see Fig.18 The upper mold M11 has a recess (bowl) M111 and a plurality of through holes M112 that open in the recess M111 and penetrate in the up-down direction on the upper surface M11b. The through holes M112 are arranged at positions facing the recessed portion 11M.

[0447] The upper mold M12 has a protrusion (push pin) M121 protruding from the lower surface M12a. When the upper surface M11b of the upper mold M11 abuts against the lower surface M12a of the upper mold M12, the protrusion M121 is inserted into the recess M111 of the upper mold M11.

[0448] Next, a method for manufacturing the sound insulating sheet member 100 using the above-mentioned metal mold MD will be described. Fig.16As shown, the metal mold MD prepared in step (1) is in a state where the upper mold M11 is in contact with the upper mold M12 , the lower mold M21 is in contact with the lower mold M22 , and the upper mold M11 and the lower mold M21 are separated.

[0449] Next, in step (2), the counterweights 23 are arranged in the plurality of cavities CV from the gaps separating the upper mold M11 and the lower mold M21. Each counterweight 23 is placed on the core part 26M in a state where the core part 27M is inserted into the through hole 124. By placing the counterweight 23 on the core part 26M, a gap is formed between the counterweight 23 and the upper surface 22Ma.

[0450] Here, the maximum value of the radial clearance between the core portion 27M and the through hole 124 is formed to be smaller than the minimum value of the radial clearance between the recess 22M and the counterweight portion 23, so that even if the counterweight portion 23 is loaded offset relative to the core portion 27M, the outer peripheral surface of the counterweight portion 23 and the inner peripheral surface of the recess 22M (i.e., the lower mold M21) can be prevented from abutting against each other.

[0451] Next, in step (3), a resin material (for example, a thermosetting resin) is poured into cavity CV.

[0452] Specifically, first, Fig.18 As shown, the upper mold M11 is separated from the upper mold M12 in a state where the lower mold M21 is in contact with the lower mold M22 and the upper mold M11 is in contact with the lower mold M21. Next, the semi-hardened resin material is supplied to the recess M111 of the upper mold M11.

[0453] Next, if Fig.19 As shown, the protrusion M121 of the upper mold M12 is inserted into the recess M111 of the upper mold M11 to compress the resin material. The compressed resin material flows into the recess 11M and the cavity CV through the through hole M112. The resin material flowing into the cavity CV is filled into the parts of the recess 22M except the counterweight part 23, the core parts 26M, and 27M (including the through hole 124).

[0454] Here, when the resin material flows into the cavity CV, the counterweight 23 may move due to the flow of the resin material, but since the core 27M is inserted into the through hole 124 to limit the radial position, the counterweight 23 is prevented from deviating significantly in the cavity CV. In particular, since the maximum value of the radial gap between the core 27M and the through hole 124 is formed to be smaller than the minimum value of the radial gap between the recess 22M and the counterweight 23, the outer peripheral surface of the counterweight 23 abuts against the inner peripheral surface of the recess 22M (i.e., the lower mold M21) and the resin material cannot be filled between the outer peripheral surface of the counterweight 23 and the inner peripheral surface of the recess 22M, thereby preventing the outer peripheral surface of the counterweight 23 from being exposed.

[0455] Next, in step (4), the resin material filled in the cavity CV is hardened by heating it for a certain period of time using the pressurizing and heating plates 161 and 62. Thus, the sound insulating sheet member 100 is formed inside the upper mold M11 and the lower mold M21.

[0456] Next, in step (5), the obtained cured product is peeled off from the metal mold MD.

[0457] Specifically, if Fig. 20 As shown, first, the hardened material filled in the through hole M112 is separated from the soundproof sheet component 100 (sheet portion 11) by separating the upper mold M11 from the lower mold M21. Next, the core portion 27M is separated from the through hole 124 of the weight portion 23 by separating the lower mold M21 from the lower mold M22. Thus, the soundproof sheet component 100 as a hardened material is supported from the lower mold M21 from the lower side. Then, the hardened material is peeled off from the upper surface side of the lower mold M21, thereby obtaining the soundproof sheet component 100.

[0458] In addition, as the above-mentioned forming, transfer forming is shown, but it can also be stamping forming (compression forming) in which the raw material is directly loaded onto the lower mold M21 and stamped using the upper mold M11. And, in the case of using casting forming, the upper mold is not necessarily required, and it becomes a process of using gravity or the like to make the liquid raw material flow in. And, in the case of using injection molding, it becomes a process of filling the molten or liquid resin into the metal mold with a push rod or a screw after the mold is closed.

[0459] Furthermore, in the above-mentioned embodiment, an example of a structure in which heat is supplied by the pressurized heating plates 161 and 62 to harden the resin material is shown, but a heat source such as a heater may be directly arranged in the upper molds M11 and M12 and the lower molds M21 and M22. Furthermore, in the case of press molding and injection molding using thermoplastic resin, cooling pipes or the like for promoting the hardening of the resin may be arranged in the metal mold or its periphery.

[0460] In addition, in the above-mentioned metal mold MD, an example of a structure in which a lower mold M21 having a recess 22M and a lower mold M22 having core parts 26M and 27M are separated is shown, but this is a structure for easily demolding the sound insulation sheet component 100, and the lower mold M21 and the lower mold M22 can also be an integrated structure.

[0461] In addition, in the above-mentioned embodiment, an example of a structure in which a semi-hardened resin material is supplied to the recess M111 of the upper mold M11 and compressed is shown, but the present invention is not limited to this structure. For example, a structure in which a solid resin material is inserted into the recess M111 of the upper mold M11 and the solid material is extruded into the cavity CV by a punching plate (punching die) inserted in the recess M111 may also be used.

[0462] As described above, in the sound insulation sheet member 100 and the manufacturing method thereof of the present embodiment, the resin is flowed into the cavity CV in a state where the core portion 27M of the lower mold M21 is inserted into the through hole 124 of the weight portion 23, so that the position of the weight portion 23 can be suppressed from being greatly deviated from the base portion 22. Therefore, it is possible to suppress the outer peripheral surface of the weight portion 23 from being exposed and being separated from the base portion 22 or rusting.

[0463] In addition, in the sound insulation sheet component 100 and its manufacturing method of the present embodiment, the core portion 26M abuts against a part of the front end of the counterweight portion 23 from below, so that a covering portion 125 covering the front end side of the counterweight portion 23 can be provided at the front end of the resonance portion 21. The covering portion 125 can prevent the counterweight portion 23 from detaching from the base portion 22 or rusting of the counterweight portion 23.

[0464] In addition, in the above-mentioned embodiment, an example of a structure in which a resin material is filled between the gap 27 and the inner peripheral surface of the through hole 124 of the counterweight portion 23 (i.e., between the core portion 27M and the inner peripheral surface of the through hole 124 during molding) is shown, but it is not limited to this structure. For example, it is also possible to have a structure in which the outer peripheral surface of the core portion 27M is fitted with the through hole 124, and the outer peripheral surface of the gap 27 is formed by the inner peripheral surface of the through hole 124. When this structure is adopted, the counterweight portion 23 can be coaxially arranged with respect to the base portion 22 without deviation. Therefore, the sound insulation characteristics of the sound insulation sheet component 100 can be stabilized.

[0465] [Fourth Embodiment of Sound Insulating Sheet Member and Method of Manufacturing the Same]

[0466] Next, refer to Fig.21 and Fig. 22 A fourth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0467] In the above drawings, Figures 11 to 20 The same elements as those in the third embodiment are denoted by the same reference numerals, and their description is omitted. In the fourth embodiment, the structure of the resonance part is different from that in the third embodiment, so the resonance part will be described below.

[0468] Fig.21 It is a partial cross-sectional view of the resonance part 21 in which the weight part 23 is embedded in the base part 22 . Fig. 22 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0469] like Fig.21 As shown, a concave portion 24A is provided on the surface on the front end side of the weight portion 23, which is concave coaxially with the outer peripheral surface of the weight portion 23. As an example, the concave portion 24A has a circular shape in a plan view.

[0470] The base 22 has a gap 27A extending vertically and opening at the front end surface and the bottom surface of the recess 24A. The gap 27A is opened at the bottom surface of the recess 24A, so that a part of the weight 23 is exposed at the front end side through the gap 27A.

[0471] like Fig. 22 As shown in FIG. 1 , a cylindrical core portion 27M for forming the gap 27A protrudes from the lower mold M22 in the metal mold MD. The diameter of the core portion 27M is smaller than the diameter of the recess 24A. The height (protrusion amount) of the core portion 27M is set so that when the front end surface supports the bottom surface of the recess 24A from below, Fig.21 The illustrated covering portion 125 is formed with a predetermined thickness between the weight portion 23 and the upper surface 22Ma.

[0472] After the weight portion 23 is placed in the state where the core portion 27M in the metal mold MD having the above structure is inserted into the recess 24A, the above resin material is flowed into the cavity CV and hardened, thereby forming Fig.21 The resonant portion 21 is shown.

[0473] The resonance portion 21 of this embodiment can obtain the same functions and effects as the resonance portion 21 shown in the third embodiment, and can also reduce the diameter of the gap 27A and increase the area of ​​the covering portion 125, thereby further preventing the weight portion 23 from detaching from the base 22 or rusting of the weight portion 23.

[0474] [Fifth Embodiment of the Sound Insulating Sheet Member and the Manufacturing Method Thereof]

[0475] Next, refer to Figure 23 to Figure 27 A fifth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0476] In the above drawings, Figures 11 to 22 The same components as those of the third and fourth embodiments are denoted by the same reference numerals, and description thereof will be omitted.

[0477] Fig.23 and Fig.24 It is a cross-sectional view showing the metal mold MD according to the fifth embodiment.

[0478] like Fig.23As shown in FIG. 1 , a hollow portion 63 extending in the surface direction is provided in the lower mold M22 and in the middle of the thickness direction (vertical direction). A movable portion 64 extending in the surface direction is provided in the hollow portion 63. Driven by a drive device 65, the movable portion 64 can move in the vertical direction at an upper end position ( 100 m) of the upper surface 63a facing the hollow portion 63. Fig.23 The position shown in the figure) is in contact with the lower surface 63b facing the cavity portion 63. Fig.24 Move between the lower positions shown.

[0479] Fig.25 and Fig.26 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 . Fig.25 and Fig.26 , the resin material flows into the cavity CV. Fig.25 and Fig.26 In the figure, the recessed portion 11M and the upper mold M11 are omitted.

[0480] The core portion 27M of this embodiment extends in the up-down direction, and the lower end is fixed to the moving portion 64 and penetrates the lower mold M22. When the moving portion 64 is at the upper end position, as shown in FIG. Fig.25 As shown, the core portion 27M is formed at a predetermined thickness at a position in the up-down direction between the weight portion 23 and the upper surface 22Ma in the covering portion 125 to support the bottom surface of the recessed portion 24A from below.

[0481] Furthermore, when the moving portion 64 is at the lower end position, as shown in FIG. Fig.26 As shown, the core portion 27M is flush with the upper surface 22Ma.

[0482] In the metal mold MD of the above structure, after the movable part 64 is moved to the upper end position by the driving device 65, the counterweight part 23 is placed in a state where the core part 27M is inserted into the recessed part 24A. After that, the above-mentioned resin material is flowed into the cavity CV. Then, before the resin material reaches the periphery of the core part 27M and the resin material is completely hardened, the core part 27M is moved to the lower end position together with the movable part 64 by the driving device 65, so that the front end surface of the core part 27M is on the same plane as the upper surface 22Ma.

[0483] When the resin material flows into cavity CV, the resin material before hardening enters the region where core portion 27M is provided in cavity CV due to the movement of core portion 27M.

[0484] The results, such as Fig.26 As shown, the resonance portion 21 is obtained in which the front end side of the weight portion 23 is entirely covered with the resin material.

[0485] After that, after the resin material is hardened, the moving part 64 is moved to the upper end position again by the driving device 65. Fig. 27 As shown, the front end of the core portion 27M causes the front end of the resonance portion 21 to protrude from below, so that the soundproofing sheet member 100 is released from the lower mold M21.

[0486] As described above, in this embodiment, in addition to being able to obtain the same functions and effects as those of the third and fourth embodiments, by moving the core portion 27M during molding, the position of the weight portion 23 in the plane direction can be restricted during molding, and the front end side of the weight portion 23 can be completely covered with the resin material. In addition, in this embodiment, by moving the core portion 27M to the upper end position after the resin material is hardened, the sound insulation sheet component 100 can be easily demolded from the lower mold M21, thereby improving productivity and reducing the inconvenience caused during demolding. In addition, the weight portion 23 may also have a through hole as in the third, sixth, seventh, and eighth embodiments. In this case, the core portions 26M and 27M are fixed to the moving portion 64, and when the moving portion 64 is located at the lower end, the upper surface of the core portion 26M is flush with the upper surface 22Ma.

[0487] [Sixth embodiment of the sound insulating sheet member and the manufacturing method thereof]

[0488] Next, refer to Figures 28 to 30 A sixth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0489] In the above drawings, Figures 11 to 20 The same components as those of the third embodiment shown are denoted by the same reference numerals, and description thereof will be omitted.

[0490] Fig.28 It is a top view of the resonance part 21 . Fig.29 yes Fig.28 AA line section view in. Fig.30 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0491] In the third embodiment described above, an example of a structure in which the recessed portion 26 provided in the resonance portion 21 is circular in a plan view is shown. However, in the present embodiment, Fig.28 As shown in FIG. 1 , the plurality of recessed portions are arranged at intervals in the circumferential direction. Specifically, as Fig.28 and Fig.29 As shown, the recessed portion 26 extends radially with the gap 27 as the center. A plurality of recessed portions 26 (here, three recessed portions 26 are provided at intervals of 120°) are provided in the circumferential direction with the gap 27 as the center. The radial outer side of the recessed portion 26 is located outside the inner peripheral surface of the through hole 124 and inside the outer peripheral surface of the weight portion 23.

[0492] like Fig.30 As shown, in the metal mold MD for forming the resonance part 21, the core part 26M extends radially with the core part 27M as the center. In addition, a plurality of core parts 26M (here, three are provided at intervals of 120°) are provided at intervals in the circumferential direction with the core part 27M as the center. The radial outer side of the core part 26M is located further outward than the inner peripheral surface of the through hole 124 and further inward than the outer peripheral surface of the counterweight part 23.

[0493] The resonance part 21 formed by the metal mold MD of the above structure can not only obtain the same functions and effects as the above third embodiment, but also forms a covering part 125 between the recessed parts 26 in the circumferential direction, thereby further preventing the weight part 23 from detaching from the base 22 or rusting.

[0494] [Seventh embodiment of the sound insulating sheet member and the manufacturing method thereof]

[0495] Next, refer to Figure 31 to Figure 33 A seventh embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0496] In the above drawings, Figures 28 to 30 The same components as those of the sixth embodiment are denoted by the same reference numerals, and description thereof will be omitted.

[0497] In the sixth embodiment, the recessed portions 26 extending in the radial direction are provided at intervals in the circumferential direction around the gap 27 . However, in the present embodiment, dot-shaped recessed portions 26 are provided to be separated from the gap 27 .

[0498] Fig.31 It is a top view of the resonance part 21 . Fig.32 yes Fig.31 BB line section view in. Fig.33 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0499] like Fig.31 and Fig.32 As shown, the recessed portion 26 is circular in plan view with a diameter smaller than that of the gap 27, and is disposed separately from the gap 27. A plurality of recessed portions 26 (here, three recessed portions 26 are disposed at intervals of 120°) are disposed in the circumferential direction centered on the gap 27. The radial position of each recessed portion 26 centered on the gap 27 is located further outside than the inner circumferential surface of the through hole 124 and further inside than the outer circumferential surface of the weight portion 23. The recessed portion 26 penetrates the covering portion 125 in the up-down direction.

[0500] like Fig.33As shown, in the metal mold MD for forming the above-mentioned resonance part 21, the core part 26M and the core part 27M are separately arranged. In addition, a plurality of core parts 26M (here, three are arranged at intervals of 120 degrees) are provided at intervals in the circumferential direction centered on the core part 27M. The radial position of each core part 26M centered on the core part 27M is further outside than the inner peripheral surface of the through hole 124 and further inside than the outer peripheral surface of the counterweight part 23.

[0501] The resonance portion 21 formed by the metal mold MD of the above-mentioned structure can not only obtain the same functions and effects as the above-mentioned sixth embodiment, but also has a covering portion 125 formed between the recessed portion 26 and the gap 27 in the radial direction, thereby further preventing the counterweight portion 23 from detaching from the base 22 or rusting.

[0502] [Eighth Embodiment of the Sound Insulating Sheet Member and the Manufacturing Method Thereof]

[0503] Next, refer to Figure 34 to Figure 37 An eighth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0504] In the above drawings, Figures 28 to 30 The same components as those of the sixth embodiment are denoted by the same reference numerals, and description thereof will be omitted.

[0505] In the above-mentioned sixth embodiment, the core portion 26M having a surface parallel to the surface on the front end side of the counterweight portion 23 is configured to form a gap corresponding to the thickness of the covering portion 125 between the counterweight portion 23 and the upper surface 22Ma, but in the present embodiment, a structure having a core portion 28M is described, which abuts against the counterweight portion 23 at a side surface (inclined portion) inclined in a direction tending downward from the center of the resonance portion 21 toward the radial outside.

[0506] Fig.34 It is a top view of the resonance part 21 . Fig.35 yes Fig.34 CC line section view in. Fig.36 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0507] like Fig.34 As shown, the recessed portion 28 extends radially with the gap 27 as the center. A plurality of recessed portions 28 (here, three recessed portions 28 are provided at intervals of 120°) are provided in the circumferential direction with the gap 27 as the center. The innermost position of the radial inner side of the recessed portion 28 is further outward than the outer peripheral surface of the gap 27 and further inward than the inner peripheral surface of the through hole 124. The radial outer side of the recessed portion 28 is further outward than the inner peripheral surface of the through hole 124 and further inward than the outer peripheral surface of the counterweight portion 23.

[0508] like Fig.35 As shown in FIG. 1 , the bottom of the radially inner side of the recessed portion 28 is located below the surface of the front end side of the weight portion 23 in the vertical direction. The recessed portion 28 has a side surface that is inclined in the direction of the surface of the front end side of the resonance portion 21 from the bottom of the radially inner side toward the radially outer side. The side surface intersects at a position where the inner peripheral surface of the through hole 124 in the weight portion 23 intersects with the surface of the front end side.

[0509] like Fig.36 As shown, in the metal mold MD for forming the above-mentioned resonance portion 21, the core portion 28M of the forming recessed portion 28 protrudes from the upper surface 22Ma of the lower mold M22. The core portion 28M extends radially with the core portion 27M as the center. In addition, a plurality of (here, three are provided at intervals of 120°) core portions 28M are provided at intervals in the circumferential direction centered on the core portion 27M. The radial inner side of the core portion 28M is located further outward than the outer peripheral surface of the core portion 27M and further inward than the inner peripheral surface of the through hole 124. The radial outer side of the core portion 28M is located at a position that intersects with the upper surface 22Ma at a position further outward than the inner peripheral surface of the through hole 124 and further inward than the outer peripheral surface of the counterweight portion 23.

[0510] The core portion 28M has a side surface that is inclined toward the upper surface 22Ma from the radially inner front end toward the radially outer side.

[0511] In the weight portion 23 of the cavity CV of the metal mold MD configured as above, the tip of the core portion 28M is inserted into the through hole 124. Fig.36 The intersection between the lower surface shown and the inner peripheral surface of the through hole 124 is supported from below by the side surface of the core portion 28M. Since the three core portions 28M are arranged in the circumferential direction with the core portion 27M as the center, the counterweight portion 23 is coaxially positioned with the recessed portion 22M and is supported from below by the side surface of the core portion 28M.

[0512] In this state, when the resin material flows into the cavity CV to form the resonance portion 21, the weight portion 23 is positioned coaxially with the core portion 27M, that is, positioned at the center of the base portion 22. In addition, even if the weight portion 23 moves upward and separates from the core portion 28M when the resin material flows in, the position of the weight portion 23 in the surface direction is restricted by the core portion 27M, so that the weight portion 23 can be prevented from deviating significantly.

[0513] As described above, in this embodiment, in addition to being able to obtain the same operations and effects as those of the sixth embodiment, the weight portion 23 can be positioned at the gap 27 (the center position of the base portion 22) with high accuracy.

[0514] In addition, when the weight portion 23 does not separate from the core portion 28M by adjusting the molding conditions, etc., the Fig.37 As shown, a structure is adopted in which the core portion 27M is not provided.

[0515] Furthermore, in the eighth embodiment described above, an example of a structure in which the core portion 27M and the core portion 28M are radially separated is shown, but the structure is not limited to this structure. For example, the radial inner side of the core portion 28M may abut against the outer peripheral surface of the core portion 27M.

[0516] [Ninth embodiment of the sound insulating sheet member and the manufacturing method thereof]

[0517] Next, refer to Fig.38 and Fig.39 A ninth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0518] In the above drawings, Figure 34 to Figure 37 The same components as those of the eighth embodiment are denoted by the same reference numerals, and description thereof will be omitted.

[0519] Fig.38 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 .

[0520] like Fig.38 As shown in FIG. 1 , the core portion 28M of the present embodiment is arranged coaxially with the recessed portion 22M. The core portion 28M is formed in a truncated cone shape whose diameter gradually increases from the front end toward the base end of the upper surface 22Ma.

[0521] The diameter of the front end surface in the core portion 28M is smaller than the diameter of the through hole 124 of the counterweight portion 23. The diameter of the base portion in the core portion 28M is larger than the diameter of the through hole 124 of the counterweight portion 23. Therefore, the intersection between the lower surface of the counterweight portion 23 disposed in the cavity CV and the inner peripheral surface of the through hole 124 is supported from below by the side surface of the core portion 28M and is coaxially positioned with the recessed portion 22M.

[0522] Therefore, in this embodiment, in addition to being able to obtain the same functions and effects as the above-mentioned eighth embodiment, since no edge portion is formed on the core portion 28M, a high-strength core portion 28M can be obtained, thereby extending the life of the metal mold MD.

[0523] In addition, as the core portion 28M of the present embodiment, in addition to the truncated cone-shaped structure, for example, Fig.39 The structure shown is that a plurality of linear portions extending from the center of the recessed portion 22M are arranged at intervals (for example, at 120° intervals) in the circumferential direction in a plan view.

[0524] [Tenth embodiment of the sound insulating sheet member and the manufacturing method thereof]

[0525] Next, refer to Fig.40 and Fig.41 A tenth embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0526] In the above drawings, Figure 34 to Figure 39 The same components as those of the eighth and ninth embodiments are denoted by the same reference numerals, and description thereof will be omitted.

[0527] Although the structure of the core portion 28M in the above-mentioned eighth and ninth embodiments is shown as being supported by abutting against the intersection between the lower surface of the counterweight portion 23 and the inner peripheral surface of the through hole 124, in the present embodiment, a structure is described as being supported by abutting against the intersection between the lower surface of the counterweight portion 23 and the outer peripheral surface.

[0528] Fig.40 It is a partial detailed view of the cavity CV which is a space for shaping the resonance part 21 . Fig.41 It is a top view of the resonance part 21 .

[0529] like Fig.40 As shown, in the metal mold MD, the radial outer side of the core portion 28M is located outside the outer peripheral surface of the counterweight portion 23. The radial inner side of the core portion 28M is located outside the inner peripheral surface of the through hole 124 and inside the outer peripheral surface of the counterweight portion 23. The core portion 28M has a side surface that is inclined toward the upper surface 22Ma as it moves from the radial outer front end toward the radial inner side.

[0530] like Fig.41 As shown, the recessed portion 28 formed by the core portion 28M extends radially with the gap 27 as the center. In addition, a plurality of recessed portions 28 are provided at intervals (here, three are provided at intervals of 120°) in the circumferential direction with the gap 27 as the center. Therefore, the core portion 28M also extends radially with the core portion 27M as the center. In addition, a plurality of core portions 28M are provided at intervals (here, three are provided at intervals of 120°) in the circumferential direction with the core portion 27M as the center.

[0531] In the counterweight 23 of the cavity CV of the metal mold MD configured as described above, the front end of the core portion 28M is located outside the outer peripheral surface and above the lower surface of the counterweight 23, and the intersection between the lower surface of the counterweight 23 and the outer peripheral surface is supported from below by the side surface of the core portion 28M. Since the three core portions 28M are arranged in the circumferential direction with the core portion 27M as the center, the counterweight 23 is coaxially positioned with the recessed portion 22M, and the counterweight 23 is supported from below by the side surface of the core portion 28M.

[0532] Therefore, in this embodiment, in addition to being able to obtain the same functions and effects as those of the eighth and ninth embodiments, since the weight portion 23 is supported at a position further outward in the radial direction, the weight portion 23 can be supported in a more stable state.

[0533] [Eleventh Embodiment of the Sound Insulating Sheet Member and the Manufacturing Method Thereof]

[0534] Next, refer to Fig.42 and Fig.43 An eleventh embodiment of the sound insulating sheet member 100 and a method for manufacturing the same will be described.

[0535] In the above drawings, Figures 11 to 20 The same components as those of the third embodiment shown are denoted by the same reference numerals, and description thereof will be omitted.

[0536] In the third embodiment, an example of a structure in which the recessed portion 26 and the gap 27 are provided on the front end side of the base 22 is shown, but in the eleventh embodiment, a structure in which only the gap 27 is provided on the front end side of the base 22 without providing the recessed portion 26 is described.

[0537] Fig.42 It is a partial cross-sectional view of the resonance portion 21 in which the weight portion 23 is buried in the base portion 22 .

[0538] like Fig.42 As shown, the base portion 22 of this embodiment is provided with a cavity 27 having a circular cross section, which is open at the front end side and extends in the axial direction. The cavity 27 is provided coaxially with the through hole 124 of the weight portion 23 .

[0539] Fig.43 It is a partial detailed view of the cavity CV which is a space forming the resonance part 21 . Fig.43 FIG. 4 shows a state where the resin material flows into the cavity CV. Fig.43 In the figure, the recessed portion 11M and the upper mold M11 are omitted.

[0540] In the present embodiment, the core portion 26M extending in the vertical direction and having its lower end fixed to the movable portion 64 and penetrating the lower mold M22, and the core portion 27M extending upward from the upper surface of the core portion 26M are provided coaxially with the counterweight portion 23. The diameter of the core portion 26M is formed to be larger than the diameter of the through hole of the counterweight portion 23 and smaller than the outer diameter of the counterweight portion 23. When the movable portion 64 is located at the upper end position, the core portion 26M supports the surface of the front end side of the counterweight portion 23 from below at a position in the vertical direction where the covering portion 125 is formed with a predetermined thickness between the counterweight portion 23 and the upper surface 22Ma.

[0541] In the metal mold MD of the above structure, as described in the fifth embodiment, after the movable portion 64 is moved to the upper end position, the counterweight portion 23 is placed on the upper surface of the core portion 26M while the core portion 27M is inserted into the through hole. Thereafter, the above-mentioned resin material is flowed into the cavity CV. Then, before the resin material reaches the periphery of the core portions 26M and 27M and the resin material is completely hardened, the core portions 26M and 27M are moved to the lower end position together with the movable portion 64, and the front end surface of the core portion 26M is flush with the upper surface 22Ma.

[0542] When the resin material flows into cavity CV, the resin material before hardening enters the region in which core portion 26M is provided in cavity CV due to the movement of core portion 26M.

[0543] The results, such as Fig.42 As shown, the resonance portion 21 is obtained in which the gap 27 is opened on the front end side and the portion of the front end side of the weight portion 23 other than the gap 27 is covered with a resin material.

[0544] After the resin material is cured, the moving portion 64 is moved to the upper end position again. As a result, the front end of the core portion 26M causes the end of the resonance portion 21 to protrude from below, and the soundproofing sheet member 100 is released from the lower mold M21.

[0545] As described above, in this embodiment, in addition to being able to obtain the same functions and effects as those of the third and fourth embodiments, by moving the core portion 26M to the upper end position after the resin material is hardened, the sound insulation sheet component 100 can be easily demolded from the lower mold M21, thereby increasing productivity and reducing the adverse conditions that may occur during demolding.

[0546] In addition, for Fig.33 The metal mold MD shown, for example, even if Fig.44 When the chamber CV without the step portion 26M is used as shown, it is also possible to form Fig.42 Even in the absence of the step portion, the resin can flow from the outer periphery of the weight portion 23 or the through hole 124, and the resin can be set under the weight portion 23. In this case, the same as using Fig.43 Compared with the case of the cavity CV having the step portion shown, it takes time for the resin to flow to the bottom of the weight portion 23, and the formed film is thin. On the other hand, the structure of the metal mold MD can be simplified.

[0547] The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is of course not limited to the examples involved. The shapes and combinations of the components shown in the above examples are only examples, and various changes can be made based on design requirements, etc. within the scope of the main purpose of the present invention.

[0548] For example, in the sixth to tenth embodiments described above, an example of a structure in which a through hole 124 is formed in the counterweight portion 23 is shown, but it is not limited to this structure, and it may also be non-through like the recessed portion 24A described in the fourth and fifth embodiments. And, contrary to the above structure, the counterweight portion 23 of the fourth and fifth embodiments may also have a through hole. In addition, as the counterweight portion 23, a part of the circumferential direction in the annular portion may also be formed separately, such as a spring washer (spring washer). The through portion in this case is a space surrounded by the front end of the counterweight portion separated from the inner circumferential surface of the counterweight portion, and is a space that is open on both the front end side and the rear end side of the counterweight portion and is connected to each other.

[0549] Industrial Applicability

[0550] The present invention can be applied to a soundproofing sheet member, a soundproofing structure using the soundproofing sheet member, and a method for producing the soundproofing sheet member.

[0551] Explanation of symbols

[0552] 11—sheet, 11a—sheet surface, 11b—sheet surface, 21—resonance portion (protrusion), 22—base, 22Ma—upper surface (bottom), 23—weight portion, 24—base, 24A—recess, 25—weight portion, 26—recess, 26M—core portion (step portion), 27—gap, 27A—gap, 27M—core portion (protrusion), 28—recess, 31—rib-shaped protrusion, 32—rib-shaped protrusion, 51—support, 61—metal mold, 61a—cavity, 61b—cavity, 70—sheet, 100—soundproof sheet component, 101—soundproof sheet component, 124—through Through hole (through part), 125—covering part, 200—sound insulation structure, 201—sound insulation structure, 203—sound insulation structure, 300—sound insulation structure setting, CV—chamber, H—maximum height of the sound insulation sheet component, H1—maximum height, H2—maximum height, M11—upper mold, M12—upper mold, M21—lower mold, M22—lower mold, M111—recess (bowl), M112—through flow path, MD—metal mold, r1—length, r2—radius, h—height, hx—height, a—sheet length, i—weight part, ii—base, iii—sheet, iv—support body.

Claims

1. A resonance sheet component, characterized in that: The invention comprises at least a sheet material and at least one resonance part, wherein the resonance part is provided in contact with a sheet material surface of the sheet material. The resonance part includes a weight part and a base part. The weight portion is supported by the base portion and has a greater specific gravity than the base portion, The counterweight portion has a through portion, The base portion covers the weight portion in a manner of contacting with a surface of the weight portion on the front end side of the resonance portion. The through portion is a space that is open at both the front end side and the rear end side of the weight portion and communicates with each other.

2. The resonance sheet component according to claim 1, characterized in that The base portion fills the outer peripheral portion of the weight portion and the through portion.

3. The resonance sheet component according to claim 1 or 2, characterized in that: The weight portion is disposed on the front end side relative to the center in the height direction of the resonance portion.

4. The resonance sheet member according to claim 1 or 2, characterized in that: The maximum height from the opposite surface of the sheet surface on which the resonance portion is provided to the front end of the resonance portion is 30 mm or less.

5. The resonance sheet member according to claim 4, characterized in that The maximum height from the opposite surface of the sheet surface on which the resonance portion is provided to the front end of the resonance portion is 20 mm or less.

6. The resonance sheet member according to claim 1 or 2, characterized in that: The resonance portion has a cavity formed by a recessed surface on the front end side of the resonance portion, and the cavity is formed in the penetration portion.

7. The resonance sheet member according to any one of claims 1 to 6, characterized in that: The through portion is a through hole.

8. A resonance structure, characterized in that: The resonance sheet member as claimed in any one of claims 1 to 7 is used.

9. A resonance sheet component, characterized in that: The invention comprises at least a sheet material and at least one resonance part, wherein the resonance part is provided in contact with a sheet material surface of the sheet material. The resonance part includes a weight part and a base part. The weight portion is supported by the base portion and has a greater specific gravity than the base portion, The counterweight portion has a through portion, The through portion is a space that is open at both the front end side and the rear end side of the weight portion and communicates with each other.

10. The resonance sheet member according to claim 9, characterized in that The base portion fills the outer peripheral portion of the weight portion and the through portion.

11. The resonance sheet member according to claim 10, characterized in that The maximum height from the opposite surface of the sheet surface on which the resonance portion is provided to the front end of the resonance portion is 30 mm or less.

12. The resonance sheet member according to claim 11, characterized in that The maximum height from the surface opposite to the surface of the sheet on which the resonance portion is provided to the front end of the resonance portion is 20 mm or less.

13. A resonance structure, characterized in that: The resonance sheet member as claimed in any one of claims 9 to 12 is used.

14. A method for manufacturing a resonance sheet component, the resonance sheet component comprising a sheet portion, at least one protrusion provided in a surface direction of the sheet portion, and a weight portion provided at a front end side of the at least one protrusion, The method for manufacturing the resonance sheet component is characterized by comprising: a weight inserting step of inserting the weight into a bottom of at least one cavity of a metal mold including at least one cavity for forming the protrusion; and a resin insertion step in which a resin is introduced into the at least one cavity. The bottom portion is provided with a protrusion, and the counterweight portion is provided with a through portion. In the weight insertion step, the protrusion is inserted into the through-hole. In the resin inserting step, the resin is flowed into the cavity in a state where the protrusion is inserted into the through portion and the position of the weight portion relative to the bottom portion in the surface direction is restricted. The through portion is a space that is open at both the front end side and the rear end side of the weight portion and communicates with each other.

15. The method for manufacturing a resonance sheet member according to claim 14, characterized in that: The bottom portion is provided with the protrusion and a step portion that protrudes at a height lower than the protrusion and contacts a portion of the surface on the front end side of the weight portion.

16. The method for manufacturing a resonance sheet member according to claim 15, characterized in that: The step portion is provided so as to be in contact with a side surface of the protrusion.

17. The method for manufacturing a resonance sheet member according to claim 15, characterized in that: The step portion is provided to be separated from a side surface of the protrusion.

18. The method for manufacturing a resonance sheet member according to claim 16 or 17, characterized in that: The step portion is inclined in a direction in which the height decreases from the radial center side of the protrusion toward the radial outer side. The maximum diameter of the step portion at the highest position is smaller than the hole diameter of the through portion provided in the weight portion, and the maximum diameter of the step portion at the lowest position is larger than the hole diameter of the through portion.

19. The method for manufacturing a resonance sheet member according to any one of claims 14 to 17, characterized in that: The metal mold comprises a lower mold and an upper mold. The lower mold is provided with the cavity in an opening on the upper surface. The upper mold is movable between a position abutting against the upper surface of the lower mold and a position separated upward, and has a depression provided on the upper surface and a through-flow path opening at the depression. In the resin inserting step, the dissolved resin is caused to flow from the recess into the cavity through the through flow path in a state where the lower mold is in contact with the upper mold.

20. The method for manufacturing a resonance sheet member according to claim 19, characterized in that: Prior to the resin inserting step, there is a step of extruding the solid material of the resin disposed in the recess by using a press die inserted in the recess.

21. The method for manufacturing a resonance sheet member according to any one of claims 14 to 16, characterized in that: The protrusion is provided on the bottom portion in a manner that inclines in a direction in which the height decreases from the radial center side of the protrusion toward the radial outer side. The maximum diameter of the protrusion at the highest position is smaller than the hole diameter of the through-portion provided in the weight portion, and the maximum diameter at the lowest position is larger than the hole diameter of the through-portion.

22. The method for manufacturing a resonance sheet member according to any one of claims 14 to 17, characterized in that: The resin inserting step may include a step of moving the protrusion provided at the bottom toward the bottom before the resin flowing into the cavity is cured.

23. The method for manufacturing a resonance sheet member according to claim 22, characterized in that: The method includes the step of moving the protrusion toward the cavity to release the resonance sheet member from the metal mold after the resin is cured.

24. The method for manufacturing a resonance sheet member according to any one of claims 14 to 17, characterized in that: A maximum value of a gap between the protrusion and the through-portion is smaller than a minimum value of a gap between the weight portion inserted into the cavity and the cavity.

25. A resonance sheet component, characterized in that: have: Sheet Department; a protrusion, at least one of which is provided in the surface direction of the sheet portion and comprises a resin material; and a weight portion, which is provided inside the front end side of at least one of the protrusions and has a through portion on the front end side, A gap is formed on the inner side of the end surface of the front end side of the counterweight portion. The through portion is a space that is open at both the front end side and the rear end side of the weight portion and communicates with each other.

26. The resonance sheet member according to claim 25, characterized in that The through portion is filled with the resin material further inside the space.

27. The resonance sheet member according to claim 26, characterized in that The resin material is filled between the surface of the through-portion and the space.

28. The resonance sheet member according to claim 26, characterized in that The protrusion has: a covering portion that covers a portion of a surface of the weight portion on the front end side with the resin material; and A through portion is provided in the radially outer side of the gap along the circumferential direction with the radial center of the protrusion as an axis, and penetrates the covering portion so as to expose a portion of the surface on the front end side of the weight portion.

29. The resonance sheet member according to claim 28, characterized in that The through portion of the protrusion has an inclined portion that is inclined in a direction approaching the surface of the covering portion as it moves from the radial center side of the protrusion toward the radial outside. The maximum diameter of the inclined portion at the innermost side is smaller than the hole diameter of the through portion of the configuration portion, and the maximum diameter of the inclined portion at the outermost side is larger than the hole diameter of the through portion of the weight portion. A portion of the surface on the front end side of the weight portion is exposed in the middle of the inclined portion.

30. The resonance sheet member according to claim 26, characterized in that The protrusion has: a covering portion that covers a portion of a surface of the weight portion on the front end side with the resin material; and a recessed portion provided in such a manner that a portion of the covering portion is missing and a portion of the surface on the front end side of the weight portion is exposed at the bottom surface, The gap opens at the bottom surface of the recessed portion.

31. The resonance sheet member according to claim 26, characterized in that The protrusion has a covering portion that covers a portion of the surface on the front end side of the weight portion with the resin material. The gap has a through portion which is circumferentially arranged on the radially outer side of the gap with the radial center of the protrusion as an axis and penetrates the covering portion in a manner that a portion of the surface on the front end side of the weight portion is exposed. The through portion of the protrusion has an inclined portion that is inclined in a direction approaching the surface of the covering portion as it moves from the radial center side of the protrusion toward the radial outside. The maximum diameter of the inclined portion at the innermost side is smaller than the hole diameter of the through-portion of the counterweight portion, and the maximum diameter of the inclined portion at the outermost side is larger than the hole diameter of the through-portion of the counterweight portion. A portion of the surface on the front end side of the weight portion is exposed in the middle of the inclined portion.

32. A resonance sheet component, characterized in that: have: Sheet Department; a protrusion, at least one of which is provided in the surface direction of the sheet portion and comprises a resin material; and a weight portion, which is provided inside the front end side of at least one of the protrusions and has a recess or a through portion on the front end side, A gap is formed on the inner side of the end surface of the front end side of the weight portion.

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