Soundproof material and manufacturing method of soundproof material

Abstract

To provide a new soundproof material in which a porous layer and a fiber layer are laminated, and to provide a manufacturing method of soundproof material.SOLUTION: A soundproof material includes: a porous layer; a first layer laminated on the porous layer and including a first material; and a second layer laminated on the first layer and including a fibrous second material. The melting point of the first material is lower than the melting point of the second material, and inside the porous layer, an impregnation part is provided where the first material is melted and solidified.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a sound insulation material and a method for manufacturing the sound insulation material.

Background Art

[0002] Patent Document 1 discloses a sound insulation material including a porous layer and a fiber layer laminated on the porous layer. In this sound insulation material, the raw material of the porous layer impregnates a part of the fiber layer, so that the fiber layer integrally forms the porous layer and the fiber layer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In such a sound insulation material, it is preferable that the fiber layer is adhered to the porous body in a manner that the fiber layer is separable from the porous layer.

[0005] The problem of the present disclosure is to provide a novel sound insulation material and a method for manufacturing the sound insulation material.

[0006] The sound insulation material according to one aspect of the present disclosure includes a porous layer, a first layer laminated on the porous layer and containing a first material, and a second layer laminated on the first layer and containing a fibrous second material. The melting point of the first material is lower than the melting point of the second material, and the porous layer has an impregnated portion in which the first material is melted and solidified.

[0007] Furthermore, a method for manufacturing a sound insulation material according to another aspect of the present disclosure includes a step of preparing a porous layer, a step of preparing a fibrous material including a first layer containing a fibrous first material and a second layer containing the fibrous second material laminated on the first layer, the second material having a melting point higher than that of the first material, a step of disposing the fibrous material on the porous layer such that the first layer faces the porous layer side, and a step of heating the fibrous material at a temperature higher than the melting point of the first material and lower than the melting point of the second material to melt the first material and impregnate the interior of the porous layer with the melted first material.

Advantages of the Invention

[0008] According to the present disclosure, a novel sound insulation material and a method for manufacturing the sound insulation material can be provided.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0010] First, with reference to FIG. 1, a sound insulation material 1 according to an embodiment of the present disclosure will be described.

[0011] The sound insulation material 1 is attached to a vehicle, for example, to prevent noise generated from a noise source from being transmitted into the passenger compartment.

[0012] FIG. 1 is a cross-sectional view showing the sound insulation material 1. As shown in FIG. 1, the sound insulation material 1 includes a porous layer 2, a first layer 4 containing a first material 41, and a second layer 6 containing a second material 61.

[0013] The porous layer 2 includes a thermosetting resin material having a continuous cell structure 21 in which cells 22 (air bubbles) are continuously connected. The thermosetting resin material is, for example, a polyurethane foam (PU; polyurethane) with a density of 20 kg / m 3 or more and 100 kg / m 3 or less, and a thickness of 10 mm or more and 50 mm or less.

[0014] The porous layer 2 includes a first surface 23 and a second surface 25 opposite to the first surface 23. On the first surface 23 and the second surface 25, the cells 22 of the continuous cell structure 21 of the porous layer 2 open to the outside.

[0015] The first layer 4 is laminated on the first surface 23 of the porous layer 2. The thickness of the first layer 4 is, for example, 0.1 mm or more and 1 mm or less.

[0016] The first layer 4 includes a first material 41. The first material 41 may be a fibrous thermoplastic resin material. The first material 41 is, for example, a fibrous aggregate formed of polypropylene (PP; polypropylene) with a fiber diameter of 2d or more and 4d or less and a basis weight of 5 g / m 2 or more and 100 g / m 2 or less. The melting point T1 of the first material 41 is, for example, 150°C or more and 170°C or less.

[0017] The first layer 4 includes a first region 4a in which the first material 41 is melted and solidified, a second region 4b in which the melted and solidified first material 41 and the fibrous first material 41 are mixed, and a third region 4c in which the first material 41 is fibrous. The first region 4a, the second region 4b, and the third region 4c are distributed in the order of the first region 4a, the second region 4b, and the third region 4c from the porous layer 2 side along the thickness direction (the arrow Z direction in FIG. 1).

[0018] In the first region 4a, the first layer 4 has an impregnated portion 42 in which a part of the melted and solidified first material 41 enters the cells of the porous layer 2. The impregnated portion 42 bites into the cells 22 of the porous layer 2, producing a so-called anchor effect. Thereby, the first layer 4 is joined to the porous layer 2 by mechanical bonding via the impregnated portion 42.

[0019] The second layer 6 is laminated on the first layer 4. The second layer 6 is in a sheet form with a thickness of 0.1 mm or more and 1 mm or less.

[0020] The second layer 6 contains a second material 61. The second material 61 is a fibrous thermoplastic resin material. The second material 61 has, for example, a fiber diameter of 2d or more and 4d or less and a basis weight of 10 g / m 2 or more and 100 g / m 2 or less and is polyethylene terephthalate (PET). The melting point T2 of the second material 61 is higher than the melting point T1 of the first material 41 and is, for example, 240°C or more and 260°C or less.

[0021] In the vicinity of the boundary between the second layer 6 and the first layer 4, the fibrous second material 61 and the fibrous first material 41 in the third region 4c are intertwined with each other to form a layered structure. The intertwined fibers generate frictional force against the force of being peeled off in the thickness direction (the direction of arrow Z in FIG. 1). Thereby, the second layer 6 is fixed to the first layer 4.

[0022] The second layer 6 contains the fibrous second material 61. The first layer 4 contains the fibrous first material 41 in the second region 4b and the third region 4c. These fiber sheets partially absorb the noise from the noise source and let the rest pass through. Although not shown in FIG. 1, there are a large number of cells 22 remaining on the first surface 23 of the porous layer 2 without the impregnation part 42 biting in, and the continuous bubble structure 21 to which these cells 22 belong absorbs the noise that has passed through the second layer 6 and the first layer 4. The soundproof material 1 absorbs the noise from the noise source in this way.

[0023] The soundproof material 1 may further include the first layer 4 and the second layer 6 laminated on the second surface 25 side of the porous layer 2.

[0024] As described above, in the present embodiment, the first layer 4 is joined to the porous layer 2 through the impregnated portion 42 by mechanical bonding rather than by adhesive bonding. As used herein, "adhesive bonding" means that different substances are adhered with a chemical bond such as an intermolecular covalent bond. Different from adhesive bonding, the bonding by the impregnated portion 42 is likely to have a bonding strength that does not exceed the breaking stress of the porous layer 2 and the first layer 4. For example, when the used soundproof material 1 is recycled, it is preferable that the first layer 4 and the second layer 6 are cleanly peeled off (without breaking) from the porous layer 2 by pulling out the impregnated portion 42 from the cells 22. In the present embodiment, the first layer 4 and the second layer 6 can be easily peeled off from the porous layer 2, and a soundproof material 1 suitable for recycling can be provided.

[0025] Further, in the present embodiment, the first layer 4 includes a fibrous first material 41, and the second layer 6 includes a fibrous second material 61. Therefore, the second layer 6 and the first layer 4 can partially absorb the noise from the noise source and allow the remaining noise to pass through to the porous layer 2. The continuous bubble structure 21 of the porous layer 2 absorbs the noise that has passed through the first layer 4. Thereby, the entire soundproof material 1 can absorb the noise from the noise source.

[0026] Further, in the present embodiment, near the boundary between the second layer 6 and the first layer 4, the fibrous second material 61 and the first material 41 are intertwined with each other. Therefore, the bonding strength between the second layer 6 and the first layer 4 is likely to be higher than the bonding strength between the first layer 4 and the porous layer 2. For example, during recycling, the soundproof material 1 is likely to be torn between the first layer 4 and the porous layer 2. As a result, the porous layer 2 containing the thermosetting resin and the first layer 4 and the second layer 6 containing the thermoplastic resin can be separated from the soundproof material 1.

[0027] Next, a method for manufacturing the soundproof material 1 will be described with reference to FIGS. 2 and 3. The manufacturing method includes a step S1 of preparing the porous layer 2, a step S2 of preparing the fiber material 8, a step S3 of disposing the fiber material 8 on the porous layer 2, and a step S4 of heating the fiber material 8 to impregnate the molten first material 41 into the cells 22 of the porous layer 2.

[0028] First, as shown in Fig. 2(a), in step S1, a porous layer 2 is prepared.

[0029] Next, as shown in Figs. 2(b) and (c), in step S2, a fibrous material 8 in which a first layer 4 and a second layer 6 are laminated is prepared. The fibrous material 8 includes a first layer 4 containing a fibrous first material 41 and a second layer 6 containing a fibrous second material 61.

[0030] As shown in Fig. 2(b), the fibrous material 8 has the second layer 6 stacked on the first layer 4, and for example, the needle punch 10 is repeatedly moved along the stacking direction (see the black arrow in Fig. 2(b)) to entangle the fibrous first material 41 and the fibrous second material 61 with each other. Thereby, as shown in Fig. 2(c), a fibrous material 8 in which the first layer 4 and the second layer 6 are integrated can be obtained while keeping the first material 41 and the second material 61 in a fibrous state.

[0031] Furthermore, as shown in Fig. 3, in step S3, the fibrous material 8 is stacked on the porous layer 2 and disposed inside the mold 12. The fibrous material 8 is disposed such that the first layer 4 faces the porous layer 2 side.

[0032] Next, in step S4, with the porous layer 2 and the fibrous material 8 disposed in the mold 12, the mold 12 is heated and pressed (see the arrow P in Fig. 3), that is, a so-called hot press is performed. In the present embodiment, the mold 12 is heated at a temperature of, for example, 180°C or higher and 200°C or lower for 30 seconds or more and 60 seconds or less.

[0033] In step S4, heating is performed until the internal temperature of the fibrous material 8 reaches the heating temperature T3. The heating temperature T3 is higher than the melting point T1 of the first material 41 and lower than the melting point T2 of the second material 61. The heating temperature T3 is, for example, 170°C or higher and 190°C or lower. As a result, the first material 41 melts and flows into the cells 22 of the porous layer 2. The first material 41 in the cells 22 solidifies to become the impregnated portion 42 as shown in Fig. 1.

[0034] As described above, the manufacturing method can obtain a soundproof material 1 including a porous layer 2, a first layer 4, and a second layer 6.

[0035] In the manufacturing method of the present embodiment, in step S3, the porous layer 2 and the fibrous material 8 are arranged inside the mold 12, and in step S4, a hot press is used to heat the fibrous material 8 and the porous layer 2 together with the mold 12. However, the present disclosure is not limited to this.

[0036] That is, in the manufacturing method of the soundproof material 1, the fibrous material 8 obtained by preheating and melting the first material 41 may be arranged on the porous layer 2, and the melted first material 41 may be impregnated into the porous layer 2.

[0037] The soundproof material 1 of the present disclosure includes a porous layer 2, a first layer 4 laminated on the porous layer 2 and containing a first material 41, and a second layer 6 laminated on the first layer 4 and containing a fibrous second material 61. The melting point T1 of the first material 41 is lower than the melting point T2 of the second material 61, and the porous layer 2 has an impregnated portion 42 in which the first material 41 is melted and solidified inside.

[0038] In addition, the first layer 4 of the soundproof material 1 contains a fibrous first material 41.

[0039] Furthermore, the fibrous first material 41 and the fibrous second material 61 are intertwined with each other to form a layered structure.

[0040] In addition, the porous layer 2 contains a thermosetting resin material having a closed-cell structure 21, and the first material 41 and the second material 61 are thermoplastic resin materials.

[0041] The manufacturing method of the soundproof material 1 of the present disclosure includes a step S1 of preparing a porous layer 2, a step S2 of preparing a fibrous material 8 including a first layer 4 containing a fibrous first material 41 and a second layer 6 laminated on the first layer 4 and containing a fibrous second material 61 having a melting point T2 higher than that of the first material 41, a step S3 of arranging the fibrous material 8 on the porous layer 2 so that the first layer 4 faces the porous layer 2 side, and a step S4 of heating the fibrous material 8 at a heating temperature T3 higher than the melting point T1 of the first material 41 and lower than the melting point T2 of the second material 61 to melt the first material 41 and impregnate the melted first material 41 into the porous layer 2.

[0042] As described above, according to the present disclosure, it is possible to provide a novel soundproof material in which a porous layer and a fiber layer are laminated, and a method for manufacturing the soundproof material.

[0043] As described above, the embodiments of the present disclosure have been described. However, the present disclosure is not limited to the above embodiments, and various modifications are possible without departing from the gist of the invention. In particular, a plurality of modifications described in this specification can be arbitrarily combined as necessary.

[0044] In the present embodiment, the first layer 4 containing polyethylene as the fibrous first material 41 and the second layer 6 containing polyethylene terephthalate as the fibrous second material 61 have been described as examples. However, the present disclosure is not limited thereto.

[0045] The first material 41 contained in the first layer 4 and the second material 61 contained in the second layer 6 may be a combination of fibrous thermoplastic resin materials in which the melting point T1 of the first material 41 is lower than the melting point T2 of the second material 61. For example, the first layer 4 may contain polyethylene (PE; polyethylene) as the fibrous first material 41, and the second layer 6 may contain polypropylene as the fibrous second material 61.

[0046] In the present embodiment, the first layer 4 is partially fibrous and partially melt-solidified. However, the present disclosure is not limited thereto. For example, the first layer 4 may not maintain a fibrous state by being entirely melt-solidified.

[0047] In the present embodiment, an example in which the first layer 4 and the second layer 6 are laminated so as not to protrude from the outer edge of the porous layer 2 when viewed in the thickness direction (the arrow Z direction in FIG. 1) has been described. However, the first layer 4 and the second layer 6 may protrude from the outer edge of the porous layer 2. For example, the first layer 4 and the second layer 6 may be laminated on the first surface 23 and the second surface 25 of the porous layer 2, and the first layer 4 and the second layer 6 laminated on each surface may protrude from the outer edge of the porous layer 2.

[0048] In this case, among the first layers 4 laminated on each surface, in the portion protruding from the outer edge of the porous layer 2, the first layers 4 may be joined together by the melted first material 41. The joining strength between the first layers 4 is likely to be higher than the joining strength between the first layer 4 and the porous layer 2. Therefore, it is possible to suppress the unintentional separation of the first layer 4 and the porous layer 2 joined by the anchor effect of the impregnated portion 42.

[0049] In the present embodiment, an example in which the first layer 4 and the second layer 6 are laminated on both surfaces (the first surface 23 and the second surface 25) of the porous layer 2 has been described. However, as shown in FIG. 4, they may be laminated on one surface (the first surface 23 in FIG. 4) of the porous layer 2.

Explanation of Reference Numerals

[0050] 1: Sound insulation material 2: Porous layer 21: Closed-cell structure 4: First layer 41: First material 42: Impregnated portion 6: Second layer 61: Second material T1: Melting point T2: Melting point S1: Step S2: Step S3: Step S4: Step

Claims

1. a porous layer, a first layer laminated on the porous layer and containing a first material, a second layer laminated on the first layer and containing a fibrous second material, characterized in that, the melting point of the first material is lower than the melting point of the second material, the porous layer has an impregnated portion in which the first material is melted and solidified, a soundproof material.

2. The first layer contains the fibrous first material, The soundproof material according to Claim 1.

3. The fibrous first material and the fibrous second material are intertwined with each other to form a layered structure, The soundproof material according to Claim 2.

4. The porous layer contains a thermosetting resin material having a closed-cell structure, The first material and the second material are thermoplastic resin materials, The soundproof material according to Claim 1.

5. a step of preparing a porous layer; a step of preparing a fibrous material including a first layer containing a fibrous first material and a second layer laminated on the first layer and containing a fibrous second material having a melting point higher than that of the first material; a step of disposing the fibrous material on the porous layer such that the first layer faces the porous layer side; a step of heating the fibrous material at a temperature higher than the melting point of the first material and lower than the melting point of the second material to impregnate the inside of the porous layer with the melted first material; characterized by comprising: a method for manufacturing a soundproof material.

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