Soundproof cover and method for manufacturing a soundproof cover

Abstract

It has a very simple structure, for example, the compressor of an air conditioner, which produces noise. The objective is to provide a soundproof cover for equipment and a method for manufacturing the soundproof cover. [Solution] A soundproof cover comprising a sound-insulating sheet, wherein the sound-insulating sheet has a bend portion for constructing the structure of the soundproof cover, and a method for manufacturing a soundproof cover comprising a cutting step of cutting the sound-insulating sheet into a shape for forming the structure of the soundproof cover, and a bend portion forming step of forming a bend portion for constructing the structure of the soundproof cover on the cut sound-insulating sheet.

Description

Technical Field

[0001] The present invention relates to a soundproof cover that suppresses the leakage of operating noise generated from devices such as a compressor arranged in an air conditioner to the outside, and a method for manufacturing the soundproof cover.

Background Art

[0002] Conventionally, for example, in a compressor housed inside an outdoor unit of an air conditioner, various sound insulation means have been provided for the purpose of suppressing the leakage of operating noise emitted from the compressor to the outside. For example, Patent Document 1 discloses a molded product of rubber or thermoplastic elastomer having sound insulation properties, and a soundproof cover molded into a shape corresponding to the outer shape of the compressor main body, thereby eliminating the complexity of the attachment work of the soundproof cover and improving the sound insulation function.

[0003] Patent Document 2 discloses a soundproof cover in which a fiber aggregate heated and molded using hot air or steam and a sound insulation sheet are integrally molded, thereby enhancing the sealing property with a device that generates noise and improving the sound insulation function.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] The invention described in Patent Document 1 is easily adaptable to the shape of an air conditioner, but because it is manufactured by vacuum forming, it requires a large mold, resulting in very high manufacturing costs. Furthermore, because rubber or thermoplastic elastomer is vacuum-formed to fit the mold, the rubber or thermoplastic elastomer is stretched, leading to problems such as thinning of molded parts like bent sections and the occurrence of defective products.

[0006] In the invention described in Patent Document 2, at least two types of molds, an upper mold and a lower mold, are required to heat-compress the soundproof cover, resulting in very high manufacturing costs for the soundproof cover. Furthermore, because the sound insulation sheet is formed thinly using heat-compression molding, problems such as the occurrence of defective products arise.

[0007] This invention has been made in view of the above-mentioned problems, and aims to provide a soundproof cover that has a very simple structure but can reduce noise leaking from all or part of equipment such as the compressor of an air conditioner. It also aims to provide a method for manufacturing a soundproof cover that can significantly reduce manufacturing costs compared to manufacturing methods such as vacuum forming. [Means for solving the problem]

[0008] In other words, the present invention includes the following inventions. [Invention 1] A soundproof cover equipped with a sound-insulating sheet, The soundproof cover is characterized in that the sound insulation sheet has a folded portion for constructing the structure of the soundproof cover. [Invention 2] The soundproof cover according to Invention 1, characterized in that it has a joint at the portion where the folded sound-insulating sheets come into contact with each other. [Invention 3] The soundproof cover according to invention 1 or 2, characterized in that it is provided with a sound-absorbing sheet on the inside of the soundproof cover. [Invention 4] The soundproof cover according to invention 1 or 2, characterized in that the sound insulation sheet is made of rubber or thermoplastic elastomer. [Invention 5] The soundproof cover according to Invention 3, characterized in that the sound insulation sheet is made of rubber or thermoplastic elastomer. [Invention 6] The soundproof cover according to invention 1 or 2, characterized in that the soundproof cover is for use with the compressor of an air conditioner. [Invention 7] The soundproof cover according to Invention 3, characterized in that the soundproof cover is for use with the compressor of an air conditioner. [Invention 8] The soundproof cover according to Invention 4, characterized in that the soundproof cover is for the compressor of an air conditioner. [Invention 9] The soundproof cover according to Invention 5, characterized in that the soundproof cover is for use with the compressor of an air conditioner. [Invention 10] The cutting process involves cutting the sound insulation sheet into the shape necessary to form the structure of the soundproof cover, A bending portion forming step is performed on the cut sound insulation sheet to form a bent portion for constructing the structure of the soundproof cover, A method for manufacturing a soundproof cover, characterized by comprising the following features. [Invention 11] A method for manufacturing a soundproof cover according to Invention 10, characterized in that the cutting process is a die-cutting process. [Invention 12] A method for manufacturing a soundproof cover according to invention 10 or 11, characterized in that the bending portion molding step is a heat hinge process. [Invention 13] A method for manufacturing a soundproof cover for a compressor of an air conditioner, as described in invention 10 or 11. [Invention 14] A method for manufacturing a soundproof cover for a compressor of an air conditioner, as described in Invention 12. [Effects of the Invention]

[0009] The soundproof cover of the present invention can effectively reduce noise generated from, for example, a compressor of an air conditioner, and can be manufactured at low cost without the need for a large mold because it is constructed with a very simple structure.

Brief Description of the Drawings

[0010] [Figure 1] FIG. 1 is a cross-sectional view of the soundproof cover when the soundproof cover according to the present invention is attached to the compressor. [Figure 2] FIG. 2 is a cross-sectional view when the soundproof cover and the compressor according to the present invention are cut along the arrow A in FIG. 1. [Figure 3] FIG. 3(a) is an extract view of the sound insulation sheet of the soundproof cover for the leg part of the compressor according to the present invention, and FIG. 3(b) is a view in which a bent portion is formed on the extracted sound insulation sheet. [Figure 4] FIG. 4 is a view in which the sound insulation sheet of FIG. 3(b) is bent along the bent portion to construct the soundproof cover for the leg part of the compressor according to the present invention. [Figure 5] FIG. 5 is a view of a mold for forming the bent portion of FIG. 3(b).

Mode for Carrying Out the Invention

[0011] The inventors, after diligent research to solve the above problems, have found that by providing a soundproof cover equipped with a sound-insulating sheet, the sound-insulating sheet having a bendable portion for constructing the structure of the soundproof cover, and by folding the sound-insulating sheet along the bendable portion and joining the parts where the folded sound-insulating sheets come into contact with each other, it is possible to easily cover, for example, the entire or a part of the compressor of an air conditioner, and to effectively reduce the noise emitted from the compressor, thus completing the present invention. The method for manufacturing the soundproof cover of the present invention comprises a cutting step of cutting the sound-insulating sheet into a shape for the structure of the soundproof cover, and a bending portion forming step of forming a bendable portion on the cut sound-insulating sheet for constructing the structure of the soundproof cover. This method does not require a large mold and allows for the low-cost manufacture of the soundproof cover, and also allows for the manufacture of a soundproof cover with a uniform thickness, thereby reducing defective products. Hereinafter, embodiments relating to the soundproof cover and the method for manufacturing the soundproof cover according to the present invention will be described with reference to Figures 1 to 5, using the compressor of an air conditioner as an example. However, the present invention is not intended to be limited to the configuration described below.

[0012] Soundproof cover Figure 1 is a cross-sectional view of the soundproof cover 100 according to the present invention when it is attached to the compressor 10. Figure 2 is a cross-sectional view of the soundproof cover 100 according to the present invention and the compressor 10 when they are cut along the arrow A in Figure 1. Figure 3(a) is a cutout of the sound insulation sheet 1 of the soundproof cover 100 for the leg portion 11 of the compressor according to the present invention, and Figure 3(b) is a diagram showing the cutout sound insulation sheet 1 with folded portions 2 (2a, 2b, 2c, 2d, 2e) formed. Figure 4 is a diagram showing the soundproof cover 101 for the leg portion 11 of the compressor 10 according to the present invention constructed by folding the sound insulation sheet 1 of Figure 3(b) along the folded portions 2 (2a, 2b, 2c, 2d, 2e).

[0013] The soundproof cover 100 of the present invention has a sound-absorbing sheet laminated on a sound-insulating sheet 1 (not shown). As shown in Figures 1 and 2, the soundproof cover 100 is structured so that the side with the laminated sound-absorbing sheet is attached to the outer surface of the compressor 10. The soundproof cover 100 of the present invention may be configured to cover the entire noise-generating equipment, such as a compressor, or to cover only a part of it.

[0014] The soundproof cover 100 of the present invention can be configured to match the shape of noise-emitting equipment such as a compressor 10. For example, as shown in Figure 1, the soundproof cover 100 may be made in parts and joined together, or they may be made as a single unit to the extent possible.

[0015] In Figure 1, the compressor 10 is covered with a soundproof cover 100. However, in order to cover the compressor 10 while avoiding the piping 15 from the compressor 10, a pipe recess for the piping 15 may be formed in the top soundproof cover 103 of the top surface portion 13, or a slit may be formed in the top soundproof cover 103 to make it easier to position the top soundproof cover 103 around the piping 15 (not shown). This makes the installation of the soundproof cover 100 easier.

[0016] As shown in Figures 1 and 2, the compressor 10 is provided with a plurality of legs 11 at its lower part to support it, and is fixed via support members. Figures 1 and 2 illustrate an example in which the compressor 10 is fixed with four legs 11. In describing the structure of the soundproof cover 100 of the present invention in detail below, the soundproof cover 101 for the legs of the compressor 10 will be described in detail.

[0017] The soundproof cover 100 of the present invention, shown in Figures 3 and 4, is a soundproof cover 101 for the legs 11 of a compressor 10, and is composed of four soundproof covers 101 for the legs, each of which covers one of the four legs 11 separately. As shown in Figure 3(a), the sound insulation sheet 1 is cut into a shape for constructing the shape of the soundproof cover 101 for the legs of the compressor 10, and then, as shown in Figure 3(b), folded portions 2 (2a, 2b, 2c, 2d, 2e) for constructing the structure of the soundproof cover 100 are formed on the cut sound insulation sheet 1. By folding the sound insulation sheet 1 in the appropriate direction along the folded portions 2, the shape of the soundproof cover 101 for the legs 11 of the compressor 10 shown in Figure 4 is obtained. Next, the contact portions 3 of the sound insulation sheet 1 are joined together to construct the structure of the soundproof cover 101. When joining the contacting portions 3 of the sound insulation sheet 1, a joint portion 4 may be provided at the contacting portion shown in Figures 3 and 4. This makes it easier to construct the structure of the soundproof cover 101 for the leg and improves sound insulation performance. When the soundproof cover 101 is placed over the leg portion 11 of the compressor 10, the sound-absorbing sheet covers the leg portion 11 of the compressor 10, and the outer surface is wrapped with the sound insulation sheet 1.

[0018] The folding method for the folded portions 2 (2a, 2b, 2c, 2d, 2e) formed on the sound insulation sheet 1, as shown in Figures 3(b) and 4, will be explained below. The order in which the sound insulation sheet 1 is folded can be any order that is easy to fold, but one example is described below. (1) Fold the folded portion 2d along the folded portion 2d so that the crease is on the front side when viewed from the front in Figure 3(b). (2) Fold the folded portion 2a along the folded portion 2a so that the crease is on the front side when viewed from the front in Figure 3(b). (3) Fold the folded portion 2c along the folded portion 2c so that the crease is on the far side when viewed from the front in Figure 3(b). (4) Fold the folded portion 2e along the folded portion 2e so that the crease is on the far side when viewed from the front in Figure 3(b). (5) Fold the folded portion 2b along the folded portion 2b so that the crease is on the front side when viewed from the front in Figure 3(b), and fold the joint portion 4. The above procedure constructs the soundproof cover 101 for the leg shown in Figure 4.

[0019] The sound insulation sheet 1 used in the present invention may be made of any material that reduces noise leaking from the compressor 10 through the sound absorption sheet, but rubber or thermoplastic elastomer is preferred from the viewpoint of ease of molding and noise reduction. If rubber or thermoplastic elastomer is used, the joint 4 may be secured with double-sided tape or staples, or the joint 4 may be welded together by heat melting to construct the soundproof cover 100.

[0020] Specific types of rubber used in the sound insulation sheet 1 used in the present invention include natural rubber, styrene-butadiene rubber, chloroprene rubber, acrylonitrile rubber, butyl rubber, ethylene propylene rubber, urethane rubber, silicone rubber, fluororubber, and ethylene propylene diene rubber (EPDM). However, ethylene propylene diene rubber (EPDM) is preferred from the viewpoint of sound insulation and weather resistance, and two or more types may be used in combination from among these.

[0021] The specific gravity of the rubber used in the sound insulation sheet 1 used in the present invention can be set as appropriate, but from the viewpoint of sound insulation against noise generated from equipment such as the compressor 10, it is preferably 1.5 to 3.0.

[0022] Specific thermoplastic elastomer materials used in the sound insulation sheet 1 used in the present invention include styrene-based, polyester-based, polyolefin-based, polyamide-based, urethane-based, and polyvinyl chloride-based materials. However, from the viewpoint of sound insulation, weather resistance, and ease of covering equipment such as the compressor 10, polyvinyl chloride-based, styrene-based, and urethane-based materials are preferred, and two or more of these may be used in combination.

[0023] The thickness of the sound insulation sheet 1 used in this invention can be appropriately set depending on the noise-generating equipment, but is preferably 1 to 5 mm from the viewpoint of sound insulation performance and moldability. The thickness may be uniform or partially varied.

[0024] The sound-absorbing sheet used in the present invention is provided at least on the inside of the soundproof cover 100. The sound-absorbing material may be attached to the inside of the sound-insulating sheet 1 by any method, for example, by fixing it with resin fixing pins (so-called tag pins) or by fixing it with adhesive.

[0025] The sound-absorbing sheet used in this invention can be made of any material that reduces noise from the compressor 10 or the like, but from the viewpoint of ease of handling and sound absorption performance, urethane, glass wool, and felt are preferred, and felt is more preferred. If felt is used, noise emitted from the compressor 10 can be effectively reduced.

[0026] Specific types of felt for the sound-absorbing sheet used in the present invention include acrylic fibers, polyester fibers (PET fibers, PBT fibers, PTT fibers, PEN fibers), nylon fibers, rayon fibers, cotton fibers, and glass wool. However, from the viewpoint of ease of handling, acrylic fibers, PET fibers, and cotton fibers are preferred, and fiber aggregates such as laminates combining two or more of these types may also be used.

[0027] The sound-absorbing sheet used in the present invention may be made by laminating felt sheets, nonwoven fabric sheets, aluminum sheets, etc.

[0028] Nonwoven fabric sheets are nonwoven fabrics that have moderate breathability without impairing the sound-absorbing properties of felt. Nonwoven fabric sheets are made from materials such as polyester fibers, low-melting-point polyester fibers, polypropylene fibers, polyethylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, and glass fibers.

[0029] For example, an aluminum sheet can be made of aluminum-laminated glass cloth (ALGC), which is a sheet made by laminating a glass fiber cloth onto aluminum foil.

[0030] Method for manufacturing soundproof covers The present invention provides a method for manufacturing the soundproof cover 100, comprising a cutting step of cutting a sound insulation sheet 1 into a shape for forming the soundproof cover 100, and a bending step of forming a bent portion 2 on the cut sound insulation sheet 1 for constructing the structure of the soundproof cover 100. As a result, since only the bending portion is formed after cutting the flat sound insulation sheet 1 into the desired shape, there is no need for large molds required when manufacturing by vacuum forming, etc., and manufacturing costs can be significantly reduced. In addition, since the bending portion 2 is formed and the structure of the soundproof cover 100 is constructed along the bending portion 2, the occurrence of defective products where the thickness is locally thinned by vacuum forming, etc., can be suppressed.

[0031] For the cutting process of the sound insulation sheet 1, any cutting method that can cut the sound insulation sheet 1 into the desired shape can be used, but die-cutting is preferred. Die-cutting is very low-cost because it only involves cutting grooves into the base plywood or resin board and embedding a die-cut steel blade bent to the same shape as the grooves.

[0032] In the bending portion forming process for creating the bent portion 2 for constructing the structure of the soundproof cover 100 on the cut sound insulation sheet 1, any processing method can be used as long as it can form the bent portion 2 of the desired shape on the sound insulation sheet 1, but thermal hinge processing is preferred. Thermal hinge processing as used in this invention means pressing while applying heat to a mold, and forming the desired bent portion 2 on the sound insulation sheet 1 with the blade portion of the mold. The thermal hinge processing used in this invention is slightly different from general thermal hinge processing, so the details will be explained.

[0033] Figure 5 shows a mold 200 for forming the bent portions 2 (2a, 2b, 2c, 2d, 2e) of Figure 3(b) using a heat hinge process. The mold is made of metal and has blades 5 on a metal plate. Although the blades 5 (5a, 5b, 5c, 5d, 5e) are depicted as pointed in the drawing, the actual cutting edges are V-shaped. The parts of the blades 5 correspond to the bent portions 2a, 5b, 5c, 5d, and 2e of the mold. In the heat hinge process, the sound insulation sheet 1 cut to the desired shape is pressed against the mold while heat is applied, causing the corresponding blades 5 (5a, 5b, 5c, 5d, 5e) to form the respective bent portions 2 (2a, 2b, 2c, 2d, 2e) of the sound insulation sheet 1.

[0034] Methods for joining the joint 4 used in the present invention include joining with adhesive, joining with double-sided tape, and joining by welding, but joining by welding is preferred.

[0035] The welding joining method used in the present invention includes a method of dissolving the joining portion 4 with a solvent to integrate them, and a method of dissolving the joining portion 4 using heat, vibration, or high frequency without using a solvent to integrate the contact portions. However, from the viewpoint of being environmentally friendly, the method of dissolving the joining portion 4 using heat, vibration, or high frequency without using a solvent to integrate the contact portions is preferred. [Industrial applicability]

[0036] The soundproofing sheet 100 of the present invention can be suitably used as a soundproofing cover to reduce noise from, for example, a compressor in an air conditioner. [Explanation of symbols]

[0037] 1. Soundproofing sheet 2(2a,2b,2c,2d,2e) Folded part 4 Joint 10 Compressor 11 Legs 100 Soundproof Cover 101 Soundproofing cover for legs

Claims

1. A soundproof cover equipped with a sound-insulating sheet, The soundproof cover is characterized in that the sound insulation sheet has a folded portion for constructing the structure of the soundproof cover.

2. The soundproof cover according to claim 1, characterized in that it is provided with a joint at the portion where the folded sound-insulating sheets come into contact with each other.

3. The soundproof cover according to claim 1 or 2, characterized in that it is provided with a sound-absorbing sheet on the inside of the soundproof cover.

4. The soundproof cover according to claim 1 or 2, characterized in that the sound insulation sheet is made of rubber or thermoplastic elastomer.

5. The soundproof cover according to claim 3, characterized in that the sound insulation sheet is made of rubber or thermoplastic elastomer.

6. The soundproof cover according to claim 1 or 2, characterized in that the soundproof cover is for the compressor of an air conditioner.

7. The soundproof cover according to claim 3, characterized in that the soundproof cover is for the compressor of an air conditioner.

8. The soundproof cover according to claim 4, characterized in that the soundproof cover is for the compressor of an air conditioner.

9. The soundproof cover according to claim 5, characterized in that the soundproof cover is for the compressor of an air conditioner.

10. The cutting process involves cutting the sound insulation sheet into the shape necessary to form the structure of the soundproof cover, A bending portion forming step is performed on the cut sound insulation sheet to form a bent portion for constructing the structure of the soundproof cover, A method for manufacturing a soundproof cover, characterized by comprising the following features.

11. The method for manufacturing a soundproof cover according to claim 10, characterized in that the cutting process is a die-cutting process.

12. The method for manufacturing a soundproof cover according to claim 10 or 11, characterized in that the bending portion molding step is a heat hinge process.

13. The method for manufacturing a soundproof cover for a compressor of an air conditioner, as described in 10 or 11.

14. The method for manufacturing a soundproof cover for a compressor of an air conditioner, as described in 12.

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