Sound insulation material

Abstract

To provide a soundproofing material having a high soundproofing effect and suitable for use as a floor silencer, dash silencer, etc. for a vehicle. [Solution] In a soundproofing material (10) consisting of a laminate of a fiber layer (11) made of felt or the like and a foamed resin layer (15) made of polyurethane foam or the like foamed from a foamed resin raw material on one side (12) of the fiber layer (11), the foamed resin layer (15) is provided so as to cover one side (12) of the fiber layer (11) and at least a part of the outer periphery (13) of the end of the fiber layer (11), and the foamed resin layer (15) covering the outer periphery (13) of the end of the fiber layer (11) is configured to provide an excellent soundproofing effect against sound leakage from the outer periphery of the end of the soundproofing layer (10).

Description

Technical Field

[0001] The present invention relates to a soundproof material and a method for manufacturing the same.

Background Art

[0002] Conventionally, there is a soundproof material made of a laminate of felt and polyurethane foam (Patent Document 1).

[0003] In a conventional soundproof material made of a laminate of felt and polyurethane foam, sound is blocked by both the felt and the polyurethane foam, and a good soundproof effect can be obtained.

[0004] However, as shown in FIG. 7, in a conventional soundproof material 100 made of a laminate of a felt 101 and a polyurethane foam 103, since the felt 101 and the polyurethane foam 103 each exist up to the outer periphery 100A of the end of the soundproof material 100, for example, when a part of the sound incident from the felt 101 side reaches the end 100A of the soundproof material through the inside of the felt 101 without entering the polyurethane foam 103 side, the soundproofing action by the polyurethane foam 103 cannot be obtained, and a sufficient soundproof effect cannot be obtained.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The present invention has been made in view of the above points, and an object thereof is to provide a soundproof material having a higher soundproof effect and a method for manufacturing the same.

Means for Solving the Problems

[0007] Aspect of the first inventionIn a soundproof material comprising a laminate of a fiber layer and a foamed resin layer formed by foaming on one side of the fiber layer, the foamed resin layer is provided so as to cover at least a part of one side and the outer periphery of the end of the fiber layer.

[0008] The aspect of the second invention is the aspect of the first invention In this case, through holes are provided in the fiber layer, the pre-foamed resin layer covers the inner peripheral surface of the through holes at the portions of the through holes in the fiber layer, and both ends of the through holes covered with the inner peripheral surface are open.

[0009] The aspect of the third invention is the aspect of the first or second invention In this case, the foamed resin layer is made of polyurethane foam.

[0010] Aspect of the fourth invention In a method for manufacturing a soundproof material comprising a laminate of a fiber layer and a foamed resin layer formed by foaming on one side of the fiber layer, by foaming a foamed resin raw material in a foaming space between a fiber layer attached to the mold surface of either the upper mold or the lower mold and the mold surface of the other mold, at least a part of the outer periphery of the end of the mold surface of the one mold to which the fiber layer is attached is larger than the outer periphery of the end of the fiber layer, the foaming space between the fiber layer and the mold surface of the other mold exists up to the outer periphery of the end of the fiber layer, and the foamed resin layer is formed so as to cover at least a part of one side and the outer periphery of the end of the fiber layer by foaming the foamed resin raw material.

[0011] The aspect of the fifth invention is the aspect of the fourth invention In this case, the fiber layer has through holes penetrating both sides of the fiber layer, the mold surface of the one mold to which the fiber layer is attached has convex portions inserted into the through holes when the fiber layer is attached, a gap communicating with the foaming space is formed between the side surface of the convex portions inserted into the through holes and the inner peripheral surface of the through holes, and the foamed resin raw material is foamed with the tip of the convex portions in contact with the other mold surface, so as to cover at least a part of one side and the outer periphery of the end of the fiber layer, cover the inner peripheral surface of the through holes at the portions of the through holes in the fiber layer, and form a foamed resin layer open at both ends of the through holes covering the inner peripheral surface.

Advantages of the Invention

[0012] Since the sound insulation material of the present invention is provided such that the foamed resin layer covers one side and the outer periphery of the end portion of the fiber layer, the sound incident on the sound insulation material is sound-insulated by each layer every time it passes through the foamed resin layer and the fiber layer, and a good sound insulation effect can be obtained. Further, even when a part of the sound incident from the fiber layer side passes through the inside of the fiber layer and reaches the end portion of the sound insulation material, by passing through the foamed resin layer covering at least a part of the outer periphery of the end portion of the sound insulation material, sound insulation is achieved by both the fiber layer and the foamed resin layer, and a good sound insulation effect can be obtained.

[0013] Further, in the sound insulation material of the present invention, when the foamed resin layer covering one side of the fiber layer covers the inner peripheral surface of the through hole at the portion of the through hole of the fiber layer and both ends of the through hole covered with the inner peripheral surface are open, even when a part of the sound incident from the fiber layer side passes through the inside of the fiber layer and reaches the inner peripheral surface of the through hole of the fiber layer, it will finally pass through the foamed resin layer covering the inner peripheral surface of the through hole, and sound insulation is achieved by both the fiber layer and the foamed resin layer, and a good sound insulation effect can be obtained, which is particularly effective for products with many through holes.

[0014] The manufacturing method of the sound insulation material of the present invention can easily manufacture a sound insulation material having a good sound insulation effect.

Brief Description of the Drawings

[0015]

Figure 1

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Figure 7

Best Mode for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present invention will be described. The sound insulation material 10 of the first embodiment shown in FIG. 1 is composed of a laminate of a fiber layer 11 and a foamed resin layer 15 formed by foaming on one side 12 of the fiber layer 11. The foamed resin layer 15 is provided so as to cover one side 12 and the outer periphery 13 of the end portion of the fiber layer 11, and the other surface 14 of the fiber layer 11 is in an exposed state. The outer periphery 13 of the end portion of the fiber layer 11 corresponds to the side surface of the end portion of the fiber layer 11. Note that the foamed resin layer 15 only needs to cover at least a part, not all, of the outer periphery 13 of the end portion of the fiber layer 11. Of course, it is more preferable from the viewpoint of sound insulation that the foamed resin layer 15 covers all of the outer periphery 13 of the end portion of the fiber layer 11. The shape of the sound insulation material 10 is not limited to a rectangular plate shape as shown in the figure, and may be a polygonal shape, an elliptical shape, an irregular plate shape, etc., and the shape is adapted to the product, place, etc. where the sound insulation material 10 is used. Further, the sound insulation material 10 can be used with either the fiber layer 11 or the foamed resin layer 15 on the sound source side.

[0017] Examples of the fiber layer 11 include fiber aggregates such as non-woven fabric and felt, and felt is particularly preferable from the viewpoints of light weight and sound insulation (sound absorption). The material of the fibers constituting the felt is not limited. Felt includes resin felt in which thermosetting resin is used as a binder to bond the fibers together, press felt in which the fibers are bonded to each other by pressing with or without using a binder, needle felt in which the fibers are entangled with each other by needle punching, etc., and any felt can be used. In particular, press felt is preferable because the fibers are densely packed by pressing, and thus the sound absorption (sound insulation) is high. The basis weight of the fiber layer 11 is 100 to 3000 g / m 2 , and the thickness is preferably about 2 to 45 mm. If the basis weight of the fiber layer 11 is too small, the sound insulation (sound absorption) will be small, and conversely, if the basis weight is too large, the sound insulation material 10 will be heavy. Also, if the thickness of the fiber layer 11 is too thin, the sound insulation (sound absorption) will be small, and conversely, if it is too thick, the sound insulation material 10 will be bulky and heavy.

[0018] The foamed resin layer 15 is formed by foaming from a foamed resin raw material on one side 12 of the fiber layer 11. During the foaming formation, a part of the foamed resin raw material impregnates and cures on one side 12 of the fiber layer 11, thereby bonding the fiber layer 11 and the foamed resin layer 15. Further, on one side 12 of the fiber layer 11 to which the foamed resin layer 15 is adhered, an impregnated cured layer formed by impregnating and curing the foamed resin raw material is formed, and the sound insulation property (noise insulation property) is also improved by the impregnated cured layer.

[0019] Examples of the resin constituting the foamed resin layer 15 include polyurethane foam, polyethylene foam, polypropylene foam, etc. In particular, polyurethane foam is a preferable foamed resin because it is lightweight and excellent in sound absorption (noise insulation). The density (JIS K7222) of the foamed resin layer 15 is 30 to 150 kg / m 3 , and the thickness is preferably 2 to 50 mm. If the density of the foamed resin layer 15 is too small, the sound insulation property will be small, and conversely, if the density is large, it will be heavy. Also, if the foamed resin layer 15 is too thin, the sound insulation property will be small, and conversely, if it is thick, the soundproofing material 10 will be bulky and heavy.

[0020] Since the soundproofing material 10 has the foamed resin layer 15 provided on one side of the fiber layer 11, the sound incident on the soundproofing material 10 is absorbed (noise-insulated) by both the fiber layer 11 and the foamed resin layer 15, and a good soundproofing effect is obtained. Also, since the foamed resin layer 15 provided on one side 12 of the fiber layer 11 covers the outer periphery 13 of the end portion of the fiber layer 11, the sound leaking from the outer periphery of the end portion of the soundproofing material 10 can also be reduced, and the sound insulation property becomes even better.

[0021] The manufacturing method of the soundproofing material 10 will be described with reference to FIG. 2. The manufacturing of the soundproofing material 10 is performed by mold forming using a mold 21. The mold 21 is composed of an upper mold 22 and a lower mold 32, and the fiber layer 11 is attached to either the upper mold 22 or the lower mold 32. In the illustrated example, as shown in (2-1) of FIG. 2, the fiber layer 11 is attached to the mold surface 23 of the upper mold 22, and the foamed resin raw material P is injected into the lower mold 32. Then, as shown in (2-2) of FIG. 2, the upper mold 22 is covered with the lower mold 32 to close the mold, and the foamed resin raw material P is foamed in the foaming formation space 35 between the fiber layer 11 and the mold surface 33 of the lower mold 32. The symbol N is an injection nozzle.

[0022] On the mold surface 23 of the upper mold 22 to which the fiber layer 11 is attached, as shown in (2-1) of FIG. 2, locking portions 25 for removably holding the fiber layer 11 are provided at the attachment positions of the fiber layer 11. The illustrated locking portions 25 are composed of pins and are erected at a plurality of locations on the mold surface 23 of the upper mold 22.

[0023] Further, the mold surface 23 of the upper mold 22 is such that the outer periphery 24 of the end portion is larger than the outer periphery 13 of the end portion of the fiber layer 11. As shown in (2-2) of FIG. 2, when the fiber layer 11 is attached to the mold surface 23, the outer periphery 24 of the end portion of the mold surface 23 protrudes from the outer periphery 13 of the end portion of the fiber layer 11 by a predetermined amount. When the foamed resin layer 15 of the soundproof material 10 covers at least a part, not all, of the outer periphery 13 of the end portion of the fiber layer 11, at least a part of the outer periphery 24 of the end portion of the mold surface 23 of the upper mold 22 is made larger than the outer periphery 13 of the end portion of the fiber layer 11, and when the fiber layer 11 is attached to the mold surface 23, at least a part of the outer periphery 24 of the end portion of the mold surface 23 protrudes from the outer periphery 13 of the end portion of the fiber layer 11 by a predetermined amount.

[0024] The lower mold 32 has a concave shape in which the mold surface 33 is recessed according to the outer shape of the soundproof material 10. When the upper mold 22 is placed on the lower mold 32 and closed, a foaming space 35 is formed between one side 12 of the fiber layer 11 on the mold surface 23 of the upper mold 22 and the mold surface 33 of the lower mold 32. Further, when the upper mold 22 is placed on the lower mold 32 and closed, the upper part of the mold surface 33 of the lower mold 32 abuts against the outer periphery 24 of the end portion of the mold surface 23 of the upper mold 22 and is located away from the outer periphery 13 of the end portion of the fiber layer 11, and the foaming space 33 is continuously formed up to the outer periphery 13 of the end portion of the fiber layer 11.

[0025] The foamed resin raw material P fills the foaming space 35 by foaming and forms a foamed resin layer 15 that covers one side 12 of the fiber layer 11 and the outer periphery 13 of the end portion of the fiber layer 11, as shown in (2-3) of FIG. 2. Further, when the foamed resin raw material P foams, a part of the foamed resin raw material P impregnates and cures on one side 12 of the fiber layer 11 and the outer periphery (side surface) 13 of the end portion of the fiber layer 11, and adheres the fiber layer 11 and the foamed resin layer 15. The foamed resin raw material P is a polyurethane foam raw material when the foamed resin is polyurethane foam. After that, the upper mold 22 is separated from the lower mold 32, the mold 21 is opened, and the soundproof material 10 composed of the fiber layer 11 and the foamed resin layer 15 shown in FIG. 1 is taken out.

[0026] FIG. 3 shows the soundproof material 50 of the second embodiment. The soundproof material 50 is an example having through holes 51, 52, and 53 at predetermined positions. The through holes 51, 52, and 53 are used, for example, to pass shafts, cables, etc. in a vehicle. The soundproof material 50 is composed of a laminate of a fiber layer 61 and a foamed resin layer 75 formed by foaming on one side 62 of the fiber layer 61. The foamed resin layer 75 is provided so as to cover one side 62 and the outer periphery 63 of the end portion of the fiber layer 61, and the other side 64 of the fiber layer 61 is in an exposed state. The outer periphery 63 of the end portion of the fiber layer 61 corresponds to the side surface of the end portion of the fiber layer 61. FIG. 4 shows a plan view of the fiber layer 61 and a cross-sectional view taken along line 4A-4A thereof. Note that the shape of the soundproof material 50 is not limited to the illustrated shape, and is a shape corresponding to the place where the soundproof material 50 is used.

[0027] As shown in FIG. 4, the fiber layer 61 is provided with through holes 65, 67, and 69 at predetermined positions. At the portions of the through holes 65, 67, and 69 of the fiber layer 61 shown in FIG. 4, as shown in FIG. 3, the foamed resin layer 75 forms portions 76, 77, and 78 that cover the inner peripheral surfaces 66, 68, and 70 of the through holes. Both ends of the portions 76, 77, and 78 that cover the inner peripheral surfaces 66, 68, and 70 of the through holes are open to form the through holes 51, 52, and 53 of the soundproof material 50.

[0028] The fiber layer 61 and the foamed resin layer 75 of the second embodiment are made of the same material, density, thickness, etc. as the fiber layer 11 and the foamed resin layer 15 of the first embodiment. The fiber layer 61 is preferably a fabric, and the foamed resin layer 75 is preferably a polyurethane foam.

[0029] In the soundproof material 50 of the second embodiment shown in FIG. 3, since the foamed resin layer 75 provided on one side 62 of the fiber layer 61 covers the outer periphery 63 of the end portion of the fiber layer 61 shown in FIG. 4 and the inner peripheral surfaces 66, 68, and 70 of the through holes 65, 67, and 69, it is possible to reduce the sound leaking from the outer periphery of the end portion and the through holes of the soundproof material 50, and the soundproof performance is improved.

[0030] The manufacturing method of the sound insulation material 50 will be described with reference to FIG. 5. The sound insulation material 50 is manufactured by mold forming using a mold 81. The mold 81 consists of an upper mold 82 and a lower mold 94, and a fiber layer 61 is attached to either the upper mold 82 or the lower mold 94. In the illustrated example, as shown in (5-1) of FIG. 5, the fiber layer 61 is attached to the mold surface 83 of the upper mold 82, and the foamed resin raw material P is injected into the lower mold 94. Then, as shown in (5-2) of FIG. 5, the upper mold 82 is covered with the lower mold 94 to close the mold, and the foamed resin raw material P is foamed in the foaming space 97 between the fiber layer 61 and the mold surface 95 of the lower mold 94.

[0031] The mold surface 83 of the upper mold 82 to which the fiber layer 61 is attached is such that the outer periphery 84 of the end of the mold surface 83 is larger than the outer periphery 63 of the end of the fiber layer 61. As shown in (5-2) of FIG. 5, when the fiber layer 61 is attached to the mold surface 83, the outer periphery 84 of the end of the mold surface protrudes a predetermined amount from the outer periphery 63 of the end of the fiber layer 61. When the foamed resin layer 75 of the sound insulation material 50 covers at least a part rather than all of the outer periphery 63 of the end of the fiber layer 61, at least a part of the outer periphery 84 of the end of the mold surface 83 of the upper mold 82 is made larger than the outer periphery 63 of the end of the fiber layer 61, and when the fiber layer 61 is attached to the mold surface 83, at least a part of the outer periphery 84 of the end of the mold surface 83 protrudes a predetermined amount from the outer periphery 63 of the end of the fiber layer 61.

[0032] As shown in (5-1) of FIG. 5, locking portions 85 for removably holding the fiber layer 61 are provided at the attachment positions of the fiber layer 61 on the mold surface 83 of the upper mold 82. The illustrated locking portions 85 are constituted by pins and are erected at a plurality of positions on the mold surface 83 of the upper mold 82.

[0033] Moreover, on the mold surface 83 of the upper mold 82, convex portions 86, 88, 90 to be inserted into the through holes 65, 67, 69 of the fiber layer 61 during attachment of the fiber layer 61 are formed in accordance with the positions of the through holes 65, 67, 69 of the fiber layer 61.

[0034] The convex portions 86, 88, and 90 are configured such that their outer perimeters are smaller than the inner perimeters of the through-holes 65, 67, and 69 of the fiber layer 61 by a predetermined dimension. When inserted into the through-holes 65, 67, and 69 of the fiber layer 61, gaps 92, 93, and 94 as shown in (5-2) of FIG. 5 are formed between the side surfaces 87, 89, and 91 of the convex portions 86, 88, and 90 and the inner peripheral surfaces 66, 68, and 70 of the through-holes 65, 67, and 69 of the fiber layer 61. Also, the height of the convex portions 86, 88, and 90 is set such that when the upper mold 82 is placed on the lower mold 94 and the mold 81 is closed, the tips (lower ends) 86a, 88a, and 90a of the convex portions 86, 88, and 90 contact the mold surface 95 of the lower mold 94.

[0035] The lower mold 94 has a concave shape in which the mold surface 95 is recessed according to the outer shape of the soundproof material 60. When the upper mold 82 is placed on the lower mold 94 and closed, a foam molding space 97 is formed between the one-sided surface 62 of the fiber layer 61 of the mold surface 83 of the upper mold 82 and the mold surface 95 of the lower mold 94 as shown in (5-2) of FIG. 5. The foam molding space 97 communicates with the gaps 92, 93, and 94 between the convex portions 86, 88, and 90 of the mold surface 83 of the upper mold 82 and the inner peripheral surfaces 66, 68, and 70 of the through-holes 65, 67, and 69 of the fiber layer 61, and is continuously formed up to the outer periphery 63 of the end portion of the fiber layer 61.

[0036] The foam resin raw material P fills the foam molding space 97 by foaming, and as shown in (5-3) of FIG. 5, covers the one-sided surface 62 of the fiber layer 61, the inner peripheral surfaces 66, 68, and 70 of the through-holes of the fiber layer 61, and the outer periphery 63 of the end portion of the fiber layer 61 to form a foam resin layer 75. The foam resin layer 75 has portions 76, 77, and 78 that cover the inner peripheral surfaces 66, 68, and 70 of the through-holes of the fiber layer 61, and the portions 76, 77, and 78 that cover the inner peripheral surfaces 66, 68, and 70 of the through-holes open at both ends of the through-holes. Also, when the foam resin raw material P foams, a part of the foam resin raw material P impregnates and cures on the one-sided surface 62 of the fiber layer 61, the inner peripheral surfaces 66, 68, and 70 of the through-holes of the fiber layer 61, and the outer periphery (side surface) 63 of the end portion of the fiber layer 61, and adheres the fiber layer 61 and the foam resin layer 75. Note that when the foam resin is polyurethane foam, the foam resin raw material P is a polyurethane foam raw material. After that, the upper mold 82 is separated from the lower mold 94, the mold 81 is opened, and the soundproof material 60 composed of the fiber layer 61 and the foam resin layer 75 shown in FIG. 3 is taken out.

Example

[0037] Sound insulation materials for Samples 1, 2, 3, and 4 were fabricated, and the transmission loss (by the acoustic intensity method) was measured based on JIS A1441-1:2007 to evaluate the sound insulation effect achieved by the foam resin layer covering both one side of the fiber layer and the outer periphery of the ends. The size of each sample was 500×500×20 mm. The sound source reverberation chamber was 36 m 3 , and the receiving anechoic chamber was 20 m 3 , and the measurement area was 400×400 mm (0.16 m 2 ). An iron plate with a thickness of 0.8 mm was placed on one side of the sample (the felt side for Samples 1 and 2), and with the periphery of the sample fixed by a 50-mm-wide frame, the iron plate side was used as the sound source, and four central discrete points (100-mm pitch) were measured at a position 100 mm away from the sample surface.

[0038] Sample 1 has the same configuration as the sound insulation material 10 in Fig. 1, with a 10-mm-thick polyurethane foam covering one side and the outer periphery of the ends of a 10-mm-thick felt. As the felt for Sample 1, a miscellaneous felt made of synthetic resin fibers with a basis weight of 580 g / m 2 , a pressed felt with a size of 480×480×10 mm was used. According to the mold forming shown in Fig. 2, the polyurethane foam raw material was injected into the mold with the felt attached to the mold surface (500×500 mm) of the upper mold and foamed to fabricate it. The polyurethane foam raw material consists of 100 parts by weight of a polyether polyol with a molecular weight of 5000 and a functionality of 3, 1.5 parts by weight of an amine catalyst, 3.5 parts by weight of water as a blowing agent, and 60 parts by weight of an isocyanate composed of MDI. The density of the polyurethane foam of Sample 1 was 70 kg / m 3 , and the total basis weight was 1640 g / m 2 .

[0039] Sample 2 has the same configuration as the conventional sound insulation material 100 shown in Fig. 7, and is a polyurethane foam with a thickness of 10 mm covering only one side of a felt with a thickness of 10 mm. Sample 2 uses a felt made of the same material as the press felt of Sample 1 with dimensions of 500 mm × 500 mm × 10 mm, uses a mold with the same configuration as the mold of Sample 1, attaches the felt to the entire surface of the mold surface of the upper mold, injects a polyurethane foam raw material with the same formulation as the polyurethane foam raw material of Sample 1, and is produced by foaming. The density of the polyurethane foam of Sample 2 is 70 kg / m 3 , and the total basis weight is 1640 g / m 2 .

[0040] Sample 3 consists of a single felt (500 mm × 500 mm × 20 mm) and is made of the same material as the press felt of Samples 1 and 2. The total basis weight of Sample 3 is 1120 g / m 2 .

[0041] Sample 4 consists of a single polyurethane foam (500 × 500 × 20 mm), uses a mold with the same configuration as the molds of Samples 1 and 2, injects a polyurethane foam raw material with the same formulation as the polyurethane foam raw materials of Samples 1 and 2 into the mold, and is produced by foaming. The density of the polyurethane foam of Sample 4 is 70 kg / m 3 , and the total basis weight is 1400 g / m 2 .

[0042] The measurement results of the transmission loss are shown in Fig. 6. Sample 1, which is covered with polyurethane foam on one side and the outer periphery of the end of the felt, had a greater transmission loss at 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz than Sample 2, which covered only one side of the felt, and was excellent in sound insulation. Furthermore, the difference in the transmission loss between Sample 1 and Sample 2 was even greater at 4 kHz and 8 kHz on the high-frequency side, and the sound insulation effect of Sample 1 was higher on the high-frequency side.

[0043] The sample 3 made of only felt had a lower transmission loss than the sample 1 at any of 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and its sound insulation effect was inferior.

[0044] The sample 4 made of only polyurethane foam had a lower transmission loss than the sample 1 at any of 500 Hz, 1 kHz, 2 kHz, 4 kHz, and 8 kHz, and its sound insulation effect was inferior.

[0045] From these facts, it can be seen that high sound insulation can be obtained by covering one side and the outer periphery of the end portion of the fiber layer with a foamed resin layer as in the sound insulation material of the present invention. Note that the sound insulation material of the present invention is not limited to the sound insulation material for vehicles such as the floor silencer and dash silencer of a vehicle, and is suitable as a sound insulation material for, for example, buildings, industrial machines, home appliances, etc.

Explanation of Signs

[0046] 10, 50 Sound insulation material 11, 61 Fiber layer 12, 62 One side of the fiber layer 13, 63 Outer periphery of the end portion of the fiber layer 15, 75 Foamed resin layer 21, 81 Mold 22, 82 Upper mold 32, 94 Lower mold 23, 83 Mold surface of the upper mold 24, 84 Outer periphery of the end portion of the mold surface of the upper mold 33, 95 Mold surface of the lower mold 35, 97 Foaming molding space 65, 67, 69 Through holes of the fiber layer 66, 68, 70 Inner peripheral surface of the through holes of the fiber layer 76, 77, 78 Portion covering the inner peripheral surface of the through hole 86, 88, 90 Protrusions on the mold surface of the upper mold 86a, 88a, 90a Tips of the protrusions 87, 89, 91 Side surfaces of the protrusions 92, 93, 94 Gaps P Foamed resin raw material

Claims

1. In a soundproof material comprising a laminate of a fiber layer and a foamed resin layer formed by foaming on one side of the fiber layer (excluding the case where a vibration damping layer made of an amorphous resin is included), the foamed resin layer is provided so as to cover at least a part of one side and the outer periphery of the end of the fiber layer, a soundproof material, characterized in that an impregnated cured layer formed by impregnating and curing the raw material of the foamed resin layer is formed on one side of the fiber layer to which the foamed resin layer is adhered.

2. In a soundproof material comprising a laminate of a fiber layer and a foamed resin layer formed by foaming on one side of the fiber layer, the foamed resin layer is provided so as to cover at least a part of one side and the outer periphery of the end of the fiber layer, an impregnated cured layer formed by impregnating and curing the raw material of the foamed resin layer is formed on one side of the fiber layer to which the foamed resin layer is adhered, a soundproof material, characterized in that the surface of the fiber layer on the side opposite to the side where the foamed resin layer is formed is in an exposed state.

3. In a soundproof material comprising a laminate of a fiber layer and a foamed resin layer formed by foaming on one side of the fiber layer, the foamed resin layer is provided so as to cover at least a part of one side and the outer periphery of the end of the fiber layer, a soundproof material, characterized in that an impregnated cured layer formed by impregnating and curing the raw material of the foamed resin layer is formed on at least a part of one side of the fiber layer to which the foamed resin layer is adhered and the outer periphery of the end.

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