Vehicle silencer and manufacturing method thereof

Abstract

To provide a vehicular silencer enabling improvement a function thereof which is exerted.SOLUTION: A vehicular silencer 1 includes: a sound insulation material layer 10 which has a first surface 11 and a second surface 12 at the opposite side of the first surface 11, and is formed of elastic material 70; and an acoustic absorption material layer 20 formed of material 80 having a void V1 and joined to the second surface 12. The sound insulation material layer 10 comprises: a function portion 30 which includes a protrusion portion 40 protruding toward the opposite side of the acoustic absorption material layer 20, on the first surface 11 and a shape changing portion 50 existing at a position corresponding to the protruding portion 40, on the second surface 12; and a general portion 60 positioned around the function portion 30. The shape changing portion 50 is formed in at least either shape of a convex shape and a concave shape. A thickness of at least a part of the function portion 30 is different from a thickness T1 of the general portion 60.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a vehicle silencer including a sound-insulating material layer and a sound-absorbing material layer, and to a method for manufacturing the same. [Background technology]

[0002] A known example of a silencer installed in an automobile is a dash silencer that is attached to the dash panel. The dash silencer has multiple through holes for passing stud bolts fixed to the dash panel. The dash silencer is attached to the dash panel by passing the stud bolts through each through hole of the dash silencer and fastening clips to the stud bolts.

[0003] The insulator dash body disclosed in Patent Document 1 has a structure in which a skin material and a sound-absorbing material are laminated. The insulator dash body is installed on the passenger compartment side of a dash panel that separates the engine compartment from the passenger compartment in an automobile. The insulator dash body has multiple slit-shaped openings for passing stud bolts fixed to the dash panel. The insulator dash body is attached to the dash panel by fastening harness clips to the stud bolts that pass through each opening. The thickness of the skin material in the insulator dash body is constant, including the periphery of each opening. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 8-276796 Summary of the Invention [Problem to be solved by the invention]

[0005] If the functions exhibited by the above-mentioned skin material are improved, convenience may be improved. The same possibility exists not only for dash insulators, but also for various vehicle silencers such as door silencers and ceiling silencers.

[0006] The present invention discloses a vehicle silencer that can enhance the performance thereof, and a method for manufacturing the same. [Means for solving the problem]

[0007] The vehicle silencer of the present invention comprises: a sound-insulating layer having a first surface and a second surface opposite to the first surface, the sound-insulating layer being made of an elastic material; a sound absorbing layer formed of a material having voids and bonded to the second surface; The sound insulation material layer is a functional portion including a protruding portion protruding from the first surface toward the opposite side of the sound-absorbing material layer, and a shape-changing portion located at a position corresponding to the protruding portion on the second surface; a general portion surrounding the functional portion, the shape-changing portion has at least one of a convex shape and a concave shape, The thickness of at least a part of the functional portion is different from the thickness of the general portion. the law of nature, the functional portion is a portion of the sound-insulating material layer that holds other members, the protruding portion includes a base portion having a base end closest to the sound-absorbing material layer and protruding from the base end in a first protruding direction opposite to the sound-absorbing material layer, and a bent portion protruding from the protruding end of the base portion in a second protruding direction different from the first protruding direction, the functional portion includes an opposing portion that faces the protruding portion, and has a shape in which the opposing portion and the protruding portion surround the other member, The general portion, the protruding portion, the opposing portion, and the functional portion including the shape-changing portion are integrally molded. , has an aspect. Furthermore, the vehicle silencer of the present invention is a sound-insulating layer having a first surface and a second surface opposite to the first surface, the sound-insulating layer being made of an elastic material; a sound absorbing layer formed of a material having voids and bonded to the second surface; The sound insulation material layer is a functional portion including a protruding portion protruding from the first surface toward the opposite side of the sound-absorbing material layer, and a shape-changing portion located at a position corresponding to the protruding portion on the second surface; a general portion surrounding the functional portion, the shape-changing portion has at least one of a convex shape and a concave shape, a thickness of at least a part of the functional portion is different from a thickness of the general portion; the functional portion is a portion of the sound-insulating material layer that is held by another member, the shape-changing portion includes a recessed portion recessed in the second surface, the functional portion has a thin portion that is thinner than the general portion between the protruding portion on the first surface and the recessed portion on the second surface, The general portion and the functional portion having the thin-walled portion and including the protruding portion and the shape-changing portion are integrally molded.

[0008] Further, a method for manufacturing a silencer for a vehicle according to the present invention is a method for manufacturing a silencer for a vehicle including a sound-insulating material layer having a first surface and a second surface opposite to the first surface, and a sound-absorbing material layer formed of a material having voids, an injection molding process for forming the sound-insulating material layer by injection molding from an elastic material so that the sound-insulating material layer has a protruding portion protruding from the first surface toward the opposite side to the sound-absorbing material layer, a functional portion including a shape-changing portion present on the second surface at a position corresponding to the protruding portion, and a general portion surrounding the functional portion, the shape-changing portion having at least one of a convex shape and a concave shape, and the thickness of at least a part of the functional portion is different from the thickness of the general portion; a sound-absorbing material layer forming step of forming the sound-absorbing material layer bonded to the second surface; Including fruit, the functional portion is a portion of the sound-insulating material layer that holds other members, the protruding portion includes a base portion having a base end closest to the sound-absorbing material layer and protruding from the base end in a first protruding direction opposite to the sound-absorbing material layer, and a bent portion protruding from the protruding end of the base portion in a second protruding direction different from the first protruding direction, the functional portion includes an opposing portion that faces the protruding portion, and has a shape in which the opposing portion and the protruding portion surround the other member, In the injection molding step, the general portion and the functional portion including the protruding portion, the opposing portion, and the shape-changing portion are integrally formed by injection molding. , has an aspect. Furthermore, the present invention provides a method for manufacturing a vehicle silencer, which includes a sound-insulating material layer having a first surface and a second surface opposite to the first surface, and a sound-absorbing material layer formed of a material having voids, the method comprising: an injection molding process for forming the sound-insulating material layer by injection molding from an elastic material so that the sound-insulating material layer has a protruding portion protruding from the first surface toward the opposite side to the sound-absorbing material layer, a functional portion including a shape-changing portion present on the second surface at a position corresponding to the protruding portion, and a general portion surrounding the functional portion, the shape-changing portion having at least one of a convex shape and a concave shape, and the thickness of at least a part of the functional portion is different from the thickness of the general portion; a sound-absorbing material layer forming step of forming the sound-absorbing material layer bonded to the second surface; Including, the functional portion is a portion of the sound-insulating material layer that is held by another member, the shape-changing portion includes a recessed portion recessed in the second surface, the functional portion has a thin portion that is thinner than the general portion between the protruding portion on the first surface and the recessed portion on the second surface, The general portion and the functional portion having the thin-walled portion and including the protruding portion and the shape-changing portion are integrally formed by injection molding. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a vehicle silencer that can enhance the functionality it exhibits, and a method for manufacturing the same. [Brief explanation of the drawings]

[0010] [Figure 1]1 is a cross-sectional view illustrating a schematic example of a main part of an automobile equipped with a silencer. [Figure 2] 1 is a cross-sectional view schematically showing an example of a vehicle silencer having a sound-insulating material layer provided with functional portions including protrusions, ridges, and recesses; [Figure 3] 1 is a cross-sectional view schematically illustrating an example of a sound-insulating material layer having a functional portion including a protrusion, a ridge, and a recess. [Figure 4] 1 is a cross-sectional view schematically illustrating an example of a vehicle silencer having a sound-insulating material layer provided with a functional portion including a pair of protrusions and a ridge; [Figure 5] 1 is a cross-sectional view schematically showing an example of a vehicle silencer having a sound-insulating material layer provided with a functional portion including a protrusion and a recess. [Figure 6] 1 is a cross-sectional view schematically illustrating an example of a sound-insulating material layer having a functional portion including a protrusion and a recess. [Figure 7] 1 is a cross-sectional view schematically showing an example of a vehicle silencer in which a sound-insulating material layer includes a functional portion having a thin portion between a protrusion and a recess. [Figure 8] 5A to 5C are diagrams schematically illustrating an example of a method for manufacturing a silencer for a vehicle. DETAILED DESCRIPTION OF THE INVENTION

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following describes embodiments of the present invention. Of course, the following embodiments are merely examples of the present invention, and not all of the features shown in the embodiments are necessarily essential to the solution of the invention.

[0012] (1) Overview of the technology included in this invention: First, an overview of the technology included in the present invention will be described with reference to the examples shown in Figures 1 to 8. Note that the figures in this application are diagrams showing schematic examples, and the magnifications in the directions shown in these figures may differ, and the figures may not be consistent. Of course, each element of the present technology is not limited to the specific example indicated by the symbol. In addition, in the present application, a numerical range "Min to Max" means a value equal to or greater than the minimum value Min and equal to or less than the maximum value Max.

[0013] [Aspect 1] As illustrated in FIG. 1 and other figures, a molded vehicle silencer 1 according to one aspect of the present technology includes a sound-insulating material layer 10 and a sound-absorbing material layer 20. The sound-insulating material layer 10 has a first surface 11 and a second surface 12 opposite the first surface 11, and is molded from an elastic material 70. The sound-absorbing material layer 20 is formed from a material 80 having a void V1 and is bonded to the second surface 12. As illustrated in FIGS. 2 to 7, the sound-insulating material layer 10 includes a functional portion 30 including a protruding portion 40 and a shape-changing portion 50, and a general portion 60 surrounding the functional portion 30. The protruding portion 40 protrudes from the first surface 11 toward the opposite side to the sound-absorbing material layer 20. The shape-changing portion 50 is located on the second surface 12 at a position corresponding to the protruding portion 40. The shape-changing portion 50 has at least one of a convex shape and a concave shape. The thickness of at least a part of the functional portion 30 (for example, thicknesses T2 and T3 shown in FIGS. 3 and 7) is different from the thickness T1 of the general portion 60.

[0014] Because the thickness (T2, T3) of at least a portion of the functional portion 30, which includes the protruding portion 40 on the first surface 11 and the shape-changing portion 50 on the second surface 12, is different from the thickness T1 of the general portion 60, the functional portion 30 of the above-mentioned aspect 1 can perform functions that cannot be performed with the thickness T1 of the general portion 60. Therefore, the above-mentioned aspect 1 can provide a vehicle silencer that can enhance the functions it performs.

[0015] Here, the locations where the vehicle silencer of the present technology can be installed include the dashboard, the side walls of the vehicle compartment, the ceiling of the vehicle compartment, the floor of the vehicle compartment, and the like. Materials that exhibit elasticity include resin materials containing soft resins, elastomer materials containing elastomers such as thermoplastic elastomers and rubber, and the like. Materials having voids include foamed resins such as polyurethane foam (foamed polyurethane resin), fiber aggregates such as felt, and the like. In this application, the terms "first," "second," etc. are terms for distinguishing between elements among a plurality of elements having similarities, and do not indicate an order. Which elements among a plurality of elements fall under the "first," "second," etc. categories is determined relatively. The presence of the shape-changing portion 50 at a position corresponding to the protrusion 40 on the second surface 12 means that when the protrusion 40 and the shape-changing portion 50 are projected onto the second surface 12, at least a portion of the projection surface of the shape-changing portion 50 overlaps with at least a portion of the projection surface of the protrusion 40. The above remarks also apply to the following aspects.

[0016] [Aspect 2] 2 to 6, the functional portion 30 may be a portion of the sound-insulating material layer 10 that holds another member M1. The protruding portion 40 may have a base end 41b closest to the sound-absorbing material layer 20, and may include a base portion 41 that protrudes from the base end 41b in a first protruding direction PD1 opposite to the sound-absorbing material layer 20. The protruding portion 40 may include a bent portion 42 that protrudes from a protruding end 41a of the base portion 41 in a second protruding direction PD2 different from the first protruding direction PD1. The functional portion 30 may include a facing portion 45 that faces the protruding portion 40, and may have a shape in which the facing portion 45 and the protruding portion 40 surround the other member M1. The protruding portion 40 including the base portion 41 and the bent portion 42 and the opposing portion 45 surround the other member M1, such as a wiring harness, thereby holding the other member M1 in the functional portion 30. Therefore, the above-mentioned aspect 2 can provide a silencer for a vehicle that can enhance the function of holding the other member.

[0017] [Aspect 3] 2 and 3, the functional portion 30 may include a claw portion 46 that protrudes from the opposing portion 45 toward the bent portion 42 at a position away from the base portion 41, and may have a shape in which the claw portion 46, the opposing portion 45, and the protruding portion 40 surround the other member M1. The shape-changing portion 50 may include a protruding strip 51 that connects on the second surface 12 from a position corresponding to the base portion 41 to a position corresponding to the claw portion 46. Since the claw portions 46 hold the other member M1 in addition to the opposing portion 45 and the protruding portion 40, the vehicle silencer of the above-mentioned aspect 3 can further enhance its function of holding the other member. Also, since the convex strips 51 on the second surface 12 are connected from a position corresponding to the base portion 41 to a position corresponding to the claw portions 46, the vehicle silencer of the above-mentioned aspect 3 can further enhance its function of holding the other member.

[0018] [Aspect 4] 5 and 6, the bent portion 42 may include a hook portion 44 having a tip 42a that is farthest from the protruding end 41a of the base portion 41. The shape-changing portion 50 may include a recessed portion 52 that is recessed in the second surface 12. The recessed portion 52 may have a through hole 53 that allows the hook portion 44 of the bent portion 42 to pass through in a state in which the opposing portion 45 and the protruding portion 40 surround the other member M1. The hook portion 44 may have a shape 44a that hooks onto the recessed portion 52 around the through hole 53. As a result, with the opposing portion 45 and the protruding portion 40 surrounding the other member M1, the worker can pass the hook portion 44 through the through hole 53 and hook it onto the recessed portion 52. Therefore, the vehicle silencer of the fourth aspect can further enhance the function of holding the other member.

[0019] [Aspect 5] 7, the functional portion 30 may be a portion of the sound-insulating material layer 10 that is held by another member M1. The shape-changing portion 50 may include a recessed portion 52 that is recessed in the second surface 12. The functional portion 30 may have a thin-walled portion 38 that is thinner than the general portion 60, between the protruding portion 40 on the first surface 11 and the recessed portion 52 on the second surface 12. The functional part 30 is held by the other member M1 by breaking through the thin-walled part 38 with the other member M1, such as a stud bolt, so that a separate member such as a clip is not required. Therefore, the above-mentioned aspect 5 can provide a vehicle silencer that can improve the function of being held by the other member.

[0020] [Aspect 6] As illustrated in FIG. 8, a method for manufacturing a vehicle silencer 1 according to one embodiment of the present technology is a method for manufacturing a vehicle silencer 1 including a sound-insulating material layer 10 having a first surface 11 and a second surface 12 opposite the first surface 11, and a sound-absorbing material layer 20 formed of a material 80 having a void V1, and includes the following steps (A1) and (A2). (A1) An injection molding process ST1 in which the sound-insulating material layer 10 comprises a functional portion 30 including a protruding portion 40 protruding from the first surface 11 toward the opposite side of the sound-absorbing material layer 20 and a shape-changing portion 50 located at a position corresponding to the protruding portion 40 on the second surface 12, and a general portion 60 surrounding the functional portion 30, the shape-changing portion 50 having at least one of a convex and a concave shape, and the sound-insulating material layer 10 is formed by injection molding from an elastic material 70 so that the thickness (T2, T3) of at least a portion of the functional portion 30 is different from the thickness T1 of the general portion 60. (A2) A sound-absorbing material layer forming step ST2 in which the sound-absorbing material layer 20 bonded to the second surface 12 is formed.

[0021] By the above manufacturing method, the sound-insulating material layer 10 is formed by injection molding so that the thickness of at least a portion of the functional portion 30, which includes the protruding portion 40 on the first surface 11 and the shape-changing portion 50 on the second surface 12, is different from the thickness T1 of the general portion 60. The formed functional portion 30 can perform functions that cannot be performed with the thickness T1 of the general portion 60. Therefore, the above-mentioned aspect 6 can provide a manufacturing method for a vehicle silencer that can enhance the functions that are performed. Here, the sound-absorbing material layer may be formed by attaching a sound-absorbing material to the second surface of the sound-insulating material layer, or by foaming and molding a liquid material (including a molten material) on the second surface of the sound-insulating material layer.

[0022] In the following description, "orthogonal" is not limited to a strict 90° angle, but includes deviations from the strict 90° angle due to error. Identical directions, positions, etc. are not limited to exact coincidence, but include deviations from exact coincidence due to error. Furthermore, the descriptions of the positional relationships of each part are merely examples. Therefore, the present technology also includes changing the left-right direction to the up-down direction or the front-back direction, changing the up-down direction to the left-right direction or the front-back direction, changing the front-back direction to the left-right direction or the up-down direction, changing the rotation direction to the opposite direction, etc.

[0023] (2) Examples of vehicle silencers: FIG. 1 is a schematic diagram illustrating a main part of an automobile 100 equipped with a vehicle silencer 1. As shown in FIG. The body of the automobile 100 is formed by body panels made of metal, such as steel plates, that surround the passenger compartment. The automobile 100 shown in FIG. 1 includes a panel 110 that separates an engine compartment side S1 from a passenger compartment side S2 as part of the body panels. The panel 110 shown in FIG. 1 is also called a dash panel, and holds a silencer 1 via bolts 120 (an example of other members M1), such as stud bolts. The silencer 1 shown in FIG. 1 is also called a dash silencer, and is arranged on the passenger compartment side S2 of the panel 110.

[0024] 1 includes a sound-insulating material layer 10 formed from an elastic material 70, and a sound-absorbing material layer 20 formed from a material 80 having a gap V1, and is attached to a panel 110 with bolts 120 in a state in which the sound-absorbing material layer 20 is in contact with the panel 110. Therefore, when the silencer 1 is attached to the panel 110, the sound-insulating material layer 10 faces the vehicle interior side S2, and the sound-absorbing material layer 20 is present between the panel 110 and the sound-insulating material layer 10 in the thickness direction TD1 of the silencer 1.

[0025] The sound-insulating material layer 10 has a first surface 11 facing the vehicle interior side S2 and a second surface 12 opposite the first surface 11. The sound-absorbing material layer 20 is bonded to the second surface 12 of the sound-insulating material layer 10. The "material 80 having voids V1" used to form the sound-absorbing material layer 20 can be a foamed resin having numerous fine air bubbles as voids V1 inside the resin 22, a fiber aggregate in which numerous fibers 23 are held together by a binder 24 while leaving fine voids V1, a combination of a foamed resin and a fiber aggregate, or the like. Because air is present in the voids V1, the material 80 having voids V1 can also be considered a material containing air. Note that the sound-absorbing material layer 20 may be formed from a "material 80 having voids V1" obtained from a liquid resin without voids V1, as long as it has fine voids V1 in the manufactured silencer 1.

[0026] The foamed resin can be obtained by foaming a resin material containing resin 22 and molding it to include fine bubbles (voids V1). The resin material may be resin 22 itself. The resin 22 may be a synthetic resin such as a thermoplastic resin or a thermosetting resin, and examples of resin that can be used include polyurethane resin, polyolefin resin such as polypropylene (PP) resin or polyethylene (PE) resin, and acrylonitrile butadiene styrene copolymer (ABS) resin. The resin material containing resin 22 may contain additives such as elastomer, fiber material, filler, colorant, etc. A specific example of foamed resin is polyurethane foam (foamed polyurethane resin).

[0027] The fiber assembly has minute gaps between the fibers 23 as voids V1 inside. For example, the fiber assembly can be obtained by press-molding a material containing a large number of fibers 23 and a binder 24 so that minute voids V1 remain. The binder 24 may be a fibrous binder fiber or may be contained in fibers having a conjugate structure such as a core-sheath structure or a side-by-side structure. The fibers 23 may be resin fibers such as thermoplastic resin fibers, cellulosic fibers such as plant fibers, natural fibers such as animal fibers, inorganic fibers such as glass fibers, or recycled fibers such as recycled clothing fibers. The resin fibers may be synthetic resin fibers such as polyester resins such as polyethylene terephthalate (PET) resin, polyolefin resins such as PP resin and PE resin, polyamide (PA) resin, and acrylic (PMMA) resin. The resin fibers may contain additives such as colorants. The binder 24 may be a thermoplastic binder, a thermosetting binder, or the like. The thermoplastic binder may be a polyolefin resin such as PP resin or PE resin, or a polyester resin such as a low-melting-point PET resin. The binder 24 may contain additives such as elastomers and colorants. The content of the binder 24 in the fiber assembly may be, for example, 1 to 40% by weight. A specific example of the fiber assembly is felt.

[0028] Noise that enters the sound-absorbing material layer 20 from the engine room side S1 through the panel 110 is attenuated by the minute gaps V1. In this way, the sound-absorbing material layer 20 exhibits a sound-absorbing effect. Noise that passes through the sound-absorbing material layer 20 is reflected by the sound-insulating material layer 10, so noise traveling from the engine room side S1 toward the passenger compartment side S2 is absorbed by the sound-absorbing material layer 20 and blocked by the sound-insulating material layer 10.

[0029] FIG. 2 is a cross-sectional view schematically illustrating a vehicle silencer 1 in which a sound-insulating material layer 10 includes a functional portion 31 including a protrusion 40, a ridge 51, and a recess 52. The upper part of FIG. 2 shows the functional portion 31 as viewed toward the first surface 11. The lower part of FIG. 2 shows a shape-changing portion 50 as viewed toward the second surface 12. FIG. 3 is a cross-sectional view schematically illustrating a sound-insulating material layer 10 including the functional portion 31, and corresponds to the sound-insulating material layer 10 shown in FIG. 2. FIG. 4 is a cross-sectional view schematically illustrating a vehicle silencer 1 in which a sound-insulating material layer 10 includes a functional portion 32 including a pair of protrusions 40 and a ridge 51. The upper part of FIG. 4 shows the functional portion 32 as viewed toward the first surface 11. The lower part of FIG. 4 shows the shape-changing portion 50 as viewed toward the second surface 12. FIG. 5 is a cross-sectional view schematically illustrating a vehicle silencer 1 in which a sound-insulating material layer 10 includes a functional portion 33 including a protrusion 40 and a recess 52. The upper part of FIG. 5 shows the functional portion 33 as viewed toward the first surface 11. The lower part of FIG. 5 shows the shape-changing portion 50 as viewed toward the second surface 12. FIG. 6 is a cross-sectional view schematically illustrating a sound-insulating material layer 10 including the functional portion 33, and corresponds to the sound-insulating material layer 10 shown in FIG. 5. In FIGS. 5 and 6, the position of the protrusion 40 when the hook portion 44 is hooked onto the recess 52 is indicated by a two-dot chain line. FIG. 7 is a cross-sectional view schematically illustrating a vehicle silencer 1 in which a sound-insulating material layer 10 includes a functional portion 34 having a thin-walled portion 38 between the protrusion 40 and the recess 52. The upper part of FIG. 7 shows the functional portion 34 as viewed toward the first surface 11. The lower part of FIG. 7 shows the shape-changing portion 50 as viewed toward the second surface 12. For ease of understanding, the orientation of the silencer 1 shown in FIGS. 2 to 7 is 90° different from the orientation of the silencer 1 shown in FIG. The functional portion 30 collectively refers to the functional portions 31, 32, 33, and 34. Although the functional portions 31 and 34 are shown in Fig. 1, the sound-insulating material layer 10 shown in Fig. 1 may include at least one of the functional portions 32 and 33.

[0030] The sound insulation material layer 10 includes a functional portion 30 and a general portion 60 surrounding the functional portion 30 . As shown in FIGS. 2, 4, 5, and 7, the functional portion 30 includes a protruding portion 40 that protrudes from the first surface 11 toward the side opposite the sound-absorbing material layer 20, and a shape-changing portion 50 that is located on the second surface 12 at a position corresponding to the protruding portion 40. The shape-changing portion 50 may be convex like the ridge 51 shown in FIGS. 2 and 4, concave like the concave portion 52 shown in FIGS. 5 and 7, or may have a shape that includes both a convex and a concave shape. The functional portion 30 may be a portion that holds another member M1 (e.g., a wire harness 130) like the functional portions 31, 32, and 33 shown in FIGS. 2, 4, and 5, or a portion that is held by another member M1 (e.g., a bolt 120) like the functional portion 34 shown in FIG. 7. The silencer 1 of this example is characterized in that the thickness of at least a portion of the functional portion 30 is different from the thickness T1 of the general portion 60 (see FIGS. 3, 6, and 7).

[0031] The "elastic material 70" used to form the sound-insulating material layer 10 including the functional portion 30 and the general portion 60 is preferably a flexible yet strong material, such as a resin with a low Young's modulus. Examples of the elastic material 70 that can be used include a resin material containing a soft resin, an elastomer material containing an elastomer such as a thermoplastic elastomer or rubber, and a combination of a resin material and an elastomer material. The sound-insulating material layer 10 including the protruding portion 40 and the shape-changing portion 50 in the functional portion 30 can be formed by injection molding, in which a liquid material that becomes the elastic material 70 is injected into a mold. In other words, the sound-insulating material layer 10 only needs to exhibit elasticity in the manufactured silencer 1, and may be formed from the "elastic material 70" obtained from a liquid material.

[0032] The resin material containing a soft resin may be the soft resin itself. The soft resin may be a synthetic resin such as a thermoplastic resin or a thermosetting resin, and may be a polyolefin resin such as a PP resin or a PE resin. The resin material may contain additives such as a filler, a colorant, an elastomer, a fiber material, etc. The elastomer material may be the elastomer itself. The elastomer material may contain additives such as a filler, a colorant, a resin, a fiber material, etc.

[0033] When a test piece having a thickness of 4 mm, a width of the narrowest part of 10 mm, and a gripping distance of 120 mm is prepared from the "elastic material 70," the tensile modulus (Young's modulus) of the "elastic material 70" is preferably 1 to 500 MPa, more preferably 20 to 200 MPa, in order to provide good functionality to the functional part 30. Here, the tensile modulus (unit: MPa) is defined as the slope of the stress / strain curve corresponding to the two strain points of ε1 = 0.05% and ε2 = 0.25% in the stress / strain curve obtained when the test piece is pulled at a test speed of 50 mm / min in accordance with JIS (Japanese Industrial Standards) K7161-1:2014 "Plastics - Determination of tensile properties - Part 1: General rules."

[0034] The functional portion 31 shown in Figures 2 and 3 includes a protruding portion 40 including a base portion 41 and a bent portion 42, a claw portion 46 protruding toward the bent portion 42 on the first surface 11, and a shape-changing portion 50 including a convex portion 51 and a concave portion 52.

[0035] The base 41 has a protruding portion 40 that protrudes from the first surface 11 toward the opposite side from the sound-absorbing material layer 20, and has a base end 41b closest to the sound-absorbing material layer 20. The protruding portion 40 protrudes from the base end 41b in a first protruding direction PD1 opposite the sound-absorbing material layer 20. The first protruding direction PD1 shown in FIG. 2 is a direction generally along the thickness direction TD1 of the silencer 1. The bent portion 42 protrudes from the protruding end 41a of the base 41 in a second protruding direction PD2 that is different from the first protruding direction PD1. The second protruding direction PD2 shown in FIG. 2 is a direction generally along the portion of the general portion 60 of the first surface 11. In other words, the second protruding direction PD2 is generally perpendicular to the first protruding direction PD1. The bent portion 42 includes a claw portion 43 that protrudes toward the sound-absorbing material layer 20 from a portion including a tip 42a that is farthest from the protruding end 41a of the base 41. The functional portion 31 includes a facing portion 45 facing the bent portion 42 on the first surface 11. The wire harness 130 can be placed in a space SP1 surrounded by the facing portion 45, the base portion 41, and the bent portion 42 including the claw portion 43. Therefore, the functional portion 31 has a shape that surrounds the wire harness 130 with the facing portion 45 and the protruding portion 40, and holds the wire harness 130 between the facing portion 45 and the bent portion 42. It can also be said that the functional portion 31 holds the wire harness 130 between the base portion 41 and the claw portion 43. As shown in FIG. 3 , the claw portion 43 has a guide surface 43a facing outward from the space SP1 and a holding surface 43b facing the space SP1. The guide surface 43a is inclined to facilitate entry of the wire harness 130 into the space SP1 and is not aligned along the thickness direction TD1. The holding surface 43b is along the thickness direction TD1 so that the wire harness 130 is unlikely to come out of the space SP1.

[0036] As shown in the upper part of FIG. 2, the protruding portion 40 includes three protruding pieces 40a and connecting portions 40b connecting adjacent protruding pieces 40a. The two connecting portions 40b correspond to the hatched portions showing the cross section in FIG. 2. Each of the protruding pieces 40a and the connecting portions 40b includes a base portion 41 and a bent portion 42 having a claw portion 43. Each of the protruding pieces 40a extends from the connecting portions 40b to the side opposite the space SP1. Therefore, the protruding pieces 40a function to improve the strength of the protruding portion 40, including the base portion 41 and the bent portion 42.

[0037] The claw portions 46 protrude from the facing portion 45 toward the claw portions 43 of the bent portion 42 at positions away from the base portion 41. The protruding direction of the claw portions 46 is generally a first protruding direction PD1. The functional portion 31 has a shape in which the facing portion 45, the protruding portion 40, and the claw portions 46 surround the wire harness 130 and hold the wire harness 130 between the base portion 41 and the claw portions 46. As shown by dashed lines in the upper part of FIG. 2, the claw portions 46 are located at positions corresponding to the claw portions 43 of the bent portion 42 so as to straddle the three protruding pieces 40a and the two connecting portions 40b. As shown in FIG. 3, the claw portions 46 have a guide surface 46a facing outward from the space SP1 and a holding surface 46b facing the space SP1. The guide surface 46a is inclined to facilitate insertion of the wire harness 130 into the space SP1 and is not aligned along the thickness direction TD1. The holding surface 46b is along the thickness direction TD1 so that the wire harness 130 is unlikely to come out of the space SP1.

[0038] The shape-changing portion 50 includes a convex rib 51 that connects from a position on the second surface 12 corresponding to the base 41 to a position on the second surface 12 corresponding to the claw portion 46, and a concave portion 52 that is located on the second surface 12 at a position corresponding to the claw portion 46. Here, the convex rib 51 refers to a longitudinal portion that protrudes toward the sound-absorbing material layer 20 on the second surface 12. The fact that the convex rib 51 connects from a position on the second surface 12 corresponding to the base 41 to a position on the second surface 12 corresponding to the claw portion 46 means that when the base 41, the claw portion 46, and the convex rib 51 are projected onto the second surface 12, part of the projected surface of the convex rib 51 overlaps with at least part of the projected surface of the base 41 and at least part of the projected surface of the claw portion 46. The concave portion 52 refers to a recessed portion on the second surface 12. The fact that the recessed portion 52 is located at a position corresponding to the claw portion 46 on the second surface 12 means that when the claw portion 46 and the recessed portion 52 are projected onto the second surface 12, at least a portion of the projection surface of the recessed portion 52 overlaps with at least a portion of the projection surface of the claw portion 46. 2, the shape-changing portion 50 includes three ridges 51 and two recesses 52. Each ridge 51 is located at a position corresponding to a protruding piece 40a. The two recesses 52 are located at positions corresponding to one of the claws 46.

[0039] As shown in FIG. 3 , the length L1 between the facing portion 45 and the bent portion 42 is equal to or greater than the diameter R1 of the wire harness 130. The length L2 between the base portion 41 and the claw portion (claw portion 43 or claw portion 46) is also equal to or greater than the diameter R1 of the wire harness 130. Therefore, the wire harness 130 can be accommodated in the space SP1 surrounded by the facing portion 45, the protruding portion 40, and the claw portion 46. Furthermore, the length L3 between the claw portion 43 and the claw portion 46 is less than the diameter R1 of the wire harness 130. Here, the functional portion 31, particularly the protruding portion 40, has elasticity. Therefore, when an operator pushes the wire harness 130 toward the space SP1 along the guiding surfaces 43a and 46a, the protruding portion 40 elastically deforms to widen the gap between the claw portion 43 and the claw portion 46, allowing the wire harness 130 to be inserted into the space SP1 from the vehicle interior side S2. The direction in which the wire harness 130 is pushed is generally perpendicular to the thickness direction TD1.

[0040] 3, the maximum thickness T2 of the functional portion 31 including the bent portion 42 and the ridge 51 is thicker than the thickness T1 of the general portion 60. Therefore, the silencer 1 including the functional portion 31 can effectively hold another member M1 such as the wire harness 130. In addition, the protrusion 40 is reinforced by the ridge 51, further enhancing the function of holding the other member M1. Since the ridge 51 connects from a position corresponding to the base 41 to a position corresponding to the claw 46, the portion of the first surface 11 surrounding the other member M1 (the protrusion 40, the opposing portion 45, and the claw 46) is reinforced by the ridge 51, further enhancing the function of holding the other member M1. The worker can remove the wire harness 130 from the functional part 31 by elastically deforming the protruding part 40 to widen the gap between the claw part 43 and the claw part 46 .

[0041] The functional portion 32 shown in FIG. 4 includes a pair of protrusions 40, an opposing portion 45, and a shape-changing portion 50 having a ridge 51. Each protrusion 40 includes a base 41 that protrudes from a base end 41b closest to the sound-absorbing material layer 20 in a first protruding direction PD1 on the side opposite the sound-absorbing material layer 20, and a bent portion 42 that protrudes from a protruding end 41a of the base 41 in a second protruding direction PD2. The second protruding directions PD2 of the two bent portions 42 are directions toward each other's bent portion 42. In FIG. 4, the second protruding direction PD2 of the left bent portion 42 is a direction toward the right bent portion 42, and the second protruding direction PD2 of the right bent portion 42 is a direction toward the left bent portion 42. The functional portion 32 includes an opposing portion 45 that faces the pair of bent portions 42 on the first surface 11. A wire harness 130 can be arranged in a space SP1 surrounded by the opposing portion 45, the pair of bases 41, and the pair of bent portions 42. Therefore, the functional portion 32 has a shape that surrounds the wire harness 130 with the opposing portion 45 and the pair of protrusions 40, and holds the wire harness 130 between the base portions 41. It can also be said that the functional portion 32 holds the wire harness 130 between the opposing portion 45 and the pair of bent portions 42. Each bent portion 42 has a guide surface 42c facing outward from the space SP1 and a holding surface 42d facing the space SP1. The guide surface 42c is inclined from a plane perpendicular to the thickness direction TD1 so that the wire harness 130 can easily enter the space SP1. The holding surface 42d is perpendicular to the thickness direction TD1 so that the wire harness 130 cannot easily come out of the space SP1.

[0042] As shown in the upper part of FIG. 4, each protrusion 40 includes three protrusion pieces 40a and a connecting portion 40b connecting adjacent protrusion pieces 40a. The two connecting portions 40b correspond to the hatched portions showing the cross section in FIG. 4. Each of the protrusion pieces 40a and the connecting portion 40b includes a base portion 41 and a bent portion 42. Each of the protrusion pieces 40a extends from the connecting portion 40b to the side opposite the space SP1. Therefore, the protrusion pieces 40a function to improve the strength of the protrusion 40, including the base portion 41 and the bent portion 42. The shape-changing portion 50 has a ridge 51 that connects from a position corresponding to one base portion 41 on the second surface 12 to a position corresponding to the other base portion 41. As shown in the lower part of Fig. 4, the shape-changing portion 50 includes three ridges 51. Each ridge 51 is located at a position corresponding to a protruding piece 40a.

[0043] Because each protrusion 40 is elastic, when an operator pushes the wire harness 130 toward the space SP1 along the guide surfaces 42c of each bent portion 42, the protrusions 40 are elastically deformed so that the spaces between the bent portions 42 widen, allowing the wire harness 130 to be inserted from the passenger compartment side S2 into the space SP1. The direction in which the wire harness 130 is pushed is generally the thickness direction TD1, which is the direction from the passenger compartment side S2 toward the engine compartment side S1. On the other hand, in the functional portion 31 shown in FIG. 2, the direction in which the wire harness 130 is pushed is generally perpendicular to the thickness direction TD1. Therefore, the silencer 1 having the functional portion 32 shown in FIG. 4 makes it easier to push the wire harness 130 into the functional portion 30 than the silencer 1 having the functional portion 31 shown in FIG. 2. 4, the maximum thickness of the functional portion 31 including the bent portion 42 and the ridges 51 is also greater than the thickness T1 of the general portion 60. Therefore, the silencer 1 including the functional portion 32 can satisfactorily perform the function of holding another member M1 such as the wire harness 130. Furthermore, since the ridges 51 reinforce the protrusions 40, the function of holding the other member M1 such as the wire harness 130 is further enhanced. Since the ridges 51 connect from a position corresponding to one base portion 41 to a position corresponding to the other base portion 41, the portion of the first surface 11 that surrounds the other member M1 (the pair of protrusions 40 and the opposing portion 45) is reinforced by the ridges 51, and the function of holding the other member M1 is further enhanced.

[0044] On the other hand, in the functional part 31 shown in Fig. 2, the claw part 46 is less likely to elastically deform than the protruding part 40 including the base part 41 and the bent part 42, and therefore the wire harness 130 is less likely to come out of the space SP1 than in the functional part 32 shown in Fig. 4. The silencer 1 including the functional part 31 shown in Fig. 2 has a higher function of holding the other member M1 than the silencer 1 including the functional part 32 shown in Fig. 4.

[0045] The functional portion 33 shown in Figures 5 and 6 includes a protruding portion 40 including a base portion 41 and a bent portion 42, a guide portion 47 protruding in a first protruding direction PD1 on the first surface 11 opposite the sound-absorbing material layer 20, and a shape-changing portion 50 having a concave portion 52. The protruding portion 40 includes a base portion 41 that protrudes in a first protruding direction PD1 from a base end 41b closest to the sound-absorbing material layer 20, and a bent portion 42 that protrudes in a second protruding direction PD2 from a protruding end 41a of the base portion 41. The second protruding direction PD2 shown in FIG. 5 is not the thickness direction TD1, but is a direction that approaches the sound-absorbing material layer 20 from a direction along the general portion 60 of the first surface 11. The bent portion 42 includes a hook portion 44 having a tip 42a that is farthest from the protruding end 41a of the base portion 41. The functional portion 33 includes a facing portion 45 that faces the bent portion of the protruding portion 40 on the first surface 11. A wire harness 130 can be placed in a space SP1 surrounded by the facing portion 45, the base portion 41, and the bent portion 42 including the hook portion 44. Therefore, the functional portion 33 has a shape that surrounds the wire harness 130 with the facing portion 45 and the protruding portion 40.

[0046] The hook portion 44 has a shape 44a that protrudes toward the opposite side of the space SP1 in the bent portion 42. An operator can pass the hook portion 44 through a through hole 53 of the recessed portion 52, which will be described later. The hook portion 44 has a shape 44a that hooks onto the recessed portion 52 around the through hole 53. The guide portion 47 has an inclination that approaches the sound-absorbing material layer 20 from the protruding end 47a, which is farthest from the sound-absorbing material layer 20, toward the through-hole 53. Therefore, the worker can insert the hook portion 44 into the through-hole 53 along the guide portion 47.

[0047] 5, the protrusion 40 includes reinforcing pieces 40c at three locations, and the guide portion 47 includes guide pieces 47c at three locations. The shape-changing portion 50 includes a recessed portion 52 having a through hole 53, and another recessed portion 52 located on the second surface 12 at a position corresponding to the base portion 41. Both recessed portions 52 are recessed portions on the second surface 12. The recessed portion 52 having the through hole 53 is located on the second surface 12 at a position corresponding to the guide portion 47. The through hole 53 allows the hook portion 44 of the bent portion 42 to pass through when the opposing portion 45 and the protruding portion 40 surround the wire harness 130. The worker can pass the hook portion 44 through the through hole 53 and hook it into the recessed portion 52 when the opposing portion 45 and the protruding portion 40 surround the wire harness 130.

[0048] As shown by the two-dot chain line in FIG. 6 , when the hook portion 44 is hooked into the recessed portion 52, the length L4 between the facing portion 45 and the protruding portion 40 is equal to or greater than the diameter R1 of the wire harness 130, and the length L5 between the base portion 41 and the bent portion 42 is also equal to or greater than the diameter R1 of the wire harness 130. Therefore, the wire harness 130 can be accommodated in the space SP1 surrounded by the facing portion 45 and the protruding portion 40. Because the protruding portion 40 is elastic, the length L6 between the hook portion 44 and the through-hole 53 may be either less than the diameter R1 of the wire harness 130 or greater than the diameter R1 of the wire harness 130. When L6 is less than R1, the worker pushes the wire harness 130 along the guiding portion 47 toward the space SP1, whereby the protruding portion 40 elastically deforms to widen the gap between the hook portion 44 and the through-hole 53, allowing the wire harness 130 to be inserted into the space SP1 from the vehicle interior side S2. Thereafter, when the worker passes the hook portion 44 through the through hole 53 and hooks it on the recessed portion 52, the wire harness 130 is held by the functional portion 33 in a state where it is surrounded by the opposing portion 45 and the protruding portion 40.

[0049] 6, the maximum thickness T2 of the functional portion 33 including the protruding portion 40 is thicker than the thickness T1 of the general portion 60. Therefore, the silencer 1 including the functional portion 33 can effectively perform the function of holding another member M1 such as the wire harness 130. In addition, the hook portion 44 inserted into the through hole 53 with the opposing portion 45 and the protruding portion 40 surrounding the other member M1 is caught by the recessed portion 52, further enhancing the function of holding the other member M1. The worker can remove the wire harness 130 from the functional part 33 by pulling out the hook part 44 from the through hole 53 .

[0050] The functional portion 34 shown in FIG. 7 includes a protruding portion 40 that protrudes from the first surface 11 toward the opposite side from the sound-absorbing material layer 20, and a recessed portion 52 that exists at a position corresponding to the protruding portion 40, and is held by a bolt 120. The shape-changing portion 50 has a recessed portion 52 that is recessed in the second surface 12. The functional portion 34 has a thin-walled portion 38 that is thinner than the general portion 60, between the protruding portion 40 on the first surface 11 and the recessed portion 52 on the second surface 12. The thin-walled portion 38 is a portion of the sound-insulating material layer 10 that is thin enough to be broken through by the bolt 120, and is set at a location where it is desired to hold the silencer 1. The thin-walled portion 38 exists at the portion of the first surface 11 and the second surface 12 that is farthest from the sound-absorbing material layer 20. The protruding portion 40 has an inclined surface 40d that slopes away from the sound-absorbing material layer 20 from the general portion 60 toward the thin-walled portion 38. The recessed portion 52 has a guide surface 52a on the second surface 12 that is aligned with the inclined surface 40d and extends from the general portion 60 toward the thin-walled portion 38, away from the sound-absorbing material layer 20. The guide surface 52a has the function of guiding the bolt 120 to the thin-walled portion 38. The sound absorbing material layer 20 has openings 21 aligned with the positions of the functional portions 34 for passing bolts 120 in the thickness direction TD1.

[0051] The minimum thickness T3 of the functional portion 34, including the protruding portion 40, is thinner than the thickness T1 of the general portion 60. Therefore, an operator can easily break through the thin-walled portion 38 with the bolt 120. Furthermore, the thread groove of the bolt 120 catches on the torn thin-walled portion 38, making it difficult for the bolt 120 to come out of the thin-walled portion 38. This allows the operator to hold the functional portion 34 to the bolt 120 without using a separate part such as a clip. Therefore, the silencer 1 including the functional portion 34 can effectively function as a member to be held by another member M1, such as the bolt 120. Furthermore, because the thin-walled portion 38 is elastic, the torn thin-walled portion 38 adheres tightly to the outer periphery of the bolt 120, preventing gaps from forming around the bolt 120. This allows the torn thin-walled portion 38 to block noise around the bolt 120 traveling from the engine compartment side S1 toward the passenger compartment side S2, thereby enabling the silencer 1 to achieve excellent sound insulation performance. In addition, when the worker passes the bolt 120 through the functional portion 34, the bolt 120 is guided into the thin-walled portion 38 along the guide surface 52a, so the worker can easily pass the bolt 120 through the thin-walled portion 38.

[0052] A slit may be formed in advance in the thin-walled portion 38. This reduces the load required to pass the bolt 120 through the thin-walled portion 38, making it even easier to pass the bolt 120 through the thin-walled portion 38.

[0053] As explained above, the thickness of at least a portion of the functional portion 30, which includes the protruding portion 40 on the first surface 11 and the shape-changing portion 50 on the second surface 12, is different from the thickness T1 of the general portion 60, and therefore the functional portion 30 can perform functions that cannot be performed with the thickness T1 of the general portion 60. Therefore, this example makes it possible to enhance the functions performed by the vehicle silencer 1.

[0054] (3) Specific examples of manufacturing methods for vehicle silencers: Fig. 8 shows a schematic example of a method for manufacturing the vehicle silencer 1. For ease of understanding, Fig. 8 shows the functional part 31 shown in Fig. 2 as functional part 30. When the silencer 1 is a dash silencer, the silencer 1 includes functional part 34 (see Fig. 7) and may also include at least one of functional part 32 (see Fig. 4) and functional part 33 (see Fig. 5). The method for producing the silencer 1 includes the following steps (A1) and (A2). (A1) An injection molding process ST1 in which the sound-insulating material layer 10 is formed by injection molding using an elastic material 70 so that the sound-insulating material layer 10 has a functional portion 30 including a protrusion 40 and a shape-changing portion 50, and a general portion 60 surrounding the functional portion 30, the shape-changing portion 50 having at least one of a convex and a concave shape, and the thickness of at least a portion of the functional portion 30 is different from the thickness T1 of the general portion 60. (A2) Sound-absorbing material layer forming step ST2 in which the sound-absorbing material layer 20 bonded to the second surface 12 is formed.

[0055] The injection molding machine 200 shown in FIG. 8 is used to form the sound-insulating material layer 10 in the injection molding step ST1. The injection molding machine 200 includes an injection molding die 210 including a movable die 212 and a fixed die 214, and an injection device 220. The dies 212, 214 are arranged so that they can move toward and away from each other. The die 212 may be fixed and the die 214 may be movable, or both dies 212, 214 may be movable. In order to remove the sound-insulating material layer 10 from the injection molding die 210 after injection molding, the fixed die 214 may be composed of multiple divisions, and the movable die 212 may also be composed of multiple divisions. The multiple divisions may be composed of, for example, a master block and one or more insert dies. The movable die 212 is a mold having a mold surface that matches the shape of the second surface 12 of the sound-insulating material layer 10. The fixed mold 214 is a mold having a mold surface that matches the shape of the first surface 11 of the sound-insulating material layer 10. The cavity CA1 that is created when both molds 212, 214 are closed and clamped has the shape of the sound-insulating material layer 10 that has the functional portion 30.

[0056] In the injection molding step ST1, the injection device 220 injects a liquid material 75, which will become the elastic material 70, into the cavity CA1 in the injection molding die 210. For example, if the elastic material 70 contains a thermoplastic material such as a thermoplastic elastomer, the liquid material 75 becomes a molten material. In this case, the injection device 220 may be equipped with a heating device that heats the material to a temperature equal to or higher than the melting point of the thermoplastic material. If the elastic material 70 contains a thermoplastic resin, the liquid material 75 becomes a molten resin. After the liquid material 75 in the cavity CA1 has solidified or hardened, the two dies 212, 214 are opened to a single-open position, allowing the sound insulation material layer 10 to be removed from the injection molding die 210. By forming the sound-insulating material layer 10 by injection molding, the functional portion 30 having a complex shape and a thickness different from the thickness T1 of the general portion 60 can be easily formed.

[0057] In the sound-absorbing material layer forming step ST2, the sound-absorbing material layer 20 is bonded to the second surface 12 of the sound-insulating material layer 10. For example, the sound-absorbing material layer 20 is bonded to the second surface 12 of the sound-insulating material layer 10 by attaching a sheet-like sound-absorbing material 85 formed of a material 80 (see FIG. 1 ) having voids V1 to the second surface 12 of the sound-insulating material layer 10. If the sound-absorbing material 85 is a flexible material, even if the second surface 12 of the sound-insulating material layer 10 has convex shape-changing portions 50 such as ridges 51, the sound-absorbing material 85 can deform to fit the shape of the convex shape-changing portions 50, thereby forming the sound-absorbing material layer 20 that is generally in close contact with the second surface 12 of the sound-insulating material layer 10. If the material 80 having voids V1 is a foamed resin, two-color molding may be performed to form the sound-absorbing material layer 20 by foaming a resin material containing a resin 22 (see FIG. 1 ) and injecting the foamed resin material into the second surface 12 of the sound-insulating material layer 10. 2 and 4, when the shape-changing portion 50 includes a plurality of ridges 51, the functional portions 31 and 32 are further reinforced by the resin foam filling between the ridges 51, and the function of holding the other component M1 is further enhanced. As a result, it is possible to reduce the number of ridges 51 formed on the sound-insulating material layer 10.

[0058] The silencer 1 shown in Fig. 2 is manufactured by the manufacturing method shown in Fig. 8. Of course, the silencer 1 having the functional part 32 shown in Fig. 4, the silencer 1 having the functional part 33 shown in Fig. 5, and the silencer 1 having the functional part 34 shown in Fig. 7 are also manufactured in the same manner. By the manufacturing method described above, the sound-insulating material layer 10 is formed by injection molding so that the thickness of at least a portion of the functional portion 30, which includes the protruding portion 40 on the first surface 11 and the shape-changing portion 50 on the second surface 12, is different from the thickness T1 of the general portion 60. The formed functional portion 30 can perform functions that cannot be performed with the thickness T1 of the general portion 60. Therefore, this example makes it possible to manufacture a vehicle silencer 1 that can enhance the functions it performs.

[0059] (4) Variation: The present invention can be modified in various ways. The vehicle silencer to which the present invention can be applied is not limited to a dash silencer, but may also be a door silencer, a silencer for the ceiling of the vehicle compartment, a silencer for the floor of the vehicle compartment, or the like.

[0060] (5) Conclusion: As explained above, the present invention provides a technology for a vehicle silencer and a manufacturing method thereof that can enhance the functions that the silencer exerts through various aspects. Of course, even if the technology consists only of the constituent elements of the independent claims, the basic functions and effects described above can be obtained. Furthermore, it is possible to implement configurations in which the components disclosed in the above examples are substituted with each other or the combination is changed, or configurations in which the components disclosed in the publicly known techniques and the above examples are substituted with each other or the combination is changed, etc. The present invention also includes these configurations. [Explanation of symbols]

[0061] 1... silencer, 10...sound insulation material layer, 11...first surface, 12...second surface, 20...sound absorbing material layer, 21...opening, 22...resin, 23...fiber, 24...binder, 30, 31, 32, 33, 34...functional parts, 38...thin-walled section, 40...protrusion, 40a...protrusion piece, 40b...connection portion, 40c...reinforcing piece, 40d...inclined surface, 41...Base, 41a...Protruding end, 41b...Base end, 42...Bending part, 42a...Tip, 42c...Guiding surface, 42d...Holding surface, 43...claw part, 43a...guiding surface, 43b...holding surface, 44...hook portion, 44a...shape, 45...opposing part, 46...claw part, 46a...guiding surface, 46b...holding surface, 47...Guiding part, 47a...Protruding end, 47c...Guiding piece, 50...shape change part, 51...Convex strip, 52...Concave portion, 52a...Guiding surface, 53...Through hole, 60...General section, 70... Elastic material, 75... Liquid material, 80...material having voids, 85...sound-absorbing material, 100...Automobile, 110...Panel, 120...Volt, 130...Wire harness, 200...injection molding machine, 210...injection mold, 220...injection device, M1...other materials, PD1...first protrusion direction, PD2...second protrusion direction, S1...engine room side, S2...passenger compartment side, ST1...Injection molding process, ST2...Sound absorbing material layer forming process, T1... general part thickness, T2, T3... thickness, TD1: thickness direction, V1...Void.

Claims

1. a sound-insulating layer having a first surface and a second surface opposite to the first surface, the sound-insulating layer being made of an elastic material; a sound absorbing layer formed of a material having voids and bonded to the second surface; The sound insulation material layer is a functional portion including a protruding portion protruding from the first surface toward the opposite side of the sound-absorbing material layer, and a shape-changing portion located at a position corresponding to the protruding portion on the second surface; a general portion surrounding the functional portion, the shape-changing portion has at least one of a convex shape and a concave shape, a thickness of at least a part of the functional portion is different from a thickness of the general portion; the functional portion is a portion of the sound-insulating material layer that holds other members, the protruding portion includes a base portion having a base end closest to the sound-absorbing material layer and protruding from the base end in a first protruding direction opposite to the sound-absorbing material layer, and a bent portion protruding from the protruding end of the base portion in a second protruding direction different from the first protruding direction, the functional portion includes an opposing portion that faces the protruding portion, and has a shape in which the opposing portion and the protruding portion surround the other member, A silencer for a vehicle, wherein the general portion and the functional portion including the protruding portion, the opposing portion, and the shape-changing portion are integrally molded.

2. the functional portion includes a claw portion that protrudes from the opposing portion toward the bent portion at a position away from the base portion, and has a shape that surrounds the other member with the claw portion, the opposing portion, and the protrusion portion; The vehicle silencer according to claim 1 , wherein the shape-changing portion includes a ridge that connects, on the second surface, a position corresponding to the base portion to a position corresponding to the claw portion.

3. the bent portion includes a hook portion having a tip farthest from the protruding end of the base portion, the shape-changing portion includes a recessed portion recessed in the second surface, the recessed portion has a through hole that allows the hook portion of the bent portion to pass through in a state in which the other member is surrounded by the facing portion and the protruding portion, The silencer for a vehicle according to claim 1 , wherein the hook portion has a shape that hooks onto the recessed portion around the through hole.

4. A sound-insulating material layer having a first surface and a second surface opposite to the first surface, the sound-insulating material layer being made of an elastic material; a sound absorbing layer formed of a material having voids and bonded to the second surface; The sound insulation material layer is a functional portion including a protruding portion protruding from the first surface toward the opposite side of the sound-absorbing material layer, and a shape-changing portion located at a position corresponding to the protruding portion on the second surface; a general portion surrounding the functional portion, the shape-changing portion has at least one of a convex shape and a concave shape, a thickness of at least a part of the functional portion is different from a thickness of the general portion; the functional portion is a portion of the sound-insulating material layer that is held by another member, the shape-changing portion includes a recessed portion recessed in the second surface, the functional portion has a thin portion that is thinner than the general portion between the protruding portion on the first surface and the recessed portion on the second surface, A silencer for a vehicle, wherein the general portion and the functional portion having the thin-walled portion and including the protruding portion and the shape-changing portion are integrally molded.

5. A method for manufacturing a silencer for a vehicle, the silencer including a sound-insulating material layer having a first surface and a second surface opposite to the first surface, and a sound-absorbing material layer formed of a material having voids, the method comprising: an injection molding process for forming the sound-insulating material layer by injection molding from an elastic material so that the sound-insulating material layer has a protruding portion protruding from the first surface toward the opposite side to the sound-absorbing material layer, a functional portion including a shape-changing portion present on the second surface at a position corresponding to the protruding portion, and a general portion surrounding the functional portion, the shape-changing portion having at least one of a convex shape and a concave shape, and the thickness of at least a part of the functional portion is different from the thickness of the general portion; a sound-absorbing material layer forming step of forming the sound-absorbing material layer bonded to the second surface; Including, the functional portion is a portion of the sound-insulating material layer that holds other members, the protruding portion includes a base portion having a base end closest to the sound-absorbing material layer and protruding from the base end in a first protruding direction opposite to the sound-absorbing material layer, and a bent portion protruding from the protruding end of the base portion in a second protruding direction different from the first protruding direction, the functional portion includes an opposing portion that faces the protruding portion, and has a shape in which the opposing portion and the protruding portion surround the other member, In the injection molding process, the general portion and the functional portion including the protruding portion, the opposing portion, and the shape-changing portion are integrally formed by injection molding.

6. A method for manufacturing a silencer for a vehicle, the silencer including a sound-insulating material layer having a first surface and a second surface opposite to the first surface, and a sound-absorbing material layer formed of a material having voids, the method comprising: an injection molding process for forming the sound-insulating material layer by injection molding from an elastic material so that the sound-insulating material layer has a protruding portion protruding from the first surface toward the opposite side to the sound-absorbing material layer, a functional portion including a shape-changing portion present on the second surface at a position corresponding to the protruding portion, and a general portion surrounding the functional portion, the shape-changing portion having at least one of a convex shape and a concave shape, and the thickness of at least a part of the functional portion is different from the thickness of the general portion; a sound-absorbing material layer forming step of forming the sound-absorbing material layer bonded to the second surface; Including, the functional portion is a portion of the sound-insulating material layer that is held by another member, the shape-changing portion includes a recessed portion recessed in the second surface, the functional portion has a thin portion that is thinner than the general portion between the protruding portion on the first surface and the recessed portion on the second surface, A method for manufacturing a silencer for a vehicle, wherein the general portion and the functional portion having the thin-walled portion and including the protruding portion and the shape-changing portion are integrally formed by injection molding.

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