soundproofing material

Abstract

To provide a sound insulating material that reduces frictional resistance on a surface of the sound insulating material when inserting the sound insulating material into a void that exists in an engine room or tire house of a vehicle and facilitates insertion work into the void.SOLUTION: There provided is a sound insulating material 10 made of a polyurethane foam molded product having a skin layer 15 that is inserted into a void 50 while in contact with the inner surface 51 of the void 50, the sound insulating material 10 including a friction reducing portion 17 outside of a surface of the skin layer 15 and / or in a part of the surface of the skin layer 15. The friction reducing portion 17 is formed outside of the surface of the skin layer 15 and / or in a part of the surface of the skin layer 15 during the molding of the polyurethane foam and is configured to be provided at least at a portion that contacts with the inner surface 51 of the void 50 when inserted into the void 50.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a sound insulating material and a method for manufacturing the same. [Background technology]

[0002] In vehicles, sound insulation materials are placed in gaps in the sound transmission path, for example, in the engine compartment, wheel wells, etc., to prevent noise from being transmitted inside the vehicle. In recent years, molded polyurethane foam products, which are produced by injecting polyurethane foam raw materials into a mold and foaming them, have been used as sound insulation materials for vehicles.

[0003] Because sound-proofing materials made of molded polyurethane foam are prone to sound leakage if there is a gap between them and the inner surface of the cavity, they are manufactured to a size equal to or larger than the cavity by a specified amount, and are inserted into the cavity while contacting the inner surface of the cavity, so that they adhere tightly to the inner surface of the cavity after insertion. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-195055 Summary of the Invention [Problem to be solved by the invention]

[0005] However, because sound-insulating materials made of molded polyurethane foams are inserted into gaps while in contact with the inner surfaces of the gaps, the frictional resistance is large, making the insertion process time-consuming and requiring a great deal of force. Furthermore, when inserting sound-insulating materials made of molded polyurethane foams into gaps, the large frictional resistance can cause them to get caught on the inner surfaces of the gaps or to break. The present invention has been made in view of the above points, and an object of the present invention is to provide a sound insulating material that reduces surface friction resistance and allows easy insertion into a gap, and a method for manufacturing the same. [Means for solving the problem]

[0006] First Aspect is a sound-insulating material consisting of a molded polyurethane foam product having a skin layer that is inserted into a void while contacting the inner surface of the void, characterized in that it has a friction-reducing portion on the outside of the surface of the skin layer and / or on a part of the surface of the skin layer, the friction-reducing portion being formed on the outside of the surface of the skin layer and / or on a part of the surface of the skin layer during molding of the polyurethane foam, and being provided in a portion that will come into contact with at least the inner surface of the void when inserted into the void.

[0007] The second aspect is the first aspect The friction reducing portion is made of urethane resin and / or acrylic resin.

[0008] The third aspect is the first or second aspect. The friction reducing portion is in the form of a film or scattered dots.

[0009] Fourth Aspect a method for producing a sound-insulating material comprising a molded polyurethane foam product having a skin layer that is inserted into a void while contacting the inner surface of the void, the method comprising: applying a release agent to the inner surface of a mold; applying paint to the release agent on the inner surface of the mold that produces at least the portion of the sound-insulating material that comes into contact with the inner surface of the void when the sound-insulating material is inserted into the void; hardening the paint to produce a friction-reducing portion; and injecting polyurethane foam raw material into the mold and foaming it, thereby producing a sound-insulating material comprising a molded polyurethane foam product having the friction-reducing portion on the outside of the skin layer surface and / or on a portion of the skin layer surface.

[0010] The fifth aspect is the fourth aspect. The coating material is a urethane emulsion and / or an acrylic emulsion.

[0011] The sixth aspect is the fourth or fifth aspect.The coating material is applied in the form of a film or in scattered dots. [Effects of the Invention]

[0012] The sound-insulating material of the present invention has a friction-reducing portion provided on the outer surface of the skin layer of the polyurethane foam and / or on a portion of the skin layer surface, thereby reducing surface frictional resistance and facilitating insertion into a gap. Furthermore, because the friction-reducing portion is formed during molding of the polyurethane foam, it can have a stronger adhesive strength with the skin layer than a friction-reducing portion provided by post-processing, such as by coating the skin layer surface. This prevents the frictional force from decreasing due to peeling of the friction-reducing portion when inserting the sound-insulating material into a gap, which could lead to a deterioration in workability or damage to the sound-insulating material itself.

[0013] The method for producing a sound-insulating material of the present invention involves applying paint onto the release agent on the inner surface of a mold and then molding a polyurethane foam, thereby producing a sound-insulating material consisting of a molded polyurethane foam product having a friction-reducing portion on the outside of the skin layer surface and / or on a portion of the skin layer surface, making the production process simpler and easier than providing a friction-reducing portion by post-processing such as applying paint.

[0014] Furthermore, the friction-reducing portion formed by applying and curing paint onto the release agent on the inner surface of the mold is firmly adhered to the skin layer of the polyurethane foam by the foaming of the polyurethane foam raw material that is then injected into the mold, and therefore has a stronger adhesive strength with the skin layer than a friction-reducing portion provided by a coating or other post-processing method, preventing a deterioration in workability when inserting the manufactured sound insulation material into a gap and preventing damage to the sound insulation material itself. In particular, when the friction-reducing portion is provided on only a portion of the surface of the skin layer, the skin layer is formed so that the polyurethane foam raw material surrounds the friction-reducing portion, and therefore the adhesive strength with the skin layer can be further increased. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a cross-sectional view of one embodiment of a sound barrier and an air gap. [Figure 2] 4A to 4C are cross-sectional views showing various forms of the friction reducing portion. [Figure 3] 3 is a cross-sectional view showing application of a release agent and application of paint in a method for manufacturing a sound-insulating material. FIG. [Figure 4] 1 is a cross-sectional view showing injection and foaming of polyurethane foam raw material in a method for manufacturing a sound-insulating material. FIG. [Figure 5] 1 is a table showing the formulations and physical properties of each example. [Figure 6] 1 is a table showing the formulations and physical properties of each comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0016] An embodiment of a sound-insulating material of the present invention will be described with reference to the drawings. Sound-insulating material 10 shown in FIG. 1 is inserted into gap 50 shown in the same figure while contacting inner surface 51 of gap 50. Gap 50 exists, for example, between vehicle components or between partition walls. Sound-insulating material 10 has an outer shape that is the same as or similar to the shape of inner surface 51 of gap 50 but larger by a predetermined amount, and has protrusions 11 on the side surfaces of sound-insulating material 10 that fit into recesses 53 on inner surface 51 of gap 50. Protrusions 11 of sound-insulating material 10 are interference parts (collision parts) that interfere with the insertion opening of gap 50 when sound-insulating material 10 is inserted into gap 50.

[0017] The sound-insulating material 10 is made of a molded polyurethane foam having a skin layer 15, and is hard enough to be compressively deformed when inserted into the cavity 50 by contacting the inner surface 51 of the cavity 50. The outer surface of the skin layer 15 and / or a portion of the surface of the skin layer has a friction-reducing portion 17.

[0018] Skin layer 15 is a layered surface portion that has a higher density than the interior (core) 16 of the polyurethane foam, and is formed by being pressed by the inner surface of a mold when molding the polyurethane foam. Skin layer 15 has a thickness of about 100 to 1000 μm.

[0019] The friction-reducing portions 17 are formed on the outer surface of the skin layer 15 and / or on a portion of the skin layer surface during molding of the polyurethane foam. They are provided at least in the portions (protruding portions 11) that come into contact with the inner surface 51 of the cavity 50 when the sound-insulating material 10 is inserted into the cavity 51. However, they may also be provided in portions other than those that come into contact with the inner surface 51 of the cavity 50. For example, they may be provided on the entire surface of the sound-insulating material 10 that comes into contact with the inner surface 51 of the cavity 50, or on the entire surface of the sound-insulating material 10 (six surfaces: front, back, left, right, top, and bottom in the case of a rectangular parallelepiped). Furthermore, the friction-reducing portions 17 may be provided on the entire surface of the relevant portion or only on a portion. When provided only on a portion, it is effective to provide them on a portion that comes into contact with the inner surface 51 of the cavity 50 and is pressed strongly against it. In the example of FIG. 1 , the friction-reducing portions 17 are provided on the entire surface of the protruding portions 11 that interfere with the insertion opening of the cavity 50 when the sound-insulating material 10 is inserted into the cavity 50.

[0020] The friction-reducing portion 17 is made of a resin having a smaller static friction coefficient (based on JIS K7125:1999) than the skin layer 15 formed solely from polyurethane foam raw material. The static friction coefficient is preferably 1 or less, more preferably 0.8 or less. Examples of resins constituting the friction-reducing portion 17 include urethane-based resins, acrylic-based resins, and mixtures of urethane-based resins and acrylic-based resins. The shape and thickness of the friction-reducing portion 17 are not limited and may be appropriately determined, such as a film, rod-like (continuous), scattered-dot (discontinuous), or a combination of a film, rod-like, and scattered-dot shapes. Figure 2 (2-A) shows an example of the friction-reducing portion 17 in the form of a film. Figure 2 (2-B) shows an example of the friction-reducing portion 17 in the form of scattered-dot (discontinuous). Figure 2 (2-C) shows an example of the friction-reducing portion 17 consisting of both a film-like (continuous) portion 171 and a scattered-dot (discontinuous) portion 172. The thickness of the friction reducing portion 17 is preferably about 10 to 100 μm when it is in a film or rod shape, and about 0.1 to 10 μm when it is in a scattered dot shape.

[0021] When sound-insulating material 10 is inserted into gap 50, friction-reducing portion 17 is provided at a portion that comes into contact with inner surface 51 of gap 50, thereby reducing frictional resistance and facilitating the insertion into gap 50. Furthermore, because friction-reducing portion 17 is formed on the outside of the surface of skin layer 15 and / or on a portion of the surface of the skin layer during molding of the polyurethane foam, it has strong adhesion to skin layer 15, preventing deterioration of workability due to peeling of friction-reducing portion 17 or the like when inserting sound-insulating material 10 into gap 50 and preventing damage to sound-insulating material 10 itself.

[0022] The sound insulation material 10 is manufactured by molding, and the steps of applying a release agent, applying paint, injecting polyurethane foam raw material, foaming and curing, and demolding are carried out in this order.

[0023] In the release agent application step, as shown in FIG. 3 (3-A), a release agent 71 is applied to the inner surface 62 of the lower mold 61 and the inner surface 66 of the upper mold 65 of the mold 60 using a spray gun or the like. Any known release agent used in molding polyurethane foams can be used, including silicone-based, fluorine-based, and wax-based agents. A more preferred release agent 71 is a wax-based agent. The mold 60 (the inner surface 62 of the lower mold 61 and the inner surface 66 of the upper mold 65) is shaped to correspond to the outer shape of the sound insulation material 10.

[0024] In the paint application step, as shown in FIG. 3 (3-B), paint 73 is applied onto release agent 71 using a spray gun or the like. At this time, paint 73 is diluted before use so as to have a viscosity suitable for the applicator (spray gun or the like) to be used. The area to which paint 73 is applied is on release agent 71 on the inner surface of mold 60, which produces the portion of sound insulation material 10 that will come into contact with at least inner surface 51 of gap 50 when sound insulation material 10 is inserted into gap 50. In this example, paint 73 is applied on release agent 71 in the area where protrusion 11 of sound insulation material 10 is to be produced. The paint is formed from a resin with a smaller static friction coefficient (based on JIS K7125:1999) than that of skin layer 15 formed from polyurethane foam raw material alone, and examples thereof include water-based / solvent-based urethane emulsion, water-based / solvent-based acrylic emulsion, and a mixture of water-based / solvent-based urethane emulsion and acrylic emulsion. When forming the friction-reducing portions 17 in a film-like (continuous) shape, the paint can be applied using a spray gun whose discharge rate has been measured in advance, adjusting the application time and visually checking whether a film-like shape has been formed. On the other hand, when forming the friction-reducing portions 17 in a dotted (discontinuous) shape, the paint can be applied by adjusting the application time and visually checking, as in the case of forming the friction-reducing portions in a film-like shape. After applying the paint 73, the paint 73 is cured to form the friction-reducing portions 17. Since the temperature of the mold 60 is adjusted in advance, the paint 73 is cured by leaving it for a predetermined time after application to volatilize the solvent (water / solvent). In particular, when the friction-reducing portions 17 are formed in a dotted shape, the amount of coating agent used can be reduced while the static friction coefficient is reduced, thereby reducing raw material costs and molding costs (shortening the molding cycle).

[0025] In the polyurethane foam raw material injection step, as shown in Fig. 4(4-A), polyurethane foam raw material 75 is injected into lower mold 61. Polyurethane foam raw material 75 contains polyol, isocyanate, a blowing agent, a catalyst, and appropriate additives.

[0026] As the polyol, known polyether polyols, polyester polyols, polyether ester polyols, polymer polyols, etc., which are used in the production of polyurethane foams, can be used alone or in combination.

[0027] Examples of polyether polyols include polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose, as well as polyether polyols obtained by adding alkylene oxides such as ethylene oxide and propylene oxide to such polyhydric alcohols. Examples of polyester polyols include polyester polyols obtained by polycondensation of aliphatic carboxylic acids such as malonic acid, succinic acid, and adipic acid, or aromatic carboxylic acids such as phthalic acid, with aliphatic glycols such as ethylene glycol, diethylene glycol, and propylene glycol. Furthermore, polyetherester polyols containing both ether and ester groups in the polyol, and polymer polyols obtained by polymerizing an ethylenically unsaturated compound in a polyether polyol, can also be used.

[0028] The isocyanate may be any of aromatic, alicyclic, and aliphatic isocyanates, and may be bifunctional isocyanates having two isocyanate groups in one molecule, or trifunctional or higher isocyanates having three or more isocyanate groups in one molecule, and these may be used alone or in combination.

[0029] For example, bifunctional isocyanates include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'- Examples of the isocyanate include aromatic isocyanates such as biphenylene diisocyanate, alicyclic isocyanates such as cyclohexane-1,4-diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, and methylcyclohexane diisocyanate, and aliphatic isocyanates such as butane-1,4-diisocyanate, hexamethylene diisocyanate, isopropylene diisocyanate, methylene diisocyanate, and lysine isocyanate.

[0030] Examples of tri- or higher functional isocyanates include 1-methylbenzene-2,4,6-triisocyanate, 1,3,5-trimethylbenzene-2,4,6-triisocyanate, biphenyl-2,4,4'-triisocyanate, diphenylmethane-2,4,4'-triisocyanate, methyldiphenylmethane-4,6,4'-triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'tetraisocyanate, triphenylmethane-4,4',4"-triisocyanate, polymeric MDI, and the like. Other urethane prepolymers include Also, the isocyanate is not limited to one type, but may be two or more types. For example, one type of aliphatic isocyanate and two types of aromatic isocyanate may be used in combination. The isocyanate index is preferably 90 to 115, more preferably 95 to 110. The isocyanate index is an index used in the field of polyurethanes, and is a numerical value that represents the equivalent ratio of isocyanate groups of isocyanate to active hydrogen groups in raw materials (for example, active hydrogen groups contained in hydroxyl groups of polyols and active hydrogen groups of water, etc., used as a blowing agent), expressed as a percentage.

[0031] The blowing agent is not particularly limited, but water is preferred. The amount of water used as the blowing agent is preferably 0.3 to 3 parts by weight per 100 parts by weight of the polyol.

[0032] The catalyst may be any known catalyst for polyurethane foams. Examples include amine catalysts such as triethylamine, triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine, tetramethylguanidine, and imidazole-based compounds; tin catalysts such as stannous octoate and dibutyltin dilaurate; and metal catalysts (also called organometallic catalysts) such as phenylmercury propionate and lead octenate. The typical amount of catalyst is about 0.2 to 3 parts by weight per 100 parts by weight of polyol.

[0033] Examples of additives that may be appropriately blended include synthetic resin stabilizers such as foam stabilizers, colorants, crosslinking agents, fillers, flame retardants, and antioxidants. The foam stabilizer may be any foam stabilizer that is used in polyurethane foams, including silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants. Colorants, such as pigments and dyes, are used depending on the desired color.

[0034] After polyurethane foam raw material 75 is injected into mold 60, mold 60 is closed. In the example of Fig. 4, polyurethane foam raw material 75 is injected while mold 60 is open, but an injection port (not shown) may be provided in upper mold 65, and polyurethane foam raw material 75 may be injected into mold 60 through the injection port while mold 60 is closed.

[0035] In the foaming and curing step, as shown in Figure 4 (4-B), polyurethane foam raw material 75 is reacted, foamed, and cured with mold 60 closed, filling mold 60 with polyurethane foam. During this process, skin layer 15 is formed on the surface of the polyurethane foam, and friction-reducing portion 17 is bonded to the outside of the surface of skin layer 15 and / or to a portion of the surface of the skin layer.

[0036] In the demolding step, the mold 60 is opened (not shown) after foaming, and the sound insulating material 10 shown in FIG. 1 is taken out. [Example]

[0037] Examples and comparative examples of the present invention are described below. Using the following components and polyurethane foam raw material having the formulations shown in Figures 5 and 6, sound-insulating material product samples and test pieces were manufactured by molding. The numerical values ​​for each component in the formulations shown in Figures 5 and 6 indicate parts by weight.

[0038] Polyol: Polyether polyol, functionality 3, weight average molecular weight 5000, hydroxyl value 35 mg KOH / g Foaming agent: Water Amine catalyst 1: DABCO 33LSI, manufactured by Air Products Japan Amine catalyst 2: DABCO BL-19, manufactured by Air Products Japan Foam stabilizer: Toray Dow Corning "SZ-1346E", silicone foam stabilizer Isocyanate: Polymeric MDI, isocyanate group content (NCO%) 31.5% Release agent: Chukyo Yushi Co., Ltd., "URM-520", linear hydrocarbon wax Coating agent 1: Dai Nippon Paint Co., Ltd., water-based urethane resin paint, "DNT View Urethane" Coating agent 2: Dai Nippon Paint Co., Ltd., solvent-based urethane resin paint, "V Top One-component Smile UNI" Coating agent 3: Dai Nippon Paint Co., Ltd., water-based acrylic resin, "DNT View Acrylic" Lubricant 4: Harves fluorine-based lubricant, "Drysurf MDF-2400EL"

[0039] The shape of the product sample was the same as that of the sound-insulating material 10 shown in Figure 1, and the overall external dimensions including the protrusions 11 were 200 mm wide (including the protrusions 11) x 150 mm deep x 400 mm high, of which the protrusions 11 were 50 mm wide x 150 mm deep x 200 mm high. The mold used was of the type that was opened and poured. The mold was heated with warm water.

[0040] The manufacturing of product samples will be explained. In Examples 1 to 8, a release agent was applied to the inner surface of a mold kept at 60°C, dried for 20 seconds, and then a coating agent was applied to the release agent and dried for 20 seconds. The polyurethane foam raw material was then poured into the mold, and the foam was removed after 3 minutes to obtain a product sample for each Example. For the coating amounts of Examples 1 to 8, allowing the coating agent to dry (or be left standing) for 20 seconds after application allowed the solvent to completely volatilize, regardless of the amount of coating agent applied. The type of coating agent (paint), application location, and coating residue amount for each Example are shown in Figure 5. The coating residue amount refers to the amount (theoretical value) of solids (non-volatile components) such as resin contained in the coating agent (water-based / solvent-based emulsion, etc.).

[0041] In Comparative Example 1, a product sample was produced in the same manner as in Example 1, except that no coating agent was applied. In Comparative Examples 2 to 9, polyurethane foams were produced in the same manner as in Example 1, except that no coating agent was applied, and product samples were produced by applying a coating agent to the polyurethane foam after demolding. The type of coating agent (paint or lubricant), the application site, and the amount of coating residue in each Comparative Example are as shown in Figure 6. In Comparative Example 10, a product sample was produced by injecting into a mold a raw material for integral skin foam, which forms a thick, strong skin layer during molding.

[0042] The test pieces were manufactured to have a shape of 400mm square x 30mm, and were subjected to the same conditions as the product samples, except for the shape of the mold used. The density was measured based on JIS K7222: 2005 by cutting the test piece into a 200 mm square x 30 mm thick sample (with skin layers only on the top and bottom surfaces). In Comparative Examples 2 to 9, the density was measured after the coating agent was applied, and in the case of emulsions, the density was measured after the solvent component was evaporated. The static friction coefficient was measured in accordance with JIS K7125:1999 by cutting the test piece into a size of 90 mm x 63 mm x 10 mm thick (with a skin layer on only one side (top or bottom)) to form a sample for static friction measurement. Since polyurethane foam has a large friction resistance and is prone to vibration during measurement, the polyurethane foam on the tensile direction side was floated during measurement. In Comparative Examples 2 to 9, the density was measured after the application of the coating agent, or in the case of an emulsion, after the solvent component was volatilized.

[0043] Furthermore, product samples of each example and comparative example were manually inserted three times into the gap 50 shown in Figure 1, and the workability was evaluated. The workability was evaluated as follows: "◎" if repeated insertion was easy, "◯" if repeated insertion was possible, "△" if repeated insertion was difficult, and "×" if repeated insertion was difficult. Note that if the friction-reducing portion 17 is provided by post-processing, the friction-reducing portion peels off during repeated insertion, making insertion difficult.

[0044] Furthermore, test pieces of each example and comparative example were cut to a predetermined size, and the static friction coefficient (with one skin layer) and density (with upper and lower skin layers) were measured.

[0045] The product samples and test pieces of each Example and Comparative Example were also evaluated for appearance, molding cycle, and environmental performance. An overall evaluation was also made by combining the evaluations of the workability of the product samples, the static friction coefficient of the test pieces, the appearance of the product samples and test pieces, the molding cycle, and the environmental performance.

[0046] Regarding appearance, if a solvent-based paint is used in post-processing, the surface of the polyurethane foam is corroded by the solvent components, causing unevenness, etc. Appearance was judged visually, with a good appearance being marked "○" and a poor appearance being marked "×".

[0047] Regarding the molding cycle, if a lubricant is used in post-processing, it takes time to apply it with a brush, etc., and if a water-based paint is used in post-processing, it takes time to dry and requires the use of a drying oven or drying process, etc. The molding cycle was judged as follows: very fast: "◎", fast: "◯", slow: "△", and extremely slow: "×".

[0048] Regarding environmental performance, the use of solvent-based paints as coating agents requires the installation of exhaust systems and the wearing of protective equipment by workers, and the use of chlorofluorocarbons, the use of which is restricted, places a heavy burden on the environment. The environmental performance was judged as "◎" if the burden on the environment is very small, "〇" if the burden on the environment is small, and "×" if the burden on the environment is large.

[0049] The overall evaluation was given as "Good" if the evaluation of workability, appearance, molding cycle, and environmental performance was only "Excellent" or "Good", and "Poor" if any of the evaluations included "Poor".

[0050] In Example 1, coating agent 1 was used, and the amount of coating residue was 0.6 μg / cm 2 In Example 1, the workability was "good", the static friction coefficient was 0.88, and the density (with skin layer) was 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0051] In Example 2, the residual amount of coating agent 1 was 1.8 μg / cm 2 The other characteristics are the same as those of Example 1. Example 2 has a workability of "Excellent", a static friction coefficient of 0.66, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0052] In Example 3, the residual amount of coating agent 1 was 3.6 μg / cm 2The other characteristics are the same as those of Example 1. Example 3 has a workability of "Excellent", a static friction coefficient of 0.49, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0053] In Example 4, the residual amount of coating agent 1 was 20 μg / cm 2 This is an example similar to Example 1 except that the friction reducing portion is provided in the form of a film only on the interference portion. Example 4 is evaluated as having workability of "Excellent", a static friction coefficient of 0.44, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0054] In Example 5, coating agent 1 was used, and the amount of coating residue was 1.8 μg / cm 2 The other features are the same as those of Example 2. Example 5 is an example in which the workability is "Excellent", the static friction coefficient is 0.66, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0055] In Example 6, the residual amount of coating agent 1 was 20 μg / cm 2 Example 6 is an example similar to Example 5 except that the friction reducing portion is provided in the form of a film. Example 6 has a workability of "Excellent", a static friction coefficient of 0.44, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0056] Example 7 is an example similar to Example 2 except that Coating Agent 2 was used. Example 7 had a workability of "Excellent", a static friction coefficient of 0.68, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0057] Example 8 is the same as Example 2 and Example 7 except that Coating Agent 3 was used. Example 8 had a workability of "Excellent", a static friction coefficient of 0.70, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Good".

[0058] Comparative Example 1 is an example similar to Example 1 except that no friction reducing portion is provided. Comparative Example 1 has a workability rating of "x", a static friction coefficient of 2.29, and a density (with skin layer) of 100 kg / m 3 The results were appearance "Good", molding cycle "Excellent", environmental performance "Excellent", and overall evaluation "Poor".

[0059] In Comparative Example 2, Coating Agent 1 was used, and friction-reducing portions were provided in scattered dots only on the interference portions by post-processing coating, and the amount of coating residue was 1.8 μg / cm , the same as in Example 2. 2 Comparative Example 2 is an example in which the workability is "Fair", the static friction coefficient is 0.72, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Excellent", and overall evaluation "Poor".

[0060] In Comparative Example 3, Coating Agent 1 was used, and a friction-reducing portion was provided in the form of a film only on the interference portion by coating in a post-process, and the amount of coating residue was 20 μg / cm 2 , the same as in Example 4. 2 Comparative Example 3 is an example in which the workability is "Fair", the static friction coefficient is 0.58, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Excellent", and overall evaluation "Poor".

[0061] In Comparative Example 4, the coating material 1 was used, and the friction-reducing portions were provided in a scattered manner over the entire surface by post-processing, and the amount of coating residue was 1.8 μg / cm , the same as in Example 5. 2 Comparative Example 4 is an example in which the workability is "Fair", the static friction coefficient is 0.72, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Excellent", and overall evaluation "Poor".

[0062] In Comparative Example 5, Coating Agent 1 was used, and a friction-reducing portion was formed in the form of a film over the entire surface by post-processing application, and the amount of coating residue was 20 μg / cm 2 , the same as in Example 6. 2 Comparative Example 5 is an example in which the workability is "Fair", the static friction coefficient is 0.58, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Excellent", and overall evaluation "Poor".

[0063] In Comparative Example 6, Coating Agent 2 was used, and the friction-reducing portions were provided in a scattered manner only on the interference portions by post-processing coating, and the amount of coating residue was 1.8 μg / cm 2 , the same as in Example 7. 2 Comparative Example 6 is an example in which the workability is "x", the static friction coefficient is 1.05, and the density (with skin layer) is 100 kg / m 3 The results were "×" for appearance, "〇" for molding cycle, "〇" for environmental performance, and an overall rating of "×".

[0064] In Comparative Example 7, the coating material 3 was used, and the friction reducing portion was provided in a scattered manner only on the interference portion by post-processing coating, and the amount of coating residue was 1.8 μg / cm 2 , the same as in Example 8. 2 Comparative Example 7 is an example in which the workability is "Fair", the static friction coefficient is 0.84, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Excellent", and overall evaluation "Poor".

[0065] In Comparative Example 8, Coating Agent 4 was used, and a friction-reducing portion was provided in the form of a film only on the interference portion by post-processing coating, and the amount of coating residue was 20 μg / cm 2 , the same as in Example 4. 2 Comparative Example 8 is an example in which the workability is "x", the static friction coefficient is 1.22, and the density (with skin layer) is 100 kg / m 3 The results were appearance "Good", molding cycle "Good", environmental performance "Good", and overall evaluation "Poor".

[0066] In Comparative Example 9, the amount of coating residue was 40 μg / cm 2 The other points are the same as those of Comparative Example 8. Comparative Example 9 is an example in which the workability is "x", the static friction coefficient is 1.19, and the density (with skin layer) is 100 kg / m 3The results were appearance "Good", molding cycle "Good", environmental performance "Good", and overall evaluation "Poor".

[0067] Comparative Example 10 is an example made of integral skin foam and having no friction reducing portion. Comparative Example 10 has a workability of "Fair", a static friction coefficient of 1.38, and a density (with skin layer) of 300 kg / m 3 The results were appearance "Good", molding cycle "Poor", environmental performance "Poor", and overall evaluation "Poor".

[0068] Thus, Examples 1 to 8 were all given an overall rating of "Good," meaning that insertion into the gaps was easy. On the other hand, Comparative Example 1, which had no friction-reducing portion, was given an "X" rating for workability, and Comparative Examples 2 to 9, which had a friction-reducing portion provided by post-processing application, and Comparative Example 10, which was an integral skin foam, were given "Fair" or "X" ratings for workability, resulting in an overall rating of "X," meaning that insertion into the gaps was not easy. [Explanation of symbols]

[0069] 10: Sound insulation material 11: Convex part (interference part) 15: Skin layer 16: Polyurethane foam interior (core) 17: Friction reduction part 50:Void 51: Inner surface of the cavity 53: Recess on the inner surface of the cavity 60: Mold 61: Lower mold 62: Inner surface of lower die 65: Upper mold 66: Inner surface of upper mold 71: Release agent 73:Paint 75: Polyurethane foam raw material

Claims

1. A sound-insulating material made of molded polyurethane foam having a skin layer that is inserted into a cavity while contacting the inner surface of the cavity, a friction reducing portion on the outside of the skin layer surface and / or on a part of the skin layer surface; the friction reducing portion is separate from the skin layer and is provided at a portion that comes into contact with at least the inner surface of the gap when the friction reducing portion is inserted into the gap, the friction reducing portion is formed in a recess on the surface of the skin layer, A sound-insulating material characterized in that the friction-reducing portion has a static friction coefficient of 1 or less.

2. A sound-insulating material made of molded polyurethane foam having a skin layer that is inserted into a cavity while contacting the inner surface of the cavity, a friction reducing portion on the outside of the skin layer surface and / or on a part of the skin layer surface; the friction reducing portion is separate from the skin layer and is provided at a portion that comes into contact with at least the inner surface of the gap when the friction reducing portion is inserted into the gap, A sound-insulating material characterized in that the friction-reducing portion is in the form of a film, and the static friction coefficient of the friction-reducing portion is 0.44 or less.

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