Soundproofing bodies and automotive floor silencers

Abstract

To provide a soundproof body and an automotive floor silencer that can provide excellent sound insulation performance for noise at least in a mid-frequency band by utilizing a laminated structure having at least a breathable base layer and a non-breathable layer containing multiple crushed materials in a dispersed state.SOLUTION: Crushed members P each have a three-dimensionally shaped crushed body Pa formed by crushing a source material having at least a thermosetting resin layer. A breathable base layer Sa is formed by dispersively positioning a plurality of three-dimensionally shaped crushed bodies Pa within thermosetting resin binder U in a layered configuration. The breathable base layer Sa comprises at least one labyrinth-like pathway K formed between two three-dimensionally shaped crushed bodies that face each other among the plurality of three-dimensionally shaped crushed bodies Pa within the thermosetting resin binder U. The non-breathable layer Sb is laminated along the surface of the breathable base layer Sa.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a soundproofing body and an automobile floor silencer suitable for preventing noise entering the interior of an automobile or a building. [Background technology]

[0002] A conventional example of this type of soundproof body is the lightweight soundproofing material for automobiles described in Patent Document 1. This lightweight soundproofing material is composed of a thin base material made of felt or the like and a material, such as a resin net, that partitions at least one surface of the thin base material.

[0003] With this configuration, when the lightweight soundproofing material is arranged, for example, along the dash panel of an automobile with its thin base material, the thin base material functions as a spring layer between the dash panel and the resin net, while the resin net functions as a sound-insulating layer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 1-032943 Summary of the Invention [Problem to be solved by the invention]

[0005] According to the above-described configuration, the lightweight soundproofing material exhibits sound insulation performance against noise, but the lightweight soundproofing material does not absorb noise in the mid-frequency band 20 of the noise. 0Hz~ To achieve good sound insulation performance against 800 Hz noise, a heavy sound insulation layer is required, which would compromise the lightweight properties of the lightweight soundproofing material.

[0006] In addition, when a car is moving, noise from low to medium frequencies is generated. AroundNoise in the frequency band is generated from roads, tires, etc. When this noise propagates into the interior of a vehicle, it causes discomfort to the occupants. For this reason, there has been a strong demand in recent years for measures to reduce this noise.

[0007] Therefore, in order to address these issues, the present invention aims to provide a soundproofing body and an automobile floor silencer that can exhibit excellent sound insulation performance at least against noise in the mid-frequency range by utilizing a laminated structure having at least an air-permeable base layer containing multiple pulverized materials dispersed therein and a non-air-permeable layer. [Means for solving the problem]

[0008] In order to solve the above problem, according to claim 1, the soundproof body of the present invention comprises a plurality of crushing members and binders made of thermosetting resin. Dar The fabric comprises a breathable base layer and a non-breathable layer.

[0009] In the soundproof body, Each of the plurality of pulverizing members has a pulverized body (Pa) having a three-dimensional shape formed by pulverizing a raw material having at least a thermosetting resin layer, The breathable base layer is made of multiple three-dimensionally shaped crushed bodies bound together by a thermosetting resin binder. Dar( U) and formed in layers, The breathable base layer is made of thermosetting resin binder. Inside the dar At least one labyrinth path (K) is formed between two opposing three-dimensional pulverized bodies among the plurality of three-dimensional pulverized bodies, The non-breathable layer is laminated to the breathable base layer along one of its two surfaces.

[0010] According to this configuration, the soundproofing body of the present invention comprises an air-permeable base layer and an air-impermeable layer. Two layers The breathable base layer is made of a laminated structure, and is made of a thermosetting resin binder. Inside the dar The binder is made of thermosetting resin and is formed in layers. Inside the darAt least one labyrinth path is formed between two opposing three-dimensionally shaped grinding bodies among the plurality of three-dimensionally shaped grinding bodies.

[0011] Therefore, when noise enters the breathable base layer, the noise propagates through the breathable base layer. During this propagation process, since the pulverizers have a three-dimensional shape, the noise propagates through each three-dimensional pulverizer, but mainly propagates in a maze-like manner through at least one maze-like path.

[0012] In this noise propagation mode, the breathable base layer vibrates in response to the incident noise, and the non-breathable layer vibrates in response to the vibration of the breathable base layer. The vibration of the non-breathable layer is out of phase with the vibration of the breathable base layer. This phase shift is determined by the content, number, and size of the three-dimensional pulverized bodies in the breathable base layer.

[0013] In this way, the vibration of the breathable base layer is suppressed by the vibration of the breathable base layer due to the phase of the vibration of the breathable layer being shifted in the opposite direction relative to the phase of the vibration of the breathable base layer. Therefore, if the degree of phase shift in the opposite direction is set so as to suppress noise at frequencies in the mid-frequency band, the vibration of the breathable layer will be suppressed by the vibration of the breathable base layer. This means that the breathable layer can exhibit excellent sound insulation performance against noise having frequencies within the mid-frequency band.

[0014] As a result, the soundproof body can exhibit good soundproofing performance due to the synergistic effect of the sound absorbing performance of the breathable base layer and the excellent sound insulating performance of the non-breathable layer.

[0015] According to claim 2 of the present invention, in the soundproofing body according to claim 1, The sound absorbing layer is laminated on the non-permeable layer so as to face the breathable base layer with the non-permeable layer interposed therebetween.

[0016] According to this, the soundproofing body is formed with a three-layer laminated structure consisting of an air-permeable base layer, an air-impermeable layer, and a sound-absorbing layer.

[0017] In such a three-layer laminated structure, the sound absorbing layer absorbs noise propagating from the non-breathable layer with its sound absorbing performance, thereby attenuating the noise. As a result, noise from the breathable base layer, which is insulated by the excellent sound insulating performance of the non-breathable layer, can be insulated more effectively in the mid-frequency range than in the soundproofing body with the two-layer laminated structure described above.

[0018] According to claim 3 of the present invention, in the soundproofing body according to claim 1 or 2, The raw material includes a thermosetting resin layer (130) and a glass fiber layer (120, 140) having a plurality of glass fibers laminated together with the thermosetting resin layer, The plurality of three-dimensionally shaped pulverized bodies each have a corresponding glass fiber portion (121, 141) corresponding to the glass fiber layer; each of the plurality of pulverizing members has a plurality of glass fibers extending from the corresponding glass fiber portion corresponding to the glass fiber layer of the three-dimensional pulverized body as the raw material is pulverized; The plurality of glass fibers extending from the corresponding glass fiber portion are located in a dispersed state within the at least one labyrinth-like path.

[0019] In this way, by having multiple glass fibers extend from the corresponding glass fiber portions of the glass fiber layer of each three-dimensional pulverized body and positioned in a dispersed manner within at least one maze-like path, noise propagating through at least one maze-like path as described above can be attenuated by colliding with the multiple glass fibers positioned in a dispersed manner within the at least one maze-like path.

[0020] This further attenuates noise propagating from the breathable base layer to the breathable layer, thereby providing better sound insulation through the breathable layer, thereby further improving the soundproofing performance of the soundproof body.

[0021] According to claim 4 of the present invention, in the soundproofing body according to claim 1 or 2, The plurality of crushing members are the plurality of first crushing members, and the breathable base layer is the plurality of second crushing members, and the plurality of first crushing members are bound together by a thermosetting resin binder. Inside the dar The particles are dispersed in layers, Each of the plurality of second pulverizing members comprises, together with the pulverized body having a three-dimensional shape, a pulverized body having a non-three-dimensional shape formed by pulverizing a raw material, The plurality of second crushing members are located in a dispersed manner within the at least one labyrinth-like path.

[0022] According to this, the breathable base layer of the soundproof body is made of a thermosetting resin binder, and the first crushing members and the second crushing members are arranged in the breathable base layer of the soundproof body. Inside the dar The plurality of second crushing members are formed in layers, dispersed in the labyrinth path. Here, each of the second crushing members is composed of a non-three-dimensional crushed body formed from a raw material by crushing the raw material together with a three-dimensional crushed body, and is dispersed in at least one labyrinth path.

[0023] Therefore, as described above, noise propagating through at least one labyrinthine path can be attenuated by colliding with the plurality of glass fibers located in a dispersed manner within the at least one labyrinthine path.

[0024] This further attenuates noise propagating from the breathable base layer to the breathable layer, thereby providing better sound insulation through the breathable layer, thereby further improving the soundproofing performance of the soundproof body.

[0025] According to claim 5 of the present invention, in the soundproofing body according to claim 1 or 2, The air-permeable base layer is made of a plurality of crushing members and the thermosetting resin binder. To Dar In addition, an auxiliary member made of a recycled fiber material is provided, The auxiliary member is a binder made of thermosetting resin. Inside the dar It is dispersed and mixed with multiple grinding elements. The content of the auxiliary member is adjusted together with the content of the plurality of pulverizing members so that the hardness of the breathable base layer is reduced to a hardness that shifts the frequency of the response vibration of the breathable base layer to incident noise to a frequency lower than the frequency of the mid-frequency band.

[0026] According to this configuration, the air-permeable base layer is made of a plurality of crushing members and a binder made of thermosetting resin. Dar and and an auxiliary member, the auxiliary member being formed from a recycled fiber material.

[0027] Here, the content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer is reduced to a hardness that shifts the frequency of the response vibration of the breathable base layer to incident noise to a frequency lower than that of the mid-frequency band.

[0028] Therefore, even if the breathable base layer vibrates in response to incident noise, the vibration of the non-breathable layer is suppressed by the vibration of the breathable base layer, even at frequencies lower than the mid-frequency band, and the non-breathable layer can therefore exhibit excellent sound insulation performance even against noise having frequencies lower than the mid-frequency band.

[0029] This allows the soundproofing body to exhibit excellent soundproofing performance even against noises having frequencies lower than those in the mid-frequency band.

[0030] According to claim 6 of the present invention, in the soundproofing body according to claim 1 or 2, The breathable base layer includes a plurality of pulverized members, a resin binder, and an auxiliary member made of chip-like foam material, The auxiliary member is a binder made of thermosetting resin. Inside the dar It is dispersed and mixed with multiple grinding elements. 、 GeneralThe content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer is increased to a level that shifts the frequency of the response vibration of the breathable base layer to incident noise to a higher frequency side than the frequency of the mid-frequency band.

[0031] According to this configuration, the air-permeable base layer is made of a plurality of crushing members and a binder made of thermosetting resin. Dar and and an auxiliary member, the auxiliary member being formed of a chip-like material.

[0032] Here, the content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer is increased to a level that shifts the frequency of the response vibration of the breathable base layer to incident noise to a frequency higher than the frequency of the mid-frequency band.

[0033] Therefore, even if the breathable base layer vibrates in response to incident noise, the vibration of the non-breathable layer in response to the vibration is suppressed by the vibration of the breathable base layer, even at frequencies higher than the mid-frequency band, and the non-breathable layer can therefore exhibit excellent sound insulation performance even against noise with frequencies higher than the mid-frequency band.

[0034] This allows the soundproofing body to exhibit excellent soundproofing performance even against noises having frequencies higher than those in the mid-frequency band.

[0035] According to claim 7, the automotive floor silencer of the present invention comprises: The device is mounted from inside the vehicle compartment along the floor wall of the vehicle compartment (10) of an automobile having at least one of an electric motor (M) and an engine (E) as a prime mover.

[0036] In this floor silencer, Multiple grinding elements and thermosetting resin binders Dar and a non-breathable layer, Each of the plurality of pulverizing members has a pulverized body (Pa) having a three-dimensional shape formed by pulverizing a raw material having at least a thermosetting resin layer, The breathable base layer is made up of multiple layers. Three-dimensional powder The crushed material is dispersed and mixed in a thermosetting resin binder to form layers. the breathable base layer has at least one labyrinth path (K) formed between two opposing three-dimensional pulverized bodies among the plurality of three-dimensional pulverized bodies in a thermosetting resin binder, The non-breathable layer is laminated to the breathable base layer along one of its two surfaces.

[0037] According to this, it is possible to achieve the same effect as in the invention of claim 1 based on the sound-proofing performance of the breathable base layer and the sound-insulating performance of the non-breathable layer in an electric vehicle, a gasoline vehicle, a hybrid vehicle, or the like. Floor slab for It will be possible to provide an eraser.

[0038] According to claim 8 of the present invention, in the automotive floor silencer according to claim 7, The sound absorbing layer is laminated on the non-permeable layer so as to face the breathable base layer with the non-permeable layer interposed therebetween.

[0039] According to this, the floor silencer is formed with a three-layer laminated structure consisting of an air-permeable base layer, an air-impermeable layer, and a sound-absorbing layer. Here, the sound-absorbing layer exhibits sound-absorbing properties against noise propagating from the air-impermeable layer.

[0040] Therefore, in addition to the sound absorbing performance of the breathable base layer and the sound insulating performance of the non-breathable layer, the sound absorbing performance of the sound absorbing layer can be achieved in automobiles such as electric automobiles, gasoline automobiles, and hybrid automobiles. Floor slab for It will be possible to provide an eraser.

[0041] In particular, in a floor silencer having the above-mentioned three-layer laminated structure, the sound insulation performance can be improved not only for mid-frequency band frequencies but also for high-frequency band frequencies, compared to the sound insulation performance of a floor silencer having a two-layer laminated structure consisting of a breathable base layer and a non-breathable layer, so that not only the road noise generated when an electric vehicle is running but also the motor noise generated by the electric vehicle can be effectively soundproofed from inside the vehicle cabin.

[0042] According to a ninth aspect of the present invention, in the automotive floor silencer according to the seventh aspect, The raw material includes, in addition to a thermosetting resin layer, a glass fiber layer having a plurality of glass fibers laminated together with the thermosetting resin layer, Each of the plurality of three-dimensionally shaped pulverized bodies has a corresponding glass fiber portion corresponding to the glass fiber layer, The plurality of pulverizing members each have a plurality of glass fibers extending from the corresponding glass fiber portion of the three-dimensional pulverized body corresponding to the glass fiber layer as the raw material is pulverized.

[0043] According to this, it is possible to realize an electric vehicle, a gasoline vehicle, a hybrid vehicle or the like, which can achieve the same effect as the invention of claim 3 while also achieving the effect of the invention of claim 7. Floor slab for It will be possible to provide an eraser.

[0044] According to claim 10, the present invention provides the following: 7 or 8 In the automotive floor silencer described above, The plurality of pulverizing members are a plurality of first pulverizing members, and the breathable base layer is formed in a layer by dispersing a plurality of second pulverizing members together with a plurality of first pulverizing members in a thermosetting resin binder; Each of the plurality of second pulverizing members comprises, together with the three-dimensional pulverized body, a non-three-dimensional pulverized body formed from the raw material by pulverizing the raw material; The plurality of second crushing members are located in a dispersed manner within the at least one labyrinth-like path.

[0045] According to this, the same effect as that of the invention described in claim 4 can be achieved, while 7 or 8 Automobiles such as electric vehicles, gasoline vehicles, and hybrid vehicles that can achieve the effects of the invention described above. Floor slab for It will be possible to provide an eraser.

[0046] According to an eleventh aspect of the present invention, in the automotive floor silencer according to the eighth or ninth aspect, The breathable base layer includes a plurality of crushing members, a thermosetting resin binder, and an auxiliary member made of a recycled fiber material, The auxiliary member is a binder made of thermosetting resin. Inside the dar and the mixture is dispersed and mixed with the plurality of grinding members. The content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer is reduced to a hardness that changes the frequency of the response vibration of the breathable base layer to incident noise to a frequency lower than the frequency of the mid-frequency band.

[0047] According to this configuration, the same effect as that of the invention of claim 5 can be achieved, while the same effect as that of the invention of claim 6 can be achieved. 8 or 9 Automobiles such as electric vehicles, gasoline vehicles, and hybrid vehicles that can achieve the effects of the invention described above. Floor slab for It will be possible to provide an eraser.

[0048] According to claim 12 of the present invention, in the automotive floor silencer according to claim 8 or 9, The breathable base layer includes a plurality of pulverized members, a thermosetting resin binder, and an auxiliary member made of a chip-like foam material; The auxiliary member is a binder made of thermosetting resin. Inside the dar It is dispersed and mixed with multiple grinding elements. The content of the auxiliary member is adjusted together with the content of the plurality of pulverizing members so that the hardness of the breathable base layer is increased to a level that shifts the frequency of the response vibration of the breathable base layer to incident noise to a frequency higher than the frequency of the mid-frequency band.

[0049] According to this, the same effect as that of the invention described in claim 6 can be achieved, while 8 or 9 Automobiles such as electric vehicles, gasoline vehicles, and hybrid vehicles that can achieve the effects of the invention described above. Floor slab for It will be possible to provide an eraser.

[0050] The symbols in parentheses for each of the above means indicate the corresponding relationship with the specific means described in the embodiments to be described later. [Brief explanation of the drawings]

[0051] [Figure 1] 1 is a schematic, partially cutaway, side view of an automobile to which a first embodiment of an automobile floor silencer according to the present invention is applied. [Figure 2] FIG. 2 is an enlarged side view of the floor silencer of FIG. 1. [Figure 3] 3 is a partially cutaway enlarged cross-sectional view of the floor silencer of FIG. 2. FIG. [Figure 4] FIG. 3 is an enlarged, partially cutaway side view of a disposal member in the first embodiment. [Figure 5] FIG. 1(a) is a side view of the first crushing member, and FIG. 1(b) is a diagram showing an example of each of the second crushing members. [Figure 6] FIG. 2 is a partially cutaway enlarged cross-sectional view illustrating a noise passage path inside the floor silencer. [Figure 7] 4 is a graph showing the relationship between insertion loss and frequency for a first example sample and a comparative sample in the first embodiment. [Figure 8] 1 is a schematic, partially cutaway, side view of an automobile to which a second embodiment of an automobile floor silencer according to the present invention is applied. [Figure 9]FIG. 4 is an enlarged side view showing the floor silencer in the second embodiment. [Figure 10] FIG. 10 is an enlarged, partially cutaway cross-sectional view of the floor silencer of FIG. 9. [Figure 11] 8A and 8B are graphs showing the relationship between the insertion loss and frequency of the second example sample in the second embodiment, together with the relationship between the insertion loss and frequency of the first example sample and the comparative sample shown in FIG. 7. [Figure 12] FIG. 10 is an enlarged, partially cutaway cross-sectional view showing a main part of a third embodiment of an automotive floor silencer according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0052] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. (First embodiment) Fig. 1 shows a first embodiment in which the present invention is applied to an automobile. The automobile is a type of automobile that uses gasoline as fuel (hereinafter referred to as a gasoline automobile). The gasoline automobile is equipped with an engine E, and the engine E is installed in an engine room ER (see Fig. 1) of the gasoline automobile.

[0053] The gasoline-powered automobile has a passenger compartment 10, which is formed in the gasoline-powered automobile so as to be positioned adjacent to an engine compartment ER via a dash panel DP.

[0054] The gasoline-powered automobile has left and right front seats 20a (only the left front seat 20a is shown in Fig. 1) and left and right rear seats 20b (only the left rear seat 20b is shown in Fig. 1) arranged in a passenger compartment 10. In Fig. 1, the symbol H indicates a steering wheel, the symbol FP indicates a floor panel of the gasoline-powered automobile, and the symbol FS indicates a floor seat.

[0055] The gasoline-powered automobile also has left and right front wheels FW and left and right rear wheels RW. The left and right front wheels FW are supported on left and right end portions of a front wheel shaft 30a, and the left and right rear wheels RW are supported on left and right end portions of a rear wheel shaft 30b.

[0056] As shown in Fig. 1, the gasoline-powered automobile is equipped with a floor silencer S according to the present invention. In this first embodiment, the floor silencer S is mounted between a floor panel FP and a floor sheet FS so as to follow the upper surface of the floor panel FP as a silencer for effectively insulating noises having frequencies in the mid-frequency range. In this first embodiment, noise will hereinafter also be referred to as noise.

[0057] 1 and 2, the floor silencer S includes a breathable base layer Sa and a non-breathable layer Sb. The floor silencer S also includes a front silencer portion 40, a rear silencer portion 50, and a middle silencer portion 60 located between the front and rear silencer portions 40, 50.

[0058] Accordingly, the front silencer portion 40 corresponds to the front layer portions of the breathable base layer Sa and the non-breathable layer Sb, the rear silencer portion 50 corresponds to the rear layer portions of the breathable base layer Sa and the non-breathable layer Sb, and the middle silencer portion 60 corresponds to the middle layer portions of the breathable base layer Sa and the non-breathable layer Sb. In this first embodiment, the thickness of the floor silencer S, i.e., the total thickness of the breathable base layer Sa and the non-breathable layer Sb, is set to, for example, 20 mm. In addition, the basis weight of the floor silencer S, i.e., the total basis weight of the breathable base layer Sa and the non-breathable layer Sb, is set to, for example, 4 kg / m2.

[0059] In this first embodiment, the front silencer section 40 is mounted along the front portion FPa of the floor panel FP, as shown in Figure 1, and the front end portion 40a of the front silencer section 40 extends along the lower end portion of the dash panel DP.

[0060] Meanwhile, the rear silencer section 50 is mounted so as to fit on the rear portion FPb of the floor panel FP. The middle silencer section 60 is formed in a generally inverted U shape so as to fit on the middle protrusion FPc (see FIG. 1) of the floor panel FP, and the middle silencer section 60 is formed integrally with the front and rear silencer sections 40, 50 between them.

[0061] Here, the configuration of the floor silencer S will be described in detail. As described above, the floor silencer S includes an air-permeable base layer Sa and an air-impermeable layer Sb. As will be described later, the air-permeable base layer Sa is composed of a plurality of pulverizing members P, a plurality of pulverizing members Q, and a thermosetting resin binder U (see FIG. 3). The plurality of pulverizing members P or the plurality of pulverizing members Q are formed from discarded parts 100 (see FIG. 4) as will be described later. In addition, isocyanate, for example, is used as the thermosetting resin that forms the binder U. In the following, in this first embodiment, the pulverizing member P will also be referred to as the first pulverizing member P, and the pulverizing member Q will also be referred to as the second pulverizing member Q.

[0062] The discarded part 100 is a roof part of an automobile that is used as a laminated composite raw material for manufacturing the floor silencer S. In the first embodiment, the roof part that is the discarded part 100 may be, for example, a roof part that is already installed in an automobile that is to be repaired or scrapped, or a newly manufactured roof part that is subject to quality defects.

[0063] The reason for using the discarded parts 100 as the laminated composite raw material for manufacturing the floor silencer S is to reduce the waste of resources by reusing discarded items.

[0064] The reason for adopting roof parts already installed in automobiles to be repaired or scrapped as discarded parts 100 is as follows.

[0065] In recent years, a wide variety of automobiles have been developed, and the number of these automobiles produced is on the rise. Accordingly, the number of automobiles that need to be repaired due to automobile accidents and the number of automobiles that are scrapped are also on the rise. In line with this increasing trend, various automobile parts tend to be disposed of as waste after use. For example, if parts mounted on the roof of an automobile (hereinafter referred to as roof parts) were disposed of as waste after use, a significant economic loss would result, given the high number of automobiles produced today. Therefore, there is a demand for the recycling of waste roof parts.

[0066] This not only allows roof parts that are to be discarded to be effectively reused, but also effectively reduces the economic loss caused by discarding the parts. Therefore, roof parts that are to be discarded are adopted as discarded parts 100.

[0067] The reason for adopting a roof part that is subject to quality defects even if it is a newly manufactured roof part as the discarded part 100 is as follows.

[0068] This is because if a newly manufactured roof component is of poor quality, it will be subject to disposal in the same way as the roof components that are discarded as a result of being used as described above.

[0069] As shown in FIG. 4, the discarded part 100 is configured by laminating a surface layer 110, a glass fiber layer 120, a urethane foam layer 130, a glass fiber layer 140, and a backing layer 150.

[0070] In the discarded part 100, the skin layer 110 is formed in a layer shape using a nonwoven fabric formed by intertwining multiple fibers without weaving or knitting them. The glass fiber layer 120 is formed in a layer shape by mixing multiple glass fibers with an adhesive, intertwining the multiple glass fibers, and allowing the adhesive to harden. In this first embodiment, the glass fiber layer 120 will be referred to as the skin layer side glass fiber layer 120 hereinafter.

[0071] The skin layer side glass fiber layer 120 is laminated between the skin layer 110 and the urethane foam layer 130. As a result, the skin layer side glass fiber layer 120 plays a role in reinforcing the strength of the skin layer 110 and the urethane foam layer 130 with the elasticity and rigidity of the entangled glass fibers.

[0072] The urethane foam layer 130 is formed in a layer shape using semi-rigid urethane foam. The reason for using semi-rigid urethane foam as the urethane foam is as follows.

[0073] The automobile roof part used as the laminated composite raw material for manufacturing the floor silencer S needs to be formed into a board shape (flat plate shape) that does not cause deformation such as bending. For this reason, the urethane foam 130 of the laminated composite raw material is required to maintain a board shape that does not cause deformation such as bending. Therefore, a semi-rigid urethane foam that can maintain the board shape described above is used as the urethane foam 130.

[0074] The glass fiber layer 140 is formed into a layer by mixing a plurality of glass fibers with an adhesive, entangling the glass fibers with each other, and allowing the adhesive to harden, similar to the skin-side glass fiber layer 120. In the first embodiment, the glass fiber layer 140 will be referred to as the backing-side glass fiber layer 140 hereinafter.

[0075] The backing layer-side glass fiber layer 140 is laminated between the urethane foam layer 130 and the backing layer 150, and the backing layer-side glass fiber layer 140 serves to reinforce the strength of the urethane foam layer 130 and the backing layer 150 by using at least one of the elasticity and rigidity of the entangled glass fibers. The backing layer 150 is formed in a layered form using nonwoven fabric. The thickness of the backing layer 150 is set thinner than the thickness of the surface layer 110.

[0076] Each of the plurality of first crushing members P is composed of a crushing body Pa and a plurality of crushed fiber parts 111, 151, 121, 141, as shown in FIG. 5(a).

[0077] Here, each pulverized body Pa is formed by pulverizing an automobile roof part as a laminated composite raw material, which is the above-mentioned discarded part 100. In other words, each pulverized body Pa is formed by integrally pulverizing the surface layer 110, the surface layer-side glass fiber layer 120, the urethane foam layer 130, the backing layer-side glass fiber layer 140, and the backing layer 150. Therefore, each pulverized body Pa maintains the rigidity (hardness) and elasticity attributable to the plurality of glass fibers constituting each glass fiber layer 120, 140 and the semi-rigid urethane foam forming the urethane foam layer 130.

[0078] The multiple pulverized fiber portions 111, 151 (multiple nonwoven fiber portions 111, 151) are each formed from multiple fibers (nonwoven fibers) extending, for example, in a whisker-like manner from each portion of the pulverized body Pa corresponding to the surface layer 110 and the back layer 150.

[0079] In addition, the multiple pulverized fiber portions 121, 141 (multiple glass fiber portions 121, 141) are formed from multiple fibers (glass fibers) extending, for example, in a whisker-like manner from each portion of the pulverized body Pa corresponding to the surface layer side glass fiber layer 120 and the back layer side glass fiber layer 140.

[0080] As shown in FIG. 5(b), each of the second pulverizing members Q is composed of non-three-dimensional pulverized bodies such as short wires (e.g., short fibers) or thin pieces. In the first embodiment, the total content of the first pulverizing members P and the second pulverizing members Q in the breathable base layer Sa is set to a value within a predetermined range of total pulverizing member content, for example, 80 wt%. The predetermined total pulverizing member content range is 80 wt% to 95 wt%. The reason why the lower limit of the predetermined total pulverizing member content range is set to 80 wt% is that if the content is less than 80 wt%, the breathable base layer Sa cannot ensure the necessary rigidity in the floor silencer S. On the other hand, the reason why the upper limit of the predetermined total pulverizing member content range is set to 95 wt% is that if the upper limit is greater than 95 wt%, the floor silencer S cannot ensure the necessary lightweightness.

[0081] The plurality of first pulverizing members P and the plurality of second pulverizing members Q configured in this manner are formed as follows: However, the first pulverizing members P and the second pulverizing members Q are each formed in the number necessary for manufacturing the breathable base layer Sa of the floor silencer S. Accordingly, the same number of discarded parts 100 as necessary for manufacturing the breathable base layer Sa of the floor silencer S are prepared.

[0082] The discarded parts 100 thus prepared are first crushed by a crusher (not shown) to form a plurality of crushed raw materials (not shown). Each of the plurality of crushed raw materials has a size within a range of, for example, 5 mm to 100 mm.

[0083] The plurality of crushed raw materials are then crushed by a crusher (not shown) to form a plurality of crushed raw materials (not shown). Each of the plurality of crushed raw materials has a size within a range of, for example, 10 mm to 50 mm.

[0084] Here, due to the nature of grinding by a grinder, the shapes of the multiple pulverized raw materials are not uniform, but rather vary, such as non-stereoscopic shapes such as three-dimensional shapes, short linear shapes, and thin chip shapes. Similarly, the sizes of the pulverized raw materials are also not uniform, but vary. The size of a three-dimensional or non-stereoscopic pulverized raw material is specified, for example, by the maximum length between two opposing portions of the outer shape of the pulverized raw material. Furthermore, the size of a linear pulverized raw material is specified, for example, by the length of the short fiber if the pulverized raw material is a short fiber.

[0085] In other words, although the size of the raw material to be pulverized varies depending on its shape, it is determined by the largest dimension of the outer shape of the raw material. Of the raw materials to be pulverized, those having a three-dimensional shape form the first pulverizing member P, while those having a non-three-dimensional shape, such as a short line shape or a thin piece shape, form the second pulverizing member Q.

[0086] Here, the reason why the first pulverizing member P is composed of the pulverizing body Pa and the plurality of pulverized fiber parts 111, 151, 121, 141 as described above will be explained.

[0087] As described above, in the process of crushing and pulverizing the disposal member 100, the materials forming the outer skin layer 110 and the inner skin layer 150 of the disposal member 100 are nonwoven fabrics. Therefore, when the pulverized body Pa is formed by crushing the crushing member as described above, the multiple fibers forming the nonwoven fabrics that are the materials forming the outer skin layer 110 and the inner skin layer 150 of the pulverized body Pa extend from the pulverized body Pa as multiple pulverized fiber portions 111, 151, for example, in a whisker-like shape, without being cut into each pulverized body Pa, at least some of the fibers.

[0088] Furthermore, in the process of crushing and then pulverizing the waste member 100 as described above, the materials forming the skin layer side glass fiber layer 120 and the backing layer side glass fiber layer 140 of the waste member 100 are a plurality of glass fibers. Therefore, when the pulverized body Pa is formed by crushing the crushed member as described above, the plurality of glass fibers forming the skin layer side glass fiber layer 120 and the backing layer side glass fiber layer 140 of the pulverized body Pa extend from the pulverized body Pa as a plurality of pulverized fiber portions 121, 141, for example, in a whisker-like shape, without being cut into individual pulverized bodies Pa, at least some of the fibers.

[0089] As can be seen from the above description, the pulverizing member Pa is composed of the pulverizing body Pa and a plurality of pulverized fiber parts 111, 151, 121, 141.

[0090] Here, in manufacturing the breathable base layer Sa of the floor silencer S, the plurality of first pulverizing members P and the plurality of second pulverizing members Q that constitute the breathable base layer Sa are specified as follows.

[0091] In the floor silencer S, in order for the breathable base layer Sa to effectively absorb noise having frequencies in the mid-frequency range, as described above, the first pulverizing members P and the second pulverizing members Q, which are dispersedly stacked within the binder U as described below, are set in size and number in addition to the above content so that the breathable base layer Sa can effectively absorb noise having frequencies in the mid-frequency range.

[0092] Furthermore, within the breathable base layer Sa of the floor silencer S, as described below, a plurality of first pulverizing members P are dispersed from the lower surface to the upper surface of the breathable base layer Sa within a binder U made of isocyanate, a type of thermosetting resin (see Figure 3 or Figure 6).

[0093] In this first embodiment, the isocyanate content of the breathable base layer Sa is set to a value within a predetermined isocyanate content range, for example, 20 wt%. Therefore, the breathable base layer Sa is formed with a total content of the plurality of first pulverizing members P and the plurality of second pulverizing members Q of 80 wt% and an isocyanate content of 20 wt%. In this first embodiment, the predetermined isocyanate content range is, for example, 5 wt% to 20 wt%. The reason why the lower limit of the predetermined isocyanate content range is set to 5 wt% is that if the amount of isocyanate is too small, it will not be possible to ensure a good dispersion state of the first pulverizing members P and the second pulverizing members Q in the breathable base layer Sa. On the other hand, the reason why the upper limit of the predetermined isocyanate content range is set to 20 wt% is that if the upper limit is greater than 20 wt%, the amount of isocyanate will be too high, resulting in an insufficient amount of the plurality of first pulverizing members P and the second pulverizing members Q required to ensure the rigidity of the breathable base layer Sa.

[0094] As described above, when the plurality of first pulverizing members P and the plurality of second pulverizing members Q are dispersed in the isocyanate within the breathable base layer Sa, the plurality of second pulverizing members Q are dispersed so as to be positioned between the plurality of pulverizing bodies Pa that face each other.

[0095] As shown in FIG. 6, a plurality of paths K are formed in the binder U from the lower surface to the upper surface of the breathable base layer Sa along the spaces between the plurality of pulverized bodies Pa facing each other.

[0096] 6, the second crushing members Q dispersed as described above are located within the binder U along with the plurality of pulverized fiber portions 111, 151, 121, 141 of the plurality of first crushing members P, dispersed within each of the paths K described above. Hereinafter, each of the paths K described above will be referred to as a maze path K.

[0097] In the breathable base layer Sa having the above-described configuration, when noise enters the breathable base layer Sa from the lower surface side thereof, the noise propagates inside the breathable base layer Sa.

[0098] Here, each of the pulverized bodies Pa of the multiple first pulverizing members P has a three-dimensional shape while being breathable. On the other hand, each of the multiple pulverized fiber parts 111, 151, 121, 141 of the multiple first pulverizing members P is, as described above, a whisker-like fiber. Also, each of the multiple second pulverizing members Q has a non-three-dimensional shape such as a short line shape or a thin piece shape, as described above.

[0099] The volume occupied by the plurality of pulverized fiber parts 111, 151, 121, 141 and the plurality of second crushing members Q within the binder U is much smaller than the volume occupied by each crushed body Pa within the binder U. Furthermore, as described above, the plurality of pulverized fiber parts 111, 151, 121, 141 and the plurality of second crushing members Q are mainly located dispersedly within each maze-like path K.

[0100] For this reason, noise is more likely to propagate through the maze-like paths K formed by dispersing the plurality of pulverized fiber parts 111, 151, 121, 141 and second pulverizing members Q as described above than through the pulverized body Pa having a three-dimensional shape.

[0101] From the above, although the noise propagates through each pulverized body Pa, it propagates mainly through each labyrinthine path K via each pulverized fiber portion 111, 151, 121, 141 and each pulverizing member Q.

[0102] In this way, in the process in which the noise propagates along each maze-like path K, the noise propagates along the maze shape of each maze-like path K. This means that each maze-like path K plays a role in dissipating the vibration energy of the noise with its maze shape.

[0103] Moreover, as described above, the noise propagating through each maze-like path K propagates while colliding with each pulverized fiber section 111, 151, 121, 141 and each pulverizing member Q. Accordingly, the multiple fibers of each pulverized fiber section 111, 151, 121, 141 and each pulverizing member Q collide with the noise, thereby dissipating the vibration energy of the noise.

[0104] As described above, each maze-like path K, due to its maze shape, plays a role in attenuating the noise by consuming the vibration energy of the noise in combination with the multiple fibers of each pulverized fiber section 111, 151, 121, 141 and each pulverizing member Q.

[0105] Based on the above-described noise propagation configuration in the breathable base layer Sa, in this first embodiment, in order for the breathable base layer Sa to effectively absorb noise having frequencies in the mid-frequency band, each of the pulverized bodies Pa of the multiple first pulverizing members P is formed from a pulverized raw material having, for example, a three-dimensional shape and a size of 15 mm or more among the multiple pulverized raw materials. Also, each of the multiple second pulverizing members Q is formed from a pulverized raw material having, for example, a non-three-dimensional shape such as a linear shape or a flake shape and a size of 5 mm or less among the multiple pulverized raw materials formed as described above.

[0106] The size of each pulverizer Pa and the size of each second pulverizer Q are set to 15 mm or more and 5 mm or less, respectively, but are not limited to this. The size of each pulverizer Pa and the size of each second pulverizer Q may be any size that satisfies the noise propagation configuration for the breathable base layer Sa as described above.

[0107] In the floor seal S, the non-breathable layer Sb is laminated on the breathable base layer Sa from its surface (upper side in FIG. 1).

[0108] In the first embodiment, the breathable layer Sb is formed of a film such as nylon. The thickness of the breathable layer Sb is set within a predetermined thickness range, for example, 30 μm. The predetermined thickness range is, for example, 10 μm to 30 μm. The reason why the lower limit of the predetermined thickness range is set to 1 mm is that if the breathable layer Sb is thinner than 1 mm, it will be too thin and easily torn. The reason why the upper limit is set to 5 mm is that the breathable layer Sb will be too thick and difficult to handle.

[0109] The basis weight of the non-breathable layer Sb is set to a value within a predetermined basis weight range of 30 g / m2 to 200 g / m2, for example, 45 g / m2. The reason why the lower limit of the predetermined basis weight range is set to 30 g / m2 is because if the basis weight is less than 30 g / m2, the non-breathable layer Sb is too light and not suitable for ensuring sound insulation. The reason why the upper limit is set to 200 g / m2 is because if the basis weight is greater than 200 g / m2, the non-breathable layer Sb is too heavy.

[0110] Here, we will explain the manufacturing method of the floor silencer S. The breathable base layer Sa of the floor silencer S is manufactured as follows using a plurality of first pulverizing members P and a plurality of second pulverizing members Q formed as described above, and a binder U.

[0111] The plurality of first pulverizing members P and the plurality of second pulverizing members Q are introduced into a mixer (not shown) together with a liquid binder U (isocyanate). The introduced plurality of first pulverizing members P and the plurality of second pulverizing members Q are stirred and mixed in the binder U by the mixer. As the binder U hardens, the plurality of first pulverizing members P and the plurality of second pulverizing members Q are formed into a stirred mixture together with the binder U. The stirred mixture is formed to have a shape that allows the plurality of first pulverizing members P and the plurality of second pulverizing members Q to be dispersed within the binder U.

[0112] The stirred mixture formed as described above is poured between the upper and lower dies of a press die (not shown). The poured stirred mixture is then press-molded into a predetermined layer shape corresponding to the three-dimensional shape of the breathable base layer Sa by lowering the upper die toward the lower die while spraying steam between the upper and lower dies of the press die using a steam generator (not shown). The breathable base layer Sa has a thickness of, for example, 25 mm. The thickness of the breathable base layer Sa is not particularly limited to 25 mm, but may be any ordinary thickness required for floor silencers installed in various automobiles.

[0113] After the breathable base layer Sa is manufactured in this manner, a non-breathable layer Sb prepared in advance is adhered to the surface of the breathable base layer Sa manufactured as described above with an adhesive, thereby manufacturing a floor silencer S having a two-layer laminate structure consisting of the breathable base layer Sa and the non-breathable layer Sb (see FIG. 2).

[0114] The floor silencer S is constructed with a two-layer laminate structure of an air-permeable base layer Sa and an air-impermeable layer Sb, as shown in Figure 2, 3, or 6. The air-permeable base layer Sa of the floor silencer S is constructed by dispersing a plurality of first pulverizing members P and a plurality of second pulverizing members Q in a binder U made of isocyanate.

[0115] According to the configuration of the breathable base layer Sa, each of the above-mentioned maze-like paths K is formed within the binder U between each of the opposing pulverized bodies Pa, from the lower surface to the upper surface of the breathable base layer Sa, as illustrated in Figure 6.

[0116] In addition, the nonwoven fabric fiber sections 111, 151 and the glass fiber sections 121, 141 extending from the opposing pulverized bodies Pa, as well as the second pulverized members Q located between the opposing pulverized bodies Pa, are each dispersed within the maze-like path K.

[0117] In the floor silencer S configured as above, the role that the breathable base layer Sa and the breathable layer Sb play against noise having frequencies in the mid-frequency band will be described.

[0118] Since the breathable base layer Sa has the above-described configuration, when the noise is incident on the breathable base layer Sa, the noise propagates throughout the breathable base layer Sa, vibrating the breathable base layer Sa as it propagates.

[0119] As described above, the breathable layer Sb is formed of a film laminated on the breathable base layer Sa. Therefore, the breathable layer Sb experiences stress fluctuations in response to pressure fluctuations caused by the vibration of the breathable base layer Sa. This means that the breathable layer Sb vibrates in response to the stress fluctuations.

[0120] In other words, when the breathable base layer Sa vibrates in response to the vibration energy of the incident noise as described above, it causes pressure fluctuations in the non-breathable layer Sb, causing stress fluctuations in response to the pressure fluctuations and causing the non-breathable layer Sb to vibrate.

[0121] In the first embodiment, the phase of vibrations caused by stress fluctuations in the non-breathable layer Sb is shifted in the opposite phase to the phase of vibrations in the breathable base layer Sa depending on the stiffness value of the breathable base layer Sa.

[0122] The stiffness of the breathable base layer Sa is determined by the contents of the first and second crushing members P, Q, and binder U. In the first embodiment, the stiffness of the breathable base layer Sa, i.e., the number and size of the first crushing members P (e.g., crushing bodies Pa) and the content of binder U, are determined so that the phase shift between the vibration of the breathable base layer Sa caused by noise propagation and the vibration of the non-breathable layer Sb in response thereto is 90 degrees (out of phase) at frequencies in the mid-frequency band.

[0123] As described above, for noise having a frequency in the mid-frequency band, the vibration of the non-breathable layer Sb is out of phase with respect to the vibration of the breathable base layer Sa. Therefore, the non-breathable layer Sb laminated on the breathable base layer Sb vibrates in response to the vibration of the breathable base layer Sa caused by the incident noise, resulting in the above-mentioned vibration phase shift. As a result, the vibration of the non-breathable layer Sb is effectively suppressed by the vibration of the breathable base layer Sa, and excellent sound insulation performance can be achieved against noise having a frequency in the mid-frequency band.

[0124] In the first embodiment configured as described above, the floor silencer S has a two-layer laminated structure of a breathable base layer Sa and a non-breathable layer Sb, and is formed to exhibit excellent soundproofing performance, as described above, by having the sound absorption performance of the breathable base layer Sa against incident noise, and the sound insulation performance of attenuating noise having frequencies in the mid-frequency band in accordance with the anti-phase shift between the vibrations generated in the breathable base layer Sa in response to the incident noise and the response vibrations of the non-breathable layer Sb in response to the vibrations.

[0125] With such a floor silencer S configured, when the gasoline automobile is put into a forward running state, for example, the gasoline automobile starts running forward with the left and right front wheels FW and left and right rear wheels RW rotating along the road surface L (see FIG. 1) as the engine E starts. Once the gasoline automobile starts running in this way, it moves forward with the left and right front wheels FW and left and right rear wheels RW rotating along the road L.

[0126] In this forward traveling state, when road noise is generated from the road surface L via both left and right front wheels FW and both left and right rear wheels RW, the road noise propagates mainly through the floor panel FP, through portions of the floor silencer S other than the front end Sd, the rear silencer portion 50, and the middle silencer portion 60, toward the interior of the vehicle compartment 10. Here, a portion of the road noise propagates toward the interior of the vehicle compartment 10 via both left and right rear wheels RW and the lower end of the dash panel DP, and through the front end Sd of the front silencer portion 40. Note that the road noise propagated as described above has a frequency within the mid-frequency range of 200 Hz to 800 Hz, as described above.

[0127] Therefore, with the above-described configuration, the floor silencer S exhibits excellent soundproofing performance against road noise due to the excellent sound absorption performance of the breathable base layer Sa and the excellent sound insulation performance of the non-breathable layer Sb. Therefore, road noise having frequencies in the mid-frequency band is well attenuated by the front silencer portion 40, the rear silencer portion 60, and the middle silencer portion 60 of the floor silencer S, and can be well soundproofed from inside the vehicle compartment 10.

[0128] In other words, road noise propagating from the left and right front wheels FW into the vehicle interior 10 via the front end 40a of the floor silencer S, and road noise propagating through parts other than the floor panel FP and the front end 40a of the floor silencer S, can be effectively soundproofed from inside the vehicle interior 10 by the floor silencer S. As a result, even when the gasoline-powered automobile is traveling forward, the occupants in the vehicle interior 10 can enjoy a comfortable ride without experiencing discomfort due to road noise.

[0129] The noise generated by the engine E (hereinafter referred to as engine noise) is absorbed by the dash silencer DS (see Figure 1) attached along the dash panel DP.

[0130] Incidentally, the insertion loss of the floor silencer S in this first embodiment was measured in relation to the frequency of noise within a frequency range of 200 Hz to 6300 Hz using a reverberation chamber sound absorption coefficient test. For this measurement, a sample (hereinafter referred to as the first example sample) having the same configuration as the floor silencer S was prepared. Therefore, the first example sample had a thickness of 20 mm and a basis weight of 4 kg / m2.

[0131] For comparison with the first example sample, a comparative sample was prepared having a two-layer laminate structure of a felt layer and a sound-insulating layer. Like the first example sample, the comparative sample had a thickness of 20 mm and a basis weight of 4 kg / m2.

[0132] The insertion loss of the first example sample was measured using the reverberation chamber sound absorption coefficient test. The measurement results were obtained as graph W1 shown in Figure 7. Graph W1 shows the insertion loss of the first example sample as a function of frequency.

[0133] The insertion loss of the comparative sample was also measured using the reverberation chamber sound absorption coefficient test. The measurement results were obtained as graph C1 in Figure 7. Graph C1 shows the insertion loss of the comparative sample as a function of frequency.

[0134] Comparing graphs W1 and 2, it can be seen that the insertion loss in graph W1 is greater than that in comparative graph C1 in the mid-frequency band, i.e., the frequency band of 200 Hz to 800 Hz. This means that the first example sample has a higher sound insulation rate than the comparative sample in the mid-frequency band.

[0135] The reason why the sound insulation rate of the first practical sample is higher than that of the comparative sample is that, in accordance with the phase shift in the opposite phase direction between the fluctuations caused by incident noise in the corresponding part (corresponding breathable base part) of the breathable base layer Sa of the practical sample 1 and the fluctuations in the corresponding part (non-breathable layer part) of the non-breathable layer Sb of the practical sample 1 that respond to these vibrations, the vibrations of the non-breathable layer part of the practical sample 1 are suppressed by the vibrations of the non-breathable layer part of the first practical sample.

[0136] Therefore, it can be seen that the first example sample can exhibit good sound insulation performance against the above-mentioned road noise in comparison with the comparative sample. This means that the floor silencer S, like the first example sample, has even better sound insulation performance than the comparative sample. (Second embodiment) FIG. 8 shows a second embodiment in which the present invention is applied to an automobile. This automobile is a type of electric automobile. This electric automobile has a passenger compartment 10 similar to the gasoline-powered automobile described in the first embodiment. Furthermore, like the gasoline-powered automobile described above, this electric automobile is provided with front seats 20a on both the left and right sides within the passenger compartment 10 (only the left front seat 20a is shown in FIG. 10) and rear seats 20b on both the left and right sides (only the left rear seat 20b is shown in FIG. 10).

[0137] Furthermore, in this electric vehicle, similar to the gasoline vehicle described above, both left and right front wheels FW (only the left front wheel is shown in Figure 8) and both left and right rear wheels RW (only the left rear wheel is shown in Figure 8) are supported by front and rear wheel axles 30a, 30b, respectively, and the floor panel FP and floor sheet FS described in the first embodiment above are similarly arranged as the floor panel and floor sheet of the passenger compartment 10 in this second embodiment as well.

[0138] Furthermore, as shown in Fig. 8, the electric vehicle is equipped with a battery set 70, which is attached to the underside of a floor panel FP. Here, the battery set 70 has a casing 71 and a battery group (not shown) made up of a plurality of batteries housed in the casing 71. The casing 71 has an upper wall attached to the underside of the floor panel FP. In this second embodiment, the floor panel FP corresponds to the floor wall of the vehicle interior 10, and therefore the casing 71 is formed in a flat rectangular shape so as to fit along the floor wall (floor panel FP) of the vehicle interior 10.

[0139] The battery group described above is arranged in a casing 71, with each battery being arranged in the casing 71, and the battery group is connected to the electric motor M via an inverter IN (see FIG. 8) so as to be able to drive the electric motor M. The electric motor M is supported on a part of the body of the electric vehicle directly above the axial center of the front wheel set 30a. The inverter IN is disposed in a part of the body of the electric vehicle near the electric motor M, and is connected between the electric motor M and the battery group, adjusting the output of the battery group and supplying it to the electric motor M.

[0140] Furthermore, the electric vehicle is provided with, as its drive system, in addition to the electric motor M described above, a transfer mechanism 80, a front differential mechanism 90a, and a rear differential mechanism 90b.

[0141] The transfer mechanism 80 distributes and transmits the power generated by the rotation of the electric motor M to the front differential mechanism 90a and the rear differential mechanism 90b. The transfer mechanism 80 is supported on another part of the vehicle body behind the electric motor M.

[0142] The front differential mechanism 90a is assembled to the axial center of the front wheel shaft 30a, and the front differential mechanism 90a transmits power differentially to both the left and right front wheels FR via the front wheel shaft 30a based on the distributed power from the transfer mechanism 80.

[0143] The rear differential mechanism 90b is mounted to the axial center of the rear wheel axle 30b. The rear differential mechanism 90b is connected to the transfer mechanism 90a via a propeller shaft 90c, and the rear differential mechanism 90b receives distributed power from the transfer mechanism 90a via the propeller shaft 90c. Accordingly, the rear differential mechanism 90b differentially transmits the distributed power from the propeller shaft 90c to both the left and right rear wheels RW via the rear wheel axle 30b.

[0144] The electric vehicle is equipped with a floor silencer S1 according to the present invention, as shown in Fig. 8. The floor silencer S1 is interposed between a floor panel FP and a floor sheet FS, and is mounted on the floor panel FP so as to face the battery set 70 across the floor panel FP.

[0145] The floor silencer S1 has the same configuration as the floor silencer S described in the first embodiment. Accordingly, as shown in Fig. 8, the floor silencer S1 includes a front silencer portion, a rear silencer portion, and a middle silencer portion located between the front and rear silencer portions, which correspond to the front silencer portion 40, the rear silencer portion 50, and the middle silencer portion 60 located between the front and rear silencer portions 40, 50 of the floor silencer S.

[0146] In this second embodiment, the front silencer portion, rear silencer portion, and middle silencer portion of the floor silencer S1 are respectively indicated by the reference numerals 40, 50, and 60, similar to the front silencer portion 40, rear silencer portion 50, and middle silencer portion 60 of the floor silencer S described in the first embodiment above.

[0147] According to this configuration, the front silencer section 40, rear silencer section 50 and middle silencer section 60 of the floor silencer S1 in this second embodiment are mounted so as to follow the upper surfaces of the front portion FPa, rear portion FPb and middle convex portion FPc of the floor panel FP, respectively, in the same manner as the front silencer section 40, rear silencer section 50 and middle silencer section 60 of the floor silencer S in the first embodiment described above.

[0148] Here, the front silencer portion 40 of the floor silencer S1 has a front end portion, similar to the front silencer portion 40 of the floor silencer S, and this front end portion extends along the lower end portion of the dash panel DP, similar to the front end portion 40a of the front silencer portion 40 of the floor silencer S. Note that, hereinafter, the front end portion of the front silencer portion 40 of the floor silencer S1 will be indicated by the reference symbol 40a, similar to the front end portion 40a of the front silencer portion 40 of the floor silencer S.

[0149] As described above, the floor silencer S1 in this second embodiment has the same configuration as the floor silencer S described in the first embodiment, and therefore the floor silencer S1 is configured with a two-layer laminate structure consisting of a breathable base layer and a non-breathable layer corresponding to the two-layer laminate structure consisting of the breathable base layer Sa and the non-breathable layer Sb of the floor silencer S. In this second embodiment, the breathable base layer and the non-breathable layer of the floor silencer S1 are respectively indicated by the symbols Sa and Sb, similar to the breathable base layer Sa and the non-breathable layer Sb in the first embodiment.

[0150] According to this configuration, the breathable base layer Sa and the non-breathable layer Sb of the floor silencer S1 in the second embodiment have the same configurations as the breathable base layer Sa and the non-breathable layer Sb of the floor silencer S in the first embodiment. The other configurations of the second embodiment are the same as those of the first embodiment.

[0151] In the second embodiment configured as above, the floor silencer S1 is configured to have the same configuration as the floor silencer S of the first embodiment, as described above.

[0152] With this configuration, when the electric vehicle starts moving, the batteries in the battery set 70 supply power to the electric motor M via the inverter, causing the electric motor M to start. As a result, power from the electric motor M is distributed by the transfer mechanism 80 to the front and rear differential mechanisms 90a, 90b.

[0153] The front differential mechanism 90a then transmits the distributed power from the transfer mechanism 80 to the left and right front wheels FW via the front wheel shaft 30a, and the rear differential mechanism 90b receives the distributed power from the transfer mechanism 80 via the propeller shaft 90c and transmits it to the left and right rear wheels RW via the rear wheel shaft 30b.

[0154] Accordingly, the electric vehicle starts moving forward, for example, with both left and right front wheels FW and both left and right rear wheels RW rotating along the road surface L (see FIG. 8). Having started moving in this way, the electric vehicle moves forward with both left and right front wheels FW and both left and right rear wheels RW rotating along the road L.

[0155] In this forward traveling state, when road noise is generated from the road surface L via the left and right front wheels FW or the left and right rear wheels RW, the road noise propagates into the vehicle interior 10 via the floor silencer S1 of the second embodiment instead of the floor silencer S described in the first embodiment. Also, when power is supplied from the batteries in the battery set 70 to the electric motor M via the inverter, and the electric motor M generates motor noise (noise generated by the electric motor) as it operates, the motor noise propagates into the vehicle interior 10 through the floor panel FP and floor silencer S1.

[0156] The road noise propagated as described above has a frequency in the mid-frequency range, while the motor noise propagated as described above has a frequency in the high-frequency range, as described above.

[0157] Therefore, since the floor silencer S1 has the same configuration as the floor silencer S of the first embodiment, the floor silencer S1 has the same configuration as the first example sample described in the first embodiment.

[0158] The first example sample has the insertion loss characteristic of graph W1 in Fig. 7 described in the first embodiment. As described in the first embodiment, the insertion loss in the insertion loss characteristic is better than the insertion loss characteristic of the comparative sample described in the first embodiment (see graphs W1 and W2 in Fig. 7) at frequencies in the mid-frequency band of noise. This means that the floor silencer S1, like the first example sample (floor silencer S), has even better sound insulation performance than the comparative sample.

[0159] Therefore, in the second embodiment, even if road noise attempts to propagate into the interior of the electric vehicle 10 as described above, the road noise can be effectively soundproofed from inside the interior of the vehicle 10 due to the sound absorption performance of the breathable base layer Sa of the floor silencer S and the sound insulation performance of the non-breathable layer Sb.

[0160] As described above, the first example sample described in the first embodiment has the insertion loss characteristic of graph W1 in Fig. 7 described in the first embodiment. According to graph W1, the insertion loss in this insertion loss characteristic is smaller in the high noise frequency band of 1000 Hz to 6300 Hz than the insertion loss in the insertion loss characteristic of the comparison sample in Fig. 7, but as shown in graph W1, it maintains a value close to the maximum insertion loss for frequencies in the mid-frequency band.

[0161] However, as described in the first embodiment above, the first example sample exhibits an insertion loss that is superior to the insertion loss of the comparative sample (see graph C1 in Figure 7) for road noise (noise in the mid-frequency band), and in addition, for motor noise (noise having frequencies in the high-frequency band), as described above, it maintains a value close to the maximum insertion loss for frequencies in the mid-frequency band.

[0162] Thus, although the comparative sample has a larger insertion loss than the first practical sample for noise having a frequency in the high frequency band (motor noise), the comparative sample only has a smaller insertion loss than the first practical sample for noise having a frequency in the mid frequency band (road noise).

[0163] That is, the first example sample exhibits a larger insertion loss for road noise than the comparative sample, and exhibits an insertion loss for motor noise that is close to the maximum value of the insertion loss for road noise.

[0164] Therefore, the first example sample, in other words, the floor silencer S1, can exhibit good insertion loss for both road noise and motor noise.

[0165] In other words, the floor silencer S1 can effectively insulate road noise and motor noise from inside the passenger compartment 10 of the electric vehicle by utilizing the sound absorption performance of the breathable base layer Sa and the sound insulation performance of the non-breathable layer Sb. As a result, even when the electric vehicle is traveling forward, passengers in the passenger compartment 10 can enjoy a comfortable ride without feeling discomfort from both road noise having frequencies in the mid-frequency range and motor noise having frequencies in the high-frequency range. Other effects are the same as those of the first embodiment. (Third embodiment) 9 shows a main part of a third embodiment of the floor silencer according to the present invention. The floor silencer (hereinafter designated by the reference symbol S2) of this third embodiment replaces the floor silencer S1 described in the second embodiment, and is mounted between the floor panel FP and floor sheet FS of the electric vehicle so as to fit along the upper surface of the floor panel FP.

[0166] The floor silencer S2 of this third embodiment has a configuration in which a sound absorbing layer Sc is employed in the floor silencer S1 of the second embodiment. The sound absorbing layer Sc is laminated to the non-breathable layer Sb of the two-layer laminate structure of the floor silencer S1, which is made up of the breathable base layer Sa and the non-breathable layer Sb, by adhesive bonding so as to face the breathable base layer Sa with the non-breathable layer Sb interposed therebetween. This means that the floor silencer S2 is formed with a three-layer laminate structure made up of the breathable base layer Sa, the non-breathable layer Sb, and the sound absorbing layer Sc.

[0167] In the third embodiment, the sound absorbing layer Sc is made of a predetermined porous material, such as felt, and has a basis weight of 100 g / m within a predetermined range of basis weights of the sound absorbing layer.

[0168] Here, the predetermined range of the basis weight of the sound absorbing layer is, for example, 15 g / m2 to 2000 g / m2. The reason why the lower limit of the predetermined basis weight range of the sound absorbing layer is set to 15 g / m2 is that if it is less than 15 g / m2, the sound absorbing performance of the sound absorbing layer Sc cannot be ensured satisfactorily. The reason why the upper limit of the predetermined basis weight range of the sound absorbing layer is set to 2000 g / m2 is that if it is greater than 2000 g / m2, the sound absorbing layer Sc becomes too heavy. Note that the predetermined porous material is not limited to the above-mentioned felt, but may also be, for example, a nonwoven fabric or urethane. The other configurations of this third embodiment are the same as those of the first embodiment.

[0169] In the third embodiment configured as described above, similar to the second embodiment, when road noise and motor noise are generated while the electric vehicle is traveling forward, the road noise and motor noise propagate through the floor silencer S2 toward the interior of the passenger compartment 10 of the electric vehicle.

[0170] During this propagation process, when road noise and motor noise enter the floor silencer S2 from its underside, the road noise and motor noise are absorbed and insulated by the sound absorption performance of the breathable base layer Sa and the sound insulation performance of the non-breathable layer Sb, and are attenuated as they enter the sound absorption layer Sc, just as described in the second embodiment above.

[0171] Since the sound absorbing layer Sc is made of felt and has sound absorbing properties, road noise and motor noise that enter the sound absorbing layer Sc from the non-breathable layer Sb are further absorbed and attenuated by the sound absorbing layer Sc using its sound absorbing properties.

[0172] This allows road noise and motor noise to be more effectively prevented from entering the vehicle interior 10 than with the floor silencer S1 of the second embodiment. As a result, even when the electric vehicle is traveling forward, passengers in the vehicle interior 10 can enjoy a more comfortable ride without experiencing discomfort due to road noise and motor noise, compared to the second embodiment. Other advantages are the same as those described in the second embodiment.

[0173] Incidentally, the insertion loss of the floor silencer S2 in the third embodiment was measured by a reverberation chamber sound absorption coefficient test, as in the first embodiment. For this measurement, a sample (hereinafter referred to as a second example sample) having the same configuration as the floor silencer S2 was prepared.

[0174] The insertion loss of the second example sample was measured by a reverberation chamber sound absorption coefficient test. The measurement results were obtained as graph W2 shown in Figure 11. Graph W2 is a graph showing the insertion loss of the second example sample as a function of frequency. Note that in Figure 10, graphs W1 and C are the same as graphs W1 and C shown in Figure 6, respectively.

[0175] According to graph W2, it can be seen that the insertion loss in the mid-frequency band within 200 Hz to 800 Hz is almost better than the insertion loss of the insertion loss characteristic of graph W1 of the first example sample described in the second embodiment.

[0176] Furthermore, according to graph W2, in the high frequency band of 1000 Hz to 6300 Hz, although the insertion loss is somewhat less than the insertion loss characteristics of the above-mentioned comparative sample (see graph C1), it can be seen that it is significantly improved compared to the insertion loss of the insertion loss characteristics of graph W1 of the first practical sample described in the above-mentioned second embodiment.

[0177] These are believed to be due to the fact that the floor silencer S2 has a three-layer laminated structure in which a sound-absorbing layer Sc is added to the two-layer laminated structure of the floor silencer S, compared to the two-layer laminated structure of the floor silencer S.

[0178] From the above, it can be seen that the floor silencer S2 has better soundproofing performance than the comparative sample and the first example sample (floor silencer S1).

[0179] The third embodiment shows an example in which the floor silencer S2 shown in FIG. 9 is applied to the electric vehicle of the second embodiment, but the present invention is not limited to this. The floor silencer S2 shown in FIG. 9 may be modified to be applied to the gasoline vehicle of the first embodiment.

[0180] In this modified example (hereinafter referred to as the modified example), the floor silencer S2 is mounted between the floor panel FP and the floor sheet FS of the gasoline-powered automobile so as to fit along the upper surface of the floor panel FP, instead of the floor silencer S described in the first embodiment. The other configurations are the same as those described in the first or second embodiment.

[0181] In this modified example configured as described above, similar to the first embodiment, when road noise occurs while a gasoline-powered vehicle is traveling forward, the road noise propagates through the floor silencer S2 toward the interior of the passenger compartment 10 of the electric vehicle.

[0182] During this propagation process, when road noise enters the floor silencer S2 from its underside, the road noise is absorbed and insulated by the sound absorption performance of the breathable base layer Sa and the sound insulation performance of the non-breathable layer Sb, and is attenuated as it enters the sound absorption layer Sc, just as described in the first embodiment above.

[0183] Then, the road noise is further absorbed and attenuated by the sound absorbing performance of the sound absorbing layer Sc described in the third embodiment.

[0184] This allows road noise to be prevented from entering the vehicle interior 10 more effectively than with the floor silencer S of the first embodiment. As a result, even when the gasoline-powered automobile is traveling forward, the passengers in the vehicle interior 10 can enjoy a more comfortable ride without experiencing discomfort due to road noise, compared to the first embodiment. Other advantages are the same as those described in the first embodiment. (Fourth embodiment) 12 shows a main part of a fourth embodiment of the floor silencer according to the present invention. The floor silencer of the fourth embodiment (hereinafter referred to as floor silencer S3) replaces the floor silencer S described in the first embodiment and is mounted between the floor panel FP and floor sheet FS of a gasoline-powered automobile so as to fit along the upper surface of the floor panel FP.

[0185] The floor silencer S3 includes an air-permeable base layer Sd and an air-impermeable layer Se, which correspond to the air-permeable layer Sa and the air-impermeable layer Sb of the floor silencer S in the first embodiment. The air-impermeable layer Se is laminated to the air-permeable base layer Sd by bonding with an adhesive. The air-impermeable layer Se is formed from the same film as the material for the air-permeable base layer Sa described in the first embodiment.

[0186] The breathable base layer Sd has a configuration in which auxiliary members R are employed instead of the plurality of pulverizing members Q in the breathable base layer Sa of the floor silencer S described in the first embodiment.

[0187] Therefore, the breathable base layer Sd has a configuration in which auxiliary members R are added to the plurality of pulverizing members P and binder U of the breathable base layer Sa described in the first embodiment.

[0188] The auxiliary member R adjusts the hardness (rigidity) of the breathable base layer Sd, thereby adjusting the frequency band that improves the sound insulation performance of the non-breathable layer Se.

[0189] In the fourth embodiment, the auxiliary member R is made of, for example, a recycled fiber material. Because recycled fiber material is made of cotton-like fibers, the softness of the breathable base layer Sd varies depending on the content of the auxiliary member R (recycled fiber material) in the breathable base layer Sd. That is, the greater (or less) the content of the auxiliary member R, the greater (or less) the softness of the breathable base layer Sd. In other words, the greater the softness of the breathable base layer Sd, the more the vibration frequency of the breathable base layer Sd shifts to a frequency lower than the lower limit frequency of the mid-frequency band. Conversely, the less the softness of the breathable base layer Sd, the less the degree to which the vibration frequency of the breathable base layer Sd shifts to a lower frequency.

[0190] Therefore, in the fourth embodiment, the content of the auxiliary members R in the breathable base layer Sd is set within a predetermined range of auxiliary member content, for example, 50 wt%. The predetermined range of auxiliary member content is, for example, 10 wt% to 70 wt%. When the content of the auxiliary members R is 50 wt%, the frequency band in which the sound insulation performance of the breathable layer Sd is improved is 125 Hz to 800 Hz, which is wider on the low frequency side than the mid-frequency band of 200 Hz to 800 Hz described in the first embodiment. This means that by setting the content of the first pulverizable members P to 30 wt% and the content of the auxiliary members R to 50 wt%, as described below, the sound insulation performance of the breathable layer Sd is improved at even lower frequencies than that of the breathable layer Sb described in the first embodiment.

[0191] In addition, in the fourth embodiment, the predetermined isocyanate content range described in the first embodiment is changed to 5 wt% to 25 wt% due to the addition of the auxiliary member R. Also, the predetermined total pulverizing member content range in the fourth embodiment is 25 wt% to 65 wt%, which is different from the first embodiment.

[0192] In the fourth embodiment, the content of the auxiliary members R is set to 50 wt%, and therefore the content of the plurality of first pulverizing members P is reduced to 30 wt% compared to the first embodiment. As a result, the breathable base layer Sd of the fourth embodiment is composed of a plurality of first pulverizing members P of 30 wt%, a content of the auxiliary members R of 50 wt%, and a content of the isocyanate described in the first embodiment of 20 wt%.

[0193] On the premise of such a configuration, in manufacturing the floor silencer S3, a plurality of pulverizing members P and auxiliary members R are put into the mixer / stirrer described in the first embodiment together with the liquid binder U described in the first embodiment, and after being stirred and mixed by the mixer / stirrer, as the binder U hardens, the plurality of pulverizing members P are dispersedly arranged in the binder U together with the auxiliary members R. In this way, the floor silencer S3 is manufactured.

[0194] Furthermore, in the floor silencer S3 of the fourth embodiment, as described above, the plurality of pulverizing members P are located together with the auxiliary members R in a dispersed manner within the binder U. Therefore, in the floor silencer S3, a plurality of labyrinth paths K are formed passing through the pulverizing bodies Pa of the plurality of pulverizing members P facing each other, as in the first embodiment, as illustrated in Fig. 12. Accordingly, the plurality of pulverized fiber portions of each pulverizing member P are located in a dispersed manner within each labyrinth path K.

[0195] Furthermore, the auxiliary members R are dispersed as a collection of cotton-like fibers between the crushing bodies Pa of the opposing crushing members P. Accordingly, the cotton-like felt fibers of the auxiliary members R are dispersed within each labyrinthine path K together with the multiple crushed fiber portions of each crushing member P. The other configurations are the same as those of the first embodiment.

[0196] In the third embodiment configured as described above, in the floor silencer S2, noise passing through each maze-like path K moves along the maze shape of each path K, as in the first embodiment, and collides with the cotton-like fibers of the auxiliary member R and the multiple pulverized fiber portions of each pulverizer member P. This allows the noise to be attenuated by the loss of its vibration energy.

[0197] Moreover, in the fourth embodiment, the content of the auxiliary member R in the breathable base layer Sd is 50 wt %, as described above. Therefore, the breathable base layer Sd is softer than the breathable base layer Sa described in the first embodiment. Therefore, the floor silencer S3, in cooperation with the breathable base layer Sd of the non-breathable layer Se, It is possible to exhibit excellent sound insulation performance against noise having frequencies even lower than the mid-frequency band frequencies described in the first embodiment.

[0198] According to this, even if the frequency of road noise is in a frequency band expanded to lower frequencies than the mid-frequency band described in the first embodiment, the floor silencer S3 can effectively attenuate road noise having frequencies in the expanded mid-frequency band by using the sound absorption performance of the breathable base layer Sd and the sound insulation performance of the non-breathable layer Se. As a result, even when the gasoline-powered automobile is traveling forward, the occupants in the passenger compartment 10 can enjoy a comfortable ride without feeling discomfort from the road noise.

[0199] Furthermore, in the fourth embodiment, unlike the breathable base layer Sa in the first embodiment, the breathable base layer Sd is formed by adding an auxiliary member R. The recycled fiber material from which the auxiliary member R is formed is a soft, cotton-like fiber. This means that the recycled fiber of the auxiliary member R gives the floor silencer S3 volume. As a result, the floor silencer S3 can be visually recognized as a plump, thick, and attractive floor silencer.

[0200] Furthermore, in the above fourth embodiment, an example is described in which the floor silencer S3 is applied to the gasoline automobile referred to in the above first embodiment. Alternatively, the floor silencer S3 may be applied in place of the floor silencer S1 in the electric automobile referred to in the above second embodiment.

[0201] According to this, even if the road noise is in a frequency band that is expanded to a lower frequency side than the mid-frequency band described in the second embodiment, the road noise can be effectively soundproofed from inside the passenger compartment 10 of the electric vehicle by the floor silencer S3, as described in the fourth embodiment.

[0202] In the fourth embodiment, the floor silencer 3 may be adopted with its breathable base layer Sd and non-breathable layer Se in place of the breathable base layer Sa and non-breathable layer Sb of the floor silencer S2 in the third embodiment.

[0203] According to this, the floor silencer 3 has a three-layer laminated structure consisting of an air-permeable base layer Sd, an air-impermeable layer Se, and a sound-absorbing layer Sc.

[0204] Therefore, the floor silencer S3 having this three-layer laminated structure can exhibit overall soundproofing performance by combining the soundproofing performance of a floor silencer having a two-layer laminated structure consisting of a breathable base layer Sd and a non-breathable layer Se, and the sound absorption performance of the sound-absorbing layer Sc described in the third embodiment above.

[0205] It should be noted that the present invention is not limited to the above-described embodiments, and various modifications such as those described below can be made. (1) In implementing the present invention, the present invention is not limited to the gasoline-powered vehicle described in the first embodiment and the electric vehicle described in the second embodiment, but may also be applied to a hybrid vehicle equipped with both an electric motor and an engine as prime movers.

[0206] In this case, a floor silencer that can exhibit excellent sound absorbing performance against both road noise and motor noise may be disposed along the floor and wall of the vehicle interior of the hybrid vehicle. (2) In carrying out the present invention, the binder U in the above embodiments is not limited to this, and may be a binder made of a thermosetting resin. (3) In carrying out the present invention, the waste material referred to in each of the above embodiments is not limited to the configuration described in the first embodiment, but may also be a laminated composite material formed by laminating a porous layer, a thermosetting resin layer, and a glass fiber layer having a plurality of glass fibers. (4) In carrying out the present invention, the front silencer portion or the rear silencer portion of the floor silencer may be used as the floor silencer.

[0207] The floor silencer may also be configured to silence road noise and motor noise from the front seat foot area to the rear seat foot area in the vehicle cabin using a front silencer, a middle silencer, and a rear silencer. (5) In implementing the present invention, the material for forming the auxiliary member R described in the fourth embodiment above is made of recycled wool. However, instead of this, a chip-shaped foam material such as chip-shaped urethane foam, which is harder than recycled wool, may be used as the material for forming the auxiliary member R.

[0208] According to this, the hardness of the breathable base layer Sd varies depending on the content of the auxiliary member R (chip-like foam material) in the breathable base layer Sd. That is, the greater (or less) the content of the auxiliary member R (chip-like foam material), the greater (or less) the hardness of the breathable base layer Sd. In other words, the greater the hardness of the breathable base layer Sd, the more the vibration frequency of the breathable base layer Sd shifts toward a higher frequency than the upper limit frequency of the mid-frequency band. Conversely, the less the hardness of the breathable base layer Sd, the less the degree to which the vibration frequency of the breathable base layer Sd shifts toward a higher frequency.

[0209] Therefore, by increasing the content of the auxiliary members R (chip-like foam material) and decreasing the content of the first pulverizable members P accordingly, the frequency band in which the sound insulation performance of the air-impermeable layer Sd is improved is expanded to the higher frequency side from the mid-frequency band of 200 Hz to 800 Hz described in the first embodiment. This means that the sound insulation performance of the air-impermeable layer Sd is improved at even higher frequencies than that of the air-impermeable layer Sb described in the first embodiment.

[0210] As a result, even if the frequency of road noise is in a frequency band that is expanded to a higher frequency than the mid-frequency band described in the first embodiment, the floor silencer S3 can effectively soundproof road noise having a frequency in the mid-frequency band expanded to the higher frequency side described above, by using the sound absorption performance of the breathable base layer Sd and the sound insulation performance of the non-breathable layer Se. (6) In carrying out the present invention, the discarded parts 100 described in the first embodiment may be a urethane layer made of semi-rigid urethane foam instead of a roof part of an automobile.

[0211] The urethane layer may be crushed and then pulverized as described in the first embodiment to form a plurality of first crushing members P and a plurality of second crushing members Q.

[0212] By using the plurality of first crushing members P and the plurality of second crushing members Q formed in this manner, the floor silencer referred to in each of the above embodiments can be formed in the same manner as described in each of the above embodiments and applied to an automobile, and substantially the same effects as those described in each of the above embodiments can be achieved. (7) In carrying out the present invention, the present invention is not limited to the floor silencer in each of the above-described embodiments, but may be applied to various soundproofing bodies for automobiles and soundproofing bodies for buildings. [Explanation of symbols]

[0213] 10...vehicle compartment, 70...battery set, 100...discarded part, 110...skin layer, 111, 121, 141, 151...crushed fiber part, 120, 140...glass fiber layer, 130...urethane foam layer, 150...lining layer, DP...Dash panel, E...Engine, ER...Engine room, FP... floor panel, FS... floor sheet, K... maze-like path, M... electric motor, P... crushing member, Pa... crushing body, R... auxiliary member, S, S1, S2, S3...floor silencer, Q...crushing member, U...binder.

Claims

1. A soundproofing body for an automobile comprising an air-permeable base layer having a plurality of pulverized members and a thermosetting resin binder, and an air-impermeable layer, each of the plurality of pulverizing members has a three-dimensional pulverizing body formed by pulverizing a raw material having at least a thermosetting resin layer; the air-permeable base layer is formed in a layer shape by dispersing the plurality of three-dimensional pulverized bodies in the thermosetting resin binder, the breathable base layer has at least one labyrinth path formed between two opposing three-dimensional pulverized bodies among the plurality of three-dimensional pulverized bodies in the thermosetting resin binder, The soundproof body is such that the non-breathable layer is laminated along one of the two surfaces of the breathable base layer.

2. 2. The soundproof body according to claim 1, further comprising a sound absorbing layer laminated on the non-permeable layer so as to face the breathable base layer with the non-permeable layer interposed therebetween.

3. the base material includes, in addition to the thermosetting resin layer, a glass fiber layer having a plurality of glass fibers laminated together with the thermosetting resin layer, Each of the plurality of three-dimensional pulverized bodies has a corresponding glass fiber portion corresponding to the glass fiber layer, each of the plurality of pulverizing members also has a plurality of glass fibers extending from a corresponding glass fiber portion of the three-dimensional pulverized body corresponding to the glass fiber layer as the raw material is pulverized, 3. The soundproof body according to claim 1, wherein the plurality of glass fibers extending from the corresponding glass fiber portion are located in a dispersed manner within the at least one labyrinth-like path.

4. the plurality of pulverizing members are a plurality of first pulverizing members, and the breathable base layer is formed in a layer shape by dispersing a plurality of second pulverizing members together with the plurality of first pulverizing members in the thermosetting resin binder; each of the plurality of second crushing members includes a crushed body having a non-three-dimensional shape formed from the raw material by crushing the raw material together with the crushed body having a three-dimensional shape; 3. The soundproof body according to claim 1, wherein the plurality of second crushing members are located in a dispersed manner within the at least one labyrinth-like path.

5. the breathable base layer includes, in addition to the plurality of pulverizing members and the thermosetting resin binder, an auxiliary member made of a recycled fiber material; the auxiliary member is dispersed and mixed together with the plurality of pulverized members in the thermosetting resin binder, 3. The soundproofing body according to claim 1, wherein the content of the auxiliary material is adjusted together with the content of the plurality of pulverized materials so that the hardness of the breathable base layer is reduced to a hardness that shifts the frequency of the response vibration of the breathable base layer to incident noise to a frequency lower than the frequency of the mid-frequency band.

6. the breathable base layer includes, in addition to the plurality of pulverizing members and the thermosetting resin binder, an auxiliary member made of chip-like foam material; the auxiliary member is dispersed and mixed together with the plurality of pulverized members in the thermosetting resin binder, 3. The soundproofing body according to claim 1, wherein the content of the auxiliary material is adjusted together with the content of the plurality of pulverized materials so that the hardness of the breathable base layer is increased to a level that shifts the frequency of the response vibration of the breathable base layer to incident noise toward a higher frequency side than the frequency of the mid-frequency band.

7. A floor silencer mounted from inside a vehicle compartment along a floor wall of the vehicle compartment of an automobile equipped with at least one of an electric motor and an engine as a prime mover, The present invention provides a method for manufacturing a pulverized sheet having a plurality of crushed members and a thermosetting resin binder, and a non-breathable layer. each of the plurality of pulverizing members has a three-dimensional pulverizing body formed by pulverizing a raw material having at least a thermosetting resin layer; the breathable base layer is formed in a layer shape by dispersing a plurality of the three-dimensional pulverized bodies in the thermosetting resin binder, the breathable base layer has at least one labyrinth path formed between two opposing three-dimensional pulverized bodies among the plurality of three-dimensional pulverized bodies in the thermosetting resin binder, The non-breathable layer is laminated on one of the two surfaces of the breathable base layer.

8. 8. The floor silencer for an automobile according to claim 7, further comprising a sound absorbing layer laminated on the non-permeable layer so as to face the breathable base layer with the non-permeable layer interposed therebetween.

9. the base material includes, in addition to the thermosetting resin layer, a glass fiber layer having a plurality of glass fibers laminated together with the thermosetting resin layer, Each of the plurality of three-dimensional pulverized bodies has a corresponding glass fiber portion corresponding to the glass fiber layer, 8. The floor silencer for an automobile according to claim 7, wherein each of the plurality of crushing members also has a plurality of glass fibers extending from the corresponding glass fiber portion of the three-dimensional crushed body relative to the glass fiber layer as the raw material is crushed.

10. the plurality of pulverizing members are a plurality of first pulverizing members, and the breathable base layer is formed in a layer shape by dispersing a plurality of second pulverizing members together with the plurality of first pulverizing members in the thermosetting resin binder; each of the plurality of second crushing members includes a crushed body having a non-three-dimensional shape formed from the raw material by crushing the raw material together with the crushed body having a three-dimensional shape; 9. The floor silencer according to claim 7, wherein the plurality of second crushing members are positioned in a dispersed manner within the at least one labyrinth-like path.

11. the breathable base layer includes, in addition to the plurality of pulverizing members and the thermosetting resin binder, an auxiliary member made of a recycled fiber material; the auxiliary member is dispersed and mixed together with the plurality of pulverized members in the thermosetting resin binder, 10. A floor silencer for an automobile as described in claim 8 or 9, characterized in that the content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer is reduced to a hardness that changes the frequency of the breathable base layer's response vibration to incident noise to a frequency lower than the frequency of the mid-frequency band.

12. the breathable base layer includes, in addition to the plurality of pulverizing members and the thermosetting resin binder, an auxiliary member made of chip-like foam material; the auxiliary member is dispersed and mixed together with the plurality of pulverized members in the thermosetting resin binder, 10. A floor silencer for an automobile as described in claim 8 or 9, characterized in that the content of the auxiliary member is adjusted together with the content of the plurality of crushing members so that the hardness of the breathable base layer increases to a hardness that changes the frequency of the breathable base layer's response vibration to incident noise to a frequency higher than the frequency of the mid-frequency band.

Images