Soundproof structure and manufacturing method thereof

Abstract

To provide a soundproof structure that has excellent soundproof performance and reduces manufacturing cost, and a manufacturing method thereof.SOLUTION: A soundproof structure 1 comprises: an elastic sheet 2; a support member 3 that supports the sheet 2 and divides the sheet 2 into a planar compartment 2A; and a filling member 4 that is interposed between the sheet 2 and the support member 3. The support member 3 has a plurality of openings 3H divided by vertical and horizontal crosspiece parts 3A. The filling member 4 is interposed between the sheet 2 and the crosspiece parts 3A, and fills a gap between the sheet 2 and the crosspiece parts 3A.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a soundproof structure used in, for example, an automobile body panel, and a method for manufacturing the same. [Background technology]

[0002] A conventional soundproof structure is described in Patent Document 1. The soundproof structure described in Patent Document 1 includes an elastic sheet and a support portion that supports the sheet and separates the sheet. The support portion is a honeycomb structure in which a large number of cylindrical cells are arranged. This soundproof structure exhibits high soundproofing performance over a wide frequency range of 2000 Hz or less. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6879369 Summary of the Invention [Problem to be solved by the invention]

[0004] However, while the conventional soundproof structures described above have excellent soundproofing performance, they are relatively expensive and it is difficult to reduce manufacturing costs, so solving these problems has been a challenge.

[0005] The present invention has been made in light of the above-mentioned conventional problems, and aims to provide a soundproof structure and a manufacturing method thereof that have excellent soundproofing performance and can reduce manufacturing costs. [Means for solving the problem]

[0006] The soundproof structure according to the present invention comprises an elastic sheet, a support member that supports the sheet and divides the sheet into planar partitions, and a filler member interposed between the sheet and the support member. The soundproof structure is such that the support member has a plurality of openings divided by vertical and horizontal bar portions, and the filler member Made of elastic material The gap between the sheet and the crosspiece is filled and the sheet is fixed to the crosspiece. The maximum deflection position of the sheet is located within the opening. It is characterized by the fact that

[0007] The method for manufacturing a soundproof structure according to the present invention is a method for manufacturing the above-mentioned soundproof structure, and is characterized by comprising the steps of applying a liquid filler material that solidifies over time to one side of a support member, bringing the applied surface of the filler material on the support member into contact with a flat film, causing the filler material to solidify over time to form a filler member, and, after peeling off the film, fixing a sheet to the surface of the support member facing the filler member.

[0008] In the above soundproof structure, examples of materials for the elastic sheet include rubber. Examples of materials for the support member include expanded metal or expanded metal-like mesh members, and wire mesh or wire mesh-like mesh members. Examples of materials for the filling member include rubber. In other words, relatively inexpensive materials can be used for the sheet, support member, and filling member.

[0009] Furthermore, when the above-mentioned soundproofing structure uses a mesh-like material such as expanded metal or wire mesh as the support member, these have unevenness in the thickness direction, which creates non-contact areas between the sheet and the mesh. Therefore, the above-mentioned soundproofing structure fills the non-contact areas with a filling material, bringing the sheet and the support member into substantial contact with each other and ensuring the sheet's surface rigidity. As a result, when a uniformly distributed pressure is applied to the sheet in the thickness direction, the soundproofing structure ensures soundproofing performance by positioning the maximum deflection of the sheet's planar partition within the support member and filling member (within the opening) that make up the planar partition. [Effects of the Invention]

[0010] By adopting the above-described configuration, the soundproof structure according to the present invention has excellent soundproofing performance and can reduce manufacturing costs. Furthermore, the method for manufacturing a soundproof structure can provide a soundproof structure with excellent soundproofing performance at low cost. [Brief explanation of the drawings]

[0011] [Figure 1] 1A is a cross-sectional view showing a first embodiment of a soundproof structure according to the present invention, and FIG. 1B is a perspective view showing the same in an exploded state. [Figure 2] 1A is an explanatory diagram showing the sound insulating effect of a soundproof structure according to an embodiment, FIG. 1B is an explanatory diagram showing a comparative example, and FIG. 1C is an explanatory diagram showing surface resonance. [Figure 3] 1 is a graph showing the sound insulation performance of a soundproof structure. [Figure 4] 1A to 1D are perspective views each illustrating a method for manufacturing a soundproof structure in the order of steps. [Figure 5] FIG. 3 is a cross-sectional view showing a second embodiment of a soundproof structure according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] First Embodiment 1 includes an elastic sheet 2, a support member 3 that supports the sheet 2 and divides the sheet 2 into planar partitions 2A, and a filler member 4 that is interposed between the sheet 2 and the support member 3. The soundproof structure 1 has a structure in which the support member 3 has a plurality of openings H that are divided by vertical and horizontal crosspieces 3A, and the filler member 3 is fixed to the sheet 2 and the crosspieces 3A in a state in which it fills the gaps between the sheet 2 and the crosspieces 3A.

[0013] The sheet 2 is a flat, film-like member made of rubber, including synthetic rubber, for example. The support member 3 is an expanded metal or an expanded metal-like mesh member. This support member 3 is manufactured using a well-known expanding device that forms slits in a flat plate-like material and then expands the slits. The above-mentioned sheet 2 and support member 3 can generally be mass-produced and are relatively inexpensive.

[0014] The support member 3 has a bending rigidity greater than that of the sheet 2. Furthermore, the support member 3 is not limited to being made of metal, and may be made of plastic that can be manufactured by an expanding method involving heating, as long as it has a bending rigidity greater than that of the sheet 2.

[0015] Due to its structure, the support member 3 described above inevitably has unevenness in the thickness direction. Therefore, if the support member 3 is fixed directly to a flat sheet 2, the unevenness will cause non-contact areas between the crosspiece 3A and the sheet 2, impairing the soundproofing performance. Note that in Figure 1(A), the unevenness of the support member 3 is exaggerated for ease of understanding.

[0016] Therefore, in the above-described soundproof structure 1, a filler member 4 is interposed between the sheet 2 and the crosspiece 3A of the support member 3, filling in the non-contact portions between the sheet 2 and the crosspiece 3A of the support member 3 caused by the unevenness. The filler member 4 is made of rubber, for example, including synthetic rubber, and is interposed mainly between the sheet 2 and the crosspiece 3A of the support member 3, so that the density (mass) of the entire soundproof structure 1 is smaller than the density (mass) of the support member 3. In this way, the soundproof structure 1 ensures that the sheet 2 and the crosspiece 3A of the support member 3 are in substantially tight contact with each other, thereby ensuring the surface rigidity of the sheet 2.

[0017] In this way, when uniformly distributed pressure is applied in the thickness direction of the sheet 2, as shown in Figure 2(A), the soundproofing structure 1 maintains the planar partition 2A while ensuring the surface rigidity of the sheet 2, thereby positioning the position of maximum deflection D of the planar partition 2A within the crosspiece 3A of the support member 3 and the inside of the filling member 4 (inside the opening H), thereby ensuring sound insulation.

[0018] 2(B) shows a case where a filler 4 made of a material with a small modulus of longitudinal elasticity, such as a sponge, is used and the cross-sectional area of ​​the filler 4 is small. In this case, the surface rigidity of the sheet 2 is lower than that of the soundproof structure 1 described above, making it difficult to maintain the planar partition 2A and increasing the maximum deflection D, resulting in a decrease in sound insulation.

[0019] Furthermore, in the above-mentioned soundproofing structure 1, the bending rigidity of the support member 3 is greater than the bending rigidity of the sheet 2, so that, as shown in Figure 2(C), acoustic waves cause resonance on the surface of the support member 3, and the sheet 2 in contact with the support member 3 also generates surface resonance vibration, thereby improving soundproofing performance near the resonance frequency.

[0020] Fig. 3 is a graph showing the relationship between frequency and insertion loss as a measure of the sound insulation performance of a soundproof structure. The solid line in Fig. 3 represents data for the soundproof structure 1 of the example. As an example, the surface density is 0.751 kg / m 2 The thick dotted line in Figure 3 shows the data for a soundproof structure of a comparative example. The soundproof structure of the comparative example has a support member bonded to a sheet and does not have a filling member. For example, the surface density is 0.588 kg / m 2 is.

[0021] As shown in Figure 3, the soundproof structure 1 of the embodiment has a filler member 4 interposed between the sheet 2 and the support member 3, so the soundproofing performance of the material exceeds the mass side, and it can be seen that the soundproofing performance is clearly improved compared to the soundproof structure of the comparative example.

[0022] 4A and 4B are diagrams illustrating a method for manufacturing the soundproof structure. In this embodiment, the manufacturing method uses an expanded metal as the support member 3 as shown in FIG. 4A, and applies a liquid filler material 4M, which solidifies over time, to one side of the support member 3 as shown in FIG. 4B. The filler material 4M is liquid rubber and may be applied to the support member 3 with a brush or the like, or the support member 3 may be immersed in a container. When immersing the support member 3, it is desirable to adjust the viscosity of the filler material 4M, the lifting speed, and the like, to ensure that the filler material 4M adheres uniformly.

[0023] Next, in the manufacturing method described above, as shown in Fig. 4(C), the surface of the support member 3 to which the filler material 4M is applied is brought into contact with a flat film F, and the filler material 4M is allowed to solidify over time to form the filler 4. The film F is made of polyethylene, for example. Through this process, the surface of the filler 4 on the film F side is formed to have the same overall planar shape (flush).

[0024] 1(B) and 4(D), the above manufacturing method involves peeling off the film F and bonding and fixing the sheet 2 to the surface of the support member 3 facing the filling member 4. This results in the above soundproof structure 1, i.e., the soundproof structure 1 having a structure in which the gap between the sheet 2 and the crosspiece 3A is filled with the filling member 3.

[0025] The soundproof structure 1 described in the above embodiment includes a sheet 2, a support member 3, and a filling member 4, and the filling member 3 fills the gap between the sheet 2 and the crosspiece 3A of the support member 3. As a result, the soundproof structure 1 can achieve excellent soundproofing performance while using a relatively inexpensive material for the support member 3, and can reduce manufacturing costs.

[0026] As described above, the soundproofing structure 1 improves sound insulation performance near the resonance frequency by making the bending rigidity of the support member 3 greater than that of the sheet 2. Furthermore, in the soundproofing structure 1, the density of the filling member 4 as a whole is made smaller than the density of the support member 3, thereby specializing the function of the filling member 4 to forming the partition 2A in the sheet 2 and improving the resonance frequency of the sheet 2 within the partition 2A.

[0027] As a result, the soundproof structure 1 does not require the filling member 4 to have the same strength and rigidity as the support member 3, so the above function can be achieved using a filling member 3 made of a low-density, lightweight elastic material, thereby achieving a reduction in overall mass.

[0028] Furthermore, in the above-mentioned soundproof structure 1, by using an expanded metal or an expanded metal-like mesh member as the support member 3, the opening H can easily form a partition section 2A in the sheet 2, and it is possible to increase the cross-sectional ratio of the opening in the support member 3, thereby contributing to a reduction in the overall mass.

[0029] Furthermore, the soundproof structure 1 can be used as a soundproofing member for an automobile, and more specifically, by placing it in the floor of an automobile, it is extremely effective in blocking running noise in the passenger compartment.

[0030] Furthermore, the manufacturing method of the soundproof structure 1 includes the steps of applying a liquid filler material 4M that solidifies over time to one side of the support member 3, bringing the coated surface of the support member 3 into contact with a flat film F and solidifying the filler material 4M over time to form the filler 4, and, after peeling off the film F, fixing the sheet 2 to the surface of the support member 3 facing the filler 4. As a result, the manufacturing method described above makes it possible to obtain a soundproof structure with excellent soundproofing performance at low cost.

[0031] Second Embodiment 5 is a diagram illustrating a second embodiment of a soundproof structure according to the present invention. In this embodiment, the same components as those in the first embodiment are designated by the same reference numerals, and detailed descriptions thereof will be omitted.

[0032] In the illustrated soundproof structure 1, the support member 3 is a wire mesh or a wire mesh-like mesh member. The support member 3 has wires woven lengthwise and widthwise that correspond to the crosspieces 3A, with openings H between the wires and unevenness in the thickness direction. The support member 3 has a bending rigidity greater than that of the sheet 2, and can be made of plastic instead of metal as long as it has a bending rigidity greater than that of the sheet 2.

[0033] In the above-described soundproof structure 1, the filler member 4 is fixed to the sheet 2 and the crosspiece 3A of the support member 3 in a state where it fills the gap between the sheet 2 and the crosspiece 3A of the support member 3. In this soundproof structure 1, as in the first embodiment, excellent soundproofing performance can be obtained while using a relatively inexpensive material for the support member 3, and manufacturing costs can be reduced.

[0034] Furthermore, by using a wire mesh or a wire mesh-like mesh member as the support member 3, the soundproof structure 1 described above can easily form a partition section 2A in the sheet 2 through the opening H, and it is possible to increase the cross-sectional ratio of the opening in the support member 3, thereby contributing to a reduction in the overall mass.

[0035] The configuration of the soundproof structure according to the present invention is not limited to the above-described embodiments, and can be modified as appropriate without departing from the spirit of the present invention. Furthermore, while the soundproof structure in each embodiment has a support member disposed on one side of the sheet, it is also possible to dispose support members on both sides of the sheet, or to dispose support members with openings of different sizes and positions on both sides of the sheet. [Explanation of symbols]

[0036] 1. Soundproofing structure 2 seats 2A Section 3 Support member 3A Cross section 3H opening 4 Filler material 4M Filler Material F film

Claims

1. The device includes an elastic sheet, a support member that supports the sheet and divides the sheet into planar partitions, and a filling member that is interposed between the sheet and the support member, the support member has a plurality of openings defined by vertical and horizontal bar portions, the filling member is made of an elastic material and is fixed to the sheet and the crosspiece in a state where the filling member fills the gap between the sheet and the crosspiece; A soundproof structure characterized in that the maximum deflection position of the sheet is located within the opening.

2. 2. The soundproof structure according to claim 1, wherein the bending rigidity of the support member is greater than the bending rigidity of the sheet.

3. 3. The soundproof structure according to claim 1, wherein the density of the filling member is lower than the density of the support member.

4. 4. The soundproof structure according to claim 1, wherein the support member is an expanded metal or an expanded metal-like mesh member.

5. 4. The soundproof structure according to claim 1, wherein the support member is a wire mesh or a wire mesh-like member.

6. A soundproofing member for an automobile, comprising the soundproof structure according to any one of claims 1 to 5.

7. A method for manufacturing the soundproof structure according to any one of claims 1 to 5, comprising: applying a liquid filler material that solidifies over time to one surface of the support member; a step of bringing the surface of the support member onto which the filler material is applied into contact with a flat film and solidifying the filler material over time to form the filler; and after peeling off the film, fixing the sheet to the surface of the support member facing the filling member.

8. A method for manufacturing a soundproofing structure comprising an elastic sheet, a support member that supports the sheet and divides the sheet into planar partitions, and a filling member interposed between the sheet and the support member, the support member having a plurality of openings divided by vertical and horizontal slats, and the filling member being fixed to the sheet and the slats while filling the gaps between the sheet and the slats, applying a liquid filler material that solidifies over time to one surface of the support member; a step of bringing the surface of the support member onto which the filler material is applied into contact with a flat film and solidifying the filler material over time to form the filler; and after peeling off the film, fixing the sheet to the surface of the support member facing the filling member.

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