Method for manufacturing sound-insulating structures

Abstract

To provide a method of manufacturing a sound insulation structure in which handling of a sound insulation sheet member is easy and sufficient adhesiveness can be secured.SOLUTION: A method of manufacturing a sound insulation structure 100 having a sheet part 10, a sound insulation sheet member 1 having a plurality of projections 11 provided on a first face of the sheet part, an adherend 2 provided on a second face 10b on the opposite side of the first face 10a of the sheet part, and an adhesion layer 3 provided between the sound insulation sheet member and the adherend includes: a preparation step for preparing a first jig 30 having a plurality of insertion parts 31 into which the projections are inserted; an installation step for inserting the projections into the insertion parts and installing the sheet part of the sound insulation sheet member on an installation face 32 of the first jig positioned on one side in the insertion direction of the projections; an application step for applying adhesive 4 to the second face of the sheet part provided in the first jig and forming the adhesion layer; a bonding step for bonding the adherend to the second face to which the adhesive is applied; and a jig removal step for removing the first jig from the sound insulation sheet member to which the adherend is bonded.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sound insulation structure.

Background Art

[0002] In buildings such as apartment houses, office buildings, and hotels, it is required to block outdoor noise from automobiles, railways, airplanes, ships, etc., equipment noise generated inside the building, and human voices, and to provide a tranquility suitable for room use. Also, in vehicles such as automobiles, railways, airplanes, and ships, it is necessary to reduce indoor noise in order to block wind noise and engine noise and provide a quiet and comfortable space for passengers. Therefore, research and development of means for blocking the propagation of noise and vibration from the outside to the inside of a building or from the outside to the inside of a vehicle, that is, sound insulation means, has been promoted. In recent years, due to the increase in building height in buildings, the improvement of energy efficiency in vehicles, and further, the improvement of the design freedom of buildings, vehicles, and their equipment, sound insulation members capable of coping with complex shapes have been demanded.

[0003] And in recent years, in order to achieve sound insulation performance exceeding the mass law, a sound insulation sheet member having a sheet having rubber elasticity and a resonance portion including a base portion and a weight portion has been proposed (Patent Document 1). The sound insulation sheet member is configured as a sound insulation structure by being supported by a support body adhered via an adhesive layer having a strong adhesive strength on the sheet surface side.

[0004] Conventionally, as a technique showing strong adhesive strength, a method has been generally used in which the surface of the adherend is subjected to degreasing treatment, surface treatment (such as blasting treatment, corona discharge treatment, plasma treatment, UV irradiation treatment, etc.), primer application, adhesive application, and the adherend is bonded and adhered through such steps.

[0005] Patent Document 2 describes a method for manufacturing a composite sheet in which a layer comprising at least one base sheet selected from a resin sheet and a metal sheet and a thermally conductive silicone rubber sheet layer is laminated and integrated, characterized in that a thermally conductive silicone rubber sheet with a thermal conductivity of 0.6 W / m·K or more is calendered to make at least the laminated surface a smooth surface, the smooth surface is subjected to at least one surface activation treatment selected from corona treatment, plasma treatment, ultraviolet irradiation treatment and electron beam treatment, a compound containing nitrogen and silicon is coated on the laminated surface of the base sheet, and at least one base sheet selected from a resin sheet and a metal sheet and the thermally conductive silicone rubber sheet layer are pressed together to laminate and integrate. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] International Publication No. 2017 / 135409 [Patent Document 2] Japanese Patent Publication No. 2018-15904 [Overview of the project] [Problems that the invention aims to solve]

[0007] While the bonding method described in Patent Document 2 is applicable to materials in a flat sheet shape, it becomes difficult to degrease, surface treat, coat, and bond sound-insulating sheet members with an arranged uneven surface due to reduced handling and workability caused by the arranged unevenness. Furthermore, the deflection of the sheet makes uniform degreasing, surface treatment, and coating difficult, which can lead to insufficient adhesion.

[0008] The present invention has been made in consideration of the above points, and aims to provide a method for manufacturing a sound-insulating structure in which the sound-insulating sheet member is easy to handle and sufficient adhesiveness can be ensured. [Means for solving the problem]

[0009] As a result of diligent research to solve the above problems, the inventors of the present invention have found that the above problems can be solved by forming an adhesive layer using a jig having an insertion part into which a protrusion is inserted, and have completed the present invention.

[0010] In other words, the present invention provides various specific embodiments as shown below. [1] A method for manufacturing a sound-insulating structure, comprising: a sheet portion; a sound-insulating sheet member having a plurality of protrusions provided on a first surface of the sheet portion; a adherend provided on a second surface of the sheet portion opposite to the first surface; and an adhesive layer provided between the sound-insulating sheet member and the adherend, comprising: a preparation step of preparing a first jig having a plurality of insertion portions into which the protrusions are inserted; an installation step of inserting the protrusions into the insertion portions and installing the sheet portion of the sound-insulating sheet member on the installation surface of the first jig located on one side in the insertion direction of the protrusions; an application step of applying an adhesive to the second surface of the sheet portion installed on the first jig to form an adhesive layer; a bonding step of bonding the adherend to the second surface to which the adhesive has been applied; and a jig removal step of removing the first jig from the sound-insulating sheet member to which the adherend has been bonded. [2] The method for manufacturing a sound-insulating structure described in [1], wherein the jig detachment step further comprises a second jig installation step of installing a second jig on the other side of the first jig in the insertion direction, and a first jig detachment step of moving the first jig toward the second jig to separate the first jig from the sound-insulating sheet member, wherein the second jig has a jig protrusion and a jig recess, and in the second jig installation step, the second jig is installed facing the first jig with the jig protrusion and the protrusion of the sound-insulating sheet member in contact, and the jig recess and the first jig having a gap, and in the first jig detachment step, the jig detaches from the sound-insulating sheet member as the jig protrusion suppresses the movement of the protrusion and the first jig moves toward the second jig in a direction that fills the gap. [3] A method for manufacturing a sound-insulating structure according to [2], wherein the first jig is positioned on the other side of the insertion direction and has engaging portions that protrude outward on both sides in a direction perpendicular to the insertion direction, and the first jig detachment step is to use the engaging portions to move the first jig towards the second jig, a method for manufacturing a sound-insulating structure. [4] A method for manufacturing a sound-insulating structure according to any one of [1] to [3], wherein the height of the protrusion from the sheet portion is less than or equal to the dimension of the insertion portion in the insertion direction of the protrusion. [5] A method for manufacturing a sound-insulating structure according to any one of [1] to [4], comprising a pressurizing step of pressurizing the sound-insulating sheet member toward the adherend after the jig detachment step. A method for manufacturing a sound-insulating structure according to any one of items [1] to [5], wherein the insertion portion of the first jig is a through hole whose cross-sectional shape is the same as that of the protrusion. A method for manufacturing a sound-insulating structure according to any one of items [1] to [6], wherein the protrusion is cylindrical, cylindrical, rectangular tube, or rectangular prism. A method for manufacturing a sound-insulating structure according to any one of items [1] to [7], wherein the adhesive is a cyanoacrylate-based, silicone-based, epoxy-based, or acrylic-based adhesive. [Effects of the Invention]

[0011] The present invention provides a method for manufacturing a sound-insulating structure that allows for easy handling of the sound-insulating sheet member and ensures sufficient adhesion. [Brief explanation of the drawing]

[0012] [Figure 1] This figure shows an embodiment of the present invention, and is a perspective view of the external appearance of the sound-insulating structure. [Figure 2] This is an external perspective view of a sound-insulating structure composed of a composite structure in which a convex portion has a weighted portion. [Figure 3]It is an external perspective view of a sound insulation structure composed of a composite structure in which a weight portion is embedded in a convex portion. [Figure 4] It is a cross-sectional view showing the procedure of a method for manufacturing a sound insulation structure. [Figure 5] It is a cross-sectional view showing the procedure of a method for manufacturing a sound insulation structure. [Figure 6] It is a cross-sectional view showing the procedure of a method for manufacturing a sound insulation structure. [Figure 7] It is a cross-sectional view showing the procedure of a method for manufacturing a sound insulation structure.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of a method for manufacturing a sound insulation structure of the present invention will be described with reference to FIGS. 1 to 7. Note that the following embodiments show one aspect of the present invention, do not limit this invention, and can be arbitrarily changed within the scope of the technical idea of the present invention. In the following drawings, in order to make each configuration easy to understand, the actual structure and the scale, number, etc. in each structure are made different.

[0014] [Sound insulation structure] First, a sound insulation structure having a concavo-convex structure manufactured using the method for manufacturing a sound insulation structure of the present invention will be described. FIG. 1 is an external perspective view of a sound insulation structure 100. The sound insulation structure 100 includes a sound insulation sheet member 1, an adherend 2, and an adhesive layer 3. The sound insulation sheet member 1 includes a sheet portion 10 having rubber elasticity and a plurality of convex portions 11 provided in contact with the first surface 10a of the sheet portion 10. A relatively concave portion is formed around the convex portion 11. That is, the sound insulation sheet member 1 has a concavo-convex structure on the first surface 10a side. The sound insulation sheet member 1 is supported by an adherend 2 provided via an adhesive layer 3 on the second surface 10b side opposite to the first surface 10a of the sheet portion 10. The adhesive layer 3 is formed of an adhesive 4 applied between the second surface 10b of the sheet portion 10 and the adherend 2.

[0015] In the sound insulation sheet member 1 and the sound insulation structure 100, for example, when sound waves are incident from a noise source on the adherend 2 side, at least one of the sheet portion 10 and the convex portion 11 resonates. At this time, a frequency region where the direction of the force acting on the adherend 2 is opposite to the direction of the acceleration generated in at least one of the sheet portion 10 and the convex portion 11 can exist, and a complete acoustic bandgap in which a part or all of the vibration at a specific frequency is canceled out, so that the vibration at the specific frequency almost completely disappears occurs. Therefore, near the resonance frequency of at least one of the sheet portion 10 and the convex portion 11, part or all of the vibration stops, and as a result, high sound insulation performance exceeding the mass law can be obtained. A sound insulation member utilizing such a principle is called an acoustic metamaterial.

[0016] [Sound insulation sheet member] The shape of the convex portion 11 is not particularly limited. For example, the outer shape of the convex portion 11 can adopt any shape such as a triangular prism shape, a rectangular prism shape, a trapezoidal prism shape, a polygonal prism shape such as a pentagonal prism or a hexagonal prism, a cylindrical shape, a cylindrical shape, an elliptical prism shape, a frustum of a pyramid shape, a frustum of a cone shape, a pyramid shape, a cone shape, a hollow cylinder shape, an irregular shape not classified into these, etc. Also, depending on the height position of the convex portion 11, it can be formed into a column shape having a cross-sectional shape in which at least one of the cross-sectional area and the cross-sectional shape is different.

[0017] The plan view shape of the sheet portion 10 is not particularly limited. The plan view shape of the sheet portion 10 may be circular, elliptical, ring-shaped, polygonal, etc. In FIGS. 1 to 3, as an example, a sheet portion 10 having a rectangular shape in plan view is shown. Also, when the plan view shape of the sheet portion 10 is rectangular, the maximum length of the uneven structure in the length direction of the sheet portion 10 may be less than or equal to the maximum length in the MD direction of the sheet portion 10, and is not particularly limited. Also, the arrangement of the uneven structure may be either periodic such as a lattice arrangement or a staggered arrangement or random. The convex portion 11 illustrated in FIG. 1 is a columnar shape extending in the normal direction of the first surface 10a. A plurality of the convex portions 11 illustrated in FIG. 1 are arranged in a lattice pattern.

[0018] Examples of materials for the sound insulation sheet member 1 include thermosetting resin elastomers such as chemically crosslinked natural rubber or synthetic rubber vulcanized thermosetting resin elastomers, urethane thermosetting resin elastomers, silicone thermosetting resin elastomers, fluorine thermosetting resin elastomers, acrylic thermosetting resin elastomers, photocurable elastomers such as acrylic photocurable elastomers, silicone photocurable elastomers, epoxy photocurable elastomers, olefin thermosetting elastomers, styrene thermoplastic elastomers, PVC thermoplastic elastomers, urethane thermoplastic elastomers, ester thermoplastic elastomers, amide thermoplastic elastomers, silicone thermoplastic elastomers, acrylic thermoplastic elastomers, and other thermoplastic elastomers.

[0019] Further specific examples of heat-curable or photocurable elastomers and thermoplastic elastomers include rubber. Specifically, these include, but are not limited to, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, urethane rubber, silicone rubber, and modified versions thereof. These can be used individually or in combination of two or more.

[0020] Furthermore, among these, natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, polyisobutylene rubber, ethylene propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, polyester rubber, urethane rubber, silicone rubber, and their modified forms are preferred, with silicone rubber, acrylic rubber, and their modified forms being more preferred. Using these materials tends to result in excellent heat resistance and cold resistance.

[0021] The sound insulation sheet member 1 may contain various additives such as flame retardants, antioxidants, plasticizers, and colorants, as long as it is a sheet with so-called rubber elasticity. Flame retardants are additives used to make flammable materials less likely to burn or to prevent ignition. Specific examples include, but are not limited to, bromine compounds such as pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, hexabromocyclododecane, and hexabromobenzene; phosphorus compounds such as triphenyl phosphate; chlorine compounds such as chlorinated paraffin; antimony compounds such as antimony trioxide; metal hydroxides such as aluminum hydroxide; nitrogen compounds such as melamine cyanurate; and boron compounds such as sodium borate. Furthermore, antioxidants are additives added to prevent oxidative degradation. Specific examples include phenolic antioxidants, sulfur-based antioxidants, and phosphorus-based antioxidants, but the product is not limited to these. Furthermore, plasticizers are additives added to improve flexibility and weather resistance. Specific examples include, but are not limited to, phthalates, adipicates, trimelliticates, polyesters, phosphates, citrates, sebacates, azelaates, maleates, silicone oils, mineral oils, vegetable oils, and modified versions thereof. Furthermore, colorants include dyes and pigments. These can be used individually or in combination of two or more types.

[0022] The protrusion 11 may be a single structure as shown in Figure 1, or it may be a composite structure comprising a sheet portion 10, a base portion 20 formed as a single structure, and a weight portion 21 supported by the base portion 20 and having a larger mass than the base portion 20, as shown in Figure 2. Furthermore, the protrusion 11 may be a composite structure in which the weight portion 21 is embedded within the base portion 20, as shown in Figure 3. In such a composite structure, when the uneven structure acts as a resonant part, the protrusion 11 effectively functions as a dynamic vibration absorber with a resonant frequency determined by the mass of the weight portion 21 acting as a weight and the spring constant of the base portion 20 acting as a spring. The protrusion 11 may also be a porous material containing voids (gas such as air).

[0023] [Adherend] The material constituting the adherend 2 is not particularly limited as long as it can support the sheet portion 10, but from the viewpoint of improving sound insulation performance, it is preferable that it is more rigid than the sheet portion 10. Specifically, the adherend 2 preferably has a Young's modulus of 1 GPa or more, and more preferably 1.5 GPa or more. There is no particular upper limit, but for example, 1000 GPa or less is an example.

[0024] The material constituting the adherend 2 is not particularly limited, but examples include general-purpose resins, engineering plastics, metal plates, alloy plates, etc. For example, general-purpose resins include polyethylene, polypropylene, polystyrene, acrylonitrile-butadiene-styrene, acrylonitrile-styrene, polyvinyl chloride, and polymethyl methacrylate. Examples of engineering plastics include polyacetal, polyamide, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, ultra-high molecular weight polyethylene, syndiotactic polystyrene, amorphous polyarylate, polysulfone, polyethersulfone, polyphenylene sulfide, polyetheretherketone, polyimide, polyetherimide, fluororesin, and liquid crystal polymer. These may also contain reinforcing materials to enhance hardness. Examples of adherend metals include general-purpose metals such as aluminum, iron, and stainless steel, as well as alloys. Adherends may also consist of laminates of the aforementioned resins and metals.

[0025] The shape of the adherend 2 can be appropriately set according to the installation surface of the sound insulation structure 100 and is not particularly limited. For example, it may be a flat sheet, a curved sheet, or a special shape processed to have curved or folded parts. Furthermore, from the viewpoint of weight reduction, notches or punched-out parts may be provided at any location on the adherend 2.

[0026] [glue] The material of the adhesive 4 constituting the adhesive layer 3 is not particularly limited, but examples include silicone resins, epoxy resins, cyanoacrylate resins, vinyl acetate resins, polyvinyl acetal resins, ethylene vinyl acetate resins, vinyl chloride resins, acrylic resins, polyamide resins, cellulose resins, olefin resins, polyvinyl butyral resins, urea resins, melamine resins, phenolic resins, resorcinol resins, polyester resins, polyurethane resins, polyaromatic resins, chloroprene rubbers, nitrile rubbers, styrene butadiene rubbers, polysulfide rubbers, butyl rubbers, silicone rubbers, acrylic rubbers, modified silicone rubbers, urethane rubbers, silylated urethane resins, telechelic polyacrylate adhesives, and mixtures thereof. Among these, from the viewpoint of achieving a balance of adhesiveness, peel durability, impact resistance, heat resistance, and chemical resistance, it is preferable that the resin be one or more types selected from the group consisting of silicone resins, epoxy resins, cyanoacrylate resins, acrylic resins, and urethane resins, and in particular, it is preferable that the resin be one or more types selected from the group consisting of silicone resins, epoxy resins, and cyanoacrylate resins. The adhesive layer 3 may contain inorganic fillers or fibers, such as silica particles, alumina particles, metal oxides such as titanium oxide, carbon particles, carbon black, graphite, and fibrous compounds thereof.

[0027] [Manufacturing method for sound-insulating structures] The manufacturing method for the sound insulation structure 100 described above includes a preparation step of preparing a first jig 30 having a plurality of insertion parts into which the protrusions 11 are inserted, as shown in Figures 4 to 6; an installation step of inserting the protrusions 11 into the insertion parts and installing the sound insulation sheet member 1 on the first jig 30; an application step of applying adhesive 4 to the second surface 10b of the sound insulation sheet member 1 installed on the first jig 30 to form an adhesive layer 3; a bonding step of bonding the adherend 2 to the second surface 10b to which the adhesive 4 has been applied; a jig removal step of removing the first jig 30 from the sound insulation sheet member 1 to which the adherend 2 has been bonded; and a pressurizing step of applying pressure to the adherend 2 side of the sound insulation sheet member 1 after the jig removal step.

[0028] Furthermore, the jig detachment step in the manufacturing method of the sound insulation structure 100 further comprises a second jig installation step of installing the second jig 40 on the other side of the insertion direction of the first jig 30, and a first jig detachment step of moving the first jig 30 toward the second jig 40 side and separating the first jig 30 from the sound insulation sheet member 1.

[0029] [First jig] The first jig 30 is, for example, a rectangular plate in plan view. The thickness of the first jig 30 is less than or equal to the height of the protrusion 11. In this embodiment, the thickness of the first jig 30 is less than the height of the protrusion 11 from the sheet portion 10. The first jig 30 has an insertion portion 31, an installation surface 32, and an engaging portion 33.

[0030] The insertion portion 31 is the space into which the protrusion 11 is inserted. The insertion portion 31 penetrates the first jig 30 in the insertion direction (hereinafter simply referred to as the insertion direction) into which the protrusion 11 is inserted. That is, the height of the protrusion 11 from the sheet portion 10 is less than or equal to the dimension of the insertion portion 31 in the insertion direction. Therefore, the tip of the protrusion 11 does not protrude from the first jig 30 but is contained inside the insertion portion 31. Multiple insertion portions 31 are provided in the sheet portion 10 at positions opposite to the protrusion 11 in the insertion direction. The insertion portion 31 is a through-hole with the same cross-sectional shape as the protrusion 11. The maximum diameter in the cross-section of the insertion portion 31 is, for example, about 300 to 500 μm larger than the maximum diameter in the cross-section of the protrusion 11. By setting the difference between the maximum diameter of the insertion portion 31 and the maximum diameter of the protrusion 11 to approximately 300 to 500 μm, it is possible to suppress the sound insulation sheet member 1 from detaching from the first jig 30 even when the first jig 30 and the sound insulation sheet member 1, in which the protrusion 11 is inserted into the insertion portion 31, are inverted.

[0031] Furthermore, since the position of the protrusion 11 varies depending on the shrinkage rate after molding the sound insulation sheet member 1, it is preferable to set the position of the insertion portion 31 in the first jig 30 to a position in which the protrusion 11 can be inserted according to the shrinkage rate of the sound insulation sheet member 1 material used.

[0032] The mounting surface 32 is an end face located on one side (the upper side in Figure 4) of the first jig 30 in the insertion direction. The mounting surface 32 is where the sheet portion 10 is placed when the protrusion 11 is inserted into the insertion portion 31.

[0033] The engaging portion 33 is positioned on the other side in the insertion direction (the lower side in Figure 4). The engaging portion 33 protrudes outward on both sides in the direction perpendicular to the insertion direction (the left-right direction in Figure 4).

[0034] [Second jig] The second jig 40 is installed on the other side of the insertion direction of the first jig 30, as shown in Figure 6. Note that in Figure 6, the insertion direction position in Figure 4 is shown upside down. The second jig 40 has a jig protrusion 41 and a jig recess 42.

[0035] The jig projection 41 protrudes to one side in the insertion direction. The jig projection 41 is positioned opposite the insertion portion 31 and projection 11 of the first jig 30 in the insertion direction. The maximum diameter of the jig projection 41 is approximately the same as the maximum diameter of the projection 11. However, the maximum diameters may be different, or their positions may be offset in a direction perpendicular to the insertion direction, as long as the jig projection 41 and the projection 11 can come into contact. Furthermore, a through hole extending in the insertion direction may be formed in the jig projection 41. If a through hole is formed, the weight of the second jig 40 can be reduced. A jig recess 42 is formed around the jig projection 41 relative to it. The amount of protrusion of the jig projection 41 is set to a value such that when the tip of the jig projection 41 comes into contact with the projection 11, a gap S is formed between the first jig 30 and the jig recess 42, that is, between the first jig 30 and the second jig 40.

[0036] [Preparation process] In the preparation process, a sound-insulating sheet member 1 in which the protrusion 11 is a single structural element is formed, for example, by injection molding. Alternatively, a sound-insulating sheet member 1 in which the protrusion 11 is composed of a composite structure including a weight portion 21 is prepared by, for example, insert molding in which the weight portion 21 is pre-installed in the mold.

[0037] [Installation process] In the installation process, as shown in Figure 4, the protrusion 11 of the sound insulation sheet member 1 is inserted from one side in the insertion direction into the insertion portion 31 of the first jig 30 with the installation surface 32 facing upward, and the first surface 10a of the sheet portion 10 of the sound insulation sheet member 1 is installed on the installation surface 32. At this time, since the protrusion 11 is housed inside the insertion portion 31, it is possible to avoid the base end of the protrusion 11 protruding from the installation surface 32 and the second surface of the sheet portion 10 curving, such as when the protrusion 11 is longer than the dimensions of the insertion portion 31 in the insertion direction.

[0038] Furthermore, if the protrusion 11 is shorter than the dimension of the insertion portion 31 in the insertion direction, the sheet portion 10 facing the insertion portion 31 may bend due to the weight of the protrusion 11. Therefore, it is preferable that the dimension of the protrusion 11 in the insertion direction is the same as the dimension of the insertion portion 31 in the insertion direction.

[0039] [Degreasing process] When the sheet portion 10 is placed on the mounting surface 32 of the first jig 30 with the second surface 10b, which is the bonding surface, facing upwards, the second surface 10b is degreased with ethanol. Similarly, the bonding surface 2a of the adherend 2 (see Figure 5) is also degreased with ethanol.

[0040] [Surface treatment process] After the degreasing process is completed, surface treatment is performed on the second surface 10b, which is the bonding surface of the sheet portion 10 installed on the mounting surface 32 of the first jig 30. Specifically, corona discharge treatment was performed on the second surface 10b using a corona discharge treatment machine (CoronaFit CFG-500 (Shinko Electric Instrumentation Co., Ltd.)) under the following conditions: discharge port-to-treatment surface gap of 2 mm, treatment speed of 20 mm / second, number of reciprocations of 2, and output voltage of 9 KV. Furthermore, the bonding surface 2a of the adherend 2 was also subjected to corona discharge treatment using the same corona discharge treatment machine under the following conditions: discharge port-treatment surface gap of 5 mm, treatment speed of 20 mm / second, number of reciprocations of 1, and output voltage of 9 KV.

[0041] [Coating process] After the surface treatment process is completed, adhesive 4 is applied to the second surface 10b of the sheet portion 10, which is placed on the mounting surface 32 of the first jig 30, to form an adhesive layer 3. Examples of adhesive 4 include "AP-1860 manufactured by Toagosei Co., Ltd." The adhesive 4 is applied to the second surface 10b using a spatula or the like.

[0042] [Lamination process] In the bonding process, the adherend 2 is bonded to the second surface 10b to which the adhesive 4 has been applied. More specifically, as shown in Figure 5, the sheet portion 10 to which the adhesive 4 has been applied to the second surface 10b is inverted vertically together with the first jig 30, so that the adhesive 4 faces downwards and is facing the bonding surface 2a of the adherend 2. Next, the bonding surface 2a of the adherend 2 and the second surface 10b of the sheet portion 10 are bonded together via adhesive 4, and pressure is applied from above using the first jig 30. At this time, any excess adhesive 4 that overflows from the outer circumference of the sheet portion 10 is removed using a spatula or the like.

[0043] [Jig removal process] The jig removal process is the process of removing the first jig 30 from the sound insulation sheet member 1 to which the adherend 2 has been bonded. The jig removal process includes the second jig installation process and the first jig removal process.

[0044] In the second jig installation step, as shown in Figure 6, the second jig 40 is installed on the other side of the insertion direction of the first jig 30. The second jig 40 is installed facing the first jig 30 with a gap S between the jig protrusion 41 and the protrusion 11 of the sound insulation sheet member 1, and the jig recess 42 and the first jig 30.

[0045] In the first jig detachment step, after the second jig installation step, for example, the second jig 40 is pressed from above with the thumb to prevent the jig protrusion 41 from moving upwards on the protrusion 11, while the engaging portion 33 of the first jig 30 is hooked from below with the other fingers and pulled upwards. As a result, the first jig 30 moves upwards in the direction of filling the gap S, as indicated by the arrow in Figure 6, and is moved towards the second jig 40, thereby detaching from and removing it from the sound insulation sheet member 1. As a result, a sound insulation structure 100 is obtained in which the adherend 2 is provided to the sound insulation sheet member 1 via the adhesive layer 3.

[0046] [Pressure, hardening, curing] For the sound-insulating structure 100 from which the first jig 30 was removed in the jig removal process, a weight 50 was placed on the protrusion 11 so that pressure was applied to the entire sheet portion 10, the protrusion 11, and the recess around the protrusion 11. The structure was then heated at 120°C for 1 hour, followed by curing at 23°C for 24 hours to manufacture the sound-insulating structure 100.

[0047] As described above, in the manufacturing method of the sound insulation structure 100 in this embodiment, even if the sound insulation sheet member 1 is a structure having a plurality of protrusions 11, the sheet portion 10 is installed on the installation surface 32 of the first jig 30 which has a plurality of insertion portions 31 into which the protrusions 11 are inserted. Therefore, the deflection that occurs on the second surface 10b, which is the bonding surface with the adherend 2, can be reduced and it can be held flat. For this reason, in the manufacturing method of this embodiment, handling is made easier when degreasing, surface treatment, application of adhesive 4, and bonding of the adherend 2 to the second surface 10b.

[0048] Furthermore, in the manufacturing method of the sound-insulating structure 100 in this embodiment, by reducing the deflection that occurs on the second surface 10b, the incorporation of air bubbles into the adhesive layer 3 can be suppressed, and sufficient adhesion can be ensured. If deflection occurs on the second surface 10b, the resulting decrease in adhesion due to air bubbles, the heterogeneity of the adhesive layer 3, and variations in thickness may adversely affect the resonance characteristics of at least one of the sheet portion 10 and the convex portion 11 when sound waves are incident from a noise source on the adherend 2 side. In contrast, in this embodiment, by using the first jig 30, the sheet portion 10 and the adherend 2 can be bonded via an adhesive layer 3 having homogeneity and a constant thickness, thereby obtaining high sound-insulating performance that surpasses the mass law.

[0049] Furthermore, in the manufacturing method of the sound-insulating structure 100 in this embodiment, the first jig 30 can be easily removed by using the second jig 40. Therefore, in this embodiment, damage to the sound-insulating structure 100 when removing the first jig 30 can be suppressed. [Examples]

[0050] The effects of the present invention will be made clearer by the following examples. However, the present invention is not limited to the following examples and can be implemented with appropriate modifications without altering its essence.

[0051] (Example 1, Comparative Examples 1-2) In this example, samples of the sound-insulating structures of Example 1 and Comparative Examples 1-2 were manufactured according to the specifications shown in [Table 1] below. The sample of Example 1 is a sample manufactured using both the first jig 30 and the second jig 40, following the process of the manufacturing method of the sound-insulating structure 100 described above. The sample of Comparative Example 1 is a sample in which the sound-insulating structure 100 was manufactured without using the second jig 40, compared to the sample of Example 1. The sample of Comparative Example 2 is a sample in which the sound-insulating structure 100 was manufactured without using either the first jig 30 or the second jig 40 compared to the sample of Example 1.

[0052] [Evaluation criteria] We conducted evaluations regarding workability and structural properties. Workability was evaluated based on the results of visual inspection to check for the presence or absence of [bending] of the sound insulation structure 100 (sound insulation sheet member 1) during each process of the manufacturing method of the sound insulation structure 100 described above (degreasing, surface treatment, adhesive application, bonding), and the results of visual inspection to check for the presence or absence of [bending, deformation, or breakage] when detaching the first jig 30. The structural properties were evaluated by visually checking for the presence or absence of [bending, deformation, and fracture] in the external appearance, and by visually checking for the presence or absence of peeling of the sound insulation sheet member 1 when the sheet portion 10 and protrusion portion 11 of the manufactured sound insulation structure 100 were pressed with a finger or tweezers. In each of the above evaluations, a circle (○) was used to indicate that there was no deflection, deformation, fracture, or delamination, while a cross (×) was used to indicate that there was.

[0053] [Table 1]

[0054] As shown in Table 1, in the sample of Comparative Example 1, in which the sound insulation structure 100 was manufactured using the first jig 30 and not the second jig 40, when the first jig 30 was detached, the sheet portion 10 stuck to the first jig 30 and was pulled in the direction of detachment of the first jig 30, resulting in deflection, deformation, and breakage of the sheet portion 10. This led to a decrease in appearance and adhesion, and a poor evaluation could not be obtained. Furthermore, in the comparative example 2 sample, in which the sound insulation structure 100 was manufactured without using either the first jig 30 or the second jig 40, deflection occurred in the sheet portion 10 during each of the degreasing, surface treatment, adhesive application, and bonding processes, making uniform degreasing, surface treatment, and adhesive application difficult. During bonding, air bubbles were incorporated and the sheets shifted, making it difficult to bond as designed, resulting in a decrease in appearance and adhesion, and thus a poor evaluation could not be obtained.

[0055] In contrast, in the sample of Example 1, which used both the first jig 30 and the second jig 40, no deflection occurred in the sheet portion 10 during the degreasing, surface treatment, adhesive application, and bonding processes, enabling uniform degreasing, surface treatment, and adhesive application. Even when the first jig 30 was removed, there was no sticking of the sheet portion 10, and the sheet portion 10 showed no deformation or damage. Both the appearance and adhesiveness were sufficient, and a good evaluation was obtained.

[0056] Preferred embodiments of the present invention have been described above with reference to the attached drawings, but it goes without saying that the present invention is not limited to these examples. The shapes and combinations of the constituent members shown in the above examples are merely examples, and can be modified in various ways based on design requirements, etc., without departing from the spirit of the present invention.

[0057] For example, in the above embodiment, a configuration was illustrated in which the sheet portion 10 has a rectangular shape in plan view, and both the first jig 30 and the second jig 40 are rectangular in plan view, but the configuration is not limited to this. For example, if the sheet portion 10 has a ring shape in plan view, and the convex portions 11 are spaced apart in the circumferential direction, the first jig 30 and the second jig 40 may have a ring shape or a circle in plan view. [Industrial applicability]

[0058] The method for manufacturing a sound-insulating structure of the present invention facilitates the bonding of sound-insulating sheet members 1 having complex structures, and is therefore applicable, for example, to the manufacture of electronic component modules, sound-insulating materials, and sound-absorbing materials. [Explanation of symbols]

[0059] 1...Sound insulation sheet member, 2...Substrate, 3...Adhesive layer, 4...Adhesive, 10...Sheet portion, 10a...First surface, 10b...Second surface, 11...Protrusion, 30...First jig, 31...Insertion portion, 32...Installation surface, 33...Engaging portion, 40...Second jig, 41...Jig protrusion, 42...Jig recess, 100...Sound insulation structure

Claims

1. A sound-insulating sheet member having a sheet portion and a plurality of protrusions provided on the first surface of the sheet portion, The adherend is provided on the second surface of the sheet portion opposite to the first surface, A method for manufacturing a sound-insulating structure having an adhesive layer provided between the sound-insulating sheet member and the adherend, The preparation step involves preparing a first jig having a plurality of insertion portions into which the aforementioned protrusions are inserted, wherein each insertion portion is a through-hole with the same cross-sectional shape as the aforementioned protrusions. Installation step: Insert the protrusion into the insertion part and install the sheet portion of the sound insulation sheet member on the installation surface of the first jig located on one side in the insertion direction of the protrusion. A coating step of applying adhesive to the second surface of the sheet portion installed in the first jig to form an adhesive layer, A bonding step of attaching the adherend to the second surface to which the adhesive has been applied, A jig removal step is performed to remove the first jig from the sound insulation sheet member to which the adherend has been attached, A method for manufacturing a sound-insulating structure having the above characteristics.

2. In the method for manufacturing a sound-insulating structure according to claim 1, The jig removal process further involves, A second jig installation step involves installing a second jig on the other side of the insertion direction of the first jig, The process includes a first jig detachment step of moving the first jig towards the second jig and separating the first jig from the sound insulation sheet member, The second jig has a jig protrusion and a jig recess, In the second jig installation step, the second jig is installed facing the first jig, with the jig's protrusion and the sound-insulating sheet member in contact, and a gap between the jig's recess and the first jig. The first jig detachment step involves the first jig being moved toward the second jig in a direction that fills the gap, while the jig's protrusion restrains the movement of the protrusion, thereby detaching the first jig from the sound-insulating sheet member. A method for manufacturing a sound-insulating structure.

3. In the method for manufacturing a sound-insulating structure according to claim 2, The first jig is, It has an engaging portion positioned on the other side of the insertion direction and protruding outward on both sides in a direction perpendicular to the insertion direction, The first jig removal step is as follows: Using the engagement portion, the first jig is moved towards the second jig. A method for manufacturing a sound-insulating structure.

4. In a method for manufacturing a sound-insulating structure according to any one of claims 1 to 3, The height of the protrusion from the sheet portion is less than or equal to the dimension of the insertion portion in the insertion direction of the protrusion. A method for manufacturing a sound-insulating structure.

5. In a method for manufacturing a sound-insulating structure according to any one of claims 1 to 3, The process includes a pressing step after the jig removal step, in which the sound-insulating sheet member is pressed against the object to be attached. A method for manufacturing a sound-insulating structure.

6. In a method for manufacturing a sound-insulating structure according to any one of claims 1 to 3, The aforementioned protrusion is one of the following shapes: cylindrical, columnar, rectangular tube, or rectangular prism. A method for manufacturing a sound-insulating structure.

7. In a method for manufacturing a sound-insulating structure according to any one of claims 1 to 3, The adhesive is one of the following: cyanoacrylate-based, silicone-based, epoxy-based, or acrylic-based. A method for manufacturing a sound-insulating structure.

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