JP2764716B2 - Manufacturing method of sound insulation material for vehicles - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for efficiently manufacturing a sound insulating material for a vehicle such as a floor carpet for a vehicle, which is laid on the floor, for example, in order to reduce noise entering from the floor of a driver's cab of the vehicle.

[0002]

2. Description of the Related Art A conventional floor carpet for a vehicle is obtained by thermoforming a carpet alone with upper and lower molding dies, pasting a high-density recycled vinyl chloride resin sheet on the back side thereof, and further forming the recycled vinyl chloride resin. Felt was stuck on the sheet surface.

[0003]

However, since a backing layer made of an olefin resin such as a polyethylene resin is usually formed on the back side of the carpet, both sides are required for attaching a high specific gravity recycled vinyl chloride resin sheet. The method of heating and fusing can not be adopted, and satisfactory adhesive strength can not be obtained even if ordinary adhesives are used, so expensive special adhesives which use primers together must be used Was.

If the carpet is formed three-dimensionally, a high-density recycled vinyl chloride resin sheet, followed by a felt, can be stuck neatly without wrinkles along the back surface shape. Requires skill and time for workers. Furthermore, in this attaching method, since the two layers are sequentially attached with the back surface of the formed carpet as a reference surface, it is difficult to finish the obtained floor carpet into a shape following the laid floor shape of the vehicle. And
It has also been pointed out that the sound insulation is deteriorated due to poor matching.

An object of the present invention is to provide a method of manufacturing a sound insulating material for a vehicle which eliminates the above-mentioned conventional disadvantages.

[0006]

According to a method of manufacturing a sound insulating material for a vehicle of the present invention, one surface of a soft vinyl chloride resin sheet having a specific gravity of 1.3 to 1.8, which is rolled by a calender and is in a softened and molten state. After the felt layer, a laminated sheet obtained by pressing a non-woven fabric on the other surface is molded into a predetermined shape and trimmed or trimmed without molding, and then the laminated sheet is placed in the lower mold of a pair of upper and lower molding dies. After arranging the felt layer side so as to be in contact with the mold surface, the carpet heated to the processing temperature is inserted between the molding dies so that the backing layer faces the nonwoven fabric side of the laminated sheet, and then clamped. The laminated sheet and the carpet are integrated.

[0007]

Since the method for producing a sound insulating material for a vehicle according to the present invention is constituted as described above, the carpet and the soft vinyl chloride resin sheet are heat-sealed via a nonwoven fabric simultaneously with the formation of the carpet, and the adhesive is formed. In addition to eliminating the need for bonding, the number of bonding steps can be omitted, and the shape can be formed in accordance with the shape of the floor of the laid floor of the vehicle, thereby improving the consistency.

[0008]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 1 is an explanatory view showing a process of manufacturing a laminated sheet 4 for manufacturing a sound insulating material for vehicles by integrating with a carpet. The soft vinyl chloride resin compound to which a large amount of a filler having a high specific gravity is added by an internal mixer or a kneading roll is put into a space 7 between two upper rolls of the inverted L-type calendar device 11 in a softened and molten state. Rolling is performed between the rolls rotating in the direction of the arrow to form a soft vinyl chloride resin sheet 1 having a thickness of 0.75 to 5.0 mm.

This soft vinyl chloride resin compound is composed of 100 to 100 parts by weight of a vinyl chloride resin, 50 to 100 parts by weight of a plasticizer, 50 to 100 parts by weight of a filler having a high specific gravity such as barium sulfate, and 50 parts by weight of a filler such as calcium carbonate. ~ 250 parts by weight, and other additives such as stabilizers, specific gravity is 1.3 ~
1.8. Sheets having a specific gravity of less than 1.3 have inferior sound insulation performance, and those having a specific gravity of more than 1.8 have a good sound insulation effect. The mechanical properties and the price of the compound of the obtained sheet are unsuitable as sound insulating materials for vehicles. Recycled products can also be used as the vinyl chloride resin. In this case, however, the filler is usually already contained. Therefore, the amount of the filler must be adjusted in consideration of the amount.

The soft vinyl chloride resin sheet 1 pulled out from the lowermost roll surface of the calendar device 11 goes to the pressure rolls 12 in a softened and molten state. At this time, a sheet-like felt layer is formed on one of the surfaces. 2, a non-woven fabric 3 is simultaneously introduced between the pressure rolls 12 and 12 on the other surface, and the pressure is reduced, and a part of the soft vinyl chloride resin sheet 1 bites between the felt layer and the surface fibers of the non-woven fabric to form a three-layered fabric. Is obtained.

Needle punch felt made of synthetic fiber or cotton can be used for the felt layer 2 and its thickness is 3 to 10 mm.
mm. As the nonwoven fabric 3, a single or mixed fiber made of polyethylene, polypropylene, nylon, polyester, or the like and having a weight of 50 to 120 g per square meter can be used.

The three-layer laminated sheet 4 that has passed between the pressure rolls 12, 12 is cut into a fixed length or is once wound into a roll. Laminated sheet 4 cut to a fixed size
Is immediately trimmed into a predetermined shape by a punch press. At this time, since the soft vinyl chloride resin sheet 1 is still in a softened state, trimming can be performed while preforming into a shape similar to the final shape depending on the shape of the punch die.

Thus, the soft vinyl chloride resin sheet 1
After forming the felt layer 2 on one surface and the non-woven fabric 3 on the other surface by pressing the laminated sheet 4 into a predetermined shape and trimming or trimming without forming, as shown in FIG. Is placed on a lower mold 14 having a pair of upper and lower molding surfaces that follow the floor surface to be laid. At this time, the laminated sheet 4 is arranged such that the felt layer 2 side is in contact with the mold surface. At this time, if the lower mold surface has a simple shape,
Even if the laminated sheet 4 is not formed at the time of the trimming, the laminated sheet 4 can follow the mold surface.

Next, the carpet 5 is inserted between the upper mold 13 and the lower mold 14. At that time, the backing layer on the back side of the carpet is arranged facing downward. The carpet 5 is passed through a heating furnace set at 150 to 250 ° C. in advance, and the backing layer on the back side is at 150 to 220 ° C.

The carpet 5 thus heated to the processing temperature is inserted between the molds so that the backing layer faces the nonwoven fabric 3 of the laminated sheet 4, and the carpet 5 is held between the molds. In this state, the upper die 13 and the lower die 14 are clamped by a pressing device (not shown) as shown in FIG. As a result, the nonwoven fabric 3 on the uppermost surface of the laminated sheet 4 cuts into the backing layer on the back surface side of the carpet 5 melted by the above-mentioned heating and acts as an anchor,
The carpet 5 and the laminated sheet 4 are integrated. By cutting off unnecessary portions of the integrated carpet 5 thus formed, the vehicle sound insulating material 9 as shown in FIG. 4 is completed.

The backing layer of the carpet 5 used in the present invention is preferably formed by melting a fine powder or a film of polyethylene, ethylene-vinyl acetate copolymer, etc., without using an adhesive. It can be integrated with the laminated sheet 4.

[0018]

According to the method for manufacturing a sound insulating material for a vehicle according to the present invention, the carpet and the soft vinyl chloride resin sheet are heat-sealed via a nonwoven fabric simultaneously with the formation of the carpet, and are securely adhered to the entire surface. Therefore, the sound insulation effect is improved. Further, no adhesive is required, and the number of bonding steps can be reduced. Furthermore, since the laminated sheet portion is also formed at the time of forming the carpet and can be formed in a shape following the laying floor of the vehicle, the matching with the laying surface is good, and the sound insulation effect is improved. Moreover, since the specific gravity of the soft vinyl chloride resin sheet is 1.3 to 1.8, its sound insulation performance is enhanced, and its workability and mechanical properties are enhanced. Furthermore, since a felt layer and a nonwoven fabric are respectively pressed on each surface of the soft vinyl chloride resin sheet which is rolled by a calender and is in a softened and molten state, a laminated sheet is manufactured, so that a laminated sheet can be obtained easily and at low cost. .

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a process of manufacturing a laminated sheet.

FIG. 2 is a cross-sectional view of a molding die and a molding material for explaining a method of integrating a laminated sheet with a carpet at the same time as molding the carpet.

3 is a cross-sectional view showing a state in which a pair of upper and lower molds are clamped from the state of FIG. 2 to form a carpet and integrate with a laminated sheet.

FIG. 4 is a cross-sectional view showing one example of a vehicle sound insulating material manufactured by the method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Soft vinyl chloride resin sheet 2 Felt layer 3 Nonwoven fabric 4 Laminated sheet 5 Carpet 9 Sound insulation material for vehicles 11 Calendar device 14 Lower mold

Claims (1)

(57) [Claims] 1. A laminated sheet obtained by rolling a felt layer on one surface and a nonwoven fabric on the other surface of a soft vinyl chloride resin sheet having a specific gravity of 1.3 to 1.8 which is rolled by a calender and is in a softened and molten state. After shaping into a predetermined shape and trimming, or trimming without shaping, after arranging the lower layer of the pair of upper and lower molds such that the felt layer side of the laminated sheet is in contact with the mold surface, the working temperature is reduced. Heat the heated carpet and make sure that the backing layer is
So as to face the side inserted between the molds, and then a manufacturing method of a vehicle sound insulator, characterized in that by clamping to integrate the product layer sheet and carpeting.