Soundproof member and production method thereof
AssigneeInoac Corporation
InventorsYosuke Hasegawa, Yasunari Kojima
Life of this patent
Estimating the term…
Abstract
In a soundproof member 10 including a polyurethane foam 11 and disposed apart from an engine E on a vehicle interior side of a dash panel 50 partitioning a space into an engine room having the engine E as a sound source and a vehicle interior, the polyurethane foam 11 has a surface layer 12 on at least a part of the surface thereof, a one side surface of the polyurethane foam 11 directly facing the vehicle interior side of the dash panel 50 has at least a surface layer 12A in an open cell state or a core, and a surface layer 12B of the other side surface opposite to the one side surface is a surface layer in a closed cell state.
Claims19
A soundproof member which comprises a polyurethane foam and is disposed apart from or at least partially in contact with a sound source,
- wherein the polyurethane foam has a surface layer on at least a part of the surface thereof,
- the surface layer is a layered part on the surface of the polyurethane foam whose density is higher than that of a core of the polyurethane foam,
- at least one side surface of the polyurethane foam facing the sound source has at least the surface layer in an open cell state, and
- the surface layer on at least the other side surface opposite to the one side surface is the surface layer in a closed cell state.
A method of producing a soundproof member including a polyurethane foam having a surface layer on the surface thereof, which comprises coating a mold release agent onto a mold surface of a mold, pouring a raw material of polyurethane foam into the mold, and foaming the poured raw material,
- wherein the soundproof member is disposed apart from or at least partially in contact with a sound source,
- the surface layer is a layered part on the surface of the polyurethane foam whose density is higher than that of a core of the polyurethane foam,
- a mold release agent containing at least linear hydrocarbon wax is coated onto at least a mold surface forming a one side surface of the polyurethane foam facing the sound source,
- a mold release agent containing at least branched chain hydrocarbon wax is coated onto at least a mold surface forming the other side surface of the polyurethane foam opposite to the one side surface
- the surface layer in an open cell state is formed on at least a part of the one side surface of the polyurethane foam on the mold surface coated with the mold release agent containing at least linear hydrocarbon wax, and
- the surface layer in a closed cell state is formed on the other side surface of the polyurethane foam opposite to the one side surface on the mold surface coated with the mold release agent containing branched chain hydrocarbon wax.
Dependencies are inferred from the claim text.