Soundproof sheet for vehicles, manufacturing method thereof, and dash silencer for vehicles using soundproof sheet

A manufacturing method of a soundproof sheet for a vehicle, comprising:

• a preparatory process for preparing a porous material layer for a first outer layer, preparing a porous material layer for a one-side outer layer portion of a second outer layer and a sound insulation material layer for the other-side outer layer portion of said second outer layer, and preparing a thermoplastic resin material film for a one-side film, a resin material film for a barrier film having a melting point higher than that of the thermoplastic resin material film, and a thermoplastic resin material film for the other-side film;
• a heating process for layering the thermoplastic resin material film for the one-side film, the resin material film for said barrier film and the thermoplastic resin material film for the other-side film, and heating and fusion-bonding them with each other at a temperature which is higher than a melting point of the thermoplastic resin material film and lower than the melting point of the resin material film for said barrier film;
• and
• a vacuum molding process for layering the porous material layer for said first outer layer on the film lamination body, layering the porous material layer for the one-side outer layer portion of said second outer layer and the sound insulation material layer for the other-side outer layer portion of said second outer layer respectively on one-side and other-side portions of the porous material layer for said first outer layer through the film lamination body, and pressing and cooling them integrally under vacuum molding so as to be adhered to each other.

A dash silencer for a vehicle which is installed along a partitionary wall member partitioning an engine room and a vehicle compartment included in the vehicle with an instrument panel disposed oppositely to an upper side portion of the partitionary wall member from the inner side of the vehicle compartment, the dash silencer comprising:

• a soundproof sheet which includes;
• a first outer layer formed from a porous material and having a one-side outer layer portion and the other-side outer layer portion being extended from the one-side outer layer portion,
• an intermediate layer formed by a film lamination body to be layered on the one-side outer layer portion of said first outer layer, and
• a second outer layer having one-side and other-side outer layer portions, the one-side layer portion of said second outer layer being formed from a porous material to be layered on at least the one-side layer portion of said first outer layer through said intermediate layer, the other-side outer layer portion of said second outer layer being formed from a sound insulation material to be layered on the other-side outer layer portion of said first outer layer,
• wherein said soundproof sheet is mounted on at least a predetermined region of the partitionary wall member to oppose the instrument panel at the one-side layer portion of said second outer layer and to extend said first outer layer along the partitionary wall member from its up-side to its lower-side.