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CN108604443B - 吸音性表皮材、吸音材及它们的制造方法 - Google Patents

吸音性表皮材、吸音材及它们的制造方法 Download PDF

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Publication number
CN108604443B
CN108604443B CN201780009031.5A CN201780009031A CN108604443B CN 108604443 B CN108604443 B CN 108604443B CN 201780009031 A CN201780009031 A CN 201780009031A CN 108604443 B CN108604443 B CN 108604443B
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China
Prior art keywords
sound
absorbing
resin
base material
skin material
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CN108604443A (zh
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小川正则
藤井慎
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Nagoya Oil Chemical Co Ltd
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Nagoya Oil Chemical Co Ltd
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Abstract

本发明提供能够使吸音性能适宜、能够抑制外观品质的降低、并且能够容易地制造的吸音性表皮材、吸音材及它们的制造方法，吸音性表皮材(10)具有通气阻力为0.01～0.1kPa·s/m的无纺布制的基材(11)、和覆盖该基材的一面的半固化状态的热固性树脂制的树脂膜(12)，在上述树脂膜(12)中分散有由平均粒径为1～100μm的粉体形成的填料(13)，吸音性表皮材整体的通气阻力为0.2～5.0kPa·s/m，此外，吸音材(20)包含：吸音性基材(21)：其由多孔质材料形成；以及吸音性表皮材(10)：其以使上述树脂膜(12)朝向该吸音性基材(21)侧的方式被层叠在上述吸音性基材(21)的单面或两面，所述吸音材(20)被形成为规定形状。

Description

吸音性表皮材、吸音材及它们的制造方法
技术领域
本发明涉及例如在汽车等车辆、房屋等建筑物、航空器、船舶等内部装饰材和外部装饰材中所使用的吸音性表皮材、吸音材及它们的制造方法。
背景技术
一般，作为汽车等车辆、房屋等建筑物、航空器、船舶等(以下，也简记为“汽车等”)的内部装饰材和外部装饰材的材料，为了抑制噪音，例如使用了玻璃棉、岩棉、毛毡等多孔质材料。但是，玻璃棉、岩棉、毛毡等多孔质材虽然对于特定的高频带的声音显示出优异的吸音特性，但是对于例如低频带的声音等那样的特定的高频带以外的声音，几乎不显示出吸音特性。此外，该多孔质材在谋求吸音性能的提高的情况下需要增加厚度，但是会产生在汽车等上的搭载空间的确保变得困难、重量增大等不良情况。
于是，专利文献1和专利文献2中公开的吸音材通过在多孔质材料的表面设置由粉体形成的粉体层、并利用上述粉体在声音的入射时的振动，从而在不增加多孔质材的厚度和重量的情况下来谋求吸音性能的提高。此外，该粉体层是通过将含有粉体的粘合剂树脂涂布于多孔质材料的表面、并使该粘合剂树脂固化而形成的。
另一方面，对于近年来的汽车等的特别是内部装饰材，要求纤维的手感所带来的外观的体现，在这样的情况下，一直通过在上述那样的多孔质材料的表面层叠由纤维形成的表皮材，从而谋求外观品质的提高。
作为上述那样的表皮材，例如专利文献3中公开了一种表皮材，其在浸渗有合成树脂的无纺布的单面(背面)涂布有粉末状的热熔粘接剂。专利文献4中公开了一种表皮材，其是从在表面形成有防水剂涂布层的纤维片材的背面浸渗水性合成树脂液而成的。专利文献5中公开了一种表皮材，其是在通过将表皮材与基材(多孔质材料)重叠、并进行热压而成形为规定形状的内部装饰材的制造方法中，使无纺布中浸渗合成树脂而得到的。
进而，提出了不仅谋求上述那样的外观品质的提高、而且赋予了吸音性能的表皮材。例如专利文献6中公开了一种表皮材，其通过在纤维片材的单面或两面层叠表面形成有许多的凹凸并且具有规定的通气阻力的拉伸性纸材，从而赋予了吸音性能。
现有技术文献
专利文献
专利文献1：日本特开平11-133980号公报
专利文献2：日本特开平11-219187号公报
专利文献3：日本特开2000-319615号公报
专利文献4：日本特开2003-301384号公报
专利文献5：日本特开2008-087430号公报
专利文献6：日本特开2009-214871号公报
发明内容
发明所要解决的问题
一般，汽车等的内部装饰材和外部装饰材是通过在多孔质材料的表面粘贴表皮材后、通过热压成形进行加热而制成规定形状来获得的。但是，对多孔质材料或表皮材涂布或使其浸渗有合成树脂的情况(例如专利文献1到专利文献3)下，往往会导致合成树脂因热压成形时的加压而从多孔质材料中或表皮材中被挤出而渗出到表皮材的表面。在表皮材的表面合成树脂渗出的部位通过成为光泽等那样的合成树脂特有的质感，从而导致由纤维带来的质感消失，外观品质降低。
此外，就近年来的汽车等特别是混合动力汽车和电动汽车而言，发动机声音减少，从而导致甚至于迄今为止不被识别为噪音的频带的声音、以及从车外侵入的路面噪音和风噪也被识别为噪音，这成为问题，为了应对该噪音，要求吸音性能的进一步提高。专利文献1和专利文献2由于主要对于高频带(2000Hz以上)的声音显示出优异的吸音特性，但是对于低频带的声音的吸音性能并不充分，所以不能说对于近年来的汽车等中变得被识别为噪音的声音具有充分的吸音性能。特别是若为了提高外观品质而在该多孔质材料粘贴表皮材，则吸音特性因该表皮材而发生变化的可能性也高，需要也考虑这种吸音特性的变化。
专利文献3、专利文献4、专利文献5关于上述的外观品质的降低尝试进行解决，但是，并非尝试提高吸音性能。并且，专利文献6虽然是尝试外观品质和吸音性能的提高，但是在纤维片材上粘贴拉伸性纸材的作业繁杂，此外由于拉伸性纸材容易破损，所以具有成形性差这样的问题。
本发明是着眼于这样的以往技术中存在的问题而进行的。其目的在于提供能够使吸音性能适宜、能够抑制外观品质的降低、并且能够容易地制造的吸音性表皮材、吸音材及它们的制造方法。
用于解决问题的手段
作为解决上述以往的问题的手段，方案1所述的吸音性表皮材的主旨在于，其具有通气阻力为0.01～0.1kPa·s/m的无纺布制的基材、和覆盖该基材的一面的半固化状态的热固性树脂制的树脂膜，在上述树脂膜中分散有由平均粒径为1～100μm的粉体形成的填料，所述吸音性表皮材整体的通气阻力为0.2～5.0kPa·s/m。
方案2所述的发明是根据方案1所述的吸音性表皮材的发明，其主旨在于，上述基材中使用的无纺布每单位面积的质量为10g/m2～120g/m2，厚度为0.1～2.0mm。
方案3所述的发明是根据方案1或方案2所述的吸音性表皮材的发明，其主旨在于，上述树脂膜中使用的热固性树脂为间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂。
方案4所述的发明是根据方案1至方案3中任一项所述的吸音性表皮材的发明，其主旨在于，在上述树脂膜中，填料/热固性树脂的混合比以固体成分比计为55/45～70/30。
方案5所述的吸音材的发明的主旨在于，其包含：吸音性基材：其由多孔质材料形成；以及方案1至方案4中任一项所述的吸音性表皮材：其以使上述树脂膜朝向该吸音性基材侧的方式被层叠在所述吸音性基材的单面或两面，所述吸音材被形成为规定形状。
方案6所述的吸音性表皮材的制造方法的发明的主旨在于，其是方案1至方案4中任一项所述的吸音性表皮材的制造方法，具备以下工序：在通气阻力为0.01～0.1kPa·s/m的无纺布制的基材上，按照涂布量以固体成分换算计成为10g/m2～50g/m2的范围的方式涂布在处于未固化状态的热固性树脂的液体中分散填料而成的涂装液的工序；和为了使上述热固性树脂成为半固化状态而将涂布有上述涂装液的上述基材在规定的温度下进行加热干燥，从而形成树脂膜的工序。
方案7所述的发明是根据方案6所述的吸音性表皮材的制造方法的发明，其主旨在于，上述热固性树脂为间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂，在120℃以上且160℃以下的温度下进行上述加热干燥。
方案8所述的吸音材的制造方法的发明的主旨在于，在由多孔质材料形成的吸音性基材的单面或两面，按照上述树脂膜朝向该吸音性基材侧的方式层叠方案1至方案4中任一项所述的吸音性表皮材，得到具有该吸音性表皮材及该吸音性基材的片材状吸音性坯材后，将该吸音性坯材在180℃以上的温度下进行热压成形，从而将该吸音性坯材成形为规定形状，并且使上述树脂膜的热固性树脂成为固化状态。
发明效果
〔作用〕
本发明的吸音性表皮材具有无纺布制的基材和覆盖该基材的一面的热固性树脂制的树脂膜，例如其被粘贴于多孔质材料的表面，是为了通过无纺布制的上述基材带来纤维的手感从而体现出外观而使用的。进而，该吸音性表皮材由于整体的通气阻力被设定为0.2～5.0kPa·s/m，所以具有适宜的吸音性能，作为吸音材是有用的。
这里，本发明的通气阻力(Pa·s/m)是指通过通气性试验机(制品名：KES-F8-AP1、Kato Tech株式会社制、稳流压差测定方式)测定得到的值。
在上述吸音性表皮材中，对于上述基材的无纺布，通过使用通气阻力为0.01～0.1kPa·s/m的无纺布，从而按照不会损害上述吸音性表皮材的整体的通气阻力的方式构成。进而，通过将该无纺布的通气阻力设定为上述的范围，从而树脂膜的热固性树脂相对于该无纺布不会超过必要地渗入，外观品质的降低得以抑制。
在上述吸音性表皮材中，上述树脂膜的热固性树脂由于被制成半固化状态，所以适宜地保持了能够塑性加工的变形性/延展性、即成形性。此外，该热固性树脂由于为半固化状态、且不为未固化状态，所以向上述基材的无纺布的渗入得以抑制。进而，对于上述树脂膜中使用的热固性树脂，在将吸音性表皮材层叠于多孔质材料的表面而进行热压成形时，通过加热而发生反应，成为固化状态。即，该热固性树脂不像以往的表皮材中使用的热塑性树脂那样在热压成形时通过加热而软化、并通过加压而被压入并渗入到上述基材的无纺布中、从而渗出到该基材的表面，因此，能够抑制外观品质的降低。
这里，所谓半固化状态是指热固性树脂的反应处于中间阶段、能够溶解于某种溶剂中、并且通过加热能够软化、但没有完全溶解或熔融的状态、即B阶(B-stage、JIS K6900-1994及JIS K 6800-2006中规定)。此外，所谓固化状态是指热固性树脂的反应处于最终阶段、事实上不溶解不熔融的状态、即C阶(C-stage、JIS K 6900-1994及JIS K 6800-2006中规定)。进而，所谓未固化状态是指热固性树脂的反应处于初期阶段、可溶于某种溶剂中、通过加热而熔融的状态、即A阶(A-stage、JIS K 6900-1994及JIS K 6800-2006中规定)。
在上述吸音性表皮材中，在上述树脂膜中分散有由平均粒径为1～100μm的粉体形成的填料。上述热固性树脂以液体的状态被涂布于上述基材的无纺布上，该热固性树脂液附着在填料表面而产生表面张力。通过该表面张力，抑制该热固性树脂液向上述基材中超过所需地渗入，不易渗出到该基材的表面，外观品质的降低得以抑制。此外，附着在填料表面的热固性树脂液由于通过表面张力而沿着该填料的表面扩展，所以形成于填料彼此之间的间隙变得难以被上述热固性树脂填埋，能够将吸音性表皮材的整体的通气阻力保持在上述范围内。并且，在将上述吸音性表皮材层叠于多孔质材料的表面而进行热压成形时，若是通常的话，树脂通过直接受到加压而被压入基材中、然后被挤出，但根据本发明的构成，由于通过上述填料受到加压，从而向半固化状态的热固性树脂的加压得以抑制，该热固性树脂向基材的压入及从该基材的挤出得以抑制，因此能够抑制使外观品质降低(方案1)。
此外，对于上述基材的无纺布，通过使用每单位面积的质量为10g/m2～120g/m2、厚度为0.1～2.0mm的无纺布，能够适宜地抑制以液体的状态涂布的热固性树脂的渗入和由该渗入引起的热固性树脂向基材的表面的渗出(方案2)。
此外，对于上述树脂膜的热固性树脂，通过使用间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂，从而半固化状态下的适用期(能够加工作业的期间、可用时间)长，性能稳定，能够使上述吸音性表皮材容易处理(方案3)。
此外，通过在上述树脂膜中将填料/热固性树脂的混合比以固体成分比计设定为55/45～70/30，从而能够适当地保持外观品质，并且发挥良好的吸音性能(方案4)。
本发明的吸音材是在由多孔质材料形成的吸音性基材的单面或两面使上述树脂膜朝向该吸音性基材侧而层叠上述的吸音性表皮材、并形成为规定形状而成的，通过使用该吸音性表皮材，能够使吸音性能变得适宜，同时能够使外观品质变得适宜(方案5)。
根据本发明的吸音性表皮材的制造方法，通过在通气阻力为0.01～0.1kPa·s/m的无纺布制的基材上，以固体成分换算计为10g/m2～50g/m2的范围的涂布量涂布在处于未固化状态的热固性树脂的液体中分散填料而成的涂装液，并在规定的温度下进行加热干燥，使上述热固性树脂成为半固化状态(B阶)而形成树脂膜，从而能够容易地制造吸音性表皮材。另外，在涂装液的涂布量(固体成分换算)低于10g/m2的情况下，没有在基材的整面形成树脂层，若超过50g/m2，则所涂布的涂装液因其自重渗入基材中而使外观品质降低的可能性变高。此外，上述以往的专利文献1和专利文献2中，涂布量以固体成分计为超过200g/m2至1000g/m2左右的范围，重量容易增大，用于达成对近来的汽车强烈要求的低燃耗的轻量化困难。但是，通过本发明的制造方法得到的吸音性表皮材中，涂装液的涂布量以固体成分换算计为10g/m2～50g/m2的范围，容易达成轻量化(方案6)
此外，在将上述热固性树脂设定为间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂、且在120℃以上且160℃以下的温度下进行上述加热干燥的情况下，能够使上述热固性树脂适宜地成为半固化状态(B阶)。另外，在将加热干燥的温度设定为低于120℃的情况下，上述热固性树脂没有成为半固化状态(B阶)而成为未固化状态(A阶)的可能性高，在超过160℃的情况下，上述热固性树脂没有停留在半固化状态(B阶)、而成为固化状态(C阶)的可能性高(方案7)。
根据本发明的吸音材的制造方法，通过相对于由多孔质材料形成的吸音性基材的单面或两面，按照上述树脂膜朝向该吸音性基材侧的方式层叠上述的吸音性表皮材，并在180℃以上的温度下进行热压成形而成形为规定形状，从而能够容易地制造该吸音材。上述吸音性表皮材的树脂膜为热固性树脂制，但由于为半固化状态(B阶)，所以保持膜状的形态、且保持了成形性，因此能够成形为规定形状，此外在热压成形后，通过成为固化状态(C阶)而能够适宜地保持该规定形状。并且，由于热固性树脂是在热压成形时固化的树脂，不是软化的树脂，所以也不会有软化后的树脂因加压被挤出到基材表面，能够适宜地抑制外观品质的降低(方案8)。
〔效果〕
根据本发明的吸音性表皮材，通过将树脂膜设定为半固化状态的热固性树脂制，进一步在该树脂膜中分散有填料，能够使吸音性能适宜、并且抑制外观品质的降低。
此外，根据本发明的吸音材，通过分散于吸音性表皮材的树脂膜中的填料受到加压时的压力，能够使吸音性能适宜、并且抑制外观品质的降低。
此外，根据本发明的吸音性表皮材的制造方法，通过在基材的一面涂布热固性树脂液，成为半固化状态而形成树脂膜，能够容易地制造该吸音性表皮材。
此外，根据本发明的吸音材的制造方法，通过将上述吸音性表皮材层叠于由多孔质材料形成的吸音性基材上并成形为规定形状，能够容易地制造该吸音材。
附图说明
图1是表示实施方式的吸音性表皮材的截面图。
图2是表示实施方式的吸音材的截面图。
具体实施方式
以下，对于将本发明具体化的一个实施方式，使用附图进行说明。
如图1中所示的那样，本实施方式的吸音性表皮材10具有基材11和覆盖该基材11的一面即背面的树脂膜12。并且，在该树脂膜12中，分散有填料13。
关于上述基材11，作为其材料，使用由纤维形成的无纺布。
若例示出上述纤维，则可列举出聚酯纤维、聚乙烯纤维、聚丙烯纤维、聚酰胺纤维、丙烯腈系纤维、氨基甲酸酯纤维、聚氯乙烯纤维、聚偏氯乙烯纤维、乙酸酯纤维等合成纤维、由从玉米或甘蔗等植物中提取的淀粉形成的生物分解性纤维(聚乳酸纤维)、纸浆、棉花、椰子纤维、麻纤维、竹纤维、洋麻纤维等天然纤维、玻璃纤维、碳纤维、陶瓷纤维、石棉纤维等无机纤维、或将使用了这些纤维的纤维制品的碎屑开纤而得到的再生纤维。并且，对于上述基材11，使用所例示的纤维的1种或2种以上。
例如，若将聚间苯二甲酰间苯二胺纤维、聚对苯二甲酰对苯二胺纤维等芳族聚酰胺纤维、聚芳酯纤维、聚醚醚酮纤维、聚苯硫醚纤维等熔点为250℃以上的耐热性合成纤维混合使用，则可得到耐热性极高的基材11。其中碳纤维从可进行焚烧处理且细片不易飞散的方面来看是有用的无机纤维，芳族聚酰胺纤维从比较廉价且容易获得的方面来看是有用的阻燃性合成纤维。
此外，对于上述纤维的全部或一部分，也可以使用熔点为180℃以下的低熔点热塑性纤维。作为该低熔点热塑性纤维，例如有熔点为180℃以下的聚乙烯、聚丙烯、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸乙酯共聚物等聚烯烃系纤维、聚氯乙烯纤维、聚氨酯纤维、聚酯纤维、聚酯共聚物纤维、聚酰胺纤维、聚酰胺共聚物纤维等。这些低熔点热塑性纤维可单独使用或将2种以上组合使用。
对于上述无纺布，使用通过以下方法制造的无纺布：一边将作为上述纤维的材料的热塑性树脂以长纤维状喷出一边形成为片材状的纺粘法；通过针刺将上述纤维网(web)的片材或垫(mat)络合的方法；将上述纤维网的片材或垫加热来使上述低熔点热塑性纤维软化而粘结的热粘结法；在上述纤维网的片材或垫中浸渗或混合合成树脂粘合剂而粘结的化学粘结法；通过针刺将上述纤维网的片材或垫络合后，将上述低熔点热塑性纤维加热软化而粘结，或用线缝入的缝编法、或用高压水流使纤维彼此进行缠合的射流喷网成布法等。
上述基材11中使用的无纺布的通气阻力被设定为0.01～0.1kPa·s/m。该通气阻力优选为0.015～0.08kPa·s/m，更优选为0.015～0.04kPa·s/m。若该无纺布的通气阻力过低，则上述基材11的密度变得过低，导致上述基材11的强度和刚性降低，并且形成上述树脂膜12的热固性树脂变得容易渗入。若该无纺布的通气阻力过高，则上述基材11的密度变高，导致刚性变大而柔软性减少，成形性变差，并且上述吸音性表皮材10整体的吸音特性变差。
对于上述无纺布，从将通气阻力设定为0.01～0.1kPa·s/m这样的观点出发，优选将每单位面积的质量设定为10g/m2～120g/m2，更优选设定为15g/m2～110g/m2，进一步优选设定为15g/m2～100g/m2。此外，对于上述无纺布，从将通气阻力设定为0.01～0.1kPa·s/m这样的观点出发，优选将厚度设定为0.1～2.0mm，更优选设定为0.12～1.0mm，更优选设定为0.14～0.8mm。若上述无纺布的每单位面积的质量过小、或厚度过薄，则通气阻力达不到0.01kPa·s/m的可能性变高。若上述无纺布的每单位面积的质量过大、或厚度过厚，则通气阻力超过0.1kPa·s/m的可能性变高。
另外，在上述基材11中使用的无纺布中，也可以添加等硬脂酸、棕榈酸等高级脂肪酸、棕榈醇、硬脂醇等高级醇；硬脂酸丁酰酯、甘油单硬脂酸酯等脂肪酸的酯类；脂肪酸酰胺类；巴西棕榈蜡；石蜡类；石蜡油等天然蜡类或合成蜡类；氟树脂、硅系树脂、聚乙烯基醇、润滑脂等这样的防水剂或防油剂、或颜料、染料、抗氧化剂、抗静电剂、结晶化促进剂、磷系化合物、氮系化合物、硫系化合物、硼系化合物、溴系化合物、胍系化合物、磷酸盐系化合物、磷酸酯系化合物、氨基系树脂等阻燃剂、膨胀石墨、防火剂、防虫剂、防腐剂、表面活性剂、润滑剂、抗老化剂、紫外线吸收剂等那样的各种药剂。
关于上述树脂膜12，作为其材料，使用热固性树脂。作为该热固性树脂，例如使用氨基甲酸酯系树脂、三聚氰胺系树脂、热固化型丙烯酸系树脂、特别是通过加热形成酯键而固化的热固性丙烯酸系树脂、尿素系树脂、酚醛系树脂、环氧系树脂、热固化型聚酯系树脂等。此外，也可以使用氨基甲酸酯系树脂预聚物、尿素系树脂预聚物(初期缩合物)、酚醛系树脂预聚物(初期缩合物)、邻苯二甲酸二烯丙酯预聚物、丙烯酸低聚物、多元异氰酸酯、甲基丙烯酸酯单体、邻苯二甲酸二烯丙酯单体等预聚物、低聚物、单体等合成树脂前体。从容易处理的方面出发，该热固性树脂优选使用制成水溶液、水性乳液、水性分散液的热固性树脂，但也可以使用有机溶剂溶液的形态的热固性树脂。此外，对于上述热固性树脂或合成树脂前体，也可以将两种以上混合使用。
另外，上述树脂膜12的每单位面积的质量取决于后述的涂装液的涂布量(固体成分换算)，从谋求上述吸音性表皮材10的轻量化、并且为了使吸音性能适宜而将整体的通气阻力设定为0.2～5.0kPa·s/m这样的观点出发，具体而言为50g/m2以下，优选为10g/m2～50g/m2的范围。
作为上述热固性树脂，优选的热固性树脂之一为酚醛系树脂。
上述酚醛系树脂中，有通过使甲醛类相对于酚系化合物过量并通过碱性催化剂进行反应而得到的甲阶酚醛型、和通过使酚相对于甲醛类过量并通过酸性催化剂进行反应而得到的酚醛清漆型这两种类型。该甲阶酚醛型由使酚与甲醛加成而得到的各种酚醇的混合物组成，通常以水溶液的形式被提供。该酚醛清漆型由使酚进一步与酚醇缩合而得到的二羟基二苯甲烷系的各种衍生物组成，通常以粉末的形式被提供。
优选的酚醛系树脂为苯酚-烷基间苯二酚共缩合物。该苯酚-烷基间苯二酚共缩合物具有以下优点：该共缩合物(初期缩合物)的水溶液的稳定性良好，并且与仅由苯酚构成的缩合物(初期缩合物)相比，在常温下能够长时间保存。此外将该水溶液涂布于上述基材11上并制成半固化状态(B阶)而得到的树脂膜12的稳定性良好，即使将上述吸音性表皮材10长时间保存，也不会丧失成形性。进而由于烷基间苯二酚与甲醛类的反应性高，捕捉游离醛并进行反应，所以还具有使树脂中的游离醛量变少等优点。
通过爱沙尼亚产的油页岩的干馏而得到的多元酚混合物由于廉价，且除了5-甲基间苯二酚以外还大量地包含反应性高的各种烷基间苯二酚，所以是本发明中特别优选的多元酚原料。
在上述酚醛系树脂中，也可以在其制造时根据需要混合催化剂或pH调整剂。进而，在本发明的酚醛系树脂的初期缩合物(包含初期共缩合物)中，也可以添加混合甲醛类或烷基醇化三嗪酮衍生物等固化剂。进而，在使用水溶性的酚醛系树脂的情况下，为了改良其稳定性，也可以将酚醛系树脂进行磺基甲基化和/或亚磺基甲基化。
作为上述热固性树脂，另外优选的树脂之一是酯键形成固化型热固性丙烯酸树脂。
酯键形成固化型热固性丙烯酸树脂也被称为伪热塑性树脂，其是含有(A)5～100质量％是由烯键式不饱和酸酐或羧酸基能够形成酸酐基的烯键式不饱和二羧酸构成且通过自由基聚合而得到的聚合物、(B)至少具有2个羟基的烷醇胺、以及相对于(A)+(B)之和少于1.5质量％的含磷反应促进剂的不含甲醛的水性粘合剂。
上述水性粘合剂一般以水性乳液、水溶液、或异丙醇、乙醇、甘醇等水溶性有机溶剂溶液、水与上述水溶性有机溶剂的混合溶剂的溶液等形状被提供，通过聚合物(A)中包含的酸与烷醇胺(B)中包含的羟基的酯化反应而固化，水溶性变化为水不溶性，热塑性变化为伪热塑性。
上述伪热塑性树脂目前由BASF公司作为商品名Acrodur被上市，作为水溶液类型，有950L、DS3530，作为水性乳液类型，有958D。
上述Acrodur在大约120℃以上的温度下通过上述酯化反应开始交联，在160℃以上的温度下进行固化，但即使在交联前的热塑性的状态下也具有充分的硬度，处理容易，而且在热成形时通过加热而硬度降低且暂时地变成热塑性(伪热塑性)，显示出良好的成形性，可得到高成形精度。此外由于上述Acrodur的交联利用酯化反应进行，所以具有仅副产水、而不副产甲醛等有害物质这样的优点。
上述伪热塑性树脂可以将两种以上、例如将水溶液类型与水性乳液类型混合，也可以混合其他的热塑性树脂水性乳液等。
上述伪热塑性树脂的详细情况例如记载于日本特表2000-506940号公报中。
另外，在上述树脂膜12的热固性树脂中，出于使填料的分散性提高、易于处理、成形性提高等目的，也可以将一般的增稠剂、分散剂、软化剂、增塑剂、或者以不阻碍该热固性树脂的程度将若干量的热塑性树脂的1种或2种以上混合使用。从处理容易的方面出发，该热塑性树脂优选使用水溶液、水性乳液、水性分散液的形态的热塑性树脂，但也可以使用有机溶剂溶液的形态的热塑性树脂。
作为上述热塑性树脂，例如可例示出丙烯酸酯树脂、甲基丙烯酸酯树脂、离聚物树脂、乙烯-丙烯酸乙酯(EEA)树脂、丙烯腈·苯乙烯·丙烯酸橡胶共聚(ASA)树脂、丙烯腈·苯乙烯共聚(AS)树脂、丙烯腈·氯化聚乙烯·苯乙烯共聚(ACS)树脂、乙烯乙酸乙烯酯共聚(EVA)树脂、乙烯乙烯醇共聚(EVOH)树脂、甲基丙烯酸树脂(PMMA)、聚丁二烯(BDR)、聚苯乙烯(PS)、聚乙烯(PE)、丙烯腈·丁二烯·苯乙烯共聚(ABS)树脂、氯化聚乙烯(CPE)、聚乙烯基醇(PVA)、聚氯乙烯(PVC)、聚偏氯乙烯(PVDC)、聚丙烯(PP)、乙酸纤维素(纤维素乙酸酯：CA)树脂、间规聚苯乙烯(SPS)、聚甲醛(＝聚缩醛)(POM)、聚酰胺(PA)、聚酰亚胺(PI)、聚酰胺酰亚胺(PAI)、聚醚酰亚胺(PEI)、聚芳酯(PAR)、热塑性聚氨酯(TPU)弹性体、热塑性弹性体(TPE)、液晶聚合物(LCP)、聚醚醚酮(PEEK)、聚砜(PSF)、聚醚砜(PES)、氟树脂、聚四氟乙烯(PTFE)、聚对苯二甲酸乙二醇酯(PET)、聚碳酸酯(PC)、聚苯醚(PPE)、改性PPE、聚苯硫醚(PPS)、聚对苯二甲酸丁二醇酯(PBT)、聚苯并咪唑(PBI)、全芳香族聚酯(POB)等。
作为上述填料13，可例示出火山灰中空球(shirasu balloon，也可以称为白砂泡球或白洲泡球)、珍珠岩(pearlite)、中空玻璃球、发泡玻璃、中空陶瓷等中空颗粒体；发泡聚乙烯、发泡聚苯乙烯、发泡聚丙烯等塑料发泡体或发泡颗粒；碳酸钙、碳酸镁、硫酸钡、硫酸钙、亚硫酸钙、磷酸钙、氢氧化钙、氢氧化镁、氢氧化铝、氧化镁、氧化钛、氧化铁、氧化锌、氧化铝、二氧化硅、胶体二氧化硅、云母、硅藻土、白云石、石膏、滑石、粘土、石棉、云母、硅酸钙、膨润土、白炭墨、炭黑、铁粉、铝粉、玻璃粉、石粉、高炉矿渣、飞尘、水泥、氧化锆粉等无机填充材料；木粉、核桃粉、椰壳粉、小麦粉、米粉等有机填充材料等。
上述中，火山灰中空球等中空颗粒体由于内部为中空，所以大大有助于吸音性能的提高，因此优选作为上述填料13。
上述吸音性表皮材10通过上述基材11的纤维的手感而谋求了外观品质的提高，并且通过设置于该基材11的背面的树脂膜12，该基材11被增强而谋求了强度等的提高。此外，在该吸音性表皮材10中，上述树脂膜12通过分散·含有于该树脂膜12中的上述填料13在该填料13彼此之间形成间隙而具有通气性。因此，该吸音性表皮材10按照以下方式构成：在噪音想要通过上述基材11及上述树脂膜12时，通过缓冲吸音作用，将该噪音吸音。
此外，通常上述吸音性表皮材10被层叠于多孔质材料的表面，与该多孔质材料一起被成形为规定形状而使用。因此，为了对上述吸音性表皮材10赋予成形性，上述树脂膜12通过制成半固化状态(B阶)的热固性树脂来形成。并且，半固化状态(B阶)的热固性树脂制的上述树脂膜12没有阻碍无纺布制的上述基材11所具有的柔软性，上述吸音性表皮材10成为具有柔软的成形性的表皮材。此外，上述树脂膜12通过使热固性树脂成为半固化状态(B阶)，从而具有由粘性带来的粘接性，还具有作为与上述多孔质材料的粘接材的功能。进而，由于上述树脂膜12通过使热固性树脂成为半固化状态(B阶)而具有粘性，所以不易渗入上述基材11的无纺布中，此外渗入的部分也变得不易渗出到该基材11的表面。
即，上述树脂膜12通过设定为半固化状态(B阶)的热固性树脂制，从而对上述吸音性表皮材10赋予成形性和粘接性，并且相对于上述基材11的无纺布的渗入和渗出得到抑制，由此赋予良好的外观品质。
关于上述吸音性表皮材10，从使吸音性能适宜这样的观点出发，将上述基材11及上述树脂膜12合计的整体的通气阻力被设定为0.2～5.0kPa·s/m。该通气阻力优选为0.25～4.5kPa·s/m，更优选为0.3～4.0kPa·s/m。在该吸音性表皮材10的通气阻力不在上述的范围内的情况下，无法发挥所期望的吸音性能。
此外，从将上述吸音性表皮材10的通气阻力设定为上述范围内这样的观点出发，对于上述填料13，使用平均粒径为1～100μm的粉体。该平均粒径优选为10～90μm，更优选为15～70μm。若该填料13的平均粒径过小，则变得难以在填料13彼此之间形成间隙，上述吸音性表皮材10的通气阻力变大，另一方面，若该填料13的平均粒径过大，则在填料13彼此之间形成过大的间隙，上述吸音性表皮材10的通气阻力变小。
此外，从将上述吸音性表皮材10的通气阻力设定为上述范围内这样的观点出发，在上述树脂膜12中，填料/热固性树脂的混合比以固体成分比计优选被设定为55/45～70/30。对于该混合比而言，若填料13的比率变得过高，则热固性树脂变得无法发挥作为填料13的粘合剂的功能，另一方面，若热固性树脂的比率变得过高，则通过填料13彼此之间的间隙被树脂填埋而上述树脂膜12的通气性丧失的可能性变高。
本实施方式的吸音材20的构成如图2中所示的那样，在吸音性基材21的表面使上述树脂膜12朝向该吸音性基材21而层叠上述吸音性表皮材10、并被形成为规定形状。另外，上述吸音材20的构成并不限于仅在上述吸音性基材21的表面(单面)层叠上述吸音性表皮材10，也可以在吸音性基材21的表面和背面这两面层叠上述吸音性表皮材10。
对于上述吸音性基材21，使用多孔质材料。作为该多孔质材料，可列举出由在上述吸音性表皮材10的基材11中列举出的纤维形成的无纺布或毛毡、此外使用玻璃棉、岩棉、石棉纤维、碳纤维、陶瓷纤维、金属纤维、单晶纤维等而成的无机系多孔质材料、或通气性聚氨酯发泡体、通气性聚乙烯发泡体、通气性聚丙烯发泡体、通气性聚苯乙烯发泡体、通气性酚醛树脂发泡体、通气性三聚氰胺树脂发泡体等通气性塑料发泡体。
上述吸音性基材21的单位面积重量、厚度原则上可以任意地设定。
上述吸音性基材21与上述吸音性表皮材10相互接合。在该接合中，由半固化状态(B阶)的热固性树脂形成的上述树脂膜12作为粘接剂被使用，但若是期望则也可以使用热熔粘接剂、丙烯酸系树脂粘接剂、丙烯酸系树脂粘合剂、合成橡胶系粘接剂、合成橡胶系粘合剂等粘接剂。在使用这样的粘接剂的情况下，保持上述吸音性基材21与上述吸音性表皮材10之间的通气性变得很重要。例如，在粘接剂中使用上述热熔粘接剂的情况下，从保持上述吸音性基材21与上述吸音性表皮材10之间的通气性这样的观点出发，优选使用粉末状的粘接剂，并且以优选2g/m2～40g/m2的散布量、更优选5g/m2～30g/m2的散布量点状地散在。
作为上述热熔粘接剂，使用熔点为80～180℃的聚乙烯树脂粉末、聚酯树脂粉末、聚酰胺树脂粉末、乙烯-乙酸乙烯酯共聚物粉末等低熔点热塑性树脂粉末的单体或2种以上的混合物。此外，上述热熔粘接剂粉末的利用筛分法得到的平均粒径优选设定为80～500μm的范围。在平均粒径低于80μm的情况下，在散布该热熔粘接剂粉末时，粉末散乱而使均匀的散布变得困难，此外粒子的微细粉末紧密地布满，所形成的热熔树脂粉末的散布层的密度变高，该散布层成为宛如没有孔的膜状，吸音材20的通气阻力存在变得过大的倾向。若平均粒径超过500μm，则有可能所得到的热熔树脂粉末的散布层的结构变得稀疏、热熔融后的粘接剂彼此没有结合而粘接力降低，此外该热熔树脂粉末的熔融物渗出到上述吸音性表皮材10的表面，使外观品质降低。进而，有可能粒子大的粉末通过热熔融而扩展，形成没有孔的膜状的膜，阻碍通气性而使吸音性能降低。
另外，上述热熔粘接剂可以在将上述吸音性表皮材10与上述吸音性基材21接合前的工序中散布于上述吸音性基材21的表面或上述吸音性表皮材10的上述树脂膜12上，或者也可以在后述的涂装液的制造时预先混合到未固化状态(A阶)的热固性树脂的液体中等而包含于上述树脂膜12中。
在制造上述吸音性表皮材10的情况下，预先使填料按照填料/热固性树脂的混合比成为上述范围的方式分散于未固化状态(A阶)的热固性树脂的液体中来制造涂装液。
接着，在通气阻力为0.01～0.1kPa·s/m的无纺布制的基材11上，涂布上述涂装液。该涂布的方法没有特别限定，例如可列举出辊涂机、刮刀涂布机、流涂机等。此外，在该涂布中，上述涂装液的涂布量以固体成分换算计被设定为10g/m2～50g/m2的范围。该涂布量优选为10g/m2～45g/m2，更优选为10g/m2～40g/m2。在该涂布量过少的情况下，该涂装液没有在上述基材11的整面上充分地展开，变得无法形成上述树脂膜12。在该涂布量过多的情况下，由于所涂布的涂装液因其自重渗入基材11的深处，所以在热压成形时等树脂渗出到上述吸音性表皮材10的表面而外观品质降低。
接着，通过将涂布有上述涂装液的上述基材11在规定的温度下进行加热干燥，将上述热固性树脂制成半固化状态(B阶)，从而形成树脂膜12。在该加热干燥中，上述规定的温度根据所使用的热固性树脂，适当设定为该热固性树脂成为半固化状态(B阶)的温度。例如，在热固性树脂中使用上述的酚醛系树脂、或上述的酯键形成固化型热固性丙烯酸树脂的情况下，上述温度被设定为120℃以上且160℃以下。在该温度低于120℃的情况下，由于上述热固性树脂没有充分地成为半固化状态(B阶)而大部分成为未固化状态(A阶)，所以变得无法抑制相对于上述基材11的无纺布的渗入和渗出。在该温度超过160℃的情况下，由于上述热固性树脂在半固化状态(B阶)没有停留而成为固化状态(C阶)，变得无法对上述吸音性表皮材10赋予成形性和粘接性。
即，上述吸音性表皮材10可以通过在无纺布制的基材11上以规定的涂布量涂布上述涂装液、并在规定的温度下进行加热干燥而容易地制造。
在制造上述吸音材20的情况下，首先，在多孔质材料制的吸音性基材21的表面，按照上述树脂膜12朝向该吸音性基材21侧的方式层叠上述吸音性表皮材10，制造具有该吸音性表皮材10及该吸音性基材21的片材状吸音性坯材。
接着，将上述吸音性坯材在180℃以上的温度下进行热压成形，成形为规定形状。此时，上述树脂膜12通过在180℃以上的温度下被加热，热固性树脂保持上述规定形状且由半固化状态(B阶)成为固化状态(C阶)。其结果是，规定形状得以保持，制造了吸音材20。
即，上述吸音材20可以通过在上述吸音性基材21上层叠上述吸音性表皮材10、并在热压成形中进行加热而容易地制造。
实施例
以下，对于将本发明进一步具体化的实施例进行说明，但本发明并不受该实施例的限定。
〔实施例1〕
(A)基材：使用了聚酯纤维制的纺粘无纺布、且每单位面积的质量为以下(A-1)～(A-3)这3种。
(A-1)每单位面积的质量：15g/m2(厚度：0.12mm、通气阻力：0.0158kPa·s/m)。
(A-2)每单位面积的质量：50g/m2(厚度：0.27mm、通气阻力：0.032kPa·s/m)。
(A-3)每单位面积的质量：100g/m2(厚度：0.39mm、通气阻力：0.10kPa·s/m)。
(B)涂装液：使用甲阶酚醛型苯酚·烷基间苯二酚初期共缩合树脂(固体成分为45质量％的水溶液)作为热固性树脂液，在其中按照基于固体成分比的混合比成为以下(B-1)～(B-2)的方式添加火山灰中空球(平均粒径：45μm)作为填料，进一步添加丙烯酸系增稠剂，按照粘度为150p且固体成分成为20质量％的水溶液的方式进行调整，得到涂装液。
(B-1)填料/热固性树脂的混合比：55/45。
(B-2)填料/热固性树脂的混合比：70/30。
(C)吸音性表皮材：相对于上述(A)基材，按照以固体成分换算计涂布量成为以下(C-1)～(C-3)这3种的方式通过辊涂法涂布上述(B)涂装液后，在120℃或160℃的加热温度下进行3分钟的加热干燥，使上述热固性树脂变成半固化状态(B阶)而形成树脂膜，得到吸音性表皮材。将所得到的吸音性表皮材的规格示于表1及表2中。
(C-1)涂布量(固体成分换算)：10g/m2。
(C-2)涂布量(固体成分换算)：25g/m2。
(C-3)涂布量(固体成分换算)：50g/m2。
(D)吸音材：相对于作为吸音性基材的未成形玻璃棉(每单位面积的质量：700g/m2、厚度：20mm)，将上述(C)吸音性表皮材通过热压成形机在220℃、60秒的条件下进行压接，得到四角板状的吸音材。具体而言，所得到的该吸音材设定为具有在俯视中呈四角框状的周缘部成为3mm的厚度、成为该周缘部的内侧的中央部成为5～10mm的厚度的凹凸部分的形状。然后，对该吸音材的外观进行目视，按照以下的5个等级进行评价。将其结果示于表1及表2中。
<外观的评价>
○：整体上粘接性良好，且在表面没有树脂的渗出。
△：整体上粘接性良好，但在表面有树脂的渗出。
▲：整体上粘接性良好，但在表面有较多树脂的渗出。
×：凹凸部分处粘接力弱，一部分处见到吸音性表皮材的剥离。
××：粘接力几乎没有，大致整体上见到吸音性表皮材的剥离。
表1
Figure BDA0001747721370000181
表2
Figure BDA0001747721370000191
〔实施例2〕
(A)基材：与上述〔实施例1〕同样。
(B)涂装液：除了使用酯键形成热固性树脂(BASF Japan制的商品名Acrodur958D、固体成分为42质量％的水溶液)作为热固性树脂液以外，与上述〔实施例1〕同样。
(C)吸音性表皮材：与上述〔实施例1〕同样地操作，得到吸音性表皮材。将所得到的吸音性表皮材的规格示于表3及表4中。
(D)吸音材：与上述〔实施例1〕同样地操作，得到吸音材。将所得到的吸音材的评价示于表3及表4中。
表3
Figure BDA0001747721370000211
表4
Figure BDA0001747721370000221
〔比较例1〕
(A)基材：除了将每单位面积的质量设定为以下(A-1)和(A-3)这2种以外，与上述〔实施例1〕同样。
(A-1)每单位面积的质量：15g/m2(厚度：0.12mm、通气阻力：0.0158kPa·s/m)。
(A-3)每单位面积的质量：100g/m2(厚度：0.39mm、通气阻力：0.10kPa·s/m)。
(B)涂装液：与上述〔实施例1〕同样。
(C)吸音性表皮材：将加热温度设定为100℃(低于120℃)而使树脂膜不成为半固化状态(B阶)而成为未固化状态(A阶)、或设定为180℃(超过160℃)而使树脂膜在半固化状态(B阶)没有停留而成为固化状态(C阶)，除此以外，与上述〔实施例1〕同样地操作，得到吸音性表皮材。将所得到的吸音性表皮材的规格示于表5及表6中。
(D)吸音材：与上述〔实施例1〕同样地操作，得到吸音材。将所得到的吸音材的评价示于表5及表6中。
表5
Figure BDA0001747721370000231
表6
Figure BDA0001747721370000241
〔比较例2〕
(A)基材：除了将每单位面积的质量设定为以下(A-1)和(A-3)这2种以外，与上述〔实施例1〕同样。
(A-1)每单位面积的质量：15g/m2(厚度：0.12mm、通气阻力：0.0158kPa·s/m)。
(A-3)每单位面积的质量：100g/m2(厚度：0.39mm、通气阻力：0.10kPa·s/m)。
(B)涂装液：与上述〔实施例1〕同样。
(C)吸音性表皮材：除了将涂装液的基于固体成分换算的涂布量设定为以下(C-4)～(C-5)这2种以外，与上述〔实施例1〕同样地操作，得到吸音性表皮材。将所得到的吸音性表皮材的规格示于表7中。
(C-4)涂布量(固体成分换算)：8g/m2。
(C-5)涂布量(固体成分换算)：60g/m2。
(D)吸音材：与上述〔实施例1〕同样地操作，得到吸音材。将所得到的吸音材的评价示于表7中。
表7
Figure BDA0001747721370000251
〔考察1〕
关于上述实施例1、2，吸音性表皮材的整体的通气阻力为0.2～5.0kPa·s/m的范围内，关于吸音材的外观也没有问题。
比较例1是在吸音性表皮材的制造时将加热温度设定为100℃或180℃而没有使树脂膜的热固性树脂成为半固化状态(B阶)的例子。在该比较例1中，将加热温度设定为100℃而使树脂膜的热固性树脂成为未固化状态(A阶)的吸音材虽然成形性和粘接性没有问题，但是在吸音材的外观上树脂向表面的渗出变多。此外将加热温度设定为180℃而使树脂膜的热固性树脂成为固化状态(C阶)的吸音材的成形性和粘接性存在问题。
比较例2是将涂装液的涂布量设定为8g/m2而没有形成充分的树脂膜的例子、和将涂装液的涂布量增加至60g/m2而过量地形成了树脂膜的例子。在该比较例2中减少涂布量(8g/m2)而没有形成充分的树脂膜的情况下，吸音性表皮材的整体的通气阻力低于0.2kPa·s/m，粘接性存在问题。此外，在增加涂布量(60g/m2)而过量地形成了树脂膜的情况下，粘接性和外观等没有问题，但通气阻力超过5.0kPa·s/m，存在树脂膜的通气性受损这样的问题。
〔实施例3〕
(A)基材：使用了聚酯纤维制的纺粘无纺布、且每单位面积的质量为20g/m2、厚度：0.14mm、通气阻力：0.04kPa·s/m的基材。
(B)涂装液：使用甲阶酚醛型磺基甲基化苯酚·烷基间苯二酚初期共缩合树脂(固体成分为50质量％的水溶液)作为热固性树脂液，在其中添加以下(B-3)～(B-7)这5种中的任一种作为填料。具体而言，将热固性树脂液70质量份、填料65质量份、进而黑色颜料(固体成分为20％水溶液)6质量份、氟系防水剂(固体成分为20％水溶液)2质量份、丙烯酸系增稠剂(固体成分为50％水溶液)5质量份、阻燃剂(多磷酸三聚氰胺)10质量份、水412质量份混合，得到固体成分为20％、粘度为200p、填料/热固性树脂的混合比：65/35的涂装液。
(B-3)滑石(平均粒径：15μm)。
(B-4)珍珠岩(平均粒径：70μm)。
(B-5)碳酸钙(平均粒径：10μm)。
(B-6)氢氧化铝(平均粒径：20μm)。
(B-7)火山灰中空球(平均粒径：30μm)。
(C)吸音性表皮材：相对于上述(A)基材，按照涂布量成为125g/m2(以固体成分换算计热固性树脂的涂布量为25g/m2)的方式通过辊涂法涂布上述(B)涂装液后，在140℃的加热温度下进行2分钟的加热干燥，使上述热固性树脂成为半固化状态(B阶)而形成树脂膜，得到吸音性表皮材。
(D)吸音材：相对于作为吸音性基材的未成形玻璃棉(每单位面积的质量：700g/m2、厚度：20mm)，将上述(C)吸音性表皮材通过热压成形机在220℃、60秒的条件下进行压接，得到在俯视中呈四角板状的厚度为15mm的吸音材。然后，按照上述的5个等级评价该吸音材的外观，同时测定规定的频率下的吸音率作为吸音性能。将其结果示于表8中。
表8
Figure BDA0001747721370000271
〔考察2〕
上述实施例3的结果是，不论填料的种类如何，均在整体上显示出优异的吸音率，关于吸音材的外观也没有问题。另外，关于各填料，在使用火山灰中空球的情况下，在低频的400Hz和630Hz下与其他填料相比吸音率良好，认为在以低频带的声音作为吸音对象的情况下，火山灰中空球作为填料是适宜的。
产业上的可利用性
本发明的吸音性表皮材、吸音材及它们的制造方法由于能够使吸音性能适宜，能够抑制外观品质的降低，并且能够容易地制造，所以可以在产业中利用。
符号说明
10 吸音性表皮材
11 基材
12 树脂膜
13 填料
20 吸音材
21吸音性基材

Claims (7)

1.一种吸音性表皮材，其特征在于，其具有通气阻力为0.01～0.1kPa·s/m的无纺布制的基材、和覆盖该基材的一面的半固化状态的热固性树脂制的树脂膜，
在所述树脂膜中分散有由平均粒径为1～100μm的粉体形成的填料，
所述吸音性表皮材整体的通气阻力为0.2～5.0kPa·s/m，
所述填料为中空颗粒体，
在所述树脂膜中，填料/热固性树脂的混合比以固体成分比计为55/45～70/30。
2.根据权利要求1所述的吸音性表皮材，其中，所述基材中使用的无纺布的每单位面积的质量为10g/m2～120g/m2，厚度为0.1～2.0mm。
3.根据权利要求1或权利要求2所述的吸音性表皮材，其中，所述树脂膜中使用的热固性树脂为间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂。
4.一种吸音材，其特征在于，其包含：
吸音性基材：其由多孔质材料形成；以及
权利要求1至权利要求3中任一项所述的吸音性表皮材：其以使所述树脂膜朝向该吸音性基材侧的方式被层叠在所述吸音性基材的单面或两面，
所述吸音材被形成为规定形状。
5.一种吸音性表皮材的制造方法，其特征在于，其是权利要求1至权利要求3中任一项所述的吸音性表皮材的制造方法，其具备以下工序：
在通气阻力为0.01～0.1kPa·s/m的无纺布制的基材上，按照涂布量以固体成分换算计成为10g/m2～50g/m2的范围的方式涂布在处于未固化状态的热固性树脂的液体中分散填料而成的涂装液的工序；以及
为了使所述热固性树脂成为半固化状态而将涂布有所述涂装液的所述基材在规定的温度下进行加热干燥，形成树脂膜的工序。
6.根据权利要求5所述的吸音性表皮材的制造方法，其中，所述热固性树脂为间苯二酚系树脂、或酯键形成固化型热固性丙烯酸树脂，在120℃以上且160℃以下的温度下进行所述加热干燥。
7.一种吸音材的制造方法，其特征在于，在由多孔质材料形成的吸音性基材的单面或两面，按照所述树脂膜朝向该吸音性基材侧的方式层叠权利要求1至权利要求3中任一项所述的吸音性表皮材，得到具有该吸音性表皮材及该吸音性基材的片材状吸音性坯材后，将该吸音性坯材在180℃以上的温度下进行热压成形，将该吸音性坯材成形为规定形状，并且使所述树脂膜的热固性树脂成为固化状态。
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