JP2000052371A - Sound absorbing and insulating material and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sound absorbing and insulating material which can ensure both sound absorbing properties and sound insulating properties by integral molding without bonding together a plurality of materials and its method for preparation. SOLUTION: After a molten resin prepd. by plasticizing fiber-contg. thermoplastic resin pellets contg. specified reinforcing fiber is injected into a mold, a cavity is expanded by retreating a movable core to expand the molten resin by a spring-back phenomenon. Interstice layers 43 provided with excellent sound absorbing properties by a number of interstices and skin layers 41 and 42 with high density and high rigidity and provided with excellent sound insulating properties are integrally formed thereby. Then, when the skin layer 41 on one side is removed, a sound absorbing and insulating material 2A in which both sound absorbing properties and sound insulating properties are ensured is obtd. even by integral molding of the same material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound-absorbing and sound-insulating material and a method for manufacturing the same, and more particularly, to a sound-absorbing material in which a skin layer having high rigidity and a void layer having sound absorbing properties by a large number of voids are integrally formed. The present invention relates to a sound insulating material and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, sound insulating materials and sound absorbing materials have been used to cut off noise and noise. Among these, as the sound absorbing material, it is common to use a soft nonwoven fabric or a foam molded product that absorbs sound waves well. Such a sound-absorbing material has no rigidity and cannot normally expect sound insulation performance. On the other hand, as the sound insulating material, a member having high density, high rigidity, and hardly vibrating by sound waves is generally used. Since such a sound insulating material reflects and blocks a sound wave, it does not absorb the sound wave and cannot normally expect sound absorbing performance. By the way, fiber resin molded products reinforced with fibers such as glass fibers are excellent in mechanical properties such as tensile strength, rigidity and heat resistance, so that instrument panel cores, bumper beams, door steps, roof racks,
Automotive parts such as rear quarter panels and air cleaner cases, building and civil engineering members such as exterior wall panels, partition wall panels and cable troughs, and OA equipment and home appliances such as personal computer cases and speaker enclosures. Widely used as parts. Such fiber-reinforced resin molded products are high in density and excellent in rigidity, so there are many excellent in sound insulation performance, and they are sometimes used as sound insulation materials.
It does not absorb sound waves and was not considered for use as a sound absorbing material.

[0003]

The conventional sound absorbing material and sound insulating material cannot secure both the sound absorbing performance and the sound insulating performance. To secure a member having both the sound absorbing performance and the sound insulating performance, A complicated process such as laminating a sound absorbing material and a sound insulating material is required, and there is a problem that manufacturing is complicated. Also, if the sound absorbing material and the sound insulating material are bonded together to ensure both sound absorbing performance and sound insulating performance, any of the product characteristics such as heat resistance, rigidity, light weight and shape may be sacrificed, and they are bonded together. It is necessary to optimize the material constituting the sound absorbing material and the sound insulating material to be used, and there is a problem that the selection of the material becomes complicated.

An object of the present invention is to provide a sound absorbing and insulating material which can secure both sound absorbing performance and sound insulating performance by integral molding without laminating a plurality of materials, and a method of manufacturing the same.

[0005]

SUMMARY OF THE INVENTION The present invention relates to a method of manufacturing a sound absorbing and insulating material for manufacturing a sound absorbing and insulating material provided with a skin layer having high rigidity and a void layer having a sound absorbing property by a large number of voids. A fiber-containing thermoplastic resin pellet containing reinforcing fibers having a length in the range of 2 to 100 mm is included, and the reinforcing fibers are 30 to 30% of the entire raw material.
Using a raw material having a weight of 80% by weight and a mold having a movable mold capable of moving back and forth with respect to an internal cavity, and injecting a molten resin obtained by plasticizing the raw material into the mold, By retracting the movable mold and expanding the cavity, an intermediate molded body having the skin layer and the void layer is formed, and the sound absorbing means including the void layer and absorbing sound waves is formed, and the skin is formed. It is characterized in that a sound insulating means for blocking sound waves including the layer is formed.
Here, as the raw material, a fiber-containing thermoplastic resin pellet including a reinforcing fiber having a length in the range of 2 to 100 mm may be used alone, or the resin pellet and another molding material may be used. May be used.

In the present invention, since a raw material containing a predetermined amount or more of reinforcing fibers of a predetermined length or more is used, a springback phenomenon occurs by retreating a movable mold during molding, and a mold inside the mold is formed. Of the molten resin expands, and a number of voids are generated inside the molten resin. As a result, a void layer to which excellent sound absorbing properties are imparted by the large number of voids is formed inside the intermediate molded body. On the other hand, since the molten resin near the molding surface of the mold hardens before the inside, if the timing at which the movable mold retreats is appropriately set, it hardens sufficiently before expansion and voids are generated, and after hardening. , Dense,
It will have high rigidity. As a result, a skin layer having excellent sound insulation performance is formed on the surface of the intermediate molded body, and this skin layer directly forms the sound insulation means.
Then, opening the surface of the intermediate molded body, exposing the void layer to the outside, making a large number of holes in the surface of the intermediate molded body, and communicating the void layer to the outside, or the surface of the intermediate molded body By making the skin layer sufficiently thin so that sound waves received by the intermediate molded body can propagate to the internal void layer, the sound waves radiated to the surface of the intermediate molded body are absorbed by the void layer. Thus, the sound absorbing means is formed by the gap layer. The sound wave transmitted through the gap layer is reflected by the skin layer and is again absorbed by the gap layer, so that even if the same material is integrally formed, both the sound absorbing performance and the sound insulating performance are ensured.

In the above, it is preferable that the movable die is advanced to compress the molten resin before the movable die is started to retreat. In this way, even with a flat sound absorbing and insulating material having a large area, the injection of the molten resin can be performed with a smaller injection pressure, and the compression of the molten resin by the advancement of the movable mold allows the intermediate molded body to be formed. The occurrence of a springback phenomenon on the surface of the intermediate molded body is suppressed, the generation of voids on the surface of the intermediate molded body is suppressed, and the moldability of the surface of the intermediate molded body is improved.

[0008] In the case where the intermediate molded body has the skin layers formed on the front and back and the gap layer is formed between the skin layers, the skin layer on one side is removed. By exposing the gap layer to the outside, the gap layer is used as the sound absorbing means, or by opening a large number of holes in the skin layer on one side thereof, the gap layer communicates with the outside, and the gap layer is Preferably, the sound absorbing means is used. In this case, by performing molding with a mold having a general structure, a void layer is formed between the front and back skin layers, and even in the case of an intermediate molded body in which the void layer is not exposed to the outside, After molding, the skin layer is removed or a hole is formed in the skin layer, so that the void layer communicates with the outside, so that sufficient sound absorbing performance is secured, and the skin layer removal operation and the perforation operation are simple. Because it is processing
In producing the sound absorbing and insulating material, the production efficiency is not hindered at all.

Further, by setting the temperature of the molding surface of the movable mold at the time of molding to be higher than that of the opposed molding surface facing the movable mold, the thickness of the skin layer molded on the molding surface of the movable mold can be reduced. It is preferable that the thickness be smaller than the skin layer formed on the facing molding surface. In this way, the skin layer on the molding surface side of the movable mold is thinned, and the thinner skin layer is removed or a number of holes are formed in the thinner skin layer when opening the surface of the intermediate molded body. By doing so, the work of removing the skin layer and the work of piercing can be easily performed, and the amount of the resin removed from the intermediate molded body and discarded is reduced, and the waste of the resin is reduced.

[0010] Further, after a skin material having heat insulating properties is mounted inside the mold, the molten resin is injected to form the intermediate molded body having the skin material integrated on the surface thereof. By removing the skin material from the obtained intermediate molded body, the void layer may be exposed to the outside, and the void layer may be used as the sound absorbing means. With this configuration, when opening the surface of the intermediate molded body, the resin is not removed from the skin layer, the resin is not wasted, and the gap layer is formed more externally than when the skin layer is removed and perforated. Work can be easily performed.

Further, after a skin material having excellent sound absorbing properties is mounted inside the mold, the molten resin is injected, whereby the sound absorbing means is integrated with the skin material and the void layer integrated on the surface. May be formed. In this way, in general, the skin material having excellent sound absorbing properties has heat insulating properties and flexibility, so that the molten resin in a portion in contact with such a skin material has a low cooling rate, and The compressive force to be applied is reduced, and expansion is possible even at the surface of the molten resin. Thereby, the skin material having excellent sound absorbing properties is integrated with the front side of the gap layer, and the sound absorbing performance is ensured.

Further, after the skin material is mounted inside the mold, the molten resin is injected to form the intermediate molded body having the skin material integrated on the surface thereof, and the molded product is formed on the surface material. By forming a large number of holes, the gap layer may communicate with the outside, and the gap layer may be used as the sound absorbing unit. Thus, by opening a large number of holes in the skin material integrated on the surface, the gap layer communicates with the outside, and the gap layer is used as the sound absorbing means. Various types can be adopted. For example, if synthetic leather having a good appearance is adopted, the appearance will be improved even if a large number of holes are formed in the skin material.

Further, after the retraction of the movable mold is started, a gas may be injected into the molten resin filled in the cavity. In this way, even when the content of the reinforcing fiber is small and the springback phenomenon alone cannot be expected to sufficiently expand the resin, the expansion of the resin due to the springback phenomenon is compensated by the gas pressure,
The resin can be sufficiently expanded, and a large number of voids are formed inside. Here, if the amount of gas to be injected is appropriately adjusted so as to complement the expansion of the resin due to the springback phenomenon, independent bubbles and large hollow portions are formed inside, as in the conventional gas injection injection molding. Is not formed. Furthermore, if the injection of gas is started after the skin layer is sufficiently formed, when forming the skin layer, since the gas does not exist inside the mold, it may adversely affect the surface of the intermediate molded body. Absent.

The raw material may contain a gas generating agent as an expansion aid. Here, it is desirable that the raw material contains 3 parts by weight or less of a gas generating agent with respect to 100 parts by weight of the raw material. If such a small amount of the gas generating agent is mixed, the content of the reinforcing fiber is small, and even if the expansion of the resin cannot be expected sufficiently by the spring back phenomenon alone, the expansion of the resin due to the spring back phenomenon is caused by the gas generating agent. Is compensated by the gas pressure generated, so that the resin can be sufficiently expanded, and a large number of voids are formed inside. In addition, since the gas generating agent to be mixed has an amount sufficient to complement the expansion of the resin due to the springback phenomenon, independent gas bubbles and large hollow portions are not formed inside unlike conventional foam molding. . Further, since the gas generating agent hardly generates gas when forming the skin layer, it does not adversely affect the surface of the intermediate molded body.

At this time, the kind of the gas generating agent is not limited as long as it decomposes by heat to generate gas. For example, azo compounds such as oxalic acid derivatives and azodicarbonamide, hydrazine derivatives, semicarbazides, azide compounds, nitroso compounds, triazoles, ureas and related compounds, nitrites, hydrides, carbonates and bicarbonates can be employed. More specifically, azodicarbonamide (ADCA), benzenesulfohydrazide, N, N-dinitropentamethylenetetramine, terephthalazide and the like can be used. In addition, in addition to the gas generating agent, a filler such as a stabilizer, an antistatic agent, a weathering agent, a coloring agent, a short fiber, and talc can be added as needed.

The thermoplastic resin serving as the main component of the resin pellets is not particularly limited. For example, polyolefins such as polypropylene, propylene-ethylene block copolymer, propylene-ethylene random copolymer, and polyethylene can be used. Resin, polystyrene resin, ABS
Resin, polyvinyl chloride resin, polyamide resin, polyester resin, polyacetal resin, polycarbonate resin, polyaromatic ether or thioether resin, polyaromatic ester resin, polysulfone resin, acrylate resin, etc. it can. Here, the thermoplastic resin may be used alone, or two or more kinds may be used in combination. Among such thermoplastic resins, polypropylene, a random copolymer of propylene and another olefin, a block copolymer, or a polypropylene resin such as a mixture thereof is preferable, particularly, an unsaturated carboxylic acid, or A polyolefin-based resin containing an acid-modified polyolefin-based resin modified with a derivative thereof is preferred. In particular, when comprehensively judging the merits and performances in production, it is preferable to adopt a polypropylene-based synthetic resin as the thermoplastic resin.

Further, as the reinforcing fibers contained in the resin pellets, the following (1) to (5) can be employed, and in particular, glass fibers are desirably employed. Ceramic fiber: boron fiber, alumina fiber, zirconia fiber Inorganic fiber: glass fiber, carbon fiber Metal fiber: copper fiber, brass fiber, steel fiber, stainless steel fiber, aluminum fiber, aluminum alloy fiber Organic fiber: polyester fiber, polyamide fiber, polyethylene Terephthalate (PET) fiber, polybutylene terephthalate (PBT) fiber, polyethylene naphthalate fiber, aramid fiber, Kevlar (trade name) fiber, polyarylate fiber

Here, the glass fibers contained in the resin pellets are E-glass or S-glass glass fibers having an average fiber diameter of 25 μm or less, preferably 3 to 20 μm. Things can be adopted.
If the diameter of the glass fiber is less than 3 μm, the glass fiber does not adapt to the resin during the production of the pellets, making it difficult to impregnate the resin.

When pellets are produced from these thermoplastic resins and reinforcing fibers by a pultrusion method or a solution impregnation method, the fibers are surface-treated with a coupling agent, and then treated with a sizing agent. 10,000,
Preferably, it is desirable to bundle them in the range of 150 to 5000. The coupling agent can be appropriately selected from so-called silane coupling agents and titanium coupling agents that have been conventionally used. For example, γ-aminopropyltriethoxysilane, N-β
Aminosilanes and epoxysilanes such as-(aminoethyl) -γ-aminopropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, and β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane can be used. In particular, it is preferable to employ the amino silane compound. In performing the surface treatment of the fiber using such a coupling agent, in addition to the sizing treatment of applying an organic solvent solution or a turbid liquid obtained by mixing the above-described coupling agent to an organic solvent to the fiber as a so-called sizing agent, a dry process Mixing and spraying methods can be adopted. Also,
In performing the surface treatment, a film-forming substance for glass can be used in combination with the above-described coupling agent. As the film-forming substance, for example, polyester-based, urethane-based, epoxy-based, acrylic-based, vinyl acetate-based, and isocyanate-based polymers can be used. As the sizing agent, for example, urethane-based, olefin-based, acrylic-based, butadiene-based, and epoxy-based can be used, and among these, urethane-based and olefin-based can be used. Of these, the urethane-based sizing agent is usually an oil-modified type, a moisture-curable type, or a moisture-curable type, as long as it contains 50% by weight or more of polyisocyanate obtained by a polyaddition reaction of a diisocyanate compound and a polyhydric alcohol. Any of a one-pack type such as a block type and a two-pack type such as a catalyst-curable type and a polyol-curable type can be adopted. On the other hand, a modified polyolefin resin modified with an unsaturated carboxylic acid or a derivative thereof can be used as the olefin sizing agent.

By attaching and impregnating a thermoplastic resin to the fibers converged with the above-mentioned converging agent, resin pellets containing the fibers are produced. As a method of attaching and impregnating the thermoplastic resin to the fiber, for example, a method of passing a fiber bundle through a molten resin put in a container or the like, a method of impregnating the resin with the fiber, a suspension, impregnating the fiber bundle with the resin by emulsion, After that, a method of impregnating the fiber bundle through the coating die or impregnating the fiber bundle by spreading the molten resin adhered around the fiber with the die can be adopted. Here, in order to make the fiber bundle and the resin well-fitted, that is, in order to improve the wettability, the molten resin is pulled out through the tensioned fiber bundle into the inside of the die provided with the uneven portion on the inner periphery. After impregnating with a fiber bundle, a pultrusion molding method in which a step of pressing the fiber bundle with a pressure roller is further incorporated can be adopted. In addition, if the fiber and the molten resin are compatible with each other, if the material has good wettability, the molten resin is easily impregnated into the fiber, and the production of pellets becomes easy. , May be omitted. If the long fiber bundle (strand etc.) containing the resin is cut along the longitudinal direction of the fiber by the above method, the resin pellet containing the long fiber having the same length as the entire length of the pellet is obtained. Can be obtained. At this time, as the resin pellets, the fiber bundle is formed into a strand, and the cross-sectional shape is not limited to a cut resin-containing long fiber bundle having a substantially circular shape. The resin-containing long fiber bundle in the shape of a band or a band may be cut into a predetermined length.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows an injection molding machine 1 for molding an intermediate molded body according to the present embodiment. This injection molding machine 1 performs molding by injecting a molten resin into a mold 10. Mold 10 is a fixed mold 10A
And a moving mold 10B. This mold
Inside the movable mold 10B, there is provided a movable core 12 which is a movable mold that can move forward and backward with respect to the cavity 11 of the mold 10. By moving the movable core 12,
The volume of the cavity 11 of the mold 10 is variable. In addition, a passage 13 such as a sprue or a runner for introducing molten resin into the inside of the fixed mold 10A of the mold 10 is formed. Around the passage 13, a strip-shaped electric heating element 14 is provided. Thus, the passage 13 forms a so-called hot runner that does not cure the molten resin flowing inside the passage 13. Further, each of the fixed mold 10A and the movable core 12 has an electric heater embedded near each molding surface.
15, 16 are provided. By appropriately adjusting the calorific values of these electric heating elements 15 and 16, the temperatures of the molding surfaces of the fixed mold 10A and the movable core 12 are controlled to a predetermined temperature. A gas pin (not shown) for injecting a pressurized gas into the molten resin injected into the cavity 11 is provided in the fixed mold 10A so as to be able to protrude and retract from the cavity 11.

The injection molding machine 1 includes a cavity 11 of a mold 10.
An injection device 1A for injecting a molten resin into a mold, a fixed die plate 3 to which a fixed mold 10A is attached, a movable die plate 4 to which a movable mold 10B is attached, and the movable die plate 4 is directed toward the fixed die plate 3. A mold clamping device 5 for moving the movable core 12 of the mold 10 to an arbitrary position within a predetermined range and stopping the movable core 12 at the position are provided. The moving die plate 4
The hydraulic cylinder device 6 for mold clamping is slidably provided along a tie bar 8 bridged between a fixed plate 7 and a fixed die plate 3 to which the fixed cylinder 7 is fixed. The mold clamping device 5 has a toggle mechanism 9 to which the piston rod 6A of the hydraulic cylinder device 6 is connected. The pressing force of the hydraulic cylinder device 6 is increased by the toggle mechanism 9 to move the movable die plate 4 forward. The movable mold 10B is brought into close contact with the fixed mold 10A to close the mold 10.

The mold moving device 20 applies a compressive force to the molten resin injected into the cavity 11 by advancing the movable core 12 with respect to the cavity 11, and retreats the movable core 12 by the movable core 12. 11 is extended, and is interposed between the movable die plate 4 and the movable mold 10B. In addition, the mold moving device 20 is a cavity clearance changing unit that can change the clearance between the molding surface of the movable core 12 and the molding surface of the fixed mold 10A by moving the movable core 12 forward and backward. is there. The mold moving device 20 has inclined surfaces 21A and 22A that are inclined with respect to the moving direction of the movable core 12, respectively.
21A, a pair of inclined members 21 and 22 that abut each other, 22A,
A base plate 23 having a flat surface perpendicular to the moving direction of the movable core 12, a mold mounting base 24 connecting the movable die plate 4 and the movable mold 10B,
And a compression plate 25 for connecting the inclined member 22.

The inclined member 21 is slidable along the surface of the base plate 23 attached to the movable die plate 4, and is orthogonal to the moving direction of the movable core 12 by the hydraulic cylinder device 26. To be driven in the direction of Here, the inclined surface of the inclined member 22
At both ends of 22A, rising portions 22B are provided along the moving direction of the inclined member 21. This rising part 22B
The groove 22 extending in the longitudinal direction of the rising portion 22B
C is provided. On the other hand, on the side surface of the inclined member 21 that is in contact with the inner side surface of the rising portion 22B, a ridge 21B that fits into the groove 22C of the inclined member 22 is provided. As a result, when the piston rod 26A of the hydraulic cylinder device 26 is advanced, the inclined member 21 presses the inclined member 22 and the movable core 12 advances. On the other hand, when the piston rod 26A of the hydraulic cylinder device 26 is retracted, the inclined member 21 draws the inclined member 22, and the movable core 12 retreats. A hydraulic unit 30 is provided to supply hydraulic pressure to the mold moving device 20. Further, a control device 31 for controlling the hydraulic unit 30 and causing the mold moving device 20 to perform a desired operation is provided. Is provided. The control device 31 has a sequence control circuit such as a digital sequencer and the like.
It is possible to set so that arbitrary different operations can be continuously performed, for example, by gradually moving forward and backward with respect to the cavity 11, temporarily stopping at a predetermined position, and then moving backward. Although not shown in the figure, the fixed mold 10
A pressurized gas supply device such as a gas cylinder for supplying a pressurized gas to a gas pin (not shown) provided in A is provided near the injection molding machine 1.

Next, the intermediate molded body and the sound absorbing and insulating material of the present embodiment will be described. First, the intermediate molded body will be described. In the present embodiment, the following four types of first to fourth intermediate molded bodies are provided as an intermediate molded body including a skin layer having sound insulation properties due to high rigidity and a void layer having sound absorption properties due to a large number of voids.
Intermediate molded bodies can be adopted. The skin layer is a synthetic resin layer having high density and high rigidity by curing a molten resin containing reinforcing fibers without expanding. On the other hand, the void layer is
Inside the molten resin containing the reinforcing fibers, by curing in a state where a large number of voids due to the springback phenomenon are generated, a large number of voids are formed inside, and the synthetic resin layer is provided with excellent sound absorbing properties. .

As shown in FIG. 2, the first intermediate molded body 1A has a structure in which skin layers 41 and 42 are formed on the front and back surfaces, and a gap layer 43 is formed between the skin layers 41 and 42. . Here, at the time of molding, the temperature of the molding surface of the movable core 12 is
The thickness of the skin layer 41 molded on the molding surface of the movable core 12 is reduced by the molding surface of the fixed mold 10A, which is lower than the molding surface of the fixed mold 10A, which is the facing molding surface facing the mold 12. It is thinner than the skin layer 42 to be formed. As shown in FIG. 3, the second intermediate molded body 1B has a skin layer 42 integrated on one surface of a void layer 43, and a skin material 44 having heat insulating properties integrated on the opposite side. It is. As the skin material 44, a thick face material having a high flexibility such as a crosslinked rubber sheet can be employed. As shown in FIG. 4, the third intermediate molded body 1C has a skin layer 42 integrated on one surface of a void layer 43, and a skin material 45 having excellent sound absorbing properties integrated on the opposite surface. It was done. As the skin material 45, a thick face material made of a synthetic resin foam such as polypropylene can be adopted. 4th
As shown in FIG. 5, in the intermediate molded body 1D, the skin layer 42 is integrated on one surface of the void layer 43, and on the opposite surface,
The decorative skin material 46 is integrated. Skin material 46
For example, synthetic leather in which a synthetic resin foam 48 such as polypropylene is lined on the back surface of a surface material 47 made of polyvinyl chloride can be used.

From the first to fourth intermediate molded bodies 1A to 1D, the following five types of first to fifth sound absorbing and insulating materials 2A to 2E are formed. As shown in FIG. 6, the first sound absorbing and insulating material 2A
One skin layer 41 was removed from the intermediate molded body 1A, and the void layer was removed.
43 is exposed on one side. 2nd sound absorbing and insulating material 2B
As shown in FIG. 7, a number of holes 51 are formed in one skin layer 41 of the first intermediate molded body 1A, and a void layer 43 is communicated to the outside. As shown in FIG. 8, the third sound absorbing and insulating material 2C removes the skin material 44 from the second intermediate molded body 1B,
This is one in which one entire surface of the void layer 43 is exposed. The fourth sound absorbing and insulating material 2D is obtained by removing runners and burrs attached to the third intermediate molded body 1C during molding, and has the same configuration as the third intermediate molded body 1C shown in FIG. Therefore, the description is omitted here. The fifth sound absorbing and insulating material 2E is
As shown in FIG. 9, the skin material 46 of the fourth intermediate molded body 1D is provided.
In addition, a large number of holes 51 are opened, and the void layer 43 communicates with the outside.

Next, a procedure for forming the intermediate molded bodies 1A to 1D of the present embodiment will be described. First, the mold 10 and the mold moving device 20 are mounted on a general injection molding machine 1 as shown in FIG. 1, and predetermined raw materials are put into a hopper (not shown). Then, after mounting the mold 10 on the injection molding machine 1 and supplying the resin pellets into the injection cylinder 11 of the injection device 1A, the injection molding machine 1 is started, and the plasticization of the resin pellets in the injection cylinder 11 is performed. Start kneading. here,
The resin pellets, which are raw materials, are made of polypropylene as a main raw material and have a total length of 2 to 100 mm.
This resin pellet contains 30 to 80% by weight of glass fiber for reinforcement having a length equal to the entire length thereof arranged in parallel with each other.

On the other hand, when a mixture of the above resin pellets and other resin pellets containing no reinforcing glass fiber is used as a raw material, the reinforcing glass fiber is used in an amount of 30 to 70% by weight of the whole raw material. % Can be used. The raw material may be mixed with a gas generating agent in an amount of 3 parts by weight or less based on 100 parts by weight of the raw material, if necessary. Here, it is preferable to mix the gas generating agent by mixing master batch pellets containing the gas generating agent into the above-mentioned resin pellets. In addition, as a masterbatch pellet containing a gas generating agent, for example, trade name: Polyslen TS-
182 (manufactured by Eiwa Chemical Co., Ltd.). In addition, in the injection cylinder 11, while suppressing the breakage of the fibers, by sufficiently plasticizing and kneading the resin pellets, the amount of molten resin necessary for molding a molded article is obtained, and the molten resin in the molten resin is obtained. Countless glass fibers, evenly distributed, and in a state in which they are sufficiently intertwined with each other,
The spring back phenomenon is easily generated.

Then, if necessary, the skin materials 44, 45, and 46 are mounted on the molding surface of the movable core 12, and
After operating the electric heating elements 15 and 16 so that the temperature of the molding surface of 12 becomes higher than the molding surface of the fixed mold 10A,
The mold clamping device 5 is operated to move the movable die plate 4 toward the fixed die plate 3, and as shown in FIG.
The movable mold 10B is brought into contact with 10A, the mold 10 is closed, the mold moving device 20 is operated, and the movable core 12 is moved to the position S as shown in FIG.
The thickness of 11 is set to t1. In this state, injection of the molten resin is performed. Here, the thickness t1 of the cavity 11 formed by the movable core 12 stationary at the position S is set so that the volume of the cavity 11 having the thickness t1 is larger than the amount of the molten resin to be injected. You.

After the injection of the molten resin is started, the mold moving device 20 is operated to move the movable core 12 to the position T as shown in FIG. t2. Thus, the volume of the cavity 11 is reduced, and the molten resin injected into the cavity 11 is compressed. Here, the skin layers 41 and 42 formed on each of the intermediate molded bodies 1A to 1D can be adjusted by adjusting the elapsed time from the start of the injection of the molten resin to the completion of the compression of the molten resin. In other words, if the above-mentioned elapsed time is made longer, the skin layers 41, 4
Since 2 is thicker, the above-described elapsed time is set so that the thickness of the skin layers 41 and 42 has a desired size.

After the movable core 12 reaches the position T, the mold moving device 20 is operated in the reverse direction, and as shown in FIG. 10C, a position U at which the cavity 11 has a volume corresponding to the molded product. The movable core 12 is moved backward until the thickness of the cavity 11 becomes t3, and a springback phenomenon occurs. Here, if necessary, while the movable core 12 is retracted, a pressurized gas is injected into the interior of the molten resin from a gas pin provided in the fixed mold 10A to promote the springback phenomenon. Further, the retreat speed Vr of the movable core 12 is 0.05 to 1
It can be set in the range of 00 mm / sec, preferably in the range of 0.05 to 50 mm / sec. When the movable core 12 is retracted, the molten resin expands due to the elastic restoring force of the glass fibers crushed in the molten resin due to a springback phenomenon, and innumerable voids are generated inside the molten resin, and the voids are generated. layer
43 is formed.

After a predetermined time required for sufficiently cooling the intermediate molded body has elapsed, the mold clamping device 5 is operated to move the movable die plate 4 backward, and the mold 10 is opened. Then, the intermediate molded product is taken out of the mold 10, and the molding is completed. Or later,
The above-mentioned molding operation is repeated as necessary. In the above-described molding procedure, a procedure of expanding the cavity 11 after so-called injection compression molding (injection into the cavity 11 in an incompletely closed state, molding after starting injection, and performing resin compression by moving the movable core 12) is described. Depending on the material of the synthetic resin, reinforcing fiber and skin material used as raw materials, the compression step is omitted. After the general injection molding (molding by injection into a completely closed cavity), the cavity 11
Can be adopted.

According to the above-described embodiment, the following effects can be obtained. That is, using a raw material containing a predetermined amount or more of reinforcing fibers having a predetermined length or more, at the time of molding, the movable core 12 is retracted, so that a springback phenomenon that expands the molten resin in the mold 10 occurs, and the molten resin A large number of voids are generated inside, and a void layer 43 having excellent sound absorbing properties is formed inside the intermediate molded bodies 1A to 1D by the large number of voids. The surface part is cured without expanding, it has a high density, the reinforcing fiber has higher rigidity, and a skin layer 42 with excellent sound insulation performance is formed. In addition, both sound insulation performance can be ensured.

Before starting the retreat of the movable core 12,
Since the movable core 12 is advanced to compress the molten resin, the molten resin can be injected with a smaller injection pressure even with a flat area sound absorbing and insulating material 2A to 2E having a large area, and the movable core 12 advances. 1A
The generation of a springback phenomenon on the surface portion of ~ 1D is suppressed, the generation of voids on the surface portion of the intermediate molded products 1A ~ 1D is suppressed, and the formability of the surfaces of the intermediate molded products 1A ~ 1D and the sound absorbing and insulating materials 2A ~ 2E Can be improved.

Further, when the intermediate molded body 1A in which the skin layers 41 and 42 are formed on the front and back surfaces and the void layer 43 is formed between the skin layers 41 and 42 is used, one surface of the intermediate molded body 1A is used. By removing the skin layer 41, the gap layer 43 is exposed to the outside, or by opening a large number of holes 51 in the skin layer 41 on one side, the gap layer 43 communicates with the outside,
Since the air gap layer 43 is used as the sound absorbing means, the mold 10 having a general structure is used.
By performing the molding with, the sound absorbing and insulating materials 2A and 2B having sufficient sound absorbing performance and sound insulating performance can be obtained, and the work of removing and perforating the skin layer 41 is a simple process. In producing 2A and 2B, the production efficiency is not hindered at all.

Further, the temperature of the molding surface of the movable core 12 at the time of molding is set higher than the molding surface of the fixed mold 10A, and the thickness of the skin layer 41 molded on the molding surface of the movable core 12 is reduced. 10A
Thinner than the skin layer 42 formed on the molding surface of the above, and remove the thinner skin layer 41, or remove the thinner skin layer.
Because a large number of holes are formed in 41, the work of removing and perforating the skin layer 41 can be easily performed, and the sound absorbing and insulating materials 2A, 2B
In addition to improving the production efficiency, the amount of resin removed from the intermediate molded body 1A and discarded is reduced, and waste of resin can be reduced.

Further, after the skin material 44 having heat insulating property is mounted inside the mold 10, the molten resin is injected,
If the intermediate molded body 1B in which the skin material 44 is integrated on the surface is adopted, by removing the skin material 44 from the intermediate molded body 1B, the void layer 43 is exposed to the outside, so that there is no waste of resin. In addition, the work of exposing the gap layer 43 to the outside can be performed more easily than the work of removing the skin layer 41 and the work of piercing. Here, the skin material 44 made of a crosslinked rubber sheet can be easily peeled off and used repeatedly many times, so that the skin material 44 is not wasted.

Further, after the skin material 45 having excellent sound absorbing properties is mounted inside the mold 10, the molten resin is injected to adopt the intermediate molded body 1C having the skin material 45 integrated on the surface. In addition, the sound absorbing and insulating material 2D in which the skin material 45 having excellent sound absorbing properties is integrated on the front side of the void layer 43 is obtained, and the sound absorbing performance can be ensured even with such a sound absorbing and insulating material 2D.

Furthermore, after a skin material 46 having excellent decorativeness is mounted inside the mold 10, a molten resin is injected, thereby
If the intermediate molded body 1D in which the skin material 46 is integrated on the surface is adopted, by forming a large number of holes in the skin material 46, even if the void layer 43 communicates with the outside, the appearance can be improved. .

Further, after the movable core 12 starts to retreat, a gas is injected into the molten resin, or an appropriate amount of a gas generating agent is mixed with the raw material, and the expansion of the resin due to the springback phenomenon is caused by the gas pressure. I tried to make up for it,
Even when the content of the reinforcing fiber is small and the springback phenomenon alone cannot sufficiently expand the resin, the resin can be expanded sufficiently, and the void layer 43 in which a large number of voids are formed can be reliably formed. Can be formed.

[0042]

Next, the effects of the present invention will be described based on specific examples. Example 1 In Example 1, a first sound absorbing and insulating material 2A was manufactured from the first intermediate molded body 1A described in the above embodiment, and the first sound absorbing and insulating material 2A was manufactured.
This is an experiment for measuring the sound absorption coefficient and the relative transmission loss of the sound absorbing and insulating material 2A. In the first embodiment, the following raw materials, mold temperature, injection molding machine, and molding procedure are employed in molding the first intermediate molded body 1A. a) Raw materials: polypropylene pellets A and glass fiber-containing polypropylene pellets B are dry-blended by 50% by weight. -Composition of pellet A; Polypropylene with MI = 60-Composition of pellet B; Glass fiber, polypropylene, and maleic acid-modified polypropylene-Total length of pellet B: 15 mm-Length of glass fiber of pellet B; 15 mm-Content of the same glass fiber Ratio: 75% by weight b) Mold temperature: ・ Temperature of molding surface of movable core 12; 90 ° C. ・ Temperature of molding surface of fixed mold 10A; 30 ° C. c) Injection molding machine: Mold for general-purpose horizontal injection molding machine Mold moving device 2
One with 0 attached. d) Molding procedure: a procedure including the following steps (see FIG. 10). Before the molten resin is injected, the resin corresponding to the volume of the cavity 11 in a state where the thickness t2 is 6 mm. Is plasticized and measured by an injection device. Next, the mold 10 is closed, and the movable core 12 of the mold 10 is moved to the position S.
Forward and stop at that position. Here, the position S
Is set such that the thickness t1 of the cavity 11 is 7.0 mm. In this state, the injection of the molten resin is started.
The injection of the molten resin is performed for 2.4 seconds. When 2.0 seconds have elapsed from the start of injection, the movable core 12 of the mold 10 is advanced to the position T, and compression of the molten resin is started. After a lapse of 3.0 seconds from the start of compression, the movable core 12 of the mold 10 is retracted to the position U, and the molten resin is expanded by utilizing a springback phenomenon. Here, the position U is set so that the thickness t3 of the cavity 11 becomes 18 mm. After 3.0 seconds have elapsed from the start of the retreat of the movable core 12, the injection of nitrogen gas adjusted to 1 MPa into the molten resin that has started to expand is started to promote the springback phenomenon. After sufficiently cooling and solidifying the molten resin in this state, the mold 10 is opened, and the intermediate molded body 1A is taken out of the mold 10. The skin layer 41 on one side (high-temperature molding surface side) of the obtained intermediate molded body 1A is entirely removed, and the sound absorbing performance and the sound insulating performance are evaluated.

Example 2 In Example 2, a second sound absorbing and insulating material 2B was manufactured from the first intermediate molded body 1A described in the above embodiment, and the sound absorbing coefficient and relative transmission of the second sound absorbing and insulating material 2B. This is an experiment for measuring loss. In the second embodiment, the molding is performed in the same manner as in the first embodiment except that the thickness t3 of the cavity 11 at the position U is set to 24 mm in molding the first intermediate molded body 1A. This intermediate molded body
A large number of holes 51 having an inner diameter of 3 mm are made in the skin layer 41 on one side (high-temperature molding surface side) of 1A, and the sound absorption performance and the sound insulation performance are evaluated.

Example 3 In Example 3, a third sound absorbing and insulating material 2C was manufactured from the second intermediate molded body 1B described in the above embodiment, and the sound absorbing coefficient and relative transmission of the third sound absorbing and insulating material 2C. This is an experiment for measuring loss. In the third embodiment, when forming the second intermediate molded body 1B, a thickness of 4 mm was used as the skin material 44.
The molding is carried out in the same manner as in Example 1 except that the cross-linked rubber sheet is used and the following molding procedures are adopted. In advance, before injecting the molten resin, the skin material 44 is mounted on the molding surface of the movable core 12, and the resin corresponding to the volume of the cavity 11 in a state where the thickness t2 is 6 mm,
Plasticize and measure with an injection device. Next, the mold 10 is closed, and the movable core 12 of the mold 10 is moved to the position S.
Forward and stop at that position. Here, the position S
Is set such that the thickness t1 of the cavity 11 is 10 mm. In this state, the injection of the molten resin is started. The injection of the molten resin is performed for 2.4 seconds. When 2.0 seconds have elapsed from the start of injection, the movable core 12 of the mold 10 is advanced to the position T, and compression of the molten resin is started. After a lapse of 3.0 seconds from the start of compression, the movable core 12 of the mold 10 is retracted to the position U, and the molten resin is expanded by utilizing a springback phenomenon. Here, the position U is set so that the thickness t3 of the cavity 11 becomes 18 mm. After 3.0 seconds have elapsed from the start of the retraction of the movable core 12, the injection of nitrogen gas adjusted to 3 MPa into the molten resin that has started to expand is started to promote the springback phenomenon. After sufficiently cooling and solidifying the molten resin in this state, the mold 10 is opened, and the intermediate molded body 1B is taken out of the mold 10. The crosslinked rubber sheet as the skin material 44 is peeled off from the obtained intermediate molded body 1B, and the sound absorbing performance and the sound insulating performance are evaluated. The skin material 44 made of a crosslinked rubber sheet
Can be easily peeled off and used many times.

Example 4 In Example 4, a fourth sound absorbing and insulating material 2D was manufactured from the third intermediate molded body 1C described in the above embodiment, and the sound absorbing coefficient and relative transmission of the fourth sound absorbing and insulating material 2D. This is an experiment for measuring loss. In the fourth embodiment, in forming the third intermediate molded body 1C, the skin material 45 is 3 mm thick.
The molding is performed in the same manner as in Example 1 except that the polypropylene foam (expansion ratio: 30 times) and the following raw materials and molding procedure are employed. a) Raw materials: polypropylene pellet C and glass fiber-containing polypropylene pellet D are each 60% by weight.
And 100 parts by weight of a mixture obtained by mixing 40 parts by weight and 0.2 part by weight of a blowing agent as a gas generating agent. -Composition of pellet C: Polypropylene with MI = 300-Composition of pellet D: Glass fiber, polypropylene, and maleic acid-modified polypropylene-Total length of pellet D: 12 mm-Length of glass fiber of pellet D; 12 mm-Content of the same glass fiber Rate: 70% by weight-Blowing agent: 2% by weight of Polyslen EE115 manufactured by Eiwa Chemical Industry Co., Ltd. b) Molding procedure: Procedure including the following steps: Before injecting the molten resin, The skin material 45 is mounted on the molding surface of the movable core 12, and the resin corresponding to the volume of the cavity 11 when the thickness t2 is 1.0 mm is plasticized and measured by an injection device. Next, the mold 10 is closed, and the movable core 12 of the mold 10 is moved to the position S.
Forward and stop at that position. Here, the position S
Is set such that the thickness t1 of the cavity 11 is 6.0 mm. In this state, the injection of the molten resin is started.
The injection of the molten resin is performed for 1.1 seconds. When 0.6 seconds have elapsed from the start of injection, the movable core 12 of the mold 10 is advanced to the position T, and compression of the molten resin is started. After a lapse of 1.0 second from the start of compression, the movable core 12 of the mold 10 is retracted to the position U, and the molten resin is expanded by utilizing the springback phenomenon. Here, the position U is set so that the thickness t3 of the cavity 11 is 7 mm. When 1.0 second has elapsed from the start of the retreat of the movable core 12, injection of nitrogen gas adjusted to 3 MPa into the molten resin that has started to expand is started to promote the springback phenomenon. After sufficiently cooling and solidifying the molten resin in this state, the mold 10 is opened, and the intermediate molded body 1C is taken out of the mold 10. Runners and burrs are removed from the obtained intermediate molded body 1C, and the sound absorbing performance and the sound insulating performance are evaluated.

REFERENCE EXAMPLE 1 The present reference example 1 is the same as the first embodiment.
In this experiment, the first intermediate molded product 1A was used as a sound absorbing and insulating material as it was, and the sound absorption coefficient and the relative transmission loss of the first intermediate molded product 1A were measured.

Reference Example 2 The present reference example 2 is the same as that of the first embodiment.
This is an experiment in which the compression step and the expansion step are omitted from the molding procedure in the above, in other words, general injection molding is performed, and the sound absorption coefficient and the relative transmission loss of the obtained molded article are measured. Note that the mold 10 is
Is fixed at a position where the thickness of the cavity 11 is 6.0 mm, and is not advanced or retracted from the start to the completion of molding.

Reference Example 3 The present reference example 3 is the same as the reference example 2 described above.
In this experiment, the raw material was changed to polypropylene containing no reinforcing fiber, and general injection molding was performed to measure the sound absorption coefficient and the relative transmission loss of the obtained molded product. In addition, the thing of MI = 30 is employ | adopted as polypropylene. In the mold 10, the movable core 12 is fixed at a position where the thickness of the cavity 11 is 6.0 mm, and is not moved forward or backward from the start to the completion of molding. further,
The mold temperature is set at 40 ° C.

REFERENCE EXAMPLE 4 This reference example 4 is an experiment in which a 20-mm-thick urethane foam is used as a sound absorbing and insulating material, and the sound absorption coefficient and the relative transmission loss of this urethane foam are measured.

[Experimental Results] The sound absorption coefficient α and the relative transmission loss TL were measured for each of Examples 1 to 4 and Reference Examples 1 to 4, and the sound absorption performance and the sound insulation performance were evaluated from the measurement results. I do. Here, the sound absorption coefficient α and the relative transmission loss TL (Transmission Loss) are given by
And Equation 2.

[0051]

Α = (Li−Lr) / Li where Li is the intensity of the incident sound (W
/ M ² ), and Lr is the intensity (W / m ² ) of the reflected sound reflected from the measured object.

[0052]

TL = 10Log ₁₀ (1 / τ) = 10Log ₁₀ (Li / Lt) = Li / Lt where the sound pressure level of the incident sound incident on the DUT (d
B), Lt is the sound pressure level (dB) of the transmitted sound transmitted through the device under test, and τ is Li, the transmittance expressed as Li / Lt.

FIG. 11 shows the measurement results of the sound absorption coefficient α in Example 1 and Reference Examples 1 to 3. FIG. 12 shows the measurement results of the relative transmission loss TL of Example 1 and Reference Examples 2 and 3. Example 2
Table 4 shows the measurement results of the sound absorption coefficient α and the relative transmission loss TL of Nos. 4 to 4 and Reference Example 4.

[0054]

[Table 1]

From the results shown in FIG. 11, comparing the sound absorption coefficient α between Example 1 and Reference Examples 2 and 3, the sound absorption coefficient α was found to be higher for Reference Examples 2 and 3 over the entire measurement range. You can see that it is better. Also, comparing the sound absorption coefficient α of Example 1 and Reference Example 1, the sound absorption coefficient α is higher than that of Example 1 in the region of about 1 kHz or less, but the sound absorption coefficient α is offensive. In the region of 1 kHz or more, the first embodiment is superior to the first embodiment. From this, it can be said that Example 1 is superior in practical sound absorbing performance as compared with any of Reference Examples 1 to 3.

From the results shown in FIG. 12, comparing the relative transmission loss TL of Example 1 with those of Reference Examples 2 and 3, the relative transmission loss TL was found to be higher in Reference Example 2 in the entire measurement range. 3 From this, it can be said that Example 1 is superior to any of Reference Examples 2 and 3 in sound insulation performance. From the above, it can be said that Example 1 is excellent in both the sound absorbing performance and the sound insulating performance.

From the results shown in Table 1, when comparing the maximum sound absorption coefficients α of Examples 2 to 4 and Reference Example 4, the maximum sound absorption coefficient α of Example 4 is inferior to that of Reference Example 4. It can be seen that Examples 2 and 3 are superior to Reference Example 4. However, the maximum sound absorption coefficient α of Example 4 does not necessarily have a larger difference than the urethane foam having excellent absorption and shielding performance.
It can be said that it has sufficient sound absorbing performance. Example 2
Comparing the relative transmission loss TL of Comparative Examples 4 to 4 and Example 4, it can be seen that Examples 2 to 4 are superior to Reference Example 4 at both 500 Hz and 1 kHz. From this, it can be said that Examples 2 to 4 have sufficient sound absorbing performance and sound insulating performance.

Although the present invention has been described with reference to the preferred embodiments and examples, the present invention is not limited to these embodiments and examples, and various modifications may be made without departing from the spirit of the present invention. And design changes are possible. For example, the mold is divided into a fixed mold and a movable mold, and is not limited to a mold provided with a movable core as a movable mold in the movable mold, and is divided into a fixed mold and a movable mold. Further, the movable mold itself may be a movable mold. The skin layer is preferably a layer that is densely filled with resin and has no voids, but may be a layer in which some voids are generated depending on the molding method and molding conditions employed.

The thermoplastic resin which is the main component of the resin pellet is not limited to polypropylene, but may be propylene-ethylene block copolymer, polyolefin resin such as polyethylene, polystyrene resin, ABS resin, polyvinyl chloride resin. , Polyamide-based resin, polyester-based resin, polyacetal-based resin, polycarbonate-based resin, polyaromatic ether or thioether-based resin, polyaromatic ester-based resin, polysulfone-based resin and acrylate-based resin may be used to form a fiber-reinforced molded product. If it is a thermoplastic resin, a specific composition can be appropriately selected. Further, the reinforcing fibers contained in the resin pellets are not limited to glass fibers, ceramic fibers, inorganic fibers,
Metal fibers, organic fibers, and the like may be used, and specific selection of the fibers may be appropriately performed in practice.

[0060]

As described above, according to the present invention, it is possible to secure both sound absorbing performance and sound insulating performance by integrally molding without bonding a plurality of materials.

[Brief description of the drawings]

FIG. 1 is a side view showing an injection molding machine according to an embodiment of the present invention.

FIG. 2 is a sectional view showing a first intermediate molded body of the embodiment.

FIG. 3 is a sectional view showing a second intermediate molded body of the embodiment.

FIG. 4 is a sectional view showing a third intermediate molded body of the embodiment.

FIG. 5 is a sectional view showing a fourth intermediate molded body of the embodiment.

FIG. 6 is a sectional view showing a first sound absorbing and insulating material of the embodiment.

FIG. 7 is a sectional view showing a second sound absorbing and insulating material of the embodiment.

FIG. 8 is a sectional view showing a third sound absorbing and insulating material of the embodiment.

FIG. 9 is a sectional view showing a fifth sound absorbing and insulating material of the embodiment.

FIG. 10 is a view for explaining a molding procedure in the embodiment.

FIG. 11 is a graph showing an experimental result on sound absorbing performance in an example of the present invention.

FIG. 12 is a graph showing experimental results on sound insulation performance in the example of the present invention.

[Explanation of symbols]

 1A ~ 1D Intermediate molded body 2A ~ 2E Sound absorbing and insulating material 10 Mold 11 Cavity 12 Moving core 41,42 Skin layer 43 Void layer 44 Skin material with heat insulation 45 Skin material with excellent sound absorption 46 Skin material 51 holes

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Hiroshi Goda 1F, 1F, Anesaki Beach, Ichihara-shi, Chiba Prefecture 4F202 AA11 AB02 AB25 AD05 AD08 AD17 AE06 AG03 AG20 AH17 AH42 AH46 AR08 CA11 CB01 CB13 CB22 CB30 CK03 CK18 CK19 CK19 CK52 CN01 4F206 AA11 AB02 AB25 AD05 AD08 AD17 AE06 AG03 AG20 AH17 AH42 AH46 AR084 AR11 JA07 JB13 JB22 JB30 JN22 JN25 JN27 JQ81 JW21 JW50 5D061 AA07 AA12 AA16 AA22 AA25 BB21 BB24 BB24

Claims (18)

[Claims] 1. A method for producing a sound absorbing and insulating material comprising a skin layer having high rigidity and a void layer having a sound absorbing property by a large number of voids, wherein the length is 2 mm. ~ 1
A fiber-containing thermoplastic resin pellet containing reinforcing fibers set in the range of 00 mm is included, and the reinforcing fibers advance and retreat with respect to the raw material, which accounts for 30 to 80% by weight of the whole raw material, and the internal cavity. By using a mold with a movable mold that has become possible, after injecting the molten resin plasticized from the raw material into the mold, by retracting the movable mold and expanding the cavity, the skin is formed. Forming an intermediate molded body having a layer and the gap layer, forming a sound absorbing means for absorbing the sound wave including the gap layer, and forming a sound insulating means for blocking the sound wave including the skin layer. Manufacturing method of the sound absorbing and insulating material. 2. The method for manufacturing a sound absorbing and insulating material according to claim 1, wherein the movable mold is advanced to compress the molten resin before starting the movable mold to retreat. The method of manufacturing the material. 3. The method for producing a sound absorbing and insulating material according to claim 1, wherein the skin layer is formed on both sides of the intermediate molded body, and the gap layer is formed between the skin layers. A method of manufacturing a sound absorbing and insulating material, characterized in that the skin layer on one side is removed to expose the gap layer to the outside, and the gap layer is used as the sound absorbing means. 4. The method for manufacturing a sound absorbing and insulating material according to claim 1, wherein the skin layer is formed on both sides of the intermediate molded body, and the gap layer is formed between the skin layers. By opening a large number of holes in the skin layer on one side, the void layer communicates with the outside,
A method for producing a sound absorbing and insulating material, wherein the gap layer is used as the sound absorbing means. 5. The method for producing a sound absorbing and insulating material according to claim 1, wherein a temperature of a molding surface of the movable mold is higher than a facing molding surface facing the movable mold during molding. The method of manufacturing a sound absorbing and insulating material, wherein the thickness of the skin layer formed on the molding surface of the movable mold is made smaller than the thickness of the skin layer formed on the opposing molding surface. 6. The method for manufacturing a sound absorbing and insulating material according to claim 1 or 2, wherein a heat insulating skin material is mounted inside the mold, and then the molten resin is injected. Forming the intermediate molded body with the skin material integrated on the surface, removing the skin material from the obtained intermediate molded body, exposing the void layer to the outside,
A method for producing a sound absorbing and insulating material, characterized in that the gap layer is used as the sound absorbing means. 7. The method for producing a sound absorbing and insulating material according to claim 1, wherein a skin material having excellent sound absorbing properties is mounted inside the mold, and then the molten resin is injected. A method of manufacturing a sound absorbing and insulating material, wherein the sound absorbing means is formed by the skin material and the void layer integrated on a surface. 8. The method for manufacturing a sound absorbing and insulating material according to claim 1, wherein a skin material is mounted inside the mold, and then the molten resin is injected, so that the surface is formed on the surface. Molding the intermediate molded body in which the material is integrated,
A method for producing a sound absorbing and insulating material, characterized in that a number of holes are formed in the skin material to communicate the gap layer to the outside, and the gap layer is used as the sound absorbing means. 9. The method for manufacturing a sound absorbing and insulating material according to claim 1, wherein a gas is introduced into the molten resin filled in the cavity after the retreat of the movable mold is started. A method for producing a sound absorbing and insulating material, characterized by injecting. 10. The method for producing a sound absorbing and insulating material according to claim 1, wherein the raw material contains a gas generating agent as an expansion aid. The method of manufacturing the material. 11. The method for producing a sound absorbing and insulating material according to claim 1, wherein the thermoplastic resin is a polypropylene-based synthetic resin. 12. The method for manufacturing a sound absorbing and insulating material according to claim 1, wherein the reinforcing fiber is at least one of glass fiber, carbon fiber, metal fiber, ceramic fiber, and organic fiber. A method for producing a sound absorbing and insulating material, comprising: 13. A method of manufacturing a sound absorbing and insulating material according to claim 1, wherein the skin layer and the gap layer are integrated, and the gap layer is communicated with the outside. Sound absorbing and insulating material. 14. A method for producing a sound absorbing and insulating material according to claim 4, wherein one of the skin layers formed on the front and back surfaces of the intermediate molded body is removed to remove the skin layer on one surface, thereby forming the one side. A sound absorbing and insulating material, wherein the entire surface of the gap layer communicates with the outside. 15. A method of manufacturing a sound absorbing and insulating material according to claim 5, wherein a plurality of holes are formed in one of the skin layers of the skin layers formed on the front and back of the intermediate molded body. The sound absorbing and insulating material, wherein the air gap layer on one side communicates with the outside. 16. The surface is opened by removing the skin material from the intermediate molded body formed by the method for manufacturing a sound absorbing and insulating material according to claim 6 and having the surface material integrated with the surface. A sound absorbing and insulating material, wherein the void layer is in communication with the outside. 17. A sound absorbing and insulating material formed by the method for manufacturing a sound absorbing and insulating material according to claim 7, wherein the surface material having excellent sound absorbing properties is integrated on a surface. 18. The method for manufacturing a sound absorbing and insulating material according to claim 8, wherein a surface is opened by forming a large number of holes in the skin material, and the void layer communicates with the outside. Sound absorbing and insulating material.