• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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  • 优先权
    • 专利摘要:
    sound absorbing material; method for preparing the sound absorbing material; and method for reducing noise from the noise generating device. The present invention relates to a sound-absorbing material and a method for preparing the sound-absorbing material. more particularly, sound-absorbing material, which can be prepared by impregnating an adherent into an unwoven fabric formed from a heat-resistant fiber, is provided. the sound-absorbing material can have sound-absorbing property, fire-retardant property, heat-resistance and heat-insulating, thus being applicable to parts operating at a temperature of 200°C or higher and being moldable due to the adherent. additionally, the method for preparing the sound-absorbing material is provided.
    公开号:BR112014031545B1
    申请号:R112014031545-0
    申请日:2013-06-19
    公开日:2021-08-24
    发明作者:Keun Young Kim；Won Jin Seo
    申请人:Hyundai Motor Company；Kia Motors Corporation；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [001] The present invention relates to a sound-absorbing material and a method to prepare it. More particularly, the present invention provides a sound-absorbing material and a method of preparing the sound-absorbing material by impregnating an adherent into an unwoven fabric formed from a heat resistant fiber. Therefore, the sound-absorbing material prepared in accordance with the present invention may have sound-absorbing property, fire-retardant property, heat resistance and heat-insulating, thus being applicable to parts operating at a temperature of 200°C or higher and being moldable due to the adherent. TECHNICAL STATUS
    [002] Noise is inevitably generated in industry or by industrial products and can gradually cause damage. In this way, several methods can be considered to prevent or eliminate noise. In an exemplary effort to eliminate noise, several innovative sound absorbing materials that may be able to retain, absorb or insulate sound have been developed.
    [003] In related techniques, sound-absorbing materials can be used in electrical appliances, such as air conditioners, refrigerators, washing machines, lawn mowers and the like; transportation, such as vehicles, ships, planes, and the like; and building materials, such as wall material, floor material, and the like. Sound absorbing material can also be used in various other industrial fields. In general, sound absorbing materials used in such industries may also need other properties such as lightness, flame retardancy, heat resistance and heat insulation, depending on the particular applications in addition to good sound absorption property. In particular, flame retardancy and heat resistance may still be needed in sound absorbing materials used in engines, exhaust systems, and the like, which operate at a high temperature of 200°C or higher. Currently, aramid fibers can be one of the sound absorbing materials having superior heat resistance.
    [004] In the related techniques, in order to provide properties such as flame retardancy, water repellent, and the like of a sound-absorbing material, many sound-absorbing materials made of a non-woven fabric that may contain aramid fibers and a functional laminated surface material have been developed.
    [005] For example, Korean Patent Application Publication Number 2007-0033310, discloses a flame retardant sound absorbing material obtained from a layer of non-woven fabric in which short heat resistant aramid fibers and polyester fibers short thermoplastics are bonded together and a layer of surface material formed from a wet non-woven fabric is laminated together.
    [006] Japanese Patent Application Publication Number 2007-0039826, discloses a water-repellent sound-absorbing material obtained from a non-woven fabric layer of a heat-resistant short aramid fiber or a blend of an aramid fiber. short and a short thermoplastic polyester fiber or a layer of surface material treated with a water-repellent laminate with the non-woven fabric layer.
    [007] Japanese Patent Application Publication Number 2007-0138953, discloses a heat-resistant sound-absorbing material, wherein a non-woven fabric layer consists of a heat-resistant aramid fiber and a surface material layer formed of a Fiber sheet containing a heat resistant aramid fiber are laminated together.
    [008] Whereas the sound-absorbing materials described above may have a structure in which a layer of surface material can be laminated to one side of an unwoven fabric to provide properties such as flame retardancy, water repellency and the like, a heat pressing process to integrate the non-woven fabric layer and the surface material layer may be required. Consequently, the overall process can be complicated and difficult. Furthermore, the provision of other properties such as flame retardancy, water repellency and the like by additives can cause unwanted toxic gases generated by combustion during the heat pressing process. Additionally, deformation of the internal structure of the non-woven fabric can occur during the heat pressing process, thus deteriorating the sound absorption property. SUMMARY OF THE INVENTION TECHNICAL PROBLEM
    [009] The present invention can provide a technical solution to the technical difficulties described above. In this way, a new sound-absorbing material, which can have superior sound-absorbing property, flame-retardant, heat-resistance and heat-insulating property and be moldable, is provided. In particular, in the new sound-absorbing material, an adhesive can be impregnated into an unwoven fabric having microcavities with a complicated three-dimensional labyrinth structure and can be cured while maintaining the three-dimensional shape within the unwoven fabric without blocking the microcavities. Therefore, the physical properties of the non-woven fabric including the sound-absorbing property can be improved and a desired shape can be obtained during adhesive curing.
    [010] In one aspect, the present invention provides a sound-absorbing material having sound-absorbing, flame-retardant, heat-resistance and heat-insulating property and being moldable into a desired shape during the curing process in which an adhesive can be impregnated into an unwoven fabric formed from a heat resistant fiber.
    [011] In another aspect, the present invention provides a method for preparing a sound-absorbing material by impregnating an adherent into an unwoven fabric formed from a heat resistant fiber and drying the impregnated unwoven fabric.
    [012] In another aspect, the present invention provides a method to reduce noise using the sound absorbing material in a noise generating device. TECHNICAL SOLUTION
    [013] In an exemplary embodiment of the present invention a sound-absorbing material (1) may include: a non-woven fabric (10) containing an amount from 30% by weight to 100% by weight of a heat resistant fiber; and an adhesive (15) impregnated into said non-woven fabric and maintaining a three-dimensional shape within the non-woven fabric.
    [014] In another exemplary embodiment of the present invention, a method for preparing a sound-absorbing material (1) may include: a) dipping a non-woven fabric (10) containing an amount of 30% by weight to 100% by weight of a heat resistant fiber in an adherent solution; and b) drying said non-woven fabric. In yet another exemplary embodiment of the present invention, a method for reducing noise from a noise generating device may include: i) checking a three-dimensional structure of a noise generating device; ii) preparing and shaping a sound-absorbing material (1) so as to correspond to said three-dimensional structure of the device partially or completely; and iii) locating the sound absorbing material adjacent to the sound generating device. ADVANTAGEOUS EFFECTS
    [015] According to the various exemplary embodiments of the present invention, when the adherent is impregnated into the non-woven fabric formed from a heat resistant fiber, the sound-absorbing material may have superior sound absorption, flame retardancy, resistance the heat and heat insulating property and the sound absorbing material can even be shaped into a three-dimensional shape due to the adherent.
    [016] Additionally, in preparing the sound-absorbing material according to the various exemplary embodiments, a hot pressing process to integrate an unwoven fabric with a surface material can be eliminated unlike other conventional sound-absorbing materials that may have structures laminated.
    [017] In addition, sound-absorbing material in several exemplary embodiments of the present invention can be prepared by including a functional additive in an adherent solution, and desired functionality can be provided to the sound-absorbing material without laminating a surface material, thus providing advantages during their manufacture and manufacturing process.
    [018] Whereas the flame retardant, heat resistance and thermal insulation property of the exemplary sound-absorbing materials of the present invention may be superior in addition to the sound-absorbing properties, the sound-absorbing material may not be deformed or denatured in a sound generating device operating at a temperature of 200°C or more.
    [019] In particular, when a thermosetting resin is used as a tackifier, a desired shape can be obtained during the curing of the thermosetting resin, thus simplifying the overall process through the simultaneous curing and shaping of the thermosetting resin. Additionally, since an unwoven fabric formed from a heat resistant fiber can be used, thermal deformation of the unwoven fabric due to the heat of reaction from the thermal cure may not occur even when a thermosetting resin is used as an adhesive.
    [020] In this way, the sound-absorbing material in several exemplary embodiments of the present invention can be used in utensils requiring containment, absorption or isolation of sound including electrical utensils, such as air conditioners, refrigerators, washing machines, power cutters. grass and the like; transportation, such as vehicles, ships, planes, and the like; and building materials, such as wall material, floor material, and the like. In particular, the sound absorbing material of the present invention can be used for a noise generating device operating at a temperature of 200°C or more. More particularly, when the sound-absorbing material of the present invention is used in a vehicle, it can be closely connected to a vehicle parts sound generating device, such as an engine, exhaust system, and the like, and can be provided with a distance from the noise generating device, or being molded as a part of the sound generating device. BRIEF DESCRIPTION OF THE DRAWINGS
    [021] Fig. 1 shows electron microscopic images (x300) of an exemplary unwoven fabric before and after impregnation of an adherent according to an exemplary embodiment of the present invention. FIG. 1(a) is a microscopic image of an exemplary unwoven fabric prior to embedding an adherent, FIG. 1(b) is a microscopic image of an unwoven fabric in which 20 parts of the weight of an exemplary adherent have been impregnated based on 100 parts of the weight of the unwoven fabric, and FIG. 1(c) is a microscopic image of an exemplary unwoven fabric onto which 50 parts of the weight of an exemplary adherent has been impregnated based on 100 parts of the weight of the nonwoven fabric.
    [022] Fig. 2 schematically shows an example of a sound-absorbing material applied to an exemplary noise-generating device of a vehicle after modeling as a part, according to an exemplary embodiment of the present invention. FIG. 2(a) illustrates an exemplary sound-absorbing material modeled for use in a vehicular engine, and FIG. 2(b) illustrates an example of a sound-absorbing material that can be applied to a part of a vehicle engine.
    [023] Fig. 3 schematically shows an example in which a sound absorbing material is applied to an exemplary noise generating device of a vehicle at a distance, according to an exemplary embodiment of the present invention. FIG. 2(a) illustrates an exemplary sound-absorbing material modeled for use in an exemplary underside of a vehicle, and FIG. 3(b) shows an example of a sound absorbing material that can be applied to an underside of a vehicle.
    [024] Fig. 4 is an exemplary graph showing the sound absorption performance of a sound absorbing material depending on a density of an unwoven fabric according to an exemplary embodiment of the present invention.
    [025] Fig. 5 is an exemplary graph showing heat insulating performance compared to a thermal insulating aluminum plate and a sound absorbing material in accordance with the exemplary embodiment of the present invention. DETAILED DESCRIPTION
    [026] The present invention relates to a sound-absorbing material (1) and a method for preparing the sound-absorbing material. The sound absorbing material of the present invention can have superior absorbent property, flame retardancy, heat resistance and heat insulating property. In addition, the sound-absorbing material can be moldable into a desired three-dimensional shape due to an adhesive that can be present on the same layer as the non-woven fabric formed from a heat resistant fiber.
    [027] In one aspect, the present invention provides a sound-absorbing material (1) which may include: a non-woven fabric containing an amount of 30% by weight to 100% by weight of a heat resistant fiber; and an adhesive (15) present on the same layer as the non-woven fabric (10) to maintain a three-dimensional shape of the non-woven fabric.
    [028] In an exemplary embodiment of the present invention, the heat resistant fiber can have a limiting oxygen index (LOI) of 25% or more and a heat resistance temperature of 200°C or more.
    [029] In an exemplary embodiment of the present invention, the heat resistant fiber can be one or more selected from the group consisting of aramid fiber, polyphenylene sulfide fiber (PPS), oxidized polyacrylonitrile fiber (oxy-PAN) ), polyimide fiber (PI), polybenzimidazole fiber (PBI), polybenzoxazole fiber (PBO), polytetrafluoroethylene fiber (PTFE), polyketone fiber (PK), metallic fiber, carbon fiber, glass fiber, fiberglass basalt, silicon fiber and ceramic fiber. In particular, the heat resistant fiber can be an aramid fiber.
    [030] In an exemplary embodiment of the present invention, the unwoven fabric may be a single layer unwoven fabric formed from an aramid fiber having a fineness in a range of 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier) and a thickness in a range of 3 mm to 20 mm.
    [031] In an embodiment of the present invention, the unwoven fabric can have a density in a range of 100 to 2000 g/m2. In particular, the unwoven fabric can have a density in the range of 200 to 1200 g/m2.
    [032] In an exemplary embodiment of the present invention, the adhesive can be a thermosetting resin. In particular, the thermosetting resin may be an epoxy resin which is capable of forming a three-dimensional network structure on the internal structure of the non-woven fabric. The epoxy resin may be one or more epoxy resin selected from the group consisting of diglycidyl A biphenolic ether, diglycidyl B biphenolic ether, diglycidyl AD biphenolic ether, diglycidyl F biphenolic ether, diglycidyl S biphenolic ether, diglycidyl polyoxypopylene ether, ether polymer biphenolic diglycidyl A, phosphazene diglycidyl ether, biphenolic novolac A epoxy, phenolic novolac epoxy and novolac o-cresol epoxy resin.
    [033] The structure of an exemplary sound-absorbing material according to the present invention will be described in more detail as shown in Fig. 1.
    [034] Fig. 1 shows electron microscopic images of an exemplary sound-absorbing material before and after impregnation of an adherent into non-woven fabric and shows the three-dimensional network structure within an unwoven fabric. In particular, Fig. 1(A) is an electron microscopic image of the internal structure within a non-woven fabric prior to impregnation of an adherent into the non-woven fabric and shows that heat resistant fiber strands cross to form irregular micro cavities. Each Fig. 1(B) or (C) is an electron microscopic image of the internal structure within the non-woven fabric after impregnation of an adherent into the non-woven fabric and shows that the adherent is finely and evenly distributed and secured to the strands of heat resistant fiber. Furthermore, the content of the adherent on the surface of the yarn increases as the content of the adhesive increases.
    [035] Although there may be differences depending on the method of preparation, the unwoven fabric fibers can be randomly arranged in a three-dimensional structure. In this way, the internal structure of an unwoven fabric can have a substantially complicated labyrinth structure, which can be formed of regularly or irregularly arranged fibers, can be interconnected three-dimensionally, rather than loops of independent capillary tubes. Thus, the unwoven fabric in accordance with the various exemplary embodiments of the present invention may have irregular micro-cavities formed as strands containing the heat resistant fiber crossing freely.
    [036] When an adhesive is impregnated into the non-woven fabric, the adhesive can be finely and evenly distributed and secured on the surface of the strands of the non-woven fabric containing the heat resistant fiber, thus providing a much finer internal structure, micro cavities having labyrinth structure, before impregnation. The formation of finely modified microcavities in the internal structure of the unwoven tissue can provide the extended sound or noise resonance pathway and further provide improved sound absorption property. When the adhesive forms a three-dimensional network structure as it cures, the sound absorption property can be further improved by forming more finer micro-cavities within the unwoven fabric.
    [037] In this way, considering that the non-woven fabric can maintain the intrinsic three-dimensional shape as the adherent is uniformly impregnated within the non-woven fabric and additionally, considering that thinner micro cavities (Micro ventilation) can be formed as the adherent is cured , the sound-absorbing material of the present invention can have remarkably improved sound-absorbing performance due to maximized noise absorption through increasing and a variety of sound resonance or noise in the non-woven fabric.
    [038] As shown in the exemplary electron microscopic images of Fig. 1, in an exemplary embodiment of the present invention, the adherent can be evenly dispersed and distributed over the surface of the heat-resistant fiber strands constituting the non-woven fabric of a material Exemplary sound absorber.
    [039] Here, the composition of the sound-absorbing material according to the various exemplary embodiments of the present invention which may have an internal structure described above will be described in more detail.
    [040] In an exemplary embodiment of the present invention, a heat resistant fiber can be used as the main fiber included in the non-woven fabric. Heat resistant fiber can be any type having superior durability and ultra high temperature or high temperature resistance. In particular, heat resistant fiber can have a limiting oxygen index (LOI) of 25% or more and a heat resistance temperature of 150°C or more. More particularly, heat resistant fiber can have a limiting oxygen index (LOI) in a range of 25% to 80% and a heat resistance temperature of 150°C to 3000°C. In addition, heat resistant fiber can have a limiting oxygen index (LOI) in a range of 25% to 70% and a heat resistant temperature in a range of 200°C to 1000°C. Additionally, the heat resistant fiber can have a fineness in a range from 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier), or particularly from 1 gram per 9000 meters (1 denier) to 1 gram by 1500 meters (6 denier); and a length of wire in a range from 20 mm to 100 mm, or particularly from 40 mm to 80 mm.
    [041] As used herein, a heat resistant fiber can be a 'super fiber' as generally known in the related art. In an exemplary embodiment, the super fiber can be one or more selected from the group consisting of aramid fiber, polyphenylene sulfide (PPS) fiber, oxidized polyacrylonitrile fiber (oxy-PAN), polyimide fiber (PI) , polybenzimidazole fiber (PBI), polybenzoxazole fiber (PBO), polytetrafluoroethylene fiber (PTFE), polyketone fiber (PK), metallic fiber, carbon fiber, glass fiber, basalt fiber, silicon fiber and fiberglass ceramics.
    [042] In an exemplary embodiment of the present invention, an aramid fiber can be used as the heat resistant fiber. In particular, meta-aramid (m-aramid) para-aramid (p-aramid) or a mixture thereof can be used as the heat resistant fiber in the present invention. The aramid fiber used as the non-woven fabric yarn may have a fineness in the range of 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier), or particularly of 1 gram per 9000 meters (1 denier). denier) at 1 gram per 1500 meters (6 denier); and a length of wire in a range from 20 mm to 100 mm, or particularly from 40 mm to 80 mm. When the length of the thread is shorter than a predetermined length, binding the threads can be difficult during fabrication, for example, in needle punching. As a result, the cohesion of the unwoven fabric may be poor. In contrast, when the length of the yarn is no longer than a predetermined length, the cohesion of the non-woven fabric may be greater, but movement of the yarns may be difficult during fabrication, for example carding.
    [043] As used herein, aramid fiber is an aromatic polyamide fiber in which aromatic rings such as a benzene ring are linked together by amide groups. Aromatic polyamide fiber is typically called 'aramid' and differentiated from an aliphatic polyamide, eg nylon. Aramid fiber can be prepared by spinning aromatic polyamide and classified as m-aramid [Chemical Formula 1], and p-aramid [Chemical Formula 2] depending on the location of the amide bonds in the aromatic ring.[Chemical Formula 1]
    [Chemical Formula 2]

    [044] The m-aramid represented by Chemical Formula 1 can be prepared by dry rotation after dissolving isophthaloyl chloride and m-phenylenediamine in a solvent of dimethylacetamide (DMAc). m-aramid can have relatively high tensile elongation at break in a range of 22% to 40% due to the uneven structure of the polymer, it can be dyed and can easily be prepared into fibers. It is realized that NomexTM (DuPont) and ConexTM (Teijin) can provide a range of options for m-aramid.
    [045] The p-aramid represented by Chemical Formula 2 can be prepared by wet rotation after dissolving terephthaloyl chloride and o-phenylenediamine in an N-methylpyrrolidone (NMP) solvent. The p-aramid can be long due to its highly oriented linear molecular structure, and the length of the p-aramid can be improved by about 3-7 times compared to m-aramid. Therefore, p-aramid can be used for reinforcement or protective materials. Also, p-aramid can have substantial chemical resistance, reduced thermal shrinkage, superior dimensional stability, high tear strength, flame resistance and self-extinguishing properties. It is realized that KevlarTM (DuPont), TwaronTM (Teijin) and TechnoraTM (Teijin) can provide a range of options for p-aramid.
    [046] In an exemplary embodiment, aramid can be provided in a form of filament, staple, wire and the like and can be used, for reinforcement materials, for example, a transformer, a motor and the like, insulating materials, for example , insulating paper, electrical tape, and the like, heat resistant fibers, eg, fireproof clothing, gloves, and the like, high temperature filters, or the like.
    [047] Although the non-woven fabric used in the sound-absorbing material according to the various embodiments of the present invention can be prepared from heat resistant fiber or super fiber yarn, the non-woven fabrics can be prepared by adding still others types of fibers to heat resistant fiber strand, to reduce cost or provide the unwoven fabric with lightness, functionality, and the like, within the scope of the present invention. In other words, although the unwoven fabric of the present invention can be prepared from heat resistant fiber yarn, the present invention may not woven fabric formed from heat resistant fiber alone. The non-woven fabric of the present invention may include the heat resistant fiber yarn in an amount of from 30% by weight to 100% by weight, or particularly from 60% by weight to 100% by weight, based on the total weight of the fabric. not plotted.
    [048] Still, in an exemplary embodiment of the present invention, the sound-absorbing material may include an adhesive that may present on the same layer as the non-woven fabric and maintain a three-dimensional shape within the non-woven fabric. Thus, the adhesive used can be any one capable of maintaining the three-dimensional shape within the non-woven fabric. As used herein, the expression 'maintaining the three-dimensional shape within the non-woven fabric' can be interpreted that the adherent, which is impregnated into the non-woven fabric, can be uniformly distributed and bonded to the fiber strand surface of the non-woven fabric and maintain the structure or facilitates the formation of irregular micro-cavities, thus maintaining the original three-dimensional shape within the unwoven fabric.
    [049] In the related techniques, although an adherent generally refers to a material used to adhere or join two materials, the term 'sticker' as used herein may refer to a material impregnated into the unwoven fabric formed from the resistant fiber. to heat.
    [050] According to various embodiments, various materials can be used as adhesive impregnated in the non-woven fabric. Firstly, a thermoplastic resin or a thermosetting resin can be considered as a sticky material.
    [051] Thermoplastic resin such as a polyamide based resin can include polar crystalline groups such as aramid fiber which is a representative heat resistant fiber as described above. When a thermoplastic adhesive is impregnated into the unwoven fabric formed from thermoplastic heat resistant fiber, a solid interfacial layer can be formed between the thermoplastic adhesive and the thermoplastic heat resistant fiber due to face-to-face contact between comparable crystalline polar groups , thus blocking or partially covering the micro-cavities of the unwoven fabric. As a consequence, when a thermoplastic resin is used as the adhesive impregnated into the non-woven fabric formed from the thermoplastic heat-resistant fiber, the sound absorption performance may be reduced due to the partial blocking of the micro-cavity of the non-woven fabric which can provide a pathway. of sound resonance within the unwoven fabric. At a glance, one might think that the sound absorption performance would be better if the micro cavities were blocked. Since noise is not eliminated within the non-woven fabric and is transmitted through external routes of the non-woven fabric, improved sound absorption performance may not be obtained if the thermoplastic adhesive is impregnated into the non-woven fabric. Additionally, when the thermoplastic adhesive is impregnated into an unwoven fabric formed of heat resistant fiber with an inorganic base, the adhesive additive can be added to the adhesive due to the poor adhesive property of the thermoplastic adhesive.
    [052] In contrast, a thermosetting bond, as used herein, may have significantly different physical and chemical properties than thermoplastic heat resistant fiber. In this way, when a thermosetting adhesive is impregnated into the unwoven fabric formed from the thermoplastic heat resistant fiber, an interfacial layer can be formed by end-to-end contact due to the different characteristics in the phase. As a result, the micro-cavities of the unwoven fabric may remain open. Therefore, when a thermosetting resin is used as the adhesive impregnated into the non-woven fabric formed from the heat resistant fiber, the three-dimensional shape including micro-cavities within the non-woven fabric can be maintained. Thus, a thermosetting resin can be used as an adhesive in an exemplary embodiment of the present invention.
    [053] Additionally, the thermosetting resin may be curable with light, heat, or a curing agent and its shape may not be deformed yet at elevated temperatures. Thus, by using the heat resistant fiber and the thermosetting adhesive in the exemplary embodiments of the present invention, the shape of the sound absorbing material can still be maintained in a high temperature condition after the forming process. Therefore, when a thermosetting resin is used as the adhesive impregnated into the non-woven fabric, shaping the non-woven fabric into a desired shape can be achieved during resin curing and the shape obtained can be maintained even at high temperatures.
    [054] As described above, when a thermosetting resin is used as the adhesive impregnated to the unwoven fabric formed from the heat resistant fiber, in addition to maintaining the three-dimensional shape within the unwoven fabric, shaping the unwoven fabric into a desired shape during curing the adhesive resin can be obtained.
    [055] In an exemplary embodiment, an epoxy resin can be used as the adhesive. The epoxy resin, as used herein, can be a representative thermosetting resin and be curable into a polymeric material having a three-dimensional network structure. In this way, considering that the epoxy resin can form a mesh structure and micro cavity therein when cured within the non-woven fabric, additional fine micro cavities can be formed within the non-woven fabric and the sound absorption performance can be further improved.
    [056] Furthermore, a complicated three-dimensional network structure can be formed when curing is performed in the presence of a curing agent, and thus the sound absorption effect can be further improved. In detail, a three-dimensional network structured polymer can be formed as the epoxy groups or hydroxyl groups of the epoxy resin react with the functional groups of the curing agent, such as amine groups or carboxylic acid groups to form crosslinks. The curing agent can serve as a catalyst that catalyzes the curing reaction and still be involved in the reaction and bonded to the chemical groups in the epoxy resin. In this way, the size and physical properties of micro cavities can be controlled by selecting different curing agents.
    [057] In an exemplary embodiment, the epoxy resin can be one or more selected from the group consisting of diglycidyl A biphenolic ether, diglycidyl B biphenolic ether, diglycyl AD biphenolic ether, diglycidyl F biphenolic ether, diglycidyl S biphenolic ether, ether diglycidyl polyoxypopylene, diglycidyl A biphenolic ether polymer, diglycidyl phosphazene ether, novolac A biphenolic epoxy, novolac phenolic epoxy resin, and novolac o-cresol epoxy resin. In particular, the epoxy resin can have an epoxy equivalent in a range of 70 to 400. When the epoxy equivalent is less than a predetermined value, the intermolecular bond can be significantly reduced to form the three-dimensional network structure or physical properties of the material. Sound absorber may be insufficient due to reduced adhesion with heat resistant fiber. In contrast, when the epoxy equivalent is greater than a predetermined value, the physical properties of the sound absorbing material may not be sufficient due to the excessively dense network structure formed by the epoxy resin.
    [058] In an exemplary embodiment, when a thermosetting resin is used as a tackifier in the present invention, the curing agent can be included in a tacky solution. As used herein, the curing agent can have a functional group that can readily react with the functional groups of the adherent, such as epoxide groups or hydroxyl groups. In particular, the curing agent can be an aliphatic amine, an aromatic amine, an acid anhydride, urea, a starch, imidazole, and the like. In an exemplary embodiment, the curing agent can be one or more selected from the group consisting of diethyltoluenediamine (DETDA), diaminophenylsulfone (DDS), boron trifluoride monoethylamine (BF3*MEA), diaminocyclohexane (DACH), methyltetrahydrophthalic anhydride ( MTHPA), methyl-5-nproborene-2,3-dicarboxylic anhydride (NMA), dicyandiamide (Dicy), and 2-ethyl-4-methylimidazole. In an exemplary embodiment, an amine or aliphatic amide based curing agent can be used due to its improved crosslinking ability, superior chemical resistance and weather resistance. In particular, dicyandiamide (Dicy) can be used in consideration of crosslinking ability, flame retardancy, heat resistance, storage capacity, processability and the like. Since dicyandiamide (Dicy) has a high melting point above 200°C, it can remain highly stable after being mixed with the epoxy resin and can provide sufficient processing time for curing and shaping.
    [059] In an exemplary embodiment of the present invention, a catalyst that facilitates the cure of the thermostable resin used as the adhesive can be used. In particular, the catalyst may be one or more selected from the group consisting of urea, dimethyl urea, a quaternary DBU tetraphenylborate salt, and quaternary phosphonium bromide. The catalyst can be included in the solution containing the adherent.
    [060] Additionally, various additives, eg flame retardancy, heat resistance additive, water repellent, and the like, can be used to provide additional functionality to the sound absorbing material. The additive may be included in the sticky solution, and thus no additional surface material to provide functionality to the sound absorbing material may be needed.
    [061] In an exemplary embodiment, the flame retardant can be melamine, phosphate, metal hydroxide and the like. In particular, the flame retardant can be one or more selected from the group consisting of melamine, melamine cyanide, melamine polyphosphate, phosphazene, and ammonia polyphosphate. More particularly, the flame retardant can be melamine, which can provide flame retardancy and heat resistance simultaneously.
    [062] In an exemplary embodiment, the heat resistance aid can be alumina, silicon, talc, clay, glass powder, fiberglass, metal powder, and the like.
    [063] In an exemplary embodiment, one or more fluorine-based waterproofers can be used as waterproofers.
    [064] Additionally, additives commonly used in the related art can be selected depending on the desired purposes.
    [065] In another aspect, the present invention provides a method for preparing a sound-absorbing material, which may include: a) dipping a non-woven fabric containing an amount of 30% by weight to 100% by weight of a strong fiber to heat in an adherent solution; and b) drying the non-woven fabric.
    [066] Here, exemplary embodiments of each step of the method for preparing a sound-absorbing material will be described in detail.
    [067] In an exemplary embodiment, in step a), an unwoven fabric formed from a heat resistant fiber can be immersed in an adherent solution. The unwoven fabric can be immersed in the bonding solution to improve sound absorption performance and sound isolation performance and to allow shaping of the sound absorbing material into a desired shape. The tacky solution can include a tacky resin and further contain a curing agent, a catalyst, conventional additives and a solvent.
    [068] The adherent, curing agent, catalyst and conventional additives included in the adherent solution may be the same as described above. The solvent used to prepare the sticky solution can be one or more selected from the group consisting of a ketone, a carbonate, an acetate and a cellosolve. In particular, the solvent may be one or more selected from the group consisting of acetone, methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), dimethyl carbonate (DMC), ethyl acetate, butyl acetate, methyl cellosolve , ethyl cellosolve, and butyl cellosolve.
    [069] In an exemplary embodiment, the sticky solution may contain an amount of 1% by weight to 60% by weight of an adherent; and a solvent like the rest. Additionally, the sticky solution may further contain a curing agent and other additives including a catalyst. In particular, the tacky solution may contain an amount of 1% by weight to 60% by weight of a tackifier, an amount of 0.1% by weight to 10% by weight of a curing agent, an amount of 0. 01% by weight to 5% by weight of a catalyst, an amount of 1% by weight to 40% by weight of additives and a solvent as the remainder. More particularly, the tacky solution may contain an amount of 1% by weight to 30% by weight of a tackifier, an amount of 0.1% by weight to 10% by weight of a curing agent, an amount of 0. 01% by weight to 5% by weight of a catalyst, an amount from 1% by weight to 30% by weight of a retardant as an additive and an amount from 40% by weight to 95% by weight of a solvent.
    [070] In an exemplary embodiment, the degree of impregnation in the unwoven fabric can be controlled by controlling the concentration of the adherent solution. For example, the sticky solution can be prepared to have a solids content in a range from 1% by weight to 60% by weight, or particularly from 20% by weight to 50% by weight. When the sticky solution has less concentrate than a predetermined value, the purpose of the present invention may not be achieved because the content of sticky impregnated in the non-woven fabric is small. In contrast, when the sticky solution is more concentrated than a predetermined value, the unwoven fabric can become rigid and may not serve as a good sound-absorbing material.
    [071] Additionally, when the content of the curing agent contained in the sticky solution is less than a predetermined amount, shaping into a desired shape can be difficult because the bonding cure cannot be completed. As a result, the effect of improving the mechanical strength of the sound absorbing material may not be achieved. And, when the content of the curing agent is greater than a predetermined amount, the sound absorbing material may become rigid and the storage capacity or the like may be unsatisfactory. Furthermore, when the catalyst content is less than a predetermined amount, the catalytic effect to facilitate the reaction may not be sufficiently provided. In contrast, when the catalyst content is greater than a predetermined amount, stability and the like may be unsatisfactory. The additives can be one or more additives conventionally used in the related art, which can include a flame retardant, a heat resistance aid, a water repellant and the like. The content of these additives can be adjusted accordingly depending on the purpose of addition. When the amount of additives is less than a predetermined amount, the desired effect may not be achieved. And, when the additive amount is greater than a predetermined amount, economical use of the additive may not be obtained and unwanted side effects may be caused.
    [072] In an exemplary embodiment of the present invention, in step b), the unwoven fabric can be dried. The drying step can be carried out by removing the unwoven fabric from the adhering solution and removing the solvent. Drying can be carried out at appropriate temperatures under pressure. In an exemplary embodiment, drying can be carried out at a temperature in a range from 70°C to 200°C, or particularly from 100°C to 150°C. Additionally, in the drying step, the tack content in the non-woven fabric can be controlled and the physical properties of the sound-absorbing material can be controlled. In addition, the content of adherent included in the non-woven fabric after drying can determine the sizes, shapes and distribution of micro-cavities within the sound-absorbing material. Thus, the sound absorbing property and mechanical property of the sound absorbing material can be controlled therewith. In an exemplary embodiment, drying can be carried out so that the final content of the tackifier can be included in the non-woven fabric in an amount of 1 part to 300 parts by weight, or particularly 30 parts to 150 parts by weight, based in 100 parts by weight of non-woven fabric.
    [073] Additionally, the method for preparing a sound-absorbing material according to an exemplary embodiment of the present invention may further include, after step b), a step of preparing a sound-absorbing material by shaping the dry non-woven fabric into elevated temperature (step c) . When step c) is included, the method for preparing a sound-absorbing material may include: a) immersing an unwoven fabric containing an amount of 30% by weight to 100% by weight of a heat resistant fiber in a solution adherent; b) drying the non-woven fabric; and c) preparing a sound-absorbing material by shaping the unwoven fabric at an elevated temperature. Particularly, in step c), a sound-absorbing material can be prepared by shaping the dry unwoven fabric at an elevated temperature. High-temperature modeling can include curing the heat-stable adhesive and can be carried out at a temperature in a range of 150°C to -300°C, or particularly 170°C to 230°C.
    [074] The method for preparing a sound-absorbing material according to an exemplary embodiment of the present invention may further include, prior to step a), a step of forming an unwoven fabric by needle punching a heat resistant fiber (step a-1). For example, in step a-1) a non-woven aramid fabric having a thickness in the range of 3 mm to 20 mm can be formed by needle punching a heat resistant aramid fiber of 1 gram by 900 meters (1 denier) at 1 gram per 600 meters (15 denier).
    [075] When step a-1) is included, the method for preparing a sound-absorbing material may include: a-1) forming an aramid non-woven fabric having a thickness in a range of 3mm to 20mm by needle punching a heat-resistant aramid fiber from 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier); a) immersing an unwoven fabric containing an amount of 30 wt% to 100 wt% of a heat resistant fiber in an adherent solution; and b) drying the non-woven fabric.
    [076] Additionally, the method for preparing a sound-absorbing material may include step a-1) according to the present invention may include: a-1) forming an aramid nonwoven fabric having a thickness in a strip 3 mm to 20 mm by needle punching a heat-resistant aramid fiber from 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier) ; a) immersing an unwoven fabric containing an amount of 30 wt% to 100 wt% of a heat resistant fiber in an adherent solution; b) drying the non-woven fabric; and c) preparing a sound-absorbing material by molding dry non-woven fabric at an elevated temperature.
    [077] In an exemplary embodiment, step a-1) of forming an unwoven fabric may include needle punching of a heat resistant fiber. Since the sound-absorbing property can vary depending on the thickness and density of the non-woven fabric, the sound-absorbing property can be improved by increasing the thickness and density of the non-woven fabric.
    [078] In an exemplary embodiment, the unwoven fabric can have a thickness in the range of 3mm to 20mm depending on its application or parts of the sound-absorbing material used. When the thickness of the unwoven fabric is less than 3mm, the durability and shaping ability of the sound absorbing material may be unsatisfactory. In contrast, when the thickness is greater than 20mm, productivity can decrease and production cost can increase during the manufacturing and manufacturing process of the same. Additionally, the density of the unwoven fabric can be in a range from 100 g/m2 to 2000 g/m2, from 200 g/m2 to 1200 g/m2, or particularly from 300 g/m2 to 800 g/m2, in the performance and cost aspects.
    [079] Aramid non-woven fabric can be formed by stacking a net from 30 g/m2 to 100 g/m2 which is formed by carding 2 to 12 times and continuously performing top-down needling, bottom-up needling and needling from top to bottom, thus forming physical bridges and providing the desired thickness, bond strength and other desired physical properties. The needle used to carry out needling may be a barbed needle having a blade of 0.5 mm to 3 mm and a needle length measured as the crank distance out of the stitch in a range of about 70 mm to 120 mm. Additionally, the needle stroke can be 30 times/m2 to 350 times/m2.
    [080] In particular, the yarn fineness for the non-woven fabric can be in a range of 1 gram per 6000 meters (1.5 denier) to 1 gram per 1125 meters (8.0 denier), the thickness of the stacked layer can be in a range of 6mm to 13mm, needle stroke can be in a range of 120 times/m2 to 250 times/m2, and density of unwoven fabric can be in a range of 300 g/m2 to 800 g/m2.
    [081] The internal structure of the sound-absorbing material prepared by the method according to several exemplary embodiments described above can be confirmed using an electron microscope. When viewed with an electron microscope the sound absorbing material of the present invention may have micro cavities which may have a size in a range of 1 µm to 100 µm, and be distributed within this. The micro cavities can be evenly or irregularly distributed with a distance between them in a range of 0.1 µm to 500 µm.
    [082] In another exemplary embodiment, the present invention provides a method for reducing the noise of a noise-generating device, including: i) verification of the three-dimensional structure of a noise-generating device; ii) preparing and shaping a sound-absorbing material to provide a partially or completely three-dimensional structure of the device; and iii) installing the sound absorbing material adjacent to the noise generating device.
    [083] An exemplary noise-generating device, as used here, might be an engine, a mechanism, an exhaust system, and the like. The sound-absorbing material can be provided in the three-dimensional structure of the device partially or completely. In particular, the sound-absorbing material according to an exemplary embodiment of the present invention can be prepared and shaped during curing of the adhesive in the three-dimensional structure of the device partially or completely.
    [084] Any operation with the term "adjacent" as used here may involve closely bonding the sound-absorbing material to the noise-generating device, providing it at a distance from the noise-generating device, or modeling it exactly as a part of the sound generating device. Furthermore, operation with the term "adjacent" may include mounting the sound absorbing material to a member connected to the noise generating device, for example, another sound absorbing material.
    [085] Fig. 2 and Fig. 3 schematically show exemplary parts of the vehicle or a noise generating device of a vehicle to which the sound-absorbing material according to an exemplary embodiment of the present invention can be applied.
    [086] In particular, Fig. 2 schematically shows the noise-generating devices of a vehicle to which the sound-absorbing material can be applied after modeling as a part. FIG. 2(a) is a schematic view of an exemplary vehicular engine, and FIG. 2(b) illustrates an example of an exemplary sound-absorbing material that can be shaped and applied to a part of a vehicle engine.
    [087] Fig. 3 schematically shows the sound absorbing material that can be applied to a vehicle noise generating device. FIG. 3(a) schematically illustrates an exemplary underside of a vehicle, and FIG. 3(b) schematically illustrates an exemplary sound-absorbing material that can be shaped and applied to an underside of a vehicle.
    [088] In several exemplary sound-absorbing materials of the present invention, the adhesive can be impregnated to maintain the three-dimensional shape within the non-woven fabric and the sound-absorbing material may have superior sound absorption property, flame retardant property, heat insulation and heat resistance. In this way, the desired sound absorption performance can be obtained when applied directly to a noise generating device operating at a temperature of 200°C or more, without deformation.
    [089] The present invention will be described in more detail through examples, despite the scope of the present invention by the examples. [EXAMPLES] PREPARATION OF SOUND ABSORBENT MATERIAL
    [090] Example 1. Preparation of the sound-absorbing material using the non-woven aramid fabric impregnated with epoxy resin.
    [091] A short fiber of m-aramid A having a limit oxygen index (LOI) of 40%, a heat resistance at a temperature of 300°C, a fineness of 1 gram per 4500 meters (2 denier) and a length of 51 mm can be blown and formed into a 30 g/m2 net by carding. The net can be stacked by overlapping 10 times on a conveyor belt operated at m/min using a horizontal packer. An aramid non-woven fabric having a density of 300 g/m2 and a thickness of 6 mm can be prepared by continuously needling from top to bottom, bottom to top and top to bottom with a needle stroke of 150 times/ m2.
    [092] The prepared unwoven fabric can be immersed in a sticky solution with 1 dip of 1 closely at the collection rate of 300%. The sticky solution may include 8% by weight diglycidyl A biphenolic ether, 2% by weight diglycidyl A biphenolic ether polymer, 0.2% by weight dicyandiamide, 0.02% by weight dimethyl urea, 10% by weight of melamine cyanide and 79.78% by weight of dimethyl carbonate (DMC).
    [093] The unwoven fabric can be removed from the sticky solution and dried at 150°C. The unwoven fabric may contain 50 parts by weight of an adherent based on 100 parts by weight of unwoven fabric.
    [094] Dry unwoven fabric can be shaped into a desired shape by curing at 200°C for 2 minutes.
    [095] Comparative Example 1. Preparation of the sound-absorbing material using the non-woven aramid fabric
    [096] An aramid nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching as described in Example 1.
    [097] Comparative Example 2. Preparation of sound absorbing material using epoxy resin coated aramid non-woven fabric
    [098] A non-woven aramid fabric having a density of 300 g/m2 and a thickness of 6 mm can be prepared by needle punching as described in Example 1. Subsequently, a coating solution can be coated onto the surface of the fabric. unwoven so that content of an adherent may be 50 parts by weight based on 100 parts by weight of the unwoven fabric. Then, the unwoven fabric can be shaped after drying at a temperature of 150°C.
    [099] The coating solution may include 8% by weight diglycidyl A diphenolic ether, 2% by weight diglycidyl A diphenolic ether polymer, 0.2% by weight dicyandiamide, 0.02% by weight dimethyl urea, 10% by weight of melamine cyanide and 79.78% by weight of dimethyl carbonate.
    [0100] Comparative Example 3. Preparation of the sound-absorbing material using the non-woven aramid fabric impregnated with thermoplastic resin
    [0101] An aramid non-woven fabric having a density of 300 g/m2 and a thickness of 6 mm can be prepared by needle punching, immersed in a sticky solution, dried and then shaped as described in Example 1.
    [0102] The sticky solution can be a thermoplastic resin solution including 10% by weight polyethylene resin, 10% by weight melamine cyanide and 80% by weight dimethyl carbonate.
    [0103] Comparative Example 4. Preparation of sound absorbing material using epoxy resin impregnated PET non-woven fabric
    [0104] A non-woven fabric of polyethylene terephthalate (PET) having a density of 300 g/m2 and a thickness of 6 mm can be prepared by needle punching, immersed in an adherent solution, dried and then shaped as described in Example 1.
    [0105] The PET unwoven fabric prepared in Comparative Example 4 was thermally deformed due to the heat of reaction produced during the curing of the epoxy and could not be shaped into a desired shape as it was completely thermally deformed during the drying and shaping processes. [EXAMPLE TEST] EVALUATION OF THE PHYSICAL PROPERTIES OF SOUND-ABSORBING MATERIALS
    [0106] The physical properties of the sound absorbing materials of the test samples were measured and compared as follows.
    [0107] 1. Evaluation of heat resistance
    [0108] To assess heat resistance, the sound-absorbing material was aged in an oven at 260°C for 300 hours. After keeping in the standard state, ie, a temperature of 23±2°C, in relation to a humidity of 50±5%, for at least 1 hour, the appearance was inspected and the tensile strength was measured for each test sample. The sample was visually inspected for shrinkage or deformation, surface peeling, swelling and cracking. Tensile strength was measured using a #1 type dumbbell for five randomly selected sheets of test specimens at a speed of 200 mm/min under a standard condition.
    [0109] 2. Thermal Cycle Assessment
    [0110] The durability of the sound absorbing material was evaluated using the thermal cycle test method. Durability was determined after performing five cycles.
    [0111] 1) Condition of a cycle
    [0112] Ambient temperature high temperature (50°C x 3h) ambient temperature low temperature (30°C x 3h) ambient temperature humid condition (50°C x 95% RH).
    [0113] 2) Durability Assessment Standard
    [0114] After the thermal cycle test, the change in appearance of each test sample was inspected. For example, surface damage, swelling, breakage and discoloration can be inspected. If there are no changes in appearance, the sound absorbing material was assessed as 'no abnormality'.
    [0115] 3. Flame retardancy assessment
    [0116] The flame retardancy of the sound absorbing material was measured according to the ISO 3795 standard flammability test.
    [0117] 4. Non-flammability assessment
    [0118] The non-flammability of the sound absorbing material was measured according to the UL94 standard vertical burn test.
    [0119] 5. Assessment of sound absorption property
    [0120] The sound-absorbing property of the sound-absorbing material was measured according to standard ISO 354 method.
    [0121] 6. Air permeability assessment
    [0122] 1) Assessment method
    [0123] The test sample was mounted in a Frazier type tester and the amount of air flowing through the test sample vertically was measured. The area of the test sample through which the air passed was 5 cm2 and the applied pressure was set at 125 pascals (Pa).
    [0124] Test Example 1. Comparison of the properties of sound absorbing materials depending on the types of heat resistant fibers.
    [0125] In Test Example 1, the physical properties of sound-absorbing materials prepared with different strands of different heat-resistant fiber were compared. Unwoven fabrics of 300 g/m2 and a thickness of 6 mm were prepared by needle punching and the sound absorbing materials were prepared by immersion in an adherent solution, dried and then shaped as described in Example 1. The unwoven fabrics were prepared using yarns having a fineness of 1 gram per 4500 meters (2 denier) and a length of 51 mm, which are described in Table 1.
    [0126] The physical properties of the sound absorbing materials of the test samples were measured as described above. The results of measuring the properties of sound absorbing materials prepared with different heat resistant fibers are shown in Table 1 and Table 2.TABLE 1
    TABLE 2

    [0127] As seen from Table 1 and Table 2, all sound-absorbing materials prepared using heat resistant fibers having an oxygen limit index of 25% or more and a heat resistance temperature of 150°C or more according to an exemplary embodiment of the present invention can obtain satisfactory heat resistance, durability, flame retardant property, non-flammability and sound absorption. In this way, conventionally used heat resistant fibers, i.e. superfiber, can be used as the non-woven fabric material of the sound absorbing material in accordance with an exemplary embodiment of the present invention.
    [0128] Test Example 2. Comparison of the properties of sound absorbing materials depending on the density of the non-woven fabric
    [0129] In Test Example 2, test samples of the sound-absorbing material were prepared as described in Example 1 using non-woven fabrics having different densities. The sound absorption performance of test samples of the sound absorbing material is shown in Fig. 4.
    [0130] As can be seen from Fig. 4, the sound-absorbing performance of the sound-absorbing material can be superior when an unwoven fabric having a density of 600 g/m2 can be used compared to a non-woven fabric. screened having a density of 300 g/m2.
    [0131] Test Example 3. Evaluation of Physical Properties of Sound Absorbing Materials
    [0132] In Test Example 3, the properties of the test samples of the sound-absorbing material depending on the method by which a heat-stable adhesive can be applied to an unwoven fabric were compared.
    [0133] In this way, the sound absorption rate of the test samples of the sound absorbing material prepared by impregnating (Example 1) and coating (Comparative Example 2) the thermostable adhesive were compared. The results of measuring the sound absorption rate of the sound-absorbing material formed from a non-woven fabric (Comparative Example 1), the sound-absorbing material on which the heat-sealable adhesive has been coated (Comparative Example 2) and the sound-absorbing material in which the thermosetting adhesive was impregnated into the non-woven fabric (Example 1) are shown in Table 3.TABLE 3


    [0134] As seen in Table 3, the sound-absorbing material of Example 1 according to an exemplary embodiment of the present invention may have higher sound absorption rate in all frequency ranges compared to the sound-absorbing material of Comparative Example 1 wherein non-woven fabric not impregnated with a heat-stable adhesive was used. In contrast, the sound-absorbing material of Comparative Example 2 of which the heat-set adhesive was coated onto the non-woven fabric may have a reduced sound absorption rate than the non-woven fabric (Comparative Example 1) in the 400 Hz frequency range at 5000 Hz.
    [0135] Test Example 4. Evaluation of the heat insulation performance of sound absorbing materials
    [0136] In Test Example 4, the heat insulation performance of each test sample of the sound-absorbing material prepared in Example 1 (aramide nonwoven fabric impregnated with thermosetting resin), Comparative Example 1 (aramid nonwoven fabric ) or Comparative Example 3 (aramide nonwoven fabric impregnated with thermoplastic resin) was evaluated. After applying 1000°C from one side of a 25 mm thick sample of each sound absorbing material for 5 minutes, the temperature was measured on the opposite side of the sample.
    [0137] The temperature measured on the opposite side of the sound-absorbing material was 250°C for Example 1 and 350°C for Comparative Example 1. Thus, the sound-absorbing material according to an exemplary embodiment of the present invention of the which thermosetting resin has been improved can have improved heat insulation performance. In contrast, the thermoplastic resin impregnated sound-absorbing material test sample of Comparative Example 3 was melted as soon as heat of 1000°C was applied.
    [0138] In this way, the sound-absorbing material according to an exemplary embodiment of the present invention can obtain superior heat insulating property.
    [0139] Test Example 5. Comparison of heat insulating performance with aluminum heat insulating plate
    [0140] In Test Example 5, the heat insulating performance of the sound absorbing material from Example 1 was compared with that of the heat insulating aluminum plate. By applying the same heat from one side of the sound-absorbing material and the heat-insulating plate at 250°C, the temperature on the opposite side of the sound-absorbing materials was measured with time. The results are shown in Fig. 5.
    [0141] As seen from Fig. 5, the sound-absorbing material according to an exemplary embodiment of the present invention can have improved heat insulation performance by decreasing the transferred temperature by at least 11°C as compared to aluminum plate heat insulating.
    [0142] Test Example 6. Comparison of the properties of sound absorbing materials depending on adhesive content
    [0143] The test samples of the sound absorbing material were prepared as described in Example 1. The epoxy resin impregnated aramid non-woven fabric was dried to have different final adherent contents. The tackifier content can be represented as parts by weight of tackifier included in the sound absorbing material based on 100 parts by weight of dry non-woven fabric.
    [0144] The results of the comparison of the mechanical properties and sound absorption rate of the sound absorbing materials of Examples and Comparative Examples with different adhesive contents are shown in Table 4 and Table 5. TABLE 4

    TABLE 5

    [0145] In Table 4 and Table 5, the sound absorption rate can be improved as the adherent is impregnated in the non-woven fabric compared to the non-woven fabric which is not impregnated with the adherent. Therefore, the sound absorption rate of the sound absorbing material can be controlled with the content of the adherent.
    [0146] Test Example 7. Comparison of the properties of sound absorbing material depending on the types of adherents
    [0147] Sound-absorbing materials in which 50 parts by weight of an adhesive has been impregnated on the basis of 100 parts by weight of an aramid nonwoven fabric can be prepared as described in Example 1. The resins described in Table 6 were used as the adherent.
    [0148] The results of comparing the mechanical properties and sound absorption rate of the sound absorbing materials of Examples and Comparative Examples with composition of different adherents are shown in Table 6. TABLE 6
    权利要求:
    Claims (32)
    [0001]
    1. SOUND-ABSORBING MATERIAL (1), characterized in that it comprises: a non-woven fabric (10) comprising an amount from 30% by weight to 100% by weight of a heat resistant fiber; and an adhesive (15) impregnated in the same layer as the non-woven fabric (10) and maintaining a three-dimensional shape within the non-woven fabric (10), wherein the adhesive (15) is distributed and fixed to the surface of the fiber strand of the fabric. non-woven (10), thereby maintaining the structure of or facilitating the formation of micro-cavities of the non-woven fabric (10).
    [0002]
    2. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the heat resistant fiber has an oxygen limit index (LOI) of 25% or more and a heat resistance temperature in a range of 150° C or more.
    [0003]
    3. SOUND-ABSORBING MATERIAL (1) according to claim 2, characterized in that the heat resistant fiber is one or more selected from the group consisting of aramid fiber, polyphenylene sulfide fiber (PPS), polyacrylonitrile fiber oxidized fiber (oxy-PAN), polyimide fiber (PI), polybenzimidazole fiber (PBI), polybenzoxazole fiber (PBO), polytetrafluoroethylene fiber (PTFE), polyketone fiber (PK), metallic fiber, carbon fiber, fiber of glass, basalt fiber, silicon fiber and ceramic fiber.
    [0004]
    4. SOUND-ABSORBING MATERIAL (1), according to claim 3, characterized in that the heat-resistant fiber is an aramid fiber.
    [0005]
    5. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the non-woven fabric (10) is a single-layer non-woven fabric (10) formed from an aramid fiber having a fineness in a range of 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier) and having a thickness in a range of 3 mm to 20 mm.
    [0006]
    6. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the non-woven fabric (10) has a density in a range from 100 g/m2 to 2000 g/m2.
    [0007]
    7. SOUND-ABSORBING MATERIAL (1), according to claim 5, characterized in that the non-woven fabric (10) has a density in a range from 200 g/m2 to 1200 g/m2.
    [0008]
    8. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the adhesive (15) is a thermostable resin.
    [0009]
    9. SOUND-ABSORBING MATERIAL (1), according to claim 8, characterized in that the thermostable resin is an epoxy resin.
    [0010]
    10. SOUND-ABSORBING MATERIAL (1) according to claim 9, characterized in that the epoxy resin is one or more selected from the group consisting of diglycidyl A biphenolic ether, diglycidyl B biphenolic ether, diglycyl AD biphenolic ether, diglycidyl ether F biphenolic, diglycidyl S biphenolic ether, polyoxypopylene diglycidyl ether, biphenolic diglycidyl ether polymer, diglycidyl phosphazene ether, biphenolic novolac A epoxy, phenolic novolac epoxy and o-cresol epoxy novolac resin.
    [0011]
    11. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the sound-absorbing material is shaped to have a three-dimensional shape to which the sound-absorbing material is applied.
    [0012]
    12. SOUND-ABSORBING MATERIAL (1), according to claim 1, characterized in that the sound-absorbing material is formed in a single layer or multiple layers.
    [0013]
    13. SOUND-ABSORBING MATERIAL (1), according to any one of claims 1 to 12, characterized in that the sound-absorbing material is used in a vehicle.
    [0014]
    14. . METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), characterized by immersing a non-woven fabric (10) comprising an amount of 30% by weight to 100% by weight of a heat resistant fiber in an adherent solution; and drying the non-woven fabric (10), wherein the adherent (15) is distributed and attached to the surface of the fiber strand of the non-woven fabric (10), thereby maintaining the structure of or facilitating the formation of micro-cavities of the non-woven fabric. plot (10).
    [0015]
    15. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to claim 14, characterized in that it further comprises, after said drying of the non-woven fabric (10), the preparation of the sound-absorbing material by shaping the non-woven fabric (10) dried at elevated temperature.
    [0016]
    16. METHOD FOR PREPARATION OF THE SOUND ABSORBENT MATERIAL (1), according to claim 14, characterized in that the heat resistant fiber has an oxygen limit index (LOI) of 25% or more and a heat resistance temperature of 150 °C or more.
    [0017]
    17. METHOD FOR PREPARATION OF SOUND-ABSORBING MATERIAL (1), according to claim 16, characterized in that the heat resistant fiber is one or more selected from the group consisting of aramid fiber, polyphenylene sulfide fiber (PPS) , oxidized polyacrylonitrile fiber (oxy-PAN), polyimide fiber (PI), polybenzimidazole fiber (PBI), polybenzoxazole fiber (PBO), polytetrafluoroethylene fiber (PTFE), polyketone fiber (PK) , metallic fiber, fiber carbon, fiberglass, basalt fiber, silicon fiber and ceramic fiber.
    [0018]
    18. METHOD FOR PREPARATION OF THE SOUND-ABSORBING MATERIAL (1), according to claim 14, characterized in that the heat resistant fiber is an aramid fiber having a fineness in a range of 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier) having a wire length in a range of 20 mm to 100 mm.
    [0019]
    19. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to claim 14, characterized in that the non-woven fabric (10) has a thickness in a range of 3 mm to 20 mm and a density in a range of 100 g /m2 to 2000 g/m2.
    [0020]
    20. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to claim 15, characterized in that it comprises, prior to said immersion of the non-woven fabric (10), the formation of a non-woven fabric (10) of aramid having a thickness in a range of 3mm to 20mm by needle punching a heat resistant aramid fiber having a fineness in a range of 1 gram per 900 meters (1 denier) to 1 gram per 600 meters (15 denier) .
    [0021]
    21. METHOD FOR PREPARATION OF THE SOUND-ABSORBING MATERIAL (1), according to claim 20, characterized in that the non-woven fabric (10) is formed by continuously performing needling from top to bottom, needling from bottom to top and needling from top to low.
    [0022]
    22. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to claim 20, characterized in that the non-woven fabric (10) is formed with a needle stroke in a range from 30 times/m2 to 350 times/m2.
    [0023]
    23. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to any one of claims 14, 15 or 20, wherein the sticky solution is characterized in that it comprises an amount of 1% by weight to 60% by weight of a adherent (15), an amount of 0.1% by weight to 10% by weight of a curing agent, an amount of 0.01% by weight to 5% by weight of a catalyst, an amount of 1% by weight to 40% by weight of an additive and a solvent as the remainder, based on the total weight of the adherent solution.
    [0024]
    24. METHOD FOR PREPARING THE SOUND-ABSORBING MATERIAL (1), according to claim 23, wherein the sticky solution is characterized in that it comprises an amount of 1% by weight to 30% by weight of an adherent (15), an amount of 0.1% by weight to 10% by weight of a curing agent, an amount of 0.01% by weight to 5% by weight of a catalyst, an amount of 1% by weight to 30% by weight of a flame retardant and an amount of 40% by weight to 95% by weight of a solvent, based on the total weight of the sticky solution.
    [0025]
    25. METHOD FOR PREPARATION OF THE SOUND ABSORBENT MATERIAL (1), according to claim 14, characterized in that the adhesive (15) is a thermostable resin.
    [0026]
    26. METHOD FOR PREPARATION OF THE SOUND ABSORBENT MATERIAL (1), according to claim 25, characterized in that the thermostable resin is an epoxy resin.
    [0027]
    27. METHOD FOR PREPARATION OF THE SOUND ABSORBENT MATERIAL (1), according to claim 26, characterized in that the epoxy resin is one or more selected from the group consisting of diglycidyl A biphenolic ether, diglycidyl B biphenolic ether, diglycyl AD biphenolic ether , diglycidyl F biphenolic ether, diglycidyl S biphenolic ether, diglycidyl polyoxypopylene ether, diglycidyl A biphenolic ether polymer, diglycidyl phosphazene ether, biphenolic novolac A epoxy, phenolic novolac epoxy and o-cresol epoxy novolac resin.
    [0028]
    28. METHOD FOR PREPARATION OF THE SOUND-ABSORBING MATERIAL (1), according to claim 14, characterized in that drying is carried out at a temperature in a range from 70°C to 200°C and the dry non-woven fabric (10) comprises an amount of 1 part to 300 parts by weight of an adherent (15) based on 100 parts by weight of the non-woven fabric (10).
    [0029]
    29. METHOD FOR PREPARATION OF THE SOUND-ABSORBING MATERIAL (1), according to any one of claims 14 to 28, characterized in that the sound-absorbing material is for an automobile.
    [0030]
    30. METHOD FOR NOISE REDUCTION OF THE NOISE GENERATING DEVICE, characterized in that it comprises: i) verification of a three-dimensional structure of the noise generating device; ii) preparation and modeling of a sound-absorbing material (1), as defined in any one of claims 1 to 12, in the three-dimensional structure of the device partially or completely; and iii) locating the sound absorbing material adjacent to the noise generating device.
    [0031]
    31. METHOD FOR NOISE REDUCTION OF THE NOISE GENERATING DEVICE, according to claim 30, characterized in that the device is an engine, a mechanism or an exhaust system.
    [0032]
    32. METHOD FOR REDUCING THE NOISE OF THE NOISE GENERATING DEVICE, according to claim 30, characterized in that the sound-absorbing material (1) is placed adjacent to the noise-generating device securing the sound-absorbing material to the noise-generating device, providing the sound-absorbing material with a distance from the noise-generating device or shaping the sound-absorbing material as a part of the noise-generating device.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112014031545B1|2021-08-24|SOUND ABSORBENT MATERIAL; METHOD FOR PREPARATION OF SOUND-ABSORBING MATERIAL; AND METHOD FOR NOISE REDUCTION OF THE NOISE GENERATING DEVICE
    RU2671058C1|2018-10-29|Sound-absorbing and insulating material having improved heat resistance and mouldability and method for producing same
    BR112016014046B1|2021-06-29|SOUND ABSORBENT AND INSULATING MATERIAL; METHOD FOR MANUFACTURING SOUND ABSORBENT AND INSULATING MATERIAL; AND METHOD TO REDUCE NOISE FROM A NOISE GENERATING DEVICE
    BR112015010321B1|2021-05-11|method for manufacturing a highly heat resistant sound absorbing and insulating material; and method for noise reduction of a noise generating device
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    同族专利:
    公开号 | 公开日
    DE102012218319A1|2013-12-24|
    CN103510274A|2014-01-15|
    RU2014153114A|2016-08-10|
    TR201910288T4|2019-07-22|
    CA2875109A1|2013-12-27|
    EP2865570A1|2015-04-29|
    AU2013278082B2|2017-04-13|
    MX2014015996A|2015-07-23|
    MY165735A|2018-04-20|
    MX353271B|2018-01-08|
    CN103510274B|2017-04-12|
    JP2015529834A|2015-10-08|
    KR20130142962A|2013-12-30|
    CN104395147B|2017-08-08|
    BR112014031545A2|2017-06-27|
    WO2013191474A1|2013-12-27|
    EP2865570A4|2016-03-02|
    CA2875109C|2019-11-12|
    US20130341121A1|2013-12-26|
    AU2013278082A1|2015-01-22|
    EP2865570B1|2019-05-22|
    KR101372073B1|2014-03-07|
    US9190045B2|2015-11-17|
    US20150233112A1|2015-08-20|
    AU2013278082A2|2015-02-19|
    JP6290198B2|2018-03-07|
    CN104395147A|2015-03-04|
    US20150259904A1|2015-09-17|
    US9412355B2|2016-08-09|
    ES2731897T3|2019-11-19|
    RU2667584C2|2018-09-21|
    ZA201409209B|2016-01-27|
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-01-14| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-04-20| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2021-08-03| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-08-24| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 19/06/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    KR10-2012-0066309|2012-06-20|
    KR20120066309|2012-06-20|
    PCT/KR2013/005424|WO2013191474A1|2012-06-20|2013-06-19|Sound absorbing and screening material and method for manufacturing same|
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