• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    METHOD FOR MANUFACTURING A SOUND ABSORPTION MATERIAL, AND SOUND ABSORPTION MATERIAL. The present invention relates to a sound-absorbing material with excellent sound-absorbing performance and a method for manufacturing the same. More particularly, it relates to a material for sound absorption, which can improve sound absorption coefficient and transmission loss by forming large surface area and air layer, so as to induce loss of viscosity of the incident sound energy, can make lightweight design possible because it can express excellent sound absorption performance even using reduced amount of fiber, and can improve sound absorption performance by using a glutinant fiber having rebound resilience, so that maintain sufficient strength between fiber and also maximize the loss of viscosity of sound energy transmitted to the fiber structure; and a method for making the same.
    公开号:BR112015006971B1
    申请号:R112015006971-1
    申请日:2013-09-26
    公开日:2021-07-13
    发明作者:Hyo Seok Kim；Do Hyun Kim；Chi Hun Kim；Kie Youn Jeong；Bong Hyun Park；Jung Wook Lee
    申请人:Hyundai Motor Company；Kia Motors Corporation；Toray Advanced Materials Korea Inc；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [001] The present invention relates to a material for sound absorption with excellent sound absorption performance and a method for manufacturing the same. More particularly, it refers to a sound-absorbing material with excellent sound-absorbing performance, which can be used for blocking the inflow of external noise into the vehicle interior when being connected as vehicle components or interior materials or exteriors of a vehicle body and can be used in electrical devices and the like that use engine parts in order to improve their noise isolation performance. HISTORY OF THE TECHNIQUE
    [002] In general, noise introduced into a vehicle can be classified as noise generated in an engine and introduced through a vehicle body and noise generated when tires contact a road surface and introduced through a body of the vehicle. There can be two ways to block these noises such as improving sound absorption performance and improving noise isolation performance. Sound absorption means that the generated sound energy is converted to thermal energy and then dissipated as it is transmitted through the internal path of a material, and noise isolation means that the generated sound energy is reflected and blocked by a shelter.
    [003] According to such sound characteristics, in order to improve the Noise, Vibration & Harshness (NVH) of a vehicle in general, a heavier and thicker material for sound absorption has been mainly used in luxury cars . However, when such sound absorbing material is used, noise can be reduced, but there is a problem of deteriorating fuel efficiency by increasing vehicle weight.
    [004] Furthermore, in order to overcome material problems for conventional sound absorption, a method in which the porosity of the material is improved by thinning the fiber thickness has been developed, thereby improving sound absorption performance and also reducing the weight of the fiber aggregate. However, this method may also have a weakness such that the fiber aggregate surface density requirement can be improved in order to improve the desired NVH performance.
    [005] Furthermore, in order to manufacture the non-woven type fiber aggregate, staple fiber and binder fiber are mixed in an appropriate ratio. As the binder fiber, in general, staple fiber made of conjugate-spun regular polyester is used for an inner layer and polyester with a low melting point is used for an outer layer.
    [006] However, when using this conventional binder fiber with low melting polyester, the fiber aggregate is hardened and so there may be a problem that the vibration generated by the propagation of the sound wave and transmitted to the matrix structure does not it is fully attenuated, thus reducing the sound absorption coefficient mainly in the low-frequency region. SUMMARY OF THE INVENTION
    [007] The present invention has been made in an effort to solve the above-described problems associated with the prior art.
    [008] The present invention aims to provide a material for sound absorption that can improve the sound absorption coefficient and the transmission loss by the formation of large surface area and air layer, in order to maximize the loss of viscosity and the incident sound energy dissipation path, and make possible the light design of the same because it can realize excellent sound absorption performance even using reduced amount of fiber; and a method for making the same.
    [009] In addition, the present invention aims to provide a material for sound absorption, which can improve malleability as well as maintain sufficient resistance between the fiber and may have improved rebound resilience, thus ultimately having excellent ability to attenuation of vibration against sound energy transmitted within the matrix; and a method for making the same.
    [010] To achieve the above objectives, in one aspect, the present invention provides a method for manufacturing a material for sound absorption which comprises the formation of fiber aggregate in a form of non-woven fabric and fiber aggregate understands:
    [011] a fiber with a non-circular shape that satisfies the following formula 1; and
    [012] the binder fiber that partially binds a plurality of non-circular shaped fibers.
    [013] Formula 1

    [014] (A: Cross-sectional area of the fiber (μm2), P: Length of fiber cross section circumference (μm))
    [015] In a preferred embodiment, the material for sound absorption can be manufactured by using fiber with a non-circular shape that satisfies the formula 1 value of 2.6 or greater.
    [016] In another preferred embodiment, the material for sound absorption can be manufactured by using fiber with a non-circular shape that satisfies the formula 1 value of 3.0 or greater.
    [017] In yet another preferred embodiment, the fiber with a non-circular shape can be at least one selected from the group consisting of a star shape with six points, flat type with 3 bars, 6 leaves type, 8 leaves type and wave type .
    [018] In yet another preferred embodiment, the non-circular shaped fiber can be 35 to 65 mm in length.
    [019] In yet another preferred embodiment, the binder fiber may comprise a low melting point (LM) elastomer having elastic recovery modulus of 50 to 80%, and the material's rebound resilience rate for sound absorption may be from 50 to 80%.
    [020] In a further preferred embodiment, the binder fiber may be conjugated fiber which is spun conjugated by using the LM elastomer as a component.
    [021] In another further preferred embodiment, the LM elastomer can be at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer and a polyurethane-based polymer.
    [022] In yet another additional preferred embodiment, the LM elastomer can be manufactured by the esterification and polymerization steps using dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) or terephthalic acid (TPA) and isophthalic acid (IPA) as an acidic ingredient (Diacid) and 1,4-butanediol (1,4-BD) and polytetramethylene glycol (PTMG) as a diol ingredient (Diol).
    [023] In yet another additional preferred embodiment, the sound-absorbing material can be manufactured by using the non-circular shaped fiber from 50 to 80% by weight based on the total weight of the sound-absorbing material and the fiber. 20 to 50% by weight binder based on the total weight of the sound absorbing material.
    [024] In addition, in another aspect, the present invention provides a material for sound absorption, which may comprise: a fiber with a non-circular shape that satisfies the following formula 1; and a binder fiber that partially binds a plurality of non-circular shaped fibers.
    [025] Formula 1

    [026] (A: Fiber cross-sectional area (μm2), P: Fiber cross-sectional circumference length (μm))
    [027] In a preferred embodiment, the non-circular shaped fiber can satisfy a Formula 1 value of 2.6 or greater.
    [028] In another preferred embodiment, the fiber with non-circular shape can be at least one selected from the group consisting of a star shape with six points, flat type with 3 bars, 6 leaves type, 8 leaves type and wave type.
    [029] In yet another preferred embodiment, the non-circular shaped fiber can be 35 to 65 mm long.
    [030] In yet another preferred embodiment, the non-circular shaped fiber can be 1.0 to 7.0 De in fineness.
    [031] In yet another preferred embodiment, the binder fiber can comprise an LM elastomer having elastic recovery modulus of 50 to 80% and the rebound resilience rate of the material for sound absorption can be 50 to 80%.
    [032] In a further preferred embodiment, the binder fiber may be conjugated fiber which is spun conjugated by using the LM elastomer as a component.
    [033] In another further preferred embodiment, the LM elastomer can be at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer and a polyurethane-based polymer.
    [034] In yet another further preferred embodiment, the sound-absorbing material may comprise the non-circular shaped fiber from 50 to 80% by weight based on the total weight of the sound-absorbing material and the binder fiber of 20 at 50% by weight based on the total weight of the material for sound absorption.
    [035] In yet another additional preferred embodiment, the non-circular shaped fiber can satisfy the formula 1 value of 3.0 or greater.
    [036] In the following, the terms used in the present invention will be described.
    [037] The term "wave-type non-circular shaped fiber", as used in the present invention, refers to the fiber that can have a transverse waveform shape and, specifically, its shape is illustrated in Figure 5.
    [038] The sound absorption material with excellent sound absorption performance of the present invention can improve the sound absorption coefficient and transmission loss by forming large surface area and air layer, so as to induce loss of viscosity of the incident sound energy. In addition, it makes light design of it possible as it can provide excellent sound absorption performance using reduced amount of fiber and can improve sound absorption performance by using binder fiber having rebound resilience so as to maintain sufficient bond strength between the fibers and also maximize the loss of sound energy viscosity transmitted to the fiber structure.
    [039] Consequently, a sound-absorbing material having excellent sound-absorbing performance, which can be used to improve the noise isolation performance of electrical devices and the like using engine parts as well as used through transport such as vehicle, train, ship, plane and the like and a method for manufacturing the same can be provided. BRIEF DESCRIPTION OF THE DRAWINGS
    [040] Figure 1 is a non-circular star-shaped fiber with six tips, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [041] Figure 2 is a fiber with a flat type non-circular shape with 3 bars, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [042] Figure 3 is a 6-ply type non-circular shaped fiber, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [043] Figure 4 is an 8-ply type non-circular shaped fiber, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [044] Figure 5 is a wave-type non-circular shaped fiber, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [045] Figure 6 is an 8-ply type non-circular shaped fiber, which is contained in the material for sound absorption according to a preferred embodiment of the present invention;
    [046] Figure 7 is an 8-ply type non-circular shaped fiber, which is contained in the material for sound absorption according to a preferred embodiment of the present invention; and
    [047] Figure 8 is a drawing showing L and W fiber with non-circular format type 8 sheets according to a preferred embodiment of the present invention as an example. DETAILED DESCRIPTION
    [048] In the following reference will be made in detail to various embodiments of the present invention, examples of which are illustrated in the attached drawings and described below. While the invention will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention to those exemplary embodiments. Rather, the invention is intended to cover not only exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
    [049] As described above, since in conventional sound absorption material for a fiber structure, the surface density and thickness of the fiber aggregate are increased in order to improve sound absorption performance and insulation performance of noise by increasing the porosity and dissipation path of the sound wave, the vehicle becomes heavy, thereby deteriorating fuel efficiency. In addition, when low melting polyester fiber binder is used for conventional sound absorbing material for a fiber structure, the fiber aggregate can be hardened. Thus, there was a problem that the absorption coefficient of low frequency sound is reduced since the vibration generated by the propagation of the sound wave and transmitted to the matrix structure is not fully attenuated.
    [050] Consequently, the present invention provides a material for sound absorption comprising: a fiber with a non-circular shape that satisfies the following formula 1; and a binder fiber that partially binds a plurality of non-circular shaped fibers to find solutions to the problems described above.
    [051] Formula 1

    [052] (A: Fiber cross-sectional area (μm2), P: Fiber cross-sectional circumference length (μm))
    [053] As such, the sound absorption coefficient and the transmission loss can be improved by the formation of large surface area and air layer, so as to induce the loss of viscosity of the incident sound energy. In addition, the lightweight design of it can be obtained because excellent sound absorption performance can be obtained using reduced amount of fiber and sound absorption performance can be improved by using binder fiber having rebound resilience, so as to keep sufficient fiber bond strength and also maximize the loss of viscosity of sound energy transmitted to a fiber structure. Thus, a sound-absorbing material having excellent sound-absorbing performance, which can be used to improve the noise isolation performance of electrical devices and the like using engine parts as well as used through transportation such as vehicle, train. , ship, plane and the like and a method for manufacturing the same can be provided.
    [054] In general, when the sound wave conflicts with a certain material, it can cause the loss of viscosity, thereby causing noise reduction while the mechanical energy of the sound wave is converted into thermal energy. In order to reduce noise by increasing the rate of energy loss against the sound wave introduced into the fiber aggregate of the same weight, it is advantageous to increase the fiber surface area where the loss of sound wave viscosity occurs.
    [055] Non-circular shaped fiber satisfies the n value of 1.5 or greater, calculated as:

    [056] (A: Fiber cross-sectional area (μm2), P: Fiber cross-sectional circumference length (μm)), and can guarantee greater surface area than the fiber used for the material for conventional sound absorption for fiber structure and improve sound absorption coefficient and transmission loss. When the n value is less than 1.5, the fiber surface area may be small. So, there is a problem that the lightweight design of the same can be impossible because a large amount of fiber needs to effectively realize the sound absorption performance. The largest n value means the largest fiber surface area. Consequently, more preferably, the non-circular shaped fiber used in the present invention may have the n value of 2.6 or greater, and more preferably the value may be 3.0 to 7.0. If the n value of the non-circular shaped fiber used in the present invention is greater than 7.0, there may be a problem that the production cost may be increased due to the increased production cost of the nozzle, replacement of facilities related to the improvement cooling efficiency, polymer modification to improve solidification rate, productivity reduction and the like.
    [057] The non-circular shaped fiber of the present invention, which satisfies the n value of 1.5 or greater, can be a star-shaped with six points, flat type with 3 bars, 6-ply type, 8-ply type or wave type or a combination thereof. In the case of the wave type, when the value n satisfies 1.5 or greater, the specific shape such as the number of the curved point in the waveform, length and width of the cross section and the like may vary. The waveform curved point number means the point where the direction is changed to the cross section length direction and, for example, the curved point number of the non-circular wave type fiber in figure 5 is 4.
    [058] Specifically, figure 1 is star-shaped fiber with six points with non-circular shape according to a preferred embodiment of the present invention and its n value is 1.51 and figure 2 is fiber with non-circular shape flat type with 3 bars according to a preferred embodiment of the present invention and its n value is 1.60. Furthermore, Figure 3 is 6-ply type non-circular shaped fiber according to a preferred embodiment of the present invention and its n value is 1.93, Figure 4 is 8-ply type non-circular shaped fiber according to a preferred embodiment of present invention and its n value is 2.50, Figure 5 is non-circular shaped fiber wave type according to a preferred embodiment of the present invention and its n value is 2.55, Figure 6 is non-circular shaped fiber 8-ply type according to a preferred embodiment of the present invention and its n value is 2.8 and Figure 7 is 8-ply type non-circular shaped fiber according to a preferred embodiment of the present invention and its n-value is 3.2 .
    [059] The n value of a general circular fiber with circular cross section is 1.0 and its sound absorption coefficient and transmission loss are significantly reduced because its surface area is not large enough (see Comparative Example 1 ) and although the fiber with a non-circular shape has a star shape with six points, flat type with 3 bars, 6 sheet type, 8 sheet type or wave type, if the n value does not satisfy 1.5 or greater, the surface area that can generate loss of viscosity of sound energy is not sufficient. Consequently, those are not suitable as the non-circular shaped fiber used for the sound absorbing material of the present invention (see Comparative Examples 2 to 5).
    [060] More preferably, the non-circular shaped fiber used in the present invention can have the value L/W from 2 to 3. L is the abbreviation for Length which is the vertical length of the fiber, and W is the abbreviation for Width which is the length against the horizontal direction connecting between the angular points. Specifically, Figure 8 shows L and W values of the 8-ply non-circular shaped fiber. In the case of 8-ply non-circular shaped fiber cross-section, when the longest direction is called vertical length, the length can be expressed as L, and in the shorter format 3, the distance between angular points can be expressed as W.
    [061] In addition, the non-circular shaped fiber used in the present invention may have 6 to 8 angle points more preferably, but it is not limited to L/W or the number of angle points. Fiber with a non-circular shape that satisfies an n value of 1.5 or greater may be preferred.
    [062] The length of the non-circular shaped fiber can be 35 to 65 mm. When it is less than 35mm, it can be difficult to form and produce the fiber aggregate due to the large gap between fibers and sound absorption, and noise isolation performance may be reduced due to excess porosity. When it is above 65mm, the porosity can be reduced due to the very narrow gap between the fibers, thereby reducing the sound absorption coefficient. In addition, the fineness of non-circular shaped fiber can be 1.0 to 7.0 De and may be more effective for sound absorption performance as the fineness becomes lower. When the fineness of the non-circular shaped fiber is less than 1.0 De, there may be a problem controlling the ideal shape of the target cross section and when it is greater than 7.0 De (denier), there may be a difficulty in non-woven fiber fabrication process and a problem of reduced sound absorption performance when it is fabricated as fiber aggregate.
    [063] The non-circular shaped fiber material included in the material for sound absorption of the present invention may preferably be polyethylene terephthalate (PET), but not particularly limited thereto. Polypropylene (PP), rayon and any polymer that can be spun into fiber form can preferably be used as a material for sound absorption.
    [064] In addition, the material for sound absorption of the present invention contains binder fiber that partially binds a plurality of non-circular shaped fibers.
    [065] The fiber binder can be any fiber binder that is generally used when making the fiber structure and it can be used in powder form as well as fiber and, more particularly, it can contain elastomer with a low melting point (LM) . Elastomer generally refers to a polymer material having excellent elasticity, such as rubbers, and that is, it means a polymer having a characteristic that extends when it is pulled by an external force and it is back to its original length when the external force is removed. The preferred LM elastomer used in the present invention can have elastic recovery modulus of 50 to 80%. When the elastic recovery modulus is less than 50%, the fiber aggregate is hardened and sound absorption performance can be reduced due to short flexibility. When it is greater than 80%, there can be problems that the processability can be reduced when manufacturing the fiber aggregate, as well as the production cost of the polymer itself can be increased.
    [066] In the past, after the binder fiber was fused and the main rebound fiber together, the fiber aggregate was stiffened such that there was a problem that the sound absorption coefficient was reduced due to the vibration generated by the propagation of the sound wave and transmitted to the matrix structure is not fully attenuated. However, in the present invention, the rebound resilience ratio (ASTM D 3574) of the fiber structure is increased up to 50 to 80% by containing an LM elastomer having an elastic recovery modulus of 50 to 80% in the fiber aggregate of the fiber and the attenuation capacity for the vibration that is finally transmitted into the matrix is improved, and thus the sound absorption coefficient and the transmission loss can be improved.
    [067] The LM elastomer can be a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer, or a polyurethane-based polymer or combinations thereof.
    [068] In addition, more preferably, the LM elastomer can be manufactured by the esterification and polymerization steps using dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) or terephthalic acid (TPA) and isophthalic acid (IPA) as an acidic ingredient ( diacid); and 1,4-butanediol (1,4-BD) and polytetramethylene glycol (PTMG) as a diol ingredient (Diol).
    [069] The acid ingredient (Diacid) uses dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) or terephthalic acid (TPA) and isophthalic acid (IPA). Dimethyl terephthalate (DMT) and terephthalic acid (TPA) form a crystalline region by reaction with the diol ingredient and dimethyl isophthalate (DMI) and isophthalic acid (IPA) form a non-crystalline region by reaction with the diol ingredient, thus , providing function and elasticity with low melting point.
    [070] The mixing ratio of dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) can be a molar ratio of 0.65~0.80: 0.2~0.35, preferably and the mixing ratio of terephthalic acid (TPA) and isophthalic acid (IPA) can also be molar in the ratio of 0.65~0.80:0.2~0.35, preferably. When the molar ratio of dimethyl isophthalate (DMI) and isophthalic acid (IPA) is less than the range described above, the elastic recovery modulus may be deteriorated, and the low melting point function may not be expressed. When the molar ratio of dimethyl isophthalate (DMI) and isophthalic acid (IPA) is greater than the range described above, the physical properties may deteriorate.
    [071] The diol ingredient (Diol) uses 1,4-butanediol (1,4-BD), polytetramethylene glycol (PTMG) and 1,4-butanediol forms a crystalline region by reaction with the acid ingredient and polytetramethylene glycol (PTMG) forms a non-crystalline region by reaction with the acidic ingredient, thus providing function and elasticity with low melting point.
    [072] The mixing ratio of 1,4-butanediol (1,4-BD), polytetramethylene glycol (PTMG may be a molar ratio of 0.85~0.95: 0.05~0.15, preferably. Molar ratio of polytetramethylene glycol (PTMG) is less than the range described above, the elastic recovery modulus may be deteriorated and the function with low melting point cannot be expressed. When the molar ratio of polytetramethylene glycol (PTMG) is greater than In the range described above, physical properties may deteriorate 1,4-Butanediol (1,4-BD) can be used as a mixture with ethylene glycol (EG) within the range described above.
    [073] Furthermore, the molecular weight of polytetramethylene glycol (PTMG) can be in a range of 1500 to 2000, preferably. When the molecular weight of polytetramethylene glycol (PTMG) is out of said range, the elasticity and physical properties of the LM elastomer to be manufactured may not be suitable for use.
    [074] The acid ingredient and the diol ingredient can be mixed in the molar ratio of 0.9~1.1:0.9~1.1 and polymerized preferably. When any ingredient between the acidic ingredient and the diol ingredient is excessively mixed, it is not used to be polymerized and discarded. Consequently, it is preferred to mix the acidic ingredient and the diol ingredient in similar amounts.
    [075] As described above, LM elastomer manufactured from dimethyl terephthalate (DMT), dimethyl isophthalate (DMI) as the acid ingredient (Diacid) and 1,4-butanediol (1,4-BD), polytetramethylene glycol (PTMG) as the diol ingredient (Diol) is manufactured to have melting point of 150~180°C and elastic recovery modulus of 50~80%.
    [076] In addition, the binder fiber of the material for sound absorption of the present invention may be a conjugated fiber that is spun conjugated by using the LM elastomer as a component. More preferably, it can be either a sheath-core or tiled type conjugate fiber. When the coating-core type conjugate fiber is formed, the LM elastomer can be used as a coating ingredient and general polyester can be used as a core ingredient. General polyester reduces production cost and acts as a support for the fiber and LM elastomer allows it to express elasticity and function with a low melting point.
    [077] Preferably, the binder fiber can be manufactured by using LM elastomer and general polyester in weight ratio of 40:60 ~ 60:40. When LM elastomer is contained by weight ratio of less than 40, elasticity and function with low melting point may deteriorate and when it is contained by weight ratio above 60, there is a problem of increased production cost.
    [078] The sound absorbing material may contain the non-circular shaped fiber from 50 to 80% by weight based on the total weight of the sound absorbing material and the binder fiber from 20 to 50% by weight based in the total weight of the material for sound absorption. When the content of the non-circular shaped fiber is less than 50% by weight, it can be difficult to achieve optimal sound absorption and noise insulation performances due to the reduced fiber surface area, but when the shaped fiber content non-circular is greater than 80% by weight, the binder fiber content becomes less than 20% by weight, relatively, and it can be difficult to maintain sufficient bond strength between the fiber. Thus, it can be difficult to form the material for sound absorption in a certain shape and the vibration, which is generated from the propagation of the sound wave and transmitted to the matrix structure, is not fully attenuated because the matrix structure is not strong, such that the absorption coefficient of sound at low frequency can be reduced. As the binder fiber content is increased by 20 to 50% by weight, the rebound modulus of elasticity (ASTM D 3574) increases by up to 50 to 80%.
    [079] This polymorphic cross-section fiber structure having excellent sound absorption performance is manufactured by a method for manufacturing a material for sound absorption which comprises forming the fiber aggregate in the form of non-woven fabric. The fiber aggregate comprises: a non-circular shaped fiber that satisfies the following formula 1; and binder fiber that partially binds a plurality of non-circular shaped fibers.
    [080] Formula 1

    [081] (A: Fiber cross-sectional area (μm2), P: Fiber cross-sectional circumference length (μm))
    [082] The material for sound absorption can be manufactured by forming the fiber aggregate containing the non-circular shaped fiber and the binder fiber in the non-woven form having a certain surface density by the general manufacturing processes for a material for the sound absorption with fiber structure such as needle punching process or thermal adhesion process and the like. In the following, the detailed description of the non-circular shaped fiber and the binder fiber described above, which are identically applied to the method for manufacturing the material for sound absorption of the present invention will be omitted.
    [083] The following examples illustrate the invention and are not intended to limit it.EXAMPLE 1
    [084] The non-circular shaped fiber based on 8-ply polyester type (figure 4, n = 2.5) (6.5 De, 61 mm, strength 5.8 g/D, elongation rate 40%, number of 14.2/inch corrugations) and the coating-core type conjugate fiber containing polyester-based LM elastomer as the binder fiber were blended in an 8:2 weight ratio, the blend was physically decomposed by the needle punching process. after controlling the weight constantly and thereafter the non-woven type fiber aggregate having a thickness of 20 mm and a surface density of 1600 g/m2 was manufactured by a general thermal adhesion process. The rebound resilience of the fabricated material for sound absorption was 55%.
    [085] The coating-core type conjugate fiber containing polyester-based LM elastomer as the binder fiber contained polyester-based LM elastomer as a coating ingredient and the polyester-based LM elastomer used a 75% terephthalic acid blend in mol and 25 mol % isophthalic acid as an acid ingredient and a mixture of 8.0 mol % polytetramethylene glycol and 92.0 mol % 1,4-butanediol as a diol ingredient and manufactured by mixing and polymerizing the acid ingredient and diol ingredient in a 1:1 molar ratio. The LM elastomer manufactured as mentioned above has a melting point of 50 °C, an intrinsic viscosity of 1.4 and an elastic recovery modulus of 80%. As the core ingredient, polyethylene terephthalate (PET) having a melting point of 260°C and an intrinsic viscosity of 0.65 was used, and the conjugate fiber having a fineness of 6 D, strength of 3.0 g/D, rate of 80% elongation, 12/inch curl number and 64mm fiber length was fabricated by spinning using a conjugate spin nozzle, which can conjugate spin polyester-based LM elastomer and general PET at spinning temperature of 275 °C and winding speed of 1000 mm/min, stretched by 3.3 bends at 77 °C and finally heated to 140 °C.EXAMPLE 2
    [086] The procedure of example 1 was repeated except for the fabrication of non-woven type fiber structure having a thickness of 20 mm, surface density of 1200 g/m2.EXAMPLE 3
    [087] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the non-circular, star-shaped fiber with six tips (figure 1, n = 1.51).EXAMPLE 4
    [088] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the fiber with a flat type non-circular shape with 3 bars (figure 2, n = 1.60).
    [089] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using 6-ply non-circular shaped fiber (figure 3, n = 1.93)•EXAMPLE 6
    [090] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the non-circular wave type fiber (figure 5, n = 2.55).
    [091] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using 8-ply non-circular shaped fiber (figure 6, n = 2.8).
    [092] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using 8-ply non-circular shaped fiber (figure 7, n = 3.2).
    [093] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using PET fiber with low melting point as the binder fiber. The rebound resilience of the manufactured material for sound absorption was 30%. COMPARATIVE EXAMPLE 1
    [094] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using fiber with a circular shape (η = 1.0).
    [095] COMPARATIVE EXAMPLE 2
    [096] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using five-pointed non-circular star-shaped fiber (n = 1.30). COMPARATIVE EXAMPLE 3
    [097] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the non-circular wave type fiber (n = 1.42). COMPARATIVE EXAMPLE 4
    [098] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the Y-type non-circular shaped fiber (n = 1.26). COMPARATIVE EXAMPLE 5
    [099] The procedure of example 1 was repeated except for the fabrication of a material for sound absorption using the non-circular, star-shaped fiber with six tips (n = 1.41). TEST EXAMPLE
    [0100] In order to evaluate the sound absorption and noise insulation performances of materials for sound absorption manufactured according to Examples 1 to 9 and Comparative Examples 1 to 5, the materials were tested as the measurement methods below and the results are shown in Tables 1 and 2. 1. SOUND ABSORPTION COEFFICIENT
    [0101] In order to measure the sound absorption coefficient, 3 specimens applicable to ISO R 354, Alpha Cabin method were manufactured, respectively, the sound absorption coefficients were measured and the average of the measured sound absorption coefficients was shown in Table 1. 2. LOSS OF TRANSMISSION
    [0102] In order to measure the effect of noise isolation, 3 specimens applicable to the transmission loss coefficient evaluation device (APAMAT-II) were manufactured, respectively, insertion loss was measured and the average value of the loss of measured insertion was shown in Table 2. 3. ELASTIC RECOVERY MODULE
    [0103] A dumbbell shaped specimen having a thickness of 2 mm and a length of 10 cm was elongated 200% at a rate of 200%/min using Instron, waited for 5 sec, the elongated length after recovering the same rate was measured and then measured the elastic recovery modulus was calculated by the following formula.
    4. REBOUND RESILIENCE RATE (BALL REBOUND)
    [0104] After dropping a metal ball from a certain height onto a test specimen, the height of the rebound ball was measured (JIS K-6301, unit: %). The test specimen was transformed into a square having a side length of 50 mm or greater and a thickness of 50 mm or greater and a steel ball having a weight of 16 g and a diameter of 16 mm was dropped from a height of 500 mm into a test specimen and then the maximum rebound height was measured. Then, for every 3 test specimens, the rebound value was measured at least 3 times raw within 1 min and the mean value was used as the rebound resilience rate (%).


    [0105] As shown in Tables 1 and 2, when comparing the results of the measurement of sound absorption and noise insulation performances in Examples 1 to 9 and Comparative Examples 1 to 5, it was found that the sound absorption and insulation performances of the fiber aggregate noise were improved as fiber surface areas were increased.
    [0106] Specifically, when comparing the result of measuring the performances of Example 2 and Comparative Example 1, it was found that the material for sound absorption using the non-circular shaped fiber of the present invention had better sound absorption and performance. noise isolation than fiber sound absorption material using fiber with circular cross section generally used, despite the reduced surface density of fiber aggregate and therefore the light design of the same is possible using reduced amount of fiber.
    [0107] Examples 1 to 9 satisfying the n value of 1.5 or greater were found to have better sound absorption coefficient and transmission loss than comparative Examples 1 to 5 having the n value of less than 1.5. Comparative Example 5 having a value of less than 1.5 was also found to have low effect on sound absorption coefficient and transmission loss due to the small surface area, although the six-pointed star-shaped fiber with non-circular shape was used.
    [0108] Furthermore, when comparing the results of the measurement performances of Example 9 using PET fiber with low melting point as the binder fiber and Examples 1 to 8 using elastomer with low melting point, it was found that the flexible structure having rebound elasticity ratio of 55% was achieved by using elastomer with low melting point as the binder fiber, and the sound absorption performance was improved by the improved attenuation ability of the vibration transmitted to the matrix structure. .
    权利要求:
    Claims (18)
    [0001]
    1. METHOD FOR THE MANUFACTURING OF A SOUND ABSORPTION MATERIAL, characterized in that it comprises: formation of a fiber aggregate into a form of non-woven fabric, wherein the fiber aggregate comprises: a fiber with a non-circular shape that satisfies the following formula 1 and; a binder fiber that partially binds a plurality of non-circular shaped fibers, Formula 1
    [0002]
    2. METHOD, according to claim 1, characterized in that the sound-absorbing material is manufactured by using fiber with a non-circular shape that satisfies the value of formula 1 of 2.6 or greater.
    [0003]
    3. METHOD, according to claim 1, characterized in that the fiber with a non-circular shape is 35 to 65 mm in length.
    [0004]
    4. METHOD, according to claim 1, characterized in that the binder fiber comprises an elastomer (LM) with low melting point having elastic recovery modulus of 50 to 80%.
    [0005]
    5. METHOD, according to claim 4, characterized in that the binder fiber is a conjugated fiber that is conjugate-spun by using the LM elastomer as a component.
    [0006]
    6. METHOD according to claim 4, characterized in that the LM elastomer is at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polymer-based polyvinyl chloride and a polyurethane-based polymer.
    [0007]
    7. METHOD according to claim 4, characterized in that the LM elastomer is manufactured by the steps of esterification and polymerization using dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) or terephthalic acid (TPA) and isophthalic acid (IPA) as an ingredient acid(Diacid) and 1,4-butanediol(1,4-BD), polytetramethylene glycol (PTMG) as a diol ingredient (Diol).
    [0008]
    8. METHOD according to claim 1, characterized in that the sound-absorbing material is manufactured by using the fiber with a non-circular shape of 50 to 80% by weight based on the total weight of the sound-absorbing material and the binder fiber 20 to 50% by weight based on the total weight of the sound absorbing material.
    [0009]
    9. METHOD, according to claim 1, characterized in that the fiber with a non-circular shape meets the value of formula 1 of 3.0 or greater.
    [0010]
    10. SOUND ABSORPTION MATERIAL, characterized in that it comprises: a non-circular shaped fiber that satisfies the following formula 1 and; a binder fiber that partially binds a plurality of non-circular shaped fibers, Formula 1
    [0011]
    11. MATERIAL according to claim 10, characterized in that the fiber with a non-circular shape meets the formula 1 value of 2.6 or greater.
    [0012]
    12. MATERIAL according to claim 10, characterized in that the non-circular shaped fiber is 35 to 65 mm in length.
    [0013]
    13. MATERIAL according to claim 10, characterized in that the non-circular shaped fiber has 1.0 to 7.0 De in fineness.
    [0014]
    MATERIAL according to claim 10, characterized in that a binder fiber comprises an elastomer (LM) with low melting point having elastic recovery modulus of 50 to 80%.
    [0015]
    15. MATERIAL according to claim 14, characterized in that the binder fiber is conjugated fiber which is conjugated-spun by using the LM elastomer as a component.
    [0016]
    16. MATERIAL according to claim 14, characterized in that the LM elastomer is at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer and a polyurethane-based polymer.
    [0017]
    17. MATERIAL according to claim 10, characterized in that it comprises the non-circular shaped fiber from 50 to 80% by weight based on the total weight of the sound absorbing material and the binder fiber from 20 to 50% by weight with based on the total weight of the sound absorbing material.
    [0018]
    18. MATERIAL according to claim 10, characterized in that the fiber with a non-circular shape meets the formula 1 value of 3.0 or greater.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112015006971B1|2021-07-13|METHOD FOR MANUFACTURING A SOUND ABSORPTION MATERIAL AND SOUND ABSORPTION MATERIAL
    US6589643B2|2003-07-08|Energy conversion fiber and sound reducing material
    JP6961336B2|2021-11-05|Non-woven fabric board for automobile exterior and its manufacturing method
    KR20110034522A|2011-04-05|Sound absorption material using shaped yarn and thereof synthetic method
    JPH11152670A|1999-06-08|Carpet material and its production
    JP6764482B2|2020-09-30|Sound absorbing insulation
    JP2021535851A|2021-12-23|3D Thermoplastic Sandwich Panel Composite
    KR101651943B1|2016-08-31|Fibrous Assemblies including Shaped cross-section hollow fiber
    JPWO2018225568A1|2020-04-16|Fiber structure, molded body and sound absorbing material
    US10249281B2|2019-04-02|Felt, soundproofing material and method for producing soundproofing material
    EP3015582B1|2018-05-23|Moldable fabric comprising petg
    KR20170112581A|2017-10-12|Fiber composites having excellent sound-absorption and sound-insulation, Non-woven fabric containining the same and Preparing method thereof
    KR101915811B1|2018-11-07|Nonwoven fabric having good sound-absorbing
    KR101617797B1|2016-05-04|Shaped cross-section fiber containing low melting polymer and fibrous assemblies using thereof
    KR101875927B1|2018-08-02|Nonwoven fabric having good sound-absorbing
    KR20170112571A|2017-10-12|Fiber composites having excellent sound absorption, water absorption and heat insulation, Non-woven fabric containining the same and Preparing method thereof
    KR101775143B1|2017-09-05|Nonwoven having high heat-resistance and sound absorption performance
    KR102140509B1|2020-08-03|Underbody cover for automobiles and method for preparing the same
    JP3800083B2|2006-07-19|Damping and sound absorbing material using nonwoven fabric structure
    KR102003889B1|2019-07-26|Sheath Core Hollow Composite Fiber Excellent In Bulky Property
    US20210355607A1|2021-11-18|Polyester hollow fiber with excellent sound absorption
    KR20210016817A|2021-02-17|Sound absorbing intake air duct comprising low melting polyester fiber
    JP6772152B2|2020-10-21|Fibers for sound absorbing / insulating materials, use of the fibers, and fiber moldings for sound absorbing / insulating materials
    US20210174779A1|2021-06-10|Soundproof member
    KR20210007115A|2021-01-20|Fiber for sound absorbing material of vehicle and sound absorbing material for vehicle including the same
    同族专利:
    公开号 | 公开日
    RU2641875C2|2018-01-22|
    EP2902266B1|2018-03-21|
    BR112015006971A2|2017-07-04|
    US9523192B2|2016-12-20|
    CN104918826A|2015-09-16|
    IN2015DN02523A|2015-09-11|
    CA2886817A1|2014-04-03|
    US20150252562A1|2015-09-10|
    US20150204066A1|2015-07-23|
    EP2902266A1|2015-08-05|
    JP2016500831A|2016-01-14|
    BR112015006971A8|2019-08-20|
    RU2015113978A|2016-11-20|
    CA2886817C|2020-03-24|
    JP6587938B2|2019-10-09|
    KR101289129B1|2013-07-23|
    WO2014051351A1|2014-04-03|
    MX2015003983A|2015-10-08|
    CN104918826B|2018-07-31|
    EP2902266A4|2016-06-15|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US3226795A|1959-08-12|1966-01-04|Celanese Corp|Method for producing a high bulk filamentary material|
    US3425893A|1965-08-03|1969-02-04|James G Sims|Textile filaments|
    JPS6136036B2|1977-10-04|1986-08-15|Toray Industries|
    JPS62282071A|1986-05-27|1987-12-07|Toyo Boseki|Polyester synthetic fiber and its production|
    JPH04136217A|1990-09-21|1992-05-11|Toray Ind Inc|Elliptical uneven cross-sectional polyester fiber|
    KR0125494B1|1993-01-07|1997-12-24|타구치 케이타|Binder fiber and nonwoven fabric produced therefrom|
    DE19708188C2|1997-02-28|2001-05-10|Lohmann Gmbh & Co Kg|Soundproofing material|
    JP3519588B2|1997-09-12|2004-04-19|カネボウ株式会社|Carpet material and method of manufacturing the same|
    JP2000160485A|1998-11-30|2000-06-13|Unitika Ltd|Dyeing of polyamide crimped bulky textured yarn|
    JP3656732B2|2000-04-21|2005-06-08|日産自動車株式会社|Energy conversion fiber and sound absorbing material|
    JP3811956B2|2000-04-21|2006-08-23|日産自動車株式会社|Energy conversion fiber and sound absorbing material|
    US20040048036A1|2001-05-24|2004-03-11|Japan Vilene Company, Ltd.|Floor mat for automobile|
    KR100416100B1|2001-06-27|2004-01-24|대한솔루션|a sound absorbing and insulation material for automobile|
    US20030138594A1|2002-01-18|2003-07-24|Honeywell International, Inc., Law Dept.|Non-woven shaped fiber media loaded with expanded polymer microspheres|
    JP3498085B1|2003-03-26|2004-02-16|株式会社タケヒロ|Ultralight soundproof material|
    DE10324257B3|2003-05-28|2004-09-30|Clion Ireland Ltd., Newton|Acoustic insulation material, especially for use in automobiles, is of two bonded nonwoven layers with structured layers towards and away from the sound source|
    WO2004107314A1|2003-05-28|2004-12-09|Clion Ireland Holding Ltd.|Sound absorbent|
    JP4739785B2|2005-03-23|2011-08-03|アイシン精機株式会社|Sound absorber and sound absorber|
    US7968480B2|2006-02-15|2011-06-28|Polymer Group, Inc.|Multi-lobal fiber containing nonwoven materials and articles made therefrom|
    KR20110034522A|2009-09-28|2011-04-05|현대자동차주식회사|Sound absorption material using shaped yarn and thereof synthetic method|
    KR101281727B1|2010-12-31|2013-07-04|웅진케미칼 주식회사|Conjugate fiber having elastic recovery properties and manufacturing method thereof|
    KR101250352B1|2010-12-31|2013-04-04|웅진케미칼 주식회사|Nonwoven fabric having elastic recovery properties|
    EP2811054A4|2012-01-31|2015-09-23|Kuraray Co|Composite fiber, method for producing polyurethane elastomer fabric, and polyurethane elastomer fabric|
    CN104755665B|2012-09-07|2017-07-11|帝人株式会社|Nonwoven fabric construct body and its manufacture method|
    KR101289129B1|2012-09-28|2013-07-23|웅진케미칼 주식회사|Sound-absorbing materials having excellent sound absorption performance and manufacturing method thereof|
    US9284663B2|2013-01-22|2016-03-15|Allasso Industries, Inc.|Articles containing woven or non-woven ultra-high surface area macro polymeric fibers|KR101289129B1|2012-09-28|2013-07-23|웅진케미칼 주식회사|Sound-absorbing materials having excellent sound absorption performance and manufacturing method thereof|
    KR101759104B1|2014-12-26|2017-07-31|도레이케미칼 주식회사|Fiber for clean material, clean materials containing the same and manufacturing method thereof|
    US9715871B2|2015-07-10|2017-07-25|Hyundai Motor Company|Multilayer dash isolation pad having superior formability and sound absorption performance|
    KR101714910B1|2015-10-23|2017-03-10|엘지하우시스|Porous single polymer fibre composite and method for preparing porous single polymer fibre composite|
    US10540952B2|2016-03-30|2020-01-21|Maryam Mohammadi Gojani|Sound absorbing structure including nanofibers|
    KR101836623B1|2016-04-26|2018-03-08|현대자동차주식회사|Non-woven fabric board for exterior of automobile and method for manufacturing same|
    CN106120148B|2016-08-23|2018-06-08|湖北崇高科工有限公司|A kind of preparation method of thermoforming heat-insulating and sound-absorbing cotton|
    ES2761887T3|2017-03-17|2020-05-21|Freudenberg Carl Kg|Acoustic absorbent textile composite material|
    DE102017002552A1|2017-03-17|2018-09-20|Carl Freudenberg Kg|Sound-absorbing textile composite|
    JP2018172535A|2017-03-31|2018-11-08|積水化成品工業株式会社|Ester-based elastomer foam molding and method for producing the same|
    KR20190027522A|2017-09-07|2019-03-15|한화큐셀앤드첨단소재 주식회사|Manufacturing method for sound absorbing and insulating material|
    CN112218977A|2018-05-29|2021-01-12|三菱化学株式会社|Profiled cross-section fiber, process for producing the same, nonwoven fabric and sound-absorbing and sound-insulating material each containing the profiled cross-section fiber|
    KR102087829B1|2018-10-30|2020-03-11|지에이치신소재 주식회사|Sound absorbing pad for automobile interior material|
    KR102230579B1|2020-01-20|2021-03-22|한국섬유개발연구원|Method of manufacturing rayon-like side by side type composite yarn with non-circular cross-section|
    法律状态:
    2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-02-18| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-04-28| B25A| Requested transfer of rights approved|Owner name: HYUNDAI MOTOR COMPANY (KR) ; KIA MOTORS CORPORATION (KR) ; TORAY ADVANCED MATERIALS KOREA INC. (KR) |
    2021-06-22| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-07-13| 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 26/09/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    KR1020120108764A|KR101289129B1|2012-09-28|2012-09-28|Sound-absorbing materials having excellent sound absorption performance and manufacturing method thereof|
    KR10-2012-0108764|2012-09-28|
    PCT/KR2013/008630|WO2014051351A1|2012-09-28|2013-09-26|Sound-absorbing material having excellent sound absorption properties and method for manufacturing same|
    [返回顶部]