CN102057421B - 多层吸声片材 - Google Patents

多层吸声片材 Download PDF

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CN102057421B
CN102057421B CN200980121374.6A CN200980121374A CN102057421B CN 102057421 B CN102057421 B CN 102057421B CN 200980121374 A CN200980121374 A CN 200980121374A CN 102057421 B CN102057421 B CN 102057421B
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rete
sound absorbing
absorbing sheet
multilayer sound
multilayer
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CN102057421A (zh
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野野木麻里
佐佐木信
花卷千秋
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3M Innovative Properties Co
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    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
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Abstract

本发明提供了多层吸声片材，所述多层吸声片材包括：膜层，所述膜层具有微通孔和小孔；以及纤维材料层，所述纤维材料层设置在所述膜层上。本发明也提供了吸声方法，所述吸声方法包括：提供本发明的所述多层吸声片材；以及将所述多层吸声片材设置在声源和声反射表面之间。

Description

多层吸声片材
技术领域
本发明整体涉及多层吸声片材，该多层吸声片材包括膜层和设置在膜层上的纤维材料层。本发明还整体涉及吸声方法，该方法包括提供多层吸声片材以及将多层吸声片材设置在声源和声反射表面之间。
背景技术
各种吸声材料用于许多不同的吸声学科中。已知的吸声材料包括开孔材料，例如玻璃棉、石棉、海绵、毡或氨基甲酸酯形式的材料；多孔材料，例如多孔烧结板、金属纤维板或泡沫金属板；开孔黑板；片状材料和非织造吸声材料的组合；或某些膜。
玻璃棉或毡已被用于吸收来自汽车发动机舱的声音。在这种情况下，吸声系数可以与吸声材料厚度成比例地增加。吸声材料的重量和成本随着厚度的增加而增加。
各种吸声材料用于电气和电子设备。随着不断地强调要降低此类设备的尺寸和成本，薄且柔韧的吸声材料是理想的。
多种非织造吸声材料已经得到应用。但在低频(例如3000Hz或更低)下，一些非织造物的能力相对较低，而在较高频下往往较高。如果吸声材料较厚，则在低频下的吸声可以得到改善。然而，在高频下的吸声能力可能降低。
已知低频下的吸声能力有时可通过使用多孔材料和膜的组合来改进。在这种情况下，吸声材料可相对较薄，但背衬空隙的最小量(如，约10mm)对保证最佳的低频性能可能是必要的。另外，在高频下的吸声能力还可能较低。
希望提供能够在宽频率范围内吸声的、较薄(甚至包括背衬空隙)并具有柔韧性的吸声材料或吸声方法。
发明内容
在一个方面，本发明提供多层吸声片材，多层吸声片材包括：膜层，其具有微通孔和小孔；以及纤维材料，其设置在膜层上。在另一方面，本发明提供吸声方法，该方法包括：提供多层吸声片材；以及将多层吸声片材设置在声源和声反射表面之间。
因此，在一个方面，本发明所公开的是多层吸声片材，多层吸声片材包括：膜层，其具有微通孔和直径至少为1mm的小孔；和纤维材料层，其设置在该膜层上。
本文也公开了吸声方法，该吸声方法包括以下步骤：提供多层吸声片材，多层吸声片材包括：膜层，其具有微通孔和直径至少为1mm的小孔；和纤维材料层，其设置在该膜层上；以及，将多层吸声片材设置在声源和声反射表面之间，使多层吸声片材和声反射表面之间具有背衬空隙。
本文也公开了吸声材料，吸声材料包括：声反射表面和多层吸声片材，多层吸声片材包括：膜层，其具有微通孔和具有直径至少为1mm的小孔；和纤维材料层，其设置在膜层上，并且设置在声反射表面附近，使多层吸声片材和声反射表面之间具有背衬空隙。
上述本发明的内容并非意图描述本发明的每一个图示实施例或每种实施方式。以下附图和具体实施方式将更具体地举例说明这些实施例。
附图说明
图1为本发明的多层吸声片材的一个实施例的横截面图。
图2为本发明的多层吸声片材的另一个实施例的横截面图。
图3为本发明的膜层的一个实施例的正视图。
图4为本发明的多层吸声片材的另一个实施例的横截面图。
图5为具有不同孔径比的多层吸声片材的吸声曲线图。
图6为具有单膜层的多层吸声片材和具有双膜层的多层吸声片材的吸声曲线图。
图7为具有微通孔的各种膜的格利透气率图。
图8为具有各种背衬空隙厚度的多层吸声片材的吸声曲线图。
图9为具有及没有微通孔的双膜层的吸声曲线图。
虽然本发明可修改为各种修改形式和替代形式，其细节已通过举例的方式在附图中示出并且将会作详细描述。然而应当理解，其目的并不是将本发明局限于所述具体实施例。相反，其目的在于涵盖所附权利要求书所限定的本发明的精神和范围内的所有修改形式、等同形式和替代形式。
具体实施方式
本发明的膜层可以包括单层、双层或更多层。根据一个实施例，多层吸声片材可以包括具有不同弹性模量的双层膜。在一个实施例中，多层吸声片材还可以相对较薄(例如，具有约510μm至约2500μm的厚度)。此类多层吸声片材可允许使用相对较薄(例如，约1mm至约20mm、约1mm至约10mm或约1mm至约5mm)的背衬空隙。
本发明的吸声方法包括提供本发明的多层吸声片材。该方法也包括在声源和声反射表面之间提供多层吸声片材。声反射表面可以包括(但不限于)电气和电子设备(例如计算机、音频仪器、复印机、洗衣机或空调)的内表面；或汽车的内表面。多层吸声片材和声反射表面之间的距离(即，背衬空隙的厚度)可相对较小(例如，约1mm至约20mm、约1mm至约10mm或约1mm至约5mm)。
多层吸声片材和吸声方法可以在各种频率下提供有效的吸声。
图1为本发明的多层吸声片材的一个实施例的横截面图。多层吸声片材100包括膜层104和纤维材料层102。在一个实施例中，膜层104包括单膜层，单膜层包括总共具有约0.1秒/100cc至约300秒/100cc透气率(在不存在小孔的情况下，且根据JIS-L-1906来测量)的微通孔108。在一个实施例中，微通孔的直径在约10μm至约200μm的范围内。在各种实施例中，微通孔存在的密为约77,500孔/m2至约6,100,000孔/m2、或约620,000孔/m2至约1,240,000孔/m2。另外，膜层104也包括直径至少为约1mm的小孔110。在各种实施例中，小孔的最大直径可为约25mm、约10mm、约5mm或约2mm。在某些实施例中，如果小孔间距为使得合适的孔径比得以维持，则小孔可包括较大的直径(如，高达100mm)。在各种实施例中，膜层的孔径比可为约3％至约50％、或约10％至约40％。
如本文所用，术语“微通孔”表示完全穿过膜层的微孔，术语“小孔”表示完全穿过膜层且大于微通孔的孔，以及术语“孔径比”表示膜层单位面积中的开孔面积百分比。微通孔、和/或小孔可以是圆形或非圆形的(如本文随后进一步解释)，并且可以是规则或不规则的。在非圆形或不规则成形的微孔或小孔的情况下，术语“直径”是指具有与非圆形成形微孔或小孔相同面积的圆形开口的直径。微孔和/或小孔的孔径也可以有差别。在这种情况下，直径是指总体微孔或小孔的平均直径。
通过进行微穿孔和小孔的组合，特别是在相对高频下，本发明的多层吸声片材的吸声效果可得到改善(例如，与具有无孔膜的纤维层相比)。尽管不希望受理论或机理的束缚，但本文所公开的多层吸声片材可以通过以下方法来吸收声音，例如通过膜层的膜振荡、通过微通孔中的空气摩擦、通过纤维层中的空气摩擦或通过这些机理的组合。
膜层可包括(但不限于)具有柔韧性的树脂膜。可用于树脂膜的示例性聚合物材料包括(但不限于)聚酯，例如聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)或聚萘二甲酸乙二醇酯(PEN)；聚碳酸酯；聚烯烃，例如聚乙烯、聚丙烯或聚丁烯；聚乙烯树脂，例如聚氯乙烯、聚偏二氯乙烯或聚乙烯醇缩醛；纤维素酯，例如三乙酸纤维素或醋酸纤维素。在各种实施例中，膜层的厚度为约10μm至约500μm或为约10μm至约250μm。在一个实施例中，膜层的每平方米重量为约5克至约500克。
纤维材料层102可包括(但不限于)织造物、非织造物、泡沫(例如，聚氨酯泡沫或纤维素泡沫)或毡。非织造物可以通过已知的熔喷法来制备。在一个实施例中，纤维材料层102的厚度为约500μm至约2000μm。在一个实施例中，此厚度范围的非织造层可通过取得现有的非织造层(例如厚度为3-4mm)并将该非织造层压缩或压实到所需厚度范围而形成。
图1的多层吸声片材的总厚度可以相对较薄，例如约510μm至约2500μm。
为了产生吸声效果，多层吸声片材可设置在声反射表面处或在其附近。在一个实施例中，膜层面向声源(如，传入的空气声)设置。多层吸声片材还可以在纤维材料层102和声反射表面之间具有背衬空隙(间隙)。即使背衬空隙相对较薄(例如为约1mm至约20mm、约1mm至约10mm或约1mm至约5mm)，本发明的多层吸声片材也可以显示具有良好的吸声效果。
具有微穿孔的膜层可以通过任何已知的方法来制备。例如，树脂膜可通过用具有针的滚筒针刺进行微穿孔以形成微通孔，然后通过单独的操作(如，机械穿孔)来形成小孔。可以使用各种形状的微通孔或小孔。小孔的示例性形状包括(但不限于)圆形、椭圆形、三角形、正方形、矩形、多边形或星形。圆形、椭圆形或圆角形可以是优选的。获得的具有微通孔和小孔两者的膜层104以及纤维材料层102可以通过已知的层合方法(例如粘合、网装固定或滚压)层合在一起，以形成多层吸声片材100。对于粘合而言，可以使用粘合剂、热熔粘合剂、粘结剂或胶带。或者，纤维材料和膜层可彼此热层合。所得的多层片制品可以卷的形式储藏。
图2为本发明的多层吸声片材的另一个实施例的横截面图。在此实施例中，多层吸声片材200包括纤维材料层202、第一膜层204(其接触纤维材料层202)以及第二膜层206(其面向声源)。在此实施例中，第一膜层204和第二膜层206可以具有彼此不同或相同的弹性模量。第一膜层204的弹性模量包括(但不限于)约5MPa至约3000MPa、或约1000MPa至约3000MPa。第二膜层206的弹性模量包括(但不限于)约5MPa至约3000MPa。第一膜层的厚度为约10μm至约250μm，并且第二膜层的厚度为约10μm至约250μm。第二膜层的厚度可以与第一膜层相同或不同。第一膜层204和第二膜层206具有微通孔和小孔。微通孔的透气率以及小孔的孔径比可以与上述相同。第一膜层和第二膜层的每平方米重量可以与上述相同。
双膜层可通过任何已知的方法(例如为通过热层合、干法层合或粘合来层合第一膜层和第二膜层)来制备。当层通过粘合层合时，在一个实施例中，合适的粘合剂可以局部涂布到第一膜层或第二膜层的表面。例如，为了局部涂布粘合剂，粘合剂可以在不连续的位置涂布、星点涂布、通过喷雾涂布等。粘合剂在膜层区域上的此类局部涂布可导致在层合膜层之间具有空气存在。这可以导致一层或两层的膜振荡，这样可以改善多层片的吸声。在一个可供选择的实施例中，双膜层可通过挤出来制备。例如，第二膜材料的熔融树脂可以通过已知的挤出法挤出到第一膜层上。
在将第一膜层和第二膜层层合在一起后，双膜层可以通过上述方法进行微穿孔，从而得到微通孔，并且进行穿孔，以形成小孔。然后，具有微通孔和小孔的双膜层可通过已知的方法(例如上述方法)层合到纤维材料层202。获得的片材可以卷的形式储藏。
图2的多层吸声片材的总厚度(包括多层膜)可以相对较薄，例如为约520μm至约2500μm、或约900μm至约2000μm。
图3为本发明的膜层的一个实施例的正视图。膜层300包括具有微通孔308和小孔310两者的膜层304。可应用微通孔，以便提供从约0.1秒/100cc至约300秒/100cc的透气率。孔径和孔径比可以与上述相同。
图4为本发明的多层吸声片材的另一个实施例的横截面图。多层吸声片材400可以按例如图4所示的形状切割和成形。片材400可以具有允许片材附接到表面420的凸缘403，使得片材400的一部分不接触表面420(即，以使得背衬空隙402存在)。片材可以抵靠声反射表面420设置，使得片材的多孔材料层在内部(面向表面420)，并且膜层在外部(如，面向传入的声音)。在此形状中，背衬空隙402可以在多层吸声片材400和表面420之间产生。与表面420间隔开的多层吸声片材400部分与表面420之间的距离可以是(但不限于)例如约1mm至约20mm、约1mm至约10mm或约1mm至约5mm。本发明的多层吸声片材为相对较薄且柔韧的，因此其可以各种形状形成，不限于图4所示的形状。例如，片材400可形成以匹配特定表面420的形状。
图5为示出孔径比与吸声系数之间关系的曲线图(作为比较，频谱500示出厚度为约10mm的非织造片材的吸声系数。在本实例以及其他实例中，10mm的非织造片材包括带有纺粘稀松布的密度为约200克/m2的熔喷聚丙烯幅材)。频谱502、504、506和508示出多层吸声片材的吸声系数，该多层吸声片材包括厚度为约0.9mm以及每平方米重量为约84克的非织造物(厚度为约3mm至约4mm的熔喷非织造片材可压制以提供这样的非织造片材)、厚度为38μm的聚对苯二甲酸乙二醇酯(PET)膜和厚度为10μm的聚乙烯(PE)膜。PET膜的弹性模量为约2700MPa，且PE膜的弹性模量为约6MPa。PE树脂被挤出以及硬化，以在PET膜上形成PE膜，然后对层合的PE-PET层进行微穿孔以及穿孔。层合双膜层具有直径为约100μm和密度为约1,240,000孔/m2的微通孔以及直径为约4.5mm、图5所示孔径比的小孔。10mm的背衬空隙(间隙)用于每一个频谱。所有吸声谱(在本实例以及所有其他实例中)根据ASTME 1050利用熟知的阻抗管试验而生成。对于多层吸声片材样品而言，样品在整个阻抗管开口上跨过样品的29mm的直径部分而设置在阻抗管中，样品的边缘使用双面胶粘附到阻抗管开口的凸缘，以使得片材垂直于入射声而设置(通常，在这些实验中，设置吸声片材，以使得声源面向多层片的膜层)。调节阻抗管的反射表面(在声源方向的样品之后)，从而得到所需的背衬空隙。对于非织造样品而言，非织造样品在没有空隙的情况下直接抵靠阻抗管的反射表面设置。
图6为示出包括单膜层的多层吸声片材和包括双膜层的吸声片材的吸声系数曲线图。图6示出吸声系数频谱602a-c和频谱604。频谱602a-c示出用于多层吸声片材的吸声系数，多层吸声片材包括厚度为约0.9mm的非织造物(图5的0.9mm的非织造幅材)，以及具有微通孔和小孔的PET膜。PET膜的厚度对于频谱602a为12μm、对于频谱602b为38μm，并且对于频谱602c为50μm。频谱604示出用于多层吸声片材的吸声系数，多层吸声片材包括厚度为约0.9mm的非织造物、厚度为38μm的PET膜和厚度为10μm的聚乙烯(PE)膜。PET膜的弹性模量为约2700MPa，并且PE膜的弹性模量为约6MPa。PE膜和PET膜通过将PE树脂挤出到PET膜上并将其硬化来形成，以形成多层膜结构。然后，多层膜结构通过上述方法来处理，从而得到平均直径为约100μm、密度为约1,240,000孔/m2的微穿孔以及直径为约4.5mm、孔径比为约22.7％的小孔。
频谱602a-c和频谱604以与参照图5所述相同的方式来生成。
图7为示出膜厚度与透气率之间关系的曲线图。密度为约1,240,000孔/m2的微通孔(并且没有小孔)的膜层根据JIS-L-1906来表征，透气率根据格利法在图7中示出。格利法中的透气率值示出其让100cc的空气穿过膜传递的时间(秒/100cc)。测量各种膜层，包括厚度为12μm、25μm、38μm和50μm的多种厚度的PET膜以及厚度为10μm、20μm、30μm、40μm和50μm的多种厚度的PE膜。优选的透气率值可以为约0.1秒/100cc至约300秒/100cc。为了获得此范围的透气率，可使用多种孔径和密度的微通孔。示例性孔径和密度的微通孔包括(但不限于)(例如)的直径范围为约10μm至200μm以及密度为约620,000孔/m2至约1,240,000孔/m2。
图8为示出吸声特性和背衬空隙(间隙)之间关系的曲线图。频谱800示出厚度为10mm的熔喷非织造片的吸声系数。频谱802、频谱804、频谱806、频谱808和频谱810示出用于本发明的多层吸声片材的吸声系数，多层吸声片材包括厚度为38μm的PET膜(第一膜层)、厚度为12μm的PE膜(第二膜层)、厚度为约0.9mm的熔喷非织造片。膜层(PET膜和PE膜)具有密度为约1,240,00孔/m2的微通孔(平均直径为约100μm)以及面积比为25％的小孔(孔径为约7.3mm)。片材的透气率为1.2秒/100cc。PET膜的弹性模量为约2700MPa，PE膜的弹性模量为约6MPa。频谱800、频谱802、频谱804、频谱806、频谱808和频谱810以与参照图5所述相同的方式生成，背衬空隙如图8所示。
图9为具有及没有微通孔的双膜层的吸声曲线图。频谱900示出厚度为10mm的熔喷非织造片的吸声系数。频谱902和频谱904示出用于双层膜的吸声系数，双层膜包括厚度为38μm的PET膜和厚度为10μm的PE膜(不存在非织造物)。PET膜的弹性模量为约2700MPa，PE膜的弹性模量为约6MPa。用于频谱902的双层膜具有密度为约1,240,000孔/m2的微通孔并且没有小孔，用于频谱904的膜没有微通孔或小孔。用于频谱902的双层膜的透气率为1.2秒/100cc，并且用于频谱902膜的微通孔的平均直径为约100μm。
频谱900、频谱902和频谱904以与参照图5所述相同的方式来生成。
根据如此所述的公开，显而易见的是本文所公开的概念可以通过多个途径进行改变。此类改变不应视为违背本公开的精神和范围，并且对本领域技术人员显而易见的是，所有此类修改旨在包含在以下权利要求书的范围内。

Claims (15)

1.一种多层吸声片材，包括：
膜层，所述膜层具有直径为10μm至200μm的微通孔和直径为至少1mm的小孔；以及
纤维材料层，所述纤维材料层设置在所述膜层上，
其中在不存在所述小孔的情况下根据JIS-L-1906来测量，所述微通孔总共具有的透气率为0.1秒/100cc至300秒/100cc，并且所述小孔的孔径比为3％至50％。
2.根据权利要求1所述的多层吸声片材，其中所述纤维材料层的厚度为500μm至2000μm。
3.根据权利要求1所述的多层吸声片材，其中所述膜层的厚度为10μm至500μm。
4.根据权利要求1所述的多层吸声片材，其中所述多层吸声片材的总厚度为510μm至2500μm。
5.根据权利要求1至4中任一项所述的多层吸声片材，其中所述纤维材料选自织造物、非织造物、聚氨酯泡沫、纤维素泡沫和毡。
6.根据权利要求1至4中任一项所述的多层吸声片材，其中所述膜层选自聚乙烯膜、聚对苯二甲酸乙二醇酯膜、聚对苯二甲酸丁二醇酯膜和聚丙烯膜。
7.根据权利要求1至4中任一项所述的多层吸声片材，其中所述膜层包括多层膜，所述多层膜具有第一膜层和第二膜层，所述第二膜层设置在所述第一膜层上。
8.根据权利要求7所述的多层吸声片材，其中所述第一膜层和所述第二膜层各自的厚度为10μm至250μm。
9.根据权利要求7所述的多层吸声片材，其中所述第一膜层的弹性模量为1000MPa至3000MPa，并且所述第二膜层的弹性模量为5MPa至3000MPa。
10.根据权利要求7所述的多层吸声片材，其中所述第一膜层的每平方米重量为5克至500克，并且所述第二膜层的每平方米重量为5克至500克。
11.根据权利要求7所述的多层吸声片材，其中所述第一膜层和第二膜层分别选自聚乙烯膜、聚对苯二甲酸乙二醇酯膜、聚对苯二甲酸丁二醇酯膜和聚丙烯膜。
12.一种吸声材料，包括：
声反射表面；
权利要求1至4中任一项所述的多层吸声片材，所述多层吸声片材设置在所述声反射表面附近，使所述多层吸声片材和所述声反射表面之间具有背衬空隙。
13.根据权利要求12所述的吸声材料，其中在所述多层吸声片材和所述声反射表面之间的所述背衬空隙的厚度为1mm至20mm。
14.根据权利要求12所述的吸声材料，其中在所述多层吸声片材和所述声反射表面之间的所述背衬空隙的厚度为1mm至10mm。
15.根据权利要求12所述的吸声材料，其中在所述多层吸声片材和所述声反射表面之间的所述背衬空隙的厚度为1mm至5mm。
CN200980121374.6A 2008-04-14 2009-04-10 多层吸声片材 Expired - Fee Related CN102057421B (zh)

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JP2016028893A (ja) 2016-03-03
JP6211037B2 (ja) 2017-10-11
US8469145B2 (en) 2013-06-25
KR101840581B1 (ko) 2018-03-20
CN102057421A (zh) 2011-05-11
KR20160130859A (ko) 2016-11-14
JP6029279B2 (ja) 2016-11-24
EP2311028A4 (en) 2016-12-07
US20110100748A1 (en) 2011-05-05
KR20110004418A (ko) 2011-01-13
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