CN111819075A - 层叠吸音材料 - Google Patents
层叠吸音材料 Download PDFInfo
- Publication number
- CN111819075A CN111819075A CN201980017119.0A CN201980017119A CN111819075A CN 111819075 A CN111819075 A CN 111819075A CN 201980017119 A CN201980017119 A CN 201980017119A CN 111819075 A CN111819075 A CN 111819075A
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- China
- Prior art keywords
- sound absorption
- sound
- layer
- fiber layer
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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Abstract
本发明的课题在于提供一种在低频区域至超高频区域中显示出优异的吸音性的吸音材料。一种层叠吸音材料,至少包含:第一纤维层与第二纤维层、以及存在于所述第一纤维层与第二纤维层之间的至少一层基材层,所述第一纤维层的平均流量细孔径为0.5μm~10μm,单位面积重量为0.1g/m2~200g/m2,所述第二纤维层的平均流量细孔径为0.5μm~10μm且为第一纤维层的平均流量细孔径以下,单位面积重量为0.1g/m2~200g/m2,所述基材层的利用弗雷泽型法所得的通气度为40cc/cm2·s以上,单位面积重量为1g/m2~700g/m2,所述第一纤维层配置在声音的入射侧,所述第二纤维层配置在声音的透过侧。
Description
技术领域
本发明涉及一种层叠有至少两种纤维层而成的层叠结构的吸音材料。
背景技术
所谓吸音材料是具有吸收声音的功能的产品,多用于建筑领域或汽车领域。作为构成吸音材料的材料,众所周知使用不织布。例如专利文献1中公开了一种复合不织布网,所述复合不织布网包含中值直径小于1μm的亚微米纤维、以及中值直径为至少1μm的微纤维。专利文献1的复合不织布网是将亚微米纤维及微纤维这两种具有不同的中值直径的纤维混合而成,通过使其混合比变化,在厚度方向上形成混合比的梯度。在具有代表性的实施形态中,公开了通过分别形成微纤维流与亚微米纤维流并将亚微米纤维流加入至微纤维流中,可形成不同纤维混合而成的网。
另外,在专利文献2中,公开了一种吸收低频及高频的声音的层叠吸音不织布,所述层叠吸音不织布包含谐振膜与至少一个其他的纤维材料层,谐振膜由直径为600nm、表面重量(单位面积重量)为0.1g/m2~5g/m2的纳米纤维层形成。公开了纳米纤维层典型而言利用电场纺丝制成,另一方面,基材层为直径10μm~45μm、单位面积重量5g/m2~100g/m2的纤维织物,进而还可层叠其他层。另外,公开了为了达到适当的厚度及单位面积重量,也可以进一步层叠该层叠体。
在专利文献3中,公开了层叠有不织布A与不织布B的层叠吸音材料来作为2000Hz下的吸音率为0.85以上的层叠吸音材料,所述不织布A包括:(1)包含含有单纤维直径为1nm~500nm的热塑性树脂的纳米纤维的层、以及(2)包含单纤维直径更大的纤维的层,所述不织布B具有特定的单位面积重量及纤维径。公开了专利文献3的层叠吸音材料是将不织布A(表层部)与不织布B(基盘部)贴合并制作而成,吸音性高,也具有隔热性,所述不织布A(表层部)通过利用短纤维直径更大的层来支持包含纳米纤维的具有极微细的空隙的层而赋予保形性或尺寸稳定性,所述不织布B(基盘部)具有充分的通气度,单位面积重量大。
专利文献4中公开了包含纳米纤维的吸音特性优异的不织布结构体。专利文献4的不织布结构体的特征在于,包含含有纤维径小于1μm的纳米纤维的纤维体,该纤维体的厚度为10mm以上。另外,公开了所述纤维体可以由支持体支持,也可以成为将纤维体与支持体反复层叠而成的结构。公开了纳米纤维例如通过熔喷法形成,在实施例中,在作为支持体的聚丙烯水刺不织布上形成纤维径0.5μm、单位面积重量350g/m2的纳米纤维体的层。
现有技术文献
专利文献
专利文献1:日本专利特表2011-508113号公报
专利文献2:日本专利特表2008-537798号公报
专利文献3:日本专利特开2015-30218号公报
专利文献4:日本专利特开2016-121426号公报
发明内容
发明所要解决的问题
如上所述,作为吸音材料,研究了各种结构的不织布层叠体,已知将纳米纤维或被称为亚微米纤维的极细纤维与其他纤维组合使用、根据层的组合或构成显示出具有特征性的吸音特性。
但是,要求一种不仅在500Hz~1000Hz的低频区域、800Hz~2000Hz的中频区域、进而在2000Hz~5000Hz的高频区域或5000Hz~11000Hz的超高频区域中也显示出优异的吸音性能且省空间性优异的吸音材料,但尚未进行开发。鉴于所述状况,本发明的课题在于提供一种在低频区域、中频区域、高频区域及超高频区域的所有区域中显示出优异的吸音性的吸音材料。
解决问题的技术手段
发明人等人为了解决所述课题而反复进行了研究。结果发现,在包含基材层与纤维层的层叠吸音材料中,如下层叠吸音材料在低频区域至超高频区域中显示出优异的吸音性且省空间性优异,从而完成了本发明,所述层叠吸音材料包含具有特定范围的通气度(平均流量细孔径)的至少两层的纤维层且在纤维层之间包含具有特定范围的空隙率及密度的基材层,且将两层纤维层设为特定的配置。
本发明具有以下结构。
[1]一种层叠吸音材料,至少包含:第一纤维层与第二纤维层、以及存在于所述第一纤维层与第二纤维层之间的至少一层基材层,
所述第一纤维层的平均流量细孔径为0.5μm~10μm,单位面积重量为0.1g/m2~200g/m2,
所述第二纤维层的平均流量细孔径为0.5μm~10μm且为第一纤维层的平均流量细孔径以下,单位面积重量为0.1g/m2~200g/m2,
所述基材层的利用弗雷泽型法(Frazier type method)所得的通气度为40cc/cm2·s以上,单位面积重量为1g/m2~700g/m2,
所述第一纤维层配置在声音的入射侧,所述第二纤维层配置在声音的透过侧。
[2]根据所述[1]所述的层叠吸音材料,其中所述第一纤维层、所述第二纤维层及所述基材层独立地为选自由不织布及织布所组成的群组中的至少一种。
[3]根据所述[1]或[2]所述的层叠吸音材料,其中所述基材层包含选自由聚邻苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚乙烯及聚丙烯所组成的群组中的至少一种纤维或者至少两种复合化而成的纤维,所述第一纤维层及第二纤维层独立地包含选自由聚偏二氟乙烯、尼龙6,6、聚丙烯腈、聚苯乙烯、聚氨基甲酸酯、聚砜、聚乙烯醇、聚邻苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚乙烯及聚丙烯所组成的群组中的至少一种纤维。
[4]根据所述[1]~[3]中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为900Hz至1120Hz为止的吸音率,算出平均吸音率(α),平均吸音率(α)的值为满足下述式的范围,
1.00≧α≧0.22。
[5]根据所述[1]~[4]中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为2800Hz至3550Hz为止的吸音率,算出吸音率的平均吸音率(β),平均吸音率(β)的值为满足下述式的范围,
1.00≧β≧0.60。
[6]根据[1]~[5]中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为4500Hz至5600Hz为止的吸音率,算出吸音率的平均吸音率(γ),平均吸音率(γ)的值为满足下述式的范围,
1.00≧γ≧0.90。
[7]根据[1]~[6]中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为9000Hz至11200Hz为止的吸音率,算出吸音率的平均吸音率(η),平均吸音率(η)的值为满足下述式的范围,
1.00≧η≧0.85。
发明的效果
根据具有所述结构的本发明,可获得低频区域至超高频区域中的吸音特性特别优异的吸音材料。本发明的层叠吸音材料处于吸音特性的峰值比以前的吸音材料高的区域中,特别是在500Hz以上的区域中的吸音性能优异。在汽车领域中,随着混合动力汽车或电动汽车的增加,对马达声音的对策成为课题,马达声音由于旋转速度而产生低频区域至超高频区域的声音,因此认为需要对这些频率区域的对策。另外,据说风噪声的音域为1,000Hz~3,000Hz左右。本发明的层叠吸音材料对于这种噪音的对策有用。另外,本发明的层叠吸音材料与包含多孔质材料或玻璃纤维等的吸音材料相比为轻量且可减少厚度,因此可实现构件的轻量化与省空间化,该方面作为面向汽车领域的吸音材料特别有用。
附图说明
图1是表示本发明的实施例(实施例1)及比较例(比较例1)的吸音特性的图表。
具体实施方式
以下,对本发明进行详细说明。
(层叠吸音材料的结构)
本发明的层叠吸音材料包含分别具有特定范围的平均流量细孔径或通气度且为特定范围的单位面积重量的基材层与纤维层。在层叠吸音材料中,纤维层包含两层以上,在纤维层之间介隔存在基材层。
平均流量细孔径及通气度均为表示层的疏密程度的尺度。本发明的层叠吸音材料大体上为致密的纤维层夹持稀疏的基材层的结构,且纤维层彼此具有特定的致密度(平均流量细孔径),具有以满足平均流量细孔径(入射侧)≧平均流量细孔径(透过侧)的关系的方式配置而成的结构。
本发明的层叠吸音材料至少包含第一纤维层与第二纤维层,纤维层也可以进而包含2层~6层。第一纤维层及第二纤维层可分别包含一个纤维结构体,也可为在一层纤维层中重叠多个纤维结构体而成的形态。
另外,在第一纤维层与第二纤维层之间介隔存在至少一层基材层。基材层可包含一个基材,也可为在一层基材层中重叠多个基材层而成的形态。在层叠吸音材料包含第一纤维层与第二纤维层这两层纤维层的情况下,层叠吸音材料具有第一纤维层/基材层/第二纤维层的结构。在层叠吸音材料为除了第一纤维层、第二纤维层以外进而加入了第三纤维层这三层的情况下,层叠吸音材料具有第一纤维层/基材层/第三纤维层/基材层/第二纤维层的结构,第三纤维层的平均流量细孔径优选为设为第一纤维层的平均流量细孔径≧第三平均流量细孔径≧第二平均流量细孔径。
只要不损害本发明的效果,则层叠吸音材料中含有的纤维层及基材层也可包含纤维层及基材层以外的结构,例如也可包含本发明中规定的范围以外的其他层(例如保护层。可为一层,也可为两层以上)、印刷层、发泡体、箔、筛状物、织布等。另外,也可以含有用于连结各层间的粘接剂层、夹子、缝合线等。
层叠吸音材料的各层间只要不显著降低通气度,则可物理性和/或化学性地粘接,也可不粘接。也可为层叠吸音材料的多个层间中的一部分被粘接、一部分未粘接的形态。粘接也可以例如在纤维层的形成步骤中或者作为后步骤进行加热,使构成纤维层的纤维的一部分熔解,使纤维层熔接在基材层上,由此将纤维层与基材层粘接。另外,也优选为在基材层或纤维层的层间赋予粘接剂,从而将层间粘接。
层叠吸音材料的厚度只要可获得本发明的效果,则并无特别限制,例如可设为1mm~50mm,优选为设为3mm~30mm,就省空间性的观点而言,更优选为设为3mm~20mm。再者,所谓层叠吸音材料的厚度典型而言是指纤维层及基材层的厚度的合计,在包含保护层等其他层的情况下,是指包含其他层的厚度。在安装有卡盘或盖等外装体的情况下,不包含该部分的厚度。
层叠吸音材料中使用的第一纤维层、第二纤维层的平均流量细孔径只要可获得所希望的吸音性能,则并无特别限制,作为第一纤维层,可使用0.5μm~10μm的范围,作为第二纤维层,可使用0.5μm~10μm的范围,第二纤维层的平均流量细孔径为第一纤维层的平均流量细孔径以下,优选为第二纤维层的平均流量细孔径比第一纤维层的平均流量细孔径小。以前,在与吸音性能一起期待隔音性能的吸音材料中,平均流量细孔径越低,声音越难以通过,认为对隔音性有效。与此相对,本发明的层叠吸音材料通过分别控制配置在基材层的两侧的纤维层的平均流量细孔径而减少声音的反射,进而通过采用吸音性优异的层结构而获得高吸音性。
层叠吸音材料成为基材层被夹持在第一纤维层与比第一纤维层致密的第二纤维层之间的层叠结构。在为此种形态时,第一纤维层与第二纤维层之间的距离(也称为基材层的厚度、层间距离)优选为2.5mm~30mm,更优选为3mm~15mm。若层间距离为2.5mm以上,则低频区域至超高频区域的吸音性能变得良好,另外,若层间距离为30mm以下,则作为吸音材料的厚度不会变得过大,适合省空间性。
基材层的通气度只要可获得所希望的吸音性能,则并无特别限制,在利用弗雷泽型法所得的通气度中为40cc/cm2·s以上,优选为40cc/cm2·s~250cc/cm2·s,更优选为40cc/cm2·s~150cc/cm2·s。以前,在与吸音性能一起期待隔音性能的吸音材料中,通气性越低,声音越难以通过,即认为对隔音性有效。与此相对,本发明的层叠吸音材料由于具有高通气性而减少声音的反射,进而通过采用吸音性优异的层结构而获得高吸音性。再者,通气度的测定可利用公知的方法进行,例如可利用格利(Gurley)试验机法或弗雷泽试验机法进行测定。
(各层的结构:纤维层)
本发明的层叠吸音材料中含有的第一纤维层及第二纤维层优选为空隙率为85%以上且96%以下,并且密度为0.04g/cm3以上且0.5g/cm3以下。若空隙率为85%以上,则通过抑制作为外层的原材料的刚性来抑制反射波的增加,可将声波引导到吸音材料内部,就该方面而言优选。若空隙率为96%以下,则通过控制由纤维层与基材层的密度差引起的流动阻力,吸音材料内部的声音由于外层与内层的密度差反复反射,可使吸音材料内部的声音衰减,因此优选。另外,若密度为0.04g/cm3以上,则具有可维持一定的层间距离的刚性,就该方面而言优选,若为0.5g/cm3以下,则作为吸音材料可维持轻量化,就该方面而言优选。
构成第一纤维层及第二纤维层的纤维优选为纤维径小于10μm的纤维。所谓纤维径小于10μm,是指平均纤维径为所述数值范围内。若纤维径小于10μm,则可获得空隙率低、密度高、致密且薄的膜,因此优选,若小于1μm,则可获得空隙率更低、密度高、致密且薄的膜,因此进而优选。纤维径的测定可利用公知的方法进行。例如纤维径是通过根据纤维层表面的放大照片测定或计算而得到的值,详细的测定方法在实施例中详述。
第一纤维层及第二纤维层优选为不织布,且优选为平均流量细孔径小于10μm。若平均流量细孔径小于10μm,则可控制纤维层与基材层的流动阻力,吸音材料内部的声音反复反射,因此可使吸音材料内部的声音衰减而良好。
本发明的层叠吸音材料中含有的第一纤维层及第二纤维层中,一层纤维层可包含一个纤维结构体,另外,在一层纤维层中含有多个纤维集合体,纤维集合体的层重叠而成者也可以形成一层纤维层。再者,在本说明书中,所谓纤维集合体,是指成为一个连续体的纤维集合体。
第一纤维层的平均流量细孔径为0.5μm~10μm,优选为0.9μm~10μm。另外,第一纤维层的单位面积重量为0.1g/m2~200g/m2,优选为0.3g/m2~100g/m2。若单位面积重量为0.1g/m2以上,则可通过形成作为致密的膜的隔离壁来形成共鸣空间,可提高吸音性。若小于200g/m2,则不会提高膜的刚性,可抑制声音的反射,从而可提高吸音率。第一纤维层的平均流量细孔径为第二纤维层的平均流量细孔径以上。
第二纤维层的平均流量细孔径为0.5μm~10μm,优选为0.5μm~5.0μm,特别优选为0.5μm~3.0μm。另外,第二纤维层的单位面积重量为0.1g/m2~200g/m2,优选为0.3g/m2~100g/m2。若单位面积重量为0.1g/m2以上,则可通过形成作为绵密的膜的隔离壁来形成共鸣空间,可提高吸音性,若小于200g/m2,则不会提高膜的刚性,可抑制声音的反射,从而可提高吸音率。
另外,本发明的层叠吸音材料具有如下特征:第一纤维层配置在声音的入射侧,夹持基材层,所述第二纤维层配置在声音的透过侧。如上所述,第二纤维层是比第一纤维层致密的层。不限于特定的理论,但本发明中认为声音通过第一纤维层被吸入至层叠吸音材料的内部,且被吸入的声音被致密的第二纤维层反射一部分,反射的声音在相当于吸音材料内部的基材层部分的封闭空间内产生共鸣、反射、干涉,由于自基材层的纤维的振动转换成热而产生能量消失,由此可实现优异的吸音性能。
构成第一纤维层及第二纤维层的纤维结构体优选为不织布,只要第一纤维层及第二纤维层具有所述范围的平均流量细孔径及单位面积重量,则并无特别限制,例如优选为熔喷不织布、通过电场纺丝法形成的不织布等。根据电场纺丝法或熔喷法,可将极细纤维效率良好地层叠在基材上,可获得具有所希望的范围的空隙率及密度的层。电场纺丝法的详细情况将在制造方法中详述。
作为构成第一纤维层及第二纤维层的纤维的原料树脂,只要可获得发明的效果,则并无特别限制,例如可列举聚烯烃系树脂、聚氨基甲酸酯、聚乳酸、丙烯酸树脂、聚对苯二甲酸乙二酯或聚对苯二甲酸丁二酯等聚酯类、尼龙6、尼龙6,6、尼龙1,2等尼龙(酰胺树脂)类、聚苯硫醚、聚乙烯醇、聚苯乙烯、聚砜、液晶聚合物类、聚乙烯-乙酸乙烯酯共聚物、聚丙烯腈、聚偏二氟乙烯、聚偏二氟乙烯-六氟丙烯等。作为聚烯烃系树脂,可例示聚乙烯、聚丙烯。作为聚乙烯,可列举低密度聚乙烯(Low-Density Polyethylene,LDPE)、高密度聚乙烯(High-Density Polyethylene,HDPE)、直链状低密度聚乙烯(Linear Low DensityPolyethylene,LLDPE)等,作为聚丙烯,可列举丙烯的均聚物、或者丙烯与其他单量体、乙烯或丁烯等聚合而成的共聚聚丙烯等。纤维集合体优选为包含所述树脂中的一种,也可包含两种以上。
在第一纤维层及第二纤维层为通过电场纺丝法形成的不织布的情况下,所述中,在电场纺丝法中,就可溶于各种溶剂的观点而言,更优选为聚偏二氟乙烯、尼龙6,6、聚丙烯腈、聚苯乙烯、聚氨基甲酸酯、聚砜及聚乙烯醇。另外,在第一纤维层及第二纤维层为熔喷不织布的情况下,所述中,优选为聚丙烯。纤维层优选为包含所述树脂中的一种,也可包含两种以上。
另外,所述纤维中也可以包含树脂以外的各种添加剂。作为可以添加到树脂中的添加剂,例如可列举:填充剂、稳定化剂、塑化剂、粘合剂、粘接促进剂(例如硅烷及钛酸盐)、二氧化硅、玻璃、粘土、滑石、颜料、着色剂、抗氧化剂、荧光增白剂、抗菌剂、表面活性剂、阻燃剂及氟化聚合物。使用所述添加物中的一种以上,可减少所得的纤维及层的重量和/或成本,也可调整粘度,或者也对纤维的热特性进行改性,或者还可赋予包含电气特性、光学特性、与密度相关的特性、与液体阻挡或粘合性相关的特性的、来自添加物的特性的各种物理特性。
(各层的结构:基材层)
层叠吸音材料中的基材层承担主要的吸音性,并且也具有支持纤维层并保持吸音材料整体的形状的功能。本发明的层叠吸音材料具有在第一纤维层与第二纤维层之间夹持有空隙率高、密度低的基材层的形态,可通过控制音源侧(入射侧)的平均流量细孔径而将声音导入至层叠吸音材料的内部,可通过在吸音材料的内部反复反射而吸音。基材层具有空隙率高、密度低的特征,另一方面,优选为具有支持纤维层且可维持一定的层间距离的刚性。
优选为空隙率为93%以上且小于100%,并且密度为0.008g/cm3~0.05g/cm3。若空隙率为95%以上,则通过控制由纤维层与基材层的密度差引起的流动阻力,吸音材料内部的声音由于外层与内层的密度差反复反射,因此可使吸音材料内部的声音衰减,就该方面而言吸音性提高。另外,通过将空隙率设为小于100%,可支持纤维层并保持层叠吸音材料的形态。另外,若密度为0.008g/m3以上,则作为吸音材料具有支持纤维层且可维持一定的层间距离的刚性,就该方面而言优选,若为0.05g/m2以下,则作为吸音材料可维持轻量化,就该方面而言优选。
基材层可包含一层基材层,或者也可为多个基材层重叠而成的形态。构成基材层的材料只要可在其至少一个表面上层叠纤维层即可,并无特别限制,可使用不织布、玻璃纤维、纸、织布、泡沫(发泡体层)、筛状物等。特别优选为不织布、织布中的任一种以上,更优选为不织布。层叠吸音材料中包含的基材可为一种,也可为两种以上。
在基材层为不织布的情况下,不织布的种类可使用熔喷不织布、水刺不织布、纺粘不织布、热风不织布、热粘合不织布、针刺不织布等,可以根据所希望的物性或功能适宜选择。
作为构成基材层的不织布的纤维的树脂,可使用热塑性树脂,例如可例示聚烯烃系树脂、聚对苯二甲酸乙二酯等聚酯系树脂、聚酰胺系树脂。作为聚烯烃系树脂,可列举乙烯、丙烯、丁烯-1或4-甲基戊烯-1等均聚物、以及它们与其他的α-烯烃、即乙烯、丙烯、丁烯-1、戊烯-1、己烯-1或4-甲基戊烯-1等中的一种以上的无规或嵌段共聚物或将它们组合的共聚物、或者它们的混合物等。作为聚酰胺系树脂,可列举尼龙4、尼龙6、尼龙7、尼龙1,1、尼龙1,2、尼龙6,6、尼龙6,10、聚己二酰间苯二甲胺、聚对苯二甲癸酰胺(polyparaxylidenedecanamide)、聚双环己基甲烷癸酰胺或它们的共聚酰胺等。作为聚酯系树脂,除了聚对苯二甲酸乙二酯以外,还可列举聚对苯二甲酸四亚甲酯、聚对苯二甲酸丁酯、聚氧乙烯苯甲酸酯、聚(1,4-二甲基环己烷对苯二甲酸酯)或它们的共聚物。它们中,就通用性高、可热熔接的观点而言,优选为使用聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚乙烯及聚丙烯中的一种或者将两种以上组合使用。
在基材层为织布或筛状物的情况下,也可以使用同样的树脂。
另外,作为构成基材层的不织布的纤维,也可使用包含单成分的纤维,若考虑到纤维彼此的交点的熔接的效果,则优选为使用包含低熔点树脂与高熔点树脂的复合成分的纤维、即、包含熔点不同的两种成分以上的复合纤维。复合形态例如可列举鞘芯型、偏心鞘芯型、并列型。另外,作为构成基材层的不织布的纤维,也优选为使用熔点不同的两种成分以上的混纤纤维。再者,所谓混纤纤维是指包含高熔点树脂的纤维与包含低熔点树脂的纤维独立存在并混合而成的纤维。
构成基材层的不织布的纤维的平均纤维径并无特别限制,可使用包含平均纤维径为10μm~1mm的纤维的基材层的不织布。若平均纤维径为10μm以上,则可控制由纤维层与基材层的密度差引起的流动阻力,若小于1mm,则不丧失通用性,另外也容易获取。若纤维径为10μm~100μm,则更优选。纤维径的测定可以利用与纤维层的纤维径的测定同样的方法进行。
基材层介隔存在于第一纤维层与第二纤维层之间。另外,除了介隔存在于第一纤维层与第二纤维层之间以外,也可以作为层叠吸音材料中位于最外面的层而含有。基材层也可以仅由一层构成基材层,也优选为两层以上连续配置而构成一层基材层。通过连续地配置两层以上的基材层,具有能够根据基材层的厚度来控制纤维层的层间距离的优点。
关于基材层的通气度,在利用弗雷泽型法所得的通气度中为40cc/cm2·s以上,优选为40cc/cm2·s~250cc/cm2·s,更优选为40cc/cm2·s~150cc/cm2·s。以前,在与吸音性能一起期待隔音性能的吸音材料中,通气性越低,声音越难以通过,即认为对隔音性有效。与此相对,认为本发明的层叠吸音材料由于基材层具有高通气性而减少声音的反射,进而通过采用吸音性优异的层结构而获得高吸音性。
另外,基材层的单位面积重量为1g/m2~700g/m2,优选为15g/m2~500g/m2。若基材层的单位面积重量为1g/m2以上,则可获得作为吸音材料的必要强度。
在本发明中,基材层优选为具有2.5mm以上的厚度。基材层的厚度的上限并无特别限制,就省空间性的观点而言,厚度的范围优选为2.5mm~25mm,更优选为3mm~20mm。
另外,构成基材层的每一片不织布等材料的厚度例如可设为2.5mm~15mm,更优选为设为3mm~10mm。若每一片基材的厚度为2.5m以上,则未发生褶皱,操作容易,生产性良好。另外,若基材层的厚度为15mm以下,则不存在妨碍省空间性的可能性。
在不妨碍本发明的效果的范围内,基材层中可添加各种添加剂、例如着色剂、抗氧化剂、光稳定剂、紫外线吸收剂、中和剂、成核剂、润滑剂、抗菌剂、阻燃剂、塑化剂及其他热塑性树脂等。另外,也可以利用各种整理剂处理表面,由此可以赋予防水性、抗静电性、表面平滑性、耐磨损性等功能。
(层叠吸音材料的吸音特性)
本发明的层叠吸音材料的特征在于,在低频区域(1000Hz的频率区域)或中频区域(3000Hz)、高频区域(5000Hz)、超高频区域(10000Hz)中的吸音性优异。不限于特定的理论,但认为本发明的层叠吸音材料通过设为在具有被控制的平均流量细孔径的纤维层之间夹持低密度的基材层的结构,而制成被纤维层夹持的封闭空间,在该封闭空间中反复发生反射,声音的吸收实现高效率化。进而,认为通过使用特定范围的平均流量细孔径的纤维层及基材层,在防止声音的反射的同时透过第一纤维层,在第二纤维层中使声音反射,由此可在基材层中更有效率地吸收,因此可获得厚度薄且具有高吸音性的吸音材料。
吸音性的评价方法在实施例中详述。
(层叠吸音材料的制造方法)
层叠吸音材料的制造方法并无特别限制,例如可通过如下制造方法获得,所述制造方法包括:制作在一层基材层上形成有一层纤维层的纤维层叠体(即,基材层/纤维层的层叠体)、或者在保护层上形成有一层纤维层的纤维层叠体(即,保护层/纤维层的层叠体)的步骤;以及将多个纤维层叠体按照规定的顺序及片数重叠而一体化的步骤。在纤维层叠体包含保护层与纤维层的情况下,可以在纤维层与纤维层之间夹持基材层的方式层叠而一体化。再者,在使纤维层叠体重叠的步骤中,也优选为加入纤维层叠体以外的其他层、例如其他基材层进行层叠。
在使用不织布作为基材层的情况下,可利用公知的方法制造不织布来使用,也可以选择市售的不织布来使用。在基材层或保护层上形成纤维层的步骤优选为使用电场纺丝法或熔喷法。
电场纺丝法为如下方法:喷出纺丝溶液且使电场作用,对喷出的纺丝溶液进行纤维化,在收集器上获得纤维的方法。例如,可列举自喷嘴挤出纺丝溶液且使电场作用并进行纺丝的方法;使纺丝溶液起泡且使电场作用并进行纺丝的方法;将纺丝溶液导出至圆筒状电极的表面且使电场作用并进行纺丝的方法等。在本发明中,在收集器上插入作为基材层(或保护层)的不织布等,可使纤维聚集到基材上。作为纺丝溶液,若为具有牵丝性的纺丝溶液,则并无特别限定,可使用使树脂分散于溶媒中的纺丝溶液、使树脂溶解于溶媒中的纺丝溶液、利用热或激光照射使树脂熔融的纺丝溶液等。
以提高纺丝的稳定性或纤维形成性为目的,也可在纺丝溶液中进一步含有表面活性剂。表面活性剂例如可列举十二烷基硫酸钠等阴离子性表面活性剂、溴化四丁基铵等阳离子表面活性剂、聚氧乙烯山梨醇酐单月桂酸酯等非离子性表面活性剂等。表面活性剂的浓度相对于纺丝溶液而言优选为5重量%以下的范围内。若为5重量%以下,则可获得与使用相符的效果的提高,因此优选。另外,只要为不显著损害本发明的效果的范围内,则也可包含所述以外的成分作为纺丝溶液的成分。
熔喷法为如下方法:将成为纤维层的树脂从喷嘴以熔融状态挤出到基材层上,利用加热压缩空气进行吹付,由此形成不织布的方法。例如,可使用包括具有螺杆、加热体及齿轮泵的两台挤出机、混纤用纺丝头、压缩空气产生装置及空气加热机、具备聚酯制网的捕集输送机以及卷绕机的不织布制造装置来制造不织布。通过调整搬运基材层的输送机的速度,可任意设定单位面积重量。作为纺丝中使用的树脂,只要是具有热塑性、具有牵丝性的树脂,则并无特别限定。
将由所述获得的纤维层叠体重叠多片而一体化的方法并无特别限定,只要不进行粘接仅重叠即可,另外,也可采用各种粘接方法、即、利用加热的平辊或压花辊进行的热压接、利用热熔剂或化学粘接剂进行的粘接、利用循环热风或辐射热进行的热粘接等。就抑制纤维层的物性降低的观点而言,其中优选为利用循环热风或辐射热进行的热处理。在利用平辊或压花辊进行的热压接的情况下,纤维层熔融而成膜,或在压花点周边部分发生破损等受到损伤,存在难以进行稳定的制造的可能性,除此以外还容易产生吸音特性降低等性能降低。另外,在利用热熔剂或化学粘接剂进行的粘接的情况下,有时会由该成分填埋纤维层的纤维间空隙,容易产生性能降低。另一方面,在利用循环热风或辐射热的热处理使其一体化的情况下,对纤维层的损伤少,且能够以充分的层间剥离强度一体化,因此优选。在通过利用循环热风或辐射热的热处理而一体化的情况下,并无特别限定,优选为使用包含热熔接性复合纤维的不织布及层叠体。
实施例
以下,利用实施例对本发明进行更详细的说明,以下的实施例仅以例示为目的。本发明的范围并不限定于本实施例。
以下示出实施例中示出的物性值的测定方法及定义。
<平均纤维径>
使用日立高新技术(Hitachi High-technologies)股份有限公司制造的扫描式电子显微镜SU8020,观察纤维结构体(不织布),使用图像解析软件测定50根纤维的直径。将50根纤维的纤维径的平均值作为平均纤维径。
<平均流量细孔径>
使用多孔材料(POROUS MATERIAL)公司制造的毛细管流动气孔测定器(CapillaryFlowPorometer)(CFP-1200-A),测定平均流量细孔径(日本工业标准(JapaneseIndustrial Standards,JIS)K 3822)。
<通气度>
(弗雷泽型法):使用东洋精机股份有限公司制造的织布通气度试验机(弗雷泽型法:A法),测定(JIS L 1096)通气度。
(格利型法):使用东洋精机股份有限公司制造的格利型密度计(GURLEY TYPEDENSOMETER)(格利型法:B法),测定(JIS L 1096)通气度。
<吸音率测定>
在吸音率测定中,从进行了各条件的层叠后的各纤维层叠体采集直径16.6mm的样品,使用垂直入射吸音率测定装置“日本音响工程公司制造的维恩杂特(WinZacMTX)”,按照美国试验材料学会(American Society for Testing Material,ASTM)E 1050测定在频率500Hz~5000Hz的试验片上垂直入射平面声波时的垂直入射吸音率。
<低频区域的吸音性>
在将以56点(3.9Hz间隔)测定频率为900Hz至1120Hz为止的吸音率而获得的曲线设为f(x)时,利用下述(式1)算出平均吸音率(α)。
[数1]
平均吸音率(α)表示900Hz~1120Hz的频率区域的吸音性能,若数值高则判断为吸音性高。在α为0.22以上的情况下,将低频区域的吸音性评价为良好,在小于0.22的情况下,将吸音性评价为不良。
<中频区域的吸音性>
在将以190点(3.9Hz间隔)测定频率为2800Hz至3550Hz为止的吸音率而获得的曲线设为f(x)时,利用下述(式2)算出平均吸音率(β)。
平均吸音率(β)表示2800Hz~3550Hz的频率区域的吸音性能,若数值高则判断为吸音性高。在β为0.60以上的情况下,将中频区域的吸音性评价为良好,在小于0.60的情况下,将吸音性评价为不良。
[数2]
<高频区域的吸音性>
在将以282点(3.9Hz间隔)测定频率为4500Hz至5600Hz为止的吸音率而获得的曲线设为f(x)时,利用下述(式3)算出平均吸音率(γ)。
平均吸音率(γ)表示4500Hz~5600Hz的频率区域的吸音性能,若数值高则判断为吸音性高。在γ为0.90以上的情况下,将高频区域的吸音性评价为良好,在小于0.90的情况下,将吸音性评价为不良。
[数3]
<超高频区域的吸音性>
在将以564点(3.9Hz间隔)测定频率为9000Hz至11200Hz为止的吸音率而获得的曲线设为f(x)时,利用下述(式4)算出平均吸音率(η)。
平均吸音率(η)表示9000Hz~11200Hz的频率区域的吸音性能,若数值高则判断为吸音性高。在η为0.85以上的情况下,将高频区域的吸音性评价为良好,在小于0.85的情况下,将吸音性评价为不良。
[数4]
<基材层的准备>
作为高密度聚乙烯,使用京叶聚乙烯制的高密度聚乙烯“M6900”(熔体流动速率(Melt Flow Rate,MFR)17g/10分钟),作为聚丙烯,使用日本聚丙烯制的聚丙烯均聚物“SA3A”(MFR=11g/10分钟),通过热熔融纺丝法,制作纤维径16μm的鞘成分由高密度聚乙烯、芯成分由聚丙烯构成的鞘芯型热熔接性复合纤维。使用所得的鞘芯型热熔接性复合纤维,制作单位面积重量为200g/m2、厚度为5mm、宽度为1000mm的梳理法热风不织布。利用商研股份有限公司制造的单轴式粉碎机(ES3280)将梳理法热风不织布粉碎至约6mm左右。
利用气流成网(Airlaid)试验机,在设定温度142℃下加热该粉碎的不织布,获得单位面积重量250g/m2、通气度95cc/cm2·s、厚度5mm的基材层P、单位面积重量373g/m2、通气度70cc/cm2·s、厚度5mm的基材层M、单位面积重量500g/m2、通气度78cc/cm2·s、厚度10mm的基材层Q、单位面积重量423g/m2、通气度83cc/cm2·s、厚度10mm的基材层N。
<保护层的准备>
作为保护层,准备了市售的聚对苯二甲酸乙二酯制梳理法热风不织布(单位面积重量18g/m2、厚度60μm)。
<纤维层的准备>
·1)纤维层A
将DIC拜耳聚合物(DIC Bayer Polymer)制造的聚氨基甲酸酯(等级名称:T1190)在N,N-二甲基甲酰胺与丙酮的共溶剂(60/40(w/w))中以15质量%的浓度溶解,制备电场纺丝溶液。准备保护层,在其上对所述聚氨基甲酸酯溶液进行电场纺丝,制作包含保护层与聚氨基甲酸酯极细纤维这两层的纤维层叠体。电场纺丝的条件使用27G针,单孔溶液供给量为2.5mL/h,施加电压为47kV,纺丝距离为20cm。
对于纤维层叠体中的聚氨基甲酸酯极细纤维,该层的单位面积重量为0.5g/m2,平均纤维径为470nm,熔解温度为175℃。将其作为纤维层A。对平均流量细孔径进行评价,结果为8.9μm。
·2)纤维层B
将阿科玛(Arkema)制造的作为聚偏二氟乙烯-六氟丙烯(PolyvinylideneFluoride-hexafluoro propylene)(以下简称为“PVDF-HFP”)的齐钠(Kynar)(商品名)3120在N,N-二甲基乙酰胺与丙酮的共溶剂(60/40(w/w))中以15质量%的浓度溶解,制备电场纺丝溶液,添加0.01质量%作为导电助剂。准备保护层,在其上对所述PVDF-HFP溶液进行电场纺丝,制作包含保护层与PVDF-HFP极细纤维这两层的纤维层叠体。电场纺丝的条件使用24G针,单孔溶液供给量为3.0mL/h,施加电压为35kV,纺丝距离为17.5cm。
对于纤维层叠体中的PVDF-HFP极细纤维,该层的单位面积重量为3.0g/m2,平均纤维径为80nm,熔解温度为168℃。将其作为纤维层B。对平均流量细孔径进行评价,结果为0.7μm。
·3)纤维层C
将阿科玛(Arkema)制造的作为聚偏二氟乙烯-六氟丙烯(以下简称为“PVDF-HFP”)的齐钠(Kynar)(商品名)3120在N,N-二甲基乙酰胺与丙酮的共溶剂(60/40(w/w))中以15质量%的浓度溶解,制备电场纺丝溶液。
准备保护层,在其上对所述PVDF-HFP溶液进行电场纺丝,制作包含保护层与PVDF-HFP极细纤维这两层的纤维层叠体。电场纺丝的条件使用24G针,单孔溶液供给量为3.0mL/h,施加电压为35kV,纺丝距离为17.5cm。对于纤维层叠体中的PVDF-HFP极细纤维,该层的单位面积重量为1g/m2,平均纤维径为200nm。将其作为纤维层C。对平均流量细孔径进行评价,结果为2.4μm。
·纤维层D
将阿科玛(Arkema)制造的作为聚偏二氟乙烯-六氟丙烯(以下简称为“PVDF-HFP”)的齐钠(Kynar)(商品名)3120在N,N-二甲基乙酰胺与丙酮的共溶剂(60/40(w/w))中以20质量%的浓度溶解,制备电场纺丝溶液。
准备保护层,在其上对所述PVDF-HFP溶液进行电场纺丝,制作包含保护层与PVDF-HFP极细纤维这两层的纤维层叠体。电场纺丝的条件使用24G针,单孔溶液供给量为3.0mL/h,施加电压为35kV,纺丝距离为17.5cm。对于纤维层叠体中的PVDF-HFP极细纤维,该层的单位面积重量为2g/m2,平均纤维径为400nm。将其作为纤维层D。对平均流量细孔径进行评价,结果为2.2μm。
·纤维层E
将阿科玛(Arkema)制造的作为聚偏二氟乙烯-六氟丙烯(以下简称为“PVDF-HFP”)的齐钠(Kynar)(商品名)3120在N,N-二甲基乙酰胺与丙酮的共溶剂(60/40(w/w))中以15质量%的浓度溶解,制备电场纺丝溶液。
准备保护层,在其上对所述PVDF-HFP溶液进行电场纺丝,制作包含保护层与PVDF-HFP极细纤维这两层的纤维层叠体。电场纺丝的条件使用24G针,单孔溶液供给量为3.0mL/h,施加电压为35kV,纺丝距离为17.5cm。对于纤维层叠体中的PVDF-HFP极细纤维,该层的单位面积重量为2.2g/m2,平均纤维径为200nm。将其作为纤维层E。对平均流量细孔径进行评价,结果为1.5μm。
·纤维层F
将DIC拜耳聚合物(DIC Bayer Polymer)制造的聚氨基甲酸酯(等级名称:T1190)在N,N-二甲基甲酰胺与丙酮的共溶剂(60/40(w/w))中以12.5质量%的浓度溶解,制备电场纺丝溶液。准备保护层,在其上对所述聚氨基甲酸酯溶液进行电场纺丝,制作包含保护层与聚氨基甲酸酯极细纤维这两层的纤维层叠体。电场纺丝的条件使用27G针,单孔溶液供给量为2.0mL/h,施加电压为47kV,纺丝距离为20cm。
对于纤维层叠体中的聚氨基甲酸酯极细纤维,该层的单位面积重量为0.5g/m2,平均纤维径为260nm。将其作为纤维层F。对平均流量细孔径进行评价,结果为2.8μm。
·纤维层G
将DIC拜耳聚合物(DIC Bayer Polymer)制造的聚氨基甲酸酯(等级名称:T1190)在N,N-二甲基甲酰胺与丙酮的共溶剂(60/40(w/w))中以12.5质量%的浓度溶解,制备电场纺丝溶液。准备保护层,在其上对所述聚氨基甲酸酯溶液进行电场纺丝,制作包含保护层与聚氨基甲酸酯极细纤维这两层的纤维层叠体。电场纺丝的条件使用27G针,单孔溶液供给量为2.0mL/h,施加电压为47kV,纺丝距离为20cm。
对于纤维层叠体中的聚氨基甲酸酯极细纤维,该层的单位面积重量为3g/m2,平均纤维径为270nm。将其作为纤维层G。对平均流量细孔径进行评价,结果为0.9μm。
·纤维层H
将DIC拜耳聚合物(DIC Bayer Polymer)制造的聚氨基甲酸酯(等级名称:T1190)在N,N-二甲基甲酰胺与丙酮的共溶剂(60/40(w/w))中以10质量%的浓度溶解,制备电场纺丝溶液。准备保护层,在其上对所述聚氨基甲酸酯溶液进行电场纺丝,制作包含保护层与聚氨基甲酸酯极细纤维这两层的纤维层叠体。电场纺丝的条件使用27G针,单孔溶液供给量为2.0mL/h,施加电压为45kV,纺丝距离为20cm。
对于纤维层叠体中的聚氨基甲酸酯极细纤维,该层的单位面积重量为3g/m2,平均纤维径为90nm。将其作为纤维层H。对平均流量细孔径进行评价,结果为0.8μm。
·纤维层I
将DIC拜耳聚合物(DIC Bayer Polymer)制造的聚氨基甲酸酯(等级名称:T1190)在N,N-二甲基甲酰胺与丙酮的共溶剂(60/40(w/w))中以12.5质量%的浓度溶解,制备电场纺丝溶液。准备保护层,在其上对所述聚氨基甲酸酯溶液进行电场纺丝,制作包含保护层与聚氨基甲酸酯极细纤维这两层的纤维层叠体。电场纺丝的条件使用27G针,单孔溶液供给量为2.0mL/h,施加电压为47kV,纺丝距离为20cm。
对于纤维层叠体中的聚氨基甲酸酯极细纤维,该层的单位面积重量为2g/m2,平均纤维径为270nm。将其作为纤维层I。对平均流量细孔径进行评价,结果为1.0μm。
·纤维层J
纤维层的形成使用包括具有螺杆(50mm直径)、加热体及齿轮泵的两台挤出机、混纤用纺丝头(孔径0.3mm、自两台挤出机交替喷出树脂的孔数501孔排成一列、有效宽度500mm)、压缩空气产生装置及空气加热机、具备聚酯制网的捕集输送机以及卷绕机的不织布制造装置。
作为原料的聚丙烯,使用聚丙烯均聚物1(MFR=82g/10分钟)与聚丙烯均聚物2(乐天化学(LOTTE CHEMICAL)公司制造的“FR-185”(MFR=1400g/10分钟)),在不织布制造装置的两台挤出机中投入所述两种聚丙烯,将挤出机在240℃下加热熔融,将齿轮泵的质量比设定为50/50,从纺丝头以每单孔0.3g/min的纺丝速度喷出熔融树脂。利用加热至400℃的98kPa(表压)的压缩空气,将喷出的纤维以距纺丝头60cm的距离吹付到捕集输送机上,形成纤维层。通过调整捕集输送机的速度,将单位面积重量设定为80g/m2。平均纤维径为1.3μm,将其作为纤维层J。对平均流量细孔径进行评价,结果为9.4μm。
·纤维层L
纤维层的形成使用包括具有螺杆(50mm直径)、加热体及齿轮泵的两台挤出机、混纤用纺丝头(孔径0.3mm、自两台挤出机交替喷出树脂的孔数501孔排成一列、有效宽度500mm)、压缩空气产生装置及空气加热机、具备聚酯制网的捕集输送机以及卷绕机的不织布制造装置。
作为原料的聚丙烯,使用聚丙烯均聚物1(MFR=82g/10分钟)与聚丙烯均聚物2(乐天化学(LOTTE CHEMICAL)公司制造的“FR-185”(MFR=1400g/10分钟)),在不织布制造装置的两台挤出机中投入所述两种聚丙烯,将挤出机在240℃下加热熔融,将齿轮泵的质量比设定为50/50,从纺丝头以每单孔0.3g/min的纺丝速度喷出熔融树脂。利用加热至400℃的63kPa(表压)的压缩空气,将喷出的纤维以距纺丝头60cm的距离吹付到捕集输送机上,形成纤维层。通过调整捕集输送机的速度,将单位面积重量设定为80g/m2。平均纤维径为1.9μm,将其作为纤维层L。对平均流量细孔径进行评价,结果为12.6μm。
[实施例1]
在第一纤维层(纤维层A)与第二纤维层(纤维层B)之间夹持基材层M,以最外层成为保护层的方式重叠成第一纤维层/基材层M/第二纤维层。将所得的样品作为吸音率测定用样品。由于存在两层纤维层,因此将纤维层的层数设为“2”。将其冲裁为直径16.6mm的圆形,作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.42而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.98而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.98而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.97而良好。
再者,在测定时,在测定试样的背后设置5mm的空气层进行测定(比较例3、比较例4除外)。
[实施例2]
在第一纤维层(纤维层C)与第二纤维层(纤维层B)之间夹持基材层M,重叠成第一纤维层C/基材层M/第二纤维层B,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.27而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.96而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.98而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.96而良好。
[实施例3]
在第一纤维层(纤维层D)与第二纤维层(纤维层B)之间夹持基材层M,重叠成第一纤维层D/基材层M/第二纤维层B,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.35而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.97而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.94而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.92而良好。
[实施例4]
在第一纤维层(纤维层E)与第二纤维层(纤维层B)之间夹持基材层M,重叠成第一纤维层E/基材层M/第二纤维层B,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.36而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.98而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.94而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.89而良好。
[实施例5]
在第一纤维层(纤维层E)与第二纤维层(纤维层E)之间夹持基材层M,重叠成第一纤维层E/基材层M/第二纤维层E,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.35而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.98而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.93而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.94而良好。
[实施例6]
在第一纤维层(纤维层C)与第二纤维层(纤维层C)之间夹持基材层M,重叠成第一纤维层C/基材层M/第二纤维层C,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.29而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.95而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.98而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.89而良好。
关于实施例1~实施例6,将层叠吸音材料的结构与吸音特性汇总示于表1中。另外,也汇总示出了各层的结构。
[表1]
作为实施例7~实施例21,与所述实施例同样地,使用各种纤维层及基材层制作层叠吸音材料,测定垂直入射吸音率。表2中汇总了层叠吸音材料的结构与吸音率。另外,也汇总示出了各层的结构。
[比较例1](实施例2的逆配置)
从实施例2中所得的样品的第二纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.39而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.97而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.90而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.73而不良。
认为原因在于,通过使细孔径变细,超高频区域中的声音的反射强烈地产生影响而使吸音特性降低。
[比较例2](仅基材层(基材层M))
利用气流成网试验机,将制成的373g/m2、厚度5mm的基材层M冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.11而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.28而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.41而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.80而不良。
[比较例3](市售品聚丙烯制不织布)
将市售的聚丙烯制不织布(3M公司制造的新雪丽(Thinsulate)TAI1590、纤维径0.7μm~4.0μm、厚度13mm)冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.12而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.47而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.69而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.88而良好。
[比较例4](市售品聚丙烯制不织布)
将市售的聚丙烯制不织布(3M公司制造的新雪丽(Thinsulate)TC3303、纤维径0.7μm~4.0μm、厚度41mm)冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.21而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.74而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.94而良好。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.88而良好。
[比较例5](实施例8的逆配置)
从实施例8中所得的样品的第二纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.52而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.92而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.81而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.67而不良。
[比较例6](仅基材层(基材层N))
利用气流成网试验机,将制成的423g/m2、厚度10mm的基材层N冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.16而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.42而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.64而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.84而不良。
[比较例7](仅基材层(基材层P))
利用气流成网试验机,将制成的250g/m2、厚度5mm的基材层P冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.06而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.17而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.26而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.64而不良。
[比较例8](仅基材层(基材层Q))
利用气流成网试验机,将制成的500g/m2、厚度10mm的基材层Q冲裁为直径16.6mm的圆形,作为吸音率测定用样品。测定该样品的垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.14而不良。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.44而不良。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.68而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.88而良好。
[比较例9](第一纤维层的平均流量细孔径为上限以上)
在第一纤维层(纤维层L)与第二纤维层(纤维层B)之间夹持基材层P,重叠成第一纤维层L/基材层P/第二纤维层B,与实施例1同样地作为吸音率测定用样品。
从所得的样品的第一纤维层侧入射声音,测定垂直入射吸音率,且作为低频区域的吸音性,测定900Hz至1120Hz为止的吸音率并评价平均吸音率(α),结果为0.30而良好。测定垂直入射吸音率,且作为中频区域的吸音性,评价2800Hz至3550Hz为止的平均吸音率(β),结果为0.97而良好。作为高频区域的吸音性,评价4500Hz至5600Hz为止的平均吸音率(γ),结果为0.87而不良。作为超高频区域的吸音性,评价9000Hz至11200Hz为止的平均吸音率(η),结果为0.87而良好。
关于比较例1~比较例9,将层叠吸音材料的结构与吸音特性汇总示于表3中。另外,也汇总示出了各层的结构。
[产业上的可利用性]
本发明的层叠吸音材料由于低频区域~超高频区域的吸音性优异、特别是高频区域的吸音性优异,因此可作为声音的侵入成为问题的领域中的吸音材料来使用。具体而言,可用作住宅的天花板、墙壁、地板等中使用的吸音材料、高速公路或铁路路线等的隔音墙、家电产品的隔音材料、配置在铁路或汽车等车辆的各部分的吸音材料等。
Claims (7)
1.一种层叠吸音材料,至少包含:第一纤维层与第二纤维层、以及存在于所述第一纤维层与所述第二纤维层之间的至少一层基材层,
所述第一纤维层的平均流量细孔径为0.5μm~10μm,单位面积重量为0.1g/m2~200g/m2,
所述第二纤维层的平均流量细孔径为0.5μm~10μm且为所述第一纤维层的平均流量细孔径以下,单位面积重量为0.1g/m2~200g/m2,
所述基材层的利用弗雷泽型法所得的通气度为40cc/cm2·s以上,单位面积重量为1g/m2~700g/m2,
所述第一纤维层配置在声音的入射侧,所述第二纤维层配置在声音的透过侧。
2.根据权利要求1所述的层叠吸音材料,其中所述第一纤维层、所述第二纤维层及所述基材层独立地为选自由不织布及织布所组成的群组中的至少一种。
3.根据权利要求1或2所述的层叠吸音材料,其中所述基材层包含选自由聚邻苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚乙烯及聚丙烯所组成的群组中的至少一种纤维或者至少两种复合化而成的纤维,所述第一纤维层及所述第二纤维层独立地包含选自由聚偏二氟乙烯、尼龙6,6、聚丙烯腈、聚苯乙烯、聚氨基甲酸酯、聚砜、及聚乙烯醇、聚邻苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚乙烯及聚丙烯所组成的群组中的至少一种纤维。
4.根据权利要求1至3中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为900Hz至1120Hz为止的吸音率,算出吸音率的平均吸音率(α),平均吸音率(α)的值为满足下述式的范围。
1.00≧α≧0.22
5.根据权利要求1至4中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为2800Hz至3550Hz为止的吸音率,算出吸音率的平均吸音率(β),平均吸音率(β)的值为满足下述式的范围。
1.00≧β≧0.60
6.根据权利要求1至5中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为4500Hz至5600Hz为止的吸音率,算出吸音率的平均吸音率(γ),平均吸音率(γ)的值为满足下述式的范围。
1.00≧γ≧0.90
7.根据权利要求1至6中任一项所述的层叠吸音材料,其中在垂直入射吸音率测定法中,通过测定频率为9000Hz至11200Hz为止的吸音率,算出吸音率的平均吸音率(η),平均吸音率(η)的值为满足下述式的范围。
1.00≧η≧0.85
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