CN117121093A - 吸声材料及车辆部件 - Google Patents

吸声材料及车辆部件 Download PDF

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Publication number
CN117121093A
CN117121093A CN202180096521.XA CN202180096521A CN117121093A CN 117121093 A CN117121093 A CN 117121093A CN 202180096521 A CN202180096521 A CN 202180096521A CN 117121093 A CN117121093 A CN 117121093A
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China
Prior art keywords
layer
sound absorbing
absorbing material
protective layer
resin
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CN202180096521.XA
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Inventor
高安慧
清水麻理
小竹智彦
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Lishennoco Co ltd
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Lishennoco Co ltd
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Publication of CN117121093A publication Critical patent/CN117121093A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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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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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Mechanical Engineering (AREA)
  • Multimedia (AREA)
  • Laminated Bodies (AREA)

Abstract

一种吸声材料，其依次具备：保护层、具有连通孔的第一基材层及具有连通孔的第二基材层，保护层的由以下式(I)表示的柔软强韧性值为1～75[MPa/μm]。柔软强韧性值＝(在25℃下的保护层的拉伸弹性模量[MPa]×保护层的肖氏A硬度)/保护层厚度[μm]···(I)。

Description

吸声材料及车辆部件
技术领域
本发明涉及一种吸声材料及车辆部件。
背景技术
作为低频区域中的吸声特性优异的吸声材料，已知有层叠两层无纺布等而形成的吸声材料(例如专利文献1)。
以往技术文献
专利文献
专利文献1：国际公开第2020/213685号
发明内容
发明要解决的技术课题
当为由无纺布形成的吸声材料时，特别是在对来自外部的机械冲击的耐久性方面有改善的余地。
本发明是鉴于上述情形而完成的，其目的在于提供一种低频区域中的吸声特性及耐久性优异的吸声材料。本发明的目的还在于提供一种具备该吸声材料的车辆部件。
用于解决技术课题的手段
本发明的一方面涉及一种吸声材料，其依次具备：保护层、具有连通孔的第一基材层及具有连通孔的第二基材层，保护层的由以下式(I)表示的柔软强韧性值为1～75[MPa/μm]。
柔软强韧性值＝(在25℃下的保护层的拉伸弹性模量[MPa]×保护层的肖氏A硬度)/保护层厚度[μm]···(I)
一实施方式中，保护层可以为包含弹性体的层。
一实施方式中，保护层可以为无纺布。
一实施方式中，吸声材料可以在保护层与第一基材层之间进一步具备树脂层。
一实施方式中，树脂层可以包含聚烯烃、聚酯或聚酰胺。
一实施方式中，吸声材料可以在树脂层的至少任一表面上进一步具备金属蒸镀层。
一实施方式中，第一基材层及第二基材层可以为树脂发泡体或无纺布。
一实施方式中，第一基材层的厚度可以比第二基材层的厚度薄。
一实施方式中，吸声材料的厚度可以为1～100mm。
本发明的一方面涉及一种具备上述吸声材料的车辆部件。
发明效果
根据本发明，能够提供一种低频区域中的吸声特性及耐久性优异的吸声材料。并且，根据本发明，能够提供一种具备该吸声材料的车辆部件。
附图说明
图1是一实施方式所涉及的吸声材料的示意性剖视图。
图2是一实施方式所涉及的吸声材料的示意性剖视图。
具体实施方式
以下，根据情况一边参考附图一边详细地说明本发明的实施方式。另外，在本说明书中，使用“～”示出的数值范围表示将记载于“～”的前后的数值分别作为最小值及最大值而包括的范围。并且，在本说明书中记载的数值范围中，该数值范围的上限值或下限值可以替换为实施例中所示出的值。
＜吸声材料＞
图1是一实施方式所涉及的吸声材料的示意性剖视图。吸声材料10依次具备保护层1和作为基材层的具有连通孔的第一基材层2及具有连通孔的第二基材层3。从保护层侧入射后的声音(声能)，在穿透吸声材料时会以热能的形式散逸。由此能够观察到声音的衰减。
图2是一实施方式所涉及的吸声材料的示意性剖视图。吸声材料20依次具备保护层1、树脂层4和作为基材层的具有连通孔的第一基材层2及具有连通孔的第二基材层3。
(基材层)
作为具有连通孔的基材层，可举出树脂发泡体、无纺布、高分子多孔体、多孔质陶瓷等。在它们之中，从低频区域中的吸声特性优异的观点考虑，基材层可以为树脂发泡体或无纺布。第一基材层与第二基材层可以由相同的材料构成，也可以由不同的材料构成。
作为树脂发泡体的材料，可举出聚乙烯树脂、聚丙烯树脂、聚氨酯(polyurethane)树脂、聚酯树脂、丙烯酸类树脂、聚苯乙烯树脂、三聚氰胺树脂、硅酮树脂、天然橡胶、合成橡胶等。从耐热性、难燃性等观点考虑，树脂发泡体的材料可以为三聚氰胺树脂。
作为用于构成无纺布的纤维，可举出有机纤维及无机纤维。作为有机纤维，可举出聚乙烯(低密度或高密度)、聚丙烯(PP)、共聚聚乙烯、共聚聚丙烯等聚烯烃纤维；聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸三甲二酯、聚对苯二甲酸丁二酯、聚萘二甲酸乙二酯、聚萘二甲酸丁二醇酯等聚酯纤维；聚酰胺纤维；丙烯酸纤维；耐纶纤维；嫘萦纤维；羊毛等天然纤维等。并且，作为无机纤维，可举出玻璃纤维、金属纤维、陶瓷纤维、碳纤维等。用于构成无纺布的纤维，能够包含它们中的1种或2种以上。
从低频区域中的吸声特性优异的观点考虑，基材层的厚度能够设为0.1～50mm，可以为0.5～20mm，也可以为2.0～10mm。第一基材层与第二基材层可以具有相同的厚度，也可以具有不同的厚度。从低频区域中的吸声特性优异的观点考虑，第一基材层(声音的入射侧的基材层)的厚度可以比第二基材层的厚度薄。
从低频区域中的吸声特性优异的观点考虑，基材层的基重能够设为50～2000g/m2，也可以为100～1000g/m2。
从低频区域中的吸声特性优异的观点考虑，吸声材料可以进一步具备具有连通孔的其它基材层。换言之，吸声材料除了具有连通孔的第一基材层及具有连通孔的第二基材层以外，还可以进一步具备具有连通孔的第三基材层及具有连通孔的第四基材层等。各基材层可以由相同的材料构成，也可以由不同的材料构成。
(保护层)
保护层的由以下式(I)表示的柔软强韧性值为1～75MPa/μm。从以更高水平兼具吸声特性及耐久性的观点考虑，柔软强韧性值可以为2～70MPa/μm，也可以为5～65MPa/μm。
柔软强韧性值＝(在25℃下的保护层的拉伸弹性模量[MPa]×保护层的肖氏A硬度)/保护层厚度[μm]···(I)
柔软强韧性值是指着眼于保护层的每单位厚度的冲击吸收性能及冲击耐久性而设定的特性值。每单位厚度的冲击吸收性能能够根据肖氏A硬度进行评价，冲击耐久性能够根据拉伸弹性模量进行评价，若两者的乘积在规定的范围内，则表示保护层适当地柔软且强韧。
使用拉伸试验机测定拉伸弹性模量。具体而言，准备20mm×50mm的样品，将使用拉伸试验机并以拉伸速度100mm/分钟拉伸该样品时的在25℃下的弹性模量的最大值作为上述拉伸弹性模量。只要满足上述式，则没有特别的限制，从耐久性的观点考虑，拉伸弹性模量能够设为1～2000MPa，也可以为10～1000MPa。
肖氏A硬度是使用硬度计(A型)测定的。具体而言，准备20mm×50mm的样品，将样品层叠为1mm以上的厚度，在25℃环境下静置1小时。将使用硬度计测定静置后的样品的硬度时的1秒以内的值(或测定后立即显示的值)作为上述肖氏A硬度。只要满足上述式，则没有特别的限制，从耐久性的观点考虑，肖氏A硬度能够设为20～95，也可以为30～92。
保护层厚度是使用厚度测定器测定的。只要满足上述式，则没有特别的限制，从耐久性的观点考虑，保护层厚度能够设为10～2000μm，也可以为50～500μm。
为了将柔软强韧性值设在上述规定的范围内，例如可以考虑根据以下观点调整各特性。
作为调整弹性模量及肖氏A硬度的方法，可举出调整保护层的密度、向材料中赋予刚直成分以及增加材料中的金属、陶瓷、二氧化硅等无机成分的比例等。还能够通过调整保护层中的空隙量来调整弹性模量及肖氏A硬度。还能够通过构成具有空隙的保护层的骨架成分、骨架的粗细、骨架的粘结的方法等来调整弹性模量及肖氏A硬度。
例如能够通过适当组合上述举出的方法来调整弹性模量及肖氏A硬度中的任一者。例如能够通过在保护层中设置空隙的同时加厚构成保护层的骨架，保持弹性模量的同时降低肖氏A硬度。
从以更高水平兼具吸声特性及耐久性的观点考虑，保护层也可以为包含弹性体的层。作为可满足上述柔软强韧性值的弹性体，可举出热塑性弹性体及热固性弹性体。作为热塑性弹性体，例如可举出聚烯烃类、聚苯乙烯类、聚氨酯类、聚酯类、聚醚类、聚丙烯酸类、聚酰胺类、氯乙烯、氯化聚乙烯类、聚二烯类、氟类、硅酮类、聚碳酸酯类等树脂、或它们的改性树脂。并且，作为热固性弹性体，例如可举出氟类、硅酮类、聚氨酯类、环氧类等的树脂、异戊二烯橡胶、乙丙橡胶、三元乙丙橡胶、腈橡胶(NBR)等合成橡胶或天然橡胶、或它们的改性树脂。从以轻量化为目的的薄膜化、耐热性、耐久性等观点考虑，优选为聚氨酯类或聚酯类树脂。
包含弹性体的层除了弹性体以外还可以包含其他成分。从提高耐热性、耐久性、吸声性、减振性、隔音性等的观点考虑，作为其他成分，可举出二氧化硅、氧化铝、滑石等无机粒子、金属粒子、有机树脂粒子等，从轻量化的观点考虑，可举出中空粒子等。从轻量化的观点考虑，包含弹性体的层可以包含发泡材料、基于发泡成形的气泡部分等。
从以更高水平兼具吸声特性及耐久性的观点考虑，保护层可以为无纺布。作为可满足上述柔软强韧性值的无纺布，从耐久性的观点考虑，可举出纤维牢固粘结的无纺布，例如可举出利用化学粘合法、热粘合法、针刺法等制造的无纺布(PET无纺布等)。
从以更高水平兼具吸声特性及耐久性的观点考虑，保护层的单位面积重量(每单位面积的重量)能够设为10～1000g/m2，也可以为50～800g/m2。
从以更高水平兼具吸声特性及耐久性的观点考虑，保护层的密度能够设为0.1～10.0g/cm3，也可以为0.2～2.0g/cm3。
当保护层为无纺布时，从以更高水平兼具吸声特性及耐久性的观点考虑，构成无纺布的纤维的平均纤维直径能够设为0.1～100μm，也可以为1～50μm。
平均纤维直径可通过对从利用电子显微镜以1000倍拍摄的照片测定的每个纤维的纤维直径进行平均而求出。具体而言，平均纤维直径可通过如下方法求出：测定从10张照片任意选择的合计100根纤维的直径至直径0.1μm的量级，对它们进行平均，并对小数点以下第2位进行四舍五入。
(树脂层)
从提高吸声特性、提高耐久性、赋予功能性等观点考虑，吸声材料可以在保护层与基材层之间进一步具备树脂层。作为用于构成树脂层的树脂，例如可举出聚乙烯(低密度或高密度)、聚丙烯(延伸或未延伸)、共聚聚乙烯、共聚聚丙烯等聚烯烃类树脂；聚对苯二甲酸乙二醇酯、聚对苯二甲酸三甲二酯、聚对苯二甲酸丁二酯、聚萘二甲酸乙二酯、聚萘二甲酸丁二醇酯等聚酯类树脂；PTFE、FEP、PFA等氟类树脂；聚酰亚胺类树脂、聚酰胺类树脂、芳纶类树脂、氯乙烯类树脂、丙烯酸类树脂、聚碳酸酯类树脂、聚苯硫醚类树脂、聚乙烯醇类树脂、聚苯乙烯类树脂、聚丙烯腈类树脂、乙烯-乙酸乙烯酯类树脂等。树脂层为不具有连通孔的层(膜)。
从低频区域中的吸声特性优异的观点考虑，树脂层的厚度能够设为0.5～500μm，可以为5～250μm，也可以为10～100μm。
从通过调整膜特性来提高吸声效果的功能及赋予红外线反射的功能的观点考虑，树脂层可以在其表面上具备金属蒸镀层。即，吸声材料可以在树脂层的表面上进一步具备金属蒸镀层。金属蒸镀层能够通过将铝、铜、锌、锌合金、银等金属进行真空蒸镀等物理蒸镀或化学蒸镀来形成。金属蒸镀层可以设置于树脂层的双面，也可以设置于树脂层的其中一面。
从提高低频区域中的吸声效果及调整吸声频率峰的观点考虑，树脂层可以为有孔膜。有孔膜可以具有排列成栅极状和菱形状的孔。从低频区域中的吸声特性优异的观点考虑，该孔可以为直径0.1～50.0mm的圆形状，也可以为直径0.2～10.0mm的圆形状，也可以为直径0.3～5.0mm的圆形状。孔的形状可以为圆形、椭圆形、长方形、多边形等。
(黏合剂层)
吸声材料的上述各层之间可以进一步具备黏合剂层。吸声材料可以在保护层与第一基材层之间、以及第一基材层与第二基材层之间中的至少任一者，具备黏合剂层。并且，吸声材料可以在保护层与树脂层之间、树脂层与第一基材层之间、以及第一基材层与第二基材层之间中的至少任一者，具备黏合剂层。
作为黏合剂层，可举出包含乙酸乙烯酯树脂、聚烯烃树脂、乙烯-乙酸乙烯酯共聚树脂、异丁烯-马来酸酐共聚树脂、丙烯酸类共聚树脂、丙烯酸类单体、丙烯酸类低聚物、苯乙烯-丁二稀橡胶、氯乙烯树脂、氯丁二烯橡胶、腈橡胶、聚氨酯树脂、硅烷化聚氨酯树脂、环氧树脂、改性环氧树脂、聚乙烯树脂、离聚物树脂、硅酮树脂、改性硅酮树脂、水玻璃、硅酸盐等黏合成分的层；或在支承体的双面上具备包含这些黏合成分的层的层叠物(例如双面胶带)等，该支承体由纸、布、树脂膜、金属带等构成。各黏合剂层可以由相同的材料构成，也可以由不同的材料构成。
黏合剂层的厚度并无特别限定，能够设为0.01～500μm，可以为1～250μm。各黏合剂层可以具有相同的厚度，也可以具有不同的厚度。
黏合剂层的重量并无特别限定，能够设为1～500g/m2，可以为5～200g/m2，也可以为10～150g/m2。各黏合剂层可以具有相同的厚度，也可以具有不同的厚度。
从吸声特性的显现、材料的施工性、节省空间化等观点考虑，吸声材料的厚度能够设为1～100mm，可以为2～50mm，也可以为5～30mm。
从低频区域中的吸声特性优异的观点考虑，按照JIS A 1405-1测定的吸声材料在500～1000Hz中的平均垂直入射吸声率能够设为0.45以上，也可以为0.5以上。从相同的观点考虑，吸声材料的500～1000Hz中的最大垂直入射吸声率能够设为0.65以上，也可以为0.7以上。
＜吸声材料的制造方法＞
吸声材料能够通过层叠各层来制造。关于吸声材料，可以如上所述在通过具备黏合剂层来将各层黏合的状态下使用，也可以在不将各层黏合的情况下使用。并且，可以仅在一部分层之间设置黏合剂层。构成吸声材料的层叠体可以在收纳于框体中的状态下使用。
＜吸声材料的用途＞
上述吸声材料不仅低频区域中的吸声特性优异，而且耐久性也优异。因此，上述吸声材料能够适用于汽车、铁道车辆、航空器、船舶、住宅等建筑物等用途。这里所说的低频区域能够设为频率为1000Hz以下的区域，上述吸声材料在250～1000Hz、特别是在500～1000Hz的频率区域中具有优异的吸声特性。
＜车辆部件＞
车辆部件具备上述吸声材料。作为车辆部件，例如可举出以下实施方式。车辆部件可以为汽车部件。
外装：作为车辆用外装材料的吸声部件的车辆部件、车辆用外装材料。
作为外装，可举出(车辆用)底盖或底保护器、隔音盖等，具体地可举出发动机底盖、地板底盖、后部底盖、变速箱盖、翼子板衬套/保护器或挡泥板等。
内装：作为车辆用内装材料的吸声部件的车辆部件、车辆用内装材料。
作为内装，可举出车辆用消音器、车辆用防音体等，具体地可举出顶棚材料(车顶消音器)、仪表板消音器、地板消音器、地板地毯、机盖消音器等。
其他：轮胎用吸声材料。
作为轮胎用吸声材料，可举出将车辆用盖、壳体等与上述吸声材料组合而得的吸声结构体。
下面列举本实施方式的内容。
一种吸声材料，其依次具备：保护层、具有连通孔的第一基材层及具有连通孔的第二基材层，保护层的由以下式(I)表示的柔软强韧性值为1～75[MPa/μm]。
柔软强韧性值＝(在25℃下的保护层的拉伸弹性模量[MPa]×保护层的肖氏A硬度)/保护层厚度[μm]···(I)
上述吸声材料中，保护层为包含弹性体的层。
上述吸声材料中，保护层为无纺布。
上述吸声材料中，在保护层与第一基材层之间进一步具备树脂层。
上述吸声材料中，树脂层包含聚烯烃、聚酯或聚酰胺。
上述吸声材料中，在树脂层的至少任一表面上进一步具备金属蒸镀层。
上述吸声材料中，第一基材层及第二基材层为树脂发泡体或无纺布。
上述吸声材料中，第一基材层的厚度比第二基材层的厚度薄。
上述吸声材料的厚度为1～100mm。
一种车辆部件，其具备上述吸声材料。
实施例
以下，通过实施例对本发明进行更详细的说明，但本发明并不限定于这些实施例。
(基材层的准备)
基材1：PET无纺布(基重200g/m2、厚度3mm)
基材2：PET无纺布(基重250g/m2、厚度7mm)
(保护层的准备)
准备了表1、表2及表3所示的保护层。
厚度：将保护层切成200mm×200mm，并使用厚度测定器(数字式测厚仪JAN-257探针φ20mm OZAKI MFG.CO.,LTD.制造)进行了测定。测定部位为中心及四个角，共5个部位，将其平均值作为保护层的厚度。
拉伸弹性模量：使用拉伸试验机(EZ-Test、SHIMADZU CORPORATION制造)进行了测定。准备20mm×50mm的样品，将使用拉伸试验机并以拉伸速度100mm/分钟拉伸该样品时的在25℃下的最大弹性模量作为上述拉伸弹性模量。当有TD方向及MD方向时，采用了弹性模量较低的方向。测定次数设为3次，将其平均值作为保护层的拉伸弹性模量。
肖氏A硬度：使用硬度计(A型)进行了测定。准备20mm×50mm的样品，将样品层叠为1mm以上的厚度，将利用硬度计对其测定的硬度作为肖氏A硬度。测定部位为中心及四个角，共5个部位，将其平均值作为保护层的肖氏A硬度。
[表1]
[表2]
[表3]
(树脂层的准备)
准备了以下树脂层。
双面经铝蒸镀的聚对苯二甲酸乙二醇酯膜(AlPET)：厚度12μm
(黏合剂层的准备)
准备了下述黏合剂层。
双面胶带：Showa Denko Materials co.,Ltd.、Hi-bon11-652、厚度0.12mm
(吸声材料的制作)
制作了具有表4及表5中所示的结构的吸声材料。各层的黏合使用了双面胶带。
(吸声材料的吸声特性评价)
按照以下来测定了所制作的各吸声材料的垂直入射吸声率。从保护层侧入射了声音。计算500～1000Hz中的垂直入射吸声率的平均值作为平均吸声率，并且将垂直入射吸声率的最大值作为最大吸声率。当平均吸声率为0.45以上且最大吸声率为0.65以上时，判断为低频区域(500～1000Hz)的吸声特性优异。将结果示于表4及表5中。
装置名：4206型阻抗管(Bruel&Kjaer公司)
测定方法：垂直入射吸声率(按照JIS A 1405-1)
测定范围：50～1600Hz
(吸声材料的耐久性评价)
对所制作的各吸声材料的耐久性(耐崩刀性)进行了评价。评价时使用飞石试验机JA400(Suga Test Instruments Co.,Ltd.制造)，使7号碎石850g以0.4MPa的压力撞击保护层。然后用肉眼确认保护层表面的状态，并根据以下基准评价了耐久性。当评价为A或B时，判断为耐久性优异。将结果示于表4及表5中。
A：不存在孔或打痕。
B：不存在孔，存在打痕。
C：存在孔(少于5个部位)。
D：存在孔(5个部位以上)。
[表4]
[表5]
符号说明
1-保护层，2-具有连通孔的第一基材层，3-具有连通孔的第二基材层，4-树脂层，10、20-吸声材料。

Claims (10)

1.一种吸声材料，其依次具备保护层、具有连通孔的第一基材层及具有连通孔的第二基材层，其中，
所述保护层的由以下式(I)表示的柔软强韧性值为1～75[MPa/μm]，
柔软强韧性值＝(在25℃下的保护层的拉伸弹性模量[MPa]×保护层的肖氏A硬度)/保护层厚度[μm]···(I)。
2.根据权利要求1所述的吸声材料，其中，
所述保护层为包含弹性体的层。
3.根据权利要求1所述的吸声材料，其中，
所述保护层为无纺布。
4.根据权利要求1至3中任一项所述的吸声材料，其中，
在所述保护层与所述第一基材层之间进一步具备树脂层。
5.根据权利要求4所述的吸声材料，其中，
所述树脂层包含聚烯烃、聚酯或聚酰胺。
6.根据权利要求4或5所述的吸声材料，其中，
在所述树脂层的至少任一表面上进一步具备金属蒸镀层。
7.根据权利要求1至6中任一项所述的吸声材料，其中，
所述第一基材层及所述第二基材层为树脂发泡体或无纺布。
8.根据权利要求1至7中任一项所述的吸声材料，其中，
所述第一基材层的厚度比所述第二基材层的厚度薄。
9.根据权利要求1至8中任一项所述的吸声材料，其厚度为1～100mm。
10.一种车辆部件，其具备权利要求1至9中任一项所述的吸声材料。
CN202180096521.XA 2021-04-16 2021-04-16 吸声材料及车辆部件 Pending CN117121093A (zh)

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