JP2008208469A - Highly heat-resistant heat insulating and sound absorbing material - Google Patents

Highly heat-resistant heat insulating and sound absorbing material Download PDF

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JP2008208469A
JP2008208469A JP2007043344A JP2007043344A JP2008208469A JP 2008208469 A JP2008208469 A JP 2008208469A JP 2007043344 A JP2007043344 A JP 2007043344A JP 2007043344 A JP2007043344 A JP 2007043344A JP 2008208469 A JP2008208469 A JP 2008208469A
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fiber
heat
absorbing material
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heat insulating
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JP2008208469A5 (en
JP5208434B2 (en
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Masaaki Takeda
正明 武田
Hideo Nakamura
英雄 中村
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Fujiko KK
Fujikoo KK
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Fujikoo KK
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat insulating and sound absorbing material for aircraft which is a flexible relatively inexpensive heat insulating and sound absorbing material having high heat insulating and sound absorbing properties and adapted to new particularly severe required specifications of the aircraft. <P>SOLUTION: This material is obtained by uniformly mixing 40-80% of highly heat-resistant inorganic fibers maintaining high-temperature strength at ≥1,000°C with 20-60% of organic fibers, heat-treating the resultant loose fibrous material and thereby forming the whole into a mat. The thickness of the resultant heat insulating and sound absorbing material is 8-50 mm. The organic fibers are composed of 10-50% of heat-resistant organic fibers having ≥200°C melting point and 10-25% of low-melting organic fibers, based on 40-80% of the inorganic fibers. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、高い断熱性と吸音性を有する屈曲可能で比較的安価な断熱吸音材に関し、特に厳しい航空機の新規要求仕様に適合する断熱吸音材に関する。   The present invention relates to a bendable and relatively inexpensive heat insulating sound absorbing material having high heat insulating properties and sound absorbing properties, and more particularly to a heat insulating sound absorbing material that meets new requirements for strict aircraft.

日本では、鉄道車両用の吸音材として、特公昭63−19622号公報に開示するように、ガラスウールやロックウールに少量の有機性樹脂を含浸し、板状に成形した断熱性の吸音材を使用していた。この吸音材は、含浸させる樹脂が可燃性であると燃焼時に有毒ガスを発生し、軽量でないので車両重量が増加しやすい。この点を改良した実公平6−47715号公報では、アクリル焼成の耐炎繊維ラップをニードルパンチングし、さらにアクリル焼成耐炎繊維のニードルフェルトまたは織布からなる表面シートを貼り合わせている。この吸音材は、比較的軽量であるので車両の重量増加が少なく、高耐熱性が必要でない新幹線車両を含む日本の鉄道車両において採用されている。   In Japan, as disclosed in Japanese Examined Patent Publication No. 63-19622, as a sound absorbing material for railway vehicles, a heat insulating sound absorbing material formed by impregnating glass wool or rock wool with a small amount of an organic resin and molding it into a plate shape is used. I was using it. If the resin to be impregnated is flammable, this sound absorbing material generates a toxic gas at the time of combustion, and the weight of the vehicle tends to increase because it is not lightweight. In Japanese Utility Model Publication No. 6-47715 in which this point is improved, an acrylic fired flame resistant fiber wrap is needle punched, and a top sheet made of needle felt or woven fabric of acrylic fired flame resistant fiber is bonded. This sound-absorbing material is used in Japanese railway vehicles including Shinkansen vehicles that do not require high heat resistance because of its relatively light weight and little increase in vehicle weight.

また、自動車用の吸音材には、従来、ガラスウールの表面にアルミシートを貼着したものを用いていた。この吸音材は、エンジンルームにおいて相当に高温になる排気マフラーの付近に設置すると、高温には耐えても吸音性が不十分であった。このため、特開昭59−227442号では、高軟化点を有する短繊維を合成繊維の不織布に散布した後にニードリングを施し、得た耐熱性の表皮材を接着剤を介してガラスウールの表面に積層し、さらに加熱・加圧で成形している。この吸音材は、仕様繊維の融点がいずれも300℃以下であるため、高温耐熱性が要求されるエンジンルームに用いるには表皮材の耐熱性が不足する。また、特開2006−138935号に開示の吸音材は、熱溶融温度または熱分解温度が370℃以上の耐熱性有機繊維を含有する繊維シートからなる表皮材と、同様の耐熱性有機繊維を含有する厚さ2〜100mmの不織布とを積層している。この吸音材は、自動車用途においてほぼ満足すべき耐熱性を有している。
特公昭63−19622号公報 実公平6−47715号公報 特開昭59−227442号公報 特開2006−138935号公報 特開2005−335279号公報
Conventionally, a sound-absorbing material for automobiles has been obtained by attaching an aluminum sheet to the surface of glass wool. When this sound-absorbing material was installed in the vicinity of an exhaust muffler that would be considerably hot in the engine room, the sound-absorbing material was insufficient in its ability to withstand high temperatures. For this reason, in Japanese Patent Application Laid-Open No. 59-227442, a short fiber having a high softening point is applied to a nonwoven fabric of synthetic fiber and then subjected to needling, and the obtained heat-resistant skin material is bonded to the surface of glass wool through an adhesive. And then molded by heating and pressing. In this sound absorbing material, since the melting point of the specification fiber is 300 ° C. or less, the heat resistance of the skin material is insufficient for use in an engine room where high temperature heat resistance is required. Further, the sound absorbing material disclosed in JP-A-2006-138935 contains a skin material made of a fiber sheet containing a heat-resistant organic fiber having a heat melting temperature or a thermal decomposition temperature of 370 ° C. or higher, and the same heat-resistant organic fiber. And a nonwoven fabric having a thickness of 2 to 100 mm. This sound-absorbing material has heat resistance that is almost satisfactory for automobile applications.
Japanese Examined Patent Publication No. 63-19622 No. 6-47715 JP 59-227442 A JP 2006-138935 A JP 2005-335279 A

断熱性の吸音材を航空機に用いる場合には、事故が発生した際の被害人数の多さおよび危険性の高さを考慮して、一般の鉄道車両用または自動車用の吸音材に比べて、耐熱・断熱性に対する要求が非常に厳しい。航空機用の吸音材は、主たる不織布が通常のガラスウールやロックウールまたは耐熱性有機繊維からなり、該不織布の表面に積層する表皮材についても同様の素材であった。このため、この吸音材は、断熱温度と耐熱性の点で航空機に関する不織布の要求仕様に適合させることは難しい。   When using heat-absorbing sound-absorbing materials for aircraft, considering the large number of victims and the high risk when accidents occur, compared to sound absorbing materials for ordinary railway vehicles or automobiles, The requirements for heat resistance and heat insulation are very strict. In the sound absorbing material for aircraft, the main nonwoven fabric is made of ordinary glass wool, rock wool or heat-resistant organic fiber, and the skin material laminated on the surface of the nonwoven fabric is the same material. For this reason, it is difficult for this sound-absorbing material to be adapted to the required specifications of nonwoven fabrics for aircraft in terms of heat insulation temperature and heat resistance.

一方、特開2005−335279号は、自動車、電車、航空機などの内装に用いる易成形性の吸音材であると開示し、該吸音材では不織布の片面に表皮材が積層され、この表皮材に樹脂バインダーを含有している。この吸音材は、成形性の点では有効であっても、有機繊維の不織布を用いる点では前記と同様であり、航空機に関する不織布の新規要求仕様に適合させることは不可能である。   On the other hand, Japanese Patent Application Laid-Open No. 2005-335279 discloses that it is an easily moldable sound absorbing material used for interiors of automobiles, trains, aircrafts, etc., and in the sound absorbing material, a skin material is laminated on one side of a nonwoven fabric. Contains a resin binder. Although this sound absorbing material is effective in terms of formability, it is the same as described above in that an organic fiber non-woven fabric is used, and it is impossible to meet the new requirements for non-woven fabric related to aircraft.

本発明は、従来の吸音材に関する高温断熱性の問題点を改善するために提案されたものであり、特に高い断熱性および吸音性によって安全性の高く且つ比較的安価な断熱吸音材を提供することを目的としている。本発明の他の目的は、高い断熱性および吸音性を達成するとともに、設置場所に応じて屈曲可能な断熱吸音材を提供することである。本発明の別の目的は、航空機に関する不織布の新規要求仕様に適合する航空機用の断熱吸音材を提供することである。   The present invention has been proposed in order to improve the problem of high-temperature heat insulation related to conventional sound-absorbing materials, and provides a heat-insulating sound-absorbing material that is highly safe and relatively inexpensive due to particularly high heat-insulating properties and sound-absorbing properties. The purpose is that. Another object of the present invention is to provide a heat insulating sound-absorbing material that achieves high heat insulating properties and sound absorbing properties and can be bent according to the installation location. Another object of the present invention is to provide an adiabatic sound-absorbing material for aircraft that meets the new requirements for nonwoven fabrics related to aircraft.

本発明に係る断熱吸音材は、ガスバーナーの炎を5分間当接する燃焼試験においてマット材に穴が開かず、この燃焼試験の際にマット背面に手をかざすことができる。本発明の断熱吸音材は、高温強度を1000℃以上で維持する高耐熱性の無機繊維40〜80%と、混綿前にあらかじめ難燃剤で処理した有機繊維20〜60%とを均一に混綿する。得た綿状素材を熱処理することによって全体をマット化し、この断熱吸音材の厚さは8〜50mmである。   The heat insulating sound-absorbing material according to the present invention does not open a hole in the mat material in a combustion test in which a flame of a gas burner is in contact for 5 minutes, and can hold a hand on the back surface of the mat during the combustion test. The heat insulating sound-absorbing material of the present invention uniformly blends 40 to 80% of highly heat-resistant inorganic fibers that maintain high-temperature strength at 1000 ° C. or more and 20 to 60% of organic fibers that have been treated with a flame retardant before blending. . The obtained cotton-like material is heat treated to form a mat, and the thickness of the heat insulating sound absorbing material is 8 to 50 mm.

本発明に係る他の断熱吸音材は、高温強度を1000℃以上で維持する高耐熱性の無機繊維40〜80%と、有機繊維20〜60%とを均一に混綿する。得た綿状素材の少なくとも片面に難燃性樹脂を付与するとともに全体がマット化され、この断熱吸音材の厚さは8〜50mmである。   The other heat insulating sound-absorbing material according to the present invention uniformly blends 40 to 80% of highly heat-resistant inorganic fibers that maintain high-temperature strength at 1000 ° C. or more and 20 to 60% of organic fibers. A flame-retardant resin is applied to at least one side of the obtained cotton-like material and the whole is matted, and the thickness of the heat insulating sound absorbing material is 8 to 50 mm.

本発明の断熱吸音材において、前記の有機繊維は、無機繊維40〜80%に対して、融点が200℃以上である耐熱性の有機繊維10〜50%と、低融点の有機繊維10〜25%とで構成すると望ましい。耐熱性の有機繊維は、ポリエステル繊維および/またはナイロン繊維であり、さらに高捲縮繊維または潜在捲縮繊維であると好ましい。   In the heat insulating sound-absorbing material of the present invention, the organic fiber is 10 to 50% heat-resistant organic fiber having a melting point of 200 ° C. or higher and 40 to 25% inorganic fiber and 10 to 25 low-melting organic fiber. % Is desirable. The heat resistant organic fiber is preferably a polyester fiber and / or a nylon fiber, and more preferably a highly crimped fiber or a latent crimped fiber.

本発明の断熱吸音材において、高耐熱性の無機繊維は、シリカ繊維、Sガラス繊維、炭化ケイ素繊維、ホウ素繊維、アルミナシリケート繊維、チタン酸アルカリ繊維、セラミック繊維の単独または混合体であり、特にシリカ繊維であると好ましい。また、本発明の断熱吸音材について、それぞれの原料繊維を混綿する前に、あらかじめ撥水剤で処理することも可能である。   In the heat insulating sound-absorbing material of the present invention, the high heat-resistant inorganic fiber is a single fiber or a mixture of silica fiber, S glass fiber, silicon carbide fiber, boron fiber, alumina silicate fiber, alkali titanate fiber, and ceramic fiber. Silica fibers are preferred. In addition, the heat insulating sound-absorbing material of the present invention can be treated in advance with a water repellent before each raw fiber is mixed.

本発明の断熱吸音材をさらに詳細に説明すると、主成分である高耐熱性の無機繊維は、全量の40〜80重量%であることが望ましい。高耐熱性の無機繊維は、全量の40重量%未満であると、他の成分が耐熱性の有機繊維であるならば、高い耐熱・断熱性に関して航空機の新規要求仕様に適合させることが困難になる。一方、全量の40重量%以上使用すると、航空機の新規要求仕様に適合させるために好適であって一般的に経済的にも有利であるが、80重量%を超えると断熱吸音材の屈曲性を欠く。   The heat insulating sound absorbing material of the present invention will be described in more detail. It is desirable that the high heat resistant inorganic fiber as the main component is 40 to 80% by weight of the total amount. If the high heat-resistant inorganic fiber is less than 40% by weight of the total amount, it will be difficult to meet the new aircraft requirements for high heat and heat insulation properties if the other components are heat-resistant organic fibers. Become. On the other hand, when 40% by weight or more of the total amount is used, it is suitable for conforming to the new required specifications of the aircraft and is generally economically advantageous. However, if it exceeds 80% by weight, the flexibility of the heat insulating sound absorbing material is improved. Lack.

本発明の断熱吸音材に関して、主成分である高耐熱性の無機繊維は、高温強度を1000℃以上で維持することを要する。熱溶融温度について、Sガラスは1493℃およびEガラスは1121℃であるが、Eガラス繊維は約800℃で高温強度が急激に低下するので、ガラス繊維のうちでSガラス繊維だけが使用可能である。また、ニッケル繊維、タングステン繊維やチタン繊維などの金属繊維および炭素繊維は、高い熱溶融温度の点では使用可能であっても、金属繊維および炭素繊維は一般に熱伝導率が高いので、吸音材の断熱性が低くなってしまう。さらに、ステンレススチール繊維は、融点1050℃であっても700〜800℃に長時間加熱すると脆化する。   With respect to the heat insulating sound-absorbing material of the present invention, the high heat-resistant inorganic fiber that is the main component is required to maintain the high-temperature strength at 1000 ° C. or higher. Regarding the heat melting temperature, S glass is 1493 ° C. and E glass is 1121 ° C., but E glass fiber is about 800 ° C., and the high-temperature strength rapidly decreases. Therefore, only S glass fiber can be used among the glass fibers. is there. In addition, even though metal fibers such as nickel fibers, tungsten fibers, and titanium fibers and carbon fibers can be used in terms of high heat melting temperature, metal fibers and carbon fibers generally have high thermal conductivity. Thermal insulation will be lowered. Further, even if the stainless steel fiber has a melting point of 1050 ° C., it becomes brittle when heated to 700 to 800 ° C. for a long time.

したがって、好適な高耐熱性の無機繊維として、シリカ繊維、Sガラス繊維、炭化ケイ素繊維、ホウ素繊維、アルミナシリケート繊維、チタン酸アルカリ繊維、セラミック繊維の単独または混合体が例示できる。金属繊維は、高耐熱性の無機繊維の一部としてならば、素材として添加できる可能性が残っている。この無機繊維について、特に、シリカ繊維を主体として用いると、コストと物性の点で好ましい。   Accordingly, examples of suitable high heat-resistant inorganic fibers include silica fibers, S glass fibers, silicon carbide fibers, boron fibers, alumina silicate fibers, alkali titanate fibers, and ceramic fibers alone or in a mixture. If metal fibers are part of highly heat-resistant inorganic fibers, there is a possibility that they can be added as raw materials. With regard to this inorganic fiber, it is particularly preferable in terms of cost and physical properties to use silica fiber as a main component.

シリカ繊維は、一般にシリカガラス繊維とも称し、原繊維から可溶性成分や有機分を除去した後に焼成する。例えば、シリカ繊維として、Eガラス、ソーダシリカガラス、ホウケイ酸ガラス、ソーダライム系ガラスなどの短繊維をブロー法によって製造し、この短繊維を酸処理して可溶性成分を溶出してから焼成してシリカ骨格を形成させると、例えばシリカ分は約95%以上に達する。一般に、シリカ繊維の原繊維として、アルカリ含有率1%以下のボロンシリケートガラスであるEガラス繊維を用いると、コストと物性の点で好ましい。   Silica fibers are generally also called silica glass fibers, and are fired after removing soluble components and organic components from the fibrils. For example, short fibers such as E glass, soda silica glass, borosilicate glass, and soda lime glass are manufactured as a silica fiber by a blow method, and the short fiber is acid-treated to elute soluble components and then fired. When the silica skeleton is formed, for example, the silica content reaches about 95% or more. In general, it is preferable to use E glass fiber, which is boron silicate glass having an alkali content of 1% or less, as silica fiber fibrils in terms of cost and physical properties.

本発明の断熱吸音材において、有機繊維は全量の20〜60重量%添加され、該有機繊維を混綿前にあらかじめ難燃剤で処理するか、または得た綿状素材の少なくとも片面に難燃性樹脂を付与することが必要である。このような付加処理を行うことにより、耐熱性にすぎない有機繊維を含んだ断熱吸音材の耐熱性を向上させることができ、航空機に関する新規要求仕様に適合させることが可能になる。   In the heat insulating sound-absorbing material of the present invention, the organic fiber is added in an amount of 20 to 60% by weight, and the organic fiber is treated in advance with a flame retardant before blending, or a flame-retardant resin is provided on at least one side of the obtained cotton-like material. It is necessary to give By performing such an additional treatment, it is possible to improve the heat resistance of the heat-absorbing sound-absorbing material containing organic fibers that are only heat-resistant, and it is possible to meet the new required specifications for aircraft.

有機繊維をあらかじめ難燃剤で処理する場合には、断熱吸音材の難燃性、特に断熱吸音材の表面での延焼性を改良できる。難燃処理で用いる薬剤は特に限定されず、リン窒素系などの難燃剤の水系ディスパージョンを用いることができ、加工性の点から水系のものを用いると好ましい。有機繊維を難燃処理する際には、例えば、市販の水系のリン系難燃剤などをスプレーなどによって所定量付与した後に有機繊維を十分乾燥させ、有機繊維の乾燥が不十分であるとカード性が悪くなる。   When the organic fiber is treated with a flame retardant in advance, it is possible to improve the flame retardancy of the heat insulating sound absorbing material, particularly the fire spreadability on the surface of the heat insulating sound absorbing material. The chemical | medical agent used by a flame retardant process is not specifically limited, The aqueous dispersion of flame retardants, such as a phosphorus nitrogen type | system | group, can be used, and it is preferable to use an aqueous thing from the point of workability. When flame-treating organic fibers, for example, a predetermined amount of commercially available aqueous phosphorus flame retardant is applied by spraying or the like, and then the organic fibers are sufficiently dried. Becomes worse.

添加する有機繊維として、融点が200℃以上である耐熱性の有機繊維を全量の10〜50重量%有することが望ましい。マット加工時に溶融しない耐熱性の有機繊維が10〜50重量%存在すると、該断熱吸音材に適切な屈曲性と柔軟性を付与できる。また、カード通過性などによるカード形成度合いが良くなり、原料の歩留まりが向上する。耐熱性の有機繊維が全量の10重量%未満であると、適当な屈曲性と柔軟性を付与できず、一方、全量の50重量%を超えると断熱吸音材の耐熱性が低下し、航空機に関する新規要求仕様に適合させるのが困難になる。   As the organic fiber to be added, it is desirable to have 10 to 50% by weight of the heat-resistant organic fiber having a melting point of 200 ° C. or higher. If 10 to 50% by weight of heat-resistant organic fibers that do not melt during mat processing are present, it is possible to impart appropriate flexibility and flexibility to the heat insulating sound-absorbing material. Further, the degree of card formation due to the card passing property is improved, and the yield of raw materials is improved. When the heat-resistant organic fiber is less than 10% by weight of the total amount, appropriate flexibility and flexibility cannot be imparted. On the other hand, when it exceeds 50% by weight of the total amount, the heat resistance of the heat insulating sound absorbing material decreases, and It becomes difficult to meet new requirements.

好適な耐熱性の有機繊維として、ポリエステル繊維、ナイロン繊維の単独または混合体が例示できる。さらに、この有機繊維が高捲縮繊維または潜在捲縮繊維であると、いっそう嵩高い断熱吸音材を得ることができる。   Examples of suitable heat-resistant organic fibers include polyester fibers and nylon fibers, either alone or as a mixture. Furthermore, if this organic fiber is a highly crimped fiber or a latent crimped fiber, a more bulky heat insulating sound absorbing material can be obtained.

添加する有機繊維には、さらに低融点の有機繊維が全量の10〜25重量%含まれることが望ましい。低融点の有機繊維を均一に混綿することにより、これが次工程の熱処理によって溶融されて綿状素材のマット化を達成するので、この熱処理は該有機繊維の融点よりも高い温度で行うことを要する。低融点の有機繊維が10重量%未満であると、硬綿状のマット材を得ることが困難になり、一方、25重量%を超えると、耐熱性が低下するとともに断熱試験時に発煙やガスが発生しやすく、航空機に関する吸音材の新規要求仕様に不合格になってしまう。   It is desirable that the organic fibers to be added contain 10 to 25% by weight of the total amount of organic fibers having a low melting point. By uniformly blending the low melting point organic fiber, it is melted by the heat treatment of the next step to achieve matting of the cotton-like material, so this heat treatment needs to be performed at a temperature higher than the melting point of the organic fiber. . If the organic fiber having a low melting point is less than 10% by weight, it becomes difficult to obtain a hard cotton mat material. On the other hand, if it exceeds 25% by weight, the heat resistance is lowered and smoke or gas is generated during the heat insulation test. It is likely to occur and it will fail the new requirements for sound-absorbing materials for aircraft.

この低融点の有機繊維は、一般に、融点が110〜150℃前後であるポリエステル、ポリプロピレン、アクリルのような熱可塑性繊維またはこれらの複合繊維などである。好ましくは、低融点の有機繊維と高融点の有機繊維との複合繊維が芯鞘型や並列型などの2層型であり、熱処理時の加熱温度で低融点の有機繊維だけが溶融し、その温度で高融点の有機繊維は形状を維持できるから、繊維自体の原形が保たれることで綿状素材のマット化を確実に達成できる。   The low melting point organic fiber is generally a thermoplastic fiber such as polyester, polypropylene, or acrylic having a melting point of about 110 to 150 ° C. or a composite fiber thereof. Preferably, the composite fiber of the low melting point organic fiber and the high melting point organic fiber is a two-layer type such as a core-sheath type or a parallel type, and only the low melting point organic fiber melts at the heating temperature during the heat treatment. Since the organic fiber having a high melting point at the temperature can maintain its shape, matting of the cotton-like material can be reliably achieved by maintaining the original shape of the fiber itself.

無機繊維および有機繊維からなる原料繊維について、あらかじめ撥水剤で処理してから、カードウェブを形成することも可能であり、この撥水処理を前記の難燃処理と同時に行うことも可能である。原料繊維をあらかじめ撥水処理しておくと、綿状素材を後から撥水処理する場合よりも嵩高な素材を得ることができる。ここで用いる撥水剤は特に限定されず、水系または溶剤系であるフッ素系やシリコーン系などの撥水剤を用いることができ、加工性の点から水系のものを用いると好ましい。原料繊維を撥水処理する際には、例えば、市販の水系のフッ素系撥水剤をスプレーなどによって所定量付与した後に、原料繊維を十分乾燥させ、カード機に通してウェブを完成させる。この際に、原料繊維の乾燥が不十分であると、カード性が不良になるので注意すべきである。   It is also possible to form a card web after previously treating with a water repellent for raw fibers made of inorganic fibers and organic fibers, and this water repellent treatment can be performed simultaneously with the above flame retardant treatment. . When the raw fiber is subjected to a water repellent treatment in advance, a bulky material can be obtained as compared with a case where the cotton-like material is subjected to a water repellent treatment later. The water repellent used here is not particularly limited, and water-based or solvent-based fluorine-based or silicone-based water repellents can be used, and water-based ones are preferable from the viewpoint of workability. When the raw fiber is subjected to water repellent treatment, for example, a predetermined amount of commercially available water-based fluorine-based water repellent is applied by spraying or the like, and then the raw material fiber is sufficiently dried and passed through a card machine to complete the web. At this time, it should be noted that if the raw material fibers are not sufficiently dried, the card property becomes poor.

有機繊維の予備的難燃処理の代わりに、得た断熱吸音材の片面または両面に、スプレー、ロールコーティングまたはディッピングなどによって難燃性樹脂を施してもよい。この難燃加工に用いる樹脂バインダーは、一般に、ポリエステルやアクリルのような耐熱性の熱可塑性樹脂の水性ディスパージョンにリン系難燃剤を加え、さらに界面活性剤を加えて安定化させる。塗布される樹脂の量は、0.5〜50g/mであり、好ましくは2〜20g/mである。塗布された樹脂は、次工程の熱処理によって乾燥して断熱吸音材のマット化を促進する。 Instead of the preliminary flame retardant treatment of the organic fiber, a flame retardant resin may be applied to one side or both sides of the obtained heat insulating sound absorbing material by spraying, roll coating or dipping. The resin binder used for this flame retardant processing is generally stabilized by adding a phosphorus-based flame retardant to an aqueous dispersion of a heat-resistant thermoplastic resin such as polyester or acrylic and further adding a surfactant. The amount of resin applied is 0.5 to 50 g / m 2 , preferably 2 to 20 g / m 2 . The applied resin is dried by the heat treatment in the next step to promote matting of the heat insulating sound absorbing material.

原料繊維の予備的撥水処理の代わりに、マット化のための溶融熱処理の前または後に、得た硬綿状のマット材を撥水加工してもよく、用いる撥水剤は無機および/または有機の市販品であり、例えば、水性のフッ素樹脂である。この撥水加工は、スプレー、ロールコーティングまたはディッピングなどのいずれによって行ってもよい。この撥水加工は、前記の難燃加工と同時に行うこともできる。   Instead of the preliminary water repellent treatment of the raw fibers, the hard cotton mat material obtained may be water repellent before or after the melt heat treatment for matting, and the water repellent used may be inorganic and / or Organic commercial products, for example, aqueous fluororesins. This water repellent process may be performed by spraying, roll coating or dipping. This water-repellent processing can be performed simultaneously with the flame-retardant processing.

得た断熱吸音材は、厚さが8〜50mmであると好ましい。この厚さが8mm未満であると、厚みが薄すぎるので自動車や航空機などへの内装作業が煩雑になり、厚さが50mmを超えると、断熱吸音材を曲げにくくなるので内装作業がやはり難しくなる。マット化した断熱吸音材について、さらにニードルパンチング、毛焼きまたはカレンダーによって表面平滑化処理を施すことが可能である。特に、ニードルパンチングで処理すると、断熱吸音材の強度を向上させることができるので好ましい。   The obtained heat-absorbing sound-absorbing material preferably has a thickness of 8 to 50 mm. If this thickness is less than 8 mm, the thickness is too thin and the interior work for automobiles and aircraft becomes complicated. If the thickness exceeds 50 mm, the heat insulating sound absorbing material becomes difficult to bend, so the interior work is still difficult. . The matted heat-absorbing sound-absorbing material can be further subjected to a surface smoothing treatment by needle punching, hair burning or calendering. In particular, the treatment by needle punching is preferable because the strength of the heat insulating sound absorbing material can be improved.

本発明の断熱吸音材において、無機繊維の織布またはフェルトからなる表面シートをマット材に不燃性樹脂で貼り合わせてもよい。この表面シートは、ガラス繊維、炭素繊維またはセラミック繊維などからなり、マット材自体は前記と同様である。この表面シートを貼り合わせると、航空機または鉄道車両への施工時に裁断したり折り曲げても、マット材からガラス繊維などの繊維粉末の落下が少なくなるので作業が容易になる。   In the heat insulating sound-absorbing material of the present invention, a surface sheet made of woven fabric or felt of inorganic fibers may be bonded to the mat material with a non-combustible resin. This surface sheet is made of glass fiber, carbon fiber, ceramic fiber, or the like, and the mat material itself is the same as described above. When this surface sheet is bonded, even if it is cut or bent during construction on an aircraft or a railway vehicle, the fiber powder such as glass fiber is less dropped from the mat material, so that the operation becomes easy.

航空機に用いる新規要求仕様のマット材の耐火性(FAR25.856(b)に規定)は、4分間で背面熱量が2W/cm以下であり、耐熱温度は規定されていないが、FAR25.856(b)に既定の条件を充足させるため、約1100℃で4分間耐えることを要する。本発明の断熱吸音材は、より厳しい航空機に関する不織布の新規要求仕様にも適合している。 The fire resistance (specified in FAR 25.856 (b)) of the newly required mat material used for aircraft has a back heat amount of 2 W / cm 2 or less in 4 minutes, and the heat resistance temperature is not specified, but FAR 25.856. In order to satisfy the predetermined condition in (b), it is necessary to endure at about 1100 ° C. for 4 minutes. The heat insulating sound-absorbing material of the present invention also meets the new requirements for nonwoven fabrics related to stricter aircraft.

本発明に係る断熱吸音材は、マット材の主成分が高耐熱性の無機繊維であって有機成分が耐熱性であることにより、ほぼ完全に不燃性であり且つ断熱性と吸音性が高く、各種の自動車や鉄道車両用の吸音材として使用できることはもとより、より厳しい航空機に関する不織布の新規要求仕様にも適合している。本発明の断熱吸音材は、より厳しい航空機の新規要求仕様に適合することにより、自動車、鉄道車両、航空機などに取り付けた際に従来よりも安全性が高くなり、航空機用として多量に納品することが期待できるうえに、鉄道車両に関して英国規格に準拠する諸外国における高速鉄道の車両にも十分に適用できる。   The heat insulating sound-absorbing material according to the present invention is almost completely non-flammable and has high heat-insulating and sound-absorbing properties because the main component of the mat material is inorganic fibers with high heat resistance and the organic component is heat resistant. Not only can it be used as a sound-absorbing material for various automobiles and railway vehicles, it also meets new requirements for nonwoven fabrics for stricter aircraft. The heat-insulating sound-absorbing material of the present invention is more safe when installed in automobiles, railway vehicles, airplanes, etc. by conforming to new and more demanding specifications for aircraft, and delivered in large quantities for aircraft. In addition, it can be fully applied to high-speed railway vehicles in other countries that conform to British standards for railway vehicles.

本発明の断熱吸音材は、比較的剛直な高耐熱性の無機繊維に対して比較的柔軟な耐熱性の有機繊維を添加し、吸音材の設置の際に屈曲させることが可能である。本発明の断熱吸音材では、低融点の有機繊維を少量均一に混綿することにより、熱処理だけで全体が均一なマット材に加工でき、後加工時に構成繊維が折損することが少ない。本発明の断熱吸音材は、柔軟で扱いやすいマット材であり、施工時に裁断したり屈曲させても繊維脱落が少なく、作業環境を悪化させることが少ない。   The heat insulating sound-absorbing material of the present invention can be bent when a sound-absorbing material is installed by adding a relatively soft heat-resistant organic fiber to a relatively rigid high-heat-resistant inorganic fiber. In the heat insulating sound-absorbing material of the present invention, a small amount of organic fiber having a low melting point is uniformly mixed, so that the whole can be processed into a uniform mat material only by heat treatment, and the constituent fibers are less likely to break during post-processing. The heat-insulating sound-absorbing material of the present invention is a mat material that is flexible and easy to handle. Even if it is cut or bent at the time of construction, there is little fiber dropout and the working environment is hardly deteriorated.

次に、本発明を実施例に基づいて説明するが、本発明は実施例に限定されるものではない。以下では、断熱吸音材の製造について説明する。   Next, the present invention will be described based on examples, but the present invention is not limited to the examples. Below, manufacture of a heat insulation sound-absorbing material is demonstrated.

原料繊維には、高耐熱の無機繊維としてシリカ繊維を、耐熱性の有機繊維として高捲縮ポリエステル繊維(東レ製)を、低融点の有機繊維として芯鞘型の低融点ポリエステル繊維(商品名:サフメット、東レ製)をそれぞれ用いた。シリカ繊維には、水系のフッ素系撥水剤を乾燥後の繊維への付着量で1重量%となるようにスプレーにより付与した後、加熱によって水分率が2重量%以下となるように乾燥処理した。また、高捲縮ポリエステル繊維および低融点ポリエステル繊維は、前記と同じ水系のフッ素系撥水剤と、ポリエステル樹脂をバインダーとするリン窒素系難燃剤の水系デイスパージョンとを、それぞれ付着量で3重量%ずつとなるようにスプレーによって付与した後に、同様に水分率で2重量%以下となるように乾燥処理した。   The raw fiber is silica fiber as high heat resistant inorganic fiber, high crimped polyester fiber (manufactured by Toray) as heat resistant organic fiber, and core-sheath type low melting point polyester fiber (trade name: Safmet and Toray) were used. The silica fiber is sprayed with a water-based fluorinated water repellent so that the amount attached to the fiber after drying is 1% by weight, and then dried by heating so that the moisture content is 2% by weight or less. did. Further, the high crimped polyester fiber and the low-melting polyester fiber each have an adhesion amount of 3 of the same aqueous fluorine-based water repellent and an aqueous dispersion of a phosphorous nitrogen-based flame retardant using a polyester resin as a binder. After applying by spray so as to be in increments of% by weight, drying treatment was similarly performed so that the moisture content was 2% by weight or less.

これらの薬剤処理したシリカ繊維65%、高捲縮ポリエステル繊維15%、低融点ポリエステル繊維20%を混綿し、カーディングによって目付250g/mのウェブを形成した。ついで針深さ6mm、針密度7本/cmの条件で両面をニードルパンチ加工した後に、170℃で3分間熱処理して厚さ20mmの硬綿状のマット素材を得た。得たマット素材の耐熱性、撥水性、延焼性を評価したところ、いずれも合格レベルである。 These chemical-treated silica fibers 65%, high-crimped polyester fibers 15%, and low-melting polyester fibers 20% were mixed, and a web having a basis weight of 250 g / m 2 was formed by carding. Subsequently, both sides were subjected to needle punching under conditions of a needle depth of 6 mm and a needle density of 7 / cm 2 , and then heat treated at 170 ° C. for 3 minutes to obtain a hard cotton mat material having a thickness of 20 mm. When the heat resistance, water repellency, and fire spreadability of the obtained mat material were evaluated, all were acceptable levels.

原料繊維には、高耐熱の無機繊維としてシリカ繊維を、耐熱性の有機繊維として潜在捲縮ポリエステル繊維(ユニチカ製)を、低融点の有機繊維として芯鞘型の低融点ポリエステル繊維(商品名:サフメット、東レ製)をそれぞれ用いた。それぞれの繊維には、水系のフッ素系撥水剤を乾燥後の繊維への付着量で1重量%となるようにスプレーにより付与した後、加熱によって水分率が2重量%以下となるように乾燥処理した。   The raw material fibers include silica fibers as high heat-resistant inorganic fibers, latent crimped polyester fibers (manufactured by Unitika) as heat-resistant organic fibers, and core-sheath type low-melting polyester fibers as low-melting organic fibers (trade name: Safmet and Toray) were used. A water-based fluorine-based water repellent is applied to each fiber by spraying so that the amount attached to the fiber after drying is 1% by weight, and then dried by heating to a moisture content of 2% by weight or less. Processed.

これらの薬剤処理したシリカ繊維65%、潜在捲縮ポリエステル繊維15%、低融点ポリエステル繊維20%を混綿し、カーディングによって目付250g/mのウェブを形成した。ついで針深さ6mm、針密度7本/cmの条件で両面をニードルパンチ加工した後に、綿状素材の両面に、ポリエステル樹脂をバインダーとするリン窒素系難燃材の水系ディスパージョンをスプレーによって付与し、その乾燥重量は10g/mであった。さらに170℃で3分間熱処理して厚さ20mmの硬綿状のマット素材を得た。得たマット素材の耐熱性、撥水性、延焼性を評価したところ、いずれも合格レベルである。 These chemical-treated silica fibers 65%, latently crimped polyester fibers 15%, and low-melting polyester fibers 20% were mixed, and a web having a basis weight of 250 g / m 2 was formed by carding. Then, after needle punching on both sides under the conditions of needle depth of 6 mm and needle density of 7 / cm 2 , an aqueous dispersion of phosphorous nitrogen-based flame retardant using polyester resin as a binder is sprayed on both sides of the cotton-like material. And the dry weight was 10 g / m 2 . Furthermore, heat treatment was performed at 170 ° C. for 3 minutes to obtain a hard cotton mat material having a thickness of 20 mm. When the heat resistance, water repellency, and fire spreadability of the obtained mat material were evaluated, all were acceptable levels.

比較例1
原料繊維には、高耐熱の無機繊維としてシリカ繊維を20%、耐熱性の有機繊維として高捲縮ポリエステル繊維(東レ製)を60%、低融点の有機繊維として芯鞘型の低融点ポリエステル繊維(商品名:サフメット、東レ製)を20%、それぞれ薬剤処理せずに混綿した。カーディングによって目付250g/mのウェブを形成した。ついで針深さ6mm、針密度7本/cmの条件で両面をニードルパンチ加工した後に、170℃で3分間熱処理して厚さ20mmの硬綿状のマット素材を得た。得たマット素材の耐熱性、撥水性、延焼性を評価したところ、いずれも不合格レベルであった。
Comparative Example 1
The raw fiber is 20% silica fiber as high heat resistant inorganic fiber, 60% highly crimped polyester fiber (manufactured by Toray) as heat resistant organic fiber, core-sheath type low melting point polyester fiber as low melting point organic fiber (Product name: SAFMET, manufactured by Toray Industries, Inc.) 20% were mixed without any chemical treatment. A web having a basis weight of 250 g / m 2 was formed by carding. Subsequently, both sides were subjected to needle punching under conditions of a needle depth of 6 mm and a needle density of 7 / cm 2 , and then heat treated at 170 ° C. for 3 minutes to obtain a hard cotton mat material having a thickness of 20 mm. When the heat resistance, water repellency, and fire spreadability of the obtained mat material were evaluated, all were at a rejected level.

比較例2
スプレーによるリン窒素系難燃剤を含む樹脂を付与しない以外は、実施例2と同様に処理してマット素材を得た。このマット素材の耐熱性、撥水性は合格レベルであったが、延焼性が不合格レベルであった。
Comparative Example 2
A mat material was obtained in the same manner as in Example 2 except that a resin containing a phosphorus nitrogen-based flame retardant was not applied by spraying. The heat resistance and water repellency of this mat material were acceptable levels, but the flame spreadability was unacceptable levels.

各実施例および比較例において、耐熱性の評価は、10cm角以上の大きさのマット材サンプルを水平な架台の上に置き、ガスバーナーの炎が高さ50〜80mmであり、内炎の高さが10〜15mmとなるように調整して、この炎の約10mmの部分が架台上サンプルの下面に当たるように架台またはガスバーナーの高さを調整する。架台上のマット材サンプルのほぼ中央に、ガスバーナーの炎を5分間当て、この5分間の間に、穴あきがなければ耐熱性は合格であり、少しでも穴が開いたら不合格である。   In each example and comparative example, the heat resistance was evaluated by placing a mat material sample of 10 cm square or more on a horizontal base, the flame of the gas burner being 50 to 80 mm in height, The height of the gantry or gas burner is adjusted so that a portion of about 10 mm of the flame hits the lower surface of the sample on the gantry. A flame of a gas burner is applied to the center of the mat material sample on the gantry for 5 minutes. If there is no hole in this 5 minutes, the heat resistance is passed, and if any hole is opened, it is rejected.

また、撥水性の評価は、ASTM C1511−04に準拠し、25cm角のサンプルを水中に15分間沈め、それを取り出してから1分間静置した後に、その重量増加が20g以下のものを合格とし、それ以外は不合格である。また、延焼性の評価は、サンプル表面にガスバーナーの炎を2分間接炎し、炎を離した後の残炎時間が1秒以内のものを合格とし、それ以外は不合格である。   The evaluation of water repellency is based on ASTM C1511-04. A 25 cm square sample is submerged in water for 15 minutes, taken out and allowed to stand for 1 minute. Otherwise, it is rejected. In the evaluation of the flame spreadability, a gas burner flame is indirectly flamed for 2 minutes on the sample surface, and the flame after the flame is released is accepted within 1 second, and the others are unacceptable.

Claims (8)

ガスバーナーの炎を5分間当接する燃焼試験においてマット材に穴が開かず、この燃焼試験の際にマット背面に手をかざすことができる断熱吸音材であって、高温強度を1000℃以上で維持する高耐熱性の無機繊維40〜80%と、混綿前にあらかじめ難燃剤で処理した有機繊維20〜60%とを均一に混綿し、得た綿状素材を熱処理することによって全体をマット化して厚さが8〜50mmである高耐熱の断熱吸音材。   A heat-absorbing sound-absorbing material that does not open a hole in the mat material in a combustion test in which the flame of a gas burner abuts for 5 minutes and can hold a hand on the back of the mat during the combustion test, maintaining a high-temperature strength at 1000 ° C or higher. 40% to 80% highly heat-resistant inorganic fibers and 20% to 60% organic fibers previously treated with a flame retardant before blending are uniformly blended, and the resulting cotton-like material is heat treated to form a mat. A heat-resistant, heat-absorbing sound absorbing material having a thickness of 8 to 50 mm. ガスバーナーの炎を5分間当接する燃焼試験においてマット材に穴が開かず、この燃焼試験の際にマット背面に手をかざすことができる断熱吸音材であって、高温強度を1000℃以上で維持する高耐熱性の無機繊維40〜80%と、有機繊維20〜60%とを均一に混綿し、得た綿状素材の少なくとも片面に難燃性樹脂を付与するとともに全体がマット化されて厚さが8〜50mmである高耐熱の断熱吸音材。   A heat-absorbing sound-absorbing material that does not open a hole in the mat material in a combustion test in which the flame of a gas burner abuts for 5 minutes and can hold a hand on the back of the mat during the combustion test, maintaining a high-temperature strength at 1000 ° C or higher. Highly heat-resistant inorganic fibers 40-80% and organic fibers 20-60% are uniformly blended, and a flame-retardant resin is applied to at least one side of the obtained cotton-like material and the whole is matted and thickened. A heat-resistant sound-absorbing material with a heat resistance of 8 to 50 mm. 前記の有機繊維は、無機繊維40〜80%に対して、融点が200℃以上である耐熱性の有機繊維10〜50%と、低融点の有機繊維10〜25%とで構成している請求項1または2記載の断熱吸音材。   The organic fiber is composed of 10 to 50% heat-resistant organic fiber having a melting point of 200 ° C. or higher and 10 to 25% organic fiber having a low melting point with respect to 40 to 80% inorganic fiber. Item 3. The heat insulating sound absorbing material according to Item 1 or 2. 耐熱性の有機繊維が、ポリエステル繊維および/またはナイロン繊維である請求項3記載の断熱吸音材。   The heat insulating sound-absorbing material according to claim 3, wherein the heat-resistant organic fiber is a polyester fiber and / or a nylon fiber. 耐熱性の有機繊維が、高捲縮繊維または潜在捲縮繊維である請求項3または4記載の断熱吸音材。   The heat insulating sound-absorbing material according to claim 3 or 4, wherein the heat-resistant organic fiber is a highly crimped fiber or a latent crimped fiber. 高耐熱性の無機繊維が、シリカ繊維、Sガラス繊維、炭化ケイ素繊維、ホウ素繊維、アルミナシリケート繊維、チタン酸アルカリ繊維、セラミック繊維の単独または混合体である請求項1または2記載の断熱吸音材。   The heat insulating sound-absorbing material according to claim 1 or 2, wherein the high heat-resistant inorganic fiber is a single fiber or a mixture of silica fiber, S glass fiber, silicon carbide fiber, boron fiber, alumina silicate fiber, alkali titanate fiber, and ceramic fiber. . 高耐熱性の無機繊維がシリカ繊維である請求項6記載の断熱吸音材。   The heat insulating sound-absorbing material according to claim 6, wherein the high heat-resistant inorganic fiber is silica fiber. それぞれの原料繊維を混綿する前にあらかじめ撥水剤で処理する請求項1または2記載の断熱吸音材。   The heat insulating sound-absorbing material according to claim 1 or 2, wherein each raw material fiber is treated with a water repellent in advance before blending.
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JP2010090508A (en) * 2008-10-08 2010-04-22 Kureha Ltd Stretchable nonwoven fabric
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CN103031666A (en) * 2013-01-07 2013-04-10 辽阳艺蒙织毯有限公司 Sound and heat insulating material and manufacturing method thereof
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008223165A (en) * 2007-03-12 2008-09-25 Fujikoo:Kk Heat insulating and sound absorbing material
JP2008291393A (en) * 2007-05-25 2008-12-04 Fujikoo:Kk Mat material for vehicle
WO2009084411A1 (en) * 2007-12-27 2009-07-09 Fuji Corporation Heat-insulating sound-absorbing material with high heat resistance
JP5530184B2 (en) * 2007-12-27 2014-06-25 株式会社フジコー High heat insulation sound-absorbing material
JP2010090508A (en) * 2008-10-08 2010-04-22 Kureha Ltd Stretchable nonwoven fabric
CN102965840A (en) * 2012-11-22 2013-03-13 芜湖跃飞新型吸音材料股份有限公司 PET (polyethylene glycol terephthalate) fiber/ceramic fiber composite sound absorbing cotton and preparation method of PET fiber/ceramic fiber composite sound absorbing cotton
CN102965842A (en) * 2012-11-22 2013-03-13 芜湖跃飞新型吸音材料股份有限公司 PET (Polyethyleneglycol Terephthalate) fiber/glass fiber composite sound absorbing cotton and preparation method thereof
CN103031666A (en) * 2013-01-07 2013-04-10 辽阳艺蒙织毯有限公司 Sound and heat insulating material and manufacturing method thereof
CN103734953A (en) * 2013-12-09 2014-04-23 苏州禄千纺织咨询服务有限公司 Multifunctional moisture preservation fabric
KR102248400B1 (en) * 2020-12-29 2021-05-06 삼성교역(주) SIC complex spun yarn and method for manufacturing the same
WO2022145674A1 (en) * 2020-12-29 2022-07-07 삼성교역(주) Silicon carbide composite spun yarn and method for manufacturing same
CN116332656A (en) * 2021-12-15 2023-06-27 山东鲁阳节能材料股份有限公司 High-temperature refractory flange gasket and preparation method thereof

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