JP2016159579A - Acoustic absorption interior material and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an antiflaming interior material having light weight property and flexibility, excellent in echo preventing effect and acoustic attenuation effect and suitable for membrane ceiling construction such as an indoor athletic field, a gymnasium, an indoor pool, an event hall, a public hall, a ceremonial hall, a station lobby, an airport lobby and a shopping mall blow-by.SOLUTION: As a two or three-layer laminated fabric molded body where a bulk fabric containing a bulky yarn on a single or more surface of a mesh sheet substrate by coating yarn elements constituting a coarse fabric with a thermoplastic resin flame retardant layer, the bulk fabric contains air of 7.5 to 25% (0.075 to 0.25 cc/cm) per unit volume (apparent unit volume) and an adhesive boundary where a part of the bulky yarn is buried in the thermoplastic resin flame retardant layer.SELECTED DRAWING: Figure 1

Description

  The present invention is a ceiling area component and sound absorbing member installed in the ceiling of indoor stadiums, gymnasiums, indoor pools, event halls, public halls, ceremonial ceremonies, etc. It is a sound-absorbing member as an accessory to the ceiling area constituent member, both have excellent dimensional stability, and have low lightness and flexibility that are unlikely to cause serious human damage even if it collapses in the unlikely event of an earthquake, The present invention relates to a flameproof interior material suitable for construction of a membrane ceiling that is excellent in an echo suppression effect and an acoustic attenuation effect, and that can produce effects by illumination and video projection.

  It consists of multiple fabrics for protective clothing using high-strength and high-elasticity fiber yarns (Patent Document 1), and multiple fabrics in which resin-coated fiber yarns in which synthetic fiber yarns are coated with resin are used as warps and / or wefts. Civil mats (Patent Document 2), civil engineering mats made of water-permeable multiple woven fabrics (Patent Document 3), a method for producing a fiber reinforced resin composite material in which multiple woven fabrics are impregnated and cured with a matrix resin (Patent Document 4), high strength Breathable three-dimensional woven fabric knitted fabric that can be used for plate-like fiber reinforced composite materials (Patent Document 5), bedclothes, cushions, car seats, tatami floor coverings, etc., made of multiple woven fabrics made of high modulus fibers. The use of various stacked structures such as document 6) is disclosed, but the stacked structures related to flexible sound-absorbing interior materials excellent in sound absorption effect and dimensional stability, including patent documents related to other stacked structures. Application examples Not yet been reported.

JP 2008-208512 A JP 2007-239330 A Japanese Patent Laid-Open No. 08-326031 JP 2005-313346 A Japanese Patent Laid-Open No. 08-207150 Japanese Patent Application Laid-Open No. 07-90757

  The present invention is a sound absorbing member as a ceiling area constituting member and a sound absorbing member installed on the ceiling of a large building, or as an accessory to a ceiling area constituting member, and particularly excellent in dimensional stability, even in the event of collapse by an earthquake Indoor stadiums and gymnasiums that have light weight and flexibility that are unlikely to cause serious human damage, are excellent in echo suppression effects and resonance sound absorption effects, and can also be produced by lighting and video projection. The objective is to provide flame proof interior materials suitable for ceilings such as indoor pools, event halls, public halls, ceremonial occasions, and ceiling membranes of station buildings, airport lobbies, shopping malls and the like.

  In order to solve the above-mentioned problems, a bulky woven fabric (having a specific air content) containing a bulky yarn on one side or more of a mesh sheet base material formed by coating a thermoplastic resin flame retardant layer on a yarn element constituting a coarse woven fabric ) Is a two- or three-layer stacked fabric molded body with a bonded interface in which part of the bulky yarn is incorporated into the thermoplastic resin flame retardant layer. A fireproof interior material that has lightness and flexibility that are unlikely to cause serious human damage even if it is used, is excellent in echo suppression effect and sound attenuation effect, and can be produced by lighting and video projection As a result, the present invention has been completed.

That is, the sound-absorbing interior material of the present invention comprises two layers in which a bulky fabric containing a bulky yarn is bonded to one or more sides of a mesh sheet substrate obtained by coating a thermoplastic resin flame retardant layer on a thread element constituting a coarse fabric. It is a three-layer pile fabric molded body, wherein the bulky fabric contains 7.5 to 25% (0.075 to 0.25 cc / cm ³ ) of air per unit volume (apparent volume), and the thermoplastic resin is difficult It is preferable that an adhesive interface in which a part of the bulky yarn is buried is formed in the fuel layer. Although it is a lightweight ceiling membrane by including a mesh sheet in the base material, it has dimensional stability and durability, and the sound absorption by the synergistic effect of the echo suppression effect in the bulky fabric layer and the soundproof attenuation effect in the mesh sheet base material It is possible to obtain a flameproof interior material that has high performance and can also be produced by illumination and video projection.

  In the sound absorbing interior material of the present invention, the bulky yarn is made of glass fiber, silica fiber, alumina fiber, silica alumina fiber, basalt fiber, carbon fiber, aramid fiber (polyparaphenylene terephthalamide fiber, polyparabenzamide fiber, paraphenyleneoxy All aromatic polyamide fibers such as diphenylene terephthalamide copolymer fibers), polyarylate fibers, polybenzoxazole fibers, polybenzimidazole fibers, polybenzothiazole fibers, and polyether ether ketone fibers Preferably it is a strip. As a result, the sound absorbing interior material of the present invention can be provided with sound absorbing properties, flameproofing properties and heat resistance.

  In the sound absorbing interior material of the present invention, the thermoplastic resin flame retardant layer mainly contains a thermoplastic resin and flame retardant particles, and the specific gravity of the thermoplastic resin flame retardant layer is 1.3 to 2.5. Is preferred. As a result, it is possible to obtain a flameproof interior material that is more excellent in echo suppression effect and sound attenuation effect.

  In the sound-absorbing interior material of the present invention, the thermoplastic resin flame retardant layer mainly contains a vinyl chloride resin and a cyclohexanedicarboxylic acid dialkyl ester, and the thermoplastic resin flame retardant layer has a specific gravity of 1.3 to 2.5. Preferably there is. Thereby, it is possible to obtain a flameproof interior material using a soft vinyl chloride resin which is more excellent in echo suppression effect and diffusion sound absorption effect and does not contain a phthalate ester compound as a substance of concern for mutagenic substances.

The sound-absorbing interior material of the present invention has a gas-containing resin breathable coating layer having a thickness of 1 to 5 mm and a density of 0.35 to 0.75 g / cm ³ formed on one surface of the stacked fabric molded body, and the stack It is preferable that a part of the bubble-containing resin breathable coating layer is impregnated inside the fabric molded body, and the depth thereof is 1 to 35% with respect to the thickness of the stacked fabric molded body. As a result, it is possible to obtain a flexible flameproof interior material that is more excellent in echo suppression effect and sound attenuation effect.

  The method for producing a sound-absorbing interior material according to the present invention comprises heating a mesh sheet base material in which a yarn element constituting a coarse woven fabric is coated with a thermoplastic resin flame retardant layer, and a bulky woven fabric containing a bulky yarn on one or more sides. The bulky woven fabric is heated and pressure-bonded to the softened thermoplastic resin flame retardant layer, and the laminated fabric molded body is cooled to cool the stacked fabric molded body to the thermoplastic resin flame retardant layer. It is preferable to form an adhesive interface in which a part of the bulky yarn is buried.

The method for producing a sound-absorbing interior material of the present invention is characterized in that the soft vinyl chloride resin flame retardant layer is formed on at least one side of a mesh sheet substrate obtained by coating a yarn element constituting a coarse woven fabric with a soft vinyl chloride resin flame retardant layer. A step of additionally applying the soft vinyl chloride resin paste composition used for coating;
An additional soft vinyl chloride resin flame retardant layer is formed by stacking a bulky woven fabric containing bulky yarn on this additional coated surface, heating in a pressure-bonded state, and completing gelation (solidification) of the soft vinyl chloride resin paste composition. Forming a stacked fabric molded body,
It is preferable that an adhesive interface in which a part of the bulky yarn is buried is formed in the additional soft vinyl chloride resin flame retardant layer.

  According to the present invention, a flameproof interior material having a sound absorbing property as a ceiling area constituting member / sound absorbing member installed on a ceiling of a large building or an accessory to a ceiling area constituting member can be obtained, and these membrane materials have dimensions. These films have excellent stability and sound damping effect while having lightness and flexibility that are unlikely to cause serious human damage in the event of an earthquake. The material provides a variety of functions as a sound-absorbing interior film material for membrane ceiling materials, such as a light shade that provides an elegant light effect as a light shade, and further enables projector projection using a bulky fabric as a projection screen. Widely used for building membrane ceilings such as gymnasiums, indoor pools, event halls, public halls, ceremonial occasions, station building lobbies, airport lobbies, shopping malls It is possible.

The figure which shows typically an example of the cross section of the sound-absorbing interior material of this invention The figure which shows typically an example of the cross section of the sound-absorbing interior material of this invention The figure which shows typically an example of the cross section of the sound-absorbing interior material of this invention

The sound-absorbing interior material of the present invention is a two-layer or three-layer structure in which a bulky fabric containing a bulky yarn is bonded to one or more sides of a mesh sheet base material obtained by coating a thermoplastic resin flame retardant layer on a yarn element constituting a coarse fabric. A two-layer stacked fabric molded body (mass 0.3 to 2.0 kg) in which one bulky fabric is bonded to one side of a mesh sheet substrate, and two bulky fabrics in a mesh sheet substrate A three-layer stacked fabric molded body (mass 0.4 to 2.0 kg) adhered to both sides of the bulky fabric, 7.5 to 25% (0.075 to 0.25 cc) of air per unit volume (apparent volume) / Cm ³ ). Although it is a lightweight ceiling membrane by including a mesh sheet as a base material, it has dimensional stability and durability. In addition, it has a synergistic effect of suppressing reverberation in a bulky fabric layer and soundproof damping effect in a mesh sheet base material. Sound absorption performance can be obtained. In particular, the bulky woven fabric used for the three-layer stacked fabric molded body may be a fabric of the same standard, but the bulky woven fabric has the requirements of fiber type, thread form, woven structure, weave density, and bulky yarn insertion density. It is preferable to use a bulky fabric A and a bulky fabric B that have at least one requirement different from each other.

  The fiber types of the coarse woven fabric used as the base material of the mesh sheet are polypropylene fiber, polyethylene fiber, polyester fiber, nylon fiber, vinylon fiber, aromatic heterocyclic polymer fiber (aramid fiber, polybenzimidazole fiber, polybenzoxazole fiber), etc. These are mixed fibers composed of two or more of these, such as synthetic fibers, glass fibers, silica fibers, alumina fibers, silica alumina fibers, carbon fibers, and other inorganic fibers, cellulose fibers, kenaf fibers, and other natural fibers. Examples of the yarn form include a monofilament yarn, a multifilament yarn, a short fiber spun yarn, a split yarn, and a tape yarn. In addition, the weaving structure is a plain fabric (minimum constitutional unit using at least two warps and wefts), twill fabric (minimum constitutional unit using at least three warps and wefts: three slashes, four slashes, 5 slashes, 6 slashes, 8 slashes, etc.), satin woven fabric (minimum structural unit using a minimum of 5 warps and wefts: 2 jumps, 3 jumps, 4 jumps, 5 jumps, etc.) , Change plain weave (clinic weave: Nanako, fish, Namiko, basket weave, Panama weave), (weave: weave, rib weave), change twill (steep, slow, Yamagata, Torn, curving, Sugiaya, Ornamental, day and night, and flying slashes, change satin fabrics (irregular vermilion, layered vermilion, spreading vermilion, day and night vermilion), mojiri fabrics ), Triaxial weave (clincher weave: Nanako, fish, Namiko, basket weave, Panama weave), four-axis weave (clincher weave: Nanako, fish, Namiko, basketball) Woven, Panama weave), and the like.

The yarn elements constituting these coarse fabrics include polyester (PET, PBT, PNT) fiber, nylon fiber, vinylon fiber, aromatic heterocyclic polymer fiber (aramid fiber, polybenzimidazole fiber, polybenzoxazole fiber), glass Multifilament yarns such as fibers (E glass, C glass, G glass, A glass, S glass, D glass, DE glass) are particularly preferred from the viewpoint of maintaining dimensional stability, and the filament diameter is 3 to 10 μm and the fineness is 69 to 2223 dtex. (62 to 2000 denier), especially 138 to 1112 dtex (124 to 1000 denier) multifilament, 50 to 500 filaments, particularly 100 to 300 filaments and 10 to 40 times / m weakly twisted yarn, or 41 Bundled up to ~ 200 times / m ordinary twisted yarn, cross-sectional shape Threads having a circular shape, an elliptical shape, or a flat shape. Also, short fiber spun yarn (spun yarn) such as polyester (PET, PBT, PNT) fiber, nylon fiber, vinylon fiber, aromatic heterocyclic polymer fiber (aramid fiber, polybenzimidazole fiber, polybenzoxazole fiber) 10th (591dtex), 14th (422dtex), 16th (370dtex), 20th (295dtex), 24th (246dtex), 30th (197dtex), 60th (97dtex), etc. Short fiber spinning yarns such as twisted yarns of three or more single yarns, two double yarns, and two double yarns can also be used. The coarse woven fabric has a mass of 50 to 200 g / m ² obtained by driving these multifilament yarns or short fiber spun yarns with 8 to 32 warps and wefts for 1 inch each. inches between triaxial coarse fabric obtained mass 75~300g / ^{m 2} at 8-32 present implanted, warp, weft, mass obtained is implanted 8-32 present between the respective per inch are bias yarns 100 to 400 g / m ² 4-axis coarse fabrics, specifications such as eye missing porosity 5-30% of coarse fabric has excellent dimensional stability. The coarse woven fabric is subjected to known fiber processing such as scouring, bleaching, dyeing, softening, water repellency, waterproofing, mildewproofing, flameproofing, hair burning, calendering, silane coupling agent treatment, and binder treatment. be able to.

  The thermoplastic resin flame retardant layer of the mesh sheet mainly includes a thermoplastic resin and flame retardant particles, and has a specific gravity of 1.3 or more and a specific gravity of 2.5 or less of the thermoplastic resin flame retardant layer, thereby providing a soundproof attenuation effect. To express. The thermoplastic resin component used in the flame retardant layer of thermoplastic resin is soft vinyl chloride resin (as plasticizer, dialkyl esters of adipic acid, dialkyl esters of sebacic acid, dialkyl esters of phthalic acid, dialkyl esters of isophthalic acid, dialkyl terephthalate) 30 to 100 parts by mass of ester, cyclohexanedicarboxylic acid dialkyl ester, aromatic phosphate ester, chlorinated paraffin, polyester oligomer, etc. with respect to 100 parts by mass of vinyl chloride resin) Polymer resins (vinyl chloride resins include homopolymers of vinyl chloride monomers, copolymers with other monomers that can be copolymerized with vinyl chloride monomers, and graft polymers), olefin resins, olefins Copolymer resin, urethane resin, urethane Polymer resin, acrylic resin, acrylic copolymer resin, vinyl acetate resin, vinyl acetate copolymer resin, styrene resin, styrene copolymer resin, polyester resin, and polyester copolymer resin, fluorine resin, Examples thereof include a fluorine-based copolymer resin.

  The flame retardant particles used in the thermoplastic resin flame retardant layer are a). Phosphorus atom-containing compounds such as metal phosphates, metal organic phosphates, phosphate derivatives, ammonium polyphosphates, and ammonium polyphosphate derivative compounds, b). Nitrogen-containing compounds (melamine cyanurate) such as (iso) cyanurate compounds, (iso) cyanuric acid compounds, guanidine compounds, urea compounds, and derivative compounds thereof, c). Inorganic compounds such as silicon compounds, metal hydroxides, metal oxides, metal carbonate compounds, metal sulfate compounds, boric acid compounds, and inorganic compound complexes; d). One or more types selected from organic bromides and organic chlorinated products, and particularly preferable flame retardant particles are lead oxide (specific gravity 9.35), antimony trioxide (specific gravity 5.7), and barium titanate (specific gravity 5.). 6), zirconium oxide (specific gravity 5.5), zinc oxide (specific gravity 5.4), iron oxide (specific gravity 5.2), barium carbonate (specific gravity 4.4), barium sulfate (specific gravity 4.4), titanium dioxide (Specific gravity 4.0), alumina (specific gravity 3.8), potassium titanate (specific gravity 3.3), magnesium oxide (specific gravity 3.3), mica (specific gravity 3.0), talc (specific gravity 2.8), Calcium carbonate (specific gravity 2.6), aluminum hydroxide (specific gravity 2.4), magnesium hydroxide (specific gravity 2.4), and the like. .5 or less. If the specific gravity exceeds 2.5, the sound-absorbing interior material obtained exceeds the mass, which increases the possibility of causing serious human damage when the ceiling material collapses. If the specific gravity is less than 1.3, the soundproofing attenuation effect may be insufficient.

  The thickness of the thermoplastic resin flame retardant layer is preferably 0.03 mm to 0.6 mm, particularly preferably 0.05 mm to 0.3 mm. Particularly preferred thermoplastic resin flame retardant layers in the present invention are vinyl chloride resins (including soft to semi-rigid vinyl chloride resins containing plasticizers, stabilizers, flame retardants, etc.), styrene copolymer resins (flame retardants). Etc.), urethane-based copolymer resins (containing flame retardants, etc.), and polyester-based copolymer resins (containing flame retardants). These flame retardant resins can be applied to viscous liquids such as vinyl chloride resin paste sols, flame retardant resin solutions solubilized in organic solvents, and flame retardant compositions based on aqueous resins such as emulsions and latex. Is dipped and dried by heat treatment to obtain a mesh sheet having a mass of 0.1 to 1.0 kg. The thermoplastic resin flame retardant layer contains known additives such as pigments, fillers, UV absorbers, deterioration inhibitors, adhesives, antifungal agents, antibacterial agents, insecticides, antistatic agents, and fragrances as necessary. be able to.

  In particular, when the thermoplastic resin flame retardant layer constituting the mesh sheet is composed of a soft vinyl chloride resin, vinyl chloride resin (specific gravity 1.4) and cyclohexanedicarboxylic acid dialkyl ester (specific gravity 0.95) as the plasticizer are vinyl chloride. 25-80 mass parts is included with respect to 100 mass parts of resin. Further, in order to make the specific gravity of the thermoplastic resin flame retardant layer 1.3 or more and specific gravity 2.5 or less, lead oxide (specific gravity 9.35), antimony trioxide (specific gravity 5.7), titanium Barium acid (specific gravity 5.6), zirconium oxide (specific gravity 5.5), zinc oxide (specific gravity 5.4), iron oxide (specific gravity 5.2), barium carbonate (specific gravity 4.4), barium sulfate (specific gravity 4) .4), titanium dioxide (specific gravity 4.0), alumina (specific gravity 3.8), potassium titanate (specific gravity 3.3), magnesium oxide (specific gravity 3.3), mica (specific gravity 3.0), talc ( What is necessary is just to mix | blend inorganic compound particle | grains, such as specific gravity 2.8), calcium carbonate (specific gravity 2.6), aluminum hydroxide (specific gravity 2.4), and magnesium hydroxide (specific gravity 2.4). If the specific gravity of the thermoplastic resin flame retardant layer exceeds 2.5, the resulting sound-absorbing interior material may exceed the mass, which may increase the possibility of serious human damage if the ceiling material collapses, If the specific gravity is less than 1.3, the soundproofing attenuation effect may be insufficient.

  The cyclohexanedicarboxylic acid dialkyl ester includes one or more compounds selected from 1,2-cyclohexanedicarboxylic acid dialkyl ester, 1,3-cyclohexanedicarboxylic acid dialkyl ester, and 1,4-cyclohexanedicarboxylic acid dialkyl ester. In the dialkyl ester, each alkyl group is the same or different and is an aliphatic monovalent group having 4 to 13 carbon atoms (C), such as a linear alkyl group, a branched alkyl group, an alicyclic group, etc. Particularly preferred are di-2-ethylhexyl cyclohexanedicarboxylate (C8: MW393) and diisononyl cyclohexanedicarboxylate (C9: MW421). All of these include all three modes in which the dicarboxylic acid dialkyl ester bond position to the cyclohexane ring is ortho-position (1.2-position), meta-position (1.3-position) and para-position (1.4-position). To do.

Specific examples of the thermoplastic resin flame retardant layer constituting the mesh sheet made of soft vinyl chloride resin include paste vinyl chloride resin, 1,2-cyclohexanedicarboxylate diisononyl (plasticizer), and antimony trioxide (flame retardant). After the coarse woven fabric is dipped in the liquid bath of the paste sol composition mainly contained, and the soft vinyl chloride resin paste sol composition is coated on the entire circumference of the coarse woven fabric, a thermoplastic resin flame retardant layer is formed by gelation heat treatment. Get a mesh sheet. For example, 1). Obtained when a coarse woven fabric having a warp and weft of 278 dtex polyester multifilament yarn and having a warp and weft of 26 inches / inch × 28 wefts / inch: mass 70 g / m ² is used for the production of the mesh sheet. The mass of the resulting mesh sheet is 135 g / m ² , the porosity is 25%, 2). Obtained when a coarse woven fabric having a warp and a weft of 555 dtex polyester multifilament yarn with a warp and weft of 20 inches / inch × 21 wefts / inch: mass 93 g / m ² is used for the production of the mesh sheet. The mass of the resulting mesh sheet is 188 g / m ² , the porosity is 28%, 3). Obtained when a coarse woven fabric having a warp and a weft of 1111 dtex polyester multifilament yarn and having a warp and a weft of 14 inches / inch × 14 wefts / inch: mass of 195 g / m ² is used for the production of the mesh sheet. The mass of the mesh sheet is 455 g / m ² , the porosity is 23%, 4). Coarse-patterned woven fabric with a length of 8 / inch × 8 weft / inch: mass 245 g / m ² using a warp and a weft of three 833 dtex polyester multifilament yarns (1 yarn) The mass of the mesh sheet obtained when used in the production of the mesh sheet is 560 g / m ² and the porosity is 16%.

As the bulky fabric that adheres to one side or more of the mesh sheet substrate, the fiber types that form the bulky fabric are glass fiber, silica fiber, alumina fiber, silica alumina fiber, basalt fiber, carbon fiber, aramid fiber (polyparaphenylene terephthalate). Wholly aromatic polyamide fibers such as amide fiber, polyparabenzamide fiber, paraphenyleneoxydiphenylene terephthalamide copolymer fiber), polyarylate fiber, polybenzoxazole fiber, polybenzimidazole fiber, polybenzothiazole fiber and polyether ether One or more bulky yarns selected from ketone fibers are preferable, and thereby the sound absorbing interior material of the present invention can be provided with sound absorbing properties, flameproof properties and heat resistance. The bulky yarn is preferably a plain woven fabric, a twill woven fabric, a satin woven fabric, a double woven fabric, a triple woven fabric or the like used for both the warp and weft forming the bulky woven fabric in terms of improving the sound absorbing property of the sound absorbing interior material of the present invention. Further, it may be a plain fabric, a twill fabric, a satin fabric, etc. (described in paragraph [0016]) in which only one of the warp yarn or the weft yarn is constituted by a bulky yarn, and a multiple fabric such as a double fabric or a triple fabric. . Further, in a triaxial bulky woven fabric (cliner weave: Nanako, fish, Namiko, basket weave, Panama weave), it is used for both warp and bias yarns to improve the sound absorption of the sound absorbing interior material of the present invention. Preferably, only one of the warp yarn or the bias yarn may be constituted by a bulky yarn. Furthermore, in a four-axis bulky fabric (cliner weave: Nanako, fish, Namiko, basket weave, Panama weave), it is used for all warps, wefts, and bias yarns to improve the sound absorption of the sound absorbing interior material of the present invention. In view of the above, one or two types of warp, weft, and bias yarn may be constituted by a bulky yarn. These bulky woven fabrics preferably contain 7.5 to 25% (0.075 to 0.25 cc / cm ³ ) of air per unit volume (apparent volume) from the viewpoint of improving the sound absorption of the sound absorbing interior material of the present invention. Bulky fabrics using glass fibers, silica fibers, alumina fibers, and silica alumina fibers are preferred for the purpose of using a bulky fabric as a light shade and a projector ceiling as a projection screen.

  The bulky yarn contained in the bulky fabric is preferably a multifilament yarn of 250 (278 dtex) to 2000 (2222 dtex) denier, particularly a multifilament yarn of 250 (278 dtex) to 750 (833 ddtex) denier. The single yarn constituting the multifilament is about 0.1 to 10 denier. Examples of the bulky yarn include air-processed yarn (taslan-processed yarn, interlace-processed yarn, air-spun yarn, etc.) or Woolley-processed yarn. More specifically, during the production of multifilament yarns, filament loosening (defibration) is performed by air jet entanglement with a Taslan nozzle, forcing loosening and entanglement in a turbulent vortex. It is preferable to use a taslan-processed yarn that is bulked by forming a large number of loops, spiral coils, and knots. It may be a core yarn form in which a multifilament core yarn is opened and a multifilament sheath yarn is opened three-dimensionally to form many loose entanglements. In addition, as a bulky multifilament yarn, heat-set in a state where a multifilament yarn made of synthetic fiber is twisted (false twist or alternating false twist), and then crimped to obtain a crimped wooly processed yarn ( It is also possible to use false twisted / cross false twisted yarn). These taslan yarn and wooly yarn use two or more types of feed yarns, and the bulkiness can be controlled arbitrarily by controlling the feed yarn characteristics (different fineness, irregular shape, different shrinkage, different crimp) and feed rate. Can do. In the present invention, the bulky yarn is particularly preferably a taslan processed yarn. Further, the bulky yarn is a Taslan plied yarn (twisted yarn) obtained by bundling one bulky yarn and one non-bulky multifilament yarn (general-purpose multifilament yarn) and applying 10 to 100 turns / m, or It may be a taslan twisted yarn (triple twisted yarn) in which two bulky yarns and one non-bulky multifilament yarn (general-purpose multifilament yarn) are bundled and twisted 10 to 100 times / m.

Specifically, these bulky woven fabrics are obtained by driving, for example, 20 to 40 bulky yarns (including Taslan plied yarn) of 555 to 1111 dtex as fibers of the paragraph [0024] as warps and wefts for 1 inch each. 125-350 g / m ² , woven fabric (blank woven fabric, twill woven fabric, satin woven fabric, etc.) having a void ratio of 0.1-5%, and the same fiber as described in paragraph [0024], for example, 555-1111 dtex bulky yarn (TASRAN A triaxial woven fabric having a mass of 150 to 400 g / m ² and a void ratio of 0.1 to 5%, which is obtained by driving 15 to 35 yarns per inch as a warp and a bias yarn, respectively. For example, 555 to 1111 dtex bulky yarn (including Taslan plied yarn) is used as the warp yarn, the weft yarn, and the bias yarn for 15 to 30 inches per inch. Examples thereof include a tetraaxial woven fabric having a mass of 200 to 450 g / m ² and a void ratio of 0.1 to 5% obtained by this driving. These bulky woven fabrics satisfy the void ratio of 0.1 to 5% and contain 7.5 to 25% (0.075 to 0.25 cc / cm ³ ) of air per unit volume (apparent volume). There is no limit to the fineness (denier) and driving density of the bulky yarn used. The air content can be obtained as the occupancy of the total volume of bubbles with respect to a specific volume (for example, 1 cm ³ ) by collecting bubbles that rise when a bulky fabric of a specific volume (for example, 1 cm ³ ) is submerged in water by the water displacement method. it can.

  Further, these bulky woven fabrics can be subjected to fiber treatment such as water repellency, antifouling, deodorization, pollen adhesion prevention, silane coupling agent treatment, and binder treatment. Specifically, the binder treatment can be performed by using an emulsion of vinyl chloride resin, vinylidene chloride resin, silicone resin, fluorine resin, etc., thermosetting resin liquid such as unsaturated polyester resin, epoxy resin, phenol resin, urea resin, etc. Can be used in concentration.

The sound-absorbing interior material of the present invention is provided on one side or both sides of the mesh sheet described in paragraphs [0016] to [0023] (a substrate for dimensional stability that exhibits a soundproof damping effect). ] To the thermoplastic resin flame retardant layer which is the outermost layer of the mesh sheet as a two- or three-layer stacked fabric molded body to which the bulky fabric according to any one of In order to improve the interfacial adhesion durability between the mesh sheet and the bulky fabric, it is preferable that a part of the bulky yarn is embedded. The method for producing the sound-absorbing interior material of the present invention is specifically a). The mesh sheet base material is heated with an electric heater, hot air, hot roll, etc. to soften the thermoplastic resin flame retardant layer covering the mesh sheet, and the surface of the mesh sheet containing the bulky yarn is included on one or both sides of the mesh sheet. A bulky fabric is formed by stacking bulky fabrics, and heat-pressing the bulky fabrics to the softened flame retardant layer of the thermoplastic resin. It forms an adhesive interface in which part of the bulky yarn is buried in the flame retardant layer. b). As another method, the soft chloride used for coating the flame retardant layer of the soft vinyl chloride resin on one side or more of the mesh sheet base material obtained by coating the yarn element constituting the coarse fabric with the flame retardant layer of the soft vinyl chloride resin. Additional application of vinyl resin paste composition is performed, and then a bulky fabric containing bulky yarn is stacked on this additional application surface and heated in a crimped state to complete gelation (solidification) of the soft vinyl chloride resin paste composition As a result, an additional soft vinyl chloride resin flame retardant layer is formed to form a stacked fabric molded body, and by cooling this stacked fabric molded body, an adhesive interface in which part of the bulky yarn is buried in the thermoplastic resin flame retardant layer is formed. To do. The stacked fabric molded body obtained in this manner preferably satisfies the air permeability (JIS L1096: Frazier method) 1 to 50 cc / cm ² / sec because of its excellent echo suppression effect. If the air permeability is less than 1 cc / cm ² / second, the echo suppression effect may be deteriorated, and if it exceeds 50 cc / cm ² / second, the sound absorption effect may be deteriorated.

In the sound-absorbing interior material of the present invention, a bubble-containing resin breathable coating layer having a density of 0.35 to 0.75 g / cm ³ may be formed on one side of the stacked fabric molded body to a thickness of 1 to 5 mm. In this case, it is preferable that a part of the bubble-containing resin breathable coating layer is impregnated inside the stacked fabric molded body, and the depth thereof is 1 to 35% with respect to the thickness of the stacked fabric molded body. . In the case of a two-layer stacked fabric molded body in which a bulky fabric is bonded to one side of the mesh sheet, the bubble-containing resin breathable coating layer is formed on the mesh sheet surface side, and the construction of the sound absorbing interior material of the present invention is bulky. The fabric side is the interior exposed surface. Further, in the case of a three-layer stacked fabric molded body in which a bulky fabric is bonded to the front and back surfaces of the mesh sheet, the cell-containing resin breathable coating layer is formed on either the bulky fabric surface side of the front or back side. In the construction of the sound absorbing interior material, the other bulky fabric surface side is used as the interior exposed surface. The bubble-containing resin breathable coating layer has a gas permeability (JIS L1096: Frazier method) of 0.1 to 10 cc / cm ² / sec formed to a density of 0.35 to 0.75 g / cm ³ by coating with a foam-like composition. It is preferable as an incidental layer for improving the echo attenuation effect. The bubble-containing resin breathable coating layer preferably contains flame retardant particles, and the flame retardant particles described in paragraph [0019] can be used. The foam composition uses a soft vinyl chloride resin paste sol containing a plasticizer, and a stiff sol composition containing 1 to 5 parts by mass of silicone oil as a foam stabilizer. A whip that is mechanically agitated by attaching a blade in the form of a tea bowl and forcibly entrained bubbles is knife coated on one side of the stacked fabric molded body as it is, so that the piled fabric molded body is impregnated and coated simultaneously. A part of the bubble-containing resin breathable coating layer formed thereby has an impregnated portion in the stacked fabric molded body, and the maximum depth of this impregnated portion is set to the thickness of the stacked fabric molded body. By setting the content to 1 to 35%, it is possible to further improve the sound absorption characteristics due to the echo attenuation effect by forming a structure that substantially contains air bubbles inside the stacked fabric molded body. When the density of the bubble-containing resin breathable coating layer exceeds 0.75 g / cm ³ , the sound absorption characteristics due to the echo attenuation effect may be insufficient, and when the density is less than 0.35 g / cm ³ , the bubble-containing resin breathability is decreased. The wear strength of the coating layer may be deteriorated.

In addition, the bubble-containing resin breathable coating layer is formed by coating the impregnated portion of the mesh sheet base material, which is a part thereof, with a chemical foaming agent-containing composition coating, and by heating at 180 to 220 ° C. Air permeability (JIS L1096: Frazier method) 0.1 to 10 cc / cm ² / sec formed with bubbles 1 to 5 mm in thickness and density 0.35 to 0.75 g / cm ³ including bubbles generated as generation marks The covering layer is preferably used as a means for improving the echo attenuation effect. The chemical foaming agent-containing composition is a soft vinyl chloride resin paste sol containing a plasticizer, and azodicarboxamide, oxybisbenzenesulfonylhydrazide, benzenesulfonylhydrazide, p-toluenesulfonylhydrazide, diazoaminobenzene, azobis Impregnating the piled fabric molding by impregnating a thick paste sol composition containing 1 to 10 parts by mass of one or more selected from isobutyronitrile on one side of the piled fabric molding A part of the bubble-containing resin breathable coating layer formed simultaneously by the coating has an impregnation portion in the stacked fabric molded body, and the maximum depth of the impregnated portion is set to the thickness of the stacked fabric molded body. From 1 to 35%. Then, the chemical foaming agent is pyrolyzed and gasified by heating at 180 to 220 ° C., and bubbles generated as gas generation traces are included in the bubble-containing resin breathable coating layer and the impregnation part, and the thickness of the bubble-containing resin breathable coating layer is 1 To 5 mm and density to 0.35 to 0.75 g / cm ³ . Also, the air-permeable resin-permeable coating layer is a soft vinyl chloride resin or styrene-based copolymer resin, and a composition obtained by calendering a composition containing 1 to 10 parts by mass of the chemical foaming agent on a stacked fabric molded body. It is formed by hot melt lamination at 150 to 175 ° C., and the chemical foaming agent is pyrolyzed and gasified by heating at 180 to 220 ° C., and bubbles generated as gas generation traces are included in the bubble-containing resin breathable coating layer and the impregnation part. The thickness of the bubble-containing resin breathable coating layer is 1 to 5 mm, and the density is 0.35 to 0.75 g / cm ³ . When the density of the bubble-containing resin breathable coating layer exceeds 0.75 g / cm ³ , the sound absorption characteristics due to the echo attenuation effect may be insufficient, and when the density is less than 0.35 g / cm ³ , the bubble-containing resin breathability is decreased. The wear strength of the coating layer may be deteriorated.

  The construction of the sound-absorbing interior material of the present invention can be freely combined with any standard sheet (stacked fabric molding) having a width of 1 m to 3 m and a length of 1 m to 50 m, and the bulky fabric surface side is used as an acoustic incident surface. Install. Especially 1). The sound absorbing interior materials, each of which has a width of about 1m to 3m and a length of about 1m to 5m, are composed of panels in which the entire circumference of the sound absorbing interior material is fixed with an aluminum frame (pressing material) in the form of a square, rectangle, triangle, rhombus, etc. It can be used for flat ceilings and geometric 3D ceilings by fixing to the ceiling beam system or by hanging 2). In addition, one long sound-absorbing interior material (stacked fabric molding) with a width of about 1m to 3m and a length of about 1m to 10m is fixed to the ceiling beam or aluminum pressing material on the two sides in the width direction, without applying tension. Can be used for design art ceilings that hang a pile of piled fabrics in a semicircular arc that is loosened by its own weight, and expresses a series of semicircular arcs by connecting multiple piled fabrics. In addition, a stacked fabric molded body with a width of about 1m to 3m and a length of about 1m to 5m is in the form of a square, rectangle, triangle, rhombus, etc. for each point on the outer periphery of the stacked fabric molded body. It can be used for design art ceilings using drapes obtained by controlling tension by providing buckles, mounting brackets, joint nuts, etc., and suspension-fixing to the ceiling beam system using ropes and springs.

EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated concretely, this invention is not limited to these. First, a method for producing and evaluating a sound absorbing interior material of the present invention will be described.
<Sound absorption rate>
An arithmetic average value of each sound absorption coefficient of 250 Hz, 500 Hz, 1000 Hz, and 2000 Hz was determined from Noise Reduction Coefficient (NRC value) according to JIS A1409 (reverberation reflection method).
<Dimensional stability>
Stacked fabric moldings 5 cm wide (weft) x 30 cm long (longitude) and 30 cm wide (weft) x 5 cm long (longitude) strip-shaped test pieces are suspended for 10 hours under a condition of 20 ° C under a load of 10 kgf. The rate was determined.
1: Less than 7.5% elongation (excellent in dimensional stability)
2: Extensibility exceeding 7.5% (inferior in dimensional stability)
<Air content of bulky fabric>
Bubbles that floated when a bulky woven fabric with a specific volume (1 cm ³ ) was submerged in water were collected by the water displacement method, and were determined as the occupation ratio of the total volume of bubbles with respect to the specific volume (1 cm ³ ).
<Adhesive interface incorporating a part of bulky yarn>
a) Observation of the cross section of the thermoplastic resin flame retardant layer with a digital microscope (200 times) 1: Fully buried as a whole 2: Superficial adhesion occupies most (insufficient)
b) Peel strength (kgf / inch) JIS L1096 between mesh sheet and bulky fabric was measured.
<Air permeability>
JIS L1096 8.27.1 Determined by the Frazier method defined in the A method.
<Fireproofing>
Measurement was performed according to JIS A1322, and flameproof grade 1, flameproof grade 2, and flameproof grade 3 were judged.
Flameproof grade 1: Carbonization length 5 cm or less: No afterflame: no residual dust after 1 minute Flameproof grade 2: Carbonization length 10 cm or less: After flame 5 seconds or less: No residual dust after 1 minute Flameproof grade 3: Carbonization length 15 cm Below: After flame 5 seconds or less: No dust after 1 minute

<Mesh sheets 1-3>
Mesh sheet 1) . Multi-filament yarns made of alkali-free glass fiber (400 number of 9 μm filaments) and subjected to Z twist 25 times / m, 75th (687 dtex) single yarn is used as a warp group and a weft group. A soft plain vinyl chloride resin paste sol composition is dipped in a paste sol composition made of a soft vinyl chloride resin of the following formulation 1 with a coarse plain woven fabric having a pitch / inch × 20 wefts / inch: 210 g / m ^2. After impregnating and covering the entire coarse woven fabric, gelation was performed at 180 ° C. to obtain a mesh sheet 1 having a mass of 465 g / m ² and a porosity of 23%. When a 10 kgf load is suspended for 1 hour under the condition of 20 ° C. on a strip-shaped test piece of 5 cm width (weft) × 30 cm length (warp) and 30 cm width (weft) × 5 cm length (warp) of this mesh sheet 1 The elongation percentage of was 2.3%.
Mesh sheet 2) . 8.3 dtex polyester multifilament yarn 3 assortment (1 yarn) warp group and weft group, the number of stakes per inch is 8 warps / inch x 8 wefts / inch: Coarse grain size of 245 g / m ² The woven fabric is dipped in a liquid bath of a paste sol composition made of a soft vinyl chloride resin of the following composition 1 to impregnate and coat the entire soft woven fabric with a soft vinyl chloride resin paste sol composition, and then gelled at 180 ° C. Thus, a mesh sheet 2 having a mass of 560 g / m ² and a porosity of 16% was obtained. When a 10 kgf load is hung for 1 hour under the condition of 20 ° C. on a strip-shaped test piece of 5 cm width (weft) × 30 cm length (warp) and 30 cm width (weft) × 5 cm length (warp) of this mesh sheet 2 The elongation percentage of 2.6 was 2.6%.
Mesh sheet 3) . Three axes of 833 dtex polyester multifilament yarns (1 yarn) as a warp group and a bias yarn group, and the number of drivings per inch is 8 warps / inch x 8 wefts / inch: three axes with a mass of 250 g / m ² The basket fabric is dipped in a liquid bath of a paste sol composition made of a soft vinyl chloride resin of the following formulation 1 to impregnate and coat the entire coarse fabric with a soft vinyl chloride resin paste sol composition, and then gelled at 180 ° C. Thus, a mesh sheet 3 having a mass of 585 g / m ² and a porosity of 10% was obtained. The elongation of the mesh sheet 3 when a 10 kgf load is hung for 1 hour at 20 ° C. on a strip-shaped test piece having a width of 5 cm (weft) × 30 cm (length) and a length of 30 cm × 5 cm bias length is 2 .5%.
[Formulation 1] Soft vinyl chloride resin paste sol composition (specific gravity 1.56)
Emulsion polymerization polyvinyl chloride resin (degree of polymerization 1700) 100 parts by mass 1,2-cyclohexanedicarboxylic acid diisononyl (plasticizer) 65 parts by mass * Product name: Hexamol DINCH (manufactured by BASF)
Epoxidized soybean oil (plasticizer) 5 parts by weight Barium / zinc composite compound (stabilizer) 2 parts by weight Antimony trioxide (flame retardant) 20 parts by weight Benzotriazole (ultraviolet absorber) 0.3 part by weight Titanium oxide (white pigment) 2 parts by mass

<Bulky fabrics 1-5>
Bulky fabric 1). A bulky yarn 75th (687 dtex) single yarn made of alkali-free glass fibers (400 number of 9 μm filaments) and Z-twisted 25 times / m with the filaments entangled loosely is used for the warp and weft groups. As the bulky woven fabric 1, a plain woven fabric having 28 woven structures per inch and a weft group of 30 woven structures per inch was used. The bulky fabric 1 had a mass of 320 g / m ² , a void porosity of 0.5%, and an air content of 16%.
Bulky fabric 2). Three twisted yarns of 75 bulky yarns (687 dtex) made of alkali-free glass fibers (number of 400 filaments of 9 μm filaments) and twisted 25 times / m with loosely entangled filaments and warp groups A double woven fabric having 48 woven structures per inch and a weft group of 42 woven structures per inch was used as the bulky woven fabric 2. The bulky fabric 2 had a mass of 750 g / m ² , a void porosity of 0.2%, and an air content of 22%.
Bulky fabric 3). A bulky yarn 66tex single yarn made of carbon fiber (3,000 μm 7 μm filaments) and twisted 75 times / m with the filaments entangled loosely is used for the warp and weft groups. A plain woven fabric having 12 woven structures and 12 weft groups per inch was used as the bulky woven fabric 3. The bulky fabric 3 had a mass of 220 g / m ² , a void porosity of 0.2%, and an air content of 18%.
Bulky fabric 4). Bulky yarn 1260dtex single yarn made of aramid fiber (polyparaphenylene terephthalamide fiber: 750 filaments of 15μm and entangled with loose filaments) and Z twist 75 times / m is used for warp and weft groups The warp group had 21 woven structures per inch, and the weft group had 23 woven structures per inch as the bulky woven fabric 4. The bulky woven fabric 4 had a mass of 260 g / m ² , a void porosity of 0.4%, and an air content of 14%.

[Example 1]
Using a mixing roll machine having two pairs of nip rolls, one mesh sheet 1 (mass 465 g / m ² ) was temporarily attached to one surface of a heat roll set at 165 ° C. for 30 seconds. The thermoplastic resin flame retardant layer of the mesh sheet 1 is sufficiently softened, and then one bulky fabric 1 (mass 320 g / m ² ) is stacked on the mesh sheet 1 between the two heat rolls. Nipped while sandwiching the stacked body, a two-layer stacked fabric molded body (mass 785 g / m ² ) was obtained. The bulky fabric portion of this two-layer stacked fabric molded body contains 16% (0.16 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer of the mesh sheet 1 has a bulky fabric 1 It had an adhesion interface in which a part of the bulky yarn included in was incorporated.

[Example 2]
A two-layer stacked woven fabric molded body (mass 1215 g / m ² ) was obtained in the same manner as in Example 1 except that the bulky fabric 1 of Example 1 was changed to a bulky fabric 2 (mass 750 g / m ² ). The bulky woven fabric portion of the two-layer stacked fabric molded body contains 22% (0.22 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer of the mesh sheet 1 has a bulky fabric 1 It had an adhesion interface in which a part of the bulky yarn included in was incorporated.

Example 3
As in Example 1, except that the mesh sheet 1 of Example 1 was changed to a mesh sheet 2 (mass 560 g / m ² ), and the bulky fabric 1 was changed to a bulky fabric 2 (mass 750 g / m ² ). A layer-stacked fabric molded body (mass 1310 g / m ² ) was obtained. The bulky woven fabric portion of the two-layer stacked fabric molded body contains 22% (0.22 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer of the mesh sheet 2 has a bulky woven fabric 1. It had an adhesion interface in which a part of the bulky yarn included in was incorporated.

Example 4
One side of the mesh sheet 3 (mass 585 g / m ² ) was subjected to 40 mesh gravure roll transfer of the soft vinyl chloride resin paste sol composition of Formulation 1 and coated with an adhesive made of a soft vinyl chloride resin. 1 (mass 320 g / m ² ) is stacked on a laminating machine having two nip rolls, and the stack is sandwiched between two heat rolls set at 175 ° C. Nipping to complete the gelation and solidification of the adhesive gave a two-layer stacked fabric molded body (mass 905 g / m ² ). Next, the soft vinyl chloride resin paste sol composition of Formula 1 was applied to the bulky fabric 1 side of the two-layer stacked fabric molded body in the same manner as in 40 mesh gravure roll transfer, and an adhesive made of soft vinyl chloride resin was applied. In addition, a stack of one bulky fabric 1 (mass 320 g / m ² ) is hung on a laminating machine having two nip rolls in the same manner, and between two hot rolls set at 175 ° C. Nipping in a state of sandwiching the stacked body, gelation and solidification of the adhesive was completed, and a three-layer stacked fabric molded body (mass 1225 g / m ² ) was obtained. The bulky fabric portion of the three-layer stacked fabric molded body contains 16% (0.16 cc / cm ³ ) of air per unit volume (apparent unit volume), and serves as a thermoplastic resin flame retardant layer (adhesive layer) of the mesh sheet 3. Formed an adhesive interface in which a part of the bulky yarn of the bulky fabric 1 was incorporated.

Example 5
A soft vinyl chloride resin paste sol composition of the following formulation 2 was mixed on the mesh sheet 1 surface of the two-layer stacked fabric molded body (mass 1215 g / m ² ) of Example 2 into a teacup shape by combining eight stainless steel wires. A whip (3-fold foaming) that was forced to entrain air bubbles and retained its shape to form a wet coating film with a thickness of 3 mm, 180 ° C. × 3 minutes subjected to gel process by electric furnace heating, 2 stratification heavy fabric molded body bubble containing resin ventilated cladding layer on the back surface of the (density 0.33 g / cm ³⁾ the mass is provided 225g / ^{m 2} 1440g / ^{m 2} The sound-absorbing interior material was obtained.
[Formulation 2] Paste sol composition with soft vinyl chloride resin Emulsion polymerization vinyl chloride resin (degree of polymerization 1700) 100 parts by mass 1,2-cyclohexanedicarboxylic acid diisononyl (plasticizer) 65 parts by mass * Product name: Hexamol DINCH ( (Made by BASF)
Antimony oxide (flame retardant) 15 parts by weight Molybdenum oxide (flame retardant) 5 parts by weight Barium zinc composite compound (stabilizer) 2 parts by weight Dimethyl silicone oil (foam stabilizer) 2 parts by weight Titanium oxide (white pigment) 2 parts by weight Isocyan Nurate-modified triisocyanate (TDI trimer) 3 parts by weight Diethylene glycol (polyol) 3 parts by weight * Adhesion with isocyanurate-modified triisocyanate improves adhesion to mesh sheet 1 and at the same time softens by polymerization with diethylene glycol. By generating a polyurethane cross-linked structure inside the vinyl chloride resin, the resin strength and shape retention of the bubble-containing resin breathable coating layer are further strengthened.

Example 6
As in Example 1, except that the mesh sheet 1 of Example 1 was changed to a mesh sheet 2 (mass 560 g / m ² ), and the bulky fabric 1 was changed to a bulky fabric 3 (mass 220 g / m ² ). A layer stacked fabric molded body (mass 780 g / m ² ) was obtained. The bulky woven fabric portion of the two-layer stacked fabric molded body contains 18% (0.18 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer of the mesh sheet 2 has a bulky woven fabric 3. It had an adhesion interface in which a part of the bulky yarn included in was incorporated.

Example 7
As in Example 1, except that the mesh sheet 1 of Example 1 was changed to a mesh sheet 3 (mass 585 g / m ² ), and the bulky fabric 1 was changed to a bulky fabric 4 (mass 260 g / m ² ). A layer-stacked fabric molded body (mass 845 g / m ² ) was obtained. The bulky woven fabric portion of this two-layer stacked fabric molded body contains 14% (0.14 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer of the mesh sheet 3 has a bulky woven fabric 4. It had an adhesion interface in which a part of the bulky yarn included in was incorporated.

Example 8
Whip (3-fold foaming) with the soft vinyl chloride resin paste sol composition of Formulation 2 used in Example 5 on the mesh sheet 3 surface of the two-layer stacked fabric molded body of Example 7 (mass 845 g / m ² ). Was coated with clearance in the same manner as in Example 5 to form a wet paint film with a paste thickness of 3 mm, and subjected to a gelation treatment by heating in an electric furnace at 180 ° C. for 3 minutes to form the back surface of the two-layer stacked fabric molded body. bubble containing resin ventilated cladding layer (density of 0.33 g / cm ³⁾ was obtained 225 g / ^{m 2} provided mass 1070 g / ^{m 2} of sound absorbing interior material.

Each of the sound absorbing interior materials of Examples 1 to 8 is a two-layer or three-layer stacked fabric molded body in which a bulky fabric including a bulky yarn is bonded to one or more sides of a mesh sheet base material, both of which are mesh sheets In the base material, it is lightweight and has dimensional stability and durability. In particular, the bulky fabric has 7.5 to 25% (0.75 to 0.25 cc / air) of air per unit volume (apparent unit volume). cm3) and has an adhesive interface in which part of the bulky yarn is incorporated into the thermoplastic resin flame retardant layer, so it has durability to withstand flexible use as a ceiling membrane, and it also has the effect of suppressing reverberations in bulky fabric layers. And the sound absorption performance by the synergistic effect of the soundproofing attenuation of the mesh sheet base material, and further the synergistic effect of the further soundproofing attenuation effect by the attachment of the bubble-containing resin breathable coating layer according to Example 5 and Example 8. According sound absorbing performance can be obtained. Moreover it was possible to obtain an excellent sound absorbing interior member to flameproof. In particular, the sound-absorbing interior materials of Examples 1 and 2 were designed to use a glass fabric for both the mesh sheet and the bulky fabric, thereby satisfying the requirement for nonflammability.
In addition, the sound absorbing interior materials of Examples 1 to 8 have a variety of functions as a sound absorbing interior film material for film ceiling materials, such as bringing about an elegant light effect as a light shade, and capable of projecting a projector using a bulky fabric as a projection screen. Was expressed.

[Comparative Example 1]
The bulky fabric 1 was omitted from the two-layer stacked fabric molded body of Example 1, and the mesh sheet 1 alone (mass 465 g / m ² , porosity 23%) was obtained. By omitting the bulky fabric 1, the sound absorption effect was extremely inferior, and the NRC value by the reverberation reflection method was reduced from 0.63 to 0.12.

[Comparative Example 2]
The mesh sheet 1 was omitted from the two-layer stacked fabric molded body of Example 1 to obtain a bulky fabric 1 alone (mass 320 g / m ² , porosity 0.5%, air content 16%). By omitting the mesh sheet 1, the dimensional stability is inferior, and there is a problem of looseness and deformation when used as a membrane ceiling, and the NRC value by the reverberation reflection method is from 0.63 to 0.23. Reduced.

[Comparative Example 3]
Except for changing the bulky woven fabric 1 of the two-layer stacked fabric molded body of Example 1 to the following non-bulky woven fabric 1 (mass 355 g / m ² , porosity 0.5%, air content 2.5%). As in Example 1, a two-layer stacked fabric molded body (mass 820 g / m ² ) was obtained. By changing the bulky woven fabric 1 to the non-bulky woven fabric 1, the formation of an adhesive interface between the mesh sheet 1 and the non-bulky woven fabric 1 becomes insufficient, and the peeling strength is reduced, which may cause peeling trouble when used as a membrane ceiling. The NRC value by the reverberation reflection method was reduced from 0.63 to 0.32.
Non-bulky woven fabric 1) Multifilament yarn 75th yarn (687 dtex) made of alkali-free glass fiber (400 number of 9 μm filaments) and phi-Z twisted 25 times / m is used for warp group and weft group. Is a plain weave with 34 weaves per inch, and the weft group is 38 weaves per inch.

[Comparative Example 4]
As in Example 1, except that the mesh sheet 1 of the two-layer stacked fabric molded body of Example 1 was changed to the following tarpaulin 1 (mass 680 g / m ² , porosity 0%, air content 0%). A layer-stacked fabric molded body (mass 1000 g / m ² ) was obtained. As a result of changing the mesh sheet 1 to tarpaulin 1 and setting the air permeability to 0 cc / cm ² / sec, the NRC value by the reverberation reflection method was reduced from 0.63 to 0.22.
Tarpaulin 1) Made of alkali-free glass fiber (number of 400 9μm filaments), multi-filament yarn 75th (687dtex) single yarn with 25 twists / m of Z twist is used as a warp group and a weft group. A soft vinyl chloride resin compound composition of the following composition 3 was melt-kneaded with a 180 ° C. calender roll on both sides of a coarse plain woven fabric of 18 / inch × 20 weft / inch: 210 g / m ² and rolled. The 0.12 mm thick film thus obtained was heat laminated at 175 ° C. to obtain Tarpaulin 1 having a mass of 680 g / m ² .
[Formulation 3] Soft vinyl chloride resin compound composition Suspension polymerization vinyl chloride resin (degree of polymerization 1300) 100 parts by mass 1,2-cyclohexanedicarboxylic acid diisononyl (plasticizer) 60 parts by mass * Product name: Hexamol DINCH (BASF (Made by company)
Antimony oxide (flame retardant) 15 parts by mass Molybdenum oxide (flame retardant) 5 parts by mass Barium zinc composite compound (stabilizer) 2 parts by mass Titanium oxide (white pigment) 2 parts by mass

[Comparative Example 5]
Except for changing the bulky fabric 1 of the two-layer stacked fabric molded body of Example 1 to the following bulky fabric 5 (mass 265 g / m ² , porosity 0%, air content 36%), the same as Example 1 A two-layer stacked fabric molded body (mass: 730 g / m ² ) was obtained. By changing the bulky fabric 1 to a bulky fabric 5 that is more excessively bulky, the NRC value by the reverberation reflection method is reduced, and is reduced from 0.63 to 0.24, and the thermoplastic resin flame retardant of the mesh sheet 1 The layer formed an adhesive interface in which part of the bulky yarn of the bulky fabric 5 was buried, but part of the bulky yarn was easily displaced from the bulky fabric 5 that was excessively bulky, resulting in a mesh sheet It was easy to peel from No. 1, and was likely to cause peeling trouble when used as a membrane ceiling.
Bulky woven fabric 5) Bulky yarn 75th (687dtex) single yarn consisting of alkali-free glass fibers (number of 400 9μm filaments) and entangled loosely with Z twist 25 times / m. As the bulky fabric 5, a warp group having a woven structure of 22 pieces per inch and a weft group having a woven structure of 25 pieces per inch were used.

  According to the present invention, a flameproof interior material having a sound absorbing property as a ceiling area constituting member / sound absorbing member installed on a ceiling of a large building or an accessory to a ceiling area constituting member can be obtained, and these membrane materials have dimensions. Excellent stability, easy construction, light weight and flexibility that are unlikely to cause serious human damage even if it collapses in the event of an earthquake, excellent in echo suppression effect and sound attenuation effect In addition, these film materials offer a variety of functions as sound-absorbing interior film materials for film ceiling materials, such as providing light effects that are elegant as light shades, and capable of projector projection using bulky fabrics as projection screens. So, membrane ceiling construction such as indoor stadium, gymnasium, indoor pool, event hall, public hall, ceremonial hall, station building lobby, airport lobby, shopping mall atrium It can be widely used in such.

1: Stacked fabric molding (sound absorbing interior material)
2: Mesh sheet 2-1: Coarse fabric 2-2: Thermoplastic resin flame retardant layer 2-3: Warp yarn (yarn)
2-4: Weft yarn (yarn)
3: Bulky woven fabric 3-1: Warp bulky yarn 3-2: Weft bulky yarn 4: Bubble-containing resin breathable coating layer 4-1: Bubble

Claims (7)

A two-layer or three-layer stacked fabric molded body in which a bulky fabric containing a bulky yarn is bonded to one side or more of a mesh sheet base material formed by coating a thermoplastic resin flame retardant layer on a yarn element constituting a coarse fabric. The bulky woven fabric contains 7.5 to 25% (0.075 to 0.25 cc / cm ³ ) of air per unit volume (apparent unit volume), and the thermoplastic resin flame retardant layer includes one of the bulky yarns. A sound-absorbing interior material characterized by forming an adhesive interface in which a portion is buried.   The bulky yarn is glass fiber, silica fiber, alumina fiber, silica alumina fiber, basalt fiber, carbon fiber, aramid fiber (polyparaphenylene terephthalamide fiber, polyparabenzamide fiber, paraphenyleneoxydiphenylene terephthalamide copolymer fiber) 2 or more kinds of yarns selected from polyallylate fibers, polyarylate fibers, polybenzoxazole fibers, polybenzimidazole fibers, polybenzothiazole fibers and polyetheretherketone fibers. Sound absorbing interior material.   The sound absorbing material according to claim 1 or 2, wherein the thermoplastic resin flame retardant layer mainly contains a thermoplastic resin and flame retardant particles, and the thermoplastic resin flame retardant layer has a specific gravity of 1.3 to 2.5. Interior material.   The thermoplastic resin flame retardant layer mainly contains a vinyl chloride resin and a cyclohexanedicarboxylic acid dialkyl ester, and the thermoplastic resin flame retardant layer has a specific gravity of 1.3 to 2.5. The sound absorbing interior material according to claim 1. A bubble-containing resin breathable coating layer having a thickness of 1 to 5 mm and a density of 0.35 to 0.75 g / cm ³ is formed on one surface of the stacked fabric molded body, and the bubbles are formed inside the stacked fabric molded body. 5. The sound-absorbing interior according to claim 1, wherein a part of the resin-permeable breathable coating layer is impregnated and a depth thereof is 1 to 35% with respect to a thickness of the stacked fabric molded body. Wood.   Heating a mesh sheet base material, which is formed by coating a thermoplastic resin flame retardant layer on a yarn element constituting a coarse woven fabric, and stacking a bulky woven fabric containing bulky yarn on one or more sides, and softening the thermoplastic The bulky woven fabric is formed by stacking the bulky fabric on the resin flame retardant layer, and an adhesive interface in which a part of the bulky yarn is buried in the thermoplastic resin flame retardant layer by cooling the stacked fabric molded body. A method for producing a sound-absorbing interior material, characterized by comprising: The soft vinyl chloride resin paste composition used for coating the soft vinyl chloride resin flame retardant layer on one side or more of the mesh sheet base material obtained by coating the yarn element constituting the coarse woven fabric with the soft vinyl chloride resin flame retardant layer A process of performing additional application of
An additional soft vinyl chloride resin flame retardant layer is formed by stacking a bulky woven fabric containing bulky yarn on this additional coated surface, heating in a pressure-bonded state, and completing gelation (solidification) of the soft vinyl chloride resin paste composition. Forming a stacked fabric molded body,
And forming an adhesive interface in which part of the bulky yarn is buried in the additional soft vinyl chloride resin flame retardant layer.