JP2018169555A - Laminated sound absorbing material including nanofibers - Google Patents
Laminated sound absorbing material including nanofibers Download PDFInfo
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Landscapes
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
Abstract
Description
本発明は、極細繊維を含んで構成される、積層構造の吸音材に関する。 The present invention relates to a sound-absorbing material having a laminated structure that includes ultrafine fibers.
吸音材とは音を吸収する機能を有する製品であって、建築分野や自動車分野において多用されている。吸音材を構成する材料として、不織布を用いることが公知である。例えば特許文献１には、メジアン直径が１μｍ未満のサブミクロン繊維と、メジアン直径が少なくとも１μｍであるマイクロファイバーとを含む複合不織布ウェブが開示されている。特許文献１の複合繊維ウェブは、サブミクロン繊維及びマイクロファイバーと称される２種類の異なるメジアン直径を有する繊維が混合されてなり、その混合比を変化させることによって、厚み方向に混合比の勾配を形成し、不均質な繊維混合物を得ている。代表的な実施形態においては、マイクロファイバー流を形成し、またサブミクロン繊維流を別個に形成してマイクロファイバー流に加えることによって、異なる繊維が混合されてなるウェブを形成できることが開示されている。 The sound absorbing material is a product having a function of absorbing sound, and is often used in the construction field and the automobile field. It is known to use a nonwoven fabric as a material constituting the sound absorbing material. For example, Patent Document 1 discloses a composite nonwoven web including submicron fibers having a median diameter of less than 1 μm and microfibers having a median diameter of at least 1 μm. The composite fiber web of Patent Document 1 is a mixture of fibers having two different median diameters called sub-micron fibers and microfibers, and the mixing ratio is changed in the thickness direction by changing the mixing ratio. To form a heterogeneous fiber mixture. In an exemplary embodiment, it is disclosed that a microfiber stream can be formed and a sub-micron fiber stream can be separately formed and added to the microfiber stream to form a web of different fibers mixed together. .
また特許文献２には、吸音性を有する多層物品として、支持体層と、支持体層上に積層されるサブミクロン繊維層とを含み、サブミクロン繊維層は、中央繊維直径が１μｍ未満かつ平均繊維直径が０．５〜０．７μｍの範囲であり、溶融フィルムフィブリル化法や電界紡糸法によって形成されることが開示されている。特許文献２の実施例においては、坪量（目付）１００ｇ／ｍ２、直径約１８μｍのポリプロピレンスパンボンド不織布を支持体層とし、その上に、目付１４〜５０ｇ／ｍ２、平均繊維直径約０．５６μｍのサブミクロンポリプロピレン繊維を積層した積層物品が開示されている。また別の実施例では、目付６２ｇ／ｍ２のポリエステルのカード処理ウェブの上に、目付６〜３２ｇ／ｍ２、平均繊維直径０．６０μｍの電界紡糸ポリカプロラクトン繊維を積層させた多層物品が開示されている。実施例で作成された多層物品は、音響吸収特性が測定され、支持体のみの音響吸収特性よりも優れた音響吸収特性を備えることが示されている。 Further, Patent Document 2 includes a support layer and a submicron fiber layer laminated on the support layer as a multilayer article having sound absorption properties. The submicron fiber layer has a center fiber diameter of less than 1 μm and an average value. It is disclosed that the fiber diameter is in the range of 0.5 to 0.7 μm and formed by a melt film fibrillation method or an electrospinning method. In Examples of Patent Document 2, a polypropylene spunbonded nonwoven fabric having a basis weight (weight per unit area) of 100 g / m 2 and a diameter of about 18 μm is used as a support layer, and a basis weight of 14 to 50 g / m 2 and an average fiber diameter of about 0 are used. Laminated articles laminated with .56 μm submicron polypropylene fibers are disclosed. In another embodiment, the basis weight 62 g / m on a polyester card processing web 2, basis weight 6~32g / m 2, the multilayer article is disclosed as a laminate of electrospun polycaprolactone fibers having an average fiber diameter of 0.60μm Has been. The multilayer articles made in the examples are measured for acoustic absorption properties and have been shown to have better acoustic absorption properties than those of the support alone.
特許文献３には、低周波及び高周波の音を吸収する積層吸音不織布であって、共振膜と、少なくとも１つの別の繊維材料層とを含み、共振膜は、直径６００ｎｍまでで表面重量（目付）０．１〜５ｇ／ｍ２のナノ繊維層によって形成されるものが開示されている。ナノ繊維層は典型的には電界紡糸によって作り出され、一方、基材層は、直径１０〜４５μｍで目付５〜１００ｇ／ｍ２の繊維織物であり、さらに別の層が積層されてもよいことが開示されている。また、適切な厚さ及び目付に到達するために、この積層体をさらに積層してもよいことが開示されている。 Patent Document 3 discloses a laminated sound-absorbing nonwoven fabric that absorbs low-frequency and high-frequency sounds, and includes a resonance film and at least one other fiber material layer. The resonance film has a surface weight (weight per unit area) up to a diameter of 600 nm. ) What is formed by 0.1-5 g / m < 2 > nanofiber layer is disclosed. The nanofiber layer is typically created by electrospinning, while the substrate layer is a fiber fabric having a diameter of 10 to 45 μm and a basis weight of 5 to 100 g / m 2 , and further layers may be laminated. Is disclosed. Further, it is disclosed that this laminate may be further laminated in order to reach an appropriate thickness and basis weight.
特許文献４には、ナノ繊維による、吸音特性に優れる不織布構造体が開示されている。特許文献４の不織布構造体は、繊維径が１μｍ未満のナノ繊維を含む繊維体を含み、当該繊維体の厚みが１０ｍｍ以上であることを特徴とする。また、前記繊維体は支持体に支持されていてもよく、繊維体と支持体とが繰り返し積層された構造になっていてもよいことが開示されている。ナノ繊維は例えばメルトブローン法で形成され、実施例においては、支持体であるポリプロピレンスパンレース不織布の上に、繊維径０．５μｍ、目付３５０ｇ／ｍ２のナノ繊維体の層を形成することが開示されている。 Patent Document 4 discloses a non-woven fabric structure that is excellent in sound absorption characteristics using nanofibers. The nonwoven fabric structure of Patent Document 4 includes a fibrous body containing nanofibers having a fiber diameter of less than 1 μm, and the thickness of the fibrous body is 10 mm or more. Further, it is disclosed that the fibrous body may be supported by a support, or may have a structure in which the fibrous body and the support are repeatedly laminated. The nanofibers are formed by, for example, a melt blown method, and in an embodiment, a nanofiber body layer having a fiber diameter of 0.5 μm and a basis weight of 350 g / m 2 is formed on a polypropylene spunlace nonwoven fabric as a support. Has been.
上述のとおり、吸音材としてさまざまな構成の不織布積層体が検討されており、繊維径が１μｍを下回るナノ繊維やサブミクロン繊維と称される極細繊維を用いることも公知である。しかしながら、より優れた吸音特性を有する吸音材、特に、１０００Ｈｚ以下の、比較的低周波数の領域において優れた吸音性能を示し、且つ、省スペース性に優れた吸音材が求められている。この状況に鑑み、本発明は、低周波領域において優れた吸音性を示す吸音材を提供することを課題とする。 As described above, non-woven fabric laminates having various configurations have been studied as sound absorbing materials, and it is also known to use ultrafine fibers called nanofibers or submicron fibers whose fiber diameter is less than 1 μm. However, there is a demand for a sound-absorbing material having more excellent sound-absorbing characteristics, particularly a sound-absorbing material that exhibits excellent sound-absorbing performance in a relatively low frequency region of 1000 Hz or less and is excellent in space saving. In view of this situation, an object of the present invention is to provide a sound-absorbing material that exhibits excellent sound-absorbing properties in a low-frequency region.
発明者は上述の課題を解決するために検討を重ねた。その結果、基材層と繊維層とを含む積層吸音材において、特定範囲の繊維径及び目付を有する繊維層を少なくとも２層含み、さらに、特定の範囲の開口率の穴開き構造体を有することで、前記課題を解決できることを見出し、本発明を完成した。 The inventor has repeatedly studied to solve the above-described problems. As a result, the laminated sound-absorbing material including the base material layer and the fiber layer includes at least two fiber layers having a specific range of fiber diameters and basis weights, and further includes a perforated structure having a specific range of aperture ratio. Thus, the inventors have found that the above problems can be solved and completed the present invention.
本発明は、以下の構成を有する。
［１］繊維層と基材層とを含む積層吸音材であって、
前記繊維層は前記積層吸音材中に少なくとも２層含まれ、また前記繊維層は４５０ｎｍ未満の繊維径の繊維からなり、目付けが５０ｇ／ｍ２以上である繊維集合体であり、
前記基材層は、不織布、フィルム、ガラス繊維および紙からなる群より選ばれる少なくとも１つからなり、目付けが１ｇ／ｍ２以上であり、
さらに、前記積層吸音材は、開口率０．０５％以上５０％未満の穴開き構造体を１層以上有する、積層吸音材。
［２］前記穴開き構造体が、前記積層吸音材に含まれる前記繊維層のうち最外層の繊維層の内面に隣接して備えられている、［１］に記載の積層吸音材。
［３］前記穴開き構造体が、前記積層吸音材に含まれる前記繊維層のうち最外層の繊維層よりも内側に、２層以上備えられている、請求項１に記載の積層吸音材。
［４］前記穴開き構造体の素材が、不織布、フィルム、ガラス繊維、織布および紙からなる群より選ばれる少なくとも１つである、［１］〜［３］のいずれかに記載の積層吸音材。
［５］前記繊維層は、０．１ｇ／ｍ２〜２５ｇ／ｍ２の目付けの繊維集合体を少なくとも２層含有してなり、繊維層の目付けが５０ｇ／ｍ２以上である、［１］〜［４］のいずれかに記載の積層吸音材。
［６］前記基材層が、ポリエチレンフタレート繊維、ポリブチレンテレフタレート繊維、ポリエチレン繊維およびポリプロピレン繊維からなる群から選ばれる少なくとも１種からなる不織布であり、前記基材層の目付けが１〜３００ｇ／ｍ２である、［１］〜［５］のいずれかに記載の積層吸音材。
［７］前記繊維層を形成する繊維が、ポリフッ化ビニリデン、ナイロン６．６、ポリアクリロニトリル、ポリスチレン、ポリウレタン、ポリスルフォンおよびポリビニルアルコールからなる群から選ばれる少なくとも１種である、［１］〜［６］のいずれかに記載の積層吸音材。
［８］垂直入射吸音率測定法（２００〜１０００Ｈｚ）において、周波数ｘが２００Ｈｚから３２００Ｈｚまでの吸音率を１Ｈｚ間隔で測定し、得られる曲線をｆ（ｘ）としたとき、２００Ｈｚから１０００Ｈｚまでの積分した値Ｓが、下記式を満たす範囲である、［１］〜［７］のいずれかに記載の積層吸音材。
［９］垂直入射吸音率測定法（２００〜１０００Ｈｚ）において、周波数ｘが２００Ｈｚから３２００Ｈｚまでの吸音率を１Ｈｚ間隔で測定し、得られる曲線をｆ（ｘ）としたとき、２００Ｈｚから１０００Ｈｚまでの積分した値Ｓが、下記式を満たす範囲である、［１］〜［７］のいずれかに記載の積層吸音材。
［１０］［１］〜［９］のいずれかに記載の積層吸音材において、前記繊維層を構成する繊維が、ポリフッ化ビニリデン、ナイロン６．６、ポリアクリロニトリル、ポリスチレン、ポリウレタン、ポリスルフォンおよびポリビニルアルコールからなる群から選ばれる少なくとも１種の高分子を含む溶液を静電スピニングすることによって作り出されることを特徴とする、積層吸音材の製造方法。
The present invention has the following configuration.
[1] A laminated sound absorbing material including a fiber layer and a base material layer,
The fiber layer is a fiber assembly including at least two layers in the laminated sound-absorbing material, the fiber layer is made of fibers having a fiber diameter of less than 450 nm, and has a basis weight of 50 g / m 2 or more.
The base material layer is composed of at least one selected from the group consisting of a nonwoven fabric, a film, glass fiber, and paper, and has a basis weight of 1 g / m 2 or more.
Furthermore, the laminated sound-absorbing material has one or more perforated structures having an opening ratio of 0.05% or more and less than 50%.
[2] The laminated sound absorbing material according to [1], wherein the perforated structure is provided adjacent to an inner surface of an outermost fiber layer among the fiber layers included in the laminated sound absorbing material.
[3] The laminated sound absorbing material according to claim 1, wherein two or more layers of the perforated structure are provided on the inner side of the outermost fiber layer among the fiber layers included in the laminated sound absorbing material.
[4] The laminated sound absorbing material according to any one of [1] to [3], wherein the material of the perforated structure is at least one selected from the group consisting of nonwoven fabric, film, glass fiber, woven fabric, and paper. Wood.
[5] The fiber layer is made by a fiber aggregate having a basis weight of 0.1g / m 2 ~25g / m 2 and contains at least two layers is the basis weight of the fiber layer is 50 g / m 2 or more, [1] The laminated sound-absorbing material according to any one of to [4].
[6] The base material layer is a nonwoven fabric made of at least one selected from the group consisting of polyethylene phthalate fiber, polybutylene terephthalate fiber, polyethylene fiber and polypropylene fiber, and the basis weight of the base material layer is 1 to 300 g / m. The laminated sound-absorbing material according to any one of [1] to [5], which is 2 .
[7] The fiber forming the fiber layer is at least one selected from the group consisting of polyvinylidene fluoride, nylon 6.6, polyacrylonitrile, polystyrene, polyurethane, polysulfone, and polyvinyl alcohol. 6] The laminated sound-absorbing material according to any one of [6].
[8] In the normal incident sound absorption coefficient measurement method (200 to 1000 Hz), when the sound absorption coefficient at a frequency x of 200 Hz to 3200 Hz is measured at intervals of 1 Hz, and the obtained curve is f (x), the frequency is 200 Hz to 1000 Hz. The laminated sound-absorbing material according to any one of [1] to [7], wherein the integrated value S is a range satisfying the following formula.
[9] In the normal incidence sound absorption coefficient measurement method (200 to 1000 Hz), the sound absorption coefficient at a frequency x of 200 Hz to 3200 Hz is measured at 1 Hz intervals, and when the obtained curve is f (x), the frequency curve is 200 Hz to 1000 Hz. The laminated sound-absorbing material according to any one of [1] to [7], wherein the integrated value S is a range satisfying the following formula.
[10] In the laminated sound-absorbing material according to any one of [1] to [9], the fibers constituting the fiber layer are polyvinylidene fluoride, nylon 6.6, polyacrylonitrile, polystyrene, polyurethane, polysulfone, and polyvinyl. A method for producing a laminated sound-absorbing material, which is produced by electrostatic spinning of a solution containing at least one polymer selected from the group consisting of alcohols.
上述の構成を有する本発明によれば、開口率０．０５％以上５０％未満の穴開き構造体を有することで、吸音材として厚みの削減ができる。
上述の構成を有する本発明によれば、低周波数領域における吸音特性に優れた吸音材が得られる。本発明の積層吸音材は、吸音特性のピークが従来の吸音材よりも低い領域にあり、１０００Ｈｚ以下の領域における吸音性能に優れる。建築分野では、生活騒音の多くは２００〜５００Ｈｚ程度といわれており、また自動車分野では、ロードノイズでは１００〜５００Ｈｚ程度、また、加速時やトランスミッション変動時の騒音は１００〜２０００Ｈｚ程度といわれている。本発明の積層吸音材は、このような騒音対策に有用である。また、本発明の積層吸音材は、多孔質材料やガラス繊維等からなる吸音材と比較して軽量であるため、部材の軽量化と省スペース化が可能であり、この点は特に自動車分野向けの吸音材として有用である。
According to the present invention having the above-described configuration, the thickness of the sound absorbing material can be reduced by having the perforated structure having an aperture ratio of 0.05% or more and less than 50%.
According to the present invention having the above-described configuration, a sound absorbing material having excellent sound absorbing characteristics in a low frequency region can be obtained. The laminated sound-absorbing material of the present invention is in a region where the peak of sound-absorbing characteristics is lower than that of conventional sound-absorbing materials, and is excellent in sound-absorbing performance in a region of 1000 Hz or less. In the construction field, most of the daily noise is said to be about 200 to 500 Hz. In the automobile field, road noise is about 100 to 500 Hz, and noise during acceleration and transmission fluctuation is said to be about 100 to 2000 Hz. . The laminated sound-absorbing material of the present invention is useful for such noise countermeasures. In addition, since the laminated sound absorbing material of the present invention is lighter than the sound absorbing material made of porous material, glass fiber, etc., it is possible to reduce the weight of the member and save space. It is useful as a sound absorbing material.
以下、本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail.
（積層吸音材の構造）
本発明の積層吸音材は、繊維層と基材層とを含む積層吸音材であって、繊維層は、４５０ｎｍ未満の繊維径の繊維からなる繊維集合体であり、かつ、積層吸音材中に少なくとも２層含有され、繊維層の目付けが５０ｇ／ｍ２以上であり、基材層は、不織布、フィルム、ガラス繊維および紙からなる群より選ばれる少なくとも１つであり、基材層の目付けが１ｇ／ｍ２以上であり、さらに、開口率０．０５％以上５０％未満の穴開き構造体を１層以上有する。
(Structure of laminated sound absorbing material)
The laminated sound absorbing material of the present invention is a laminated sound absorbing material including a fiber layer and a base material layer, and the fiber layer is a fiber assembly made of fibers having a fiber diameter of less than 450 nm, and the laminated sound absorbing material is At least two layers are contained, the basis weight of the fiber layer is 50 g / m 2 or more, the base material layer is at least one selected from the group consisting of a nonwoven fabric, a film, glass fiber, and paper, and the base material layer has a basis weight. 1 g / m 2 or more, and further has one or more perforated structures having an opening ratio of 0.05% or more and less than 50%.
積層吸音材において、繊維層は、４５０ｎｍ未満の繊維径の繊維からなる繊維集合体であり、かつ、積層吸音材中に少なくとも２層含有され、好ましくは３〜６層、より好ましくは３〜４層含まれる。各繊維層は、１つの繊維集合体から構成されていてもよいし、１つの繊維層の中に複数の繊維集合体が含まれ、複数の繊維集合体から１層の繊維層が構成されていてもよい。
また、繊維層の間には基材層が介在する。各基材層は、１層からなってもよく、または、複数が重ねられてなる形態であってもよい。
In the laminated sound-absorbing material, the fiber layer is a fiber assembly composed of fibers having a fiber diameter of less than 450 nm, and at least two layers are contained in the laminated sound-absorbing material, preferably 3 to 6 layers, more preferably 3 to 4 layers. Layers included. Each fiber layer may be composed of one fiber assembly, and a plurality of fiber assemblies are included in one fiber layer, and one fiber layer is composed of a plurality of fiber assemblies. May be.
A base material layer is interposed between the fiber layers. Each base material layer may consist of one layer, or may be a form in which a plurality of layers are stacked.
積層吸音材に含まれる繊維層及び基材層は、それぞれ１種類ずつでもよいが、異なる２種以上の繊維層または基材層が含まれていてもよい。また、本発明の積層吸音材には、本発明の効果を損なわない限り、繊維層、基材層及び穴あき構造体以外の構成が含まれていてもよく、例えば、本発明に規定する範囲外のさらなる繊維層（１層でも２層以上でもよい）、印刷層、発泡体、箔、メッシュ、織布等が含まれていてもよい。また、各層間を連結するための接着剤層、クリップ、縫合糸等を含んでいてもよい。 The fiber layer and the base material layer included in the laminated sound-absorbing material may each be one kind, but two or more different fiber layers or base material layers may be included. In addition, the laminated sound-absorbing material of the present invention may contain a configuration other than the fiber layer, the base material layer, and the perforated structure as long as the effects of the present invention are not impaired. For example, the range specified in the present invention Additional external fiber layers (which may be one layer or two or more layers), printing layers, foams, foils, meshes, woven fabrics and the like may be included. Further, an adhesive layer, a clip, a suture thread and the like for connecting the respective layers may be included.
積層吸音材の各層の間は、物理的及び／または化学的に接着されていてもよいし、接着されていなくてもよい。積層吸音材の複数の層間の一部が接着され、一部は接着されていない形態であってもよい。接着は、例えば、繊維層の形成工程において、または後工程として加熱を行い、繊維層を構成する繊維の一部を融解し、繊維層を基材層に融着させることによって繊維層と基材層とを接着してもよい。また、基材層ないし繊維層の表面に接着剤を付与し、さらに基材層ないし繊維層を重層することによって、層間を接着することもできる。 The layers of the laminated sound absorbing material may be physically and / or chemically bonded, or may not be bonded. The laminated sound-absorbing material may have a form in which a part of the plurality of layers is bonded and a part of the laminated sound-absorbing material is not bonded. Adhesion is performed, for example, by heating in the formation process of the fiber layer or as a subsequent process, melting a part of the fibers constituting the fiber layer, and fusing the fiber layer to the base material layer. The layers may be adhered. Moreover, an interlayer can also be adhere | attached by providing an adhesive agent on the surface of a base material layer or a fiber layer, and also overlaying a base material layer or a fiber layer.
積層吸音材の厚みは、本発明の効果が得られる限り特に制限されないが、例えば、０．１〜５０ｍｍとすることができ、０．３〜４０ｍｍとすることが好ましく、０．３〜３０ｍｍであれば、省スペース性の観点からより好ましい。なお、積層吸音材の厚みとは、繊維層、基材層及び穴開き構造体の厚みの合計のことを意味し、カートリッジや蓋等の外装体が取り付けられている場合、その部分の厚みは含まないものとする。 The thickness of the laminated sound-absorbing material is not particularly limited as long as the effect of the present invention can be obtained. For example, the thickness can be 0.1 to 50 mm, preferably 0.3 to 40 mm, and 0.3 to 30 mm. If it exists, it is more preferable from a viewpoint of space-saving property. The thickness of the laminated sound-absorbing material means the total thickness of the fiber layer, the base material layer, and the perforated structure. When an exterior body such as a cartridge or a lid is attached, the thickness of that part is Not included.
積層吸音材の通気度は、所望の吸音性能が得られる限り特に制限されるものではないが、１０〜１０００μｍ／Ｐａ・ｓとすることができ、１０〜５００μｍ／Ｐａ・ｓであればより好ましい。なお、通気度の測定は公知の方法によることができ、例えば、ガーレ試験機法で測定できる。 The air permeability of the laminated sound absorbing material is not particularly limited as long as the desired sound absorbing performance can be obtained, but can be 10 to 1000 μm / Pa · s, and more preferably 10 to 500 μm / Pa · s. . The air permeability can be measured by a known method, for example, the Gurley tester method.
積層吸音材は、繊維層と基材層の積層体によって穴開き構造体が挟まれた積層構造となっていることが好ましく、このような形態であるとき、繊維層と繊維層との間の距離（基材層の厚みと穴開き構造体の厚みの合計であり、層間距離とも称する）は、１００μｍ〜１５ｍｍであることが好ましく、１ｍｍ〜１５ｍｍであることがより好ましい。層間距離が１００μｍ以上であれば、低周波数領域の吸音性能が良好となり、層間距離が１５ｍｍ以下であれば、吸音材としての厚みが大きくなり過ぎることがなく、省スペース性に適している。 The laminated sound-absorbing material preferably has a laminated structure in which the perforated structure is sandwiched between the laminated body of the fiber layer and the base material layer, and in such a form, between the fiber layer and the fiber layer The distance (the total of the thickness of the base material layer and the thickness of the perforated structure, also referred to as the interlayer distance) is preferably 100 μm to 15 mm, and more preferably 1 mm to 15 mm. If the interlayer distance is 100 μm or more, the sound absorption performance in the low frequency region is good, and if the interlayer distance is 15 mm or less, the thickness of the sound absorbing material does not become too large, which is suitable for space saving.
（繊維層）
本発明の積層吸音材に含まれる繊維層は、繊維径が４５０ｎｍ未満である繊維からなる繊維集合体である。繊維径が４５０ｎｍ未満であるとは、平均繊維径がこの数値範囲内であることを意味する。繊維径が４５０ｎｍ未満であれば、高い吸音性が得られるため好ましく、４２０ｎｍ未満であれば、より高い吸音性が得られるためさらに好ましい。繊維径の測定は、公知の方法によることができる。例えば、繊維層表面の拡大写真から測定ないし算出することによって得られる値であり、詳細な測定方法は実施例に詳述される。
(Fiber layer)
The fiber layer contained in the laminated sound-absorbing material of the present invention is a fiber assembly composed of fibers having a fiber diameter of less than 450 nm. The fiber diameter being less than 450 nm means that the average fiber diameter is within this numerical range. If the fiber diameter is less than 450 nm, it is preferable because high sound absorption is obtained, and if it is less than 420 nm, it is more preferable because higher sound absorption is obtained. The fiber diameter can be measured by a known method. For example, it is a value obtained by measurement or calculation from an enlarged photograph of the fiber layer surface, and a detailed measurement method will be described in detail in Examples.
本発明の積層吸音材に含まれる繊維層は、１層の繊維層が一つの繊維集合体からなっていてもよく、また、１層の繊維層中に複数の繊維集合体を含み、繊維集合体の層が重ね合わされたものが１層の繊維層を形成していてもよい。
なお、本明細書において、繊維集合体とは、一層の基材層上に形成される一つの連続体となった繊維集合体のことを意味している。繊維集合体の目付けは、０．１〜２５ｇ／ｍ２であることが好ましく、０．３〜２０ｇ／ｍ２であることがさらに好ましい。目付けが０．１ｇ／ｍ２以上であれば、繊維層と基材層を構成する繊維との密度差による流れ抵抗の制御が良好となり、５０ｇ／ｍ２未満であれば、吸音材として反りが大きくなる恐れが低くなる。
The fiber layer included in the laminated sound-absorbing material of the present invention may have one fiber layer made of one fiber assembly, and a plurality of fiber assemblies in one fiber layer, The layer of body layers may form a single fiber layer.
In addition, in this specification, a fiber assembly means the fiber assembly used as one continuous body formed on one base-material layer. Basis weight of the fiber aggregate is preferably 0.1~25g / m 2, further preferably 0.3 to 20 g / m 2. If the basis weight is 0.1 g / m 2 or more, control of flow resistance due to the difference in density between the fiber layer and the fibers constituting the base material layer will be good, and if it is less than 50 g / m 2 , warping will occur as a sound absorbing material. The risk of growing is reduced.
繊維層を構成する繊維集合体は、好ましくは不織布であり、前記の範囲の繊維径及び目付を有している限り特に制限されないが、メルトブローン不織布、電界紡糸法によって形成される不織布等であることが好ましい。電界紡糸法によれば、極細繊維を基材層上に効率よく積層させることができる。電界紡糸法の詳細は製造方法に詳述する。 The fiber aggregate constituting the fiber layer is preferably a non-woven fabric, and is not particularly limited as long as it has a fiber diameter and basis weight within the above range, but is a melt-blown non-woven fabric, a non-woven fabric formed by electrospinning, or the like. Is preferred. According to the electrospinning method, ultrafine fibers can be efficiently laminated on the base material layer. Details of the electrospinning method will be described in detail in the manufacturing method.
繊維集合体を構成する樹脂としては、発明の効果を得られる限り特に制限されないが、例えば、ポリプロピレンやポリエチレン等のポリオレフィン、ポリウレタン、ポリ乳酸、アクリル樹脂、ポリエチレンテレフタレートやポリブチレンテレフタレート等のポリエステル類、ナイロン６、ナイロン６．６、ナイロン１２等のナイロン（アミド樹脂）類、ポリフェニレンスルフィド、ポリビニルアルコール、ポリスチレン、ポリスルフォン、液晶ポリマー類、ポリエチレン−酢酸ビニル共重合体、ポリアクリロニトリル、ポリフッ化ビニリデン、ポリフッ化ビニリデン−ヘキサフルオロプロピレン等が挙げられる。これらの中でも、ポリフッ化ビニリデン、ナイロン６．６、ポリアクリロニトリル、ポリスチレン、ポリウレタン、ポリスルフォンおよびポリビニルアルコールが、電界溶液紡糸法においては、各種溶剤に可溶である観点から、より好ましい。
繊維集合体は、前記の樹脂の１種を含むことが好ましく、２種類以上を含んでいてもよい。
The resin constituting the fiber assembly is not particularly limited as long as the effects of the invention can be obtained.For example, polyolefins such as polypropylene and polyethylene, polyurethane, polylactic acid, acrylic resins, polyesters such as polyethylene terephthalate and polybutylene terephthalate, Nylon 6, nylon 6.6, nylon 12 such as nylon (amide resin), polyphenylene sulfide, polyvinyl alcohol, polystyrene, polysulfone, liquid crystal polymer, polyethylene-vinyl acetate copolymer, polyacrylonitrile, polyvinylidene fluoride, polyfluoride And vinylidene chloride-hexafluoropropylene. Among these, polyvinylidene fluoride, nylon 6.6, polyacrylonitrile, polystyrene, polyurethane, polysulfone and polyvinyl alcohol are more preferable from the viewpoint of being soluble in various solvents in the electric field solution spinning method.
The fiber assembly preferably contains one kind of the above-mentioned resins, and may contain two or more kinds.
また、繊維集合体には、樹脂以外の各種の添加剤類を含んでもよい。樹脂に添加されうる添加剤としては例えば、充填剤類、安定化剤類、可塑剤類、粘着剤類、接着促進剤類（例えば、シラン類およびチタン酸塩類）、シリカ、ガラス、粘土、タルク、顔料類、着色剤類、酸化防止剤類、蛍光増白剤類、抗菌剤類、界面活性剤類、難燃剤類、およびフッ化ポリマー類が挙げられる。前記添加物類のうち１つ以上を用いて、得られる繊維および層の重量および／またはコストを軽減してもよく、粘度を調整してもよく、または繊維の熱的特性を変性してもよく、あるいは電気特性、光学特性、密度に関する特性、液体バリアもしくは粘着性に関する特性を包含する、添加物の特性に由来する様々な物理特性活性を付与してもよい。 The fiber assembly may contain various additives other than the resin. Examples of additives that can be added to the resin include fillers, stabilizers, plasticizers, adhesives, adhesion promoters (eg, silanes and titanates), silica, glass, clay, talc. Pigments, colorants, antioxidants, fluorescent brighteners, antibacterial agents, surfactants, flame retardants, and fluorinated polymers. One or more of the above additives may be used to reduce the weight and / or cost of the resulting fiber and layer, to adjust the viscosity, or to modify the thermal properties of the fiber. Alternatively, various physical property activities derived from the properties of the additive may be imparted, including electrical properties, optical properties, density properties, liquid barrier or tack properties.
（基材層）
積層吸音材における基材層は、吸音性を有するとともに、繊維層を支持して吸音材全体の形状を保持する機能を有している。本発明の積層吸音材において、繊維層は１０ｎｍ〜４５０ｎｍという極めて細い繊維径の繊維から形成される繊維集合体であるため、強度（剛性）が低い。そのため、基材層が実質的に積層吸音材の強度を担うことになる。
(Base material layer)
The base material layer in the laminated sound absorbing material has a sound absorbing property and also has a function of supporting the fiber layer and maintaining the shape of the entire sound absorbing material. In the laminated sound-absorbing material of the present invention, since the fiber layer is a fiber assembly formed from fibers having an extremely thin fiber diameter of 10 nm to 450 nm, the strength (rigidity) is low. Therefore, the base material layer substantially bears the strength of the laminated sound absorbing material.
基材層は、その少なくとも一方の表面上に繊維層を積層できるものであれば特に制限されず、不織布、フィルム、ガラス繊維、紙、織布、フォーム（発泡体層）、箔、メッシュ等を用いることができる。特に、不織布、フィルム、ガラス繊維、紙のいずれか１種以上であることが好ましく、不織布であることがより好ましい。積層吸音材に含まれる基材層は１種であってもよく、２種以上の基材層を含むことも好ましい。 The base material layer is not particularly limited as long as the fiber layer can be laminated on at least one surface thereof, and includes nonwoven fabric, film, glass fiber, paper, woven fabric, foam (foam layer), foil, mesh, and the like. Can be used. In particular, one or more of nonwoven fabric, film, glass fiber, and paper are preferable, and nonwoven fabric is more preferable. One type of base material layer may be included in the laminated sound absorbing material, and it is also preferable that two or more types of base material layers are included.
基材層が不織布である場合、不織布の種類は、メルトブローン不織布、スパンレース不織布、スパンボンド不織布、スルーエア不織布、サーマルボンド不織布、ニードルパンチ不織布等を用いることができ、所望の物性や機能によって適宜選択できる。 When the base material layer is a nonwoven fabric, the type of nonwoven fabric can be selected from melt blown nonwoven fabric, spunlace nonwoven fabric, spunbond nonwoven fabric, through-air nonwoven fabric, thermal bond nonwoven fabric, needle punched nonwoven fabric, etc., depending on the desired physical properties and functions. it can.
不織布の繊維を構成する樹脂としては、熱可塑性樹脂を用いることができ、例えば、ポリオレフィン系樹脂、ポリエチレンテレフタレートなどのポリエステル系樹脂、ポリアミド系樹脂が例示できる。ポリオレフィン系樹脂としては、エチレン、プロピレン、ブテン−１、若しくは４−メチルペンテン−１等の単独重合体、及びこれらと他のα−オレフィン、即ち、エチレン、プロピレン、ブテン−１、ペンテン−１、ヘキセン−１あるいは４−メチルペンテン−１などのうちの１種以上とのランダム若しくはブロック共重合体あるいはこれらを組み合わせた共重合体のことであり、またはこれらの混合物などを挙げることができる。ポリアミド系樹脂としてはナイロン４、ナイロン６、ナイロン７、ナイロン１１、ナイロン１２、ナイロン６．６、ナイロン６．１０、ポリメタキシリデンアジパミド、ポリパラキシリデンデカンアミド、ポリビスシクロヘキシルメタンデカンアミドもしくはこれらのコポリアミド等を挙げることができる。ポリエステル系樹脂としては、ポリエチレンテレフタレートの他、ポリテトラメチレンテレフタレート、ポリブチルテレフタレート、ポリエチレンオキシベンゾエート、ポリ（１，４−ジメチルシクロヘキサンテレフタレート）若しくはこれらの共重合体を挙げることができる。これらの中でも、ポリエチレンテレフタレート繊維、ポリブチレンテレフタレート繊維、ポリエチレン繊維及びポリプロピレン繊維の１種、又は２種以上を組み合わせて用いることが好ましい。
基材層が、フィルム、織布、メッシュである場合にも同様の樹脂を用いることができる。
As the resin constituting the fibers of the nonwoven fabric, a thermoplastic resin can be used. Examples thereof include polyolefin resins, polyester resins such as polyethylene terephthalate, and polyamide resins. Examples of polyolefin resins include homopolymers such as ethylene, propylene, butene-1, or 4-methylpentene-1, and these and other α-olefins, that is, ethylene, propylene, butene-1, pentene-1, A random or block copolymer with one or more of hexene-1 or 4-methylpentene-1, or a combination of these, or a mixture thereof. Polyamide resins include nylon 4, nylon 6, nylon 7, nylon 11, nylon 12, nylon 6.6, nylon 6.10, polymetaxylidene adipamide, polyparaxylidenedecanamide, polybiscyclohexylmethanedecane. Amides or their copolyamides can be mentioned. Examples of the polyester resin include polyethylene terephthalate, polytetramethylene terephthalate, polybutyl terephthalate, polyethylene oxybenzoate, poly (1,4-dimethylcyclohexane terephthalate), and copolymers thereof. Among these, it is preferable to use one or a combination of two or more of polyethylene terephthalate fiber, polybutylene terephthalate fiber, polyethylene fiber, and polypropylene fiber.
The same resin can be used when the substrate layer is a film, a woven fabric, or a mesh.
基材層の不織布を構成する繊維としては、１成分のみで使用することもできるが、熱接着性繊維同士の交点の融着の効果を考慮したとき、低融点樹脂と高融点樹脂の複合成分からなる繊維、すなわち、融点が異なる二成分以上からなる複合繊維を用いることも好ましい。複合形態は例えば鞘芯型、偏心鞘芯型、並列型を挙げることができる。また、基材層の不織布を構成する繊維として、融点が異なる二成分以上の混繊繊維を用いることも好ましい。なお、混繊繊維とは、高融点樹脂からなる繊維と低融点樹脂からなる繊維とが独立して存在し、混合されてなる繊維を意味している。基材が、織布である場合にも同様の繊維を用いることができる。 As a fiber constituting the nonwoven fabric of the base material layer, it can be used with only one component. It is also preferable to use a composite fiber composed of two or more components having different melting points. Examples of the composite form include a sheath core type, an eccentric sheath core type, and a parallel type. Moreover, it is also preferable to use two or more mixed fiber fibers having different melting points as the fibers constituting the nonwoven fabric of the base material layer. The mixed fiber means a fiber in which fibers made of a high melting point resin and fibers made of a low melting point resin exist independently and are mixed. Similar fibers can also be used when the substrate is a woven fabric.
基材層の不織布を構成する繊維の繊維径は、特に制限されるものではないが、繊維径が０．５μｍ〜１ｍｍである繊維からなるものを用いることができる。繊維径が０．５μｍ〜１ｍｍであるとは、平均繊維径がこの数値範囲内であることを意味する。繊維径が０．５μｍ以上であれば、繊維層と基材層の不織布を構成する繊維との密度差による流れ抵抗を制御することができ、１ｍｍ未満であれば、汎用性が失われることがなく、また入手も容易となる。繊維径は、１．０〜１００μｍであれば、繊維層と基材層の不織布を構成する繊維との密度差による流れ抵抗を制御することができ入手も容易であるためより好ましい。繊維径の測定は、繊維層の繊維径の測定と同様の方法で行うことができる。基材が、織布である場合にも同様の繊維を用いることができる。 Although the fiber diameter of the fiber which comprises the nonwoven fabric of a base material layer is not restrict | limited in particular, what consists of a fiber whose fiber diameter is 0.5 micrometer-1 mm can be used. The fiber diameter of 0.5 μm to 1 mm means that the average fiber diameter is within this numerical range. If the fiber diameter is 0.5 μm or more, the flow resistance due to the density difference between the fiber layer and the fibers constituting the nonwoven fabric of the base material layer can be controlled, and if it is less than 1 mm, the versatility may be lost. It is also easy to obtain. A fiber diameter of 1.0 to 100 μm is more preferable because the flow resistance due to the density difference between the fiber layer and the fibers constituting the nonwoven fabric of the base material layer can be controlled and is easily available. The measurement of the fiber diameter can be performed by the same method as the measurement of the fiber diameter of the fiber layer. Similar fibers can also be used when the substrate is a woven fabric.
基材層は、積層吸音材において最外面に位置する２層として含まれてもよい。基材層は、１層のみで構成されていてもよく、２層以上が積層されて構成されていてもよい。基材層を２層以上積層することで、基材層の厚みにより繊維層の層間距離を制御できるという利点がある。 The base material layer may be included as two layers positioned on the outermost surface in the laminated sound-absorbing material. The base material layer may be composed of only one layer, or may be composed of two or more layers laminated. By laminating two or more base material layers, there is an advantage that the interlayer distance of the fiber layer can be controlled by the thickness of the base material layer.
基材層の目付けは、１ｇ／ｍ２以上であればよく、１〜３００ｇ／ｍ２であることが好ましく、１５〜３００ｇ／ｍ２であることがより好ましい。基材層の目付けが１ｇ／ｍ２未満であると、吸音材として必要な強度を得ることができない恐れがある。 Basis weight of the base layer may be any 1 g / m 2 or more, preferably 1 to 300 g / m 2, and more preferably 15~300g / m 2. If the basis weight of the base material layer is less than 1 g / m 2 , the strength required for the sound absorbing material may not be obtained.
本発明において、基材層の合計の厚みは、特に制限されるものではないが、省スペース性の観点からは０．１〜６０ｍｍであることが好ましく、０．１〜３０ｍｍであることがより好ましい。
基材層の単層の厚みは、例えば、２０μｍ〜２０ｍｍとすることができ、３０μｍ〜１０ｍｍとすることがより好ましい。基材層の厚みが２０μｍ以上であれば、皺の発生がなく取り扱いが容易で、生産性が良好であり、基材層の厚みが２０ｍｍ以下であれば、省スペース性を妨げる恐れがない。
In the present invention, the total thickness of the base material layer is not particularly limited, but is preferably 0.1 to 60 mm, more preferably 0.1 to 30 mm from the viewpoint of space saving. preferable.
The thickness of the single layer of the base material layer can be, for example, 20 μm to 20 mm, and more preferably 30 μm to 10 mm. If the thickness of the base material layer is 20 μm or more, wrinkles are not generated and handling is easy and productivity is good, and if the thickness of the base material layer is 20 mm or less, there is no risk of hindering space saving.
基材層には、本発明の効果を妨げない範囲内で、各種の添加剤、例えば、着色剤、酸化防止剤、光安定剤、紫外線吸収剤、中和剤、造核剤、滑剤、抗菌剤、難燃剤、可塑剤及び他の熱可塑性樹脂等が添加されていてもよい。また、表面が各種の仕上げ剤で処理されていてもよく、これによって撥水性、制電性、表面平滑性、耐摩耗性などの機能が付与されていてもよい。 For the base material layer, various additives such as a colorant, an antioxidant, a light stabilizer, an ultraviolet absorber, a neutralizer, a nucleating agent, a lubricant, an antibacterial agent are used within the range not impeding the effects of the present invention. Agents, flame retardants, plasticizers and other thermoplastic resins may be added. Moreover, the surface may be processed with various finishing agents, and functions, such as water repellency, antistatic property, surface smoothness, and abrasion resistance, may be provided by this.
（穴開き構造体）
本発明の積層吸音材は、前述の繊維層及び基材層に加えて、穴開き構造体を有することを特徴とする。穴開き構造体とは、不織布や織布等が有する、それらの製造工程そのものによって生じる微細な開口（例えば、不織布や織布を構成する繊維間の隙間）以外に、恣意的に設けられる一定以上の大きさを有する穴を、１つまたは複数有する構造体のことを意味する。穴の大きさは円形でもそれ以外の形状（例えば、三角形、四角形、六角形、星形、不定形等）であってよく、特に制限されないが、円形であることが好ましい。穴の大きさは、例えば、円形の穴である場合、直径０．２〜３０ｍｍとすることができ、０．２〜１０ｍｍであることが好ましい。
(Perforated structure)
The laminated sound-absorbing material of the present invention has a perforated structure in addition to the above-described fiber layer and base material layer. A perforated structure is a certain number of openings other than fine openings (for example, gaps between fibers constituting the nonwoven fabric or woven fabric) that are produced by the manufacturing process itself of the nonwoven fabric or woven fabric. Means a structure having one or more holes having a size of. The size of the hole may be circular or any other shape (for example, a triangle, a quadrangle, a hexagon, a star, or an indeterminate shape), and is not particularly limited, but is preferably a circle. For example, in the case of a circular hole, the size of the hole can be 0.2 to 30 mm in diameter, and preferably 0.2 to 10 mm.
穴開き構造体の素材としては、不織布、フィルム、ガラス繊維、織布および紙を用いることができる。特に、穴開き加工がし易い、不織布、フィルム、紙を用いることが好ましい。積層吸音材に含まれる穴開き構造体は、１枚であってもよく、２枚以上であってもよい。穴開き構造体の素材は、例えば、厚みが０．０１〜５ｍｍの紙又は樹脂製フィルムを用いることが好ましく、樹脂製フィルムとしては、ポリオレフィン（ポリプロピレン、ポリエチレン）樹脂フィルム、ポリエステル樹脂フィルム等が挙げられる。穴開き構造体は、繊維層及び基材層と比較して剛性が高く、通気性の低い（通気性がほとんどみられない）素材を用いることが好ましい。 As the material for the perforated structure, nonwoven fabric, film, glass fiber, woven fabric, and paper can be used. In particular, it is preferable to use a non-woven fabric, a film, or paper that can be easily perforated. The number of perforated structures included in the laminated sound absorbing material may be one, or two or more. As the material for the perforated structure, for example, it is preferable to use a paper or resin film having a thickness of 0.01 to 5 mm. Examples of the resin film include polyolefin (polypropylene, polyethylene) resin films, polyester resin films, and the like. It is done. For the perforated structure, it is preferable to use a material that has higher rigidity and lower air permeability (almost no air permeability) compared to the fiber layer and the base material layer.
１枚の穴開き構造体に１つの穴が設けられている場合、当該穴は穴開き構造体の中央部にあってもよいし、周辺部にあってもよいが、吸音性の観点からは中央部に穴が存在することが好ましい。また、１枚の穴開き構造体に複数の穴が設けられている場合、当該複数の穴は規則的に配置されていてもランダムに配置されていてもよいが、穴開き構造体の表面に分散的に設けられていることが好ましい。なお、穴開き構造体と基材層とは同種の素材からなるものであってよいが、穴開き構造体は、開口径が０．２ｍｍ以上の円形の穴、或いはそれと同等以上の開口面積を有する穴を有しているのに対して、基材層はこのような穴を有さない点で区別することができる。 When one hole is provided in one perforated structure, the hole may be in the central part or the peripheral part of the perforated structure, but from the viewpoint of sound absorption It is preferable that a hole exists in the center part. In addition, when a plurality of holes are provided in one perforated structure, the plurality of holes may be arranged regularly or randomly, but on the surface of the perforated structure. It is preferable that they are provided in a dispersed manner. The perforated structure and the base material layer may be made of the same kind of material, but the perforated structure has a circular hole with an opening diameter of 0.2 mm or more, or an opening area equivalent to or larger than that. In contrast to having holes with holes, the substrate layer can be distinguished by not having such holes.
穴開き構造体の開口率とは、１枚の構造体の表面積に対する、当該構造体に設けられた穴の面積の合計の割合を意味するところ、開口率は該構造体表面の０．０５％以上５０％未満であればよく、０．０５％以上３５％以下が好ましく、０．１％以上２０％以下がより好ましい。特定の理論に拘束されるものではないが、本発明の積層吸音材では、吸音材内に前記穴開き構造体を有することで、吸音材内で音の反射をさせ吸音材内での迷路度が向上しその結果、吸音率の向上に繋がるものと考えられている。 The aperture ratio of the perforated structure means the ratio of the total area of the holes provided in the structure to the surface area of one structure. The aperture ratio is 0.05% of the surface of the structure. It may be at least 50%, preferably 0.05% to 35%, and more preferably 0.1% to 20%. Although not bound by a specific theory, the laminated sound absorbing material of the present invention has the perforated structure in the sound absorbing material, so that the sound is reflected in the sound absorbing material and the maze degree in the sound absorbing material. As a result, it is considered that the sound absorption coefficient is improved.
積層吸音材において、穴開き構造体は、積層吸音材の最外層に配置されていてもよく、最外層以外の層として含まれてもよい。なかでも、積層吸音材における穴開き構造体の好ましい位置は、繊維層との相対的な位置関係によって規定される。すなわち穴開き構造体は、積層吸音材に含まれる前記繊維層のうち最外層の繊維層の内面に隣接するように備えられていることが好ましい。最外層の繊維層が２面ある場合（つまり、積層吸音材の表面及び裏面のそれぞれから等しい位置に、それぞれ繊維層が位置している場合）、穴開き構造体はそれらの一方の内面に隣接するように設けられていればよいが、それらの両方の内面に隣接するように設けられていてもよい。特定の理論に拘束されるものではないが、最外層の繊維層の内側に隣接して穴開き構造体が配置されることによって、積層吸音材としての剛性を付与することができ、１０００Ｈｚ以下の周波数域の吸音率を向上させるものと考えられている。 In the laminated sound absorbing material, the perforated structure may be disposed in the outermost layer of the laminated sound absorbing material or may be included as a layer other than the outermost layer. Especially, the preferable position of the perforated structure in the laminated sound-absorbing material is defined by the relative positional relationship with the fiber layer. That is, the perforated structure is preferably provided so as to be adjacent to the inner surface of the outermost fiber layer among the fiber layers included in the laminated sound absorbing material. When there are two outermost fiber layers (that is, when the fiber layers are located at the same position from the front and back surfaces of the laminated sound-absorbing material, the perforated structure is adjacent to one inner surface thereof) However, it may be provided so as to be adjacent to both inner surfaces thereof. Although not bound by a specific theory, by arranging the perforated structure adjacent to the inside of the outermost fiber layer, rigidity as a laminated sound absorbing material can be imparted, and the frequency is 1000 Hz or less. It is considered to improve the sound absorption coefficient in the frequency range.
また、積層吸音材における穴開き構造体は、積層吸音材に含まれる繊維層のうち、最外層の繊維層よりも内側に、２層以上備えられていることも好ましい。 Moreover, it is also preferable that the perforated structure in the laminated sound absorbing material is provided with two or more layers inside the outermost fiber layer among the fiber layers contained in the laminated sound absorbing material.
（積層吸音材の吸音特性）
本発明の積層吸音材は、特に低周波数領域（１０００Ｈｚ以下の周波領域）における吸音性が優れることを特徴としている。本発明の積層吸音材は、特に４００Ｈｚ〜１０００Ｈｚ領域の吸音性に優れるという、従来の吸音材と異なる吸音特性を示すものである。特定の理論に拘束されるものではないが、本発明の積層吸音材は、繊維層と基材層の密度差を利用し音波の流れ抵抗を制御し、さらに穴開き構造体を設置した結果、低周波領域の吸収性に優れるという性能が得られるものと考えられている。
吸音性の評価方法は、実施例に詳述される。
(Sound absorption characteristics of laminated sound absorbing material)
The laminated sound-absorbing material of the present invention is particularly characterized by excellent sound-absorbing properties in a low frequency region (frequency region of 1000 Hz or less). The laminated sound-absorbing material of the present invention exhibits sound-absorbing characteristics different from those of conventional sound-absorbing materials, in particular, excellent in sound-absorbing properties in the 400 Hz to 1000 Hz region. Although not bound by a specific theory, the laminated sound-absorbing material of the present invention uses the density difference between the fiber layer and the base material layer to control the flow resistance of sound waves, and further, as a result of installing a perforated structure, It is considered that the performance of excellent absorbency in the low frequency region can be obtained.
The sound absorption evaluation method is described in detail in Examples.
（積層吸音材の製造方法）
積層吸音材の製造方法は特に制限されないが、例えば、１層の基材層上に１層の繊維層を形成した繊維層と基材層の積層体を作成する工程、複数の繊維層と基材層の積層体と、穴開き構造体とを所定の順番及び枚数で重ね合わせて一体化する工程、を含む製造方法によって得ることができる。なお、繊維層と基材層の積層体を重ね合わせる工程において、穴開き構造体をこれらに積層する。穴開き構造体は、最外層に積層してもよく、繊維層と繊維層の間、繊維層と基材層の間、基材層と基材層の間に積層してもよい。具体的には、吸音材を構成する最外層の繊維層の内面のうち、いずれか片方に穴開き構造体を積層することや、吸音材を構成する最外層の繊維層の内面に、穴開き構造体を２層以上積層することが例示できる。さらに、繊維層と基材層の積層体以外のさらなる層（例えばさらなる基材層）をさらに加えて積層することもできる。
(Production method of laminated sound-absorbing material)
The production method of the laminated sound-absorbing material is not particularly limited. For example, a step of creating a laminated body of a fiber layer and a base material layer in which one fiber layer is formed on one base material layer, a plurality of fiber layers and a base It can be obtained by a manufacturing method including a step of stacking and integrating a laminate of material layers and a perforated structure in a predetermined order and number. In addition, in the process of superimposing the laminated body of a fiber layer and a base material layer, a perforated structure is laminated | stacked on these. The perforated structure may be laminated on the outermost layer, or may be laminated between the fiber layer, the fiber layer, between the fiber layer and the substrate layer, or between the substrate layer and the substrate layer. Specifically, the inner surface of the outermost fiber layer constituting the sound absorbing material may be laminated with a perforated structure on one side, or the inner surface of the outermost fiber layer constituting the sound absorbing material may be perforated. It can be exemplified that two or more structures are laminated. Furthermore, it can also laminate | stack by adding further layers (for example, further base material layer) other than the laminated body of a fiber layer and a base material layer.
基材層として不織布を用いる場合、公知の方法で不織布を製造して用いてもよいし、市販の不織布を選択して用いることもできる。基材層上に繊維層を形成する工程は、電界紡糸法を用いることが好ましい。電界紡糸法は、紡糸溶液を吐出させるとともに、電界を作用させて、吐出された紡糸溶液を繊維化し、コレクター上に繊維を得る方法である。例えば、紡糸溶液をノズルから押し出すとともに電界を作用させて紡糸する方法、紡糸溶液を泡立たせるとともに電界を作用させて紡糸する方法、円筒状電極の表面に紡糸溶液を導くとともに電界を作用させて紡糸する方法などを挙げることができる。本発明においては、コレクター上に基材層となる不織布等を挿入し、基材層上に繊維を集積させることができる。 When using a nonwoven fabric as a base material layer, a nonwoven fabric may be manufactured and used by a well-known method, and a commercially available nonwoven fabric can also be selected and used. The step of forming the fiber layer on the base material layer preferably uses an electrospinning method. The electrospinning method is a method in which a spinning solution is discharged and an electric field is applied to fiberize the discharged spinning solution to obtain fibers on a collector. For example, a method of spinning by spinning the spinning solution from the nozzle and applying an electric field, a method of spinning by spinning the spinning solution and applying an electric field, and spinning by directing the spinning solution to the surface of a cylindrical electrode and applying an electric field. And the like. In this invention, the nonwoven fabric etc. which become a base material layer are inserted on a collector, and a fiber can be integrated | stacked on a base material layer.
紡糸溶液としては、曳糸性を有するものであれば特に限定されないが、樹脂を溶媒に分散させたもの、樹脂を溶媒に溶解させたもの、樹脂を熱やレーザー照射によって溶融させたものなどを用いることができる。 The spinning solution is not particularly limited as long as it has spinnability, but a solution in which a resin is dispersed in a solvent, a solution in which a resin is dissolved in a solvent, a solution in which a resin is melted by heat or laser irradiation, and the like. Can be used.
樹脂を分散または溶解させる溶媒としては、例えば、水、メタノール、エタノール、プロパノール、アセトン、Ｎ，Ｎ−ジメチルホルムアミド、Ｎ，Ｎ−ジメチルアセトアミド、ジメチルスルホキシド、Ｎ−メチル−２−ピロリドン、トルエン、キシレン、ピリジン、蟻酸、酢酸、テトラヒドロフラン、ジクロロメタン、クロロホルム、１，１，２，２−テトラクロロエタン、１，１，１，３，３，３−ヘキサフルオロイソプロパノール、トリフルオロ酢酸及びこれらの混合物などを挙げることができる。混合して使用する場合の混合率は、特に限定されるものではなく、求める曳糸性や分散性、得られる繊維の物性を鑑みて、適宜設定することができる。 Examples of the solvent for dispersing or dissolving the resin include water, methanol, ethanol, propanol, acetone, N, N-dimethylformamide, N, N-dimethylacetamide, dimethyl sulfoxide, N-methyl-2-pyrrolidone, toluene, and xylene. Pyridine, formic acid, acetic acid, tetrahydrofuran, dichloromethane, chloroform, 1,1,2,2-tetrachloroethane, 1,1,1,3,3,3-hexafluoroisopropanol, trifluoroacetic acid, and mixtures thereof. be able to. The mixing ratio in the case of mixing and using is not particularly limited, and can be appropriately set in view of the required spinnability and dispersibility and the physical properties of the obtained fiber.
電界紡糸の安定性や繊維形成性を向上させる目的で、紡糸溶液中にさらに界面活性剤を含有させてもよい。界面活性剤は、例えば、ドデシル硫酸ナトリウムなどの陰イオン性界面活性剤、臭化テトラブチルアンモニウムなどの陽イオン界面活性剤、ポリオキシエチレンソルビタモンモノラウレートなどの非イオン性界面活性剤などを挙げることができる。界面活性剤の濃度は、紡糸溶液に対して５重量％以下の範囲であることが好ましい。５重量％以下であれば、使用に見合う効果の向上が得られるため好ましい。また、本発明の効果を著しく損なわない範囲であれば、上記以外の成分も紡糸溶液の成分として含んでもよい。 For the purpose of improving the electrospinning stability and fiber forming property, a surfactant may be further contained in the spinning solution. Examples of the surfactant include an anionic surfactant such as sodium dodecyl sulfate, a cationic surfactant such as tetrabutylammonium bromide, and a nonionic surfactant such as polyoxyethylene sorbitamon monolaurate. Can be mentioned. The concentration of the surfactant is preferably in the range of 5% by weight or less with respect to the spinning solution. If it is 5 weight% or less, since the improvement of an effect commensurate with use is obtained, it is preferable. In addition, components other than those described above may be included as components of the spinning solution as long as the effects of the present invention are not significantly impaired.
紡糸溶液の調製方法は、特に限定されず、撹拌や超音波処理などの方法を挙げることができる。また、混合の順序も特に限定されず、同時に混合しても、逐次に混合してもよい。撹拌により紡糸溶液を調製する場合の撹拌時間は、樹脂が溶媒に均一に溶解または分散していれば特に限定されず、例えば、１〜２４時間程度撹拌してもよい。 The method for preparing the spinning solution is not particularly limited, and examples thereof include methods such as stirring and ultrasonic treatment. Also, the order of mixing is not particularly limited, and they may be mixed simultaneously or sequentially. The stirring time for preparing the spinning solution by stirring is not particularly limited as long as the resin is uniformly dissolved or dispersed in the solvent, and may be stirred for about 1 to 24 hours, for example.
電界紡糸により繊維を得るためには、紡糸溶液の粘度を、１０〜１０，０００ｃＰの範囲に調製することが好ましく、５０〜８，０００ｃＰの範囲であることがより好ましい。粘度が１０ｃＰ以上であると、繊維を形成するための曳糸性が得られ、１０，０００ｃＰ以下であると、紡糸溶液を吐出させるのが容易となる。粘度が５０〜８，０００ｃＰの範囲であれば、広い紡糸条件範囲で良好な曳糸性が得られるのでより好ましい。紡糸溶液の粘度は、樹脂の分子量、濃度や溶媒の種類や混合率を適宜変更することで、調整することができる。 In order to obtain fibers by electrospinning, the viscosity of the spinning solution is preferably adjusted in the range of 10 to 10,000 cP, more preferably in the range of 50 to 8,000 cP. If the viscosity is 10 cP or more, spinnability for forming fibers is obtained, and if it is 10,000 cP or less, the spinning solution can be easily discharged. A viscosity in the range of 50 to 8,000 cP is more preferable because good spinnability can be obtained over a wide range of spinning conditions. The viscosity of the spinning solution can be adjusted by appropriately changing the molecular weight, concentration, type of solvent, and mixing ratio of the resin.
紡糸溶液の温度は、常温で紡糸することもできるし、加熱・冷却して紡糸してもよい。紡糸溶液を吐出させる方法としては、例えば、ポンプを用いてシリンジに充填した紡糸溶液をノズルから吐出させる方法などが挙げられる。ノズルの内径としては、特に限定されないが、０．１〜１．５ｍｍの範囲であるのが好ましい。また吐出量としては、特に限定されないが、０．１〜１０ｍＬ／ｈｒであるのが好ましい。 The spinning solution can be spun at room temperature, or heated and cooled for spinning. Examples of the method of discharging the spinning solution include a method of discharging the spinning solution filled in the syringe from a nozzle using a pump. Although it does not specifically limit as an internal diameter of a nozzle, It is preferable that it is the range of 0.1-1.5 mm. The discharge amount is not particularly limited, but is preferably 0.1 to 10 mL / hr.
電界を作用させる方法としては、ノズルとコレクターに電界を形成させることができれば特に限定されるものではなく、例えば、ノズルに高電圧を印加し、コレクターを接地してもよい。印加する電圧は、繊維が形成されれば特に限定されないが、５〜１００ｋＶの範囲であるのが好ましい。また、ノズルとコレクターとの距離は、繊維が形成されれば特に限定されないが、５〜５０ｃｍの範囲であるのが好ましい。 The method of applying an electric field is not particularly limited as long as an electric field can be formed at the nozzle and the collector. For example, a high voltage may be applied to the nozzle and the collector may be grounded. Although the voltage to apply is not specifically limited if a fiber is formed, It is preferable that it is the range of 5-100 kV. The distance between the nozzle and the collector is not particularly limited as long as fibers are formed, but is preferably in the range of 5 to 50 cm.
前記によって得られた、基材層と繊維層からなる積層体を、複数枚重ね合わせて一体化する方法は、特に限定されるわけではなく、接着を行わず重ね合わせるだけでもよく、また、各種の接着方法、つまり、加熱したフラットロールやエンボスロールによる熱圧着、ホットメルト剤や化学接着剤による接着、循環熱風もしくは輻射熱による熱接着などを採用することもできる。極細繊維を含む繊維層の物性低下を抑制するという観点では、なかでも循環熱風もしくは輻射熱による熱処理が好ましい。フラットロールやエンボスロールによる熱圧着の場合、繊維層が溶融してフィルム化したり、エンボス点周辺部分に破れが発生したりする等のダメージを受け、安定的な製造が困難となる可能性があるほか、吸音特性が低下等の性能低下を生じやすい。また、ホットメルト剤や化学接着剤による接着の場合には、該成分によって繊維層の繊維間空隙が埋められ、性能低下を生じやすい場合がある。一方で、循環熱風もしくは輻射熱による熱処理で一体化した場合には、繊維層へのダメージが少なく、かつ十分な層間剥離強度で一体化できるので好ましい。循環熱風もしくは輻射熱による熱処理によって一体化する場合には、特に限定されるものではないが、熱融着性複合繊維からなる不織布および積層体を使用することが好ましい。 A method for stacking and integrating a plurality of laminates composed of a base material layer and a fiber layer obtained as described above is not particularly limited, and may be performed without bonding, and various methods may be used. It is also possible to adopt the above-mentioned bonding method, that is, thermocompression bonding using a heated flat roll or embossing roll, bonding using a hot melt agent or chemical adhesive, thermal bonding using circulating hot air or radiant heat, and the like. From the viewpoint of suppressing deterioration of physical properties of the fiber layer containing ultrafine fibers, heat treatment with circulating hot air or radiant heat is particularly preferable. In the case of thermocompression bonding using a flat roll or embossing roll, the fiber layer may be melted to form a film, or damage may occur such as tearing around the embossing point, which may make stable production difficult. In addition, performance deterioration such as a decrease in sound absorption characteristics tends to occur. Moreover, in the case of adhesion | attachment by a hot-melt agent or a chemical adhesive agent, the inter-fiber space | gap of a fiber layer is filled with this component, and it may be easy to produce a performance fall. On the other hand, it is preferable to integrate by heat treatment with circulating hot air or radiant heat because the fiber layer is less damaged and can be integrated with sufficient delamination strength. In the case of integration by heat treatment with circulating hot air or radiant heat, although not particularly limited, it is preferable to use a nonwoven fabric and a laminate made of heat-fusible conjugate fibers.
＜平均繊維径＞
株式会社日立ハイテクノロジーズ製の走査型電子顕微鏡ＳＵ８０２０を使用して、極細繊維を観察し、画像解析ソフトを用いて極細繊維５０本の直径を測定した。極細繊維５０本の繊維径の平均値を平均繊維径とした。
<Average fiber diameter>
A scanning electron microscope SU8020 manufactured by Hitachi High-Technologies Corporation was used to observe the ultrafine fibers, and the diameter of 50 ultrafine fibers was measured using image analysis software. The average value of the fiber diameters of 50 ultrafine fibers was defined as the average fiber diameter.
＜吸音率測定＞
吸音率測定は、各繊維積層体より直径６３ｍｍのサンプルを採取し、各条件の積層をした後、垂直入射吸音率測定装置「ブリュエル＆ケアー社製ＴＹＰＥ４２０６」を用いＡＳＴＭ Ｅ １０５０に準拠し、周波数２００〜３２００Ｈｚにおける試験片に平面音波が垂直に入射するときの垂直入射吸音率を測定した。
＜低周波数領域の吸音性＞
周波数ｘが２００Ｈｚから３２００Ｈｚまでの吸音率を１Ｈｚ間隔で測定し、得られる曲線をｆ(ｘ)としたとき、２００Ｈｚから１０００Ｈｚまでの積分値Ｓが下記数式で得られる。
<Measurement of sound absorption coefficient>
The sound absorption coefficient is obtained by collecting a sample having a diameter of 63 mm from each fiber laminate, laminating the respective conditions, and using a normal incident sound absorption coefficient measuring device “TYPE 4206 manufactured by Brüel & Care Co.” in accordance with ASTM E 1050. The normal incidence sound absorption coefficient when a plane sound wave was perpendicularly incident on a test piece at 200 to 3200 Hz was measured.
<Sound absorption in low frequency range>
When the sound absorption rate from the frequency x of 200 Hz to 3200 Hz is measured at intervals of 1 Hz, and the obtained curve is f (x), an integral value S from 200 Hz to 1000 Hz is obtained by the following equation.
積分値Ｓは２００〜１０００Ｈｚの周波数領域の吸音性能を示し、数値が高ければ、吸音性が高いと判断される。Ｓ値が１７０を超える場合、低周波数領域の吸音性を良好と評価し、１７０未満の場合、吸音性を不良と評価した。 The integrated value S indicates the sound absorption performance in the frequency range of 200 to 1000 Hz. If the numerical value is high, it is determined that the sound absorption is high. When the S value exceeded 170, the sound absorption in the low frequency region was evaluated as good, and when it was less than 170, the sound absorption was evaluated as poor.
＜通気度＞
通気度測定は、株式会社東洋精機製作所製ガーレ式デンソメーター（型式：ＧＢ−３Ｃ）にてＩＳＯ ５６３６に準拠し測定した。
<Air permeability>
The air permeability was measured according to ISO 5636 using a Gurley type densometer (model: GB-3C) manufactured by Toyo Seiki Seisakusho.
＜＜穴開き構造体の準備＞＞
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径４．５ｍｍの穴を１０ｍｍ間隔で千鳥配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体１（図１）とした。開口率は、３２％である。
<< Preparation of perforated structure >>
A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 4.5 mm were provided in a staggered arrangement at intervals of 10 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 1 (FIG. 1). The aperture ratio is 32%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径４．５ｍｍの穴を１０ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体２（図２）とした。開口率は、１６％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 4.5 mm were provided by a grid arrangement at intervals of 10 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 2 (FIG. 2). The aperture ratio is 16%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径４．５ｍｍの穴を１０ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体３（図３）とした。開口率は、１６％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 4.5 mm were provided by a grid arrangement at intervals of 10 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 3 (FIG. 3). The aperture ratio is 16%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径２ｍｍの穴を５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体４（図４）とした。開口率は、１３％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 2 mm were provided by a grid arrangement at intervals of 5 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 4 (FIG. 4). The aperture ratio is 13%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径２ｍｍの穴を１０ｍｍ間隔で千鳥配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体５（図５）とした。開口率は、６％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 2 mm were provided by staggered arrangement at intervals of 10 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 5 (FIG. 5). The aperture ratio is 6%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径２ｍｍの穴を１０ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体６（図６）とした。開口率は、３％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 2 mm were provided by a grid arrangement at intervals of 10 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 6 (FIG. 6). The aperture ratio is 3%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体７（図７）とした。開口率は、１％である。 A high-quality paper having a thickness of 0.19 mm (basis weight of 157 g / m 2 ) was prepared, and openings having a diameter of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 7 (FIG. 7). The aperture ratio is 1%.
厚み０．１９ｍｍ（坪量１５７ｇ/ｍ２）の上質紙を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体８（図８）とした。開口率は、０．１％である。 A high-quality paper having a thickness of 0.19 mm (basis weight 157 g / m 2 ) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 8 (FIG. 8). The aperture ratio is 0.1%.
厚み２０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「２０Ａ」 ）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体９（図８）とした。開口率は、０．１％である。 A polypropylene film having a thickness of 20 μm (product name “20A” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 9 (FIG. 8). The aperture ratio is 0.1%.
厚み５０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「５０Ａ」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１０（図８）とした。開口率は、０．１％である。 A polypropylene film having a thickness of 50 μm (product name “50A” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circular shape having a diameter of 63 mm to form a perforated structure 10 (FIG. 8). The aperture ratio is 0.1%.
厚み８０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「８０Ａ」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１１（図８）とした。開口率は、０．１％である。 A polypropylene film having a thickness of 80 μm (product name “80A” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 11 (FIG. 8). The aperture ratio is 0.1%.
厚み１５０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「１５０Ａ」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１２（図８）とした。開口率は、０．１％である。 A 150 μm thick polypropylene film (product name “150A” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole with a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 12 (FIG. 8). The aperture ratio is 0.1%.
厚み１００μｍのポリエステル製フィルム（東レ株式会社製 製品名「ルミラー」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１３（図８）とした。開口率は、０．１％である。 A polyester film having a thickness of 100 μm (product name “Lumirror” manufactured by Toray Industries, Inc.) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 13 (FIG. 8). The aperture ratio is 0.1%.
厚み２００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「２００Ｐ」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１４（図８）とした。開口率は、０．１％である。 A polypropylene sheet having a thickness of 200 μm (product name “200P” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 14 (FIG. 8). The aperture ratio is 0.1%.
厚み４００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「４００Ｐ」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１５（図８）とした。開口率は、０．１％である。 A polypropylene sheet having a thickness of 400 μm (product name “400P” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 15 (FIG. 8). The aperture ratio is 0.1%.
厚み４００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「Ｅ０６」）を準備し、直径２ｍｍの穴を中心に1つの開口部を設けた。このポリプロピレン製フィルムを直径６３ｍｍの円形に切り出し、穴開き構造体１６（図８）とした。開口率は、０．１％である。 A polypropylene sheet having a thickness of 400 μm (product name “E06” manufactured by OJK Corporation) was prepared, and one opening was provided around a hole having a diameter of 2 mm. This polypropylene film was cut into a circle with a diameter of 63 mm to form a perforated structure 16 (FIG. 8). The aperture ratio is 0.1%.
厚み５０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「５０Ａ」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体１７（図７）とした。開口率は、１％である。 A polypropylene film having a thickness of 50 μm (product name “50A” manufactured by OJK Corporation) was prepared, and openings having a diameter of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 17 (FIG. 7). The aperture ratio is 1%.
厚み８０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「８０Ａ」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体１８（図７）とした。開口率は、１％である。 A polypropylene film having a thickness of 80 μm (product name “80A” manufactured by OJK Co., Ltd.) was prepared, and holes with a diameter of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 18 (FIG. 7). The aperture ratio is 1%.
厚み１５０μｍのポリプロピレン製フィルム（オージェイケイ株式会社製 製品名「１５０Ａ」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体１９（図７）とした。開口率は、１％である。 A polypropylene film having a thickness of 150 μm (product name “150A” manufactured by OJK Corporation) was prepared, and openings with openings of 2 mm in diameter were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 19 (FIG. 7). The aperture ratio is 1%.
厚み１００μｍのポリエステル製フィルム（東レ株式会社製 製品名「ルミラー」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体２０（図７）とした。開口率は、１％である。 A polyester film having a thickness of 100 μm (product name “Lumirror” manufactured by Toray Industries, Inc.) was prepared, and openings having diameters of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 20 (FIG. 7). The aperture ratio is 1%.
厚み２００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「２００Ｐ」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体２１（図７）とした。開口率は、１％である。 A polypropylene sheet having a thickness of 200 μm (product name “200P” manufactured by OJK Corporation) was prepared, and openings having diameters of 2 mm were provided by a grid arrangement at intervals of 15 mm. This high-quality paper was cut into a circle having a diameter of 63 mm to form a perforated structure 21 (FIG. 7). The aperture ratio is 1%.
厚み４００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「４００Ｐ」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体２２（図７）とした。開口率は、１％である。 A polypropylene sheet having a thickness of 400 μm (product name “400P” manufactured by OJK Corporation) was prepared, and openings having a diameter of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle having a diameter of 63 mm to form a perforated structure 22 (FIG. 7). The aperture ratio is 1%.
厚み４００μｍのポリプロピレン製シート（オージェイケイ株式会社製 製品名「Ｅ０６」）を準備し直径２ｍｍの穴を１５ｍｍ間隔で格子配列により開口部を設けた。この上質紙を直径６３ｍｍの円形に切り出し、穴開き構造体２３（図７）とした。開口率は、１％である。 A polypropylene sheet having a thickness of 400 μm (product name “E06” manufactured by OJK Co., Ltd.) was prepared, and holes with a diameter of 2 mm were provided by a grid arrangement at intervals of 15 mm. This fine paper was cut into a circle with a diameter of 63 mm to form a perforated structure 23 (FIG. 7). The aperture ratio is 1%.
＜＜基材層の準備＞＞
高密度ポリエチレン樹脂として、ＫＥＩＹＯポリエチレン製の高密度ポリエチ「Ｍ６９００」（ＭＦＲ１７ｇ／１０分）を用い、ポリプロピレン樹脂として、日本ポリプロ製のポリプロピレンホモポリマー「ＳＡ３Ａ」（ＭＦＲ＝１１ｇ／１０分）を用いて、熱溶融紡糸法により、繊維径２２μｍの鞘成分が高密度ポリエチレン樹脂、芯成分がポリプロピレン樹脂からなる鞘芯型熱融着性複合繊維を作製した。
この鞘芯型熱融着性複合繊維を用いて、目付が２００ｇ／ｍ２、厚み５ｍｍのカード法スルーエア不織布を製造し、基材層Ａとした。
<< Preparation of base material layer >>
A high-density polyethylene “M6900” (MFR 17 g / 10 min) made by KEIYO polyethylene is used as the high-density polyethylene resin, and a polypropylene homopolymer “SA3A” (MFR = 11 g / 10 min) made by Nippon Polypro is used as the polypropylene resin. Then, a sheath-core type heat-fusible conjugate fiber having a sheath component with a fiber diameter of 22 μm and a core component composed of a high-density polyethylene resin and a core component composed of a polypropylene resin was produced by a hot melt spinning method.
Using this sheath-core type heat-fusible conjugate fiber, a card method through-air nonwoven fabric having a basis weight of 200 g / m 2 and a thickness of 5 mm was produced as a base material layer A.
［実施例１］
ディーアイシーバイエルポリマー製のポリウレタン樹脂（グレード名：Ｔ１１９０）を、Ｎ，Ｎ−ジメチルホルムアミドとアセトンの共溶媒（６０／４０（ｗ／ｗ））に１５質量％の濃度で溶解し、電界紡糸溶液を調製した。基材層Ａ上に前記ポリウレタン溶液を電界紡糸して、基材層Ａの不織布と繊維層のポリウレタン極細繊維との２層からなる積層体を作製した。
電界紡糸の条件は、２７Ｇニードルを使用し、単孔溶液供給量は２．０ｍＬ／ｈ、印加電圧は４７ｋＶ、紡糸距離は２０ｃｍとした。
得られた繊維層の目付は１０．０ｇ／ｍ２であり、平均繊維径は４２０ｎｍであり、融解温度は１７５℃であった。
得られた積層体を直径６３ｍｍに打ち抜き、積層体４枚と穴開き構造体２を１枚使用し、穴開き構造体２／基材層Ａ／繊維層／繊維層／基材層Ａ／基材層Ａ／繊維層／繊維層／基材層Ａとなるよう重ね合わせた。得られたサンプルを吸音率測定用サンプル（層間距離１０ｍｍ）とした。繊維層と繊維層とが重層される部分は、両者を併せて１層の繊維層と考えるため、繊維層の層数を「２」とした。
垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３２５であり良好であった。
[Example 1]
A polyurethane resin (grade name: T1190) made by DCI Bayer Polymer was dissolved in a co-solvent of N, N-dimethylformamide and acetone (60/40 (w / w)) at a concentration of 15% by mass, and an electrospinning solution. Was prepared. The polyurethane solution was electrospun onto the base material layer A to prepare a laminate composed of two layers of the non-woven fabric of the base material layer A and the polyurethane ultrafine fiber of the fiber layer.
The electrospinning conditions were a 27G needle, a single-hole solution supply rate of 2.0 mL / h, an applied voltage of 47 kV, and a spinning distance of 20 cm.
The basis weight of the obtained fiber layer was 10.0 g / m 2 , the average fiber diameter was 420 nm, and the melting temperature was 175 ° C.
The obtained laminate was punched to a diameter of 63 mm, and 4 laminates and 1 perforated structure 2 were used, and perforated structure 2 / base material layer A / fiber layer / fiber layer / base material layer A / base The layers were laminated so as to be material layer A / fiber layer / fiber layer / base material layer A. The obtained sample was used as a sound absorption coefficient measurement sample (interlayer distance 10 mm). The portion where the fiber layer and the fiber layer are overlaid is considered as a single fiber layer, and therefore the number of fiber layers is “2”.
When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 325, which was good.
［実施例２］
実施例１と同様にポリウレタン樹脂を溶解し、電界紡糸溶液を調製し、基材層Ａ上に電界紡糸しポリウレタン極細繊維（繊維層）との２層からなる積層体を作製した。
得られた積層体を直径６３ｍｍに打ち抜き、積層体４枚と穴開き構造体３を１枚使用し、穴開き構造体３／基材層Ａ／繊維層／繊維層／基材層Ａ／基材層Ａ／繊維層／繊維層／基材層Ａとなるよう重ね合わせた。得られたサンプルを吸音率測定用サンプル（層間距離１０ｍｍ）とした。繊維層／繊維層の積層を１層と数えるため、繊維層の層数「２」とした。
穴開き構造体３を音源側に設置し、垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３１５であり良好であった。
[Example 2]
In the same manner as in Example 1, a polyurethane resin was dissolved to prepare an electrospinning solution, and electrospun onto the base material layer A to prepare a laminate composed of two layers of polyurethane ultrafine fibers (fiber layers).
The obtained laminate was punched to a diameter of 63 mm, and four laminates and one perforated structure 3 were used, and perforated structure 3 / base material layer A / fiber layer / fiber layer / base material layer A / base The layers were laminated so as to be material layer A / fiber layer / fiber layer / base material layer A. The obtained sample was used as a sound absorption coefficient measurement sample (interlayer distance 10 mm). Since the fiber layer / fiber layer stacking was counted as one layer, the number of fiber layers was set to “2”.
When the perforated structure 3 was installed on the sound source side, the normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例３］
Ａｒｋｅｍａ製のポリフッ化ビニリデン−ヘキサフルオロプロピレン（以下、「ＰＶＤＦ−ＨＦＰ」と略記する。）樹脂であるＫｙｎａｒ（商品名）３１２０を、Ｎ，Ｎ−ジメチルアセトアミドとアセトンの共溶媒（６０／４０（ｗ／ｗ））に１５質量％の濃度で溶解し、電界紡糸溶液を調製した。基材層の不織布Ａを準備し、この上に前記ＰＶＤＦ−ＨＦＰ溶液を電界紡糸して、基材層の不織布Ａと繊維層のＰＶＤＦ−ＨＦＰ極細繊維との２層からなる積層体を作製した。電界紡糸の条件は、２４Ｇニードルを使用し、単孔溶液供給量は３．０ｍＬ／ｈ、印加電圧は３５ｋＶ、紡糸距離は１７．５ｃｍとした。得られた積層体におけるＰＶＤＦ−ＨＦＰ極細繊維の層の目付は１．０ｇ／ｍ２であり、平均繊維径は１８０ｎｍであり、融解温度は１６８℃であった。積層体を直径６３ｍｍの円形に打ち抜き、積層体を３枚と、目付が２００ｇ／ｍ２、厚み５ｍｍ、カード法スルーエア不織布（基材層Ａ）、穴開き構造体１とを、基材層Ａ／繊維層／穴開き構造体１／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるように重ね合わせ、吸音率測定用サンプル（層間距離１０ｍｍ）とした。
繊維層が２層あるため、繊維層の層数「２」とした。
垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１８７であり良好であった。
[Example 3]
Kynar (trade name) 3120, which is a polyvinylidene fluoride-hexafluoropropylene (hereinafter abbreviated as “PVDF-HFP”) resin manufactured by Arkema, was used as a co-solvent (60/40 ( w / w)) was dissolved at a concentration of 15% by mass to prepare an electrospinning solution. A non-woven fabric A of a base material layer was prepared, and the PVDF-HFP solution was electrospun onto the non-woven fabric A to produce a laminate composed of two layers of the non-woven fabric A of the base material layer and the PVDF-HFP ultrafine fiber of the fiber layer. . The electrospinning conditions were as follows: a 24G needle was used, the single-hole solution supply rate was 3.0 mL / h, the applied voltage was 35 kV, and the spinning distance was 17.5 cm. The basis weight of the PVDF-HFP ultrafine fiber layer in the obtained laminate was 1.0 g / m 2 , the average fiber diameter was 180 nm, and the melting temperature was 168 ° C. The laminate is punched into a circle with a diameter of 63 mm, the laminate is divided into three pieces, the basis weight is 200 g / m 2 , the thickness is 5 mm, the card method through-air nonwoven fabric (base material layer A), and the perforated structure 1 The samples were stacked so as to be: / fiber layer / perforated structure 1 / base material layer A / base material layer A / fiber layer / base material layer A to obtain a sample for measuring sound absorption (interlayer distance 10 mm).
Since there are two fiber layers, the number of fiber layers is “2”.
When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 187, which was favorable.
［実施例４］
基材層Ａ／繊維層／穴開き構造体４／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１８６であり良好であった。
[Example 4]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 4 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 186, which was good.
［実施例５］
基材層Ａ／繊維層／穴開き構造体５／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２５６であり良好であった。
[Example 5]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 5 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 256, which was good.
［実施例６］
基材層Ａ／繊維層／穴開き構造体６／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２１０であり良好であった。
[Example 6]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 6 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 210, which was good.
［実施例７］
基材層Ａ／繊維層／穴開き構造体７／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３３３であり良好であった。
[Example 7]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 7 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例８］
基材層Ａ／繊維層／穴開き構造体２／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２０１であり良好であった。
[Example 8]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 2 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 201, which was good.
［実施例９］
穴開き構造体７／基材層Ａ／繊維層／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２３４であり良好であった。
[Example 9]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be perforated structure 7 / base material layer A / fiber layer / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１０］
基材層Ａ／繊維層／基材層Ａ／穴開き構造体７／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２０１であり良好であった。
[Example 10]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / base material layer A / perforated structure 7 / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 201, which was good.
［実施例１１］
基材層Ａ／繊維層／穴開き構造体８／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２８０であり良好であった。
[Example 11]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 8 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 280, which was good.
［実施例１２］
基材層Ａ／繊維層／穴開き構造体７／基材層Ａ／基材層Ａ／穴開き構造体７／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２７２であり良好であった。
[Example 12]
Example 3 with the exception that the base material layer A / fiber layer / perforated structure 7 / base material layer A / base material layer A / perforated structure 7 / fiber layer / base material layer A were overlaid. It carried out similarly. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１３］
基材層Ａ／繊維層／穴開き構造体９／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１７１であり良好であった。
[Example 13]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 9 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１４］
基材層Ａ／繊維層／穴開き構造体１０／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１９９であり良好であった。
[Example 14]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 10 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１５］
基材層Ａ／繊維層／穴開き構造体１１／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２５９であり良好であった。
[Example 15]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 11 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１６］
基材層Ａ／繊維層／穴開き構造体１２／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２５７であり良好であった。
[Example 16]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 12 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 257, which was good.
［実施例１７］
基材層Ａ／繊維層／穴開き構造体１３／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２９０であり良好であった。
[Example 17]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 13 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 290, which was good.
［実施例１８］
基材層Ａ／繊維層／穴開き構造体１４／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３２２であり良好であった。
[Example 18]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 14 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例１９］
基材層Ａ／繊維層／穴開き構造体１５／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２９８であり良好であった。
[Example 19]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 15 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例２０］
基材層Ａ／繊維層／穴開き構造体１６／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３５４であり良好であった。
[Example 20]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 16 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例２１］
基材層Ａ／繊維層／穴開き構造体１７／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２２３であり良好であった。
[Example 21]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be substrate layer A / fiber layer / perforated structure 17 / substrate layer A / substrate layer A / fiber layer / substrate layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例２２］
基材層Ａ／繊維層／穴開き構造体１８／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１８８であり良好であった。
[Example 22]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 18 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 188, which was favorable.
［実施例２３］
基材層Ａ／繊維層／穴開き構造体１９／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２２５であり良好であった。
[Example 23]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be substrate layer A / fiber layer / perforated structure 19 / substrate layer A / substrate layer A / fiber layer / substrate layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 225, which was good.
［実施例２４］
基材層Ａ／繊維層／穴開き構造体２０／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２１８であり良好であった。
[Example 24]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 20 / base material layer A / base material layer A / fiber layer / base material layer A. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated.
［実施例２５］
基材層Ａ／繊維層／穴開き構造体２１／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２７８であり良好であった。
[Example 25]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 21 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 278, which was good.
［実施例２６］
基材層Ａ／繊維層／穴開き構造体２２／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、２８６であり良好であった。
[Example 26]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be substrate layer A / fiber layer / perforated structure 22 / substrate layer A / substrate layer A / fiber layer / substrate layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 286, which was good.
［実施例２７］
基材層Ａ／繊維層／穴開き構造体２３／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３０３であり良好であった。
[Example 27]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / perforated structure 23 / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 303, which was good.
［比較例１］
基材層Ａ／繊維層／繊維層／基材層Ａ／基材層Ａ／繊維層／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例１と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１５７であり、低周波数領域吸音性が不良であった。
[Comparative Example 1]
The same procedure as in Example 1 was performed except that the layers were laminated so as to be substrate layer A / fiber layer / fiber layer / substrate layer A / substrate layer A / fiber layer / fiber layer / substrate layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 157, and the low frequency region sound absorption property was poor.
［比較例２］
基材層Ａ／繊維層／基材層Ａ／基材層Ａ／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例３と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、１４４であり、低周波数領域吸音性が不良であった。
[Comparative Example 2]
The same procedure as in Example 3 was performed except that the layers were laminated so as to be base material layer A / fiber layer / base material layer A / base material layer A / fiber layer / base material layer A. When the normal incident sound absorption coefficient was measured and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated, it was 144, which was poor in the low frequency region sound absorption property.
［比較例３］
基材層Ａ／繊維層／繊維層／基材層Ａ／基材層Ａ／繊維層／繊維層／基材層Ａ／基材層Ａ／繊維層／繊維層／基材層Ａとなるよう重ね合わせた以外は、実施例１と同様に実施した。垂直入射吸音率を測定し、低周波数領域の吸音性（２００Ｈｚから１０００Ｈｚまでの積分した値Ｓ）を評価したところ、３２４であり、低周波数領域吸音性が良好であるものの、トータル厚みが３０ｍｍを超え省スペース性が劣った。
[Comparative Example 3]
Base material layer A / fiber layer / fiber layer / base material layer A / base material layer A / fiber layer / fiber layer / base material layer A / base material layer A / fiber layer / fiber layer / base material layer A The same operation as in Example 1 was carried out except for superposition. The normal incident sound absorption coefficient was measured, and the sound absorption property in the low frequency region (integrated value S from 200 Hz to 1000 Hz) was evaluated. As a result, it was 324 and the low frequency region sound absorption property was good, but the total thickness was 30 mm. Inferior space saving performance.
実施例１〜６の積層吸音材の構造及び物性、吸音性能を表１にまとめる。
実施例７〜１２の積層吸音材の構造及び物性、吸音性能を表２にまとめる。
実施例１３〜２０の積層吸音材の構造及び物性、吸音性能を表３にまとめる。
実施例２１〜２７の積層吸音材の構造及び物性、吸音性能を表４にまとめる。
比較例１〜３の積層吸音材の構造及び物性、吸音性能を表５にまとめる。
Claims (10)
前記繊維層は前記積層吸音材中に少なくとも２層含まれ、また前記繊維層は４５０ｎｍ未満の繊維径の繊維からなり、目付けが５０ｇ／ｍ２以上である繊維集合体であり、
前記基材層は、不織布、フィルム、ガラス繊維および紙からなる群より選ばれる少なくとも１つからなり、目付けが１ｇ／ｍ２以上であり、
さらに、前記積層吸音材は、開口率０．０５％以上５０％未満の穴開き構造体を１層以上有する、積層吸音材。 A laminated sound absorbing material including a fiber layer and a base material layer,
The fiber layer is a fiber assembly including at least two layers in the laminated sound-absorbing material, the fiber layer is made of fibers having a fiber diameter of less than 450 nm, and has a basis weight of 50 g / m 2 or more.
The base material layer is composed of at least one selected from the group consisting of a nonwoven fabric, a film, glass fiber, and paper, and has a basis weight of 1 g / m 2 or more.
Furthermore, the laminated sound-absorbing material has one or more perforated structures having an opening ratio of 0.05% or more and less than 50%.
In the normal incidence sound absorption rate measurement method (200 to 1000 Hz), the sound absorption rate from 200 Hz to 3200 Hz is measured at intervals of 1 Hz, and the obtained curve is f (x), and the integrated value from 200 Hz to 1000 Hz. The laminated sound-absorbing material according to any one of claims 1 to 7, wherein S is a range satisfying the following formula.
In the normal incidence sound absorption rate measurement method (200 to 1000 Hz), the sound absorption rate from 200 Hz to 3200 Hz is measured at intervals of 1 Hz, and the obtained curve is f (x), and the integrated value from 200 Hz to 1000 Hz. The laminated sound-absorbing material according to any one of claims 1 to 7, wherein S is a range satisfying the following formula.
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