JP6500929B2 - 機能性積層体およびその製造方法 - Google Patents
機能性積層体およびその製造方法 Download PDFInfo
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- JP6500929B2 JP6500929B2 JP2017072516A JP2017072516A JP6500929B2 JP 6500929 B2 JP6500929 B2 JP 6500929B2 JP 2017072516 A JP2017072516 A JP 2017072516A JP 2017072516 A JP2017072516 A JP 2017072516A JP 6500929 B2 JP6500929 B2 JP 6500929B2
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Description
多孔質表面層と樹脂発泡層との間に、通気性を有する多孔質中間層が積層されており、
前記多孔質中間層が、前記多孔質表面層の平均空隙率よりも小さい平均空隙率を有している、機能性積層体に関する。
本発明の機能性積層体はまた、断熱性にも十分に優れている。
本発明の機能性積層体は少なくとも吸音性を備えた積層体に関するものであり、機能性は、吸音性、断熱性および制振性等の性能を包含する。
多孔質中間層3は通気性を有する。多孔質中間層3が有する「通気性」は「通液性」と換言可能な特性であり、すなわち当該多孔質中間層3が機能性積層体の製造時に自己の内部を発泡性樹脂(液体)に適度に通過させ得る特性のことである。多孔質中間層3はこのような通気性を有するため、多孔質表面層1と樹脂発泡層2と多孔質中間層3との一体化が達成される。多孔質中間層3が有する通気性は、詳しくは、後述の混層部11が形成され得る程度の通気性である。
1.05≦Rs/Rm≦2 (x2)
1.1≦Rs/Rm≦1.5 (x3)
また、別の繊維間の空隙の体積割合の測定方法として、機能性積層体から、発泡性樹脂が含浸された多孔質中間層の当該不織布を切り出し、当該不織布の体積と、計算機トモグラフィー法、液浸法、水蒸発法、懸吊法、水銀圧入法、ガス吸着法等の方法で測定した当該不織布の空隙体積を得た後、当該不織布を構成する繊維および発泡性樹脂のうち、繊維材料のみを溶解する溶剤により、繊維材料を溶解し、発泡性樹脂を単独で得る。この発泡性樹脂における空隙体積を上記同様の手法で測定し、当該不織布の体積−当該発泡性樹脂の空隙体積+当該不織布の空隙体積から繊維不織布の空隙体積を算出し、この値と当該不織布の体積から繊維不織布における空隙の体積割合を算出することができる。
1.01≦Ds/Dm≦10 (y2)
1.1≦Ds/Dm≦10 (y3)
多孔質表面層1を構成する材料は、多孔性を有し、かつ多孔質中間層よりも毛細管現象を起こし難いものである限り特に限定されず、例えば、繊維不織布であってもよいし、またはポリマー発泡体であってもよい。
樹脂発泡層2はポリマーの発泡層である。樹脂発泡層を構成するポリマーは、プラスチックの分野で発泡体を構成し得るポリマーとして知られているあらゆるポリマーであってもよい。樹脂発泡層の具体例として、例えば、ポリウレタン発泡層;ポリエチレン発泡層、ポリプロピレン発泡層等のポリオレフィン発泡層;PET発泡層等のポリエステル発泡層;シリコーン発泡層;ポリ塩化ビニル発泡層からなる群から選択されるポリマー発泡層が挙げられる。
本発明の機能性積層体10は、多孔質中間層3と多孔質表面層1との間に、混層部11を備えている。詳しくは、多孔質表面層1が多孔質中間層3側に、混層部11を備えている。より詳しくは、多孔質表面層1における多孔質中間層3側の一部が混層部11に変換されており、換言すると、多孔質表面層1内における多孔質中間層3側の一部において混層部11が生成している。混層部により、機能性積層体の剛性が向上する。
本発明の機能性積層体は以下の積層用基材形成工程および発泡成形工程を含む製造方法により製造することができる。
本工程においては、多孔質表面層1および多孔質中間層3を重ね合わせ、積層用基材40を得る。重ね合わせは、単に、一方の層の上に、他方の層を載置すればよいが、積層用基材の取り扱い性の観点から多孔質表面層1と多孔質中間層3とは接着することが好ましい。
本工程においては、図2Aに示すように、成形型50内において、発泡成形を行う。成形型50は通常、上型51および下型52からなっている。図2Aは、発泡成形工程の発泡準備段階を説明するための成形型およびその内部の模式的断面図を示す。
本発明の機能性積層体10は、吸音性、断熱性および制振性(特に吸音性)に優れているため、吸音材、断熱材かつ/または制振材(特に吸音材)として有用である。
本発明の機能性積層体10が有用な分野として、例えば、車両(例えば、自動車、トラック、バスおよび電車等)および農業機械(例えば、草刈り機および耕耘機等)等のエンジンを備えた機械等の分野が挙げられる。
各層の各種物性は前記した方法により測定した。
吸音率(α):
日本音響エンジニアリング社製 垂直入射吸音率測定システム WinZacMTXを使用し、測定周波数範囲 200〜4800Hz(1/3オクターブバンド)にて、内径40mmの音響管を用いた垂直入射吸音率の測定(JIS A 1405−2、ISO 10534−2準拠)を行い、1000〜4000Hzの平均垂直入射吸音率を算出した。機能性積層体は、多孔質表面層1側が音源に対向するように、使用した。
NETZSCH社製 定常法熱伝導率測定装置 HFM436/3/1Lambdaを使用し、測定温度30℃にて、機能性積層体の厚み方向の熱伝導率をJIS A1412−2第2部熱流計法に基づいて測定した。
・積層用基材形成工程
平均繊維径約7.5μmのグラスウールAを、表1に記載の平均空隙径、平均空隙率および厚みになるよう熱プレス成形し、多孔質表面層1を得た。この多孔質表面層1に、表1の多孔質中間層3を接着して、積層用基材40を得た。接着は多孔質表面層と多孔質中間層との接触面の一部で接着剤により達成した。
発泡性樹脂20として表1のポリウレタンフォームの原料をミキサーで混合し、図2Aに示すように、下型52の成形面520上に注入した。次いで、当該発泡性樹脂20の上に積層用基材40を、多孔質表面層3が発泡性樹脂20と接触するように、配置させた。その後、25℃および常圧の環境下で、図2Bに示すように、上型51を閉じ、発泡が開始されると、発泡性樹脂20が膨張し、上型51と下型52との間のキャビティ(寸法100mm×100mm×25mm)内を充たし、樹脂発泡層2が形成された。冷却後、成形体を脱型することにより、多孔質表面層1、樹脂発泡層2および多孔質中間層3が一体化された機能性積層体を得た。
多孔質表面層1として平均繊維径約3.5μmのグラスウールBを、表1に記載の平均空隙径、平均空隙率および厚みになるよう、熱プレス成形したものを用いたこと、および表1の多孔質中間層3を用いたこと以外、実施例1と同様の方法により、積層用基材形成工程および発泡成形工程を行った。
多孔質表面層1として繊維長51mmおよび繊度2.2デニール(平均繊維径約16μm)のPET繊維を、表1に記載の平均空隙径、平均空隙率および厚みになるよう、ニードルパンチおよび接着剤にてシート状に成形したものを用いたこと、および表1の多孔質中間層3を用いたこと以外、実施例1と同様の方法により、積層用基材形成工程および発泡成形工程を行った。
グラスウールB:平均繊維径約3.5μmおよび平均繊維長約50mmの硝子繊維(グラスウールBによる多孔質表面層1の目付 実施例3:1920g/m2、実施例4:960g/m2、実施例5:480g/m2、比較例1:960g/m2、比較例2:6000g/m2)
PP不織布A:SP−1040E(前田工繊(株)製、目付40g/m2)
PP不織布B:SP−1200E(前田工繊(株)製、目付200g/m2)
PP不織布C:SP−1017E(前田工繊(株)製、目付17g/m2)
ポリウレタンフォームAの原料:DKシステム(第一工業製薬(株)製)
2:樹脂発泡層
3:多孔質中間層
10:機能性積層体
11:混層部
12:多孔質表面層の外表面
13:多孔質表面層における多孔質中間層との界面
20:発泡性樹脂
22:樹脂発泡層における多孔質中間層との界面
32:多孔質中間層における多孔質表面層との界面
33:多孔質中間層における樹脂発泡層との界面
40:積層用基材
50:成形型
51:上型
52:下型
520:下型の成形面
Claims (28)
- 多孔質表面層と樹脂発泡層との間に、通気性を有する多孔質中間層が積層されており、
前記多孔質中間層が、前記多孔質表面層の平均空隙率よりも小さい平均空隙率を有しており、
前記多孔質表面層が前記多孔質中間層側に、前記樹脂発泡層と前記多孔質表面層との混層部を備えており、
前記混層部が0.3〜1.7mmの厚みを有する、機能性積層体。 - 前記混層部が60〜200μmの樹脂平均空隙径を有する、請求項1に記載の機能性積層体。
- 前記混層部が50〜90%の平均空隙率を有する、請求項1または2に記載の機能性積層体。
- 多孔質表面層と樹脂発泡層との間に、通気性を有する多孔質中間層が積層されており、
前記多孔質中間層が、前記多孔質表面層の平均空隙率よりも小さい平均空隙率を有しており、
前記多孔質表面層が前記多孔質中間層側に、前記樹脂発泡層と前記多孔質表面層との混層部を備えており、
前記混層部が60〜200μmの樹脂平均空隙径を有する、機能性積層体。 - 前記混層部が50〜90%の平均空隙率を有する、請求項4に記載の機能性積層体。
- 多孔質表面層と樹脂発泡層との間に、通気性を有する多孔質中間層が積層されており、
前記多孔質中間層が、前記多孔質表面層の平均空隙率よりも小さい平均空隙率を有しており、
前記多孔質表面層が前記多孔質中間層側に、前記樹脂発泡層と前記多孔質表面層との混層部を備えており、
前記混層部が50〜90%の平均空隙率を有する、機能性積層体。 - 前記多孔質中間層が、平均空隙径の差に起因して、前記多孔質表面層よりも毛細管現象を起こし易い、請求項1〜6のいずれかに記載の機能性積層体。
- 前記多孔質中間層が、前記多孔質表面層の平均空隙径よりも小さい平均空隙径を有している、請求項1〜7のいずれかに記載の機能性積層体。
- 前記多孔質中間層が60〜95%の平均空隙率を有する、請求項1〜8のいずれかに記載の機能性積層体。
- 前記多孔質中間層が0.04〜90μmの平均空隙径を有する、請求項1〜9のいずれかに記載の機能性積層体。
- 前記多孔質中間層が0.1〜2mmの厚みを有する、請求項1〜10のいずれかに記載の機能性積層体。
- 前記多孔質中間層が繊維不織布である、請求項1〜11のいずれかに記載の機能性積層体。
- 前記多孔質中間層がポリエステル繊維、ポリアミド繊維、ポリビニルアルコール繊維、ポリオレフィン繊維およびセルロース繊維からなる群から選択される有機繊維の不織布である、請求項1〜12のいずれかに記載の機能性積層体。
- 前記多孔質中間層の繊維不織布を構成する繊維が0.005〜50μmの平均繊維径を有する、請求項12または13に記載の機能性積層体。
- 前記多孔質中間層の繊維不織布が5〜500g/m2の目付を有する、請求項12〜14のいずれかに記載の機能性積層体。
- 前記多孔質表面層が80〜99.5%の平均空隙率を有する、請求項1〜15のいずれかに記載の機能性積層体。
- 前記多孔質表面層が10〜300μmの平均空隙径を有する、請求項1〜16のいずれかに記載の機能性積層体。
- 前記多孔質表面層が1〜50mmの厚みを有する、請求項1〜17のいずれかに記載の機能性積層体。
- 前記多孔質表面層が繊維不織布である、請求項1〜18のいずれかに記載の機能性積層体。
- 前記多孔質表面層が無機繊維の不織布または有機繊維の不織布である、請求項1〜19のいずれかに記載の機能性積層体。
- 前記多孔質表面層の繊維不織布を構成する繊維が0.005〜50μmの平均繊維径を有する、請求項19または20に記載の機能性積層体。
- 前記多孔質表面層の繊維不織布が50〜6000g/m2の目付を有する、請求項19〜21のいずれかに記載の機能性積層体。
- 前記樹脂発泡層が0.04〜800μmの平均空隙径を有する、請求項1〜22のいずれかに記載の機能性積層体。
- 前記樹脂発泡層がポリウレタン発泡層、ポリオレフィン発泡層、ポリエステル発泡層、シリコーン発泡層およびポリ塩化ビニル発泡層からなる群から選択されるポリマー発泡層である、請求項1〜23のいずれかに記載の機能性積層体。
- 前記機能性積層体は吸音材、断熱材かつ/または制振材として使用される、請求項1〜24のいずれかに記載の機能性積層体。
- 前記機能性積層体は、前記樹脂発泡層側が熱源および/または音源に接触するように配置され使用される、あるいは、前記多孔質表面層側が熱源および/または音源に非接触で対向するように配置され使用される、請求項1〜25のいずれかに記載の機能性積層体。
- 前記機能性積層体は、自動車のエンジンおよびトランスミッションを含むパワートレイン部材のためのカバー部材として、使用される、請求項1〜26のいずれかに記載の機能性積層体。
- 請求項1〜27のいずれかに記載の機能性積層体の製造方法であって、
前記多孔質表面層および前記多孔質中間層を重ね合わせ、積層用基材を得る工程;および
成形型内において、前記樹脂発泡層を構成する発泡性樹脂の発泡成形を、前記積層用基材の多孔質中間層側で行う、方法。
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- 2018-02-16 US US16/498,337 patent/US11260620B2/en active Active
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CN110461588B (zh) | 2022-04-05 |
EP3603951A1 (en) | 2020-02-05 |
WO2018179977A1 (ja) | 2018-10-04 |
EP3603951A4 (en) | 2020-02-12 |
CN110461588A (zh) | 2019-11-15 |
EP3603951B1 (en) | 2021-07-07 |
JP2018171819A (ja) | 2018-11-08 |
US20200368996A1 (en) | 2020-11-26 |
US11260620B2 (en) | 2022-03-01 |
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