JPH0122146B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a flexible sound insulating sheet and a method for manufacturing the same. Conventionally, flexible sound insulating sheets have been made by pasting rubber-based polymers or thermoplastic resins containing high-density substances such as heavy metals and other inorganic compounds onto a coarse-density base fabric using calender rolls, etc. Widely used. However, such sound insulating sheets only have the bridge effect of high-density materials, and because the adhesive strength is poor, the base fabric is likely to peel off, and because of the low-density base fabric, it is difficult to hang or store it vertically for long periods of use. When used, the sheet's own weight causes defects such as partial elongation and cracks in the fixed portion. Although it is conceivable to use a high-density base fabric to improve the strength and form stability of the sound insulating sheet, the use of a high-density base fabric has the disadvantage that the peel strength is further reduced. The inventors of the present invention solved the above-mentioned drawbacks of conventional methods, and as a result of intensive research to provide a sound insulation sheet that is flexible, mechanically strong, stable in size and form, and has excellent sound insulation performance, the present invention was developed. A sound insulating sheet and its manufacturing method have been achieved. That is, the present invention provides a bulky fabric made by weaving differential shrinkage filament mixed yarns as warp and/or weft yarns with a specific gravity of 2.
A sound insulating sheet characterized by being provided with the above metal or inorganic compound and a film-forming polymer. and a mixed fiber density of 40, consisting of at least two types of differently shrinkable filaments with a difference in heat shrinkage rate of 3% or more.
After the fabric made by weaving the above blended yarns as warp and/or weft is bulked by heat treatment,
This is a method for producing a sound insulating sheet, which is characterized by impregnating a metal or inorganic compound with a specific gravity of 2 or more and a film-forming polymer. The sound insulation sheet according to the present invention is flexible, strong, and has excellent dimensional and form stability.
Moreover, it has many features such as the base fabric and the high-density composition (metal or inorganic compound and film-forming polymer) not peeling off, and excellent sound insulation performance. The dimensional and morphological stability of the sound insulating sheet is mainly maintained by the high shrinkage filaments of the base fabric, and the low shrinkage filaments that provide bulkiness mainly act effectively on the impregnation and adhesive properties of the high density composition. Since the high-density composition easily penetrates and adheres between the fiber bundles constituting the woven fabric and between the single fibers of the fiber bundles, the adhesiveness with the high-density composition can be achieved without any special preparation for adhesion. This results in significantly improved shape stability and strength. The sound insulation sheet of the present invention can be used in many ways, such as as a sound insulation sheet for construction work, demolition work, renovation work, civil engineering work, road construction, and other civil engineering construction work, and as a sound insulation sheet for the interior and exterior of houses, vehicles, ships, and other buildings. Can be done. Although there are no particular limitations on the filament material used in the present invention, it is effective to apply it to polyester, aromatic polyamide, etc., which are highly hydrophobic and have poor adhesion to high-density compositions. In addition, the difference in heat shrinkage rate of the filaments that make up the mixed yarn is usually 3%.
or more, preferably 5 to 10%. The difference in thermal shrinkage rate in the present invention is usually 15 with hot air at 160℃.
This is the value (SHD) under the condition of 1 minute, but when the heat treatment in bulk processing is hot water treatment, it may be the hot water shrinkage difference (30 minutes of hot water). Different shrinkage filament blend yarns are usually produced by aligning a multifilament yarn with high shrinkage filaments and a multifilament yarn with low shrinkage filaments, passing them through a high-pressure air nozzle (interlacer), and mixing them with turbulent air. Ru. At that time, the blending degree Di is usually 40
or more, preferably 50 or more. If the degree of blending is too small, the bulkiness becomes partially non-uniform during bulk processing, resulting in a disadvantage of poor smoothness. The mixing ratio of high shrinkage filaments and low shrinkage filaments is preferably 7:3 to 3:7 by weight. The denier of the mixed yarn is usually 500 to 2000 deniers, preferably 1000 to 1500 deniers. The filament can be provided with various properties such as flame retardancy and light resistance, if desired. A woven fabric is woven using such differentially contracted filament mixed yarns for either the warp or the weft, preferably for both. Although there are no limitations on the texture, fabrics with floating textures such as satin weave, twill weave, and variations thereof are particularly preferred from the viewpoint of incorporating the high-density composition after bulking. The fabric thus obtained is subjected to dry heat treatment, hot water treatment,
Bulky properties are developed through moist heat treatment, etc. The thickness of the woven fabric is preferably set to be 1.2 times or more, particularly 1.5 times or more, the thickness before treatment. Dry heat treatment conditions are usually
The temperature is 150-220°C, preferably 170-190°C. In addition, hot water treatment conditions are usually 90 to 100℃, preferably 95 to 100℃, moist heat treatment conditions are usually 100 to 140℃,
Preferably it is 110-130°C. The high-shrinkage filament shrinks due to the bulking process, mainly forming the center of the yarn and exhibiting dimensional stability. After developing bulkiness, the fabric usually has a basis weight of 200g/m2 ^or more, especially
It is preferably 300 g/m ² or more. In addition, when considering impregnability, the air permeability (measured with a pressure difference of 12.7 cm in the water column using a Frazier type air permeability tester) is 5.
It is preferably cc/cm ² /sec or more, particularly 15 to 100 c.c./cm ² /sec. After the woven fabric has developed bulkiness, it is then processed with a high-density composition mainly consisting of a metal or inorganic compound with a specific gravity of 2 or more and a film-forming compound to produce a sound insulating sheet. Examples of metals or inorganic compounds with a specific gravity of 2 or more include metals such as iron, lead, zinc, tin, and copper, iron oxide, zinc sulfide, barium sulfate, glass, clay,
An example is an inorganic compound such as talc, which can be used alone or in combination of two or more. A metal and an inorganic compound may be used together. Particularly preferred are those having a specific gravity of 2.5 to 8.0. The metal or inorganic compound is used in the form of a powder, preferably a fine powder with a diameter of 0.5 mm or less, particularly preferably 0.1 mm or less. The film-forming polymer is preferably a rubber or a thermoplastic resin, such as rubbers such as ethylene propylene rubber, acrylonitrile rubber, chloroprene rubber, styrene butadiene rubber, chloroprene styrene rubber, acrylonitrile butadiene rubber, vinyl chloride resin, and polyurethane rubber. Thermoplastic resins such as resins, ethylene vinyl acetate resins, acrylic resins, polyester resins, polyester polyether resins, polyamide resins, and modified nylon resins can be used alone or in combination of two or more. The film-forming polymer is usually used in the form of a solution or latex, but it can also be used by extrusion lamination, calendering, etc. Usually, it is preferable to use a vinyl chloride resin or a rubber or thermoplastic resin based on this resin.
The mixing ratio of the metal or inorganic compound and the film-forming polymer is generally 1:1 to 10:1 by weight, preferably 5:1 to 8:1. The amount of the high-density composition to be applied is preferably such that the weight of the fabric, the composition of the high-density composition, and the amount of the high-density composition to be applied are appropriately selected so that the weight of the sound insulation sheet is 1 kg/m ² or more in consideration of sound insulation performance. Stabilizers for dense compositions,
Various additives such as light stabilizers, flame retardants, antifouling agents, and antistatic agents can be added. The sound insulating sheet according to the present invention can further have a heat insulating or heat retaining property by forming a non-thermal conductive layer, and can also be given a design by applying a printed pattern, an embossed pattern, etc. to the surface. The present invention will be explained below with reference to Examples. In addition,
In the present invention, the degree of blending, fabric thickness, and other physical properties were measured by the following methods. 1) Mixing degree (Di) One yarn is hung with an initial load of 0.1g/d and marks are made at 1000mm intervals. Insert the needle into the mark below and move the needle upward. Measure the distance Xmm when the needle is caught in the tangle of single fibers and lifts the initial load. Repeat the same measurement 20 times by changing the yarn, and calculate Di using the following formula. 2) Thickness of the cloth Cut the cloth into 5 cm x 5 cm samples.
Three sheets were prepared, and the thickness was measured by stacking three sheets alternately in the warp direction and the weft direction and applying an initial load of 240 g/cm ² using a compressive elasticity tester (manufactured by Maeda Seiki Co., Ltd.). 3) Tensile strength JIS L 1096 Tensilon tensile tester was used. Example Polyester filament yarn A (1000d/95f,
SHD=5%) and polyester filament yarn B
(500d/96f, SHD=20%) were aligned and mixed at an air pressure of 3 Kg/cm ² using an air nozzle to obtain a differential shrinkage filament mixed yarn with a mixing degree of 100. The obtained mixed fiber yarn 1500d/191f is passed through a rapier type loom.
MAV allows warp density of 26 threads/inch and weft thread density of 26
book/inch, woven width 227cm, 1/3 diagonal (basis weight)
330 g/cm ² ) and air permeability 13 c.c./cm ² /sec. Next, the base fabric was heat-treated with hot air at 180°C for 1 minute to develop bulkiness. The thickness of the cloth before heat treatment is 0.59
mm, and the thickness of the cloth after heat treatment was 1.1 mm, which became 1.86 times thicker after heat treatment. In addition, the basis weight is
The weight was 490 g/m ² and the air permeability was 25 c.c./cm ² /sec. Next, the base fabric was coated with vinyl chloride resin paste (50% by weight).
A high-density composition prepared by mixing 650 parts by weight of barium sulfate with 100 parts by weight (solid content) was impregnated by a coating method to obtain a sound insulating sheet with a thickness of 1.25 mm and a weight of 1800 g/m ² . The characteristics of the obtained sound insulation sheet were
Shown in the table. In addition, the characteristic values of a product laminated with a calender roll on a coarse density fabric using polyester filament yarn (comparative example product) are also shown for comparison.

【table】

[Table] * Repeated lamination process 4 times As is clear from Table 1, the desired amount of impregnation can be obtained through a single impregnation process, resulting in a sound insulating sheet with excellent sound insulating properties, tensile strength, peel strength, and durability. Obtained. On the other hand, the comparative example product requires repeated lamination to obtain the desired amount of high-density composition, which is not only disadvantageous in terms of process, but also has completely insufficient tensile strength and especially peel strength, and is inferior in durability. All you can get is a soundproof sheet. When a similar sheet was made from a thick plain woven fabric, the tensile strength was improved, but the bridge effect (anchor effect) disappeared and the peel strength further decreased. Furthermore, in a comparative example in which a bulky fabric made of crimped yarn was impregnated by a coating method, the impregnability was relatively good, but the resulting sound insulation sheet had poor dimensional and morphological stability, especially when hanging. When used lowered, large dimensional changes and surface cracks occurred.

Claims (1)

[Scope of Claims] 1. A bulky fabric made by weaving differential shrinkage filament mixed yarns as warp and/or weft yarns with a specific gravity of 2.
A sound insulating sheet characterized by being provided with the above metal or inorganic compound and a film-forming polymer. 2. A woven fabric made of warp and/or weft yarns composed of at least two types of differently shrinkable filaments with a difference in thermal shrinkage of 3% or more and a blending degree of 40 or more is bulked by heat treatment, and then the specific gravity is increased. 2
A method for producing a sound insulation sheet, comprising impregnating the above metal or inorganic compound with a film-forming polymer.