JPH11200244A - Fiber formed body for acoustic use and sound-insulating wall - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an acoustic fiber formed body having excellent acoustic properties in the audio frequency band and at the same time fireproof properties. SOLUTION: This fiber formed body for acoustic use is a fiber formed body constructed of at least two or more kinds of fibers. One of the constituting fibers of the fiber formed body is a fiber A containing a thermoplastic polymer R1 having a melting point lower than the other fiber, and the fiber A is substantially bonded at a part of the contact points between constituting single fibers of the fiber A or between the single fiber of the fiber A and a single fiber of the other fiber, with the thermoplastic polymer R1. Further, at least one side of the fiber formed body has a fireproofing agent adhered to it. Furthermore, the sound-insulating wall of the present invention is characterized in that it is constituted with such a fiber formed body for acoustic use.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound-absorbing fiber molded article having excellent sound-absorbing properties as well as sound-absorbing sound in the audible frequency band. And sound absorbing materials used for sound absorbing walls and the like.

[0002]

2. Description of the Related Art Conventionally, glass wool, rock wool, aluminum fiber, lightweight foamed concrete, porous ceramic, and the like have been used as sound absorbing materials for vehicles, houses, and highway roads. However, no satisfactory sound-absorbing material was obtained in terms of workability improvement, prevention of obstacles to the human body, protection of the global environment, ease of waste treatment for efficient use of resources, and the possibility of reuse. .

[0003]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a sound-absorbing fiber molded article having excellent sound-absorbing properties in the audible frequency band as well as flame retardancy, and a soundproof wall comprising the same.

[0004]

The present invention employs the following means in order to solve the above-mentioned problems. That is, the sound-absorbing fiber molded article of the present invention is a fiber molded article composed of at least two or more types of fibers,
One of the constituent fibers of the fiber molded body is a fiber A containing a thermoplastic polymer R1 lower than the melting point of the other fibers, and the thermoplastic polymer R1 allows the fibers A to be inter- and between the fibers A and the fibers A. It is characterized in that it is substantially adhered at a part of the contact points with other fibers, and at least one surface of the fiber molded body contains and contains a flame retardant. Further, the soundproof wall of the present invention is characterized by being configured using such a sound absorbing fiber molded body.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a sound-absorbing fiber molded article of the present invention will be described in detail with reference to the drawings and using examples.

FIG. 1 is a schematic perspective view schematically showing an example of a fiber arrangement in a block shape of the sound-absorbing fiber molded article of the present invention.

The sound-absorbing fiber molded product is a fiber molded product composed of at least two types of fibers, and one type of the constituent fibers contains a thermoplastic polymer R1 having a melting point lower than that of the other fibers. And the fibers A are substantially adhered and fixed between the fibers A and at some of the contact points between the fibers A and other fibers. In view of the shape retention and durability of the sound-absorbing fiber molded article, the content of the fiber A is 20% by weight or more,
It is preferred to be less than 0% by weight. Particularly, the range of 20 to 50% by weight is preferable.

The fiber A is preferably composed of the two components of the thermoplastic polymer R1 and the thermoplastic polymer R2, and has little form stability and little dust generation due to friction or rubbing action during use of the fiber molded article. From the viewpoint, the thermoplastic polymer R2
A core-sheath type composite fiber having a core as the component and a sheath as the thermoplastic polymer R1 component is particularly preferable. Thermoplastic polymer R1
Examples thereof include polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, polyolefin such as ethylene vinyl acetate copolymer or olefin copolymer, polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, polyhexamethylene terephthalate At least one polymer selected from thermoplastic polymers such as polyesters such as isophthalate and copolyesters can be used. Although the thermoplastic polymer R2 is not particularly limited, for example, polyethylene terephthalate, poly (ethylene terephthalate) having terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component, A polyester such as butylene terephthalate or polyethylene 2,6-naphthalate can be used.

When the fiber A is of a nylon type, for example, the thermoplastic polymer R2 component is nylon 6, and the thermoplastic polymer R1 component is nylon 6 copolymerized with nylon 66 to lower the melting point. It is possible.

In selecting the thermoplastic polymer R1, R
The melting point of one is lower than the melting points of the other fibers. Also,
The melting point of R1 is preferably lower than the lowest melting point among the fibers other than the fiber A and the thermoplastic polymer R2 from the viewpoint of thermal adhesiveness, and is preferably 20 ° C. or more from the viewpoint of thermal adhesiveness. It is more preferable that the temperature is lower by 50 ° C. or more.

The melting point of R1 is preferably in the range of 80 to 170 ° C., and more preferably in the range of 100 to 170 ° C., from the viewpoint of improving the bonding effect and preventing thermal deterioration. .

The weight ratio represented by R1 / R2 in the fiber A is preferably in the range of 20/80 to 60/40 from the viewpoints of shape retention, durability and cost of the sound absorbing fiber molded article. . In addition to the pigments such as titanium oxide and carbon black other than R1 and R2, an antioxidant, an anti-coloring agent, a light-proofing agent, an antistatic agent and the like may be added to the fiber A as required. Such a fiber A can be produced by an ordinary composite spinning method.

Next, in order to improve the sound absorption of the fiber molded article of the present invention, the fiber A preferably has a mechanical crimp or the like. The number of crimps is preferably 3 to 10 peaks / 25 mm, and the degree of crimp is preferably in the range of 5 to 30%.
In order to further improve the sound absorbing property, the fineness of the fiber A is preferably small, but from the viewpoint of processing stability in the manufacturing process of the sound absorbing fiber molded article, 0.2 to 30 denier, and the fiber length is 10 to 10.
Short fibers of 100 mm are preferably used.

The other fibers constituting the fiber molded article of the present invention are not particularly limited, but those which are easily heat-fused with the thermoplastic polymer R1 of the fiber A are preferable. further,
In order to improve the sound absorbing property, it is preferable that other fibers also have a mechanical crimp or the like, and the number of crimps is 3 to 10 peaks / 2.
5 mm and the degree of crimp are preferably in the range of 5 to 30%. Also,
In order to improve the sound absorbing property, other finenesses are preferably fine, but from the viewpoint of processing stability in the manufacturing process of the sound absorbing fiber molded article, 0.2 to 30 denier, and the fiber length is 10 to 100.
mm short fibers are preferably used.

The fiber arrangement of the fibers A and other fibers in the sound-absorbing fiber molded body is improved in a plane parallel to the surface of the sound-absorbing fiber molded body as shown in FIG. Must be arranged in random directions. Further, it is more preferable that the fibers are arranged in a random direction within a plane parallel to the plane Irohani of the sound absorbing fiber molded article, and the fiber axis direction is arranged substantially parallel to the plane Irohani of the sound absorbing fiber molded article. In general, when a fiber is used as a sound absorbing material, it is said that the sound absorbing material has a higher density, a larger thickness, and a finer fineness of the constituent fibers, so that a better sound absorbing property is exhibited. However, the density, thickness, and fineness of the constituent fibers of the sound absorbing material are naturally limited depending on the processing stability in the manufacturing process, the cost, or the place of use. In the sound-absorbing material of the same density, thickness and fineness of the constituent fibers, by arranging the fiber array in a random direction in a plane parallel to the surface of the sound-absorbing material as described above, for example, wrapping the fiber on a card to form a web, As compared with a web obtained by laminating the webs, fibers exhibiting excellent sound absorbing properties are exhibited.

The sound absorption coefficient is preferably high (100%) in the human audible frequency band. However, among the audible frequencies measured by the method described later, when the sound absorption coefficient is 400 Hz as a representative value at a low temperature and the sound absorption coefficient is 30% or more. It is preferable that the high-pitched sound has a typical value of 1000 Hz and a sound absorption coefficient of 70% or more. If the sound absorption coefficient is less than 30% at 400 Hz, the sound absorption of low sound tends to be low, and a sufficient sound absorption effect of low sound tends to be hardly obtained. If the sound absorption coefficient is less than 70% at 1000 Hz, the sound absorption of high sound is low and sufficient. It tends to be difficult to obtain a high-pitched sound absorbing effect.

The sound-absorbing fiber molded article of the present invention is characterized in that the flame retardant is attached to the surface of the fiber molded article. In the production method, the flame retardant is applied after producing a fiber molded body.

Examples of such flame retardants include tricresyl phosphate, tris 2-chloroethyl phosphate, tris 2,4,6 tribromophenyl phosphate, hexabromocyclododecane, halogenated phenylglycidyl ether derivatives, vinylphosphonic acid, triallyl Phosphorus compounds such as phosphates, halogen compounds and inorganic flame retardants can be used, but are not limited thereto.

Among such flame retardants, an aliphatic cyclic phosphonate represented by the following chemical formula can be easily exhausted into the interior of the fiber molded article by simply adhering to the surface of the fiber molded article and simply subjecting to heat treatment. In addition to this, it is possible to provide a product having both excellent flame retardancy and water repellency, which is excellent in compatibility with a water repellent and does not impair the water repellency of the water repellent. Therefore, it is preferably used.

[0020]

Embedded image Such a flame retardant is preferably 1.5% by weight in the fiber molding.
Above, more preferably 2% by weight or more is preferable in terms of performance. Such a flame retardant made of a phosphorus compound does not generate a harmful gas such as a halogen compound at the time of combustion, and is therefore preferable from the viewpoint of environmental protection.

As the water repellent used in combination with the flame retardant, a fluorine water repellent, a silicon water repellent, or the like is preferably used. As the fluorine-based water repellent, for example, those used as water- and oil-repellents such as polypentadecafluorooctyl acrylate, polytrifluoroethyl acrylate, and tetrafluoroethylene-hexafluoropropylene are preferably used. Examples of the silicon-based water repellent include dimethylpolysiloxane, a hydroxyl group at a molecular terminal or a side chain of dimethylpolysiloxane,
Those used as water repellents, softening agents and leveling agents, such as polysiloxane compounds modified by introducing amino groups, epoxy groups or polyether groups, are preferably used. These water repellents can be used alone or in combination of two or more. Such a water repellent is preferably contained in the fiber molded body in an amount of preferably 0.5% by weight or more, more preferably 1% by weight or more. If the amount of the water repellent is less than 0.5% by weight, the water repellency in outdoor exposure tends to be poor.

As a method for applying a fiber molding using such a flame retardant or a treatment liquid containing the flame retardant and a water repellent, post-processing such as putting, dipping, spraying, and coating may be used. Can be adopted. The heat treatment in the present invention means a dry heat treatment or a wet heat treatment. The wet heat treatment includes a steam treatment. As the steam processing, normal pressure saturated steam processing, heating steam processing, high pressure steam processing, and the like can be employed. Temperature of dry heat treatment or wet heat treatment is 80 ~ 200 ℃
Position is preferred. If the heat treatment temperature is lower than 80 ° C., the durability of the flame retardant performance tends to be insufficient.
If the temperature exceeds 0 ° C., yellowing and deformation embrittlement of the fiber molded body tend to occur. Note that other chemicals such as a softening agent, a water absorbing agent, an antistatic agent, and a hard finishing agent may be added to the treatment liquid.

The cross-sectional shape of the fiber constituting such a fiber molded article may be a round cross-section, a polygonal, multi-leaf, elliptical or other irregular cross-section, or a hollow cross-section thereof.

The sound-absorbing fiber molded article of the present invention is characterized in that a flame retardant is contained on at least one surface. It is more preferable that the front surface (hexagon) contains a flame retardant, but it is sufficient if the flame retardant is contained on at least one outer surface in terms of productivity, cost and the like.

The fiber molded article of the present invention can be used as a soundproof wall. That is, the product of the present invention can be used as a soundproof wall or a sound absorbing material for noise suppression in vehicles, houses, factories, karaoke boxes, highways, high speed railways, and the like.

Next, a method for producing the sound-absorbing fiber molded article of the present invention will be described. FIG. 1 is a schematic longitudinal sectional view schematically showing a mold of an apparatus used in an example of the method for producing a sound-absorbing fiber molded article of the present invention.

A cotton feeder, a cotton blender, or a fiber opening machine using at least two types of fibers containing at least the fiber A in a usual spinning process is blended and spread to a desired blending ratio, and aeration according to the purpose is performed. The mold is blown and filled together with a gas such as an air flow by a cotton fan.

For filling by blowing, it is preferable that the mold has appropriate air permeability. For example, JIS L
As measured by a 1079-1966 Frazier type air permeability tester, the air permeability is 5 to 200 cc / cm ² ···
The range of sec is preferable.

As such a mold, for example, an upper mold 2 and a lower mold 1 using a punched metal plate shown in FIG.
Can be used.

As a method of blowing into the air-permeable lower mold 1, first, at least two or more types of fibers including the fiber A are mixed, opened, and blown from the blowing port 3. Next, the filling fiber is compressed with the air permeable upper mold 2 and the air permeable upper mold 2 is formed at a desired density.
Is compressed and fixed. Further, the compression-fixed fibers are heat-treated together with the air-permeable mold to substantially adhere some of the contact points between the fibers A and between the fibers A and other fibers to fix the form. The temperature of the heat treatment is the thermoplastic polymer R of the fiber A.
Any temperature may be used as long as it is a temperature at which No. 1 is melt-adhered. The thickness of such a sound-absorbing fiber molded body is preferably at least 1 cm, more preferably 2.5 to 5 cm. If it is less than 1 cm, the sound absorbing effect tends to decrease. Further, the fiber density may be appropriately selected according to the sound absorption target of the fiber molded body, but is preferably 0.01 to 0.1 g / c.
Those having a range of m ³ are preferred from the viewpoint of sound absorbing effect. If the fiber density is less than 0.01 g / cm ³ , the sound-absorbing fiber molded article tends to be too soft, resulting in poor form stability, and if the density exceeds 0.1 g / cm ³ , it tends to be disadvantageous in terms of cost. .

[0031]

Next, the present invention will be described in more detail with reference to Examples and Comparative Examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Sound absorption coefficient Measured in accordance with JIS A 1495, normal incidence sound absorption measurement method (in-tube method).

(2) Flame retardancy The carbonized area, residual flame time, residual dust time according to JIS L 1091 A-1 method, and the number of flame contact times according to JIS L 1091 D method were measured.

(3) Water repellency Measured according to JIS L 1092 (spray method).

(4) Fineness The fineness was measured according to the method of JIS L 1015-7-51A.

(5) Average fiber length (cut length) Measured according to JIS L 1015A method (staple diagram method). (6) Number of crimps and degree of crimp The number of crimps and degree of crimp are as defined in JIS L 1015-7-12.
-1 and JIS L1015-7-12-2.

(7) Density Fiber molded article for sound absorption (vertical: 20 cm, horizontal: 20 cm,
Thickness: 1 cm) in an atmosphere of 20 ° C. × 65% RH for 24 hours.
The weight (w) after being left for a time was measured and determined by the following equation.

Density (g / cm ³ ) = w / 400 Examples 1 to 3, Comparative Example 1 Ordinary polyethylene terephthalate having a melting point of 255 ° C. was made into pellets, a spinning temperature of 280 ° C., and a take-up speed of 135.
The undrawn yarn is spun at 0 m / min, the undrawn yarn is drawn at a draw ratio of 3 times, at a drawing bath temperature of 80 ° C., mechanically crimped with a crimper, cut to a cut length of 32 mm and cut at 175 ° C. Heat treated, about 2 denier, 4.3 crimps / 25
mm, a normal polyester fiber having a crimp degree of 26.1% was produced.

Separately, as the thermoplastic polymer R2, a normal polyethylene terephthalate having a melting point of 255 ° C. is used, and as the thermoplastic polymer R1, a polyethylene terephthalate-based polyester copolymerized with 40 mol% of isophthalic acid and having a melting point of 110 ° C. is used. Spinning temperature 285 ° C, take-off speed 1
350 m / min, weight ratio represented by R1 / R2 is 50/5
A thermoplastic polymer R2 as a core, and a thermoplastic polymer R2
An undrawn yarn of a concentric conjugate fiber having a sheath portion of 1 was spun, and the undrawn yarn was drawn at a draw ratio of 3 times at a drawing bath temperature of 80 ° C, and mechanically crimped with a crimper. In addition, 70
After drying with a heat setter at ℃, apply a finishing oil
The fiber A was cut to a cut length of 64 mm to produce a fiber A having a fineness of about 2 denier and a melting point of the surface layer of about 110 ° C.

The normal polyester fineness of 60% by weight and the fiber A are mixed with 40% by weight, and further mixed and opened with a roller card. It is blown into a lower mold having a size of × 1000 × 1000 mm together with an air flow, and compressed by an upper mold having a punched surface, and a packing density of 0.04 g / c.
m ³ and a thickness of 30 mm. Using a heat setter used for setting a spun yarn together with the mold filled with the fibers and compressed, heat setting was performed at 130 ° C. for 25 minutes to produce a sound absorbing fiber molded body. The sound-absorbing fiber molded product had a stable form, and the constituent fibers were arranged in random directions within a plane parallel to the surface of the sound-absorbing fiber molded product.

A treatment liquid having the composition shown in Table 1 was applied to the obtained fiber molded body by a spray method. That is, treatment liquids were used in which the mixing amounts of the aliphatic cyclic phosphonic acid ester flame retardant (flame retardant a) and Asahi Guard AG710 (fluorine water and oil repellent manufactured by Meisei Chemical Co., Ltd.) were changed.

The applying method is as follows.
kg / m ² and dry heat treatment at 130 ° C for 20 minutes.
A dry heat treatment was performed at 0 ° C. for 3 minutes, and the sample was subjected to evaluation. Table 1 shows the results
Shown in

In Comparative Example 1, the sound-absorbing fiber molded product produced in the example was subjected to evaluation without any treatment, neither flame-retardant treatment nor water-repellent treatment.

[0044]

[Table 1] As is clear from Table 1, the comparative example was inferior in all of the flame retardancy, water repellency and sound absorbing property to the sound absorbing fiber molded article of the example.

[0045]

According to the present invention, it is possible to provide a sound-absorbing material which is excellent in audible frequency band sound-absorbing properties and flame-retardant, and a soundproof wall made of the same.

[Brief description of the drawings]

FIG. 1 is a schematic vertical sectional view schematically showing a mold of an apparatus used in an example of a method for manufacturing a sound-absorbing fiber molded article according to the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas inlet 4: Fiber

Claims (11)

[Claims] 1. A fiber molded product comprising at least two types of fibers, wherein one of the constituent fibers of the fiber molded product contains a fiber A containing a thermoplastic polymer R1 lower than the melting point of other fibers. And at the contact points between the fibers A and at some of the contact points between the fibers A and other fibers by the thermoplastic polymer R1, and the surface of the fiber molded body A sound-absorbing fiber molded article characterized in that at least one surface thereof contains and contains a flame retardant. 2. The sound absorbing fiber molded article according to claim 1, wherein at least one surface of the fiber molded article has a water repellent attached thereto. 3. The sound-absorbing fiber molded article according to claim 1, wherein the constituent fibers are arranged in a random direction within one cross section of the fiber molded article. 4. The sound-absorbing fiber molding according to JIS A1
The sound absorption coefficient at 400 Hz measured according to 495 is 3
0% or more and the sound absorption coefficient at 1000 Hz is 7
The sound-absorbing fiber molded product according to any one of claims 1 to 3, which is 0% or more. 5. The fiber A is a core-sheath type conjugate fiber, wherein the core portion of the conjugate fiber is a thermoplastic polymer R2, and the sheath portion is the thermoplastic polymer R1. The sound-absorbing fiber molded product according to claim 1 or 2, wherein the melting point of the thermoplastic polymer R2 is higher than the melting point of the thermoplastic polymer R1. 6. The thermoplastic polymer R1 and the thermoplastic polymer R2 have a weight ratio of R1 / R2 of 20/80 to 60/60.
The fiber molded article for sound absorption according to claim 5, which is in a range of 40. 7. The thermoplastic polymer R1 may be 80 to 170.
7. The composition of claim 1, 2 or 5, wherein
The fiber molded article for sound absorption according to any one of the above. 8. The sound-absorbing fiber molded article is composed of 0.2 to 30 denier fiber.
The fiber molded article for sound absorption according to any one of the above. 9. The sound-absorbing fiber molded product according to claim 6, wherein the sound-absorbing fiber molded product is 0.01 to 0.5.
9. A fiber having a fiber density of 1 g / cm < ³ >.
The fiber molded article for sound absorption according to any one of the above. 10. The molded fiber for sound absorption according to claim 1, wherein
The sound-absorbing fiber molded product according to any one of claims 1 to 9, which has a thickness of 10 cm. 11. A soundproof wall comprising the sound-absorbing fiber molded product according to any one of claims 1 to 10.