KR100601401B1 - Sound insulation composition and material - Google Patents

Abstract

The present invention relates to a sound insulation composition and a sound insulation material produced by the sound insulation composition. The sound insulating composition and the sound insulating material according to the present invention are at least one synthetic resin selected from metallocene alpha olefin polyethylene, linear low density polyethylene (LLDPE) and acetate-based polymer, ethylene propylene rubber ( Synthetic resin mixture formed by mixing EPM, EPDM) and polypropylene (PP); It is characterized in that it comprises granular, acicular and plate-shaped inorganic fillers added to the mixture. Thereby, the sound insulation material which is light, excellent in vibration isolation and a sound insulation characteristic, and excellent in moldability and workability can be provided.

Thermoplastic Elastomer, EPDM, PP, Metallocene Alpha Olefin Polyethylene, LLDPE

Description

Sound insulation composition and its sound insulation material {SOUND INSULATION COMPOSITION AND MATERIAL}

1 is a partial cross-sectional view of the sound insulation material according to an embodiment of the present invention;

2 is a partial cross-sectional view of the sound insulation material according to another embodiment of the present invention;

3a and 3b is a partial cross-sectional view of the sound insulating material according to another embodiment of the present invention,

4a and 4b is a partial cross-sectional view of the sound insulating material according to another embodiment of the present invention,

5 is a view for explaining a method for manufacturing a sound insulating material according to the present invention.

* Explanation of symbols for main parts of the drawings

10: sound insulation layer 20: surface layer

30: ESTER film layer 40: NYLON film layer

The present invention relates to a sound insulation composition that blocks and reflects sound waves and prevents transmission of energy, and a sound insulation material using the sound insulation composition.

In general, sound insulation materials must maintain a certain level of specific gravity in order to exhibit sound insulation effects. In general, resins have a specific gravity of 1 or less, so that a high specific gravity filler is incorporated to increase the specific gravity of the sound insulating material. Therefore, in order to increase the sound insulation performance of the conventional sound insulation material, a heavy layer sound insulation material was used by incorporating a heavy material such as a hard filler into the resin mixture.

However, a heavy layer sound insulation material has a problem of being heavy, poor formability, poor workability, poor heat resistance, abrasion resistance, and environmental resistance. In addition, due to the relatively low elasticity, the damping characteristics were not good, and the sound absorption was poor.

In addition, some heavy layer sound insulation materials are added with ingredients such as APP (Atatic Polypropylene), but these components have an unpleasant odor and are not environmentally friendly.

Accordingly, an object of the present invention is to provide a sound insulation composition having low weight, excellent moldability and workability, and excellent sound insulation, vibration damping line, and dustproof performance, and a sound insulation material produced using the composition.

The object is, according to the present invention, at least one synthetic resin selected from metallocene alpha olefin polyethylene, linear low density polyethylene and acetate-based polymers (EEA, EVA, EAA), ethylene propylene A synthetic resin mixture formed by mixing rubber (EPM, EPDM) and polypropylene (PP); It is achieved by a sound insulating composition comprising a spherical, acicular and plate-like fillers added to the mixture and the sound insulating material produced by the sound insulating composition.

Here, the synthetic resin mixture and the filler is preferably made of a weight ratio of 2: 8 to 8: 2 relative to the total weight.

And, the sound insulating composition may be further prepared by further comprising 2 to 30 wt% of the total weight.

On the other hand, the synthetic resin mixture is made of ethylene propylene rubber (EPM, EPDM) 5 ~ 60wt%, polypropylene (PP) 5 ~ 40wt% and linear low density polyethylene (LLDPE) 5 ~ 60wt% based on the total weight of the resin mixture Can be,

5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 60 wt% of polypropylene (PP) and 10 to 60 wt% of metallocene alpha olefin polyethylene, or

20 to 70 wt% of ethylene propylene rubber (EPM, EPDM), 20 to 70 wt% of polypropylene (PP) and 5 to 20 wt% of Acetate Base Polymer (EEA, EVA, EAA).

In addition, the synthetic resin mixture is 5 to 60wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40wt% of polypropylene (PP), and acetate-based polymer (Acetate Base Polymer; EEA, EVA, EAA) 1 ~ 20wt% and metallocene alpha olefin polyethylene (Metallocene alpha olefin polyethylene) can be made of 10 ~ 60wt%,

5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40 wt% of polypropylene (PP), 1 to 20 wt% of Acetate Base Polymer (EEA, EVA.EAA) and linear low density polyethylene ( LLDPE) can be made of 5 ~ 60wt%,

5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40 wt% of polypropylene (PP), 10 to 60 wt% of metallocene alpha olefin polyethylene and linear low density polyethylene (LLDPE) 5 It may be made of ~ 60wt%.

The synthetic resin mixture may include 10 to 60 wt% of metallocene alpha olefin polyethylene, 5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), and polypropylene (PP) based on the total weight of the synthetic resin mixture. 5 ~ 40wt%, linear low density polyethylene (LLDPE) 5 ~ 60wt% and acetate-based polymers (Acetate Base Polymer; EEA, EVA, EAA) can be made of 0 to 30%.

On the other hand, the filler is 10 ~ 80wt% of granular inorganic fillers such as barium sulfate, calcium carbonate, fine silicate, silica sand, vermiculite, etc., and 1 ~ 50wt% of mica, iron oxide, kaolin clay, and the like based on the total weight of the filler. It is preferable that it consists of 1-50 wt% of needle fillers, such as sepiolite, wollastonite, and attapalzite.

The additive is preferably composed of 2 to 50 wt% of surfactant, 2 to 50 wt% of stabilizer, 2 to 50 wt% of pigment, and 0 to 30 wt% of flame retardant based on the total weight of the additive.

In addition, it provides a sound insulation material comprising a sound insulation layer manufactured using the sound insulation composition made by the above-described components and weight ratio.

Here, it is attached to either side of the sound insulation layer, 1 ~ 10wt% of at least one resin selected from EMA (Ethyl Methyl Acetate) and BMA (Bi Methyl Amine), and polypropylene (PP) 10 ~ 30wt And a surface layer molded using a composition comprising 5 to 20 wt% of polyethylene (PE), 10 to 60 wt% of ethylene propylene rubber (EPM, EPDM), and 10 to 30% wt of EAA. It is preferable to prepare.

The sound insulation material may be manufactured by selecting and attaching any one of an ester film layer and a nylon film layer to one surface of the sound insulation layer or the sound insulation material.

Hereinafter, the sound insulation composition of the present invention and a molded article manufactured using the composition will be described in detail with reference to the accompanying drawings.

Example 1

1 is a partial cross-sectional view of a sound insulation material according to an embodiment of the present invention. Synthetic resin, which is the main component of the composition of the present invention, is easy to mix so as to meet the object of the present invention among various kinds of synthetic resins, that is, suitable for producing molded articles of sheets, and it is preferable to select a material suitable for the rolling process.

The sound insulating material of the present invention is one or more synthetic resins selected from metallocene alpha olefin polyethylene, linear low density polyethylene (LLDPE) and acetate base polymer, ethylene propylene rubber (EPDM), polypropylene ( 20 to 80 wt% of a synthetic resin mixture containing PP); The sound insulation layer 10 is manufactured using the sound insulation composition containing 20-80 wt% of spherical, acicular and plate-shaped fillers. The component ratios of the resins forming the synthetic resin mixture are as described above.

Here, the metallocene alpha olefin polyethylene (Metallocene alpha olefin polyethylene) is a product synthesized elasticity compared to the conventional PE or LLDPE as a material synthesized PE and Octene or Butene. In particular, the metallocene alpha olefin polyethylene (Metallocene alpha olefin polyethylene) has a structure capable of high charging, but does not reduce the elasticity.

In addition, the linear low density polyethylene (LLDPE) is made of PE using a low pressure method, it is difficult to crystallize the linear polyethylene is obtained. Although softening point is low, it is lighter than water and has strong impact resistance. The propagation density polyethylene (LLDPE) is also characterized by having a high charge molecular structure. Thus, granular, plate- and needle-shaped inorganic fillers are filled to complement the sound insulation properties.

The ethylene propylene rubbers (EPM, EPDM) are amorphous polymer materials obtained by hybridizing ethylene and propylene. The ethylene propylene (EPM, EPDM) is chemically stable, and the vulcanized material exhibits an intermediate property between natural rubber and SBR. The elasticity of the sound insulating material produced depends on the addition ratio of the ethylene propylene rubber (EPM, EPDM).

Meanwhile, the polypropylene (PP) is a material obtained by polymerizing propylene. In the sound insulating material according to the present invention, the polypropylene (PP) acts as a matrix of the material, depending on the addition ratio of the polypropylene (PP). Is adjusted.

Finally, acetate-based polymers such as EAA (Ethyl Aceto Acetate), EEA (Ethylene Ethyl Acetate), and EVA (Ethyl Vinyl Acetate) include the ethylene propylene rubber (EPM, EPDM) and the polypropylene (PP). ) Makes the image of Homogeneous uniform. In other words, when a mixed composition is prepared by mixing different polymers at a certain ratio, it is difficult to form a uniform phase because the molecular phases are different. However, a coupling agent or commercialization that allows each component to be uniformly mixed to maintain the properties of each component. It acts like a compatibilizer.

As described above, the physical properties of the sound insulating material are changed as described above according to the blending ratio of each resin component. The reason for limiting the blending ratio of each resin is because the sound insulating material is a limit value for functioning as a sound insulating material while maintaining its original properties. to be.

In order to compensate for the sound insulation performance, 20 to 80 wt% of filler is added to the total weight, and the filler is uncontaminated with heavy metals, silica sand, vermiculite, barium sulfate, and calcium carbonate based on the total weight of the filler. 10 to 80 wt% of granular inorganic fillers such as 10 to 50 wt% of plate fillers such as kaolin clay, iron oxide and mica, and 10 to 50 wt% of needle fillers such as sepiolite, wollastonite and attapalzite. The reason why granular inorganic fillers are used more than plate-shaped or acicular inorganic fillers is that they are relatively inexpensive and do not significantly reduce the physical properties of the resin. Sound insulation materials used in automobiles and the like should generally satisfy the required conditions (physical properties). If manufactured only with the plate or needle filler, it is very difficult to satisfy the requirements (physical properties).

According to the present invention, by adding a needle and a plate-like filler to the sound insulating composition and the sound insulating material containing a thermoplastic elastomer, the performance loss due to the decrease in density, which is the biggest parameter in the sound insulation performance of the material is minimized . The addition of needle and plate fillers to the material increases the dispersibility and adsorption of the resin and material, making the material of the sound insulation material uniform, thus reducing the number of week points of the sound insulation material in the finished state, thereby reducing the noise, vibration and harshness. It has an internal structure that can improve the performance and effectively block any wave waves and particles of sound waves from any direction.

As described above, the resin system should not be added more than 80wt% with respect to the total weight. Sound insulation means a material with a high specific gravity, that is, a heavy layer. Usually, the specific gravity should be in the range of 1 to 2.5. Since most of the polymer resin is a substance having a specific gravity of 1 or less, if the resin system exceeds 80wt% based on the total weight, it cannot have a specific gravity to function as a sound insulating material. In addition, in order to satisfy the specific gravity required as the sound insulating material, the above-mentioned granular, plate and needle-shaped inorganic fillers in the specific gravity range of 2 to 4 are added. It is important to effectively fill the resin with the filler and to prepare a sound insulation material having a reasonable manufacturing cost. So they choose a low-cost resin that can be filled at a reasonable price with high filling. These resins are the metallocene alpha olefin polyethylene, linear low density polyethylene (LLDPE) and acetate polymer (Acetate base) polymer), ethylene propylene rubber (EPM, EPDM), polypropylene (PP).

2 to 50 wt% of the surfactant based on the total weight of the additive to selectively compensate for the sound insulating composition of the present invention, such as heat resistance and flame resistance of the sound insulating material; By using an additive including a stabilizer 2 ~ 50wt%, a pigment 2 ~ 50wt% and a flame retardant 0 ~ 30wt% based on the total weight can be prepared the sound insulation layer 10 with a functional supplement. The additive may be added by adding a plasticizer, antioxidant, etc. according to the needs of the consumer.

The preparation of the sound insulating layer is sufficiently mixed with the mixture of the resin-based and filler-based systems or the mixture of the resin-based, filler-based and additives into the reactor until it becomes uniform using a mixer or mixing roller at a temperature of 100 ° C to 150 ° C. Obtain the composition of the invention. The obtained composition is extruded and rolled to obtain a sound insulating layer 10 that is a molded article.

Example 2

Figure 2 is a partial cross-sectional view of the sound insulating material according to another embodiment, a method of laminating the surface layer 20 on any one surface of the sound insulating layer 10, which is a molded article excellent in sound insulation performance manufactured by [Example 1] The sound insulation sheet is manufactured by integrating the surface layer 20 and the sound insulation layer 10.

Since the manufacturing of the sound insulation layer 10 is the same as the above [Example 1], a detailed description thereof will be omitted. The surface layer 20 is to enhance the vibration damping function and to reduce the weight and sound insulation of the vehicle sound insulation material. The sound insulation sheet manufactured as described above not only enhances sound insulation and vibration damping per unit weight, but also has a characteristic of reducing high weight, which is the biggest problem of the conventional heavy layer sound insulation material. In addition, the surface layer may be manufactured and used as the bottom surface to prevent the contamination of the bottom surface of the vehicle, such as trucks or vans, and to facilitate the cleaning.

The surface layer 20 is 10 to 30wt% polypropylene (PP) based on the total weight; 5-20 wt% polyethylene (PE); 10-40 wt% ethylene propylene rubber (EPM, EPDM); 10 to 30 wt% Ethyl Aceto Acetate (EAA); 1-10 wt% of at least one resin selected from BMA (Bi Methyl Amine) and EMA (Ethyl Meth acrylate) is placed in a reactor and sufficiently mixed until it becomes uniform using a mixer or mixing roller at a temperature of 100 ° C to 150 ° C. Obtain the composition of the present invention. The obtained composition is extruded and rolled to produce a surface layer 20, and then laminated on either side of the sound insulation layer 10, and then the sound insulation layer 10 and the surface layer 20 are integrated in a thermally fused manner. do.

Example 3

3A and 3B are partial cross-sectional views of a sound insulation material according to still another embodiment of the present invention. Since the manufacturing of the surface layer 20 and the sound insulation layer 10 is the same as in [Examples 1 and 2], a detailed description thereof will be omitted. 3A shows the addition of the ESTER film layer 30 to one side of the sound insulation layer 10, and FIG. 3B shows the addition of the NYLON film layer 40 in contact with either side of the sound insulation layer 10. The ESTER film layer 30 and NYLON film layer 40 has a higher melting point than the sound insulating material of the present invention serves as a reinforcing material to minimize the unwanted deformation (shrinkage and expansion) of the material that may appear during secondary molding. Other manufacturing processes of the sound insulating material are the same as in [Examples 1 and 2], so a detailed description thereof will be omitted.

Example 4

Figures 4a and 4b is a partial cross-sectional view of the sound insulation material according to another embodiment of the present invention. Since the manufacturing of the sound insulation layer 10 is the same as in [Example 1], a detailed description thereof will be omitted. FIG. 4A shows the addition of the ESTER film layer 30 in contact with one surface of the sound insulation layer 10 manufactured according to [Example 1], and FIG. 4B shows the NYLON in contact with one surface of the sound insulation layer 10. The film layer 40 is added. The function of the ESTER film layer 30 and the NYLON film layer 40 is the same as described in [Example 3]. Other manufacturing process of the sound insulating material is the same as the previous embodiment, so a detailed description thereof will be omitted.

The above embodiment specifically describes a preferred embodiment of the present invention, and the present invention is not limited to the embodiment, and may be combined with other sound absorbing materials or sound insulating materials.

The properties of the material of the present invention are largely divided into two types: resin type and inorganic filler (filler) type. The resin-based properties of the metallocene alpha olefin polyethylene, ethylene propylene rubber, polypropylene, linear low-density polyethylene is composed of a homogeneous (Homogeneous) form without phase separation. This means that the properties of synthetic resins in products are complementary. The composition of the present invention is excellent in thermal or aging resistance, ozone resistance, impact strength, excellent in crystalline or partial crystallinity, long-term initial physical properties, external chemical factors such as vibration, moisture, chemicals, etc. Show temper

In addition, according to the composition change of the inorganic filler added in a chemically high chargeable structure, the specific gravity of the composition is changed to the range of 1.0 to 2.5, and the production of the product is possible, thereby providing a product suitable for the needs of the customer. Thus, the present invention provides a sound insulation composition and its molded article capable of manufacturing the product in accordance with the elongation, tensile strength, specific gravity and hardness to meet the specifications required in the final product.

5 is a view for explaining a method for manufacturing a sound insulating material of Example 3 according to the present invention. The sound insulating material different from the above [Example 3] has better sound insulation and vibration isolation performance, formability, and processability than the sound insulating material manufactured by other components and component ratios. As shown in the figure, the mixture containing the synthetic resin, filler and additives described in detail above are sufficiently mixed using a mixer or a mixing roller (S10). Extruding the kneaded composition to form the sound insulating layer (10) (S20), after laminating the surface layer 20 prepared on any surface of the sound insulating layer 10 to be extruded and transported by heat-sealing the surface layer 20 And the sound insulation layer 10 is integrated (S30). Any one selected from the ESTER film layer 30 and the NYLON film layer 40 is laminated on one surface of the sound insulation layer 10 (S40). When the sheeting of the sound insulating material is completed, it is cut to a predetermined size so as to correspond to the installation surface (S50). The cut sound insulating material is placed in a mold corresponding to the shape of the mounting surface, and heated and pressed to form a predetermined shape corresponding to the shape of the mounting surface (S60). The manufacturing method is the manufacturing method of Figures 3a and 3b, except for a part of the manufacturing process of the manufacturing method of any one of Examples 1, 2 and 4.

As described above, according to the present invention, a sound insulation composition having light weight, excellent vibration isolation and sound insulation characteristics, and excellent moldability and workability and a sound insulation material using the sound insulation composition are provided.

Claims (16)

In the sound insulation composition, At least one synthetic resin selected from metallocene alpha olefin polyethylene, linear low density polyethylene (LLDPE) and acetate base polymer, ethylene propylene rubber (EPM, EPDM) and polypropylene (PP) Synthetic resin mixture made by mixing; Granular, acicular and plate-shaped inorganic fillers added to the mixture, The synthetic resin mixture and the inorganic filler is a sound insulating composition, characterized in that mixed in a weight ratio of 2: 8 to 8: 2. delete The method of claim 1, The sound insulating composition, characterized in that it further comprises 2 to 30wt% of the total weight. The method of claim 1, The synthetic resin mixture is composed of 5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40 wt% of polypropylene (PP) and 5 to 60 wt% of linear low density polyethylene (LLDPE), based on the total weight of the synthetic resin mixture. Sound insulation composition. The method of claim 1, The synthetic resin mixture is 5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 60 wt% of polypropylene (PP) and metallocene alpha olefin polyethylene 10 to 9 to the total weight of the synthetic resin mixture. Sound insulating composition, characterized in that consisting of 60wt%. The method of claim 1, The synthetic resin mixture is composed of 20 to 70 wt% of ethylene propylene rubber (EPM, EPDM), 20 to 70 wt% of polypropylene (PP) and 5 to 20 wt% of an acetate base polymer based on the total weight of the synthetic resin mixture The sound insulation composition characterized by the above-mentioned. The method of claim 1, The synthetic resin mixture is 5 to 60 wt% of ethylene propylene rubber (EPDM), 5 to 40 wt% of polypropylene (PP), 1 to 20 wt% of acetate base polymer, and metallocene, based on the total weight of the synthetic resin mixture. Sound insulation composition, characterized in that made of alpha-olefin crab polyethylene (Metallocene alpha olefin polyethylene) 10 ~ 60wt%. The method of claim 1, The synthetic resin mixture is 5 to 60wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40wt% of polypropylene (PP), 1 to 20wt% of acetate base polymer and linear to the total weight of the resin mixture Sound insulation composition, characterized in that consisting of low density polyethylene 5 ~ 60wt%. The method of claim 1, The synthetic resin mixture is 5 to 60 wt% of ethylene propylene rubber (EPM, EPDM), 5 to 40 wt% of polypropylene (PP), and metallocene alpha olefin polyethylene (10) based on the total weight of the synthetic resin mixture. Sound insulating composition, characterized in that consisting of ~ 60wt% and linear low density polyethylene 5 ~ 60wt%. The method of claim 1, The synthetic resin mixture is 10 to 60 wt% of metallocene alpha olefin polyethylene, ethylene propylene rubber (EPM, EPDM) 5 to 60 wt%, and polypropylene (PP) 5 based on the total weight of the synthetic resin mixture. Sound insulating composition, characterized in that consisting of ~ 40wt%, linear low density polyethylene (LLDPE) 5 ~ 60wt% and acetate based polymer (Acetate base polymer) 0 ~ 30%. The method of claim 1, The filler is 10 to 80 wt% of granular inorganic fillers of barium sulfate, calcium carbonate, fine silicate, silica sand and vermiculite, 10 to 50 wt% of mica, iron oxide and kaolin clay, and sepiolite, based on the total weight of the filler. Sound insulation composition comprising at least one filler from 10 to 50wt% of wollastonite and attapalzite needle filler. The method of claim 3, The additive is a sound insulating composition, characterized in that consisting of 2 to 50wt% surfactant, 2 to 50wt% stabilizer, 2 to 50wt% pigment and 0 to 30wt% flame retardant based on the total weight of the additive. A sound insulation material comprising a sound insulation layer molded by any one of claims 1 to 3. The method of claim 13, Attached to either side of the sound insulation layer, 1 to 10 wt% of at least one resin selected from EMA (Ethyl Methyl Acrylate) and BMA (Bi Methyl amine), 10 to 30 wt% of polypropylene (PP), 5 to 20 wt% of polyethylene (PE), A sound insulating material produced by attaching a surface layer molded using a composition comprising an ethylene propylene rubber (EPM, EPDM) 10 ~ 60wt% and EAA (Ethyl Aceto Acetate) 10 ~ 30% wt. The method of claim 13, Sound insulating material, characterized in that manufactured by selecting any one of the ester film layer (ESTER film) and nylon film (NYLON film) layer attached to any one surface of the sound insulation layer. The method of claim 14, The sound insulation material manufactured by selecting and attaching any one of an ester film layer and a nylon film layer to one surface of the sound insulation material.

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