KR100832351B1 - Noise absorbent carpet for vehicle - Google Patents

Abstract

A noise absorbent carpet for a vehicle is provided to absorb effectively noise of the vehicle by using a carpet layer, an air permeable adhesive layer, a non-woven fabric sound absorbing layer, and a porous elastic layer. A noise absorbent carpet(1) for a vehicle includes a carpet layer(11), a non-woven fabric layer(13), and a porous elastic layer(14). The carpet layer is formed by kneading a yarn selected from a group consisting of polyester, nylon, polypropylene, acryl, cotton, hemp, and wooly hair onto a sheet of non-woven fabric foam paper made of polypropylene or polyester. The carpet layer has a bottom surface which is back-coated by at least one material selected from a group consisting of ethylene vinyl acetate, styrene butadiene rubber, natural latex and polyethylene. The non-woven fabric layer is made of at least one material selected from a group consisting of polyester, polyamide, polyolefine, polyethylene, and polystyrene. The porous elastic layer is made of polyurethane. The non-woven fabric layer contains superfine fiber having a denier of 0.05 to 1.5 deci-tex. The superfine fiber has 30 to 100 weight percent to the total weight of non-woven fabric.

Description

Sound absorption carpet for car {NOISE ABSORBENT CARPET FOR VEHICLE}

The present invention relates to a sound absorbing carpet for automobiles, and more particularly to a sound absorbing carpet for automobiles consisting of a carpet layer, a breathable adhesive layer, a nonwoven sound absorbing layer, a porous elastic layer.

Carpets are installed in automobiles to block noise and vibration from the outside.

The noise flowing into the vehicle may include noise generated by an engine while driving, noise generated by contact between a tire and a road surface, and noise generated by friction between the wind and the vehicle while driving. In order to improve such noise, a technology for improving sound insulation performance and a sound absorption performance have been developed in a vehicle, and in recent years, in order to absorb noise introduced into a vehicle rather than sound insulation that blocks external noise. Technology is being developed.

Various methods have been attempted to introduce sound absorbing performance to automotive carpets, for example, by laminating non-woven sound absorbing layers through an adhesive film on the back side of carpet dough where piles are planted on the surface side and heat-pressing them so that they are bonded and integrated. It is known.

In addition, in order to shield external noise, a method of using a separate sound insulation material is mainly used. In this case, since a heavy weight sound insulation material is used, the weight of the vehicle body increases, fuel economy deteriorates, and cost increases.

As a prior art related to automobile sound absorbing carpet, Korean Patent No. 289318 discloses a porous spring layer formed of an open-open foam layer, an air composite layer between a vehicle body and a package assembly, and an open-open fibrous layer or fiber to reduce noise of a vehicle. A kit consisting of a porous hard layer formed of a / foam composite layer is described.

Korean Patent Laid-Open Publication No. 2003-0057388 describes a carpet in which the skin material layer and the nonwoven fabric sound absorbing layer are adhesively integrated through a breathable adhesive resin layer.

Korean Patent No. 553408 describes a dual structure carpet absorber comprising a carpet, a polyethylene film layer, a second stage sound absorber and a first stage sound absorber without using a heavy layer layer.

The present inventors have further developed this sound absorbing carpet for automobiles having improved sound absorption performance without using the heavy layer.

SUMMARY OF THE INVENTION An object of the present invention is to provide a sound absorbing carpet for automobiles having excellent sound absorption against noise coming from the outside of the vehicle.

In a sound absorbing carpet for automobiles composed of a carpet layer, a breathable adhesive layer, a nonwoven fabric layer and a porous elastic layer, a non-slip function and a non-slip function between the non-woven fabric layer and the material in contact with the sound absorbing carpet, which have a sound absorbing function and a shape retaining function as a backing material, and additionally It provides a sound-absorbing carpet for automobiles, characterized in that the use of a double structured backing material composed of a porous elastic layer showing a sound-absorbing function and the nonwoven fabric layer comprises microfiber fibers.

In the present invention, by the sound-absorbing carpet for automobiles manufactured by stacking non-woven fabric layers and porous elastic layers having different sound absorption rates and air permeability, it is possible to effectively absorb the interior noise of the vehicle and the noise coming from the outside.

According to a preferred embodiment of the present invention, in an automobile sound absorbing carpet comprising a carpet layer, a breathable adhesive layer, a nonwoven fabric layer and a porous elastic layer, a nonwoven fabric layer having a sound absorbing function and a shape retaining function as a backing material and a material in contact with the sound absorbing carpet are provided. A backing material having a double structure composed of a porous elastic layer exhibiting an anti-slip function and an additional sound absorption function is used, and the nonwoven fabric layer is characterized by including microfiber fibers.

According to a preferred embodiment of the present invention, tufts or needles of one kind selected from the group consisting of polyester, nylon, polypropylene, acrylic, cotton, hemp, and wool on a nonwoven fabric made of polypropylene or polyester Bonded by a ring, the bottom surface is a carpet layer back-coated with at least one selected from the group consisting of ethylene vinyl acetate, styrene butadiene rubber, natural latex and polyethylene; A nonwoven layer formed of at least one selected from the group consisting of polyesters, polyamides, polyolefins, polyethylenes, and polystyrenes with a nonwoven fabric; And a porous elastic layer made of polyurethane, and the nonwoven fabric layer provides a sound absorbing carpet for automobiles, characterized in that the microfiber having a single yarn fineness of 0.05 to 1.5 decitex is 30 to 100% by weight based on the total weight of the nonwoven fabric. .

According to another suitable embodiment of the present invention, at least one of the adhesive layer adhering the carpet layer, the nonwoven fabric layer and the porous elastic layer is formed by heating and melting a thermoplastic resin of irregular network structure.

According to another suitable embodiment of the present invention, at least one of the adhesive layers adhering the carpet layer, the first nonwoven fabric layer and the second nonwoven fabric layer is formed by pulverizing a mixture of the thermoplastic resin and the inorganic filler in powder form and then heating and melting The amount of the inorganic filler in the mixture of the thermoplastic resin and the inorganic filler is 1 to 10% by weight of the thermoplastic resin.

According to another suitable embodiment of the present invention, the nonwoven layer has a thickness of 0.5 to 20 mm, a surface density of 100 to 1,000 g / m 2, a damping coefficient of 0.2 to 0.8, and the porous elastic layer has a thickness of 1 to 50 mm. , Air permeability is characterized in that 10 ~ 70 cm 3 / cm 2 / sec.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

1 is a cross-sectional view of a sound absorbing carpet 1 for a vehicle according to an embodiment of the present invention.

Referring to FIG. 1, an automobile sound absorbing carpet according to the present invention includes a carpet layer 11, two adhesive layers 12, and a double structure sound absorbing layer, that is, a nonwoven fabric layer 13 and a porous elastic layer 14.

The present invention provides an automobile sound absorbing carpet that can effectively absorb the vehicle interior noise and the noise introduced from the outside by using a carpet including a sound absorbing layer having a double structure made of a nonwoven fabric material having a sound absorbing function and a porous elastic layer. .

In the sound absorbing carpet according to the present invention, the carpet layer 11 is not particularly limited and generally known carpet fabrics may be used.

Bubble fibers made of polypropylene, polyester, polyester / polypropylene, or mixed materials thereof include synthetic fibers such as polyester fibers, nylon fibers, polypropylene fibers, and acrylic fibers, or natural fibers such as hemp, cotton, and wool. Tufted yarns made of fibers, or those in which various fibers or yarns are mechanically bound by a needling process or bound by an adhesive or the like can be used. If necessary, the bottom surface of the carpet layer may be backcoated to 50 to 400 g / m 2 by using ethylene vinyl acetate (EVA), styrene butadiene rubber (SBR), natural latex, polyethylene, or a mixture thereof.

The nonwoven fabric layer 13 not only acts as a backing material of the shape-carrying function of the vehicle carpet, but also exhibits an effect of improving sound absorption. A nonwoven fabric having a thickness of 0.5 to 20 mm and a surface density of 100 to 1,000 g / m 2 is suitable. If the surface density is less than 100g / ㎡ the effect of contributing to the shape retention ability and sound absorption performance is low, and if it exceeds 1,000g / ㎡ excess weight of the vehicle parts is a problem, the surface becomes too hard and the sound absorption performance is also poor.

The nonwoven fabric layer 13 uses a nonwoven fabric of a single or mixed material such as polyester, polyamide, polyolefin, polyethylene, and polystyrene. The method for manufacturing the nonwoven fabric is not particularly limited, such as needle punch, spunlace, spunbond, and the like. Known methods can be used.

The fibers constituting the nonwoven fabric layer may be composed of fibers having a single yarn fineness of 0.05 to 20 decitex. One fiber may be used, and more preferably, the ultrafine fibers having a 0.05 to 1.5 decitex are 30% of the total weight of the nonwoven fabric. Take up ~ 100%. In this case, since the fibers of the general fineness and the ultrafine fibers are mixed, it is advantageous for the role of the backing material and the sound absorption performance. At this time, when the fineness of the fibers constituting the nonwoven fabric is less than 0.05 decitex, it is difficult to absorb low frequency noise, and the cushioning property is also lowered. On the other hand, exceeding 20 decitex is undesirable because it is difficult to absorb high frequency noise. Microfibers with 0.05 to 1.5 decitex can be polyester / polyamide split microfibers, polyester direct spun microfibers, electrospun microfibers, etc. These microfibers have noise in the range of 500 Hz to 2,000 Hz, which is the airborne noise in automobile interiors. Highly effective in exhibiting sound absorption performance.

The air permeability of the nonwoven fabric layer 13 thus prepared is 3 to 60 cm 3 / cm 2 / sec, and the sound absorption coefficient, which is a numerical value representing sound absorption performance, is 0.2 to 0.8.

The porous elastic layer 14 includes a sponge layer or foam foam layer made of synthetic rubber or polyurethane, etc. The formed porous elastic layer has a thickness of 1 to 50 mm and has an air permeability of 10 to 70 cm 3 / cm 2 / sec. to be. The porous elastic layer has a function of preventing slipping with the material in contact with the sound absorbing carpet and additionally dispersing and absorbing noise.

The adhesive layer 12 is positioned between the carpet layer 11 and the nonwoven layer 13, and each layer for bonding the nonwoven layer 13 and the porous elastic layer 14, and may be formed in various ways. A general industrial adhesive may be used and one thermoplastic resin selected from the group consisting of low melting point polyester, polyethylene, ethylene vinyl acetate, polypropylene and polyvinyl chloride may be attached while being laminated in a molten state. Alternatively, the thermoplastic resin may be applied in the form of powder or pellet, and then laminated by laminating two layers in a heat-melted state and then attached by passing the pressing roller.

In this case, the inorganic filler having a plate-like crystal structure such as porous silica or zeolite, or porous silica, zeolite, etc. is added to the thermoplastic resin to form a masterbatch, which is then pulverized into powder or used as a nonwoven fabric to heat the thermoplastic resin. It can improve the adhesive strength of the fusion bonding surface and improve breathability. The amount of inorganic material added is preferably 1 to 10% by weight of the thermoplastic resin. Since the porous inorganic filler has irregular surface and many fine protrusions, it acts as a kind of reinforcing material, and the surface adhesion between materials is improved, and if air gap is formed between the resin and the inorganic filler, the air permeability of the adhesive name can be expected to be improved. In addition, by using an inorganic filler such as mica having a plate-shaped crystal structure, there is an additional advantage that it is possible to reinforce the sound insulation degradation due to the absence of the sound insulating coating layer.

Another method of constituting the adhesive layer is to form a thermoplastic resin in the form of a thin nonwoven fabric or porous hot melt film of irregular mesh structure between the carpet layer 11 and the nonwoven layer 13, the nonwoven layer 13 and the porous elastic layer 14. After positioning, the two layers may be laminated in a heat-melted state, and then bonded by passing the pressing roller.

Due to the adhesive layer of the irregular mesh structure, it is possible to additionally absorb noise in the non-absorbed frequency region while passing through the nonwoven fabric layer, and the adhesive layer itself is breathable so that the sound absorbing performance of the entire carpet is not impaired.

Any one of the two adhesive layers may be formed in a mesh structure, and the remaining adhesive layers may be formed by applying a thermoplastic resin in the form of powder or pellets, or both adhesive layers may be formed in a mesh structure. In the case of forming the adhesive layers having different structures, the air permeability is secured and the frequency range of the absorbable noises is changed and the noises are dispersed due to the different structures, thereby providing more excellent sound absorption performance.

At this time, the amount of the thermoplastic resin used for the heat adhesion function is suitable 50 ~ 300g / ㎡. If the amount of the thermoplastic resin is less than 50g / ㎡ It does not indicate sufficient adhesive strength, but if it exceeds 300g / ㎡ Excessive weight of the vehicle parts is a problem, and the air-absorbing performance of the adhesive layer is lowered, sound absorption performance is lowered.

The nonwoven fabric layer and the porous elastic layer including the ultrafine fibers have different air permeability and sound absorption rate, and additionally, the structure of two adhesive layers can effectively absorb the noise inside the vehicle and the noise coming from the outside.

Since the sound absorbing carpet for automobiles of the present invention has excellent sound absorbing performance as described above, it can be used as a floor carpet or an auxiliary mat for automobiles, but it is not particularly limited to these applications.

Hereinafter, the present invention will be described in more detail with reference to Examples, but embodiments according to the present invention can be modified in many different forms, and the scope of the present invention is construed as being limited to the embodiments described below. Can not be done.

<Example 1>

1300den / 68fila nylon BCF yarn is dyed in a polyester spun nonwoven fabric with a surface density of 130g / m2, and the fabric is woven in the form of a flush pile so that the weight of the pile fiber is 9mm and 610g / m2. After processing, 80 g / m 2 backcoating was performed with ethylene vinyl acetate (EVA) latex.

The nonwoven fabric layer is made of 65den / 190fila direct spun polyester microfiber with a single yarn fineness of 0.3 decitex 50% of the weight and 50% of 75den / 36fila polyester fiber with a single yarn fineness of 1.9 decitex. A needle punch nonwoven fabric having 31 cm 3 / cm 2 / sec of air permeability, 0.32 of attenuation coefficient, and 0.32 of permeation rate was used.

As the porous elastic layer of the urethane material attached to the nonwoven fabric layer, one having a thickness of 1.5 mm, a surface density of 50 g / m 2, and an air permeability of 60 cm 3 / cm 2 / sec was used. Adhesion of the nonwoven fabric layer and the porous elastic layer was attached to the top of the nonwoven fabric layer by spraying polyethylene powder at 60 g / m 2 and heating by heating at 150 ° C. with hot air and then passing through a cold press roll while overlapping the porous elastic layer. The adhesion between the double structured backing layer and the carpet is dispersed by spraying polyethylene powder at 150g / m2 on the top of the nonwoven fabric layer, heated by 150 ℃ hot air, and melted. It was.

<Example 2>

Bonding between the double backing layer and the carpet is placed on the top of the non-woven fabric layer of polyethylene non-woven fabric of irregular net form on the non-woven fabric layer and then heated and melted by heating at 150 ℃ hot air, the carpet layer is passed through a cold press roll It manufactured like Example 1 except having attached.

<Example 3>

Bonding of the nonwoven fabric layer and the porous elastic layer was prepared in the same manner as in Example 1, except that the nonwoven fabric was bonded using a polyethylene nonwoven fabric having an irregular mesh form as in Example 2.

<Example 4>

Adhesion between the nonwoven fabric layer, the porous elastic layer, the backing layer and the carpet was prepared in the same manner as in Example 1 except for using a polyethylene nonwoven fabric in an irregular mesh form.

<Example 5>

It is heated and melted by the amount of powder or hot air, except that the polyethylene masterbatch containing 8 wt% of zeolite having an average particle size of 2.5 to 3.5 μm is used as the powder for bonding the nonwoven fabric layer and the porous elastic layer and the adhesion of the carpet and the nonwoven fabric layer. The method and the like were prepared in the same manner as in Example 1.

Comparative Example 1

The nonwoven fabric is composed of a needleless nonwoven fabric with a thickness of 2.5mm, a surface density of 500g / m2, a breathability of 37 cm3 / cm2 / sec, and a coiling coefficient of 0.25 using 100% single yarn of 75den / 36fila polyester fiber of 1.9 decitex. Except that manufactured in the same manner as in Example 1.

Comparative Example 2

It was prepared in the same manner as in Comparative Example 1 except that only the carpet layer and the nonwoven fabric layer were attached by removing the porous foam layer attached to the nonwoven fabric layer.

The breathability and sound absorption coefficient of the carpet produced through the above Examples and Comparative Examples are shown in Table 1 based on the following evaluation method.

<Evaluation of breathability>

The breathability evaluation of the nonwoven fabric material and the whole carpet was measured by the method of JISL1096-1999 (A method of 8.227.1) standard. The unit is expressed in cm 3 / cm 2 / sec and means the amount of air (cm 3) permeating 1 cm 2 unit area per second.

<Evaluation of sound absorption rate>

When the negative energy incident on the surface of the sound absorbing material is Ei and the negative energy reflected on the surface is Er, the sound absorption coefficient (α) is defined as follows.

 α = 1- (Er / Ei)

The sound absorption coefficient was measured by the reverberation chamber method measured in the reverberation chamber according to the KS F 2805 standard, which is a condition near random incidence, and the performance of the sound absorption coefficient was evaluated by the sound absorption coefficient. Noise Reduction Coefficient (NRC) is a value that represents the characteristic of sound absorption coefficient value in 500 ~ 2000Hz, which is the frequency range of air transmission noise flowing into the vehicle interior. It is an arithmetic mean value, the better the value is.

TABLE 1

division Nonwoven Layer Porous elastic layer Remarks Carpet full Breathability (cm 3 / cm 2 / sec) Attenuation coefficient Breathability (cm 3 / cm 2 / sec) Breathability (cm 3 / cm 2 / sec) Attenuation coefficient Example 1 31 0.32 60 50% each of microfiber and common yarn for nonwoven layer 26 0.60 Example 2 31 0.32 60 Bonding using a mesh-type polyethylene nonwoven fabric 28 0.62 Example 3 31 0.32 60 Bonding using a mesh-type polyethylene nonwoven fabric 27 0.62 Example 4 31 0.32 60 Bonding using a mesh-type polyethylene nonwoven fabric 30 0.65 Example 5 31 0.32 60 Adhesion using polyethylene powder containing inorganic filler 27 0.64 Comparative Example 1 37 0.25 60 100% normal yarn use for non-woven layer 31 0.53 Comparative Example 2 37 0.25 - Clear porous elastic layer 33 0.51

The damping coefficient, which is a numerical value of sound absorption performance, was obtained in Example 1, in which 50% of microfibers were used for the nonwoven fabric layer. It was higher and was excellent.

Example 2 is a case of using a non-woven polyethylene nonwoven fabric in the process of bonding the backing layer of the double structure and the carpet and Example 3 is an irregular mesh shape of the non-woven layer and the porous elastic layer of the double structure backing layer In the case of using the polyethylene nonwoven fabric of the present invention, since the air permeability of the adhesive surface was better than that of Example 1, the result of the improvement of the acoustic coefficient of the entire carpet was obtained. In the case of Example 4, where the nonwoven fabric of the double structured backing layer and the carpet and the nonwoven fabric layer and the porous elastic layer of the double structured backing layer were used in the irregular mesh type polyethylene nonwoven fabric, the highest acoustic coefficient was obtained. Excellent sound absorption can be obtained. In the case of Example 5 using the polyethylene powder mixed with an inorganic filler, the air permeability and the coefficient of attenuation were slightly improved than in the case of Example 1 without using the inorganic filler.

In Comparative Example 2, the attenuation coefficient was slightly reduced than that of Comparative Example 1 by removing the porous elastic layer bonded to the nonwoven fabric layer in Comparative Example 1.

Although the present invention has been described in detail only with respect to specific examples, it will be apparent to those skilled in the art that various changes and modifications can be made within the technical spirit of the present invention, and the present invention is directed to such modifications and variations. It is not limited.

In the present invention, by the sound-absorbing carpet for automobiles manufactured by stacking non-woven fabric layers and porous elastic layers having different sound absorption rates and air permeability, it is possible to effectively absorb the interior noise of the vehicle and the noise coming from the outside.

1 is a cross-sectional view of a sound absorbing carpet for automobiles according to the present invention.

Claims (6)

In car sound absorbing carpet, Tufted or needled yarns of one kind selected from the group consisting of polyester, nylon, polypropylene, acrylic, cotton, hemp and wool on a nonwoven fabric made of polypropylene or polyester, Carpet layer 11 back-coated with at least one selected from the group consisting of ethylene vinyl acetate, styrene butadiene rubber, natural latex and polyethylene, Non-woven fabric layer 13 formed of a nonwoven fabric of at least one selected from the group consisting of polyester, polyamide, polyolefin, polyethylene and polystyrene, and It consists of a porous elastic layer 14 made of polyurethane, The nonwoven fabric layer 13 is a sound absorbing carpet for automobiles, characterized in that the ultrafine fiber having a single yarn fineness of 0.05 to 1.5 decitex is 30 to 100% by weight based on the total weight of the nonwoven fabric. The method of claim 1, wherein at least one of the adhesive layer 12 for bonding the carpet layer 11, the nonwoven fabric layer 13, and the porous elastic layer 14 is bonded by heating and melting a thermoplastic resin nonwoven fabric having an irregular network structure. Car sound absorbing carpet, characterized in that. The method of claim 1, wherein at least one of the adhesive layer 12 adhering the carpet layer 11, the nonwoven fabric layer 13, and the porous elastic layer 14 is pulverized in a powder form after the mixture of the thermoplastic resin and the inorganic filler Sound absorbing carpet for automobiles, characterized in that formed by melting. 4. The sound absorbing carpet for automobiles according to claim 3, wherein the amount of the inorganic filler is 1 to 10% by weight of the thermoplastic resin in the mixture of the thermoplastic resin and the inorganic filler. The sound absorbing carpet for automobiles according to claim 1, wherein the nonwoven fabric layer (13) has a thickness of 0.5 to 20 mm, a surface density of 100 to 1,000 g / m 2, and a damping coefficient of 0.2 to 0.8. The method of claim 1, wherein the porous elastic layer 14 has a thickness of 1 to 50mm, the air-absorbing carpet for cars, characterized in that 10 ~ 70 cm 3 / cm 2 / sec.

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