KR20030022552A - A sound absorbing and insulation material for automobile and method thereof - Google Patents

Abstract

PURPOSE: A noise absorbing/isolating material for a vehicle and manufacturing method thereof is provided to promote the efficiency of noise absorption/isolation by improving the distribution of low melting fiber. CONSTITUTION: A noise absorbing/isolating material for a vehicle is composed of a top layer(21), an inner layer(22), and a bottom layer(23), and is made of polyester staple fiber and low melting binder fiber. The inner layer(22) has a minute porosity laminated structure by polyester with 0.5-3 denier.

Description

A sound absorbing and insulation material for automobile and method

The present invention relates to a sound absorbing and insulating material and a method of manufacturing the same. More specifically, the present invention relates to a sound absorbing and insulating material suitable for an interior portion of a vehicle engine room (Dash Inner, Dash Inner).

As the industrial civilization is advanced, in recent years, the general environment required for automobiles is rapidly progressing in order to maintain a light and comfortable and quiet indoor environment in accordance with international nature-friendly environment. In particular, NVH (Noise, Vibration, Hashness) technology that blocks or inhales and extinguishes noise and vibration generated in high temperature and high frequency areas in the engine room in the process of inflowing into the interior of a car, In terms of cost saving and recyclability, it is emerging as the most important field of automobile noise and vibration technology.

The sound absorbing and insulating material that has been used in the past has been used as a raw material of resin felt, foamed urethane foam, PET felt, etc., but resin felt has already been limited in use due to phenol resin dust, gas, odor, etc. In the case of expensive and heavy, dioxin generation and recycling during combustion, there is a problem, the normal felt PET felt is less sound-absorbing power, the sound insulation plate is bonded to the trimming process of the fiber to damage the epidermis of the fiber to be temporarily reheated There was a problem.

In addition, as shown in FIG. 1, the sound absorbing and insulating material used in the related art is not limited depending on the material properties, but is structurally formed in a straight line without division. There was.

Therefore, in order to satisfy the demand, the present invention uses polyester, which is a material that does not cause environmental pollution, and forms a sheet with a fine porous structure by fineness for the purpose of improving sound absorption effect. In order to prevent the fiber surface from being damaged in the process of pressing, pressing and trimming, it is divided into upper layer, inner layer and bottom layer. In order to improve the quality of the upper layer, the fine layer of the top layer is cleanly treated by heat treatment, thereby reducing the manpower and time required to partially reprocess the damaged surface after the trimming process with a torch.

Accordingly, it is an object of the present invention to provide a sound absorbing and insulating material for automobiles and a method of manufacturing the same to improve the distribution of low melting point fibers in order to overcome such conventional technical limitations.

Another object of the present invention is to form a microporous structure in which the sound energy of the incident sound waves generated in the high frequency region passes through the inner layer formed of the upper layer and the microporous structure and is mostly converted into thermal energy by friction to be easily absorbed and extinguished. To provide a sound absorbing and insulating material for automobiles and its manufacturing method.

Still another object of the present invention is to provide a sound absorbing and insulating material for automobiles and a method of manufacturing the same by improving the finishing treatment method by heat treatment of the epidermis and the like.

In order to achieve the above object, the sound absorbing and insulating material of the present invention is composed of an upper layer, an inner layer, and a bottom layer, and is made of polyester staple fiber and low melting point binder fiber as a raw material, and the inner layer has a fiber structure of 0.5 to 3 denier or less. The low melting binder fiber is composed of fine porous laminated structure by ester, and the low melting point binder fiber is any one selected from fineness 2-6 denier, mono PP (Polypropylene), Cisco core PET / PE, PET / COPOLYESTER, and melting point 110-170. Use a mixture in the range of ℃ 20 ~ 50%

The upper layer is composed of PET 3 ~ 6D x 51mm 60 ~ 70% and low melting point binder fiber 2 ~ 4D 30 ~ 40%, the inner layer is a flat section PET 2D 40 ~ 60%, conjugate 3D 20 ~ 30 %, Low melting point binder fiber 2 ~ 4D 30 ~ 40%, the bottom layer is composed of PET 1.5 ~ 4D 60 ~ 80% and low melting point binder fiber 2 ~ 4D 20 ~ 40%,

The manufacturing method of the present invention is a fibrous thin film state through the mixing and carding process to release the raw material in the compressed state and mix by their type to facilitate spinning, and a card machine formed of large and small cylindrical cylinders uniformly mixed and opened fiber A carding process for forming a web, a molding process for laminating the web several times with a predetermined width and weight using a molding machine, a heat treatment process for giving strength by thermally setting the laminated web, and cutting to a certain standard It includes the process and consists of forming a bulky web structure of microporous by using a semi-random card machine in the carding process and using a separate super opening to improve the carding ability of the low melting point fibers before the mixing and carding process In addition to the carding treatment, the mixing and carding process includes a hopper feeder and a combined vibra chute feeder. Secondary horn and carding process is performed by the super cleaner, and after the heat treatment process, the surface of the upper layer is heat treated with a separate heating roll to reinforce the peeling resistance of the upper layer.

1 is a view showing a conventional fiber array cross section,

2 is a view showing a porous web laminate structure of a random structure according to the present invention,

Figure 3 is a view showing a flow chart of the production of sound absorbing and insulating material of the present invention,

4 is a view showing a comparison of sound absorption measurements.

* Description of the symbols for the main parts of the drawings *

21: upper layer 22: inner layer

23: bottom layer 100: super opening

200, 210, 220: Hopper feeder 300, 310, 320: Vibra suit feeder / super cleaner

400, 410, 420: Semi-random card machine 500, 510, 520: Molding machine

600: oven 610: cooling unit

700: cutting part

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

2 is a view showing a porous web laminate structure of a random structure according to the present invention.

Sound absorbing and insulating material according to the present invention has a three-layer structure consisting of an upper layer, an inner layer and a bottom layer. The upper layer is used to finish the surface only with a heating press roll in order to prevent the problem of peeling after the press operation. Preferably, the upper layer is PET 3 ~ 6D x 51mm 60 ~ 70%, using a low melting point binder fiber 2 ~ 4D 30 ~ 40% is preferably composed of a unit weight of 0.2 ~ 0.3kg / m².

The inner layer is a PET fiber used as having a microporous structure, the release cross-section fiber and the conjugate hollow type (Conjugate Hollow Type) mainly by the three (되도록) denier to be adopted within the range of 70 ~ 80%. Preferably, the inner layer is composed of PET 2D 40 ~ 60% of the flat cross section, conjugate 3D 20 ~ 30%, low melting point binder fiber 2 ~ 4D 30 ~ 40% unit weight 0.6 ~ 0.8kg / m² It is good to configure.

The bottom layer uses a regular type of fiber to which the sound insulation board is attached. Preferably, the bottom layer is composed of PET 1.5 ~ 4D 60 ~ 80% and low melting point binder fiber 2 ~ 4D 20 ~ 40% of unit weight 0.2 ~ 0.3kg / m². In addition, the low melting point binder fiber used in the combination of these structures is optionally mixed 15 ~ 30% of fineness 2 ~ 6 denier, mono PP (Polypropylene), Cisco core PET / PE, PET / COPOLYESTER and the total unit weight is It should be 800 ~ 1600g / m2, and the melting point is in the range of 110 ~ 170 ℃, and the mixing ratio of 20 ~ 50% is used. The total weight of the upper layer, the inner layer, the bottom layer configured as described above is 0.8 ~ 1.4kg / m², the thickness is 20 ~ 45mm.

Since the structure of the sound absorbing and insulating material of the present invention has a porous structure having a random porosity, the sound energy of incident sound waves generated in the high frequency region is formed in the upper layer and the fine porous structure than the conventional laminate in one direction. During the course of the layer, most of the energy is converted into thermal energy by friction, which is easily absorbed and dissipated.

3 is a flowchart illustrating a production process of the sound absorbing and insulating material of the present invention.

The sound absorbing and insulating material of the present invention is manufactured by a mixing and opening process, a carding process, a molding process, a heat treatment process, and a cutting process.

The mixing and carding process is to loosen the raw material of the compressed state (開 纖) to mix by their type (混 綿) to facilitate spinning, and the carding process is uniformly mixed, the carded fiber phase is large and small It is a process of forming a web of thin fibrous film form through a carding machine formed by a cylindrical cylinder (toothed needle wound on the surface), and the cross lapping process uses a molding machine to form multiple layers of a certain width and weight. It is a process of laminating and laminating, and the heat treatment process is a process of imparting strength by thermally setting the laminated web, and the cutting process is a process of cutting to a predetermined standard.

As described above, since the upper layer, the inner layer, and the bottom layer of the sound absorbing and insulating material of the present invention have different characteristics, different fiber raw materials are used as described above, and different jaws (hopper feeder, vibra, etc.) are formed for each layer. It is configured to horn and open the island through a chute feeder / super cleaner, a semi-random card machine, and a molding machine).

In the mixing and opening process of the present invention, an automatic hopper feeder (Hopper Feeder 200, 210, 220) is used. The automatic hopper feeder automatically separates the input amount of the fiber raw material through a weighing scale device using a load cell method.

And, the super opening 100 composed of seven cylindrical bitter rolls is used to reinforce the horn and islet distribution capacity of the low melting point fiber of the present invention. The super opening 100 is to reinforce the carding ability of the three denier fiber is less open.

Since low melting point fibers are relatively less open, the low melting point fibers are first processed before being blended with other fibers and fed into the automatic hop feeder of this process.

Other raw materials except low melting point fibers are fed directly to the automatic hopper feeders (200, 210, 220) without passing through the super opening (100), and are fed into Kirchner bitter rolls (not shown) through the lower conveying conveyor. do. The Kirschner bitter roll is a wooden board in which a pointed needle is uniformly embedded in the shape of a wing, and three sets are arranged on one axis so as to uniformly loosen the mixed surface of the fiber agglomerate state by high-speed rotation.

After passing through the Kirschner bitter roll, the fiber raw material that passed through the first horn and the open island is a combination of two sets of vibra Shute Feeder / Super Cleaner, which is a secondary horn and the open island process by the airflow method by the supply fan. , 310, 320) to be sufficiently resolved. The vibra chute feeder / super cleaner 300, 310 and 320 is a device for secondary raw material mixing and opening, and the vibra chute feeder and the super cleaner are connected in one set.

The vibra chute feeder (300, 310, 320) is discharged from the Kirschner beater to the upper chamber through the air flow doctor through the mesh net out the chamber and the mixed surface in the lower chamber It is sent to a set of feeder rolls to be moved back to the lower conveyor belt by a stripper roll. The rear surface of the chamber is vibrated by a vibration motor so that the mixed surface falling from above is uniformly compressed and uniformity is improved.

The mixed surface sent out from the vibra chute feeder is supplied to the super cleaner which is installed in succession. The super cleaner is formed of a set of feeding rolls (not shown), one cylindrical bitter roll (not shown), and five rolls (not shown) to improve the openness of the mixed surface. In the present invention, in order to improve the sufficient horn and carding ability of the low-melting point fibers, the Vibra suit feeders (300, 310, and 320), which are not used in the general fiber mat process, are additionally installed and refurbished so that the fibers are not damaged. Horn, open to the island.

In order to determine the blending performance by the horn and the opening method, the color uniformity was measured by inserting black pre-dyed yarn in the ratio of 50:50 with the white thread instead of the low melting point fiber. As a result, it was found that the color distribution is much improved compared to the case of the conventional one or two mixers. The mixed raw material sufficiently mixed and opened as described above is finally supplied to another automatic weight weighting hopper device (not shown) and normalized to a predetermined weight sheet state before being fed into the card.

As described above, the carding process and the molding process are performed after the mixed surface process is completed. First, the first semi-random card machine 400 and the first molding machine 500 forming the bottom layer 23 are installed in one set, and the web is formed by injecting regular PET fibers to form the bottom layer 23. Next, using the second semi-random card machine 410 and the second molding machine 510 forming the inner layer 22 as a second set, the fibers having microporous properties are introduced to form a web to form the inner layer 22. In the third set to the third semi-random card machine 420 and the third molding machine 520 to form the upper layer 21, the PET fiber is introduced to form a web to form the upper layer 21. As described above, these mixed fibers introduced into each of the card machines 400, 410, and 420 repeat the combing action and the transfer action seven times or more to form a fibrous thin film. The bottom layer 23, the inner layer 22, and the upper layer 21 are formed by overlapping the web several layers.

The carding machine of the present invention is a semi-random carding machine having two upper and lower condensing rolls (not shown) to condense the fibers mechanically rather than combing in one direction when only a conventional doffer roll is used. As a result, it is possible to impart highly bulky porous properties, thereby greatly improving sound absorption.

In the molding machines 500, 510 and 520 connected to the respective semi-random card machines 400, 410 and 420, the webs formed in the above steps are stacked. Since the web laminated in the molding machine has a considerable height, it may need to be pre-needed to be within 60Points / ㎠ in order to reduce the height before entering into the oven and to maintain a uniform surface state. Or step through the press roll to reduce the height is put into the oven.

The fibers forming the web in the oven 600 are heat-treated at 130 to 150 ° C. in the front chamber of the oven and at 180 to 210 ° C. in the rear chamber of the oven for aging and fusion. The heat treatment method uses a hot air circulation method, and the low melting fiber is melted through the heat treatment such that the upper layer 21, the inner layer 22, and the bottom layer 23 are bonded to each other. In order to heat-set the height of the sheet to the desired standard, the conveyor plate of the oven has a structure in which upper and lower parts are connected by perforated metal plates, and the upper conveyor plate is adjusted up and down by screws. It is thermally set to a height of about -45mm.

The sound absorbing and insulating material for automobiles which have undergone the heat treatment process as described above is subjected to the electroforming process through the cooling unit in order to prevent the surface of the skin from being torn off due to friction or worsening of peeling resistance due to the PRESS process in which the sound insulation plate is attached. Immediately after cooling by the cooling fan in the cooling unit 610 through the cutting process to complete the sound absorbing and insulating material of the present invention.

The sound absorbing and insulating material of the present invention can be made into a shape of a hard board by compressing it within a thickness of 3-7mm during the process or as a separate crimping device for use for the purpose of improving the sound absorbing performance of the dash part or for use as a headliner. As a crimping device used, 3 ~ 5 trillion heating press rolls may be used, or heat setting may be performed by pressing a thermocompression method by an upper and lower conveyor after going through an infrared preheating device.

Depending on the application, a reinforcing material such as a separate nonwoven fabric, glass fiber sheet, PP bag, abrasion, etc. may be added to the upper layer 21, the inner layer 22, and the bottom layer 23 of the vehicle sound absorbing and insulating material for strength. have.

Experimental Example 1

Absorption Coefficient of the sound absorbing and insulating material manufactured by the manufacturing method of the present invention and the sound absorbing and insulating material having a linear structure in one direction manufactured by the conventional method were tested using Alpha Cabin Measurements. As shown in Table 1 and FIG. 5, it can be seen that the sound absorbing effect of the sound absorbing material of the present invention is superior to that of the conventional sound absorbing material.

Frequency (Hz) Sound absorbing material of the present invention Conventional sound absorbing material 500 0.82 0.75 650 0.86 0.75 850 1.08 0.94 1000 1.0 0.92 2000 0.95 0.86 4000 0.92 0.88 8000 1.04 1.0

By the above configuration, the present invention brings the following effects.

The sound absorbing and insulating material of the present invention is excellent in the distribution of low melting point fibers, since the internal structure of the porous structure having a random porous structure so that the sound energy of incident sound waves generated in the high frequency region passes through the upper layer and the inner layer formed of a fine porous structure Most of the energy is converted into thermal energy by friction, so it is easily absorbed and extinguished. And heat insulation, moldability, and durability become excellent.

In addition, since environmentally friendly materials are used, environmental pollution can be reduced. In addition, since no surface heat treatment is required even during the molding finishing treatment, there is an effect of greatly improving the work force and working time.

Claims (9)

It is composed of a top layer, an inner layer and a bottom layer, and is made of polyester staple fiber and low melting point binder fiber, and the fiber structure of the inner layer is characterized in that it consists of a microporous laminated structure made of polyester of 0.5 to 3 denier or less. Sound absorbing and insulating material for cars. The method of claim 1, wherein the low-melting binder fiber is any one selected from fineness of 2-6 denier, monopropylene (Polypropylene), Cisco core PET / PE, PET / COPOLYESTER, melting point is in the range of 110 ~ 170 ℃ The sound absorbing and insulating material for automobiles, characterized by using 20 to 50% of the mixing ratio. According to claim 1, wherein the upper layer is composed of PET 3-6D x 51mm 60-70% and low melting binder fibers 2-4D 30-40%, The inner layer is composed of a flat cross-section PET 2D 40 ~ 60%, conjugate 3D 20 ~ 30%, low melting point binder fiber 2 ~ 4D 30 ~ 40%, The bottom layer is composed of PET 1.5 ~ 4D 60 ~ 80% and low melting point binder fiber 2 ~ 4D 20 ~ 40%, the total weight of the top layer, inner layer, bottom layer is 0.8 ~ 1.4kg / m², the thickness is 20 ~ 45mm Sound absorbing and insulating material for cars, characterized in that. According to claim 1, wherein the upper layer and the sound absorbing and insulating material for automobiles Strengthen the inner and bottom layers A sound absorbing and insulating material for automobiles, wherein reinforcing materials such as nonwoven fabric, glass fiber sheet, PP bag, and abrasion are added. Mixing and opening process to release the raw materials in the compressed state and mix them by type to facilitate spinning; A carding process for uniformly forming the horn and opened fibers into a fibrous thin film through a carding machine formed of large and small cylindrical cylinders; A molding process of laminating the web several times with a predetermined width and weight using a molding machine, and a heat treatment process of thermally setting the laminated web to give strength; And a cutting process for cutting to a predetermined standard, wherein the sound absorbing and insulating material for automobiles is formed using a semi-random card machine in the carding process to form a bulky web structure of micropores. 6. The method for manufacturing a sound absorbing and insulating material for automobiles according to claim 5, wherein a primary carding treatment is added before the mixing and carding process using a separate super opening to improve the carding ability of the low melting point fiber. The method of claim 5, wherein the mixing and carding process is a secondary horn, carding process is performed by a hopper feeder and a composite vibra chute feeder / super cleaner. The method according to claim 5, wherein after the pre-heating treatment using an infrared heat treatment or a hot air permeation type preheating method or the like to the automotive sound absorbing and insulating material which has undergone the heat treatment step, it is compressed to compress the automotive sound absorbing and insulating material about 3 to 7 mm. Method for manufacturing a sound absorbing and insulating material for cars, characterized in that. The method of manufacturing a sound absorbing and insulating material for automobiles according to claim 5, wherein after the heat treatment step, the surface of the upper layer is heat treated with a separate heating roll to reinforce the peeling resistance of the upper layer.