KR200421094Y1 - Non-woven composite sheet for indoor construction materials having excellent flame retardancy and sound-absorbing and sound-blocking properties - Google Patents

Abstract

A metal film layer for increasing flame retardancy and sound insulation; And a nonwoven composite sheet laminated on at least one surface of the metal film layer and having a nonwoven layer having a flaw characteristic that absorbs sound waves. The nonwoven composite plate according to the present invention of the above structure has a flame spread test in a state where the nonwoven fabric layer is exposed to a flame according to ASTM (American Society for Testing and Materials) E84 without a flame retardant treatment using a flame retardant and When the smoke development test is carried out, excellent flame retardancy corresponding to the A grade (the best grade) can be achieved. In addition, by the introduction of the metal film layer it is possible to achieve the sound insulating properties very simply. Since the sound insulation characteristics of the metal film layer are such that the flaw characteristics of the nonwoven fabric layer are added, the composite plate of the present invention may exhibit more excellent sound insulation characteristics.

Description

Non-woven composite sheet for indoor construction materials having excellent flame retardancy and sound-absorbing and sound-blocking properties

1 is a schematic perspective view of a nonwoven composite plate for building interior materials according to a first embodiment of the present invention.

2 is a schematic perspective view of a nonwoven composite plate for building interior materials according to a second embodiment of the present invention.

<Description of Major Symbols in Drawing>

1: metal thin film layer

3: upper nonwoven fabric layer

5: lower nonwoven fabric layer

The present invention relates to a nonwoven composite plate for building interior materials, and more particularly to a nonwoven composite plate for building interior materials excellent in flame retardancy, sound absorption properties, and sound insulation properties without the use of a flame retardant.

Nonwoven fabric sheet manufactured by pressing organic polymer short fibers has been used for building interior and exterior materials, partition board, etc. because of its excellent sound absorption properties.

For example, Korean Patent Publication No. 87-5764 discloses a web made by crushing fibrous polypropylene finely and cutting chemical fibers such as acrylic, polyester, and nylon into about 10 mm and putting it in a carding machine in a heating chamber. Disclosed is a fiber board material which is cut after heating for time and compression-molded with a press plate. However, there is a problem in that the fiber board by cutting the fiber is cut into short fibers of about 10mm is less entangled between the short fibers are broken well.

Korean Patent Publication No. 95-6863 discloses a fiber thread by cutting waste islands into 50 ~ 100mm long fibers, and then spinning them on the other side of the machine to make cotton. Disclosed is a method of manufacturing a fiber board material by heating and pressing at high temperature and high pressure so as to be integral with each other. However, since the fiber board produced by this method is molded at high temperature and high pressure, it causes decomposition of the polymer material, which is a fiber constituent, and has a problem in that the intrinsic properties of the fiber are lost.

Korean Laid-Open Patent Publication No. 2001-0084426 discloses a polyester nonwoven plate made by mixing 50 wt% or more of a high melting point polyester fiber and 50 wt% or less of a low melting polyester fiber having a melting point of 50 ° C. or more lower than the high melting point polyester fiber. It is starting. However, the polyester nonwoven fabric sheet produced by this method has excellent sound absorption effect, but low sound insulation effect, leaving room for improvement in terms of sound insulation effect.

Korean Laid-Open Patent Publication No. 2001-0107523 applies a workpiece, which is a cotton or low-density non-woven fabric sheet containing heat-sealing fibers, to a hot plate type hot press to heat and compress it, but not to be fused to the hot plate at the operating temperature of the hot plate type hot press. A non-woven fabric or woven fabric which is heated and compressed in a state covering at least the surface and the backside of the workpiece perpendicular to the compression direction of the heating plate with a nonwoven fabric or woven fabric, and then formed into a high-density nonwoven plate material, and then discharged from a hot press to cover the nonwoven fabric or woven fabric. Disclosed is a method for producing a high density nonwoven plate material, characterized in that it comprises a step of cooling at. However, this method can produce a high-density nonwoven board having excellent quality uniformity through a simple manufacturing equipment and process, but the nonwoven board produced thereby also has a good sound absorption effect, but the sound insulation effect is low and the sound insulation effect is not sufficient.

As such, when the nonwoven board is used for building interior materials, it is required to have flame retardancy above a certain standard in addition to the sound absorbing and sound insulating properties. In particular, in the United States, in order to sell such non-woven boards for building interior use indoors, flame spread test and smoke development test in accordance with American Society for Testing and Materials (ASTM) E84. When A is given, it should satisfy A grade (best grade). Examples of the attempt to impart flame retardancy to a nonwoven fabric sheet include the following.

Korean Laid-Open Patent Publication No. 2002-0014032 discloses a flame retardant polyester nonwoven plate material having a flame retardant coating coated on a surface of a polyester nonwoven plate material. Non-woven fabric produced by this method is excellent in flame retardancy and can exhibit self-extinguishing which is extinguished even when the flame is removed in the event of fire.However, when applied as a building interior material or partition plate, it still achieves sound insulation effect only by sound absorbing mechanism and sound insulation. There is a lot of room for improvement in terms of sound insulation effect because it cannot exert an effect. Another method for imparting flame retardancy to a nonwoven fabric sheet includes a method of producing a nonwoven fabric sheet using fibers to which a flame retardant is added, or a method of treating the nonwoven fabric sheet with a flame retardant composition. For example, in the case of a polyester nonwoven board, a method for producing a nonwoven board using polyester fibers to which a flame retardant compound such as octabromo biphenyl, hexabromobiphenyl amine, tetrabromo-bisphenol A is added, or poly The nonwoven plate made of ester fibers is treated with a liquid composition comprising a flame retardant compound such as 2- (2,4,6, -tribromophenoxy) phenol, tris (2,3-dibromopropyl) phosphate, and the like. The method etc. are mentioned. However, if the flame retardant treatment using a flame retardant as described above, there is a problem that the sound absorption characteristics are lowered than before treatment, in addition to a significant increase in the production cost.

Accordingly, the technical problem to be achieved by the present invention is to eliminate the problems of the conventional nonwoven plate as described above can exhibit not only sound absorbing properties but also sound insulation properties to provide a non-woven composite plate for building interior materials excellent in soundproofing effect as well as flame retardant properties. It is.

The present invention to achieve the above technical problem,

A metal film layer for increasing flame retardancy and sound insulation properties; And

Provided is a nonwoven composite plate material for building interior materials laminated on at least one surface of the metal film layer and having a nonwoven layer having a flaw characteristic that absorbs sound waves.

In one embodiment of the present invention, the non-woven composite plate for building interior materials is excellent flame retardancy corresponding to A grade when the carbon screen test and smoke generation test in the state in which the nonwoven fabric layer is exposed to the flame in accordance with ASTM E84 Can be exercised.

In one embodiment of the present invention, the nonwoven layer may be made of one to three selected from polyester fibers, polyolefin fibers, acrylic fibers, modacryl fibers and nylon fibers.

In one embodiment of the present invention, the metal film layer may be an aluminum thin film layer.

Nonwoven composite plate for building interior materials according to the present invention can be used as a finishing material for the room that requires soundproofing and flame retardant properties such as meeting rooms, performance halls, cinemas. At this time, the metal film layer is attached to the wall or ceiling, and the nonwoven fabric layer is used in an arrangement state exposed to the room. Therefore, there is an advantage that the flame retardancy can be exhibited without the appearance damage caused by the addition of the metal film layer.

The nonwoven composite plate according to the present invention having the simple structure described above has a flammability test in a state where the nonwoven fabric layer is exposed to a flame according to ASTM (American Society for Testing and Materials) E84 without a flame retardant treatment using a conventional flame retardant. When the spread test and smoke development test are performed, the excellent flame retardancy corresponding to the A grade (the best grade) can be obtained. In addition, by the introduction of the metal film layer it is possible to achieve the sound insulating properties very simply. Since the sound insulation characteristics of the metal film layer are added to the scratch characteristics of the nonwoven fabric layer, the composite plate of the present invention may exhibit more excellent sound insulation characteristics. As such, the nonwoven composite plate of the present invention can exhibit excellent flame retardancy as well as increased sound insulation properties. In particular, it is surprising that such excellent flame retardancy can be obtained by simply applying only a metal film layer to the nonwoven fabric layer without the use of a separate flame retardant.

Hereinafter, the nonwoven composite plate according to the present invention will be described in detail.

Nonwoven composite plate according to the present invention is a metal film layer for increasing the flame retardant properties and sound insulation properties; And a nonwoven fabric layer laminated on at least one surface of the metal film layer and having a flaw characteristic that absorbs sound waves.

1 is a schematic perspective view showing a nonwoven composite plate according to a first embodiment of the present invention. Referring to FIG. 1, the nonwoven composite plate of the present invention includes a metal film layer 1, an upper nonwoven layer 3, and a lower nonwoven layer 5. The upper nonwoven fabric layer 3 and the lower nonwoven fabric layer 5 have the same thickness, and are attached to the metal film layer 1 by any known method. The metal film layer (1) is a result of a careful review through the test of the present inventors several times in order to improve the conventional nonwoven plate material is composed of only the nonwoven plate material only exhibits the function of absorbing sound waves so that the sound insulation effect is not sufficient. As an adopted, it exhibits a function to block sound waves. Unexpectedly, however, it was found that the nonwoven composite sheet exhibited excellent flame retardancy even though the flame retardant treatment was not performed separately by applying the metal film layer 1 to the nonwoven fabric layer.

The metal film layer 1 is not particularly limited as long as it can be formed on the nonwoven fabric layer. However, the metal film layer 1 may be formed of an aluminum thin film in terms of flame retardancy, sound wave blocking property, shape stability, and convenience in manufacturing process.

The material of the upper nonwoven fabric layer 3 and the lower nonwoven fabric layer 5 adhered to the metal film layer 1 is not particularly limited, but is generally used in polyester fibers, polyolefin fibers, acrylic fibers, modacryl fibers and nylon fibers. It consists of 1 to 3 selected. In particular, it is often made of one type in terms of process convenience and economy. On the other hand, even when the fiber is made of one kind of the same material, different melting points may be used in combination. For example, both the upper nonwoven fabric layer 3 and the lower nonwoven fabric layer 5 have the same high melting point polyester (PE) fiber 30 to 90% by weight and low melting point PE having a melting point of 20 ° C. or more lower than that of the high melting point PE fiber. 10 to 70% by weight of the fiber may be composed of a nonwoven layer that is randomly mixed. In this case, the high melting point PE fiber serves to increase the heat resistance and mechanical strength, and the low melting point PE fiber is melted by heat when the PE fiber assembly is heat-compressed and molded into the nonwoven fabric layers 3 and 5 to bond with the high melting point PE fiber. It can increase the role and adhesion with the metal film layer. If the ratio of the low melting point PE fiber is less than 10% by weight, there is a problem that the bonding strength is not sufficient, if the ratio exceeds 70% by weight there is a problem that the mechanical strength and heat resistance of the composite plate is lowered.

The fineness of the fibers constituting the nonwoven layers 3 and 5 may be the same or different from each other. Preferred fineness is in the range of 2 to 50 denier. If the fineness is less than 2 denier has the advantage that the touch of the composite plate is soft and beautiful, but there is a problem that the manufacturing cost increases rapidly. If the fineness is more than 50 days, the touch of the composite plate is landscaped, and there is a problem that the soundproofing effect is poor.

The fiber lengths of the fibers constituting the nonwoven layers 3 and 5 may be the same or different from each other. Preferred fiber length ranges from 40 to 70 mm. If the fiber length is less than 40mm, there is a problem in carding and formability when manufacturing the nonwoven web. If the fiber length exceeds 70mm, the processability during carding during web manufacturing tends to decrease.

High melting point PE fibers include ethylene glycol, 1,3-propanediol or 1,4-butanediol and dimethyl terephthalate (DMT), terephthalic acid (TPA), dimethyl-2,6-naphthalenedicarboxylate (NDC) or 2, Polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) and polyethylene naphthalate (PEN), which are polymerization products of 6-naphthalenedicarboxylic acid (NDA), are preferred. PET, PTT, and PBT are particularly preferable in view of availability and economy.

Low melting point PE fibers are polyethylene succinate, polyethylene glutarate, polyethylene adipate, poly, which is a polymerization product of ethylene glycol, 1,3-propanediol or 1,4-butanediol and aliphatic dicarboxylic acids having 4 to 10 carbon atoms. Ethylene pimelate, polyethylene subberate, polyethylene azelate, polyethylene sebacate, polytrimethylene succinate, polytrimethylene adipate, polytrimethylene azelate, polytetramethylene succinate, polytetramethylene adipate, polytetramethylene Azelates, polytetramethylene sebacate, etc. are preferable.

Instead of using a fiber assembly composed of a mixture of high melting point PE fibers and low melting point PE fibers, as described above, the high melting point PE melt and the low melting point PE melt are side-by-side, sheath / core, and multi-sided. A fiber assembly of composite fibers obtained by complex spinning in the form of a biside type, an axial composite type, or a fiber assembly of mixed fiber spun by spinning with a high melting point PE melt and a low melting point PE melt can be used.

The composite plate according to the first embodiment is suitable for interior partition use because the metal film layer 1, which may damage the aesthetic appearance, is concealed therein. Meanwhile, in FIG. 1, the upper nonwoven fabric layer 3 and the lower nonwoven fabric layer 5 are illustrated to have the same thickness, but the present invention is not limited thereto and the two layers may have different thicknesses.

Figure 2 is a schematic perspective view showing a nonwoven composite plate according to a second embodiment of the present invention. The nonwoven composite plate according to the second embodiment differs from the composite plate according to the first embodiment only in that only one layer of nonwoven fabric layer 5 is provided. The composite sheet according to the second embodiment is mainly used as a ceiling and wall finishing material in the room rather than as a partition. In particular, in the composite sheet according to this embodiment, the metal film layer 1, such as an aluminum thin film, is attached to a wall or a ceiling, and the nonwoven fabric layer 5 is used in an arrangement in which it is exposed indoors. Therefore, since the metal film layer 1 is not exposed, the flame retardancy can be improved without the appearance damage caused by the addition of the metal film layer 1.

Hereinafter, a method for manufacturing a nonwoven composite plate material according to the present invention will be described. First, for convenience, the method of manufacturing the nonwoven composite plate according to the second embodiment will be described.

The nonwoven fabric layer is first prepared by a conventional known nonwoven fabric manufacturing method. Detailed description thereof may be obtained by referring to Korean Laid-Open Patent Publication No. 2003-76890. Then, a thin metal film such as aluminum foil is placed in contact with the nonwoven layer and then passed through a heat roller. At this time, the organic polymer film of low melting point is previously located between the metal thin film and the nonwoven fabric layer. Then, the organic polymer film of low melting point is melted by the heat and pressure applied by the heat roller and acts as an adhesive, and is attached to the nonwoven fabric layer, and the nonwoven fabric layer is compressed and reduced in thickness to be converted into a dense and hard board. do. On the other hand, in the case of manufacturing the composite plate material for partition use according to the first embodiment is passed through the heat roller in the state of sandwiching one sheet of metal thin film between the two non-woven fabric layer, at this time between the nonwoven fabric layer and the metal thin film Each low melting point organic polymer film is placed. In the imagined composite plate manufacturing method, the nonwoven layer may be covered with a woven or nonwoven fabric upon passing through the heat roller. This is to protect the nonwoven layer from the heat applied by the heat roller. The woven or nonwoven fabric used for this purpose is preferably made of high melting point fibers that are not fused at the time of heat compression in a heat roller. In addition, it is more effective if the material does not pyrolyze at the time of heat compression. The covered woven fabric or nonwoven fabric can be made of synthetic fibers, natural fibers or mixed fibers thereof. Although not particularly limited, the nonwoven fabric is preferably a long woven fabric, and the woven fabric is an effective PE woven or cotton woven fabric having a thickness of 0.5 mm or more, in terms of separability and insulation. Of course, the present invention is not limited to the above-described woven fabric, and can be effectively used even if it is made of any thickness, weaving method and material as long as it can ensure heat resistance and uniform heating and cooling to withstand heat compression.

Hereinafter, the present invention will be described in more detail with reference to the embodiments, which are merely illustrative and the present invention is not limited thereto. This will make the features and other advantages of the present invention clear.

Example

First, aluminum having a low melting point ethylene-vinylacetate film laminated on a web aggregate of about 56 mm thickness in which polyethylene terephthalate (PET) fibers prepared according to a conventional method are randomly disposed. The foil was placed so that the ethylene-vinylacetate film was in contact with the fiber assembly. This was then passed over a heat roller maintained at a temperature of about (85) DEG C while transported on a conveyor belt to obtain a nonwoven composite plate material of about 20 mm in thickness.

Comparative example

According to the same method as in Example except that the metal film layer was not attached to prepare a PET non-woven fabric sheet consisting of only the PET non-woven fabric layer of about 20mm thickness same as the composite plate of the embodiment.

 Soundproof test

The soundproof test results of the nonwoven fabric plates obtained in Examples and Comparative Examples were summarized in Table 1 below. The soundproof test is performed by covering both the wall and ceiling of a room of 3m × 5m × 2.3m size using the nonwoven plate obtained in Examples and Comparative Examples, and then operating the cassette tape player at the maximum volume in the room. Ten observers assessed the level of noise coming from a room 1 meter away.

Noise level  The number of people who answered that it was quiet  The number of people who answered that it was normal  Number of people who answered loud Example 8 2 0 Comparative example 0 4 6

Referring to Table 1, the nonwoven composite plate obtained in the embodiment according to the present invention can be seen that the soundproof effect is superior to the nonwoven plate obtained in the comparative example. This is because the nonwoven fabric plate of the comparative example exhibits sound absorption function, but the sound insulation function is insignificant, whereas the nonwoven composite plate of the embodiment is considered to contribute to the soundproofing effect as well as the sound absorption function.

 Flame retardant test

The nonwoven fabric sheet obtained in Examples and Comparative Examples was subjected to a flame retardant test as follows.

The composite nonwoven composite plate for building interior materials is subjected to the carbon screen test and smoke generation test in the state in which both the nonwoven fabric layer is exposed to the flame according to ASTM E84 ("Method of Test of Surface Burning Characteristics of Building Materials"). It was. In other words, in the composite plate obtained in the embodiment it should be noted that the aluminum film was not exposed to the flame. Table 2 summarizes these flame retardant test results.

Evaluation in Table 2 was made according to the following criteria. In other words, they were evaluated in accordance with the provisions of the "Interior Wall and Ceiling Finish Classification" of the National Fire Protection Association Life Safety Code 101, Section 6-5.3. According to this standard, the flame retardancy of wall and ceiling finishes for building interior materials according to the Flame Spread Index and Smoke Development Value obtained by the test according to ASTM E84 are as follows: Are classified and evaluated.

Class A: 0-25 test value, 0-450 smoke generation test value

Class B: Carbon Field Test Index 26-75, Smoke Production Test Value 0-450

Grade C: carbon screening test index 76-200, smoke generation test value 0-450

Carbon screening test index Smoke generation test value evaluation Example 25 115 A grade Comparative example 50 350 B grade

Referring to Table 2, it can be seen that the composite plate of the present invention corresponds to grade A and, in the case of the comparative example, corresponds to grade B. It can be seen that by additionally applying a metal plate such as aluminum foil on the back side of the nonwoven fabric layer, it can satisfy A grade, which is a pass standard that can be marketed as a product in the United States.

As described above, the nonwoven composite plate material according to the manufacturing method of the present invention can be effectively used as a composite sheet material for building interior materials because it has excellent sound resistance and sound insulation properties as well as flame retardancy. In particular, when used as a floor finishing material, an interlayer sound insulation material, a wall finishing material, such as a conference room, a movie theater, an opera house, a performance hall, and the like, have the following advantages.

(1) The nonwoven composite plate of the present invention has excellent flame retardancy even without a flame retardant treatment. In particular, the excellent flame retardancy can satisfy the A grade in the classification of wall and ceiling finish for building interior materials, which is a pass standard that can be marketed as a product in the United States by simply applying only a metal film layer to the nonwoven fabric layer without the use of a separate flame retardant. .

(2) In the room, the nonwoven composite plate of the present invention has an excellent function of absorbing sound waves, which can greatly reduce the problem of noise caused by interference from incident waves and reflections on walls and floors.

(3) In the outdoor, the nonwoven composite plate of the present invention is also excellent in blocking the sound wave, so the sound wave is prevented from propagating to the outdoors, and excellent soundproofing effect.

(4) The nonwoven fabric layer of the nonwoven composite plate of the present invention has excellent thermal insulation, which reduces the cost of heating the room in winter and increases the cooling efficiency in the summer.

Claims (4)

A metal film layer for increasing flame retardancy and sound insulation; And A nonwoven composite plate material for building interior materials, which is laminated on at least one surface of the metal film layer and has a nonwoven layer having a flaw characteristic that absorbs sound waves. According to claim 1, The non-woven composite plate for building interior materials is a non-woven composite material for building interior materials corresponding to A grade when the carbon screen test and smoke generation test in the state in which the nonwoven fabric layer is exposed to the flame in accordance with ASTM E84 Plate. The nonwoven composite plate for building interior materials according to claim 1, wherein the nonwoven fabric layer is one to three selected from polyester fibers, polyolefin fibers, acrylic fibers, modacryl fibers, and nylon fibers. The nonwoven composite plate material of claim 1, wherein the metal film layer is an aluminum thin film layer.

Images