KR20090073722A - Method for manufacturing sound absorbing and insulating material with 3 layer - Google Patents
Method for manufacturing sound absorbing and insulating material with 3 layer Download PDFInfo
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- KR20090073722A KR20090073722A KR1020070141746A KR20070141746A KR20090073722A KR 20090073722 A KR20090073722 A KR 20090073722A KR 1020070141746 A KR1020070141746 A KR 1020070141746A KR 20070141746 A KR20070141746 A KR 20070141746A KR 20090073722 A KR20090073722 A KR 20090073722A
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- 238000000034 method Methods 0.000 title claims abstract description 70
- 239000011810 insulating material Substances 0.000 title claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 239000011358 absorbing material Substances 0.000 title claims description 29
- 239000000835 fiber Substances 0.000 claims abstract description 134
- 239000002313 adhesive film Substances 0.000 claims abstract description 24
- 238000003825 pressing Methods 0.000 claims abstract description 17
- 238000010438 heat treatment Methods 0.000 claims abstract description 16
- 238000010030 laminating Methods 0.000 claims abstract description 14
- 238000001816 cooling Methods 0.000 claims abstract description 13
- 238000005520 cutting process Methods 0.000 claims abstract description 11
- 238000004804 winding Methods 0.000 claims abstract description 8
- 238000002844 melting Methods 0.000 claims description 34
- 230000008018 melting Effects 0.000 claims description 34
- 238000003475 lamination Methods 0.000 claims description 11
- 238000002156 mixing Methods 0.000 abstract description 10
- 238000009960 carding Methods 0.000 abstract description 8
- 238000003892 spreading Methods 0.000 abstract description 2
- 239000002994 raw material Substances 0.000 abstract 2
- 239000002657 fibrous material Substances 0.000 description 5
- -1 polypropylene Polymers 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B37/1207—Heat-activated adhesive
- B32B2037/1215—Hot-melt adhesive
- B32B2037/1223—Hot-melt adhesive film-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
Abstract
Description
본 발명은 흡차음재 제조방법에 관한 것으로서, 특히 자동차의 내장재로 사용되는 흡차음재를 가열공정에 의해 3층 구조로 결합하여 제조하는 3층구조의 흡차음재 제조방법에 관한 것이다.BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sound absorbing and insulating material, and more particularly, to a method for manufacturing a sound absorbing and insulating material having a three-layer structure, in which a sound-absorbing and insulating material used as an interior material of an automobile is combined into a three-layer structure by a heating process.
흡차음재는 소음을 흡수하거나 차단하는 부재로서 특히 자동차에 설치되어 주행 중 엔진이나 동력전달계통에서 발생하는 소음이 자동차 실내로 침투하는 것을 방지한다.The sound absorbing and insulating material is a member that absorbs or blocks noise, and is installed in a vehicle, in particular, to prevent noise generated from an engine or a power transmission system from penetrating into a vehicle interior.
일반적으로 이러한 흡차음재는 소음을 주로 흡수하는 소프트층과 소음을 반사하여 차단하는 하드층으로 구성된다. In general, the sound absorbing and insulating material is composed of a soft layer that mainly absorbs noise and a hard layer that reflects and blocks the noise.
이러한 소프트층과 하드층은 폴리에스테르나 폴리프로필렌, 폴리에틸렌 등의 섬유로 이루어지며, 이들은 대개 융점이 200℃ 이상인 고융점 섬유와 융점이 대략 100∼150℃ 정도인 저융점 섬유가 혼합되어 구성된다.The soft layer and the hard layer are made of fibers such as polyester, polypropylene, polyethylene, etc., and are usually composed of a high melting point fiber having a melting point of 200 ° C. or higher and a low melting point fiber having a melting point of about 100 to 150 ° C.
종래의 흡차음재는 소프트층과 하드층을 열압착에 의해 각각 별도로 제조한 다음에 이를 상호 접합시키는 방법에 의해 제조된다. Conventional sound absorbing and insulating materials are produced by a method of separately manufacturing a soft layer and a hard layer by thermal compression, and then bonding them together.
즉, 고융점 섬유와 저융점 섬유로 구성된 흡차음재 소재 섬유를 중첩적으로 적층한 다음에 열압착을 가하면, 상기 저융점 섬유가 용융되면서 섬유 소재를 상호 바인더하게 된다. That is, when the sound absorbing and insulating material fibers composed of the high melting point fibers and the low melting point fibers are superimposed and then thermocompressed, the low melting point fibers are melted to mutually bind the fiber materials.
이 과정에서, 저융점 섬유의 양이 많을수록 하드층이 형성되고 그렇지 않을 경우 소프트층이 형성된다.In this process, the higher the amount of low melting fibers, the harder layer is formed, otherwise the softer layer is formed.
이상과 같이 제조된 소프트층과 하드층을 접착제 또는 별도의 바인더 섬유를 개재시킨 상태에서 서로 밀착시키고 압착함으로써 소프트층과 하드층의 복합체로 이루어진 흡차음재를 얻게 된다.The sound absorbing and insulating material made of the composite of the soft layer and the hard layer is obtained by closely contacting and compressing the soft layer and the hard layer prepared as described above with the adhesive or the separate binder fibers interposed therebetween.
그러나, 이러한 제조공정은 소프트층과 하드층을 별도로 열압착하여 제조한 후 이를 다시 압착하여 상호 결합시키기 때문에 소프트층과 하드층의 결합력이 약하고, 불필요한 공정이 수행되는 단점이 있었다.However, such a manufacturing process has a disadvantage in that the soft layer and the hard layer are separately thermally compressed and manufactured by separately compressing the soft layer and the hard layer, and then bonding the soft layer and the hard layer to each other so that the soft layer and the hard layer have a weak bonding force and an unnecessary process is performed.
이러한 문제점을 해결하기 위해 공개특허공보 제10-2006-34909호에는 소프층과 하드층을 가열하여 상호 접합시키는 흡차음재 제조방법에 관한 기술이 나타나 있다.In order to solve this problem, Korean Patent Laid-Open Publication No. 10-2006-34909 discloses a technology related to a sound absorbing and insulating material manufacturing method for heating and bonding the soap layer and the hard layer to each other.
여기에는 소프트층과 하드층을 히팅수단에 의해 가열하여 저융점섬유를 녹임으로써, 소프트층과 하드층으로 이루어진 2층구조의 흡차음재를 결합하는 방법이 기재되어 있다.Here, a method of bonding a two-layer sound absorbing and insulating material composed of a soft layer and a hard layer by melting the low melting fiber by heating the soft layer and the hard layer by a heating means is described.
이때, 가열에 의해 저융점섬유를 녹이기 위해서는 섬유조직을 통과할 수 있는 열풍에 의해 가열되는데, 열풍은 조직이 치밀한 하드층을 통과하기 힘들다.At this time, in order to melt the low melting point fiber by heating, it is heated by hot air that can pass through the fibrous tissue, which is difficult to pass through the dense hard layer of the tissue.
따라서, 소프트층과 하드층으로 이루어진 2층구조에서는 열풍이 소프트층까 지 쉽게 이동할 수 있지만, 소프트층의 상하부에 각각 하드층이 적층되는 3층구조에서는 열풍이 소프트층까지 쉽게 이동하지 못하기 때문에 소프트층과 하드층의 결합력이 약화되어 3층구조의 흡차음재를 제조하기가 곤란한 문제점이 있었다.Therefore, in a two-layer structure consisting of a soft layer and a hard layer, hot air can easily move to the soft layer. However, in a three-layer structure in which hard layers are stacked on the upper and lower portions of the soft layer, the hot air cannot easily move to the soft layer. Since the bonding force between the layer and the hard layer is weakened, it is difficult to manufacture a sound absorbing and insulating material having a three-layer structure.
또한, 열선을 이용하여 소프트층과 하드층을 가열하는 경우에도, 열선에서 발생하는 열이 소프트층의 상하부에 적층되는 하드층을 투과하여 소프트층까지 전달되기 어렵기 때문에 소프트층과 하드층의 결합력이 약화되어 3층 구조의 흡차음재를 제조하기가 곤란한 문제점이 있다.In addition, even when the soft layer and the hard layer are heated using a hot wire, the heat generated from the hot wire is difficult to transmit to the soft layer through the hard layer stacked on the upper and lower portions of the soft layer. This weakening has a problem in that it is difficult to manufacture a sound absorbing and insulating material having a three-layer structure.
본 발명은 전술한 문제점을 해결하기 위하여 안출된 것으로서, 소프트층의 상하부에 각각 하드층이 적층되는 3층구조의 흡차음재를 제조함에 있어서, 가열에 의해 소프트층과 하드층의 결합력을 강화시킬 수 있는 3층구조의 흡차음재 제조방법를 제공하는데 그 목적이 있다.The present invention has been made to solve the above-described problems, in the manufacture of the sound absorbing and insulating material of the three-layer structure in which the hard layers are respectively laminated on the upper and lower portions of the soft layer, it is possible to enhance the bonding strength of the soft layer and the hard layer by heating. The purpose is to provide a three-layer sound absorbing and insulating material manufacturing method.
상기 목적을 달성하기 위하여 본 발명의 3층구조의 흡차음재 제조방법은, 소프트층 섬유시트의 일면에 제1하드층 섬유시트를 적층하는 제1적층공정과; 상기 소프트층 섬유시트와 제1하드층 섬유시트를 가열하여 결합하는 제1결합공정과; 상기 소프트층 섬유시트 타면에 접착필름 및 제2하드층 섬유시트를 적층하는 제2적층공정과; 상기 소프트층 섬유시트 타면에 접착필름 및 제2하드층 섬유시트를 가열하여 결합하는 제2결합공정과; 상기 제2결합공정을 마친 섬유시트를 일정 규격으로 절단하여 권취하는 절단 및 권취공정으로 이루어진 것을 특징으로 한다.In order to achieve the above object, a method for manufacturing a sound absorbing and insulating material having a three-layer structure includes: a first laminating step of laminating a first hard layer fiber sheet on one surface of a soft layer fiber sheet; A first bonding step of heating and bonding the soft layer fibrous sheet and the first hard layer fibrous sheet; A second lamination process of laminating an adhesive film and a second hard layer fiber sheet on the other surface of the soft layer fiber sheet; A second bonding process of bonding an adhesive film and a second hard layer fiber sheet by heating the other surface of the soft layer fiber sheet; It is characterized by consisting of a cutting and winding process of cutting the fiber sheet after the second bonding process by cutting to a predetermined standard.
상기 소프트층 섬유시트에는 상기 제1하드층 섬유시트보다 녹는 점이 낮은 저융점섬유가 내포되어 있고, 상기 제1결합공정에서는 열풍에 의해 상기 저융점섬유를 녹여 상기 소프트층 섬유시트와 제1하드층 섬유시트를 결합시킨다.The soft layer fiber sheet contains low melting point fibers having a lower melting point than the first hard layer fiber sheet, and in the first bonding process, the low melting point fibers are melted by hot air, and the soft layer fiber sheet and the first hard layer are formed. Join the fiber sheets.
상기 제1결합공정과 제2적층공정 사이에는, 가열된 상기 소프트층 섬유시트와 제1하드층 섬유시트를 상호 압착하는 압착공정이 더 포함된다.Between the first bonding step and the second lamination step, the pressing step of mutually pressing the heated soft layer fiber sheet and the first hard layer fiber sheet is further included.
상기 압착공정 수행 후 압착된 섬유시트를 냉각하는 냉각공정을 더 포함하여 이루어진다.It further comprises a cooling step of cooling the crimped fiber sheet after performing the pressing process.
상기 접착필름은 상기 소프트층 섬유시트 및 하드층 섬유시트보다 녹는점이 낮아, 상기 제2결합공정에서 상기 접착필름에 열이 가하여 상기 접착필름은 녹여 상기 소프트층 섬유시트의 타면과 상기 제2하드층 섬유시트를 상호 결합시킨다.The adhesive film has a lower melting point than the soft layer fibrous sheet and the hard layer fibrous sheet, and heat is applied to the adhesive film in the second bonding process to melt the adhesive film, and the other surface of the soft layer fibrous sheet and the second hard layer. The fiber sheets are bonded to each other.
상기 제2결합공정은 가열된 롤러에 의해 상기 소프트층 섬유시트, 접착필름 및 제2하드층 섬유시트를 압착 결합시킨다.In the second bonding process, the soft layer fiber sheet, the adhesive film, and the second hard layer fiber sheet are press-bonded by a heated roller.
이상에서 설명한 바와 같은 본 발명의 3층구조의 흡차음재 제조방법에 따르면 다음과 같은 효과가 있다.According to the method for manufacturing a sound absorbing and insulating material having a three-layer structure as described above, the following effects are obtained.
소프트층 섬유소재의 일면에 배치되는 제1하드층 섬유시트를 가열하여 결합하고, 타면에 접착필름을 통해 제2하드층 섬유시트를 결합함으로써, 3층 구조의 흡차음재를 용이하게 제조할 수 있다.By heating and bonding the first hard layer fiber sheet disposed on one surface of the soft layer fiber material, and bonding the second hard layer fiber sheet to the other surface through an adhesive film, a sound absorbing and insulating material having a three-layer structure can be easily manufactured. .
또한, 압착공정에 의해 소프트층 섬유소재와 제1하드층 섬유시트를 더욱 강하게 밀착 결합시킬 수 있고, 두께를 조정할 수 있다.In addition, by the crimping step, the soft layer fiber material and the first hard layer fiber sheet can be more tightly bonded and the thickness can be adjusted.
또한, 냉각공정에 의해 흡차음재의 두께 및 표면을 고정시킬 수 있어, 성형 후 변형량을 최소화시킬 수 있다.In addition, the thickness and the surface of the sound absorbing and insulating material can be fixed by the cooling process, thereby minimizing the amount of deformation after molding.
또한, 소프트층 섬유소재와 제1하드층 섬유시트를 열풍에 의해 결합함으로써, 저융점섬유가 녹아 상호 결합력을 증대시킬 수 있다.In addition, by combining the soft layer fiber material and the first hard layer fiber sheet by hot air, the low melting point fibers can be melted to increase the mutual bonding force.
또한, 가열된 롤러에 제2하드층을 소프트 섬유시트에 압착결합시킴으로써, 접착필름을 녹임과 동시에 상호 강하게 밀착되도록 하여 결합력을 증대시킬 수 있 다.In addition, by pressing and bonding the second hard layer to the soft fiber sheet on the heated roller, it is possible to increase the bonding strength by melting the adhesive film and at the same time strongly adhered to each other.
또한, 소프트 섬유소재의 일면과 타단 모두에 접착필름을 사용하는 경우보다 비용을 절감시킬 수 있고, 접착력을 증대시킬 수 있다.In addition, it is possible to reduce the cost and increase the adhesive strength than when using the adhesive film on both the one side and the other end of the soft fiber material.
도 1은 본 발명의 실시예에 따른 3층구조의 흡차음재 제조방법의 공정도이다.1 is a process diagram of a method for manufacturing a sound absorbing and insulating material having a three-layer structure according to an embodiment of the present invention.
도 1에 도시된 바와 같이, 본 발명의 제조방법은, 개면 및 혼면공정(S1)과, 소면공정(S2)과, 제1적층공정(S3)과, 제1결합공정(S4)과, 압착공정(S5)과, 냉각공정(S6)과, 제2적층공정(S7)과, 제2결합공정(S8)과, 절단 및 권취공정(S9)으로 이루어진다.As shown in Figure 1, the manufacturing method of the present invention, the opening and blending step (S1), the carding step (S2), the first lamination step (S3), the first bonding step (S4), compression It consists of a process (S5), a cooling process (S6), a 2nd lamination process (S7), a 2nd bonding process (S8), and a cutting and winding process (S9).
상기 개면 및 혼면공정(S1)은, 배합비율에 따라 여러 섬유가 섞어 있는 원료 섬유덩어리를 잡아당기거나 벌리는 공정으로서, 이를 통해 섬유덩어리 내에 함유되어 있는 불순물이나 이물질을 분리시키고 동시에 여러 섬유를 상호 혼합하는 작용을 한다.The opening and blending process (S1) is a process of pulling or spreading raw fiber masses in which several fibers are mixed according to the blending ratio, thereby separating impurities or foreign substances contained in the fiber mass and simultaneously mixing several fibers together. It works.
원료 섬유덩어리는 폴레에스테르, 폴리프로필렌, 폴리에틸렌 성분으로 이루어진 잡섬유, 재생섬유, 펠트 등으로 이루어지며, 이들은 융점이 대략 200℃ 이상인 고융점 섬유와 융점이 대략 100∼150℃정도인 저융점 섬유를 포함한다.The raw fiber mass is composed of polyester, polypropylene, polyethylene, mixed fibers, regenerated fibers, felts, and the like. These include high melting point fibers having a melting point of about 200 ° C. or higher and low melting point fibers having a melting point of about 100 to 150 ° C. Include.
상기 개면 및 혼면공정(S1)은 마친 섬유덩어리는 상기 소면공정(S2)으로 이송된다.The opening and blending step (S1) is finished fiber mass is transferred to the carding step (S2).
상기 소면공정(S2)은 상기 개면 및 혼면공정(S1)에 의해 상호 혼합된 섬유덩 어리를 얇은 막상태로 시트화시키는 공정이다.The carding step (S2) is a step of sheeting the fiber masses mixed with each other by the opening and blending step (S1) in a thin film state.
상기 개면 및 혼면공정(S1) 및 소면공정(S2)을 통해 섬유덩어리는 소프트층 섬유시트 또는 하드층 섬유시트가 된다.Through the opening and blending step (S1) and the carding step (S2), the fiber mass becomes a soft layer fiber sheet or a hard layer fiber sheet.
위와 같은 상기 개면 및 혼면공정(S1)과 소면공정(S2)은 공개특허공보 제10-2006-34909에 자세하게 기재되어 있는바, 이에 대한 자세한 설명은 생략한다.The opening and blending process (S1) and the carding process (S2) as described above are described in detail in Korean Patent Publication No. 10-2006-34909, a detailed description thereof will be omitted.
상기 제1적층공정(S3)은 상기 소면공정(S2)에 의해 시트화된 소프트층 섬유시트의 일면에 제1하드층 섬유시트를 적층하는 공정이다.The first lamination step (S3) is a step of laminating the first hard layer fiber sheet on one surface of the soft layer fiber sheet sheeted by the carding step (S2).
이때, 상기 제1적층공정(S3)에서는 상기 소프트층 섬유시트를 일정 폭과 중량으로 여러겹 적층하고, 그 후에 상기 제1하드층 섬유시트를 적층함이 바람직하다.In this case, in the first lamination step (S3), it is preferable that the soft layer fiber sheet is laminated in multiple layers with a predetermined width and weight, and then the first hard layer fiber sheet is laminated.
또한 상기 소프트층 섬유시트에 상기 제1하드층 섬유시트를 적층하기 이전에, 상기 제1하드층 섬유시트도 여러겹으로 적층시키고 이를 니들펀칭에 의해 자체적으로 상호 결합하는 작업을 수행하도록 한다.In addition, before laminating the first hard layer fibrous sheet to the soft layer fibrous sheet, the first hard layer fibrous sheet is also laminated in a plurality of layers, and the operation of mutually bonding them by needle punching.
상기 니들펀칭에 대해서는 공개특허공보 제10-2006-34909에 자세하게 기재되어 있는바, 이에 대한 자세한 설명은 생략한다.The needle punching is described in detail in Korean Patent Publication No. 10-2006-34909, and a detailed description thereof will be omitted.
상기 제1결합공정(S4)은 상기 소프트층 섬유시트와 상기 제1하드층 섬유시트를 가열하여 결합하는 공정이다.The first bonding step (S4) is a step of heating and bonding the soft layer fiber sheet and the first hard layer fiber sheet.
상기 제1결합공정(S4)의 가열에 의해 상기 소프트층 섬유시트에 내장된 저융점섬유가 녹아 상기 소프트층 섬유시트와 제1하드층 섬유시트를 결합시킨다.The low melting fiber embedded in the soft layer fiber sheet is melted by heating of the first bonding process S4 to bond the soft layer fiber sheet and the first hard layer fiber sheet.
이때, 상기 저융점섬유는 상기 제1하드층 섬유시트보다 녹는점이 낮아야 한 다.At this time, the low melting point fibers should have a lower melting point than the first hard layer fiber sheet.
상기 저융점섬유를 가열하여 녹이는 방법은 열풍을 이용한다.The method of heating and melting the low melting point fiber uses hot air.
즉, 상기 소프트층 섬유시트와 제1하드층 섬유시트를 적층시킨 후 일정한 속도로 열풍이 발생하는 오븐기를 통과시켜 열풍이 소프트층 섬유시트에 내장되어 있는 저융점섬유를 녹이도록 한다.That is, after laminating the soft layer fibrous sheet and the first hard layer fibrous sheet, the hot air is passed through an oven that generates hot air at a constant rate so that the hot air melts the low melting point fibers embedded in the soft layer fibrous sheet.
이때, 상기 오븐기는 140℃ 정도의 열풍을 발생하도록 한다.At this time, the oven is to generate hot air of about 140 ℃.
위와 같은 상기 제1결합공정(S4)에 의해 즉 열풍에 의해 상기 저융점섬유가 녹아 상기 소프트층 섬유시트와 제1하드층 섬유시트는 상호 결합된다.The low melting point fiber is melted by the first bonding process S4 as described above, that is, by hot air, and the soft layer fiber sheet and the first hard layer fiber sheet are bonded to each other.
상기 압착공정(S5)은, 상기 제1결합공정(S4)에 의해 가열된 상기 소프트층 섬유시트와 제1하드층 섬유시트를 상호 압착하는 공정이다.The pressing step (S5) is a step of mutually pressing the soft layer fiber sheet and the first hard layer fiber sheet heated by the first bonding step (S4).
상기 압착공정(S5)에 의해 상기 소프트층 섬유시트와 상기 제1하드층 섬유시트는 더욱 밀착하여 강하게 결합되고, 일정한 두께를 유지할 수 있게 된다.By the pressing process (S5) the soft layer fiber sheet and the first hard layer fiber sheet is more closely bonded to be stronger, it is possible to maintain a constant thickness.
상기 냉각공정(S6)은 상기 압착공정(S5)에 의해 밀착된 2층 구조를 갖는 섬유시트를 냉각시켜 두께 및 표면을 고정시키는 공정이다.The cooling step (S6) is a step of fixing the thickness and the surface by cooling the fiber sheet having a two-layer structure in close contact by the pressing step (S5).
상기 냉각공정(S6)은 상기 압착공정(S5)과 동시에 이루어질 수도 있고, 별개로 이루어질 수도 있다.The cooling step (S6) may be made at the same time as the pressing step (S5), or may be made separately.
상기 제2적층공정(S7)은 위와 같은 공정에 의해 2층 구조를 갖는 섬유시트에 접착필름 및 제2하드층 섬유시트를 적층하는 공정이다.The second lamination step (S7) is a process of laminating an adhesive film and a second hard layer fiber sheet on the fiber sheet having a two-layer structure by the above process.
자세하게는 상기 소프트층 섬유시트 타면에 상기 접착필름과 제2하드층 섬유시트를 순서대로 적층한다.In detail, the adhesive film and the second hard layer fiber sheet are laminated on the other surface of the soft layer fiber sheet.
상기 제2결합공정(S8)은 상기 소프트층 섬유시트의 타면에 상기 접착필름 및 제2하드층 섬유시트를 가열하여 결합시키는 공정이다.The second bonding step (S8) is a step of heating and bonding the adhesive film and the second hard layer fiber sheet to the other surface of the soft layer fiber sheet.
결합방법은 가열된 롤러에 의해 상기 소프트층 섬유시트, 접착필름 및 제2하드층 섬유시트를 압착하여 결합시킨다.In the bonding method, the soft layer fiber sheet, the adhesive film, and the second hard layer fiber sheet are compressed by a heated roller.
이때, 상기 접착필름은 상기 소프트층 섬유시트 및 제1,2하드층 섬유시트보다 녹는점이 낮아야 한다.At this time, the adhesive film should have a lower melting point than the soft layer fibrous sheet and the first and second hard layer fibrous sheets.
따라서, 상기 가열된 롤러에 의해 섬유시트에 열이 전달되면, 상기 접착필름이 가장 먼저 녹아 상기 소프트층 섬유시트의 타면에 상기 제2하드층 섬유시트를 결합시키게 된다.Therefore, when heat is transferred to the fiber sheet by the heated roller, the adhesive film is melted first to bond the second hard layer fiber sheet to the other surface of the soft layer fiber sheet.
이와 동시에 롤러에 의해 상기 소프트층 섬유시트와 제2하드층 섬유시트는 상호 압착되어 강한 결합력을 가지게 되고, 또한 일정한 규격의 두께를 유지하게 된다.At the same time, the soft layer fiber sheet and the second hard layer fiber sheet are compressed to each other by a roller to have a strong bonding force, and to maintain a constant thickness.
한편, 상기 소프트층 섬유시트의 타면에 상기 제2하드층 섬유시트를 열풍에 의해 결합시키고자 할 경우에는 열풍이 상기 제2하드층 섬유시트를 관통하여 상기 소프트층 섬유시트까지 도달하기가 어렵고, 또한 상기 소프트층 섬유시트에 내장되어 있는 저융점섬유가 상기 제1결합공정(S4)에서 다 녹아 버렸기 때문에 열풍에 의해서는 상기 소프트층 섬유시트와 상기 제2하드층 섬유시트를 결합하기 곤란하다.On the other hand, when the second hard layer fiber sheet is to be bonded to the other surface of the soft layer fiber sheet by hot air, it is difficult for the hot air to reach the soft layer fiber sheet through the second hard layer fiber sheet, In addition, since the low melting fiber embedded in the soft layer fiber sheet is melted in the first bonding step (S4), it is difficult to combine the soft layer fiber sheet and the second hard layer fiber sheet by hot air.
상기 절단 및 권취공정(S9)은 상기 제2결합공정(S8)을 마친 섬유시트를 일정한 규격으로 절단하여 권취하는 공정이다.The cutting and winding step (S9) is a step of winding by cutting the fiber sheet after the second bonding step (S8) to a certain standard.
위와 같이 상기 소프트층 섬유시트의 일면에 배치되는 상기 제1하드층 섬유 시트는 열풍에 의해 상기 소프트 섬유시트에 결합하고, 상기 소프트 섬유시트의 타면에 배치되는 제2하드층 섬유시트는 접착필름에 의해 결합함으로써 3층 구조를 갖는 흡차음재를 쉽게 제조할 수 있다.As described above, the first hard layer fiber sheet disposed on one surface of the soft layer fiber sheet is bonded to the soft fiber sheet by hot air, and the second hard layer fiber sheet disposed on the other surface of the soft fiber sheet is attached to an adhesive film. By bonding together, a sound absorbing and insulating material having a three-layer structure can be easily produced.
또한, 상기 압착공정(S5) 및 제2결합공정(S8)에서 롤러를 사용함으로써, 소프트층 섬유시트와 하드층 섬유시트를 더욱 강하게 결합시킴과 동시에 일정한 두께를 유지하도록 할 수 있다.In addition, by using the roller in the pressing step (S5) and the second bonding step (S8), it is possible to more strongly bond the soft layer fiber sheet and the hard layer fiber sheet and to maintain a constant thickness.
또한, 상기 냉각공정(S6)에 의해 흡차음재의 두께 및 표면을 일정하게 고정시켜 차후 흡차음재의 변형이 최소화되도록 할 수 있다.In addition, by the cooling step (S6) it can be fixed to the thickness and surface of the sound absorbing and insulating material constantly to minimize deformation of the sound absorbing and insulating material in the future.
본 발명인 3층구조의 흡차음재 제조방법은 전술한 실시예에 국한하지 않고, 본 발명의 기술 사상이 허용되는 범위 내에서 다양하게 변형하여 실시할 수 있다.The method for manufacturing a sound absorbing and insulating material having a three-layer structure according to the present invention is not limited to the above-described embodiments, and may be variously modified and implemented within the allowable technical spirit of the present invention.
도 1은 본 발명의 실시예에 따른 3층구조의 흡차음재 제조방법의 공정도.1 is a process chart of the sound absorbing and insulating material manufacturing method of a three-layer structure according to an embodiment of the present invention.
<도면의 주요부분에 대한 부호의 설명><Description of the symbols for the main parts of the drawings>
S1 : 개면 및 혼면공정, S2: 소면공정, S3 : 제1적층공정, S4 : 제1결합공정, S5 : 압착공정, S6 : 냉각공정, S7 : 제2적층공정, S8 : 제2결합공정, S9 : 절단 및 권취공정.S1: Opening and blending process, S2: Carding process, S3: First lamination process, S4: First bonding process, S5: Pressing process, S6: Cooling process, S7: Second lamination process, S8: Second bonding process, S9: Cutting and winding process.
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