KR20130112689A - Sound-absorbing member, method for producing sound-absorbing member, and sheet for sound-absorbing member - Google Patents

Abstract

The sound absorption material excellent in the sound absorption characteristic in a low frequency area | region is provided. This sound absorbing material is formed on the surface of the porous substrate directly or through a nonwoven fabric with an acrylic gel formed by gelling an acrylic sol containing 50 to 150 parts by mass of a plasticizer having a boiling point of 180 ° C. or more with respect to 100 parts by mass of acrylic resin.

Description

Sound absorbing material, manufacturing method of sound absorbing material and sheet for sound absorbing material {SOUND-ABSORBING MEMBER, METHOD FOR PRODUCING SOUND-ABSORBING MEMBER, AND SHEET FOR SOUND-ABSORBING MEMBER}

The present invention relates to a sound absorbing material excellent in sound absorption properties.

Porous base material selected from inorganic fiber mats such as glass wool and rock wool, organic fiber mats such as polyester, sintered metal foams, glass foams, porcelain foams, cement foams, foams such as rubber sponges, urethane foams, melamine foams, and the like. Is widely used as a sound absorbing material. These porous substrates have microcavities such as complex bubbles and pore flow paths that communicate with each other. When sound waves are incident on the porous substrate, acoustic energy is converted into heat by the air viscous resistance of the microcavity, friction with the materials, and vibration of the materials, and the sound waves are absorbed by the porous substrate.

However, these porous substrates were excellent in sound absorption characteristics in the high frequency region, but were poor in the sound absorption characteristics in the medium frequency and low frequency region of 2000 Hz or less. By increasing the thickness of the porous substrate, the sound absorption characteristics in the medium and low frequency regions can be improved, but they have not reached a satisfactory characteristic. In addition, as the thickness of the porous substrate increases, the material cost of the sound absorbing material increases, the weight increases, and there is a problem that the workability deteriorates as the thickness increases.

In addition, Patent Document 1 discloses a sound absorbing material in which a porous layer is laminated on a resin film made of an acrylic resin.

Japanese Patent Application Laid-Open No. 2007-3827

According to Patent Literature 1, a porous material layer is laminated on both the back side and the front side of a resin film made of an acrylic resin, so that a sound absorption material having a high sound absorption in a high frequency region of 200 Hz or less and a low frequency region of 200 Hz or less can be obtained. Since it is necessary to laminate | stack a porous body layer on both surfaces of a resin film, the thickness and weight of a sound absorption material increased, and there existed a problem that handleability was inferior. Moreover, even if it was the sound absorption material disclosed by patent document 1, the sound absorption characteristic in the low frequency area was not fully satisfactory. In addition, it was not possible to make the sound absorption characteristics in the low frequency region to the high frequency region compatible at a level sufficiently satisfying.

Therefore, the objective of this invention is providing the sound absorption material excellent in the sound absorption characteristic in a low frequency region, the manufacturing method of this sound insulation material, and the sheet for sound absorption material used for manufacture of this sound insulation material.

MEANS TO SOLVE THE PROBLEM As a result of various examination, the present inventors found that the acryl sol obtained by gelatinizing the acryl sol containing a plasticizer on the surface of a porous base material adhere | attached in an independent or continuous island shape, and was made in the low frequency range from the high frequency range. It has been found that a sound absorbing material having excellent sound absorption characteristics can be obtained. Furthermore, it was found that the sound absorption rate of sound waves in the low frequency region is improved by applying an acrylic sol containing a plasticizer to a nonwoven fabric and laminating the sheet material obtained by gelling the acrylic sol on a porous substrate.

That is, the 1st of the sound absorption material of this invention has a porous base material and the adhesion layer of the acrylic gel formed in the surface, The adhesion layer of the said acrylic gel has 50-150 plasticizers whose boiling point is 180 degreeC or more with respect to 100 mass parts of acrylic resins. It is formed by attaching 70 parts by mass to 70-400 g / m ² of an acryl sol containing a mass part and attaching it to the surface of said porous substrate, forming an independent or continuous island shape on said surface of said porous substrate, The part to which the said acryl gel is not attached comprises the part by which the said porous base material was exposed.

According to the first aspect of the sound absorbing material of the present invention, an acrylic gel obtained by adhering the acrylic sol to the surface of the porous substrate by gelling 70 to 400 g / m ^{2 is} attached to the surface of the porous substrate to form an independent or continuous island shape. Since the portion where the gel is not attached forms a portion where the porous substrate is exposed, the sound waves in the low and medium frequency regions are effectively absorbed by the acrylic gel and the porous substrate in cooperation with each other, and the sound waves in the high frequency region are exposed from the surface where the porous substrate is exposed. Sound absorption is effective. For this reason, it is excellent in the sound absorption characteristic in a low frequency range from a high frequency range. Moreover, even if the thickness of a porous base material is thin, since it is excellent in sound absorption characteristic, it is excellent in handleability and workability.

In addition, the second of the sound absorbing material of the present invention has a porous substrate and an adhesion layer of an acrylic gel formed on the surface thereof through a nonwoven fabric, and the adhesion layer of the acrylic gel has a plasticizer having a boiling point of 180 ° C. or higher relative to 100 parts by mass of acrylic resin. An acrylic sol containing ˜150 parts by mass is formed by adhering to 150 to 600 g / m ² of the nonwoven fabric and gelling it, and the nonwoven fabric is laminated on the porous substrate.

According to the second aspect of the sound absorbing material of the present invention, since the adhesive layer of the acrylic gel formed by adhering the acrylic sol to a nonwoven fabric by gelation of 150 to 600 g / m ^{2 is} formed on the surface of the porous substrate through the nonwoven fabric, in the low frequency region, Its sound absorption characteristics are excellent.

On the other hand, the 1st of the manufacturing method of the sound absorption material of this invention spray-coats the acrylic sol containing 50-150 mass parts of plasticizers whose boiling point is 180 degreeC or more with respect to 100 mass parts of acrylic resins, and 70-400 g / m ^{2 is} attached to gel the acrylic sol attached to the porous substrate.

According to the first of the method for producing a sound absorbing material of the present invention, an acrylic gel is formed by spray-coating the acrylic sol on the surface of the porous substrate, adhering 70 to 400 g / m ² , and gelling the acrylic sol attached to the porous substrate. An independent or continuous island shape may be attached to the surface of the porous substrate to form a sound absorbing material having excellent sound absorption characteristics in the high frequency region from the low frequency region.

Moreover, 2nd of the manufacturing method of the sound absorption material of this invention contains acrylic resin and the plasticizer whose boiling point is 180 degreeC or more, and contains the acrylic sol which contains 50-150 mass parts of said plasticizers with respect to 100 mass parts of said acrylic resins to a nonwoven fabric. After sticking 150-600 g / m <^2> and gelling this acryl sol, the said nonwoven fabric is adhere | attached on the surface of a porous base material.

According to the second method of manufacturing the sound absorbing material of the present invention, after gelling the nonwoven fabric with the acrylic sol, the nonwoven fabric is adhered to the surface of the porous substrate to form an adhesive layer of the acrylic gel through the nonwoven fabric on the surface of the porous substrate. Thus, a sound absorbing material excellent in sound absorption characteristics in the low frequency region can be produced.

Moreover, the 3rd of the manufacturing method of the sound absorption material of this invention contains acrylic resin and the plasticizer whose boiling point is 180 degreeC or more, and the acrylic sol which contains 50-150 mass parts of said plasticizers with respect to 100 mass parts of said acrylic resins to a nonwoven fabric. 150-600 g / m <^{2> is} adhere | attached, this acryl sol is made into a pregel sheet, this pregel sheet is laminated | stacked on a porous base material, and this pregel sheet is characterized by gelling.

According to the third method of manufacturing the sound absorbing material of the present invention, the pregel sheet is gelated by laminating a pregel sheet obtained by pregelling the nonwoven fabric with the acryl sol on a porous substrate and then gelling the pregel sheet. In this case, the sound absorbing material which is integrated with a porous base material and excellent in the sound absorption characteristic in a low frequency area | region can be manufactured efficiently.

On the other hand, the sheet for sound absorption materials of this invention contains acrylic resin and the plasticizer whose boiling point is 180 degreeC or more, and the acrylic sol which contains 50-150 mass parts of said plasticizers with respect to 100 mass parts of said acrylic resins is 150-150 nonwoven fabric. 600 g / m <^{2> is} adhere | attached and it is obtained by gelatinizing this acryl sol. It is characterized by the above-mentioned.

Since the sheet for sound absorption material of this invention is excellent in the sound absorption characteristic in a low frequency area | region, by laminating | stacking this sound absorption material sheet to a porous base material, the sound absorption material excellent in the sound absorption characteristic in a low frequency area | region can be obtained.

In this invention, it is preferable that the basis weight (weight per unit area) of the said nonwoven fabric is 10-500 g / m <^2> .

In this invention, it is preferable that the thickness of the said nonwoven fabric is 0.05-5 mm.

In this invention, it is preferable that the said nonwoven fabric is an organic fiber type nonwoven fabric, and the density of this nonwoven fabric is 0.1-0.5 g / cm <^3> .

In this invention, it is preferable that the said acryl gel gelatinized the said acryl sol containing a blowing agent.

In this invention, it is preferable that the said porous base material is a fiber mat.

In the present invention, the porous substrate preferably has a density of 10 kg / m ³ or more.

In this invention, it is preferable that the thickness of the said porous base material is 2 mm or more.

According to this invention, even if the thickness of a porous base material is thin, since it can be set as the sound absorption material excellent in sound absorption characteristics, it is excellent in handleability and workability.

1 is an enlarged photograph of the sound absorbing material of Example 1-3;
2 is an enlarged photograph of the sound absorbing material of Example 1-4.

EMBODIMENT OF THE INVENTION Hereinafter, preferred embodiment is described and this invention is demonstrated in detail. In addition, below, what is described as (meth) acrylate means an acrylate or a methacrylate. In addition, in the present specification, the sound wave in the low frequency region means sound waves of about 800 Hz or less, the sound wave in the middle frequency region means sound waves of 800 to 2000 Hz, and the sound wave in the high frequency region means sound waves of about 2000 Hz or more.

[Acryl sol]

First, the acryl sol used for the sound absorption material of this invention is demonstrated.

Acrylic sol contains acrylic resin and the plasticizer whose boiling point is 180 degreeC or more.

(Acrylic resin)

Acrylic resin can use preferably what is obtained by superposing | polymerizing the monomer or monomer mixture containing the alkyl (meth) acrylate of a C1-C8 linear, branched or alicyclic alcohol.

As alkyl (meth) acrylate, methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, i-butyl (meth) acrylate, t-butyl (meth) acrylate, hexyl ( Meth) acrylate, 2-ethylhexyl (meth) acrylate, octyl (meth) acrylate, cyclohexyl (meth) acrylate, etc. are mentioned.

Moreover, the monomer copolymerizable with alkyl (meth) acrylate can also be used together. Such monomers include styrene, α-methylstyrene, β-methylstyrene, o-methylstyrene, m-methylstyrene, p-methylstyrene, 2,4-dimethylstyrene, pn-butylstyrene, p-tert-butylstyrene, pn -Hexyl styrene, pn-octyl styrene, pn-nonyl styrene, pn-decyl styrene, pn-dodecyl styrene, p-methoxy styrene, p-phenyl styrene, polyethylene glycol di (meth) acrylate, propylene glycol di (meta ) Acrylate, 1,6-hexanediol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, divinylbenzene, divinyl naphthalene, divinyl ether, itaconic acid, crotonic acid, maleic acid, maleic acid Triaryl isocyanurate, such as ester, maleic anhydride, a fumaric acid, and a fumaric acid ester, etc. are mentioned.

10,000-5,000,000 are preferable and, as for the weight average molecular weight of acrylic resin, 100,000-2,000,000 are more preferable. When the weight average molecular weight is less than 10,000, the storage stability of the acryl sol is lowered and the gel strength tends to be lowered. If it exceeds 5,000,000, the acrylic sol becomes difficult to gel. If the weight average molecular weight of acrylic resin is in the said range, the storage stability of an acryl sol can be made favorable. In addition, it can be easily gelatinized and a gel excellent in strength can be obtained.

0.1-10 micrometers is preferable and, as for the particle diameter of acrylic resin, 0.1-2 micrometers is more preferable. If the particle diameter is less than 0.1 µm, the storage stability of the acryl sol tends to be lowered. When it exceeds 10 micrometers, the viscosity of an acryl sol rises and application | coating workability falls and it exists in the tendency for spray coating to become difficult. When the particle diameter of acrylic resin is in the said range, thixotropy is expressed and it can be set as the acryl sol excellent in non-sag property. Here, the particle diameter of acrylic resin is the measured value (median diameter) measured using the laser diffraction / scattering type particle size distribution analyzer LA-910 (made by HORIBA).

60 degreeC or more is preferable and, as for Tg of acrylic resin, 75 degreeC or more is more preferable. If Tg is 60 degreeC or more, stability at the time of storage becomes comparatively favorable.

What is marketed may be used for acrylic resin. For example, "Dialal LP" (brand name, Mitsubishi Rayon), etc. are mentioned.

(Plasticizer)

The plasticizer uses a thing whose boiling point is 180 degreeC or more. If a boiling point is less than 180 degreeC, the plasticizer may volatilize by the heating at the time of gelatinizing an acryl sol, and it is unpreferable. 190 degreeC or more is preferable and, as for the boiling point of a plasticizer, 200 degreeC or more is more preferable.

As a plasticizer, phthalic acid, such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, di-2-ethylhexyl phthalate, dimaloctyl phthalate, diisononyl phthalate, dinonyl phthalate, diisodecyl phthalate, and butyl benzyl phthalate Ester plasticizer, dimethyl adipic acid, dibutyl adipic acid, diisobutyl adipic acid, dihexyl adipic acid, di-2-ethylhexyl adipic acid, dibutyl diglycol adipic acid, dioctyl adipic acid, adipic acid diisono Adipic acid ester plasticizers, such as nil, dimethyl sebacate, dibutyl sebacate, dioctyl sebacate, and di-2-ethylhexyl sebacate, trimethyl phosphate, triethyl phosphate, tributyl phosphate, and triphosphate Phosphate ester plasticizers, such as 2-ethylhexyl, tributoxyethyl phosphate, triphenyl phosphate, tricredi phosphate, trixylenyl phosphate, and credil phosphate, tributyl acetyl citrate, and trimethic acid tri-2- on Trimellitic acid ester plasticizers such as hexyl and trioctyl trioctyl, azelaic acid ester plasticizers such as dioctyl azelaate, aliphatic polyester plasticizers such as poly-1,3-butanediol adipate, and epoxy such as epoxidized soybean oil Alkyl sulfonic acid phenyl ester plasticizers, such as a ester ester plasticizer and an alkyl sulfonate phenyl ester, an alicyclic dibasic acid ester plasticizer, polyether plasticizers, such as a polypropylene glycol and polybutylene glycol, etc. are mentioned. Especially, the phthalate ester plasticizer which has a C8-10 alkyl group is preferable from the reason that compatibility with acrylic resin is good and storage stability of an acryl sol is favorable.

As for the solubility parameter (SP value) of a plasticizer, 18-21 (J / cm <^3> ) ^0.5 is preferable and 19.5-20.5 (J / cm <^3> ) ^0.5 is more preferable. If the solubility parameter is less than 18 (J / cm ³ ) ^0.5 , the plasticizer tends to bleed out after gelation. When the solubility parameter exceeds 21 (J / cm ³ ) ^0.5 , the storage stability of the acryl sol tends to be lowered. If the solubility parameter is in the above range, the compatibility between the acrylic resin and the plasticizer is good, and the storage stability of the acrylic sol is good. Here, the solubility parameter of a plasticizer is a value computed by the Fedors method (polymer engineering and science, Vol. 14, 147 (1974)).

It is more preferable that a plasticizer contains 50-150 mass parts with respect to 100 mass parts of acrylic resin, and contains 70-130 mass parts. When content of a plasticizer is less than 50 mass parts, the viscosity of an acryl sol becomes high too much, and it becomes difficult to apply an acryl sol to a nonwoven fabric or a porous base material, and spray coating is difficult. In addition, the sound absorbing properties of the sound absorbing material are insufficient. When it exceeds 150 parts by mass, the plasticizer component is likely to stick out from the nonwoven fabric or the porous substrate even after gelation.

(Other components)

It is preferable that the acryl sol used by this invention contains a foaming agent further. By containing a foaming agent in an acryl sol, the gel containing foam can be obtained and a sound absorption characteristic can be improved more. Moreover, since the sound absorption characteristic can be improved, the application amount of an acryl sol can be reduced, it is economical, and a sound absorption material can be made lighter.

As a foaming agent, a microcapsule type foaming agent and a thermal decomposition type foaming agent are preferable, and what decomposes and foams in the vicinity of gelation temperature can be used more preferably.

Examples of the microcapsular foaming agent include thermally expandable microcapsules. As the thermally expandable microcapsules, for example, "Matsumoto microsphere F series" (trade name) or the like, which is commercially available from Matsumoto Yushi Seiyaku Co., Ltd. can be used.

Examples of the thermal decomposition blowing agent include an azo compound, a nitroso compound, and a hydrazine derivative. Azo dicarbonamide, azobisisobutyronitrile, etc. are mentioned as an azo compound. Examples of the nitroso compound include N, N'-dinitrosopentamethylenetetramine, N, N'-dimethyl-N, N'-dinitrosoterephthalamide, and the like. Examples of the hydrazine derivatives include benzenesulfonylhydrazide, p, p'-oxybis (benzenesulfonylhydrazide), toluenesulfonylhydrazide, and the like.

25 mass parts or less are preferable with respect to 100 mass parts of acrylic resin, and, as for content of a foaming agent, 5-20 mass parts is more preferable. When it exceeds 25 mass parts, the smoothness after gelling may worsen. If it is less than 5 mass parts, the addition effect is hardly obtained.

The acryl sol used by this invention can contain a flame retardant, a filler, a foaming adjuvant, etc. in the range which does not impair sound absorption characteristics. However, since the sound absorption characteristic may be reduced, it is preferable not to contain a filler.

Examples of the flame retardant include phosphate ester flame retardants, hydrous silicic acid, metal hydroxides such as aluminum hydroxide and magnesium hydroxide, polyphosphate flame retardants, and halogen-containing ester flame retardants. 100 mass parts or less are preferable with respect to 100 mass parts of acrylic resin, and, as for content of a flame retardant, 50 mass parts or less are more preferable.

Examples of the filler include calcium carbonate, talc, silica, glass fibers, and the like. 100 mass parts or less are preferable with respect to 100 mass parts of acrylic resin, and, as for content of a filler, 50 mass parts or less are more preferable, and it is especially preferable not to contain.

Zinc oxide etc. are mentioned as a foaming adjuvant. By containing a foaming aid, the thermal decomposition temperature of a foaming agent can be lowered, and foaming efficiency can be improved.

[Sheet for sound absorbing material]

Next, the sheet for sound absorption materials of this invention is demonstrated.

The sheet for sound absorbing materials of the present invention is obtained by attaching the acryl sol to a nonwoven fabric and gelling the acryl sol.

As a nonwoven fabric, organic fiber type nonwoven fabric, inorganic fiber type nonwoven fabric, and metal fiber type nonwoven fabric can all be used preferably, These mixed nonwoven fabric and laminated nonwoven fabric can also be used suitably. Examples of the organic fiber include polyethylene terephthalate fiber, polyester fiber, polypropylene fiber, polybutylene terephthalate fiber, nylon fiber and vinylon fiber. Glass fiber, carbon fiber, etc. are mentioned as an inorganic fiber. Examples of the metal fibers include aluminum fibers and steel fibers. Especially, since it is lightweight and flexible, an organic fiber type nonwoven fabric can be used especially preferably.

10-500 g / m <^2> is preferable, as for the basis weight of a nonwoven fabric, 20-200 g / m <^2> is more preferable, 40-150 g / m <^2> is especially preferable. When the basis weight is less than 10 g / m ² , the acryl sol adhered to the surface is excessively oozed out to the back side, resulting in stickiness, resulting in poor handling. In addition, the sound absorption characteristics in the low frequency region are insufficient. Moreover, when basis weight exceeds 500 g / m < ² >, stiffness will arise and handleability will worsen. If the basis weight of a nonwoven fabric is in the said range, the bleeding to the back surface of the acryl sol adhering to the surface can be suppressed, and the gel film which consists of an acryl sol can be formed on the surface of a nonwoven fabric. In addition, there is no stickiness or stiffness, and the sheet for sound absorbing material having good handleability can be obtained.

0.05-5 mm is preferable and, as for the thickness of a nonwoven fabric, 0.1-1 mm is more preferable. If the thickness is less than 0.05 mm, the acrylic sol adhered to the surface is excessively soaked to the back surface, resulting in stickiness, resulting in poor handleability. In addition, the sound absorption characteristics in the low frequency region are insufficient. Moreover, as the thickness of a nonwoven fabric increases, since the thickness of the sound absorption material which is a final product increases, there exists a tendency for the workability of a sound absorption material to worsen. For this reason, 5 mm is preferable for the upper limit of the thickness of a nonwoven fabric.

0.1-0.5 g / cm <^3> is preferable and, as for the density of a nonwoven fabric, 0.2-0.4 g / cm <^3> is more preferable. If the density is less than 0.1 g / cm ³ , the acrylic sol adhered to the surface is excessively soaked to the back surface, resulting in stickiness, resulting in poor handling. In addition, as the density of the nonwoven fabric increases, the weight of the sound absorbing material, which is the final product, increases, and thus the workability of the sound absorbing material tends to be deteriorated. For this reason, 0.5 g / cm <^3> is preferable for the upper limit of the density of a nonwoven fabric.

The adhesion amount of the acryl sol to a nonwoven fabric is 150-600 g / m <^2> , and 200-500 g / m <^2> is more preferable. If the adhesion amount of the acryl sol is less than 150 g / m ² , the sound absorption characteristics in the low frequency region are insufficient. Even if it exceeds 600 g / m <^2> , the effective improvement of a sound absorption characteristic cannot be expected, and it is uneconomical, and handleability and workability fall as weight increases.

Next, the manufacturing method of the sheet | seat for sound absorption materials of this invention is demonstrated.

The acrylic sol is applied to a nonwoven fabric.

There is no limitation in particular as a coating method of an acryl sol. Spray coating, spread coating, dip coating, die coating, gravure printing, screen printing, and the like. Among them, die coating is preferred for obtaining a coating thickness of 150 g / m ² or more and for uniformity of film thickness.

The adhesion amount of an acryl sol is 150-600 g / m <^2> , and 200-500 g / m <^2> is more preferable.

Next, the acrylic sol attached to the nonwoven fabric is gelled. And it cuts to a predetermined dimension and the sheet for sound absorption materials is obtained.

It is preferable to perform gelatinization of an acryl sol by heating the nonwoven fabric with an acryl sol at 130-200 degreeC for 1 to 20 minutes. As for heating temperature, 150-180 degreeC is more preferable. As for heating time, 5 to 10 minutes are more preferable. When heating temperature is less than 130 degreeC, the gelation of an acryl sol may be inadequate and the sound absorption characteristic in a low frequency range may be inadequate. In the case where the acryl sol contains a foaming agent, gelation at a temperature lower than the foaming temperature may result in insufficient generation of foaming gas, which hardly contains bubbles, and the effect of addition by the foaming agent is hardly obtained. There is a case. Moreover, when heating temperature exceeds 200 degreeC, a plasticizer will volatilize or decomposition of resin by excessive heating will arise, and it is unpreferable.

[Absorption material]

Next, the sound absorption material of this invention is demonstrated.

(First Embodiment)

1st Embodiment of the sound absorption material of this invention is a thing formed by the acryl gel which gelatinized the said acryl sol formed on the surface of a porous base material in an independent or continuous island shape, and sticking.

Examples of the porous substrate include inorganic fiber mats such as glass wool and rock wool, organic fiber mats such as polyester, sintered metal foams, glass foams, porcelain foams, cement foams, foams such as rubber sponges, urethane foams, melamine foams, and the like. The lamination | stacking of these is used suitably.

Among them, inorganic or organic fiber mats are preferred because of their excellent sound absorption.

Since the thickness and density of a porous base material differ with a kind, it does not specifically limit. For example, in the case of an inorganic fiber mat, 2 mm or more is preferable, as for thickness, 5-100 mm is more preferable, 10-50 mm is especially preferable. Moreover, 10 kg / m <^3> or more is preferable and, as for density, 16-250 kg / m <^3> is more preferable. If the thickness is less than 2 mm, sound absorption characteristics may be insufficient. Even if the thickness exceeds 100 mm, almost no change in the sound absorbing properties is observed, and as the thickness increases, the handleability is lowered and the workability tends to be deteriorated. Moreover, when a density is less than 10 kg / m <^3> , the handleability of a sound absorption material will fall, and workability will worsen. When density exceeds 250 kg / m < ³ >, sound absorption characteristic may be inadequate.

The adhesion amount per unit area of acryl sol is 70-400 g / m <^2> , and 150-300 g / m <^2> is preferable. If the adhesion amount of the acryl sol is less than 70 g / m ² , the sound absorption characteristics in the low frequency region and the medium frequency region are insufficient. When it exceeds 400 g / m < ² >, a porous base material will be concealed by the acryl gel obtained by gelatinizing the apply | coated acryl sol. For this reason, although the detailed reason is not known, although the sound absorption characteristic in a low frequency range is comparatively favorable, the sound absorption characteristic in a high frequency range will fall.

As for the sound absorption material of this invention, the skin material may be stuck more. Examples of the skin material include aluminum foil-based, vinyl chloride-based, polyolefin-based, polyester-based, and polytetrafluoroethylene-based material films, nonwovens, or woven fabrics, or nonwoven fabrics such as glass fibers and carbon fibers, or woven fabrics. As for the thickness of a skin material, 0.05-1 mm is preferable. The skin material can be stuck with an adhesive or the like.

Although the sound absorption rate of the sound absorption material of this invention changes with the kind and thickness of a porous base material, For example, when the fiber mat of thickness 10-50 mm is made into a porous base material, the sound absorption rate of the sound wave of a low frequency range is 0.1-1, and a medium frequency range It is preferable that the sound absorption rate of a sound wave is 0.4-1, and the sound absorption rate of the sound wave of a high frequency range is 0.7-1. By increasing the thickness of the porous substrate, the sound absorption rate of sound waves from low frequency to high frequency can be improved as a whole. In order to increase the sound absorption rate of sound waves in the high frequency region, the application amount of the sol may be reduced, and in order to increase the sound absorption rate of the sound waves in the low frequency region, the application amount of the sol may be increased a little. In addition, the value of a sound absorption rate means the value measured by the method shown in the Example mentioned later.

The said sound absorption material can be manufactured as follows.

First, the surface of the porous substrate, using a spray, spray coating the acrylic sol and per unit area 70~400g / m ^2, and preferably are attached 150~300g / m ^2.

The acrylic sol attached to the porous substrate is then gelled. Preferably, after spray-coating an acryl sol on the porous substrate, the acryl sol attached to the porous substrate is subjected to a pressing member such as a roll or spatula without uniformly spreading or painting, that is, porous The acrylic sol attached to the substrate is gelled without pressure. By gelling the acryl sol in this manner, the acryl gel gelled with the acryl sol can be attached to the surface of the porous substrate in an independent or continuous island shape. Further, whether or not the acrylic gel is attached to the surface of the porous substrate in an independent or continuous island shape can be determined by coloring the acrylic gel with an oily marker or the like and magnifying the surface with a microscope or the like. .

It is preferable to perform gelatinization of an acryl sol by heating the porous base material with an acryl sol at 130-200 degreeC for 1 to 20 minutes. As for heating temperature, 150-180 degreeC is more preferable. As for heating time, 5 to 10 minutes are more preferable. When heating temperature is less than 130 degreeC, the gelation of an acryl sol may be inadequate, and the sound absorption characteristic in the low frequency and mid frequency range may be inadequate. In addition, in the case where the acrylic sol contains a foaming agent, gelling below the foaming temperature may result in insufficient generation of foaming gas, which hardly contains bubbles, and the effect of addition of the foaming agent is hardly obtained. There is a case. Moreover, when heating temperature exceeds 200 degreeC, a plasticizer volatilizes or resin decomposes by excessive heating, and it is unpreferable.

For example, a glass wool of 1000 mm in length, 1000 mm in width, 15 mm in thickness and 32 kg / m ³ in density is installed on the belt conveyor and conveyed at a speed of 5 m / min. Spray coating is applied to the upper surface to attach a predetermined amount. And the acrylic sol is gelatinized by passing through the drying furnace, conveying the glass wool with an acryl sol to a belt conveyor.

In this way, the sound absorption material of this invention can be manufactured.

In the case of producing a sound absorbing material having a skin material adhered thereon, after gelling the acrylic sol, an adhesive is applied to the surface of the porous substrate or the back surface of the skin material, and the skin material is laminated on the porous substrate through the adhesive, after which the adhesive It is obtained by hardening.

In the sound absorbing material of the present invention thus obtained, the acryl sol obtained by gelling the above acryl sol is attached to the surface of the porous substrate in an independent or continuous island shape. The sound absorbing material of the present invention has excellent sound absorbing properties for any sound wave in the low frequency region to the high frequency region, as shown in Examples described later. Although this detailed reason is not known, since the acrylic gel composed of an acrylic sol containing a specific plasticizer adheres to the surface of the porous substrate in an independent or continuous island shape, the sound waves in the low frequency and the medium frequency regions are different from each other in the acrylic gel and the porous substrate. It is thought that this is because the sound wave in the high frequency region is effectively absorbed in conjunction with the sound absorbed from the exposed surface of the porous substrate.

(Second Embodiment)

Next, 2nd Embodiment of the sound absorption material of this invention is described.

The sound absorbing material of the second embodiment has a porous substrate and an adhesion layer of an acrylic gel formed on the surface thereof through a nonwoven fabric, and the adhesion layer of the acrylic gel is formed by adhering the acrylic sol to a nonwoven fabric by 150 to 600 g / m ² . This nonwoven fabric is laminated | stacked on the porous base material.

The skin material may be further stuck on the surface of the adhesion layer of the acrylic gel. As the skin material, the same ones used in the sound absorbing material of the first embodiment can be used. The skin material can be stuck with an adhesive or the like.

As a nonwoven fabric, the thing similar to what was used by said sheet for sound absorption materials can be used.

As a porous base material, the thing similar to what was used for the sound absorbing material of 1st Embodiment mentioned above can be used.

The sound absorption material of 2nd Embodiment is especially excellent in the sound absorption characteristic in the low frequency area of 500 Hz or less.

The sound absorption material of 2nd Embodiment can be manufactured by the method of the following (1) and (2).

(1) 150-600 g / m <^2> of acrylic sol is made to adhere to a nonwoven fabric, and this acrylic sol is gelatinized, and a nonwoven fabric is adhere | attached on the surface of a porous base material. That is, the sheet for sound absorption materials of this invention is stuck to the surface of a porous base material.

(2) 150-600 g / m <^2> of acryl sol is made to adhere to a nonwoven fabric, this acryl sol is pregelled, it is made into a pregel sheet, and this pregel sheet is laminated | stacked on a porous base material, and this pregel sheet is gelatinized.

In the method of said (1), styrene-butadiene rubber | gum aerosol, a hot melt, a heat welding film etc. are mentioned as an adhesive agent used for adhesion | attachment of a porous base material and the sheet | seat for sound absorption materials.

In the method of said (2), it is preferable to carry out pregelation of an acryl sol by heating at 100-130 degreeC for 5 to 20 minutes. 105-125 degreeC of heating temperature is more preferable. In addition, the heating time is more preferably 5 to 10 minutes. If the heating temperature is less than 100 ° C., the pregelation of the acryl sol takes time, and the productivity becomes poor or the pregelation is insufficient, so that it cannot be handled. When it exceeds 130 degreeC, an acryl sol may gelatinize almost completely. Moreover, in the case of the acryl sol containing a foaming agent, it may foam.

It is preferable to perform gelation of a pregel sheet by hot-pressing at 130-200 degreeC for 1 to 20 minutes. As for heating temperature, 150-180 degreeC is more preferable. In addition, the heating time is more preferably 2 to 10 minutes. If heating temperature is less than 130 degreeC, gelation may be inadequate. When it exceeds 200 degreeC, a plasticizer volatilizes and decomposition | disassembly of resin by excessive heating occurs easily, and it is unpreferable.

By gelling the pregel sheet in a state where the pregel sheet and the porous substrate are laminated, the gel is integrated with a part of the surface of the porous substrate at the time of gelling of the pregel sheet. Even if it does not, a porous base material and a gel sheet can be joined firmly, and a sound absorption material can be manufactured efficiently.

Moreover, the skin material may be stuck to the surface of a gel sheet. In order to obtain the sound absorption material with the skin material affixed, the method of the following (A) and (B) is mentioned, for example.

(A) An adhesive is apply | coated to the surface of a gel sheet or the back surface of a skin material, a skin material is laminated | stacked on a gel sheet via an adhesive agent, and an adhesive agent is hardened after that.

(B) The pregel sheet is gelated in a state where the skin material is disposed on the surface of the pregel sheet.

If it is the method of said (B), since it integrates with a part of back surface of a skin material at the time of gelatinization of a pregel sheet, the sound absorption material with which a skin material adhered can be obtained, without using an adhesive agent.

The sound absorbing material of the present invention is excellent in sound absorption characteristics, and is suitable for sound absorbing materials such as walls, floors and roofs of buildings, sound absorbing materials as general factory facilities and devices, sound absorbing materials such as vehicle interior materials and insulators, and walls and floors requiring sound insulation performance. Is adopted.

The sound absorbing material of the present invention is suitably employed for sound absorbing materials such as walls, floors, roofs of buildings, sound absorbing materials for general factory facilities and devices, sound absorbing materials such as vehicle interior materials and insulators, and walls and floors requiring sound insulation performance.

(Example)

Hereinafter, although an Example and a comparative example demonstrate this invention further in detail, these do not limit this invention at all. In addition, the sound absorption rate described in the Example was measured as follows.

-Measurement of sound absorption rate: According to JIS A 1405 perpendicular incident sound absorption rate measuring method, the back air layer was 0 mm.

[Production of Acrylic Sol]

(Production Example 1)

100 parts by mass of acrylic resin (brand name: "Dialal LP-3106", made by Mitsubishi Rayon), 100 parts by mass of phthalic acid diisodecyl as a plasticizer, and a foaming agent (brand name: "Matsumoto microsphere F-79D", Matsumoto Yu 10 parts by mass of Shikagaku Co., Ltd. was mixed to obtain an acryl sol of Production Example 1.

(Production Example 2)

In Production Example 1, an acrylic sol of Production Example 2 was obtained in the same manner as in Production Example 1 except that no blowing agent was added.

(Production Example 3)

In Production Example 1, an acrylic sol of Production Example 3 was obtained in the same manner as in Production Example 1 except that the amount of the plasticizer added was 70 parts by mass.

(Production Example 4)

In Production Example 1, an acrylic sol of Production Example 4 was obtained in the same manner as in Production Example 1 except that the amount of the plasticizer added was 130 parts by mass.

(Production Example 5)

In Production Example 1, an acrylic sol of Production Example 5 was obtained in the same manner as in Production Example 1 except that the amount of the plasticizer added was 40 parts by mass.

(Production Example 6)

In Production Example 1, an acrylic sol of Production Example 6 was obtained in the same manner as in Production Example 1 except that the amount of the plasticizer added was 160 parts by mass.

The compounding composition of the acryl sol of the manufacture examples 1-6 is put together in Table 1, and is described.

Production Example 1 Production Example 2 Production Example 3 Production Example 4 Production Example 5 Production Example 6 Acrylic resin
(Parts by mass)
100
100
100
100
100
100 Plasticizer
(Parts by mass)
100
100
70
130
40
160 blowing agent
(Parts by mass)
10
0
10
10
10
10

[Production of Sound Absorbing Material]

<Test Example 1-1>

(Example 1-1)

Glass wool (thickness: 25mm, density: 16kg / cm ^3, a basis weight: 400g / m ^2), the spray-coated with an acrylic sol of Preparation Example 1, 360g / m ² adhesion was later, by heating for 5 minutes to 170 ℃ embodiment The sound absorbing material of Example 1-1 was obtained. This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.36, the sound absorption rate at 1000 Hz was 0.90, and the sound absorption rate at 2000 Hz was 0.75, and the sound absorption rate at 3150 Hz was 0.90 and 4000 Hz, respectively.

(Example 1-2)

In Example 1-1, the sound absorbing material of Example 1-2 was obtained like Example 1-1 except having spray-coated the acryl sol of manufacture example 2, and making it adhere to 313g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the absorption rate at 500 Hz was 0.21, the absorption rate at 1000 Hz was 0.46, and the absorption rate at 0.8 Hz was 0.81, and the absorption rate at 3150 Hz was 0.92, and the absorption rate at 4000 Hz was 0.81.

(Comparative Example 1-1)

In Example 1-1, glass wool was used as a sound absorption material as it was. This sound absorbing material had a sound absorption rate of 0.17 at 500 Hz, a sound absorption rate of 0.35 at 1000 Hz, a sound absorption rate of 0.61 at 2000 Hz, a sound absorption rate of 0.83 at 3150 Hz, and a sound absorption rate of 0.70 at 4000 Hz.

(Comparative Example 1-2)

The acryl sol of Production Example 2 was spread out in a film shape using a coater, or heated at 105 ° C. for 10 minutes to obtain a film-shaped pregelled acrylic gel. This acrylic gel was affixed on glass wool (thickness: 25 mm, density: 16 kg / cm <^3> , basis weight: 400 g / m <^2> ), and it heated at 170 degreeC for 5 minutes, and obtained the sound absorption material of the comparative example 1-2. 303 g / m < ² > had acryl gel adhered to this sound absorption material. Moreover, there was no part from which the glass wool was exposed from the surface of the acrylic gel. The sound absorption rate of the sound absorbing material at 500 Hz was 0.41, the sound absorption rate at 1000 Hz was 0.98, the sound absorption rate at 2000 Hz was 0.51, and the sound absorption rate at 3150 Hz was 0.48 and 4000 Hz at 0.19.

(Comparative Example 1-3)

In Example 1-1, the sound absorbing material of Comparative Example 1-3 was obtained like Example 1-1 except having spray-coated the acryl sol of manufacture example 2, and adhering 45g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. The absorbance at 500 Hz was 0.19, the absorbance at 1000 Hz was 0.34, the absorbance at 2000 Hz was 0.62, and the absorbance at 0.83 and 4000 Hz was 0.75.

(Comparative Example 1-4)

In Example 1-1, the sound absorbing material of Comparative Example 1-4 was obtained like Example 1-1 except having spray-coated the acryl sol of manufacture example 5, and making it adhere to 332g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.21, the sound absorption rate at 1000 Hz was 0.47, and the sound absorption rate at 2000 Hz was 0.72, and the sound absorption rate at 3150 Hz was 0.85 and 4000 Hz at 0.85.

The said result is put together in Table 2 and shown. As shown in Table 2, the sound absorption rate of the sound absorbing material of Examples 1-1 and 1-2 was improved compared with the comparative example 1-1 which used glass wool as a sound absorbing material as it is, in any range of a low frequency range from a high frequency range. .

Example
1-1 Example
1-2 Comparative Example
1-1 Comparative Example
1-2 Comparative Example
1-3 Comparative Example
1-4 Type of acryl sol Production Example 1 Production Example 2 none Production Example 2 Production Example 2 Production Example 5 Acryl sol adhesion Island shape Island shape - Membrane shape Island shape Island shape Amount of Acryl Sol (g / m ² ) 360 313 - 303 45 332
Suction
Well
Rate
500Hz 0.36 0.21 0.17 0.41 0.19 0.21 1000Hz 0.90 0.46 0.35 0.98 0.34 0.47 2000Hz 0.75 0.81 0.61 0.51 0.62 0.72 3150Hz 0.90 0.92 0.83 0.48 0.83 0.85 4000 Hz 0.72 0.81 0.70 0.19 0.75 0.80

<Test Example 1-2>

(Example 1-3)

Glass wool (thickness: 10mm, density: 51kg / cm ^3, a basis weight: 510g / m ^2), the coating spraying the acrylic sol of Preparation Example 1, 163g / m ² adhesion was back, and heated for 5 minutes at 170 ℃ carried The sound absorption material of Example 1-3 was obtained. This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In Fig. 1, a portion of the acrylic gel is colored with a black oil marker and an enlarged photograph enlarged 100 times is shown. In addition, the sound absorption rate at 500 Hz was 0.12, the sound absorption rate at 1000 Hz was 0.43, the sound absorption rate at 2000 Hz was 0.81, and the sound absorption rate at 3150 Hz was 0.92, and the absorption rate at 4000 Hz was 0.95.

(Examples 1-4)

In Example 1-3, the sound absorbing material of Example 1-4 was obtained like Example 1-3 except spray coating of the acryl sol of manufacture example 2, and making it adhere to 342g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In Fig. 2, a portion of the acrylic gel is colored with a black oil marker, and an enlarged photograph enlarged by 25 times is shown. In addition, the sound absorption rate at 500 Hz was 0.21, the sound absorption rate at 1000 Hz was 0.62, and the sound absorption rate at 2000 Hz was 0.72, and the sound absorption rate at 3150 Hz was 0.97 and 4000 Hz at 0.92.

(Comparative Example 1-5)

In Example 1-3, glass wool was used as a sound absorption material as it was. This sound absorbing material had a sound absorption rate of 0.05 at 1000 Hz, a sound absorption rate of 0.17 at 1000 Hz, a sound absorption rate of 0.50 at 2000 Hz, and a sound absorption rate of 0.76 at 3150 Hz, and 0.89 at 4000 Hz.

(Comparative Example 1-6)

In Example 1-3, the sound absorbing material of Comparative Example 1-6 was obtained like Example 1-3 except spray-coating the acryl sol of manufacture example 1 and making it adhere to 414g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.27, the sound absorption rate at 1000 Hz was 0.69, the sound absorption rate at 2000 Hz was 0.41, and the sound absorption rate at 3150 Hz was 0.44 and 4000 Hz at 0.19.

The said result is put together in Table 3 and shown. As shown in Table 3, in the sound absorbing materials of Examples 1-3 and 1-4, the sound absorption rate was improved in any range of the low frequency region to the high frequency region, as compared with Comparative Example 1-5 in which glass wool was used as the sound absorbing material as it is. .

Example
1-3 Example
1-4 Comparative Example
1-5 Comparative Example
1-6 Type of acryl sol Production Example 1 Production Example 2 none Production Example 1 Acryl sol adhesion Island shape Island shape - Island shape Amount of Acryl Sol (g / m ² ) 163 342 - 414
Suction
Well
Rate
500Hz 0.12 0.21 0.05 0.27 1000Hz 0.43 0.62 0.17 0.69 2000Hz 0.81 0.72 0.50 0.41 3150Hz 0.92 0.97 0.76 0.44 4000 Hz 0.95 0.92 0.89 0.19

<Test Example 1-3>

(Example 1-5)

The glass sol (thickness: 6 mm, density: 85 kg / cm ³ , basis weight: 510 g / m ² ) was spray-coated with the acrylic sol of Preparation Example 1, adhered to 117 g / m ² , and then heated at 170 ° C. for 5 minutes. The sound absorbing material of Example 1-5 was obtained. This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.07, the sound absorption rate at 1000 Hz was 0.25, the sound absorption rate at 2000 Hz was 0.70, and the sound absorption rate at 3150 Hz was 0.83 and 4000 Hz at 0.90.

(Comparative Example 1-7)

In Example 1-5, glass wool was used as a sound absorption material as it was. The sound absorption material was 0.03 at 500 Hz, 0.09 at 1000 Hz, 0.29 at 2000 Hz, and 0.59 at 3150 Hz, 0.69 at 4000 Hz.

(Comparative Example 1-8)

In Example 1-5, the sound absorbing material of Comparative Example 1-8 was obtained like Example 1-5 except having spray-coated the acryl sol of manufacture example 2, and making it adhere to 478g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.10, the sound absorption rate at 1000 Hz was 0.53, the sound absorption rate at 2000 Hz was 0.53, and the sound absorption rate at 3150 Hz was 0.44 and 4000 Hz at 0.35.

The said result is put together in Table 4 and shown. As shown in Table 4, the sound absorption material of Example 1-5 improved the sound absorption rate in the range from the low frequency range to the high frequency range compared with the comparative example 1-7 which used glass wool as a sound absorption material as it is.

Example
1-5 Comparative Example
1-7 Comparative Example
1-8 Type of acryl sol Production Example 1 none Production Example 2 Acryl sol adhesion Island shape - Island shape Amount of Acryl Sol (g / m ² ) 117 - 478
Suction
Well
Rate
500Hz 0.07 0.03 0.10 1000Hz 0.25 0.09 0.53 2000Hz 0.70 0.29 0.53 3150Hz 0.83 0.53 0.44 4000 Hz 0.90 0.69 0.35

<Test Example 1-4>

(Examples 1-6)

The glass wool (thickness: 4 mm, density: 125 kg / cm ³ , basis weight: 500 g / m ² ) was spray-coated with the acrylic sol of Preparation Example 1, adhered to 232 g / m ² , and heated at 170 ° C. for 5 minutes. The sound absorption material of Example 1-6 was obtained. This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.05, the sound absorption rate at 1000 Hz was 0.24, the sound absorption rate at 2000 Hz was 0.55, and the sound absorption rate at 3150 Hz was 0.71 and 4000 Hz at 0.83.

(Example 1-7)

In Example 1-6, the sound absorbing material of Example 1-7 was obtained like Example 1-6 except having spray-coated the acryl sol of manufacture example 2, and making it adhere to 341 g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.07, the sound absorption rate at 1000 Hz was 0.37, the sound absorption rate at 2000 Hz was 0.62, and the sound absorption rate at 3150 Hz was 0.58 and the 4000 Hz was 0.56.

(Comparative Example 1-9)

In Example 1-6, glass wool was used as a sound absorption material as it was. The sound absorption material was 0.03 at 500 Hz, 0.06 at 1000 Hz, 0.04 at 2000 Hz, 0.24 at 0.2 Hz, 0.42 at 3150 Hz, and 0.54 at 4000 Hz.

(Comparative Example 1-10)

In Example 1-6, the sound absorbing material of Comparative Example 1-10 was obtained like Example 1-6 except having spray-coated the acryl sol of manufacture example 1, and making it adhere to 426g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.10, the sound absorption rate at 1000 Hz was 0.53, the sound absorption rate at 2000 Hz was 0.44, and the sound absorption rate at 3150 Hz was 0.11 and 4000 Hz at 0.11.

The said result is put together in Table 5 and shown. As shown in Table 5, in the sound absorbing materials of Examples 1-6 and 1-7, the sound absorption rate was improved in any range of the low frequency region to the high frequency region, as compared with Comparative Example 1-9 in which glass wool was used as the sound absorbing material as it is. .

Example
1-6 Example
1-7 Comparative Example
1-9 Comparative Example
1-10 Type of acryl sol Production Example 1 Production Example 2 none Production Example 1 Acryl sol adhesion Island shape Island shape - Island shape Amount of Acryl Sol (g / m ² ) 232 341 - 426
Suction
Well
Rate
500Hz 0.05 0.07 0.03 0.10 1000Hz 0.24 0.37 0.06 0.53 2000Hz 0.55 0.62 0.24 0.44 3150Hz 0.71 0.58 0.42 0.11 4000 Hz 0.83 0.56 0.54 0.11

<Test Example 1-5>

(Examples 1-8)

The glass sol (thickness: 2 mm, density: 250 kg / cm ³ , basis weight: 500 g / m ² ) was spray-coated with the acrylic sol of Preparation Example 2, adhered to 100 g / m ² , and then heated at 170 ° C. for 5 minutes. The sound absorption material of Example 1-8 was obtained. This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.04, the sound absorption rate at 1000 Hz was 0.12, and the sound absorption rate at 0.3 Hz was 0.35, and the sound absorption rate was 0.44 at 3150 Hz, and the sound absorption rate was 0.59 at 4000 Hz.

(Examples 1-9)

In Example 1-8, the sound absorbing material of Example 1-9 was obtained like Example 1-8 except having spray-coated the acryl sol of manufacture example 1, and making it adhere to 335g / m <^2> . This sound-absorbing material was attached to the surface of the glass wool in an acryl gel form an independent or continuous island shape. In addition, the sound absorption rate at 500 Hz was 0.05, the sound absorption rate at 1000 Hz was 0.24, the sound absorption rate was 0.41 at 2000 Hz, and the sound absorption rate was 0.46 at 3150 Hz, and the sound absorption rate was 0.43 at 4000 Hz.

(Comparative Example 1-11)

In Example 1-8, glass wool was used as a sound absorption material as it was. This sound absorption material was 0.02 at 500 Hz, 0.04 at 1000 Hz, 0.03 at 2000 Hz, 0.13 at 0.2 Hz, 0.21 at 3150 Hz, 0.31 at 4000 Hz.

The said result is put together in Table 6 and shown. As shown in Table 6, in the sound absorbing materials of Examples 1-8 and 1-9, the sound absorption rate was improved in any range of the low frequency region to the high frequency region, as compared with Comparative Example 1-11 in which glass wool was used as the sound absorbing material as it is. .

Example
1-8 Example
1-9 Comparative Example
1-11 Type of acryl sol Production Example 2 Production Example 2 none Acryl sol adhesion Island shape Island shape - Amount of Acryl Sol (g / m ² ) 100 335 -
Suction
Well
Rate
500Hz 0.04 0.05 0.02 1000Hz 0.12 0.24 0.04 2000Hz 0.35 0.41 0.13 3150Hz 0.44 0.46 0.22 4000 Hz 0.59 0.43 0.31

&Lt; Test Example 2 &

(Example 2-1)

200 g / m <^2> of acryl sol of manufacture example 1 was made to adhere to the nonwoven fabric (Basic weight: 50 g / m <^2> , thickness: 0.16 mm, density: 0.31 g / cm <^3> ) which consists of polyethylene terephthalate fibers, and it is 10 minutes at 105 degreeC. The sheet | seat material heated and obtained pregelled was obtained. The obtained sheet | seat material was laminated | stacked on the glass wool (thickness: 25 mm, density: 16 kg / cm <^3> ), it was integrated by heat press at 180 degreeC for 2 minutes, and the sound absorption material of Example 2-1 was obtained. This sound absorption material was thickness 25.2mm, and was 26.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.32, and the sound absorption rate at 400Hz was 0.64.

(Example 2-2)

In Example 2-1, 500 g / m ² of the acryl sol of Preparation Example 1 was attached to a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. A sound absorbing material of Example 2-2 was obtained under the same conditions as in Example 1 except for this. This sound absorption material was thickness 25.2mm, and was 34.3 kg / m <^{3> in} density. In addition, the sound absorption rate at 315 Hz was 0.42 and the sound absorption rate at 400 Hz was 0.69.

(Example 2-3)

In Example 2-2, the same nonwoven fabric as that of Nonwoven Fabric (Basic weight: 12.5 g / m ² , Thickness: 0.06 mm, Density: 0.21 g / cm ³ ) was used. The sound absorbing material of Example 2-3 was obtained under conditions. This sound absorption material was thickness 25.1mm, and was 33.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.24, and the sound absorption rate at 400Hz was 0.44.

(Example 2-4)

Production Example 2 in Example 2-1, in place of the acryl sol of Preparation Example 1, in a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. A sound absorbing material of Example 2-4 was obtained under the same conditions as in Example 2-1 except that 200 g / m ² of the acryl sol was attached. This sound absorption material was thickness 25.2mm, and was 25.5 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.24, and the sound absorption rate at 400Hz was 0.36.

(Example 2-5)

In Example 2-1, the same conditions as in Example 2-1 except that a nonwoven fabric (a basis weight: 390 g / m ² , thickness: 3.6 mm, density: 0.11 g / cm ³ ) made of polyethylene terephthalate fiber was used as the nonwoven fabric. The sound absorbing material of Example 2-5 was obtained. This sound absorption material was thickness 28.6 mm, and was 37.4 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.49, and the sound absorption rate at 400Hz was 0.89.

(Example 2-6)

In Example 2-1, a nonwoven fabric (a basis weight: 70 g / m ² , thickness: 0.25 mm, density: 0.28 g / cm ³ ) consisting of 70% polybutylene terephthalate fiber and 30% glass fiber was used as the nonwoven fabric. Obtained the sound absorbing material of Example 2-6 under the same conditions as in Example 2-1. This sound absorption material was thickness 25.2mm, and was 26.9 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.31, and the sound absorption rate at 400Hz was 0.66.

(Example 2-7)

In Example 2-1, the same conditions as in Example 2-1 except that a nonwoven fabric (a basis weight: 113 g / m ² , thickness: 0.77 mm, density: 0.15 g / cm ³ ) made of glass fiber was used as the nonwoven fabric. The sound absorbing material of Example 2-7 was obtained. This sound absorption material was thickness 25.8mm, and was 29.8 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.21, and the sound absorption rate at 400Hz was 0.45.

(Example 2-8)

Preparation Example 3 in Example 2-1, in place of the acryl sol of Preparation Example 1, in a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. A sound absorbing material of Example 2-8 was obtained under the same conditions as in Example 2-1 except that 200 g / m ² of the acryl sol was attached. This sound absorption material was thickness 25.2mm, and was 26.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.32 and the sound absorption rate at 400Hz was 0.67.

(Example 2-9)

Production Example 4 in Example 2-1, in place of the acryl sol of Production Example 1, to a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. The sound absorbing material of Example 2-9 was obtained under the same conditions as in Example 2-1 except that 200 g / m ² of the acryl sol was attached. This sound absorption material was thickness 25.2mm, and was 26.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.32 and the sound absorption rate at 400Hz was 0.62.

(Example 2-10)

In Example 2-1, the same conditions as in Example 2-1 except that a nonwoven fabric (a basis weight: 450 g / m ² , thickness: 1.5 mm, density: 0.21 g / cm ³ ) made of polyethylene terephthalate fiber was used as the nonwoven fabric. The sound absorbing material of Example 2-10 was obtained. This sound absorption material was thickness 25.6mm, and was 41.0 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.50, and the sound absorption rate at 400Hz was 0.80.

(Comparative Example 2-1)

The acrylic sol of Production Example 1 was adhered to a glass wool (thickness: 25 mm, density: 16 kg / cm ³ ) with a coater, 200 g / m ² , and then gelled by heating at 150 ° C. for 10 minutes to obtain a sound absorbing material of Comparative Example 2-1. Got. This sound absorption material was thickness 25.2mm, and was 24.6 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.22 and the sound absorption rate at 400Hz was 0.35.

(Comparative Example 2-2)

In Example 2-1, 100 g / m ² of the acryl sol of Preparation Example 1 was attached to a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. A sound absorbing material of Comparative Example 2-2 was obtained under the same conditions as in Example 2-1 except for this. This sound absorption material was thickness 25.2mm, and was 22.2 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.16, and the sound absorption rate at 400Hz was 0.20.

(Comparative Example 2-3)

A nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber was laminated on glass wool (thickness: 25 mm, density: 16 kg / cm ³ ), followed by hot melt. It integrated and obtained the sound absorption material of the comparative example 2-3. This sound absorption material was thickness 25.2mm, and was 18.2 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.12, and the sound absorption rate at 400Hz was 0.17.

(Comparative Example 2-4)

A nonwoven fabric (a basis weight: 12.5 g / m ² , thickness: 0.06 mm, density: 0.21 g / cm ³ ) made of polyethylene terephthalate fiber was laminated on glass wool (thickness: 25 mm, density: 16 kg / cm ³ ), and hot melted. It integrated with and obtained the sound absorption material of the comparative example 2-4. This sound absorption material was thickness 25.2mm, and was 16.4 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.10, and the sound absorption rate at 400Hz was 0.14.

(Comparative Example 2-5)

The acrylic sol of Production Example 2 was adhered to a glass wool (thickness: 25 mm, density: 16 kg / cm ³ ) with a coater, 200 g / m ² , and then gelled by heating at 150 ° C. for 10 minutes to obtain a sound absorbing material of Comparative Example 2-5. Got. This sound absorption material was thickness 25.2mm, and was 24.6 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.20, and the sound absorption rate at 400Hz was 0.28.

(Comparative Example 2-6)

Production Example 5 was replaced with the acrylic sol of Preparation Example 1 in Example 2-1 to a nonwoven fabric (a basis weight: 50 g / m ² , thickness: 0.16 mm, density: 0.31 g / cm ³ ) made of polyethylene terephthalate fiber. A sound absorbing material of Comparative Example 2-6 was obtained under the same conditions as in Example 2-1, except that 200 g / m ² of acryl sol was attached. The acrylic sol of the manufacture example 5 had high viscosity, and was difficult to apply to a nonwoven fabric. The obtained sound absorption material was thickness 25.2mm, and was 26.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.15, and the sound absorption rate at 400Hz was 0.22.

(Comparative Example 2-7)

In Example 2-1, in the nonwoven fabric (a basis weight: 50 g / m <^2> , thickness: 0.16 mm, density: 0.31 g / cm <^3> ) which consists of polyethylene terephthalate fiber, a manufacture example instead of the acryl sol of manufacture example 1 A sound absorbing material of Comparative Example 2-7 was obtained under the same conditions as in Example 2-1 except that 200 g / m ² of the acryl sol was attached. This sound absorption material was thickness 25.2mm, and was 26.1 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.17, and the sound absorption rate at 400Hz was 0.24. In addition, even after gelation of the acryl sol, plasticizer was oozed out of the nonwoven fabric, resulting in stickiness.

(Comparative Example 2-8)

300 g / m <^{2> of} acrylic resin (brand name: "Dialal LP-3106", Mitsubishi Rayon) was made to adhere to glass wool (thickness: 25 mm, density: 16 kg / cm <^3> ), and it heats and gelatinizes at 150 degreeC for 10 minutes. Thus, the sound absorbing material of Comparative Example 2-8 was obtained. This sound absorption material was thickness 25.3mm, and was 27.7 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.18, and the sound absorption rate at 400Hz was 0.22.

(Comparative Example 2-9)

³⁰⁰ g / of acrylic resin (brand name: "Dialal LP-3106", Mitsubishi Rayon) is made of nonwoven fabric (a basis weight: 50 g / m <^2> , thickness: 0.16 mm, density: 0.31 g / cm <^3> ) which consists of polyethylene terephthalate fibers. m ² was attached, to 150 ℃, the gelation by heating for 10 minutes, to obtain a sound-absorbing material of Comparative example 2-9. This sound absorption material was thickness 25.3mm, and was 27.7 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.20, and the sound absorption rate at 400Hz was 0.26.

(Comparative Example 2-10)

In Example 2-1, the same conditions as in Example 2-1 except that a nonwoven fabric (a basis weight: 5 g / m ² , thickness: 0.03 mm, density: 0.21 g / cm ³ ) made of polyethylene terephthalate fiber was used as the nonwoven fabric. The sound absorbing material of Comparative Example 2-10 was obtained. This sound absorption material was thickness 25.2mm, and was 23.8 kg / m <^{3> in} density. Moreover, the sound absorption rate at 315Hz was 0.22 and the sound absorption rate at 400Hz was 0.37.

The results are summarized in Tables 7, 8 and recorded.

Example
2-1 Example
2-2 Example
2-3 Example
2-4 Example
2-5 Example
2-6 Example
2-7 Example
2-8 Example
2-9 Example
2-10 density
(kg / cm ³ )
26.1
34.3
33.1
25.5
37.4
26.9
29.8
26.1
26.1
41.0 thickness
(mm)
25.2
25.2
25.1
25.2
28.6
25.3
25.8
25.2
25.2
25.6 Sound absorption 315 Hz 0.32 0.42 0.24 0.24 0.49 0.31 0.21 0.32 0.32 0.50 400 Hz 0.64 0.69 0.44 0.36 0.89 0.66 0.45 0.67 0.62 0.80

Comparative Example
2-1 Comparative Example
2-2 Comparative Example
2-3 Comparative Example
2-4 Comparative Example
2-5 Comparative Example
2-6 Comparative Example
2-7 Comparative Example
2-8 Comparative Example
2-9 Comparative Example
2-10 density
(kg / cm ³ )
24.6
22.2
18.2
16.4
24.6
26.1
26.1
27.7
27.7
23.8 thickness
(mm)
25.2
25.2
25.2
25.2
25.2
25.2
25.2
25.3
25.3
25.2 Sound absorption 315 Hz 0.21 0.16 0.12 0.10 0.20 0.15 0.17 0.18 0.20 0.22 400 Hz 0.35 0.20 0.17 0.14 0.28 0.22 0.24 0.22 0.26 0.37

Claims (24)

It has a porous base material and the adhesion layer of the acrylic gel formed in the surface,
The adhesion layer of the said acrylic gel is formed by making 70-400 g / m <^2> adhere and gelatinize the acrylic sol containing 50-150 mass parts of plasticizers whose boiling point is 180 degreeC or more with respect to 100 mass parts of acrylic resin, The acrylic gel is attached to the surface of the porous substrate to form an independent or continuous island shape, and the portion to which the acrylic gel is not attached forms a portion where the porous substrate is exposed. It has a porous base material and the adhesion layer of the acrylic gel formed in the surface through the nonwoven fabric,
Adhesion layer of the acrylic gel is formed by the acrylic sol containing 50 to 150 parts by mass of a plasticizer having a boiling point of not less than 180 ℃ with respect to 100 parts by mass of acrylic resin, 150~600g / m ² adhered to the nonwoven fabric and gel, a non-woven fabric Is laminated on the porous base material. The sound absorption material of Claim ² whose basis weight of the said nonwoven fabric is 10-500 g / m <^2> . The sound absorption material of Claim 2 or 3 whose thickness of the said nonwoven fabric is 0.05-5 mm. The sound absorbing material according to any one of claims 2 to 4, wherein the nonwoven fabric is an organic fibrous nonwoven fabric, and the density of the nonwoven fabric is 0.1 to 0.5 g / cm ³ . The sound absorbing material according to any one of claims 1 to 5, wherein the acrylic gel gelates the acrylic sol containing a blowing agent. The sound absorption material as described in any one of Claims 1-6 whose said porous base material is a fiber mat. The sound absorption material as described in any one of Claims 1-7 whose density of the said porous base material is 10 kg / m <^3> or more. The sound absorption material as described in any one of Claims 1-8 whose thickness of the said porous base material is 2 mm or more. An acrylic sol containing 50 to 150 parts by mass of a plasticizer having a boiling point of 180 ° C. or more is spray-coated to the surface of the porous substrate, and adhered to 70 to 400 g / m ² , and the acrylic sol adhered to the porous substrate. Method for producing a sound absorbing material characterized in that the gelation. An acrylic sol containing a plasticizer having a boiling point of 180 ° C. or more and containing 50 to 150 parts by mass of the plasticizer relative to 100 parts by mass of the acrylic resin is attached to a nonwoven fabric by 150 to 600 g / m ² , and the acrylic sol is After gelling, the nonwoven fabric is bonded to the surface of the porous substrate. An acrylic sol containing a plasticizer having a boiling point of 180 ° C. or more and containing 50 to 150 parts by mass of the plasticizer relative to 100 parts by mass of the acrylic resin is attached to a nonwoven fabric by 150 to 600 g / m ² , and the acrylic sol is A method for producing a sound absorbing material, wherein the pregel sheet is gelated after pregelation to form a pregel sheet, and the pregel sheet is laminated on a porous substrate. The method for producing a sound absorbing material according to claim 11 or 12, wherein the basis weight of the nonwoven fabric is 10 to 500 g / m ² . The thickness of the said nonwoven fabric is 0.05-5 mm, The manufacturing method of the sound absorption material in any one of Claims 11-13 characterized by the above-mentioned. The method for producing a sound absorbing material according to any one of claims 11 to 14, wherein the nonwoven fabric is an organic fibrous nonwoven fabric, and the density of the nonwoven fabric is 0.1 to 0.5 g / cm ³ . The method for producing a sound absorbing material according to any one of claims 10 to 15, wherein a foaming agent is contained as the acryl sol. The method for producing a sound absorbing material according to any one of claims 10 to 16, wherein the porous substrate is a fiber mat. The method for producing a sound absorbing material according to any one of claims 10 to 17, wherein the porous substrate has a density of 10 kg / m ³ or more. The method for producing a sound absorbing material according to any one of claims 10 to 18, wherein the porous substrate has a thickness of 2 mm or more. An acrylic sol containing a plasticizer having a boiling point of 180 ° C. or more and containing 50 to 150 parts by mass of the plasticizer relative to 100 parts by mass of the acrylic resin is attached to a nonwoven fabric by 150 to 600 g / m ² , and the acrylic sol is It is obtained by gelling, The sheet for sound absorption materials characterized by the above-mentioned. 21. The sound absorbing sheet according to claim 20, wherein the basis weight of the nonwoven fabric is 10 to 500 g / m ² . 22. The sound absorbing sheet according to claim 20 or 21, wherein the thickness of the nonwoven fabric is 0.05 to 5 mm. 23. The sound absorbing sheet according to any one of claims 20 to 22, wherein the nonwoven fabric is an organic fibrous nonwoven fabric, and the density of the nonwoven fabric is 0.1 to 0.5 g / cm ³ . The sound absorbing sheet according to any one of claims 20 to 23, wherein the acryl sol further contains a blowing agent.

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