TWI504512B - 具吸音性之多層物件及其製造與使用方法 - Google Patents
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Description
本發明揭示內容係關於具吸音性之多層物件及製造及使用該等多層物件之方法。
此項技術中持續需要提供包括吸音性之聲學特性的物件。
本發明揭示內容係針對提供包括吸音性之聲學特性的多層物件。根據本發明揭示內容之一個例示性實施例,多層物件包含一載體層及一在該載體層上之次微米纖維層,其中該次微米纖維層包含平均纖維直徑小於1微米(μm)之聚合物纖維。
本發明揭示內容亦針對製造提供包括吸音性之聲學特性的多層物件之方法。在本發明揭示內容之一例示性實施例中,該方法包含(i)形成平均纖維直徑小於1微米(μm)之複數根纖維;及(ii)將該複數根纖維沈積於基板上以在該基板上形成次微米纖維層。該基板可為該次微米纖維層之臨時或永久載體層。該方法可進一步包含額外步驟,諸如點式黏合步驟,其中將該次微米纖維層進一步黏合至諸如載體層之基板。
本發明揭示內容又針對使用多層物件之方法。在本發明揭示內容之一個例示性實施例中,該方法包含在一區域中吸音之方法,其中該方法包含以次微米纖維層環繞該區域之至少一部分的步驟,其中該次微米纖維層包含平均纖維直徑小於1微米(μm)之纖維。
本發明揭示內容之該等及其他特徵及優勢將在綜述所揭示之實施例的下列實施方式及附加申請專利範圍之後變得顯而易見。
本發明揭示內容係針對提供聲學特性之多層物件,該等聲學特性包括(但不限於)吸音性及音障性。該等多層物件(1)具有非凡的吸音性;(2)具有使其能夠用於多種應用之結構特徵;及(3)可用於以成本效益方式製造。本發明揭示內容亦針對製造多層物件之方法,以及在多種吸音應用中使用多層物件之方法。
本發明揭示內容之一例示性多層物件係示於圖1中。圖1之例示性多層物件10包含載體層12上之次微米纖維層11。次微米纖維層11具有一上表面13,其可至少部分覆蓋有一或多個額外層(未圖示)。此外,載體層12具有與次微米纖維層11相對之下表面14,如下所述在該下表面14上可連接額外層及/或構件(未圖示)。
本發明揭示內容之多層物件係設計用於提供聲學特性至給定基板及/或區域。以下提供用於本發明揭示內容之多層物件之可能構件以及所得多層物件之特性的描述。
本發明揭示內容之多層物件可包含下列構件中之一或多種。
A.多層物件構件本發明揭示內容之多層物件可包含下列構件中之一或多種。
1.次微米纖維層本發明揭示內容之多層物件可包含一或多個次微米纖維層,諸如圖1所示之例示性多層物件10之次微米纖維層11。各次微米纖維層包含聚合物纖維,其中該等聚合物纖維具有小於1微米(μm)之平均纖維直徑。在一些例示性實施例中,次微米纖維層包含聚合物纖維,其中該等聚合物纖維具有約0.3 μm至約0.9 μm範圍內之平均纖維直徑。在其他例示性實施例中,次微米纖維層包含聚合物纖維,其中該等聚合物纖維具有約0.5 μm至約0.7 μm範圍內之平均纖維直徑。
在本發明揭示內容中,給定次微米纖維層中纖維之"平均纖維直徑"係如下測定:諸如使用掃描電子顯微鏡生成纖維結構之一或多個像;量測一或多個像中之清晰可見纖維的纖維直徑,產生纖維直徑之總數,x
;及計算x
根纖維直徑之平均纖維直徑。x
一般大於約50,且理想地在約50至約200之間的範圍內。
次微米纖維層之纖維可包含一或多種聚合物材料。適當聚合物材料包括(但不限於)諸如聚丙烯及聚乙烯之聚烯烴類;諸如聚對苯二甲酸乙二酯及聚對苯二甲酸丁二酯之聚酯類;聚醯胺(耐綸-6及耐綸-6,6);聚胺酯類;聚丁烯;聚乳酸類;聚乙烯醇;聚苯硫醚;聚碸;液晶聚合物;聚乙烯-共聚-乙酸乙烯酯;聚丙烯腈;環聚烯烴類;或其組合。在一個例示性實施例中,次微米纖維層包含複數根纖維,其中該等纖維包含聚丙烯纖維。
次微米纖維層可包含單組份纖維,其包含上述聚合物或共聚物中之任一種。在此實施例中,單組份纖維可含有如下所述之添加劑,但包含選自上述聚合物材料之單一纖維成形材料。此外,在此實施例中,單組份纖維一般包含至少75重量百分比之上述聚合物材料中之任一種及至多25重量百分比之一或多種添加劑。理想地,單組份纖維包含至少80重量百分比,更理想地至少85重量百分比,至少90重量百分比,至少95重量百分比及多達100重量百分比之上述聚合物材料中之任一種,其中所有重量係以纖維之總重量計。
次微米纖維層亦可包含多組份纖維,該等多組份纖維由(1)兩種或兩種以上上述聚合物材料及(2)一或多種如下所述之添加劑形成。如本文所用之術語"多組份纖維"係用於指由兩種或兩種以上聚合物材料所形成之纖維。適當多組份纖維組態包括(但不限於)殼-核組態、肩並肩組態及"海島型"組態。
對於由多組份纖維所形成之次微米纖維層而言,多組份纖維理想地包含以纖維之總重量計(1)約75至約99重量百分比之兩種或兩種以上的上述聚合物及(2)約25至約1重量百分比之一或多種額外纖維成形材料。
各次微米纖維層可具有視物件之特定最終用途而變化之基重。各次微米纖維層一般具有小於約1000公克/平方米(gsm)之基重。在一些實施例中,各次微米纖維層具有約1.0 gsm至約500 gsm之基重。在其他實施例中,各次微米纖維層具有約10 gsm至約150 gsm之基重。
與基重一樣,各次微米纖維層可具有視物件之特定最終用途而變化之厚度。各次微米纖維層一般具有小於約150毫米(mm)之厚度。在特定實施例中,各次微米纖維層一般具有約0.1 mm至約200 mm之厚度。在一些實施例中,各次微米纖維層具有約0.5 mm至約100 mm之厚度。在其他實施例中,各次微米纖維層具有約1.0 mm至約50 mm之厚度。
在大多數實施例中,次微米纖維層內之纖維係大體上均勻分佈於該層內。然而,在一些實施例中希望具有在次微米纖維層內非均勻分佈的纖維。
除上述纖維成形材料之外,可添加各種添加劑至熔融並擠壓之纖維中以將添加劑併入纖維中。添加劑的量以纖維之總重量計一般小於約25重量%,理想地至多約5.0重量%。適當添加劑包括(但不限於)填料、穩定劑、增塑劑、增黏劑、流動控制劑、固化速率阻滯劑、助黏劑(例如矽烷及鈦酸鹽)、佐劑、抗衝擊改質劑、可膨脹微球、導熱粒子、導電粒子、二氧化矽、玻璃、黏土、滑石、顏料、著色劑、玻璃珠或玻璃泡、抗氧化劑、光學增亮劑、抗菌劑、界面活性劑、阻燃劑及氟聚合物。可使用一或多種上述添加劑以減少所得纖維與層之重量及/或成本、調節黏度或改質纖維之熱學特性或賦予廣泛源自添加劑之物理特性活性的物理活性,包括電學、光學、密度相關、阻液或增黏相關特性。
2.載體層本發明揭示內容之多層物件可進一步包含一載體層,諸如圖1所示之例示性多層物件10之載體層12。載體層若存在則提供多層物件之大部分強度。在一些實施例中,上述次微米纖維層趨於具有極低強度,且可在正常操作過程中被破壞。將次微米纖維層附著於載體層會將強度給予該次微米纖維層,同時保留該次微米纖維層之聲學特性。多層結構亦提供足夠強度用於其他加工,其包括(但不限於)以捲筒形式拉緊、自捲筒除去、模製、打褶、折疊、分級(stapling)及編織。
可將多種載體層用於本發明揭示內容中。適當載體層包括(但不限於)非編織織物、編織織物、針織織物、發泡體層、薄膜、紙層、背膠層、箔、網狀織物(mesh)、彈性織物(即具有彈性之上述編織、針織或非編織織物中之任一種)、有孔網狀物、背膠層或其任意組合。在一個例示性實施例中,載體層包含非編織織物。適當非編織織物包括(但不限於)紡黏織物、熔噴織物、定長短纖維(即具有小於約100 mm之纖維長度的纖維)之經梳網狀物、針刺織物、撕裂薄膜網狀物、水力纏絡式網狀物、氣流式(airlaid)短纖維網狀物或其組合。
載體層可具有視多層物件之特定最終用途而定之基重及厚度。在本發明揭示內容之一些實施例中,希望多層物件之總基重及/或厚度保持在最小程度。在其他實施例中,需要總最小基重及/或厚度用於給定應用。在例示性實施例中,載體層可具有約1公克/平方米(gsm)至約200 gsm之基重。載體層一般具有小於約100 gsm之基重。在一些實施例中,載體層具有約5.0 gsm至約75 gsm之基重。在其他實施例中,載體層具有約10 gsm至約50 gsm之基重。
與基重一樣,載體層可具有視多層物件之特定最終用途而變化之厚度。載體層一般具有小於約150毫米(mm)之厚度。在一些實施例中,載體層具有約1.0 mm至約35 mm之厚度。在其他實施例中,載體層具有約2.0 mm至約25 mm之厚度。
上述次微米纖維層可永久或臨時黏合於給定載體層。在本發明揭示內容之大多數實施例中,次微米纖維層係永久黏合於載體層(即次微米纖維層係抱有永久與其黏合之目的附著於載體層)。在本發明揭示內容之一些實施例中,上述次微米纖維層係臨時黏合於諸如釋放襯墊之載體層(即可自該載體層移除)。在此實施例中,次微米纖維層可在臨時載體層上承載想要長度的時間,且視情況進一步在臨時載體層上被加工,且隨後永久黏合於第二載體層。
在本發明揭示內容之一個例示性實施例中,載體層包含紡黏織物,其包含聚丙烯纖維。在本發明揭示內容之另一例示性實施例中,載體層包含定長短纖維之經梳網狀物,其中該等定長短纖維包含(i)低熔點或黏合用纖維及(ii)高熔點或混成纖維之摻合物。黏合用纖維一般具有小於混成纖維之熔點至少10℃之熔點,儘管黏合用纖維與混成纖維之熔點之間的差值可高於10℃。適當黏合用纖維包括(但不限於)上述聚合物纖維中之任一種。適當混成纖維包括(但不限於)上述聚合物纖維中之任一種,以及諸如陶瓷纖維、玻璃纖維及金屬纖維之無機纖維;及諸如纖維素纖維之有機纖維。
在一個想要之實施例中,載體層包含定長短纖維之經梳網狀物,其中該等定長短纖維包含(i)約20重量%雙組份黏合用纖維(購自Invista,Inc.(Wichita,KS)之Invista T254纖維)(12d×1.5")及(ii)約80重量%混成纖維(Invista T293 PET纖維(32d×3"))之摻合物。
如上所述,載體層可包含彼此黏合之一或多個層。在一個例示性實施例中,載體層包含第一層,諸如非編織織物或薄膜,及在該第一層上與該次微米纖維層相對之黏接層。在此實施例中,黏接層可覆蓋第一層之一部分或整個外表面。黏接劑可包含已知黏接劑,包括壓敏黏接劑、熱激發之黏接劑等。當黏接層包含壓敏黏接劑時,多層物件可進一步包含釋放襯墊以提供對壓敏黏接劑之臨時保護。
3.額外層本發明揭示內容之多層物件可包含與次微米纖維層、載體層或兩者黏合之額外層。一或多個額外層可存在於次微米纖維層之外表面上(諸如圖1所示之次微米纖維層11之外表面13)、存在於載體層之外表面上(諸如圖1所示之載體層12之外表面14),或存在於兩者上。
適當額外層包括(但不限於)含顏料層(例如印刷層)、任一上述載體層;具有不同平均纖維直徑及/或物理組成之一或多個額外次微米纖維層;用於額外絕緣效能之一或多個第二細纖維層(諸如熔噴網狀物或玻璃纖維織物);發泡體;一層粒子;箔層;薄膜;裝飾織物層;膜(即具有受控滲透率之薄膜,諸如透析膜、逆滲透膜等);網眼織物(netting);網狀織物;線形及管形網狀物(即用於傳輸電之導線層或用於傳輸各種流體之管群,諸如用於電熱毯之線形網狀物,及用於冷卻劑流動通過冷卻毯之管形網狀物);或其組合。
4.附著裝置本發明揭示內容之多層物件可進一步包含一或多個附著裝置以使該多層物件能夠附著於基板。如上所述,黏接劑可用於附著多層物件。除黏接劑外,可使用其他附著裝置。適當附著裝置包括(但不限於)任何機械扣件,諸如螺釘、釘子、夾子、卡釘、縫紉、線、鉤狀及環狀材料等。
可將一或多個附裝置用於附著多層物件至多種基板。例示性基板包括(但不限於)車輛構件;車輛內部(即駕駛室、馬達室、行李箱等);建築物牆壁(即內牆表面或外牆表面);建築物天花板(即天花板內表面或天花板外表面);形成建築物牆壁或天花板之建築材料(例如天花板瓦、木材構件、石膏板等);隔間;金屬片;玻璃基板;門;窗;機器構件;家用電器構件(即家用電器內表面或家用電器外表面);管或軟管表面;電腦或電子構件;錄音或還音裝置;家用電器、電腦之外罩或殼等。
本發明揭示內容亦針對製造含有至少一個次微米纖維層的多層物件之方法。在本發明揭示內容之一個實施例中,製造多層物件之方法包含(i)形成平均纖維直徑小於1微米(μm)之複數根纖維;及(ii)將該複數根纖維沈積於載體層或基板上以在該載體層或基板上形成次微米纖維層。該方法可包含載體層或基板通過平均纖維直徑小於1微米之次微米纖維之纖維流的步驟。在通過纖維流時,次微米纖維係沈積於載體層或基板上以臨時或永久黏合於該載體層或基板。在特定加工條件下,當纖維沈積於載體層或基板上時,該等纖維可彼此黏合,且進一步在該載體層或基板上時硬化。
在特定例示性實施例中,次微米纖維之層可在載體層上陷入。儘管不願受任何特定理論束縛,然本發明者相信在一些實施例中,在次微米纖維層與載體層之間存在物理黏合。在一些實施例中,物理黏合可使得載體可支撐其他加工步驟及操作之負載。載體亦可吸收任何會導致次微米纖維壓縮之壓力,該壓縮會不利影響次微米纖維之吸音性。
可將許多方法用於沈積次微米纖維。適當方法包括(但不限於)揭示於美國專利第4,536,361號(Torobin)、美國專利第6,183,670號(Torobin)及DE 19929709 C2(Gerking)中之方法。適當方法亦包括電子紡絲(electro-spinning)法。
製造本發明揭示內容之多層物件的方法可用於形成次微米纖維層,其含有自上述聚合物材料中之任一種所形成的纖維。形成次微米纖維之方法步驟一般涉及在約130℃至約350℃之熔融擠出溫度下熔融擠出可熱成形材料。模組件及/或同軸噴嘴組件(例如參見Torobin法)包含熔融可熱成形材料經由其擠出之複數個噴絲頭及/或同軸噴嘴。在一個例示性實施例中,同軸噴嘴組件包含形成為一排之複數個同軸噴嘴以擠出纖維多重流至載體層或基板上。例如參見美國專利第4,536,361號(圖1)及第6,183,670號(圖1-2)。
除形成次微米纖維層之步驟之外,製造多層物件之方法可包括下列方法步驟中之一或多個:(1)沿製程路徑推動該多層物件進行其他加工操作;(2)使一或多個額外層與次微米纖維層及/或載體層之外表面接觸;(3)壓延該多層物件;(4)以表面處理或其他組合物(例如阻燃組合物、黏接劑組合物或印刷層)塗佈該多層物件;(5)將多層物件附著於紙板或塑料管;(6)拉緊捲筒形式之多層物件;(7)切割多層物件以形成兩個或兩個以上切割捲筒(slit roll);(8)將多層物件置放於模中且模製該多層物件;(9)施加釋放襯墊至曝露之壓敏黏接層(若存在)上;及(10)經由黏接劑或任何其他包括(但不限於)夾子、托架、螺栓/螺釘、釘子及帶子之附著裝置將該多層物件附著於另一基板。
本發明揭示內容之多層物件可用於多種應用中。多層物件尤其用於諸如吸音及音障應用之聲學應用中。在一個例示性實施例中,使用多層物件之方法包含吸收一區域中之聲音的方法,其中該方法包含以次微米纖維層環繞該區域之至少一部分,其中該次微米纖維層包含平均纖維直徑小於1微米之纖維。在一些實施例中,整個區域可被次微米纖維層單獨環繞或被載體層上之次微米纖維層環繞。
環繞一區域之步驟可包含將多層物件置於該區域之至少一部分上,其中該多層物件包含任一上述載體層上之次微米纖維層。在一些實施例中,環繞步驟可包含將多層物件置於該區域之至少一部分上,其中該多層物件包含一載體層上之次微米纖維層,其中在該次微米纖維層上具有一額外層。如上所述,適當額外層可包含一含顏料層(例如印刷層)、任一上述載體層;具有不同平均纖維直徑及/或物理組成之一或多個額外次微米纖維層;用於額外絕緣效能之一或多個第二細纖維層(諸如熔噴網狀物或玻璃纖維織物);發泡體;一層粒子;箔層;薄膜;裝飾織物層;膜;網眼織物;網狀織物;線形及管形網狀物;或其組合。
環繞步驟可進一步包含將次微米纖維層或多層物件附著於基板之步驟。任一上述附著裝置可用於將次微米纖維層或多層物件附著於給定基板。適當基板可包括(但不限於)建築物牆壁、建築物天花板、形成建築物牆壁或天花板之建築材料、金屬片;玻璃基板、門、窗、車輛構件、機器構件或家用電器構件。
在本發明揭示內容之其他實施例中,使用多層物件之方法包含在聲音產生物與區域之間提供音障之方法。在此例示性方法中,該方法可包含在聲音產生物與區域之間提供次微米纖維層之步驟,其中該次微米纖維層包含平均纖維直徑小於1微米之纖維。聲音產生物可為產生聲音之任何物體,其包括(但不限於)車輛馬達、一部機器、家用電器馬達或其他移動構件、諸如電視之電子裝置、動物等。
任一上述使用多層物件之例示性方法中的區域可為任何聲音可被吸收及/或受限制的區域。適當區域可包括(但不限於)房間內部;車輛內部;一部機器;家用電器;辦公室或工業區之獨立聲音減少區域;錄音或還音區域;劇院或音樂廳之內部;其中聲音有害之消聲、分析或實驗房間或室;及用於隔離保護耳朵免受噪音危害之耳套或耳罩。
以上描述本發明揭示內容且進一步以實例加以說明,不應以任何方式將該等實例解釋為限制本發明揭示內容。相反,明顯應瞭解熟習此項技術者在閱悉本文發明內容之後可在不背離本發明揭示內容之精神及/或附加申請專利範圍之範疇的情況下提出其他各種實施例、改良及其等價物。
在下列實例中,使用紡黏法或熔噴(即吹製微纖維)法製備各種載體或基板。適當製備該等載體之方法係描述於美國專利第4,729,371號中。
將使用紡黏法所製造之具有標稱110公克/平方米(gsm)基重的聚丙烯紡黏網狀物送至Nanofiber Technology,Inc.(NTI)(Aberdeen,NC)用於塗佈次微米纖維。該紡黏網狀物為聚丙烯紡黏網狀物,其具有100 gsm之基重,0.045英吋之厚度及18微米之EFD。所使用之聚丙烯為Total Dypro 3860(Total Petrochemicals,Houston,TX)。
使用基於美國專利第4,536,631號、第6,183,670號及第6,315,806號(即Torobin專利)之NTI法將不同基重之次微米聚丙烯纖維沈積於紡黏網狀物上。所得樣本具有沈積於紡黏網狀物基板上之平均纖維直徑為約0.56微米的14、25及50 gsm之次微米纖維。後文分別將該等樣本稱作樣本A、B及C。單獨的紡黏網狀物後文中稱作樣本D。
由於纏結作用與熱黏合兩者,次微米纖維層固有黏合至紡黏網狀物層。當次微米纖維沈積於紡黏網狀物基板上時發生黏合。
測試樣本之聲學吸收率(即吸音性)。根據ASTM標準E 1050,使用63 mm管進行測試。將樣本置於測試管中,在該樣本與該管後壁之間具有25 mm間隙。如此改良測試過程中樣本的差異。圖2顯示此測試結果。
如圖2所示,與單獨的紡黏網狀物相比添加即使少量次微米纖維仍會極大地增加吸音性。
將具有35 gsm基重之聚丙烯紡黏網狀物通過如實例1所述的奈米纖維法之纖維流下。該紡黏網狀物為聚丙烯紡黏纖維,其具有35 gsm之基重,0.018英吋之厚度及20微米之EFD。所使用之聚丙烯為Total Dypro 3860(Total Petrochemicals,Houston,TX)。
將紡黏網狀物送至NTI用於使用其30"寬製程生產線塗佈。使用三種不同塗佈重量(4.6 gsm、7.0 gsm、27.44 gsm)之奈米纖維,分別給予39.6、42.0及62.4 gsm之總基重。奈米纖維具有約0.65微米之平均纖維直徑。將裸露的紡黏網狀物稱作樣本E,三種經塗佈樣本以奈米纖維基重增加的順序稱作樣本F、G及H。給定樣本之樣本基重、厚度及壓力降係如下提供於表1中。
根據ASTM標準E 1050,使用63 mm管測試四樣本。將各樣本裝於測試管中,在各樣本後具有25 mm空氣間隙。測試各網狀物之吸音性,結果示於圖3中。
如圖3所示,樣本F、G及H與單獨的紡黏網狀物(樣本E)顯示改良之吸音性。此外,當奈米纖維基重增加時,吸音效能增加。
使用鑽孔模製造且具有55 gsm基重、0.040英吋厚度及8.4EFD之聚丙烯熔噴纖維網狀物係在3M Research Center(St.Paul,MN)之20英吋寬生產線上生成且塗佈有來自NTI奈米纖維生產線之聚丙烯奈米纖維。所使用之聚丙烯為Total Dypro 3960(Total Petrochemicals,Houston,TX)。使用三種不同塗佈基重(1.8 gsm、3.0 gsm及7.2 gsm)以製備三種獨立樣本。奈米纖維具有約0.77微米之平均纖維直徑。將裸露之熔噴網狀物稱作樣本I,而經奈米纖維塗佈之樣本以奈米纖維基重增加的順序定為樣本J、K及L。給定樣本之樣本基重、厚度及壓力降係如下提供於表1中。
如實例2中所述測試四樣本。結果示於圖4中。
將氣流式(Rando-Webber)非編織網狀物送至Nanofiber Technology,Inc.(NTI)(Aberdeen,NC)用於塗佈次微米纖維。氣流式網狀物係在12"寬Rando-Webber機器上生成。饋料纖維組成為80重量% Invista T293纖維(32d×3" PET)及20重量% Invista T254纖維(以商標名CELBONDT M
出售之12d×1.5"雙組份纖維,包含coPET/PET殼/核纖維,殼熔點為約110℃)。氣流式網狀物具有42 gsm的平均基重。NTI使用如實例1所述之方法將不同基重之次微米聚丙烯纖維沈積於氣流式網狀物上。所生成之樣本具有沈積於氣流式網狀物上平均纖維直徑為約0.60微米之30、41及126 gsm次微米纖維。後文中將該等樣本分別稱作樣本M、N及O。給定樣本之樣本基重、厚度及壓力降係如下提供於表1中。
根據ASTM標準E 1050,使用63 mm管在3M Center測試三樣本加兩層之樣本M。將各樣本固定倚靠於測試管背部進行測試。測試結果示於圖5中。亦使用掃描電子顯微鏡檢測實例2之樣本F以根據Davies,C.N.,"The Separation of Airborne Dust and Particles,"Institution of Mechanical Engineers,London Proceedings 1B,(1952)中所述之方法確定有效纖維直徑(EFD)。基於132根纖維之有效纖維直徑的數目分佈係呈現於下表2中,而分佈統計係呈現於表3中。
以來自電子紡絲方法之奈米纖維塗佈短纖維網狀物。基板網狀物為由American Nonwovens(RB 282-57 K/F)製造的聚酯纖維經梳樹脂黏合之網狀物。該基板網狀物具有62公克/米2
之基重。將裸露基板稱作樣本P。使用習知基於針的電子紡絲裝置將聚己內酯次微米纖維(TONET M
P-787來自Dow Chemical Company)從甲基乙基酮溶液直接電子紡到基板上。將三種不同基重之次微米纖維紡到基板上,生成三個樣本。樣本Q具有6.0公克/米2
之次微米纖維基重。樣本R具有11.2公克/米2
之次微米纖維基重。樣本S具有32.1公克/米2
之次微米纖維基重。樣本Q至S之組合基重分別為68.0、73.2及94.1公克/米2
。次微米纖維具有0.60微米之平均纖維直徑。
根據ASTM標準E 1050,使用63 mm管在3M Center測試樣本P、Q、R及S。各樣本背部距測試管端部前方25毫米進行測試。該等測試結果示於圖6中。
使用如Hak-Yong Kim之PCT公開案WO2005/073441中所述之方法製造由聚胺酯製得之次微米纖維。次微米纖維網狀物具有14公克/米2
之基重及0.61微米之平均直徑。將此網狀物冷焊至實例5中所述之經梳網狀物。藉由從兩網狀物切開單一樣本同時使用尖模完成冷焊。切開樣本之過程導致形成為樣本邊緣之堅固焊接。將裸露次微米纖維網狀物為樣本T。如實例5中所述,裸露經梳網狀物為樣本P。焊接樣本稱作樣本U。
根據ASTM標準E 1050,使用63 mm管測試樣本。各樣本背部距測試管端部前方25毫米進行測試。該等測試結果示於圖7中。
儘管已參照具體實施例詳細描述發明內容,但應瞭解熟習此項技術者在理解前述內容之後可易於對該等實施例作出改變、變更及等價物。因此,本發明揭示內容之範疇應評定為與附加申請專利範圍及其等價物一致。
10...多層物件
11...次微米纖維層
12...載體層
13...上表面/外表面
14...下表面/外表面
圖1描繪本發明揭示內容之例示性多層物件;圖2圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線;圖3圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線;圖4圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線;圖5圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線;圖6圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線;及圖7圖示發明揭示內容之例示性多層物件的吸音係數對頻率之曲線。
10...多層物件
11...次微米纖維層
12...載體層
13...上表面/外表面
14...下表面/外表面
Claims (23)
- 一種多層物件,其包含:一載體層;及一在該載體層上之次微米纖維層,該次微米纖維層包含中值纖維直徑小於1微米(μm)之聚合物纖維,其中該聚合物纖維包含至少75重量百分比之下列聚合物:聚烯烴、聚丙烯、聚乙烯、聚酯、聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯、聚醯胺、聚胺酯、聚丁烯、聚乳酸、聚乙烯醇、聚苯硫醚、聚碸、液晶聚合物、聚乙烯-共聚-乙酸乙烯酯、聚丙烯腈、環聚烯烴,或其組合。
- 如請求項1之多層物件,其中該等聚合物纖維具有約0.3μm至約0.9μm範圍內之平均纖維直徑。
- 如請求項1之多層物件,其中該等聚合物纖維具有約0.5μm至約0.7μm範圍內之平均纖維直徑。
- 如請求項1之多層物件,其中該等聚合物纖維包含至多約99重量百分比之兩種或兩種以上下列聚合物:聚烯烴、聚丙烯、聚乙烯、聚酯、聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯、聚醯胺、聚胺酯、聚丁烯、聚乳酸、聚乙烯醇、聚苯硫醚、聚碸、液晶聚合物、聚乙烯-共聚-乙酸乙烯酯、聚丙烯腈或環聚烯烴。
- 如請求項1之多層物件,其中該等聚合物纖維包含聚烯烴纖維。
- 如請求項1之多層物件,其中該等聚合物纖維係均勻分 佈於該次微米纖維層內。
- 如請求項1之多層物件,其中該載體層包含一非編織織物、編織織物、針織織物、發泡體層、薄膜、紙層、背膠層,或其組合。
- 如請求項1之多層物件,其中該載體層包含一紡黏織物、熔噴織物、定長短纖維之經梳網狀物,或其組合。
- 如請求項1之多層物件,其中該載體層包含一黏合短纖維之網狀物,其中該該載體層係使用熱黏合、冷焊、黏接劑黏合、粉末狀黏合劑、水力纏絡、電子紡絲、針刺、壓延,或其組合黏合。
- 如請求項1之多層物件,其進一步包含一在該載體層上與該次微米纖維層相對之黏接層。
- 如請求項1之多層物件,其進一步包含一在該次微米纖維層上之額外層。
- 如請求項11之多層物件,其中該額外層包含一含顏料層、非編織織物、編織織物、針織織物、發泡體層、薄膜、紙層、一層粒子、箔層、裝飾織物層、膜、網眼織物、網狀織物、線形或管形網狀物,或其組合。
- 如請求項1之多層物件,其附著於一基板,該基板包含建築物之牆壁、建築物之天花板、用於形成建築物之牆壁或天花板之建築材料、金屬片、玻璃基板、門、窗、車輛構件、機器構件或家用電器構件。
- 一種在一區域中吸音之方法,該方法包含以下步驟:以一次微米纖維層環繞該區域之至少一部分,其中該 次微米纖維層包含中值纖維直徑小於1微米(μm)之聚合物纖維,其中該聚合物纖維包含至少75重量百分比之下列聚合物:聚烯烴、聚丙烯、聚乙烯、聚酯、聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯、聚醯胺、聚胺酯、聚丁烯、聚乳酸、聚乙烯醇、聚苯硫醚、聚碸、液晶聚合物、聚乙烯-共聚-乙酸乙烯酯、聚丙烯腈、環聚烯烴,或其組合。
- 如請求項14之方法,其中該區域包含房間之內部;車輛之內部;一部機器;家用電器;辦公室或工業區之一獨立聲音減少區域;錄音或還音區域;劇院或音樂廳之內部;一其中聲音有害之消聲、分析或實驗房間或室;用於隔離保護耳朵免受噪音危害之耳套或耳罩。
- 如請求項14之方法,其中該環繞步驟包含將一多層物件置於該區域之至少一部分上,該多層物件包含一載體層上之該次微米纖維層。
- 如請求項16之方法,其中該載體層包含一非編織織物、編織織物、針織織物、發泡體層、薄膜、紙層、背膠層,或其組合。
- 如請求項16之方法,其中該環繞步驟包含將一多層物件置於該區域之至少一部分上,該多層物件包含一載體層上之該次微米纖維層,其中在該次微米纖維層上具有一額外層。
- 如請求項18之方法,其中該額外層包含一含顏料層、非 編織織物、編織織物、針織織物、發泡體層、薄膜、紙層、一層粒子、箔層、裝飾織物層、膜、網眼織物、網狀織物、線形或管形網狀物,或其組合。
- 如請求項14之方法,其中該環繞步驟包含將該次微米纖維層附著於一基板,該基板包含建築物之牆壁、建築物之天花板、用於形成建築物之牆壁或天花板之建築材料、金屬片、玻璃基板、門、窗、車輛構件、機器構件或家用電器構件。
- 一種在一聲音產生物與一區域之間提供音障之方法,該方法包含以下步驟:在該聲音產生物與該區域之間提供一次微米纖維層,其中該次微米纖維層包含中值纖維直徑小於1微米(μm)之聚合物纖維,其中該聚合物纖維包含至少75重量百分比之下列聚合物:聚烯烴、聚丙烯、聚乙烯、聚酯、聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯、聚醯胺、聚胺酯、聚丁烯、聚乳酸、聚乙烯醇、聚苯硫醚、聚碸、液晶聚合物、聚乙烯-共聚-乙酸乙烯酯、聚丙烯腈、環聚烯烴,或其組合。
- 如請求項21之方法,其中該聲音產生物包含車輛馬達、一部機器、家用電器馬達或其他移動家用電器構件、電子裝置、電視、動物,或其組合。
- 如請求項21之方法,其中該區域包含房間之內部;車輛之內部;一部機器;家用電器;辦公室或工業區之一獨 立聲音減少區域;錄音或還音區域;劇院或音樂廳之內部;一其中聲音有害之消聲、分析或實驗房間或室;用於隔離保護耳朵免受噪音危害之耳套或耳罩。
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- 2006-10-10 KR KR1020087009265A patent/KR101367509B1/ko active IP Right Grant
- 2006-10-10 WO PCT/US2006/039544 patent/WO2007047263A1/en active Application Filing
- 2006-10-10 US US11/539,885 patent/US7691168B2/en active Active
- 2006-10-10 JP JP2008536682A patent/JP2009512578A/ja active Pending
- 2006-10-18 TW TW095138328A patent/TWI504512B/zh not_active IP Right Cessation
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Also Published As
Publication number | Publication date |
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US7757811B2 (en) | 2010-07-20 |
JP2009512578A (ja) | 2009-03-26 |
US7691168B2 (en) | 2010-04-06 |
US20100043639A1 (en) | 2010-02-25 |
JP5856107B2 (ja) | 2016-02-09 |
WO2007047263A1 (en) | 2007-04-26 |
JP2014015042A (ja) | 2014-01-30 |
US20080230309A1 (en) | 2008-09-25 |
KR20080055929A (ko) | 2008-06-19 |
EP1945445A4 (en) | 2012-05-30 |
EP1945445A1 (en) | 2008-07-23 |
TW200720085A (en) | 2007-06-01 |
KR101367509B1 (ko) | 2014-02-27 |
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