US20150252562A1 - Sound-absorbing material with excellent sound-absorbing performance and method for manufacturing thereof - Google Patents

Sound-absorbing material with excellent sound-absorbing performance and method for manufacturing thereof Download PDF

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Publication number
US20150252562A1
US20150252562A1 US14/432,047 US201314432047A US2015252562A1 US 20150252562 A1 US20150252562 A1 US 20150252562A1 US 201314432047 A US201314432047 A US 201314432047A US 2015252562 A1 US2015252562 A1 US 2015252562A1
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United States
Prior art keywords
sound
fiber
absorbing material
circular shaped
manufacturing
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US14/432,047
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English (en)
Inventor
Hyo Seok Kim
Do Hyun Kim
Chi Hun KIM
Kie Youn Jeong
Bong Hyun Park
Jung Wook Lee
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Hyundai Motor Co
Toray Advanced Materials Korea Inc
Kia Corp
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Hyundai Motor Co
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Assigned to KIA MOTORS CORPORATION, TORAY CHEMICAL KOREA INC., HYUNDAI MOTOR COMPANY reassignment KIA MOTORS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JEONG, KIE YOUN, KIM, CHI HUN, KIM, DO HYUN, KIM, HYO SEOK, LEE, JUNG WOOK, PARK, BONG HYUN
Publication of US20150252562A1 publication Critical patent/US20150252562A1/en
Assigned to TORAY ADVANCED MATERIALS KOREA INC. reassignment TORAY ADVANCED MATERIALS KOREA INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TORAY CHEMICAL KOREA INC.
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor

Definitions

  • the present invention relates to a sound-absorbing material with excellent sound-absorbing performance and a method for manufacturing the same. More particularly, it relates to a sound-absorbing material with excellent sound-absorbing performance, which can be used for blocking inflow of external noise into vehicle interior by being attached as vehicle components or interior and exterior materials of a vehicle body, and can be used in electric devices and the like that use motor parts so as to improve noise insulation performance thereof
  • noise introduced into a vehicle may be classified into a noise generated at an engine and introduced through a vehicle body and a noise generated when tires are contacted with a road surface and introduced through a vehicle body.
  • There may be two ways to block theses noises such as improving sound-absorbing performance and improving noise insulation performance.
  • Sound-absorbing means that generated sound energy is converted into thermal energy and then dissipated while it is transmitted through internal route of a material
  • noise insulation means that generated sound energy is reflected and blocked by a shelter.
  • NASH Vibration & Harshness
  • non-woven type fiber aggregate staple fiber and binder fiber are mixed together at a proper ratio.
  • binder fiber in general, staple fiber manufactured by conjugate-spinning regular polyester is used for an inner layer and low melting polyester is used for an outer layer.
  • the present invention has been made in an effort to solve the above-described problems associated with prior art.
  • the present invention is objected to provide a sound-absorbing material, which may improve sound absorption coefficient and transmission loss by forming large surface area and air layer, so as to maximize viscosity loss and dissipation route of incident sound energy, and makes light-weight design thereof possible because it can realize excellent sound-absorbing performance even using reduced amount of fiber; and a method for manufacturing thereof
  • the present invention is objected to provide a sound-absorbing material, which may improve formability as well as maintain enough strength between fiber, and may have improved rebound resilience, thereby ultimately having excellent vibration attenuation capability against sound energy transmitted inside matrix; and a method for manufacturing thereof
  • the present invention provides a method for manufacturing a sound-absorbing material that comprises forming fiber aggregate in a nonwoven fabric form, and the fiber aggregate comprises:
  • a binder fiber that partly binds a plurality of the non-circular shaped fibers.
  • the sound-absorbing material may be manufactured by using the non-circular shaped fiber satisfying the value of the Formula 1 of 2.6 or greater.
  • the sound-absorbing material may be manufactured by using the non-circular shaped fiber satisfying the value of the Formula 1 of 3.0 or greater.
  • the non-circular shaped fiber may be at least one selected from the group consisting of six-pointed star shape, 3-bar flat type, 6 leaf type, 8 leaf type and wave type.
  • the non-circular shaped fiber may be 35 to 65 mm in length.
  • the binder fiber may comprise a low melting (LM) elastomer having elastic recovery modulus of 50 to 80%, and rebound resilience rate of the sound-absorbing material may be 50 to 80%.
  • LM low melting
  • the binder fiber may be conjugated fiber which is conjugate-spun by using the LM elastomer as one component.
  • the LM elastomer may be at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer and a polyurethane-based polymer.
  • the LM elastomer may be manufactured by esterification and polymerization steps using dimethyl terephthalate(DMT) and dimethyl isophthalate(DMI), or terephthalic acid(TPA) and isophthalic acid(IPA) as an acid ingredient(Diacid), and 1,4-butanediol(1,4-BD) and polytetramethyleneglycol(PTMG) as a diol ingredient (Diol).
  • DMT dimethyl terephthalate
  • DMI dimethyl isophthalate
  • TPA terephthalic acid
  • IPA isophthalic acid
  • the sound-absorbing material may be manufactured by using the non-circular shaped fiber of 50 to 80 wt % based on the total weight of the sound-absorbing material and the binder fiber of 20 to 50 wt % based on the total weight of the sound-absorbing material.
  • the present invention provides a sound-absorbing material, which may comprise: a non-circular shaped fiber satisfying the following Formula 1; and a binder fiber which partly binds a plurality of the non-circular shaped fibers.
  • the non-circular shaped fiber may satisfy the value of the Formula 1 of 2.6 or greater.
  • the non-circular shaped fiber may be at least one selected from the group consisting of six-pointed star shape, 3-bar flat type, 6-leaf type, 8-leaf type and wave type.
  • the non-circular shaped fiber may be 35 to 65 mm in length.
  • the non-circular shaped fiber may be 1.0 to 7.0 De in fineness.
  • the binder fiber may comprise a LM elastomer having elastic recovery modulus of 50 to 80%, and rebound resilience rate of the sound-absorbing material may be 50 to 80%.
  • the binder fiber may be conjugated fiber which is conjugate-spun by using the LM elastomer as one component.
  • the LM elastomer may be at least one selected from the group consisting of a polyester-based polymer, a polyamide-based, polystyrene-based polymer, a polyvinylchloride-based polymer and a polyurethane-based polymer.
  • the sound-absorbing material may comprise the non-circular shaped fiber of 50 to 80 wt % based on the total weight of the sound-absorbing material and the binder fiber of 20 to 50 wt % based on the total weight of the sound-absorbing material.
  • the non-circular shaped fiber may satisfy the value of the Formula 1 of 3.0 or greater.
  • wave type non-circular shaped fiber refers to fiber that may have cross section shape in wave form, and specifically, its shape is illustrated in FIG. 5 .
  • the sound-absorbing material with excellent sound-absorbing performance of the present invention can improves sound absorption coefficient and transmission loss by forming large surface area and air layer, so as to induce viscosity loss of incident sound energy. Further, it makes light-weight design thereof possible since it can provide excellent sound-absorbing performance using reduced amount of fiber, and can improve sound-absorbing performance by using binder fiber having rebound resilience, so as to maintain enough bonding strength between fibers and also to maximize viscosity loss of sound energy transmitted to fiber structure.
  • a sound-absorbing material having excellent sound-absorbing performance which can be used for improving noise insulation performance of electric devices and the like using motor parts as well as used through transport such as vehicle, train, ship, aircraft and the like, and a method for manufacturing thereof can be provided.
  • FIG. 1 is a six-pointed star shaped non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention
  • FIG. 2 is a 3-bar flat type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention
  • FIG. 3 is a 6-leaf type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention
  • FIG. 4 is a 8-leaf type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention
  • FIG. 5 is a wave type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention
  • FIG. 6 is a 8-leaf type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention.
  • FIG. 7 is a 8-leaf type non-circular shaped fiber, which is contained in the sound-absorbing material according to a preferred embodiment of the present invention.
  • FIG. 8 is a drawing showing L and W of the 8-leaf type non-circular shaped fiber according to a preferred embodiment of the present invention as an example.
  • the present invention provides a sound-absorbing material which comprises: a non-circular shaped fiber satisfying the following Formula 1; and a binder fiber which partly binds a plurality of the non-circular shaped fibers, to find solutions for the above described problems.
  • sound absorption coefficient and transmission loss may be improved by forming large surface area and air layer, so as to induce viscosity loss of incident sound energy.
  • -weight design thereof may be obtained because excellent sound-absorbing performance may be obtained using reduced amount of fiber, and sound-absorbing performance may be improved by using binder fiber having rebound resilience, so as to maintain enough binding strength between fiber and also to maximize viscosity loss of sound energy transmitted to a fiber structure.
  • a sound-absorbing material having excellent sound-absorbing performance which can be used for improving noise insulation performance of electric devices and the like using motor parts as well as used through transport such as vehicle, train, ship, aircraft and the like, and a method for manufacturing thereof may be provided.
  • the non-circular shaped fiber satisfy the ⁇ value of 1.5 or greater, calculated as
  • the non-circular shaped fiber used in the present invention may have the ⁇ value of 2.6 or greater, and more preferably the value may be 3.0 to 7.0.
  • ⁇ value of the non-circular shaped fiber used in the present invention is greater than 7.0, there may be a problem that production cost may be increased due to increase of nozzle production cost, facilities replacement related to cooling efficiency improvement, polymer modification for solidification rate improvement, productivity reduction and the like.
  • the non-circular shaped fiber of the present invention which satisfies the ⁇ value of 1.5 or greater, may be a six-pointed star shape, 3-bar flat type, 6-leaf type, 8-leaf type or wave type, or a combination thereof.
  • specific shape such as the number of the curved point in the wave shape, length and width of the cross section and the like may vary.
  • the number of the curved point in the wave shape means the point where the direction is changed to the length direction of the cross section, and for example, the number of the curved point of the wave type non-circular shaped fiber in FIG. 5 is 4.
  • FIG. 1 is six-pointed star shape non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 1.51
  • FIG. 2 is 3-bar flat type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 1.60
  • FIG. 3 is 6-leaf type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 1.93
  • FIG. 4 is 8-leaf type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 2.50
  • FIG. 5 is wave type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 2.55,
  • FIG. 1 is six-pointed star shape non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 1.51
  • FIG. 2 is 3-bar flat type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value
  • FIG. 6 is 8-leaf type non-circular shaped fiber according to a preferred embodiment of the present invention, and its ⁇ value is 2.8
  • FIG. 7 is 8-leaf type non-circular shaped fiber according to a preferred embodiment of the present invention, and its 11 value is 3.2.
  • the ⁇ value of a general circular type fiber with circular cross section is 1.0, and its sound absorption coefficient and transmission loss are significantly reduced because its surface area is not large enough (see Comparative Example 1), and although the non-circular shaped fiber are a six-pointed star shape, 3-bar flat type, 6-leaf type, 8-leaf type or wave type, if the ⁇ value does not satisfy 1.5 or greater, the surface area which can generate viscosity loss of the sound energy is not enough. Accordingly, those are not suitable as the non-circular shaped fiber used for the sound-absorbing material of the present invention (see Comparative Examples 2 to 5).
  • the non-circular shaped fiber used in the present invention may have the L/W value of 2 to 3.
  • L is the abbreviation for Length which is vertical length of fiber
  • W is the abbreviation for Width which is length against horizontal direction connecting between angular points.
  • FIG. 8 shows L and W values of the 8-leaf type non-circular shaped fiber.
  • the length may be expressed as L
  • the distance between angular points may be expressed as W.
  • non-circular shaped fiber used in the present invention may have 6 to 8 angular points more preferably, but it is not limited to the L/W or the number of the angular point.
  • the non-circular shaped fiber which satisfies the ⁇ value of 1.5 or greater may be preferred.
  • Length of the non-circular shaped fiber may be 35 to 65 mm. When it is less than 35 mm, it may be difficult to form and produce fiber aggregate due to wide gap between the fibers, and sound-absorbing and noise insulation performance may be reduced due to excess porosity. When it is over 65 mm, porosity may be reduced due to too narrow gap between the fibers, thereby reducing sound absorption coefficient. Further, fineness of the non-circular shaped fiber may be 1.0 to 7.0 De, and it may be more effective to sound-absorbing performance as fineness becomes lower.
  • the fineness of the non-circular shaped fiber is less than 1.0 De, there may be a problem to control the optimum shape of the targeted cross section, and when it is greater than 7.0 De (denier), there may be a difficulty on non-woven fiber manufacturing process and a problem of reduction of sound-absorbing performance when it is manufactured as the fiber aggregate.
  • the material of the non-circular shaped fiber included in the sound-absorbing material of the present invention may be preferably polyethylene terephthalate (PET), but not particularly limited thereto.
  • PET polyethylene terephthalate
  • Polypropylene (PP), rayon, and any polymer that may be spun in fiber form may be used preferably as a sound-absorbing material.
  • the sound-absorbing material of the present invention contains binder fiber which partly binds a plurality of the non-circular shaped fibers.
  • the binder fiber may be any binder fiber which is generally used when manufacturing fiber structure, and it may be used in the form of powder as well as fiber, and more particularly, it may contain low melting (LM) elastomer.
  • the elastomer generally refers to a polymer material having excellent elasticity such as rubbers, and i.e., it means a polymer having a characteristic that stretches when it is pulled by external force, and it is back to the original length when the external force is removed.
  • the preferable LM elastomer used in the present invention may have elastic recovery modulus of 50 to 80%. When elastic recovery modulus is less than 50%, the fiber aggregate is hardened, and sound-absorbing performance may be reduced due to short flexibility. When it is greater than 80%, there may be problems that processability may be reduced when manufacturing the fiber aggregate, as well as production cost of the polymer itself may be increased.
  • the LM elastomer may be a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer or polyurethane-based polymer, or combinations thereof
  • the LM elastomer may be manufactured by esterification and polymerization steps using dimethyl terephthalate(DMT) and dimethyl isophthalate(DMI), or terephthalic acid(TPA) and isophthalic acid(IPA) as an acid ingredient(Diacid); and 1,4-butanediol(1,4-BD) and polytetramethyleneglycol(PTMG) as a diol ingredient (Diol).
  • the acid ingredient (Diacid) uses dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI), or terephthalic acid (TPA) and isophthalic acid (IPA).
  • DMT dimethyl terephthalate
  • TPA terephthalic acid
  • IPA isophthalic acid
  • Mixing ratio of dimethyl terephthalate (DMT) and dimethyl isophthalate (DMI) may be a molar ratio of 0.65 ⁇ 0.80:0.2 ⁇ 0.35, preferably, and mixing ratio of terephthalic acid (TPA) and isophthalic acid (IPA) also may be molar ratio of 0.65 ⁇ 0.80:0.2 ⁇ 0.35, preferably.
  • TPA terephthalic acid
  • IPA isophthalic acid
  • IPA isophthalic acid
  • the molar ratio of dimethyl isophthalate (DMI) and isophthalic acid (IPA) is less than the above described range, elastic recovery modulus may be deteriorated, and the low melting function may not be expressed.
  • the molar ratio of dimethyl isophthalate (DMI) and isophthalic acid (IPA) is greater than the above described range, physical properties may be deteriorated.
  • the diol ingredient (Diol) uses 1,4-butanediol (1,4-BD), polytetramethyleneglycol(PTMG), and 1,4-butanediol forms a crystal region by reacting with acid ingredient and polytetramethyleneglycol(PTMG) forms a non-crystal region by reacting with acid ingredient, thereby providing low-melting function and elasticity.
  • PTMG Polytetramethyleneglycol
  • EG ethyleneglycol
  • molecular weight of the polytetramethyleneglycol may be in a range of 1500 to 2000, preferably.
  • elasticity and physical properties of the LM elastomer to be manufactured may not be suitable for use.
  • the acid ingredient and the diol ingredient may be mixed at molar ratio of 0.9 ⁇ 1.1:0.9 ⁇ 1.1 and polymerized, preferably. When any one ingredient of the acid ingredient and the diol ingredient is excessively mixed, it is not used to be polymerized and is discarded. Accordingly, it is preferred to mix the acid ingredient and the diol ingredient at similar amounts.
  • the LM elastomer manufactured from dimethyl terephthalate(DMT), dimethyl isophthalate(DMI) as the acid ingredient(Diacid) and 1,4-butanediol(1,4-BD), polytetramethyleneglycol(PTMG) as the diol ingredient(Diol) is manufactured to have melting point of 150 ⁇ 180° C. and elastic recovery modulus of 50 ⁇ 80%.
  • the binder fiber of the sound-absorbing material of the present invention may be a conjugated fiber which is conjugate-spun by using the LM elastomer as one component. More preferably, it may be sheath-core type or side by side type conjugated fiber.
  • the LM elastomer may be used as a sheath ingredient, and general polyester may be used as a core ingredient. The general polyester reduces production cost and functions as fiber supporter, and the LM elastomer allows to express elasticity and low melting function.
  • the binder fiber may be manufactured by using the LM elastomer and the general polyester at weight ratio of 40:60 ⁇ 60:40.
  • the LM elastomer is contained at weight ratio of less than 40, elasticity and low melting function may be deteriorated, and when it is contained at weight ratio of over 60, there is a problem of increase of production cost.
  • the sound-absorbing material may contain the non-circular shaped fiber of 50 to 80 wt % based on the total weight of the sound-absorbing material and the binder fiber of 20 to 50 wt % based on the total weight of the sound-absorbing material.
  • the content of the non-circular shaped fiber is less than 50 wt %, it may be difficult to embody the optimal sound-absorbing and noise insulation performances due to reduced fiber surface area, but when the content of the non-circular shaped fiber is greater than 80 wt %, the content of the binder fiber becomes less than 20 wt %, relatively, and it may be difficult to maintain enough binding strength between the fiber.
  • This fiber structure with polymorphic cross section having excellent sound-absorbing performance is manufactured by a method for manufacturing a sound-absorbing material that comprises forming fiber aggregate in the nonwoven fabric fabric form.
  • the fiber aggregate comprises: a non-circular shaped fiber satisfying the following Formula 1; and binder fiber which partly binds a plurality of the non-circular shaped fibers.
  • the sound-absorbing material may be manufactured by forming the fiber aggregate containing the non-circular shaped fiber and the binder fiber in the non-woven form having a certain surface density by general manufacturing processes for a fiber structure sound-absorbing material such as needle punching process or thermal adhesion process and the like.
  • a fiber structure sound-absorbing material such as needle punching process or thermal adhesion process and the like.
  • the sheath-core type conjugated fiber containing polyester-based LM elastomer as binder fiber contained polyester-based LM elastomer as a sheath ingredient, and the polyester-based LM elastomer used a mixture of terephthalic acid of 75 mole % and isophthalic acid of 25 mole % as an acid ingredient and a mixture of polytetramethyleneglycol of 8.0 mole % and 1,4-butanediol of 92.0 mole % as a diol ingredient, and manufactured by mixing and polymerizing the acid ingredient and the diol ingredient at molar ratio of 1:1.
  • the LM elastomer manufactured as mentioned above has melting point of 50° C., intrinsic viscosity of 1.4 and elastic recovery modulus of 80%.
  • As the core ingredient polyethylene terephthalate(PET) having melting point of 260° C. and intrinsic viscosity of 0.65 was used, and conjugated fiber having fineness of 6 D, strength of 3.0 g/D, elongation rate of 80%, crimp number of 12/inch and fiber length of 64 mm was manufactured by spinning using a conjugate spinning nozzle, which can conjugate spin the polyester-based LM elastomer and the general PET at spinning temperature of 275° C. and winding speed of 1,000 mm/min, elongated by 3.3 folds at 77° C., and finally heated at 140° C.
  • Example 1 The procedure of Example 1 was repeated except for manufacturing non-woven type fiber structure having thickness of 20 mm, surface density of 1200 g/m 2 .
  • Example 1 The procedure of Example 1 was repeated except for manufacturing a sound-absorbing material using low melting PET fiber as binder fiber. Rebound resilience of the manufactured sound-absorbing material was 30%.
  • a dumbbell shape specimen having thickness of 2 mm and length of 10 cm was elongated 200% at a rate of 200%/min using Instron, waited for 5 sec, and the elongated length after recovered at the same rate was measured, and then elastic recovery modulus was calculated by the following Formula.
  • the height of the rebound ball was measured (JIS K-6301, unit: %).
  • Test specimen was made into a square having a side length of 50 mm or greater and thickness of 50 mm or greater, and a steel ball having weight of 16 g and diameter of 16 mm was dropped from a height of 500 mm to the test specimen, and then the maximum rebound height was measured. Then, for each 3 test specimens, the rebound value was measured at least 3 times in a raw within 1 min, and the median value was used as rebound resilience rate (%).
  • Example 2 As comparing the result of measuring performances of Example 2 and Comparative Example 1, it was found that the sound-absorbing material using the non-circular shaped fiber of the present invention had better sound-absorbing and noise insulation performances than the fiber sound-absorbing material using fiber with circular cross section generally used, despite the reduced surface density of the fiber aggregate, and therefore, light-weight design thereof is possible by using reduced amount of fiber.
  • Examples 1 to 9 satisfying the ⁇ value of 1.5 or greater had improved sound absorption coefficient and transmission loss than Comparative Examples 1 to 5 having the ⁇ value of less than 1.5. It was found that Comparative Example 5 having the value of less than 1.5 also had low effect on sound absorption coefficient and transmission loss due to small surface area, although six-pointed star shape non-circular shaped fiber was used.
  • Example 9 As comparing the results of measuring performances of Example 9 using the low melting PET fiber as binder fiber and Examples 1 to 8 using the low melting elastomer, it was found that flexible structure having rebound elasticity rate of 55% was obtained by using low melting elastomer as binder fiber, and sound-absorbing performance was improved by improved attenuation capability of the vibration transmitted to the matrix structure.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Multimedia (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Electromagnetism (AREA)
  • Nonwoven Fabrics (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
US14/432,047 2012-09-28 2013-09-26 Sound-absorbing material with excellent sound-absorbing performance and method for manufacturing thereof Abandoned US20150252562A1 (en)

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PCT/KR2013/008630 WO2014051351A1 (ko) 2012-09-28 2013-09-26 흡음성능이 우수한 흡음재 및 그 제조방법

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BR112015006971A8 (pt) 2019-08-20
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JP2016500831A (ja) 2016-01-14
JP6587938B2 (ja) 2019-10-09
US20150204066A1 (en) 2015-07-23
BR112015006971B1 (pt) 2021-07-13
CN104918826B (zh) 2018-07-31
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EP2902266A4 (en) 2016-06-15
MX2015003983A (es) 2015-10-08
CA2886817A1 (en) 2014-04-03
CA2886817C (en) 2020-03-24
BR112015006971A2 (pt) 2017-07-04
US9523192B2 (en) 2016-12-20
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