Classifications

• • 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
  • 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
  • D04H1/413—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 containing granules other than absorbent substances

Definitions

• the present invention relates to a fiber sheet used for interior materials of automobiles and buildings.
• Patent Document 1
• Patent Document 2
• This type of fiber sheet is required to have soundproofing and heat insulating properties. It is desirable to increase the porosity in the fiber sheet for sound insulation and heat insulation. However, if the porosity in the fiber sheet is increased, the rigidity of the fiber sheet is reduced, and the fiber sheet is easily deformed during carrying, and the molded shape becomes unstable when molded. Furthermore, simply increasing the porosity in the fiber sheet does not guarantee sound absorption for a wide range of frequencies from low frequencies to high frequencies. Disclosure of the invention
• the present invention solves the above-mentioned conventional problems by mixing thermally expandable particles with fibers to form a sheet, and heating while controlling the thickness to thermally expand the thermally expandable particles. It is intended to provide a reinforced fiber sheet.
• the fiber is preferably a hollow fiber or a mixture of a hollow fiber, and the fiber is preferably mixed with a low-melting fiber having a melting point of 180 ° C. or lower.
• the fibers are desirably bound by a synthetic resin binder.
• the thermally expandable particles are microcapsules in which a low boiling point solvent is sealed in a thermoplastic resin shell having a low softening point, or thermoplastic resin beads having a low softening point are impregnated with a low boiling point solvent. Desirably, they are foam beads or, alternatively, thermally expandable inorganic particles.
• the present invention provides a molded product obtained by molding the above fiber sheet into a predetermined shape.
• the thermally expandable particles expand. Since the thickness of the fibrous sheet is regulated as described above, the surrounding fibers are compressed by the expansion of the granules, and the density of the fibrous portion is increased and the rigidity is improved. However, the porosity of the fiber sheet as a whole does not change, and thus the weight does not change.
• the fiber is compressed by the expansion of the thermally expandable particles, and the density of the fiber portion can be increased without increasing the weight.
• the fibers used in the present invention include, for example, polyester fibers, polya Synthetic fibers such as mid fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinyl chloride fiber, and acetate fiber, wool, mohair, cashmere, camel hair, alpaca, bikuna, angora, silk, silk, and ama Natural fibers such as fiber, pulp, cotton, palm fiber, hemp fiber, bamboo fiber, kenaf fiber, etc., cellulosic man-made fibers such as rayon (human silk, soup), polynosic, cuvula, acetate, triacetate, glass fiber, carbon Inorganic fibers such as fibers, ceramic fibers and asbestos fibers, and recycled fibers obtained by defibrating scraps of textile products using these fibers. These fibers are used alone or in combination of two or more. More desirable fibers include hollow fibers.
• the hollow fiber is made of polyester such as polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, nylon 6, nylon 66, nylon 46, and nylon mouth.
• thermoplastic resins such as polyamide, polyethylene, polypropylene, and other polyolefins, acrylic, urethane, polyvinyl chloride, polyvinylidene chloride, acetate, and the like. These hollow fibers are used alone or in combination of two or more.
• the hollow fiber is produced by a known method such as a melt spinning method or a method in which one component of a fiber obtained by composite spinning two kinds of polymers is preferentially eluted and removed.
• the hollow fiber has one or two or more hollow tubular portions having a circular or elliptical cross section, and has a hollow ratio of 5% to 70%, preferably 10% to 50%. It is.
• the void ratio is the ratio of the cross-sectional area of the hollow tube to the cross-sectional area of the fiber.
• the fineness of the hollow fiber is in the range of 1 dtex to 50 dtex, preferably in the range of 2 dtex to 2 O dte.
• the above-mentioned hollow fiber is used by being mixed with another fiber, it is preferable that the above-mentioned hollow fiber is mixed with 30% by mass or more.
• the rigidity of the fiber sheet is improved by the tube effect.
• a low melting point fiber having a melting point of 180 ° C. or less may be used.
• the low-melting-point fiber include polyolefin-based fibers such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride fiber, polyurethane fiber, polyester fiber, and polyester fiber.
• the low melting point fiber is usually mixed with the above fiber in an amount of 1 to 50% by mass.
• the thermally expandable particles used in the present invention are composed of, for example, a thermoplastic resin having a low softening point and a low boiling point solvent.
• thermoplastic resin having a low softening point examples include methyl acrylate, ethyl acrylate, n-propyl acrylate, iso-propyl acrylate, ⁇ -butyl acrylate, iso-butyl acrylate, and t-butyl acrylate.
• ⁇ ,] 3-unsaturated carboxylic acids such as olefins, isoprene, chloroprene, and benzoic acid, and acrylic acid, methacrylic acid, itaconic acid, maleic acid, crotonic acid, atropic acid, and citraconic acid.
• water-soluble monomers such as bierpyrrolidone, vinylpyridine, and vinylcarbazole, and the above-mentioned methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane, P-trimethoxysilylstyrene, and P-triethoxysilyl.
• Styrene P-trimethoxy Silyl- -methylstyrene, P-triethoxysilyl- -methylstyrene, T-acryloxycyprovir trimethoxysilane, vinyltrimethoxysilane, N-i3 (N-vinylbenzylaminoethyl-aminopropyl) trimethoxysilane '
• One or two or more polymers such as hydrolyzable silyl group-containing vinyl monomers such as hydrochloride or the above-mentioned polymers are converted to polyvalent acrylates or methacrylates such as divinylbenzene, diethylene dalicol diacrylate, etc.
• thermoplastic resin having a softening point of preferably 180 ° C. or less such as a polymer crosslinked with a crosslinking agent such as diaryl phthalate or arylglycidyl ether, a low softening point polyamide, or a low softening point polyester.
• low-boiling solvents include, for example, n-hexane, cyclohexane, n-pentane, isopentane, n
• organic solvents with a boiling point of 150 ° C or less such as butane, isobutane, n-heptane, n-octane, isooctane, gasoline, ethyl ether, acetone and benzene.
• the thermally expandable particles are expanded beads obtained by impregnating the above-mentioned thermoplastic resin particles with the above-mentioned low-boiling-point solvent, and a microphone having a low-boiling-point solvent filled in a shell of the above-mentioned low-softening-point thermoplastic resin.
• Etc. The diameter of the granules is usually from 0.5 to 100 m.
• thermally expandable particles used in the present invention there are thermally expandable inorganic particles such as vermiculite, perlite, and shirasparun.
• the fiber sheet of the present invention is obtained by needle panning a fiber web sheet or mat.
• a fiber web sheet or mat is impregnated or mixed with a synthetic resin binder, or a fiber web sheet or mat is entangled by $ 21 punching. It is manufactured by a method of binding and impregnating a synthetic resin binder, or a method of knitting and weaving fibers.
• the thermally expandable particles are usually mixed with the fibers before the fibers are converted into a sheet or mat, but when the sheets or mats are impregnated or mixed with a synthetic resin binder, they are mixed with the synthetic resin binder. You may keep it.
• the mixing ratio may be arbitrarily selected, but usually, the granules are added in an amount of from 0.1 to 50% by mass based on the fiber.
• the sheeted fiber In order to impregnate the sheeted fiber with the synthetic resin, the sheeted fiber is usually immersed in a liquid synthetic resin or a synthetic resin solution, or the liquid synthetic resin or the synthetic resin solution is sprayed on the sheeted fiber. Or, apply with a knife co.
• the sheeted fiber is squeezed using a drawing roll or a press machine.
• the thickness of the sheeting fiber decreases, but when the sheeting fiber contains hollow fibers, the sheeting fiber has high rigidity, and after being squeezed, the thickness is sexually restored.
• the sheeted fiber contains a low-melting fiber
• the fiber is sheeted, heated to melt the low-melting fiber, and the fiber is bonded by the melt. Then, the strength and rigidity of the fiber sheet are further improved, the workability during impregnation with the synthetic resin is improved, and the thickness of the sheet after drawing is remarkably restored.
• the sheet becomes highly rigid when formed into a sheet, and the content of the synthetic resin binder in the sheeted fiber is adjusted to a sheet not including the hollow fiber. Content of the synthetic fiber binder can be reduced.
• the synthetic fibers After impregnating or mixing the synthetic fibers with the synthetic fibers, the synthetic fibers are dried.
• the synthetic resin binder contained in the sheeted fiber is a thermosetting resin, setting the resin to the B state enables long-term storage, and enables low-temperature short-time molding. It will work.
• Examples of the synthetic resin used as a binder for the above fiber include polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, and fluorine acetate.
• thermoplastic acrylic resin thermoplastic polyester, thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-butadiene copolymer, styrene-butene copolymer, acrylonitrile-butadiene-styrene copolymer, ethylene-propylene copolymer
• Thermoplastic synthetic resins such as polymers, ethylene-propylene copolymers, ethylene-vinyl acetate copolymers, urethane resins, melamine resins, thermosetting acrylic resins, urea resins, phenolic resins, epoxy resins, thermosetting polyesters
• a thermosetting durable synthetic resin such as phenolic resin is used, but a urethane resin prepolymer, an epoxy resin prepolymer, a melamine resin prepolymer, a urea resin prepolymer, a phenol resin prepolymer, and a phenol resin prepolymer which produce the synthetic resin are used.
• Synthetic resin precursors such as prepolymers, oligomers and monomers such as diaryl phthalate prepolymer, acryl oligomer, polyvalent isocyanate, methyl acrylate ester monomer, and diaryl phthalate monomer may be used.
• the above synthetic resins may be used alone or in combination of two or more, and are usually used as an emulsion, a latex, an aqueous solution, an organic solvent solution or the like.
• Preferred as the synthetic resin binder used in the present invention is a phenolic resin.
• the phenolic resin used in the present invention will be described.
• a phenolic resin is obtained by condensing a phenolic compound with an aldehyde and a Z or aldehyde donor.
• the phenolic resin may be sulfoalkylated and Z- or sulfialkylated to impart water solubility.
• the phenolic resin of the present invention is impregnated on a sheet substrate as an aqueous solution of a precondensate (a precondensate solution).
• a precondensate solution may be, if desired, methanol, ethanol, isopropanol, n-propanol, isopropanol, n-butanol, isopropanol.
• the phenolic compound used in the phenolic resin may be a monovalent phenol, a polyvalent phenol, or a mixture of a monovalent phenol and a polyvalent phenol. However, if only monovalent phenol is used, formaldehyde is easily released during curing and after curing, so polyvalent phenol or a mixture of monovalent phenol and polyvalent phenol is preferably used. .
• the above monovalent phenols include phenol, o-cresol, m-cresol , P_cresol, ethyl phenol, isopropyl phenol, xylenol,
• Alkylphenols such as 3,5-xylenol, butylphenol, t-butylphenol, nonylphenol, o-fluorophenol, m-fluorophenol, p-fluorophenol, 0-cloth Phenol, m-chlorophenol, ⁇ -chlorophenol, o-bromophenol, m-bromophenol, ⁇ -bromophenol, o-dophenol, m-dophenol, p-phenol, o-Aminophenol, m-Aminophenol, p-Aminophenol, o-Nito Mouth phenol, m-Nitrophenol, p-Ditrophenol, 2,4-Dinitrophenol, 2,4,6-Trinitro Examples thereof include monovalent phenol-substituted products such as phenol, and polycyclic monovalent phenols such as naphthol. These can be mixed and used.
• polyvalent phenol examples include resorcin, alkyl resorsis pyrogallol, catechol, alkyl catechol, octahydroquinone, alkyl octahydroquinone, fluorolodarcin, bisphenol, dihydroxynaphthalene, and the like. These polyphenols may be used alone or in combination of two or more. They can be mixed and used. Preferred among the polyhydric phenols are resorcinol and alkylresorcinol, and particularly preferred is alkylresorcinol, which has a higher reaction rate with aldehydes than resorcinol.
• alkyl resorcinol examples include 5-methyl resorcin, 5-ethyl resorcinol, 5-propyl resorcinol, 5-n-butyl resorcinol, 4,5-dimethyl resorcinol, 2,5-dimethylresorcinol, 4,5-getyl resorcinol, 2,5 monoethyl resorcinol, 4,5-dipropyl resorcinol, 2,5-dipropyl resorcinol, 4-methyl-5-ethyl resorcinol, 2-methyl-5-ethyl resorcinol, 2-methyl-5-propyl resorcinol, 2,, There are 4,5-trimethylresorcinol and 2,4,5-triethylresorcinol.
• Polyvalent phenol mixture obtained by dry distillation of Estonian oil shale Is a particularly preferable polyvalent phenol raw material in the present invention because it is inexpensive and contains a large amount of highly reactive various alkylresorcinols in addition to 5-methylresorcinol.
• the phenolic compound and the aldehyde and Z or aldehyde donor are condensed, and the aldehyde donor means a compound which decomposes to produce an aldehyde or a mixture thereof.
• aldehydes include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, capaldehyde, arylaldehyde, benzaldehyde, crotonaldehyde, acrolein, and phenylacetaldehyde.
• aldehyde donors include, for example, paraformaldehyde, trioxane, hexamethylenetetramine, tetraoxymethylene and the like.
• Sulfomethylating agents that can be used to improve the stability of the water-soluble phenolic resin include, for example, sulfurous acid, bisulfite or metabisulfite, and alkali metals or trimethylamine or benzyltrimethylammonium.
• Water-soluble sulfites obtained by reacting quaternary amines or quaternary ammoniums, and aldehyde adducts obtained by reacting these water-soluble sulfites with aldehydes are exemplified.
• the aldehyde adducts include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, dalioxal, n-butyraldehyde, forceproaldehyde, acrylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o-
• An addition reaction between an aldehyde such as tolualdehyde and salicylaldehyde and the above-mentioned water-soluble sulfite.
• an aldehyde adduct composed of formaldehyde and sulfite is hydroxymethane sulfoxide. It is a fonate.
• Sulfimethylating agents that can be used to improve the stability of the water-soluble phenolic resin include aliphatic and aromatic aldehydes such as formaldehyde sodium sulfoxylate (Rongalit) and benzaldehyde sodium sulfoxylate. 7 Alkali metal sulfoxylates, sodium hydrosulfite, magnesium hydrosulfite, etc. 7 alkali metals, alkaline earth metal hydrosulfites (dithionites), hydroxymethane sulfinates, etc. And the like.
• phenolic resin if necessary, for example, hydrochloric acid, sulfuric acid, orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid, paratoluenesulfonic acid, naphthalene- ⁇ Inorganic or organic acids such as sulfonic acid, naphthalene- ⁇ -sulfonic acid, etc., esters of organic acids such as dimethyl oxalate, acid anhydrides such as maleic anhydride, phthalic anhydride, ammonium chloride, ammonium sulfate Ammonium, ammonium nitrate, ammonium succinate, ammonium acetate, ammonium phosphate, ammonium thiocyanate, ammonium imidesulfonate, etc., monochloroacetic acid or its sodium salt, and organic halogens such as ⁇ ,
• Urea adducts such as hydrochloride of amines, urea salicylate, urea stearate, urea heptanoate, acidic substances such as trimethyltaurine, zinc chloride, ferric chloride, ammonia, amines, Alkali earth metal hydroxides such as sodium hydroxide, potassium hydroxide, barium hydroxide and calcium hydroxide, oxides of alkaline earth metals such as lime, sodium carbonate, sodium sulfite, acetic acid An alkaline substance such as a weak acid salt of an alkaline metal such as sodium or sodium phosphate may be mixed as a catalyst or a ⁇ modifier.
• the phenolic resin (initial condensate) can be produced by a conventional method. Specifically, (a) a method of condensing a phenol and an aldehyde with a polyhydric phenol and Z, or (b) a precondensate and a Z or a polycondensate obtained by combining a monohydric phenol and an aldehyde with an aldehyde.
• a method of condensing an initial condensate condensed (e) an initial condensate obtained by condensing a phenol and an aldehyde, and an initial condensate obtained by condensing an aldehyde with a Z or polyphenol.
• a desirable phenolic resin is a phenol monoalkyl resorcinol cocondensate.
• the phenol-alkyl resorcinol co-condensate has good aqueous stability of the co-condensate (initial co-condensate) and is longer at room temperature than a condensate consisting of phenol alone (initial condensate).
• a condensate consisting of phenol alone initial condensate
• alkyl resorcin captures and reacts with a free aldehyde having a high reactivity with an aldehyde, it also has an advantage that the amount of the free aldehyde in the resin is reduced.
• a preferred method for producing the phenol monoalkyl resorcinol cocondensate is to first react phenol with an aldehyde to produce a phenolic resin precondensate, and then to convert the phenolic resin precondensate to alkyl This is a method in which resorcinol is added and, if desired, an aldehyde is added and reacted.
• a sulfomethylating agent and Z or a sulfimethylating agent are added to the precondensate at any stage to obtain a phenolic compound or Sulfomethylate and Z or sulfimethylate the precondensate.
• the sulfomethylating agent and the Z or sulfimethylating agent may be added at any stage before, during, or after the condensation reaction.
• the total amount of the sulfomethylating agent and / or sulfimethylating agent is usually 0.001 to 1.5 mol per 1 mol of the phenolic compound.
• the amount is less than 0.01 mol, the hydrophilicity of the phenolic resin is not sufficient, and when the amount is more than 1.5 mol, the water resistance of the phenolic resin becomes poor.
• the amount is preferably about 0.01 to 0.8 mol.
• the sulfomethylating agent and the Z or sulfimethylating agent added for sulfomethylating and Z or sulfimethylating the precondensate are combined with the methyl group of the precondensate and Z or the aromatic ring of the precondensate. Upon reaction, a sulfomethyl group and a Z or sulfistyl group are introduced into the precondensate.
• the aqueous solution of the precondensate of the phenolic resin thus sulfomethylated and Z- or sulfimethylated is stable in a wide range from acidic (pH 1.0) to alkaline, and is acidic, neutral and alkaline. It can harden in any area. In particular, when curing is performed on the acidic side, residual methylol groups are reduced, and there is no possibility that the cured product is decomposed to generate formaldehyde.
• the phenolic resin may be urea, thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine, acetoguanamine, benzoguanamine, 2,6-diamino-1,3-diamine amino-based resin.
• Addition of monomer or initial condensate composed of the amino resin monomer It may be co-condensed with a anol compound and z or a precondensate.
• a curing agent such as an aldehyde and Z or an aldehyde donor or an alkylolated triazone derivative may be further added to and mixed with the initial condensate (including the initial cocondensate) of the phenolic resin of the present invention.
• the Ruidan triazone derivative is obtained by reacting a urea compound, an amine, an aldehyde and Z or an aldehyde donor.
• Examples of the urea-based compound used in the production of the alkylated triazone derivative include urea, thiourea, alkyl urea such as methyl urea, alkyl thiourea such as methyl thiourea, phenyl urea, naphthyl urea, halogenated phenyl urea, A single type or a mixture of two or more types, such as a nitrile alkyl urea, is exemplified.
• a particularly desirable urea compound is urea or thiourea.
• amines aliphatic amines such as methylamine, ethylamine, propylamine, isopropylamine, butylamine, amylamine, etc .; amines such as benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine, hexamethylenetetramine, etc.
• amines such as benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine, hexamethylenetetramine, etc.
• ammonia which are used alone or as a mixture of two or more.
• the aldehyde and Z or aldehyde donor used in the production of the above alkylated triazone derivative are the same as the aldehyde and Z or the aldehyde donor used in the production of the initial condensate of the phenolic resin.
• alkylolated triazone derivative usually 0.1 to 1.2 mol of amines and Z or ammonia, and 1.5 to 1.2 mol of aldehyde and Z or aldehyde donor are used per 1 mol of urea compound.
• the reaction is performed at a ratio of 4.0 mol.
• the order of addition is arbitrary, but a preferable reaction method is that a required amount of aldehyde and Z or an aldehyde donor is first charged into a reactor, and usually the temperature is reduced to 60 or less at 60 or less.
• reaction of a urea compound, an amine and / or ammonia with an aldehyde and Z or an aldehyde donor is usually carried out in an aqueous solution, but methanol, ethanol, isopropanol, n —Alcohols such as butanol, ethylene glycol and diethylene glycol may be used alone or in combination of two or more, and water-soluble organic solvents such as ketones such as T-cetone and methyl ethyl ketone may be used alone. Alternatively, a mixture of two or more can be used.
• the amount of the curing agent added is 10 to 100 parts by mass, and 100 to 100 parts by mass of the initial condensate (initial cocondensate) of the phenolic resin of the present invention.
• the amount is 10 to 500 parts by mass with respect to 100 parts by mass of the initial condensate (initial cocondensate) of the phenolic resin.
• the synthetic resin binder used in the present invention further includes calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, 7K aluminum oxide, magnesium oxide, and magnesium oxide.
• Organic foaming agents such as azodicarbonamide, dinitrosopentamethylenetetramine, P, P'-oxobis (benzenesulfonylhydrazide), azobis-2,2,-(2-methylglopinitrile); Sodium bicarbonate, bicarbonate rim, bicarbonate ammonium, etc.
• Inorganic foaming agents such as glass balloons, perlite, glass powder, foamed glass, hollow ceramics; plastic foams and foamed particles such as foamed polyethylene, foamed polystyrene and foamed polypropylene; pigments, dyes, antioxidants , Antistatic agent, crystallization accelerator, flame retardant, flame retardant, water repellent, oil repellent, insect repellent, preservative, waxes, lubricant, antioxidant, ultraviolet absorber; DBP, DOP, dicyclohexyl A phthalic acid ester-based plasticizer such as a latex or other plasticizers such as tricresyl phosphate may be added and mixed.
• plastic foams and foamed particles such as foamed polyethylene, foamed polystyrene and foamed polypropylene
• the fiber sheet of the present invention causes the thermally expandable particles to thermally expand by heating to a temperature equal to or higher than the thermal expansion temperature of the thermally expandable particles contained while regulating the thickness.
• the fiber sheet of the present invention is formed into a flat plate or a predetermined shape. Usually, hot press molding is applied, and the thermal expansion of the thermally expandable particles regulates the thickness of the fiber sheet during the press molding. It is performed while doing.
• the fiber sheet of the present invention may be formed into a flat shape by hot pressing, and then formed into a predetermined shape by hot pressing, and when the low melting point fiber or the thermoplastic resin binder is contained. May be heated to soften the low-melting fiber or the thermoplastic resin binder and then formed into a predetermined shape by a cold press.
• the fiber sheet of the present invention may be used by stacking a plurality of sheets. Further, the fiber sheet may be laminated with another member such as a skin material, a back material, and a core material.
• the fiber sheet of the present invention can be used, for example, in automobile ceiling materials, dash silencers, food silencers, engine Cover silencer, cylinder head cover silencer, dasher-base material for interior materials such as silencer, floor mat, dash pod, door trim, or reinforcing material laminated on the base material, sound absorbing material, heat insulation It is useful as materials and building materials.
• Polyester fiber fineness: 4dtex, fiber length: 54 mm
• sheeted fiber by needle punching method (basis weight: 500 g / m Thickness: 1 5mm).
• 95 mass parts of phenol formaldehyde precondensate (45 mass% solid content) 5 mass parts of microcapsules filled with isopentane in polyvinylidene chloride shell (softening point 150 ° C) as thermally expandable granules
• the impregnating liquid to which the mixture was added and mixed was impregnated into the sheeted fiber so as to have a solid content of 50% by mass, and dried at 100 ° C for 3 minutes while sucking in a drying chamber.
• the sheet fiber was precured to obtain a fiber sheet.
• the precured fiber sheet was subjected to hot press molding at 200 ° C. for 60 seconds, and the microcapsules were expanded while controlling the thickness to obtain a molded product having a thickness of 8.pi.
• Example 1 The molded articles of Example 1 and Comparative Example 1 were subjected to a bending test, a sound absorption coefficient, and a ventilation resistance test.
• the bending test was performed according to the bending strength of 5.17 in JI S-K6911, and the test conditions were as follows: width: 25 mm, distance between supporting points: 10 Omrn.
• the sound absorption coefficient was in accordance with JIS-A1405 "Method of measuring the normal incidence sound absorption coefficient of building materials by the in-pipe method". Ventilation resistance according to the Frazier type air permeability tester, using force Totekku Ltd. breathable tester (KE S- F 8- AP I) , and the airflow rate per unit area and 4 cc / s' cm 2 The ventilation resistance at that time was measured. Table 1 shows the test results. ⁇ table 1 ⁇
• polyester hollow fiber 50% by mass of polyester hollow fiber (fineness: 5dtex, hollow ratio: 20%, fiber length: 56mm), 35% by mass of polyester fiber (fineness: 7dtex, fiber length: 60mm), and polyester low melting point fiber (fineness: 2. 5 dtex, melting point: 120 ° (:, fiber length: 65 mm)
• a sheet of a mixed fiber web consisting of 15% by mass is heated at 180 ° C for 5 minutes to melt the polyester low melting point fiber, and the fiber melt is caused by the melt.
• Aqueous solution of phenol-alkyl resorcinol-formaldehyde initial cocondensate (50 mass% solids) 90 parts by mass 2 parts by weight of nitrogen-based flame retardant, 2 parts by weight of fluorine-based water-repellent and oil-repellent, and heat-expandable granules (capsule type, Matsumoto Microsphere I F-100: manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd.
• Polyester hollow fiber fineness: 7dtex, hollow ratio: 30%, fiber length: 75mm) 45% by mass, polyamide fiber (fineness: 12dtex, fiber length: 75mm) 30% by mass, and kenaf fiber (fineness: 20-25dtex, Fiber length: 50mm) 10% by mass, polyester low melting point fiber (fineness: 12dtex, melting point: 110 ° C, fiber length: 65mm) 15
• sheeted fiber basis weight: 400 gm 2 , thickness: 18 mm
• the sheet fiber was impregnated with the impregnating liquid used in Example 2 so as to have a solid content of 50% by mass, and dried at 100 ° C for 4 minutes while sucking in a drying chamber. Then, the sheeted fiber was precured to obtain a fiber sheet. The precured fiber sheet was subjected to hot press molding in the same manner as in Example 2, and the granules were expanded while regulating the thickness to obtain a molded product having a thickness of 15 mm.
• Example 2 The molded products of Examples 2 and 3 and Comparative Example 2 were subjected to a bending test, a workability, a P ratio, and a ventilation resistance test. Table 2 shows the results of the test.
• Dust derived from glass was scattered during molding operation and the like, and the dust (glass) was stabbed, resulting in extremely poor workability and adversely affecting the human body.
• Example 1 has a higher sound absorption coefficient and a higher bending strength over a wider frequency range than the sample of Comparative Example 1. This is because the sample fiber is thermally expanded This is thought to be due to the decrease in the incident sound energy due to the compression due to the expansion of the granular material and the increase in the ventilation resistance. This can be seen from the value of ventilation resistance.
• polyester hollow fiber fineness: 4dtex, hollow ratio: 15%, fiber length: 55mm
• vinylon fiber fineness: 7.5dtex, fiber length: 60mm
• rayon fiber fineness: 6dtex
• a hot melt adhesive polyamide resin, melting point: 160 ° C, particle size: all through 200 mesh
• application amount: 8 gZm 2 is applied to one side of the fiber sheet.
• Production and a basis weight of 30 gZm 2 were laminated as a skin material, and hot-pressed at 200 ° C. for 60 seconds to thermally expand the thermally expandable granules while controlling the thickness to obtain a molded product.
• the molded product was excellent in flame retardancy, water repellency, rigidity, and sound absorption.
• Polyester hollow fiber fineness: 7dtex, hollow ratio: 20%, fiber length: 75mm
• flame-retardant polyester fiber fineness: 4dte X , fiber length: 55mm
• a sheet-shaped web of the mixed fiber having the amount of 100% by weight
• a sheeted fiber (basis weight: 400 g / m ⁇ thickness: 12 mm) was produced by a needle punching method.
• a molded article having a thickness of 1 Omm was obtained in the same manner as in Example 5, except that the thermally expanded particles were omitted.
• Example 5 Using the samples obtained in Example 5 and Comparative Example 3, a flammability test was performed in accordance with the horizontal test method of FMVSS-302. Table 3 shows the results.
• Example 5 has better flammability than Comparative Example 3. This is considered to be due to the fact that the void force S of the fiber of the sample is buried due to the expansion effect of the expandable particles, and the amount of air in the sample decreases during combustion.
• the fiber sheet molded article of the present invention is extremely useful, for example, as a sound absorbing material or a heat insulating material for automobiles and buildings.

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• 2003
  • 2003-07-02 JP JP2003189922A patent/JP2005023470A/ja active Pending
• 2004
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