WO2009101712A1 - 吸音性表皮材、及びそれを用いた吸音材 - Google Patents
吸音性表皮材、及びそれを用いた吸音材 Download PDFInfo
- Publication number
- WO2009101712A1 WO2009101712A1 PCT/JP2008/059532 JP2008059532W WO2009101712A1 WO 2009101712 A1 WO2009101712 A1 WO 2009101712A1 JP 2008059532 W JP2008059532 W JP 2008059532W WO 2009101712 A1 WO2009101712 A1 WO 2009101712A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- sound absorbing
- sound
- fiber sheet
- resin
- paper
- Prior art date
Links
Images
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
- G10K11/168—Plural layers of different materials, e.g. sandwiches
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/007—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/08—Corrugated paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/026—Knitted fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
- B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
- B32B2255/102—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer synthetic resin or rubber layer being a foamed layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/028—Paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0223—Vinyl resin fibres
- B32B2262/0238—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0246—Acrylic resin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
- B32B2262/0269—Aromatic polyamide fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0292—Polyurethane fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/04—Cellulosic plastic fibres, e.g. rayon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/14—Mixture of at least two fibres made of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0221—Vinyl resin
- B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0271—Epoxy resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/04—Mats
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
Definitions
- the present invention relates to a sound absorbing surface material such as a floor material of a car, a wall material of a house, and a sound absorbing material using the sound absorbing surface material.
- the sound absorbing material is often used by laminating a sound absorbing surface material on a base material and appropriately molding the laminate.
- Patent Document 1 describes a sound absorbing felt made of a single layer felt.
- the interior material for motor vehicles which consists of a resin binder adhesion fiber web is described in patent document 2.
- FIG. 3 describes an insulator for an automobile, which is formed of a laminate of a sound absorbing layer made of a fiber assembly and a skin layer made of a foam material.
- the conventional invention has the following problems.
- a sound absorbing material for a car or a building wall material is stretched on a floor or wall with as little gaps as possible to ensure sound absorbing performance. Therefore, the sound absorbing material should be made of only a fiber sheet or only a porous material.
- the weight of the sound absorbing material is considerable. This leads to a deterioration in workability due to an increase in weight, and in the case of an automobile in particular, it is disadvantageous for achieving fuel consumption reduction and weight reduction.
- paper is used as the material to reduce the weight, there is a problem in the sound absorbing performance, and furthermore, the followability to the formed shape, the durability to the forced fit and the like are inferior.
- the air flow resistance value between the surface layer on one side of the felt and the surface layer on the opposite side is continuously changed according to the difference in the coating amount of the binder resin. It becomes large with m 2 .
- the invention of Patent Document 2 also weighs 1750 g / m 2 as an interior material. In the invention of Patent Document 3, although the weight is reduced, there is a problem that the surface strength is weak because the foam layer is the surface.
- the present invention has been made focusing on the problems existing in such prior art, and the object of the present invention is to be able to achieve weight reduction while maintaining suitable sound absorption performance, and It is an object of the present invention to provide a sound absorbing surface material having good formability so that it can be used for the purpose of the present invention, and a sound absorbing material using the sound absorbing surface material.
- the present invention is a sound-absorbing skin material characterized in that a stretchable paper material having a large number of irregularities formed on its surface is laminated on one side or both sides of a fiber sheet. Further, the present invention is a sound-absorbing surface material characterized in that a stretchable paper material having a large number of ridge-like irregularities formed by creping is laminated on one side or both sides of a fiber sheet. The present invention is also a sound-absorbing surface material characterized in that a stretchable paper material having a large number of projections formed by embossing on one side or both sides of a fiber sheet is laminated.
- a stretchable paper material having a large number of ridge-like irregularities formed by creping and a large number of protrusions formed by embossing is laminated on one side or both sides of a fiber sheet. It is a sound absorbing skin material that is characterized.
- the crepe ratio is preferably 10 to 50%.
- the height of the projections be 0.02 to 2.00 mm and the number of projections be 20 to 200 / cm 2 .
- the basis weight of the stretchable paper material is preferably 10 to 50 g / m 2 .
- stacked through a porous adhesive layer is desirable.
- the fiber sheet and / or the stretchable paper material may be configured to be coated and / or impregnated with a synthetic resin.
- the air flow resistance of the stretchable paper material is preferably at least 0.060 kpa ⁇ s / m or more.
- the air flow resistance of the sound absorbing skin material is appropriately set according to the required frequency, but it is preferably 0.100 to 1.000 kpa ⁇ s / m.
- the present invention is a sound absorbing material characterized in that a sheet-like air-permeable porous material is laminated on the above-mentioned sound absorbing surface material.
- the synthetic resin may be applied and / or impregnated to at least one of the fiber sheet, the stretchable paper material, and the air-permeable porous material.
- the air flow resistance of the sound absorbing material is appropriately set according to the required frequency, but is preferably 0.400 to 20.000 kpa ⁇ s / m. Further, the sound absorbing material may be formed into a predetermined shape.
- the sound absorbing property of the fiber sheet and the sound absorbing property of the stretchable paper material having a large number of irregularities on the surface combine to exhibit a preferable sound absorbing performance.
- the sound absorbing performance is significantly superior to other sheet materials (for example, flat paper) having the same air flow resistance as the sound absorbing surface material of the present invention.
- the sound absorbing surface material can be lighter and lighter than the conventional sound absorbing surface material.
- the extensibility of the extensible paper material is improved, and the followability to the formed shape such as the concavo-convex shape and the curved surface shape, and the durability to the unreasonable fit Can be suitably adopted as a sound absorbing material used for floor materials, wall materials and the like of automobiles and houses.
- the synthetic resin is applied and / or impregnated to the fiber sheet and / or the stretchable paper material, the water resistance, the strength, the durability and the like of the sound absorbing skin material are improved.
- the sound absorbing material using the sound absorbing surface material can be formed into a predetermined shape according to the purpose.
- the sound-absorbing surface material and the sound-absorbing material of the present invention have a structure in which the fiber sheet and the stretchable paper material are laminated, so that weight saving can be achieved while maintaining suitable sound absorption performance, and moldability is good. It can be used for various applications.
- FIG. 6 is a longitudinal side view of the sound absorbing material 8;
- the fiber material of the fiber sheet used in the present invention is, for example, polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, synthetic fiber such as acetate fiber, corn And biodegradable fibers consisting of starch extracted from plants such as sugar cane, pulp, cotton, palm fibers, hemp fibers, natural fibers such as bamboo fibers and kenaf fibers, inorganic materials such as glass fibers, carbon fibers, ceramic fibers and asbestos fibers Fibers, or one or more kinds of regenerated fibers obtained by disintegrating scraps of fiber products using these fibers are used, for example, glass fibers, carbon fibers, ceramic fibers, asbestos fibers , Inorganic fibers such as stainless fiber, poly (metaphenylene isophthalamide) fiber, poly- -If heat-resistant synthetic fibers such as aramid fibers such as phenylene tere
- carbon fibers are useful inorganic fibers in that they can be incinerated and the scraps are unlikely to scatter
- aramid fibers are useful synthetic fibers in that they are relatively inexpensive and easy to obtain.
- low melting thermoplastic fibers having a melting point of 180 ° C. or less can be used as all or part of the above fibers.
- the low melting point thermoplastic fiber is, for example, polyolefin fiber such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer or the like having a melting point of 180 ° C. or less, polyvinyl chloride fiber, polyurethane fiber, polyester fiber And polyester copolymer fibers, polyamide fibers, polyamide copolymer fibers and the like.
- These low melting point thermoplastic fibers are used singly or in combination of two or more.
- the fineness of the low melting thermoplastic fiber is preferably in the range of 0.1 to 60 dtex.
- a desirable low melting thermoplastic fiber to be used in the present invention for example, a core comprising the above-mentioned normal fiber as a core and a sheath of a low melting thermoplastic resin having a melting point of 100 to 180 ° C. which is a material resin of the low melting thermoplastic fiber.
- sheath type fiber When the core-sheath type fiber is used, the rigidity and heat resistance of the resulting fiber sheet do not decrease.
- the fiber sheet of the present invention may be formed by a method of entanglement of the sheet or mat of the fiber web by needle punching or a spunbond method, or a sheet or mat of the web of the fiber comprises the low melting thermoplastic fiber or
- a thermal bond method is used in which a sheet or mat of the above fiber web is heated to soften the low melting point thermoplastic fiber, or a web of the above fiber is made
- a chemical bonding method in which a sheet or mat is impregnated or mixed with a synthetic resin binder for binding, or a sheet or mat of a web of the above fibers is entangled by needle punching, and then the low melting thermoplastic fiber is heat softened Stitch bond method to bind or sew with thread or high pressure Spunlace entangled in the flow, a method of forming wear impregnated with the synthetic resin binder into a sheet or mat subjected to the needle punching, is further produced by a method in which woven knitted the fibers.
- the stretchable paper material of the present invention includes a creped paper having crimped wrinkles (ridge-like unevenness) formed on the surface, an embossed paper having many protrusions formed on the surface, crimped wrinkles and many protrusions on the surface Embossed creped paper etc. which formed the are illustrated.
- the above-described creped paper is a base paper subjected to creping. In the above-described creping, the paper is compressed in the longitudinal direction (paper forming direction) using a press roll, a doctor blade or the like in the wet paper state to perform brazing.
- the creped stretchable paper material preferably has a crepe ratio of 10 to 50%.
- the crepe ratio is a rate at which the paper web is compressed in the longitudinal direction (papermaking direction) by creping (Reference: JP-A-2002-327399, JP-A-10-510886).
- the crepe ratio is less than 10%, the sound absorbing performance of the creped paper (stretchable paper material) will deteriorate, and the drawability will be insufficient, and wrinkles will easily occur during molding. On the other hand, if the crepe ratio exceeds 50%, wrinkles may easily form during molding.
- the embossed paper described above is obtained by pressing a roll (emboss roll) or plate (emboss plate) having a large number of irregularities on the surface against the base paper to form a large number of projections on the surface of the paper, and the projections of the projections
- the height is 0.02 to 2.00 mm and the number of protrusions is 20 to 200 / cm 2 .
- the height of the projections is less than 0.02 mm, the sound absorbing performance of the embossed paper (stretchable paper material) will be poor, and the stretchability will be insufficient, and wrinkles will easily occur during molding. In addition, even if the height of the projections exceeds 2.00 mm, wrinkles are easily formed during molding. If the number of protrusions is less than 20 pieces / cm 2 , the sound absorbing performance of the embossed paper (stretchable paper material) will deteriorate, and the stretchability will be insufficient, and wrinkles will easily occur during molding.
- embossed paper As the base paper, embossed creped paper can be obtained.
- pulp used for the above creped paper and embossed paper include hardwood wood pulp, softwood wood pulp, hemp pulp, kenaf pulp, bamboo pulp, esbalt pulp, bagasse pulp, rattan pulp and the like.
- synthetic fibers may be mixed at about 40 to 50%.
- the basis weight of the stretchable paper material is preferably 10 to 50 g / m 2 . If the basis weight is less than 10 g / m 2 , the moldability is reduced, wrinkles are likely to occur during molding, and the sound absorption performance is also poor. On the other hand, when the basis weight of rice exceeds 50 g / m 2 , the mass increases and the formability decreases.
- the air flow resistance of the stretchable paper material is preferably at least 0.060 kpa ⁇ s / m or more.
- the above-mentioned ventilation resistance (Pa ⁇ s / m) is a scale that represents the degree of ventilation of the breathable material.
- the measurement of the ventilation resistance is performed by a steady flow differential pressure measurement method. As shown in FIG. 1, the test strip T is disposed in the cylindrical air passage W, and the pressure in the air passage W at the start point side of the arrow in the figure in a state of constant air flow V (direction of arrow in the drawing). By measuring the pressure difference between P1 and the end point P2 of the arrow in the figure, the air flow resistance R can be obtained from the following equation.
- R ⁇ P / V
- V air permeability per unit area (m 3 / m 2 ⁇ s).
- the ventilation resistance can be measured, for example, by a ventilation tester (product name: KES-F8-AP1, manufactured by Kato Tech Co., Ltd., steady flow differential pressure measurement method).
- the air flow resistance of the stretchable paper material of the present invention is appropriately set according to the frequency required for the final product.
- the adjustment of the air flow resistance can be made by the entanglement of fibers of the stretchable paper material and the coated amount, and the application amount of the resin to be applied and / or impregnated.
- fiber sheets such as non-woven fabric, fiber woven fabric, polyurethane foam, polyethylene foam, polypropylene foam, polystyrene foam
- resin foams such as polyvinyl chloride foam, epoxy resin foam, melamine resin foam, urea resin foam, phenol resin foam etc., resin foam having air permeability, sintered body of beads of the above plastic, etc. Is used.
- the sound absorption is formed by laminating the fiber sheet 3 and the creped paper 1b (stretchable paper material) through the porous adhesive layer 5a and further comprising the fiber sheet 3 and the creped paper 1b.
- the sound absorbing material 8 in which the porous surface material 6 and the felt 7 (air-permeable porous material) are laminated via the porous adhesive layer 5 b is exemplified.
- a solution-type or aqueous-emulsion-type adhesive it is desirable to apply the adhesive in a dot-like manner by spray coating, silk printing coating, offset printing coating or the like to ensure the breathability of the laminated material.
- the air flow resistance of the sound absorbing skin is desirably set in the range of 0.100 to 1.000 kPa ⁇ S / m. When the air flow resistance exceeds 1.000 kPa ⁇ s / m, the formability is reduced. Further, the air flow resistance of the sound absorbing material is desirably set in the range of 0.400 to 20.000 kpa ⁇ s / m. When the air flow resistance is less than 0.400 kPa ⁇ s / m, the sound absorption is deteriorated, and when it exceeds 20.00 kPa ⁇ s / m, the performance becomes more sound insulation than the sound absorption.
- the air flow resistance of the stretchable paper material of the present invention is appropriately set according to the frequency required for the final product.
- the adjustment of the air flow resistance can be made by the entanglement of fibers of the stretchable paper material and the coated amount, and the application amount of the resin to be applied and / or impregnated.
- the adhesive layer may not be formed using an adhesive.
- At least one of the fiber sheet, the stretchable paper material, and the breathable porous material may be coated and / or impregnated with a synthetic resin.
- a synthetic resin a thermoplastic resin and / or a thermosetting resin are illustrated, for example.
- thermoplastic resin examples include acrylic acid ester resin, methacrylic acid ester resin, ionomer resin, ethylene-ethyl acrylate (EEA) resin, acrylonitrile-styrene-acrylic rubber copolymer (ASA) resin, acrylonitrile-styrene copolymer ( AS) resin, acrylonitrile, chlorinated polyethylene, styrene copolymer (ACS) resin, ethylene vinyl acetate copolymer (EVA) resin, ethylene vinyl alcohol copolymer (EVOH) resin, methacrylic resin (PMMA), polybutadiene (BDR), polystyrene (PS), polyethylene (PE), acrylonitrile butadiene styrene copolymer (ABS) resin, chlorinated polyethylene (CPE), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polypropylene (PP), cellulose acetate (cellulose acetate: CA)
- the thermoplastic resin may be used as a mixture of two or more, and may be used as a mixture of one or two or more of a small amount of thermosetting resin as long as the thermoplastic resin of the thermoplastic sheet is not inhibited.
- the thermoplastic resin is preferably used in the form of an aqueous solution, an aqueous emulsion or an aqueous dispersion from the viewpoint of easy handling, but it may be used in the form of an organic solvent solution.
- thermosetting resin for example, a urethane resin, a melamine resin, a thermosetting acrylic resin, particularly a thermosetting acrylic resin which forms and cures an ester bond by heating, a urea resin, a phenol resin, an epoxy resin, a thermosetting resin
- polyesters and the like are used, urethane resin prepolymers, urea resin prepolymers (initial condensation products), phenol resin prepolymers (initial condensation products), diallyl phthalate prepolymers, acrylic oligomers, polyvalent isocyanates which produce the synthetic resin are used.
- thermosetting resin precursors such as prepolymers such as nitrates, methacrylic ester monomers, and diallyl phthalate monomers, oligomers, and monomers may be used.
- the thermosetting resin is also preferably in the form of an aqueous solution, an aqueous emulsion or an aqueous dispersion from the viewpoint of easy handling, but it may be in the form of an organic solvent solution.
- the addition of the above-mentioned synthetic resin, particularly a thermosetting resin improves both the retention of the molded shape and the rigidity of the fiber sheet, the stretchable paper material or the air-permeable porous material.
- the phenolic resin is obtained by condensing a phenolic compound with formaldehyde and / or a formaldehyde donor.
- the phenolic compound used for the phenolic resin may be a monohydric phenol, a polyhydric phenol, or a mixture of a monohydric phenol and a polyhydric phenol.
- polyhydric phenol or a mixture of monohydric phenol and polyhydric phenol is preferably used because formaldehyde is easily released during and after curing.
- Examples of the monohydric phenol include phenol, alkylphenols such as o-cresol, m-cresol, p-cresol, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol, butylphenol, t-butylphenol and nonylphenol, o-fluoro Phenol, m-fluorophenol, p-fluorophenol, o-chlorophenol, m-chlorophenol, p-chlorophenol, o-bromophenol, m-bromophenol, p-bromophenol, o-iodophenol, m-iodo Phenol, p-iodophenol, o-aminophenol, m-aminophenol, p-aminophenol, o-nitrophenol, m-nitrophenol, p-nitrophenol, 2,4-dinitro And monohydric phenol substitutes
- alkylphenols
- polyhydric phenol examples include resorcin, alkyl resorcin, pyrogallol, catechol, alkyl catechol, hydroquinone, alkyl hydroquinone, phloroglucin, bisphenol, dihydroxynaphthalene and the like, and these polyhydric phenols may be used alone or in combination of two or more kinds can do.
- polyhydric phenols preferred are resorcin and alkyl resorcins, and particularly preferred are alkyl resorcins, which have a faster reaction rate with aldehyde than resorcin.
- alkylresorcin examples include 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-n-butylresorcinol, 4,5-dimethylresorcinol, 2,5-dimethylresorcinol, 4,5-diethylresorcinol, 2 , 5-diethylresorcinol, 4,5-dipropylresorcinol, 2,5-dipropylresorcinol, 4-methyl-5-ethylresorcinol, 2-methyl-5-ethylresorcinol, 2-methyl-5-propylresorcinol, 2 , 4,5-trimethyl resorcinol, 2,4,5- triethyl resorcinol and the like.
- the polyhydric phenol mixture obtained by dry distillation of Estonian oil shale is a particularly preferable polyhydric phenol raw material in the present invention because it is inexpensive and contains a large amount of various highly reactive alkylresorcins in addition to 5-methylresorcinol.
- polyhydric phenols one or a mixture of two or more of resorcinol compounds such as resorcin and alkyl resorcin (including polyhydric phenol mixtures obtained by dry distillation of Estonian oil shale), and aldehyde and / or aldehyde donating It is desirable that resorcinol resin composed of a body is used as the phenolic resin of the present invention.
- Formaldehyde donor In the present invention, the above-mentioned phenolic compound and formaldehyde and / or a formaldehyde donor are condensed, but the above-mentioned formaldehyde donor means a compound which forms and donates formaldehyde when decomposed, or a mixture of two or more thereof. Examples of such aldehyde donors include paraformaldehyde, trioxane, hexamethylenetetramine, tetraoxymethylene and the like. In the present invention, the combination of formaldehyde and a formaldehyde donor is hereinafter referred to as formaldehyde.
- the above-mentioned phenolic compound and formaldehyde are condensed to form a precondensate, and the precondensate is adhered to a fiber sheet, and then a curing catalyst and / or a curing catalyst and / or It resinifies by heating.
- a monohydric phenol and formaldehyde may be condensed to form a monohydric phenol single initial condensation product, or a mixture of monohydric phenol and polyhydric phenol may be condensed with formaldehyde. It may be a monohydric phenol-polyphenol initial co-condensate.
- one or both of monohydric phenol and polyhydric phenol may be made as an initial condensate beforehand.
- desirable phenolic resins are phenol-alkyl resorcin cocondensates.
- the above-mentioned phenol-alkyl resorcin co-condensates have good stability of the aqueous solution of the co-condensates (initial co-condensates) and can be stored for a long time at ordinary temperature as compared with condensates consisting only of phenols (pre-condensates) It has the advantage of being able to In addition, the aqueous solution is impregnated or applied to a sheet substrate, and the fiber sheet obtained by precuring is excellent in stability, and the formability is not lost even if the fiber sheet is stored for a long time.
- alkylresorcin is highly reactive with formaldehyde and captures and reacts with free aldehyde, it also has the advantage of reducing the amount of free aldehyde in the resin.
- the desirable method for producing the above-mentioned phenol-alkyl resorcin co-condensate is to first react phenol and formaldehyde with each other to produce a phenolic resin initial condensate, and then add an alkyl resorcin to the phenolic resin initial condensate. It is the method of adding formaldehyde and making it react.
- formaldehyde is 0.2 to 3 moles of formaldehyde with respect to 1 mole of monohydric phenol, and 1 mole of polyhydric phenol is formaldehyde.
- a solvent and a third component are added, and the mixture is heated and reacted at a liquid temperature of 55 to 100 ° C. for 8 to 20 hours.
- the formaldehydes may be added all at the start of the reaction, or may be added in portions or continuously.
- phenolic resin if desired, urea, thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine, acetoguanamine, benzoguanamine, amino of 2,6-diamino-1,3-diamine
- An initial condensation product of a resin based resin monomer and / or the amino resin monomer may be added and co-condensed with the phenolic compound and / or the initial condensation product.
- a curing agent such as the above-mentioned formaldehyde or alkylolated triazone derivative may be further added to and mixed with the initial condensation product (including the initial co-condensation product) of the phenolic resin of the present invention.
- the alkylolated triazone derivative is obtained by the reaction of a urea compound, amines and formaldehydes.
- urea compounds used for producing alkylolated triazone derivatives include urea, alkylureas such as thiourea and methylurea, alkylthioureas such as methylthiourea, phenylurea, naphthylurea, halogenated phenylurea, nitrated alkyl
- alkylureas such as thiourea and methylurea
- alkylthioureas such as methylthiourea
- phenylurea, naphthylurea halogenated phenylurea
- nitrated alkyl A single or a mixture of two or more such as urea is exemplified.
- Particularly desirable urea compounds are urea or thiourea.
- aliphatic amines such as methylamine, ethylamine, propylamine, isopropylamine, butylamine and amylamine, benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine, hexamethylenetetramine and the like, and further ammonia are used alone or as a mixture of two or more.
- the formaldehydes used in the preparation of the above alkylolated triazone derivatives are similar to the formaldehydes used in the preparation of precondensates of phenolic resins.
- the order of addition is arbitrary, but as a preferable reaction method, the required amount of formaldehyde is first charged into the reactor, and the temperature is usually 60 ° C. or less while maintaining the temperature at 60 ° C. The required amount is gradually added, and further, the required amount of urea compound is added, and the reaction is carried out with stirring and heating at 80 to 90 ° C. for 2 to 3 hours.
- formaldehyde 37% formalin is usually used, but in order to increase the concentration of the reaction product, part of it may be replaced with paraformaldehyde. Also, using hexamethylenetetramine, higher solids reaction products are obtained.
- the reaction of a urea compound, an amine and / or ammonia, and a formaldehyde is usually carried out in an aqueous solution, but replacing part or all of the water with methanol, ethanol, isopropanol, n-butanol, ethylene glycol, diethylene glycol, etc.
- One or a mixture of two or more alcohols may be used, or a mixture of one or more water-soluble organic solvents such as ketones such as acetone and methyl ethyl ketone may be used.
- the amount of the curing agent added is 10 to 100 parts by mass with respect to 100 parts by mass of the initial condensation product (initial cocondensate) of the phenolic resin of the present invention in the case of formaldehydes, and the above phenol in the case of the alkylolated triazone derivative
- the amount is 10 to 500 parts by mass with respect to 100 parts by mass of the initial condensation product (initial cocondensation product) of the resin.
- sulfomethylating agent examples include, for example, sulfite, bisulfite or metabisulfite, alkali metals or quaternary amines such as trimethylamine or benzyltrimethylammonium. Examples thereof include water-soluble sulfites obtained by reacting with a class ammonium and aldehyde adducts obtained by reacting these water-soluble sulfites with aldehydes.
- aldehyde adduct examples include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde and the like
- the aldehyde of the present invention is an addition reaction of the above-mentioned water-soluble sulfite, and an aldehyde adduct consisting of, for example, formaldehyde and sulfite is hydroxymethane sulfonate.
- Sulfymethylating agents that can be used to improve the stability of water-soluble phenolic resins include alkali metal sulfoxylates of aliphatic and aromatic aldehydes such as formaldehyde sodium sulfoxylate (longgarite) and benzaldehyde sodium sulfoxylate Examples thereof include alkali metal such as sodium hydrosulfite and magnesium hydrosulfite, hydrosulfite (dithionite) of alkaline earth metal, and hydroxyalkanesulfinate such as hydroxymethanesulfinate.
- alkali metal such as sodium hydrosulfite and magnesium hydrosulfite, hydrosulfite (dithionite) of alkaline earth metal, and hydroxyalkanesulfinate such as hydroxymethanesulfinate.
- a sulfomethylating agent and / or a sulfimethylating agent is added to the precondensate at any stage to obtain a phenolic compound and / or precondensate Is sulfomethylated and / or sulfimethylated.
- the addition of the sulfomethylating agent and / or the sulfimethylating agent may be performed at any stage before, during or after the condensation reaction.
- the total amount of the sulfomethylating agent and / or sulfimethylating agent added is usually 0.001 to 1.5 moles relative to 1 mole of the phenolic compound. If it is less than 0.001 mol, the hydrophilicity of the phenolic resin is not sufficient, and if it is more than 1.5 mol, the water resistance of the phenolic resin is deteriorated. In order to maintain good properties such as the curability of the precondensed product to be produced and the physical properties of the resin after curing, it is preferable to use about 0.01 to 0.8 mol.
- the sulfomethylating agent and / or sulfimethylating agent added to sulfomethylate and / or sulfimethylate the precondensate is reacted with the methylol group of the precondensate and / or the aromatic ring of the precondensate.
- a sulfomethyl group and / or a sulfimethyl group is introduced into the initial condensation product.
- the aqueous solution of the pre-condensate of sulfomethylated and / or sulfimethylated phenolic resin is stable in a wide range of acidity (pH 1.0) to alkalinity, whether in the acid, neutral or alkaline region. It can be cured. In particular, when curing is carried out on the acid side, the residual methylol group is reduced, and there is no possibility that the cured product is decomposed to generate formaldehyde.
- a flame retardant may be added to at least one of the fiber sheet, the stretchable paper material, and the breathable porous material.
- the flame retardant include phosphorus-based flame retardants, nitrogen-based flame retardants, sulfur-based flame retardants, boron-based flame retardants, bromine-based flame retardants, guanidine-based flame retardants, phosphate-based flame retardants, phosphate-based flame retardants, and amino
- resin-based flame retardants expanded graphite and the like.
- the powdery solid flame retardant which is poorly soluble or insoluble in water imparts excellent sound resistance and durability to the sound absorbing surface material and sound absorbing material.
- the fiber sheet and the air-permeable porous material of the present invention have a rough structure, the powdery solid flame retardant penetrates smoothly to the inside to impart high flame retardancy and non-combustibility.
- inorganic fibers such as carbon fibers, glass fibers and ceramic fibers, mineral fibers such as asbestos fibers, aramid fibers (aromatic polyamide fibers), and wool as fibers of the above-mentioned fiber sheet or air-permeable porous material
- flame-retardant and flame-retardant fibers such as animal hair fibers (natural wool) and the like, imparting flame-retardant and flame-retardant properties to the sound absorbing surface material and sound absorbing material without using a flame retardant described later It becomes possible.
- the thermoplastic resin used in the present invention further includes calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, titanium oxide, oxide Iron, zinc oxide, alumina, silica, mica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos, mica, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, glass powder, stone powder, blast furnace slag , Inorganic fillers such as fly ash, cement, and zirconia powder; natural rubber or derivatives thereof; styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, ethylene-propylene rubber, isoprene rubber, isoprene-iso Synthetic rubbers such as tyrene rubber, polyvinyl alcohol, sodium alginate
- the colloidal silica used in the present invention is fine silica particles or fine silica particles coated with alumina on the surface, and usually has an average particle diameter of 1 to 100 ⁇ m, preferably 3 to 50 ⁇ m.
- the colloidal silica is usually provided as a dispersion dispersed in water.
- silica fine particles having an average particle size of more than 100 ⁇ m the resin exudation layer may become whitish, and in the case of silica fine particles having an average particle size of less than 1 ⁇ m, the surface area becomes excessive and the stability of the dispersion becomes worse.
- water and oil repellent agent there are natural wax, synthetic wax, fluorocarbon resin, silicone resin and the like.
- the fiber sheet In order to impregnate the above-mentioned fiber sheet with the above-mentioned thermoplastic resin, the fiber sheet is usually dipped in an aqueous emulsion or dispersion of a thermoplastic resin, or coated by a knife coater, a roll coater, a flow coater or the like.
- the fiber sheet In order to adjust the amount of thermoplastic resin in the fiber sheet impregnated or coated with the thermoplastic resin, after impregnating or coating the thermoplastic resin, the fiber sheet is squeezed using a squeeze roll or a press machine. In this case, the fiber sheet reduces its thickness, but if the fiber sheet consists of low melting point fibers or contains low melting point fibers, the fiber sheet is heated before the impregnation with the thermoplastic resin.
- thermoplastic resin impregnation After impregnating or applying the thermoplastic resin to the fiber sheet, the fiber sheet is dried at room temperature or under heating to form a thermoplastic sheet.
- thermoplastic fiber may be used for the fiber sheet, in that case the fiber sheet itself can have thermoplasticity, so that the thermoplastic resin is necessarily applied or impregnated. There is no need.
- Example 1 A hot melt adhesive made of heat-melted polyamide (melting point: 130 ° C) is applied to the back of a fiber sheet with a basis weight of 80 g / m 2 by a needle punching method made of polyester fibers to a coating amount of 15 g / m 2
- creped paper consisting of 60% by mass of softwood pulp and 40% by mass of hardwood pulp is stacked on the hot melt coated surface of the fiber sheet and laminated, and the surface temperature is adjusted to 140 to 150 ° C.
- the pressure was applied by the heat roll, and the pressure was then applied by the cold heat roll to obtain a sound absorbing surface material made of a laminate of a creped paper and a fiber sheet.
- the creped paper the following four types of creped paper were used.
- a felt made of a polyester fiber comprising 30% by mass of low melting fiber sheet (melting point: 160 ° C.) of core / sheath structure made of polyester fiber and having a basis weight of 600 g / m 2 and a thickness of 15 mm is made of breathable porous material
- the above hot melt adhesive was applied to one side of the felt by a spray method so that the coating amount would be 15 g / m 2 .
- the creped surface of the sound absorbing surface material and the hot melt adhesive surface of the felt are polymerized, heated for 50 seconds in a heating furnace adjusted to 200 ° C., and then cold pressed and formed into a predetermined shape , I got a sound absorbing material.
- a flat-plate-shaped sound absorbing material with a thickness of 10 mm was simultaneously formed for the sound absorption performance test.
- Example 2 The creped paper in Example 1 was replaced with embossed paper to obtain a sound absorbing skin material and a sound absorbing material. In addition, a flat-plate-shaped sound absorbing material with a thickness of 10 mm was simultaneously formed for the sound absorption performance test.
- the embossed paper used was the following four types of embossed paper.
- Projection height 0.2 mm, number of projections 150 pieces / cm 2 and rice basis weight 15 g / m 2 2 Projection height 0.2 mm, number of projections 150 pieces / cm 2 and rice basis weight 40 g / m 2 3: Height of protrusion 1.5 mm, number of protrusions 20 pieces / cm 2 and rice basis weight 15 g / m 2 4: Projection height 1.5 mm, projection number 20 pieces / cm 2 and rice basis weight 40 g / m 2
- Comparative Example 1 A molding for sound absorption performance test was obtained in the same manner as in Example 1 except that the crepe ratio of the creped paper was made 5% and 55%.
- Comparative Example 2 A molded product for a sound absorbing performance test was obtained in the same manner as in Example 1 except that the basis weight of rice of the creped paper was changed to 8 g / m 2 and 55 g / m 2 .
- Example 3 In Example 1, in place of the creped paper, a paper having a smooth flat surface before creping was used. In addition, the papermaking had a basis weight of 15 g / m 2 and 40 g / m 2 . And others obtained the molding for a sound absorption performance test similarly.
- Example 2 a protrusion for a sound absorption performance test was obtained in the same manner as in Example 2 except that the protrusion height of the embossed paper was 0.01 mm and 1.5 mm was 2.5 mm.
- Comparative Example 5 The same procedure as in Example 2 was repeated except that the protrusion height of the embossed paper was 0.2 mm and the number of protrusions was 250 pieces / cm 2 , and the protrusion height was 1.5 mm and the number of protrusions was 10 pieces / cm 2. A molded product for sound absorption performance test was obtained.
- Comparative Example 6 A molded product for sound absorption performance test was obtained in the same manner as in Example 2 except that the rice basis weight of the embossed paper was changed to 8 g / m 2 and 55 g / m 2 .
- Moldability The moldability of the molded product having a predetermined shape was examined. ⁇ : There were no wrinkles, tears, etc., and the deep-drawn portion could be formed well.
- samples having a small crepe ratio had a significantly worse sound absorption coefficient and inferior formability as compared with this example.
- the samples having large crepe ratio as in the samples 11 and 12 have the same sound absorbing performance as the present example, but wrinkles occurred during molding because there were too many irregularities due to crepe wrinkles.
- Samples 13 and 15 of Comparative Example 2 samples having a small basis weight were inferior in sound absorption performance and inferior in formability as compared with the present example. When the basis weight of the rice was large as in the samples 14 and 16, tearing of wrinkles was observed at the deep drawing portion at the time of molding as compared with the present example.
- Example 3 Using a fiber sheet having a basis weight of 70 g / m 2 by a needle punching method consisting of polyester fibers, a hot melt adhesive consisting of thermally melted polyester (melting point: 130 ° C.) is coated on one side of the fiber sheet at 10 g / m After spray coating so as to become 2 , a crepe-treated paper (crepe ratio: 30%, rice basis weight: 20 g / m 2 ) consisting of 80% by mass of softwood pulp and 20% by mass of hardwood pulp is coated with the hot melt adhesive After press-contacting with a heat roll whose surface temperature was adjusted to 140 to 150 ° C., press-contacting with a cooling roll was performed to bond the creped paper to the fiber sheet.
- a hot melt adhesive consisting of thermally melted polyester (melting point: 130 ° C.) is coated on one side of the fiber sheet at 10 g / m
- a crepe-treated paper consisting of 80% by mass of softwood pulp and 20% by mass of hardwood
- Example 3 a sound absorbing material was obtained in the same manner as in Example 3 except that the creped paper was replaced by a flat paper (rice basis weight: 20 g / m 2 ) made of paper.
- the air flow resistance of this skin material was 0.65 kPa ⁇ s / m, and the air flow resistance of a 10 mm-thick molded product was 1.26 kPa ⁇ s / m.
- the test results of the sound absorption coefficient and the moldability of the molded product are shown in Table 5.
- Example 3 a hot melt adhesive comprising a copolyester (melting point: 130 ° C.) heat-melted on one side of the fiber sheet using a fiber sheet having a basis weight of 70 g / m 2 by a needle punching method consisting of polyester fibers.
- a hot melt adhesive comprising a copolyester (melting point: 130 ° C.) heat-melted on one side of the fiber sheet using a fiber sheet having a basis weight of 70 g / m 2 by a needle punching method consisting of polyester fibers.
- the skin material air flow resistance: 0.03 kPa ⁇ s / m
- a fiber web having a basis weight of 600 g / m 2 comprising 70% by mass of polyester fibers and 30% by mass of low melting point fiber sheet (melting point: 160 ° C.) having a core-sheath configuration. 3.
- a fiber web consisting of the same polyester fibers and having a basis weight of 1800 g / m 2 In addition, a flat plate-shaped molded product with a thickness of 10 mm was simultaneously molded for sound absorption performance test.
- the air flow resistance of each molded product with a thickness of 10 mm is 0.38 kPa ⁇ s / m for the basis weight 600 g / m 2 and 0.56 kPa ⁇ s / m for the 900 g / m 2 , 1800 g / m 2.
- the value of m 2 was 1.28 kPa ⁇ s / m.
- Table 5 The test results of the sound absorption coefficient and the moldability of the molded product are shown in Table 5.
- Example 9 an acrylic ester / methacrylic acid ester copolymer emulsion (solid content: 40%, MFT) is used on one side of the fiber sheet using a fiber sheet having a basis weight of 70 g / m 2 by a needle punching method comprising polyester fibers. : 110 ° C., particle size:: 4 °C) 60 parts by weight, copolymerized polyester (melting point as a hot-melt adhesive 100 ⁇ 150 [mu] m) 20 parts by weight, a mixed solution consisting of 20 parts by mass of water of 250 g / m 2 as a solid The coated material was spray-coated and dried at 140 ° C. for 10 minutes while being sucked to obtain a skin material.
- solid content 40%, MFT
- the air flow resistance of the skin material was 0.67 kPa ⁇ s / m.
- the skin material is applied to an air-permeable porous material having a basis weight of 900 g / m 2 and comprising 70% by mass of polyester fiber and 30% by mass of low melting point fiber sheet (melting point: 160 ° C.) having a core-sheath configuration.
- the resultant was cold-pressed and molded into a predetermined shape to obtain a sound absorbing material.
- the air flow resistance of the 10 mm thick molded product was 1.30 kPa ⁇ s / m.
- the test results of the sound absorption coefficient and the moldability of the molded product are shown in Table 5 (Samples 33 to 36).
- Example 4 A hot melt adhesive comprising a copolyamide resin (melting point: 120 ° C., particle size: 200 to 250 ⁇ m) on the back surface of a fiber sheet having a basis weight of 50 g / m 2 by a spun bond method comprising polyester fibers.
- Powders are scattered at random by a scattering method so that the coating amount is 10 g / m 2, and then embossed paper comprising 50% by mass of softwood pulp and 50% by mass of hardwood pulp (protrusion height: 0.10 mm, the number of projections) : 72 pieces / cm 2 , rice basis weight: 15 g / m 2 ), and press contact with a heat roll whose surface temperature is adjusted to 140 to 150 ° C., press contact with a cold heat roll, and the embossed paper The fiber sheet was adhered.
- a regenerated felt uncured raw cotton (area weight 50 g / m 2 , thickness: 20 mm) to which 20% of a novolak type phenolic resin powder containing a curing agent is added is used, and the regenerated felt is uncured.
- the above-mentioned sound-absorbing surface material was polymerized on one side of the raw cotton, and hot-pressing was performed at 200 ° C. ⁇ 60 seconds to obtain a sound absorbing material as a predetermined shape.
- the above-mentioned sound absorbing material is light and excellent in moldability and sound absorbing performance, and is most suitable for floor mats and room partitions of automobiles.
- Example 5 Using a fiber sheet having a basis weight of 70 g / m 2 by a needle punching method consisting of polyester fibers, a comb-like hot melt adhesive consisting of a copolyamide (melting point: 135 ° C., a basis weight of 15 g / m) on the back surface of the fiber sheet m 2 ) overlapping, and further 20% by weight softwood pulp and 20% crepe ratio consisting of 80% by weight hardwood pulp by stacking creped paper with a basis weight of 20 g / m 2 and adjusting the surface temperature to 140 to 150 ° C.
- the above-mentioned sound-absorbing surface material is polymerized on an uncured glass wool raw cotton (weight: 450 g / m 2 , thickness: 30 mm) containing 20% by mass of uncured resol-type phenolic resin Then, it was molded with a hot press at 200 ° C. for 1 minute to obtain a sound absorbing material of a predetermined shape.
- This sound absorbing material is a light weight, excellent in sound absorption and flame retardancy, has no wrinkles at the time of molding, is a molded article excellent in design in appearance, and is useful for automobile engine undercovers, hood silencers, dash outer silencers, etc. is there.
- Hot melt adhesive consisting of copolymerized nylon (melting point: 135 ° C, particle size: 200 to 300 ⁇ m) on the back of a fiber sheet with a basis weight of 70 g / m 2 by needle punching method consisting of 70% by mass of polyester fiber and 30% by mass of carbon fiber Is coated by a scattering method so that the coating amount is 5 g / m 2 and then embossed creped paper consisting of 90 parts by mass of hemp pulp and 10 parts by mass of rayon (crepe ratio 35%, protrusion height: 0.2 mm, number of projections: 50 pieces / cm 2 , rice basis weight 15 g / m 2 ), and pressure contact is performed with a heat roll whose surface temperature is adjusted to 140 to 150 ° C.
- a sulfomethylated phenol-alkyl resorcinol-formaldehyde first laminate obtained by adhering the fiber sheet to an embossed creped paper 40 parts by mass of condensate (solid content: 45% aqueous solution), 1 part by mass of carbon black (solid content: 20% aqueous dispersion), 2 parts by mass of fluorine-based water repellent, oil repellent agent (solid content: 20% aqueous solution), phosphorus -A resin mixed solution consisting of 10 parts by mass of a chisso flame retardant (solid content: 40% aqueous solution) and 47 parts by mass of water is impregnated to have a coating amount of 15 g / m 2 as solid content, and further embossed creped paper 30 parts by mass of acrylic ester / methacrylic acid ester copolymer emulsion (solid content: 48%, Tg: -40 ° C, MFT: ⁇ 0 ° C), polyamide as a hot melt adhesive (particle
- the above sound absorbing skin material is polymerized on both sides of a melamine foam sheet having a basis weight of 250 g / m 2 and a thickness of 25 mm as a breathable porous material, and heat pressed for 50 seconds at 200 ° C. Sound absorbing material was obtained.
- the sound absorbing material is a molded article having good weather resistance, light weight, excellent sound absorbing property, flame retardancy, no wrinkles at the time of molding, and excellent designability in appearance, and is an automobile undercover, cylinder head cover, hood Useful for silencers, dash outer silencers, fender liners, etc.
- Example 7 40 parts by weight of a sulfimethylated phenol-alkyl resorcinol-formaldehyde precondensate (solid content: 45% aqueous solution), carbon black (solid content: 20%) in a fiber sheet of 80 g / m 2 basis weight by needle punching method comprising polyester fibers 1 part by mass water-dispersed solution, 2 parts by mass fluorine-based water repellent, oil-repellent agent (solid content: 20% aqueous solution), 10 parts by mass phosphorus-chisso flame retardant (solid content: 40% aqueous solution), 47 parts by mass water
- the mixed solution is impregnated as a solid content at a coating amount of 30 g / m 2 , dried at 150 ° C.
- the copolyamide is formed on the back surface of the fiber sheet.
- Kumono focal hot melt adhesive mp: 135 ° C., basis weight 15 g / m 2
- further embossed paper thereon projection height: 0. 05 mm, number of projections: 225 / cm 2 , rice basis weight: 25 g / m 2
- the hot melt adhesive is further laminated and laminated, and the laminate is coated at a basis weight of 340 g / m 2 and a thickness of 17 mm
- the both sides of the foamed urethane foam were polymerized, and hot press molding was performed at 180 ° C.
- the sound absorbing material is a molded article having good weather resistance, light weight, excellent sound absorbing property, flame retardancy, no wrinkles at the time of molding, and excellent designability in appearance, and is an automobile undercover, cylinder head cover, hood Useful for silencers, dash outer silencers, fender liners, etc.
- Example 8 Cubic-nested hot melt adhesive (melting point: 110 ° C, basis weight) consisting of copolyester on the back surface of a fiber sheet with a basis weight of 30 g / m 2 by thermal bonding method consisting of 80% by mass of polyester fiber and 20% by mass of polypropylene fiber 15 g / m 2 ) stacked on top of each other, and embossed creped paper consisting of 90 parts by mass of manila hemp pulp and 10 parts by mass of rayon (crepe ratio: 45%, protrusion height: 0.1 mm) The number of protrusions: 64 / cm 2 , US basis weight 15 g / m 2 ) was polymerized, and pressure contact was made with a heat roll pressure whose surface temperature was adjusted to 140 to 150 ° C.
- the above-mentioned cloud-like hot melt adhesive was superposed on the above, and heated at 120 ° C. for 10 seconds to obtain a sound-absorbing surface material.
- a fiber web having a basis weight of 300 g / m 2 comprising 70% by mass of polyester fibers and 30% by mass of low melting point fiber sheet (melting point: 130 ° C.) having a core-sheath configuration is used as a breathable porous material.
- the above-mentioned sound-absorbing surface material was polymerized on both sides of the fiber web and heated at 200 ° C. for 60 seconds, and then a plate-like sound-absorbing material having a thickness of 5 mm was obtained with a cold press.
- the sound absorbing material is excellent in heat insulation and is used by being bonded to a plywood, a gypsum board or the like of a building.
- Example 9 Fiber sheet of 80 g / m 2 in basis weight by needle punching method consisting of polyester fiber, 30 parts by mass of acrylic emulsion (solid content: 45%), colloidal silica (anhydrous silicic acid content: 20% aqueous solution), 65 parts by mass of water The resulting mixture solution was impregnated to a coating amount of 30 g / m 2 as solid content, dried at 120 ° C. for 2 minutes, and precured.
- a cloud-like hot melt adhesive (melting point: 110 ° C., fabric weight: 15 g / m 2 ) made of copolyamide is superimposed, and further 80% by weight softwood pulp A heat roll with a surface temperature adjusted to 120 to 125 ° C. by overlapping a creped paper (crepe ratio: 30%, rice basis weight 20 g / m 2 ) consisting of 20% by weight of hardwood pulp on the hot melt adhesive coated surface.
- press-contacting press-contacting was carried out with a cooling roll, and creped paper was adhered to the fiber sheet.
- a regenerated felt uncured base cotton (weight per unit area 500 g / m 2 , thickness: 20 mm) to which 20% of a novolak-type phenolic resin powder with a curing agent is added is used as a breathable porous material.
- the above-mentioned sound-absorbing surface material was polymerized and hot-pressed at 200 ° C. for 60 seconds to form a predetermined shape to obtain a sound-absorbing material.
- the sound absorbing material is a molded product light in weight, excellent in moldability, sound absorbing performance and flame retardancy, and free from wrinkles during molding and excellent in design in appearance, and is an automobile undercover, cylinder head cover, hood silencer, dash Useful for outer silencers, dash inner silencers, fender liners, etc.
- Sulfomethylated phenol-alkylresorcinol-A fiber web consisting of 60% by mass of kenaf fiber, 15% by mass of polyester fiber, and 25% by mass of low melting point polyester fiber (melting point: 160 ° C.) having a core-sheath structure is 400 g / m 2
- a resin mixed solution consisting of 40 parts by mass of formaldehyde initial condensation product (solid content: 45% aqueous solution), 10 parts by mass of ammonium polyphosphate powder, and 50 parts by mass of water is impregnated to a coating amount of 200 g / m 2 as solid content. Drying at 110 ° C.
- the sulfomethylated phenol-alkyl resorcinol-formaldehyde precondensate was precured to obtain a 20 mm thick air-permeable porous material.
- the sound-absorbing surface material used in Example 6 and the air-permeable porous material were polymerized, and hot press-molded at 200 ° C. for 50 seconds to obtain a sound-absorbing material having a predetermined shape.
- This sound absorbing material is a molded article having good weather resistance, light weight, excellent sound absorbing property, flame retardancy, no wrinkles at the time of molding, and excellent appearance in appearance, and is an automobile undercover, cylinder head cover, hood silencer. Moldings useful for dash outer silencers, fender liners and the like.
- the present invention is industrially applicable because it is a light-weight, sound-absorbing, sound-absorbing surface material excellent in formability.
- a sound absorbing material using the sound absorbing skin material can be used industrially because it can be used for automobiles and buildings.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Multimedia (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
Abstract
Description
例えば、特許文献1には、単層フェルトからなる吸音フェルトが記載されている。また、特許文献2には、樹脂バインダ付着繊維ウエブからなる自動車用内装材が記載されている。また、特許文献3には、繊維集合体からなる吸音層と発泡材からなる表皮層との積層体から構成される自動車用インシュレータが記載されている。
本発明に係る吸音性表皮材にあっては、繊維シートによる吸音性と表面に多数の凹凸のある延伸性紙材の吸音性とが相俟って好適な吸音性能が発揮される。例えば、本発明である吸音性表皮材と同じ通気抵抗を有する他のシート材(例えばフラットな紙)と比べても吸音性能が格段に優れている。また、該吸音性表皮材は、吸音性能を維持したまま繊維シートの厚みを減少させることができるため、従来の吸音性表皮材に比べて軽く、軽量化を図ることができる。また、クレープ率や突起高さ等を上記範囲内とすることにより、延伸性紙材の伸び性が向上することとなり、凹凸形状、曲面形状等の成形形状に対する追従性、無理嵌め性に対する耐久性が向上し、自動車や家屋の床材、壁材等に使用する吸音材料に好適に採用され得る。なお、繊維シート及び/又は延伸性紙材に合成樹脂が塗布及び/又は含浸されると、該吸音性表皮材の耐水性、強度、耐久性等が向上する。さらに、上記吸音性表皮材を用いた吸音材を目的に応じて所定形状に成形することもできる。
本発明の吸音性表皮材、及び吸音材は、繊維シートと延伸性紙材とを積層した構成としたため、好適な吸音性能を保持しつつ、軽量化を図ることができると共に、成形性が良く種々の用途に利用することができる。
1b クレープ加工紙(延伸性紙材)
2 突起
3 繊維シート
5a,5b 多孔性接着剤層
6 吸音性表皮材
7 通気性多孔質材料
8 吸音材
R 通気抵抗
〔繊維シート〕
本発明に用いられる繊維シートの繊維材料としては、例えばポリエステル繊維、ポリエチレン繊維、ポリプロピレン繊維、ポリアミド繊維、アクリル繊維、ウレタン繊維、ポリ塩化ビニル繊維、ポリ塩化ビニリデン繊維、アセテート繊維等の合成繊維、とうもろこしやサトウキビ等の植物から抽出された澱粉からなる生分解繊維、パルプ、木綿、ヤシ繊維、麻繊維、竹繊維、ケナフ繊維等の天然繊維、ガラス繊維、炭素繊維、セラミック繊維、石綿繊維等の無機繊維、あるいはこれらの繊維を使用した繊維製品のスクラップを解繊して得られた再生繊維の1種または2種以上の繊維が使用されるが、例えばガラス繊維、炭素繊維、セラミック繊維、石綿繊維、ステンレス繊維等の無機繊維やポリメタフェニレンイソフタルアミド繊維、ポリ-p-フェニレンテレフタルアミド繊維等のアラミド繊維、ポリアリレート繊維、ポリエーテルエーテルケトン繊維、ポリフェニレンサルファイド繊維等の望ましくは融点が250℃以上の耐熱性合成繊維を使用すれば、耐熱性の極めて高い吸音性表皮材が得られる。その中でも炭素繊維は焼却処理が可能で細片が飛散しにくい点で有用な無機繊維であり、アラミド繊維は比較的安価で入手し易い点で有用な合成繊維である。
上記低融点熱可塑性繊維としては、例えば融点180℃以下のポリエチレン、ポリプロピレン、エチレン-酢酸ビニル共重合体、エチレン-エチルアクリレート共重合体等のポリオレフィン系繊維、ポリ塩化ビニル繊維、ポリウレタン繊維、ポリエステル繊維、ポリエステル共重合体繊維、ポリアミド繊維、ポリアミド共重合体繊維等がある。これらの低融点熱可塑性繊維は、単独あるいは2種以上組み合わせて使用される。該低融点熱可塑性繊維の繊度は、0.1~60dtexの範囲であることが好ましい。本発明に使用する望ましい低融点熱可塑性繊維としては、例えば上記通常繊維を芯部分とし、該低融点熱可塑性繊維の材料樹脂である融点100~180℃の低融点熱可塑性樹脂を鞘とする芯鞘型繊維がある。該芯鞘型繊維を使用すると、得られる繊維シートの剛性や耐熱性が低下しない。
なお、本発明に係る繊維シートの米坪量、厚みは原則任意に設定可能であるが、望ましくは、米坪量10~200g/m2、厚み0.01~10mmに設定され得る。
本発明の延伸性紙材としては、表面に縮緬状の皺(皺状凹凸)を形成したクレープ加工紙、表面に多数の突起を形成したエンボス加工紙、表面に縮緬状の皺と多数の突起を形成したエンボスクレープ加工紙等が例示される。
上記クレープ加工紙は、原紙にクレープ加工を施したものであり、上記クレープ加工には、湿紙の状態でプレスロールやドクターブレード等を用いて縦方向(抄造方向)に圧縮して皺付けを行なうウェットクレープと、シートをヤンキードライヤーやカレンダーで乾燥した後、ドクターブレード等を用いて縦方向に圧縮して皺付けを行なうドライクレープとがある。例えばクレープ加工された延伸性紙材は、クレープ率が10~50%であることが望ましい。
ここで、該クレープ率は、
クレープ率(%)=(A/B)×100(Aは紙製造工程における抄紙速度、Bは紙の巻き取り速度)
換言すれば、該クレープ率はペーパーウェブがクレーピングで縦方向(抄造方向)に圧縮される割合である(参考:特開2002-327399、特表平10-510886)。
ここで、クレープ率が10%に満たないとクレープ加工紙(延伸性紙材)の吸音性能が悪くなり、かつ延伸性が不十分となって成形時に皺が入り易くなる。一方、該クレープ率が50%を越えると、やはり成形時に皺が入り易くなる。
上記エンボス加工紙は、表面に多数の凹凸が彫られたロール(エンボスロール)やプレート(エンボスプレート)を原紙に押圧して紙の表面に多数の突起を形成したものであり、該突起の突起高さが0.02~2.00mmであり、かつ、突起数が20~200個/cm2であることが望ましい。該突起高さが0.02mmに満たないと、エンボス加工紙(延伸性紙材)の吸音性能が悪くなり、かつ延伸性が不十分となって成形時に皺が入り易い。また、突起高さが2.00mmを越えても、やはり成形時に皺が入り易い。また、突起数が20個/cm2に満たないと、エンボス加工紙(延伸性紙材)の吸音性能が悪くなり、また延伸性が不十分となって成形時に皺が入り易い。また、突起数が200個/cm2を越えても、エンボス加工紙(延伸性紙材)の吸音性能が悪くなる。なお、図2において、エンボス加工紙1a(延伸性紙材)には突起2が多数形成されており、突起高さは、図2に示す「h」に相当する。
なお、上記エンボス加工工程において、原紙にクレープ加工紙を用いれば、エンボスクレープ加工紙が得られる。
上記クレープ加工紙やエンボス加工紙等に使用するパルプとしては、例えば広葉樹木材パルプ、針葉樹木材パルプ、麻パルプ、ケナフパルプ、竹パルプ、エスバルトパルプ、バガスパルプ、葦パルプ等がある。また、これら木材パルプや、非木材パルプ等の天然パルプ以外に合成繊維を40~50%程度、混合してもよい。
ここで、上記の通気抵抗(Pa・s/m)とは、通気性材料の通気の程度を表す尺度である。この通気抵抗の測定は定常流差圧測定方式により行われる。図1に示すように、シリンダー状の通気路W内に試験片Tを配置し、一定の通気量V(図中矢印の向き)の状態で図中矢印の始点側の通気路W内の圧力P1と、図中矢印の終点P2の圧力差を測定し、次式より通気抵抗Rを求めることが出来る。
ここで、ΔP(=P1-P2):圧力差(Pa)、V:単位面積当りの通気量(m3/m2・s)である。
通気抵抗は、例えば、通気性試験機(製品名:KES-F8-AP1、カトーテック株式会社製、定常流差圧測定方式)によって測定することが出来る。
本発明に用いられる通気性多孔質材料としては上記で記載されたものと同じ繊維材料のほかに不織布、繊維編織物等の繊維シート、ポリウレタン発泡体、ポリエチレン発泡体、ポリプロピレン発泡体、ポリスチレン発泡体、ポリ塩化ビニル発泡体、エポキシ樹脂発泡体、メラミン樹脂発泡体、尿素樹脂発泡体、フェノール樹脂発泡体等の樹脂発泡体のうち通気性を有する樹脂発泡体、上記プラスチックのビーズの焼結体等が使用される。
上記繊維シートと上記延伸性紙材とを積層して吸音性表皮材とする場合、または該吸音性表皮材と上記通気性多孔質材料とを積層して吸音材とする場合(図3参照)は、通常の溶液型や水性エマルジョン型の接着剤、粉末状、くもの巣状、溶液型、あるいは水性エマルジョン型のホットメルト接着剤等が使用される。粉末状、くもの巣状のホットメルト接着剤の場合には多孔性接着剤層となるため通気性を確保でき、積層材の通気性を阻害しない。例えば、図3に示すように、繊維シート3とクレープ加工紙1b(延伸性紙材)とが多孔性接着剤層5aを介して積層され、さらに繊維シート3とクレープ加工紙1bとからなる吸音性表皮材6とフェルト7(通気性多孔質材料)とが多孔性接着剤層5bを介して積層された吸音材8が例示される。
溶液型あるいは水性エマルジョン型の接着剤の場合にはスプレー塗装あるいはシルク印刷塗装、オフセット印刷塗装等によって点状に接着剤を塗布し、積層材の通気性を確保することが望ましい。
なお、該吸音性表皮材の通気抵抗は0.100~1.000kPa・S/mの範囲に設定することが望ましい。該通気抵抗が1.000kPa・s/mを超えると、成形性が低下する。
また、該吸音材の通気抵抗は0.400~20.000kpa・s/mの範囲に設定することが望ましい。該通気抵抗が0.400kPa・s/mに満たない場合には吸音性が悪くなり、また20.00kPa・s/mを超えると、性能が吸音性よりも遮音性となってくる。
なお、本発明の延伸性紙材の通気抵抗は、最終製品において必要となる周波数に応じて適宜設定される。該通気抵抗の調整は、延伸性紙材の繊維相互の絡みや目付量ならびに塗布及び/又は含浸される樹脂の塗布量で調整することができる。なお、塗布および/または含浸される樹脂が接着性を有する場合は、特別に接着剤を用いて上記接着層を形成しなくてもよい。
本発明に係る吸音性表皮材及び吸音材にあって、繊維シート、延伸性紙材、及び通気性多孔質材料のうち少なくともいずれかに、合成樹脂を塗布及び/又は含浸させてもよい。合成樹脂としては、例えば熱可塑性樹脂及び/又は熱硬化性樹脂が例示される。
上記合成樹脂、特に熱硬化性樹脂の添加は、繊維シート、延伸性紙材、あるいは通気性多孔質材料の成形形状保持性と剛性を共に向上せしめる。
上記フェノール系樹脂に使用されるフェノール系化合物としては、一価フェノールであってもよいし、多価フェノールであってもよいし、一価フェノールと多価フェノールとの混合物であってもよいが、一価フェノールのみを使用した場合、硬化時および硬化後にホルムアルデヒドが放出され易いため、好ましくは多価フェノールまたは一価フェノールと多価フェノールとの混合物を使用する。
上記一価フェノールとしては、フェノールや、o-クレゾール、m-クレゾール、p-クレゾール、エチルフェノール、イソプロピルフェノール、キシレノール、3,5-キシレノール、ブチルフェノール、t-ブチルフェノール、ノニルフェノール等のアルキルフェノール、o-フルオロフェノール、m-フルオロフェノール、p-フルオロフェノール、o-クロロフェノール、m-クロロフェノール、p-クロロフェノール、o-ブロモフェノール、m-ブロモフェノール、p-ブロモフェノール、o-ヨードフェノール、m-ヨードフェノール、p-ヨードフェノール、o-アミノフェノール、m-アミノフェノール、p-アミノフェノール、o-ニトロフェノール、m-ニトロフェノール、p-ニトロフェノール、2,4-ジニトロフェノール、2,4,6-トリニトロフェノール等の一価フェノール置換体、ナフトール等の多環式一価フェノールなどが挙げられ、これら一価フェノールは単独でまたは二種以上混合して使用することが出来る。
上記多価フェノールとしては、レゾルシン、アルキルレゾルシン、ピロガロール、カテコール、アルキルカテコール、ハイドロキノン、アルキルハイドロキノン、フロログルシン、ビスフェノール、ジヒドロキシナフタリン等が挙げられ、これら多価フェノールは単独でまたは二種以上混合して使用することができる。多価フェノールのうち好ましいものは、レゾルシンまたはアルキルレゾルシンであり、特に好ましいものはレゾルシンよりもアルデヒドとの反応速度が速いアルキルレゾルシンである。
エストニア産オイルシェールの乾留によって得られる多価フェノール混合物は安価であり、かつ5-メチルレゾルシンのほか反応性の高い各種アルキルレゾルシンを多量に含むので、本発明において特に好ましい多価フェノール原料である。
なお上記多価フェノールのうち、レゾルシンおよびアルキルレゾルシン等のレゾルシノール系化合物の一種または二種以上の混合物(エストニア産オイルシェールの乾留によって得られる多価フェノール混合物を含む)と、アルデヒド及び/又はアルデヒド供与体からなるレゾルシノール系樹脂は、本発明のフェノール系樹脂として使用されることが望ましい。
本発明では上記フェノール系化合物とホルムアルデヒドおよび/またはホルムアルデヒド供与体が縮合せしめられるが、上記ホルムアルデヒド供与体とは分解するとホルムアルデヒドを生成供与する化合物またはそれらの二種以上の混合物を意味する。このようなアルデヒド供与体としては例えばパラホルムアルデヒド、トリオキサン、ヘキサメチレンテトラミン、テトラオキシメチレン等が例示される。本発明ではホルムアルデヒドとホルムアルデヒド供与体とを合わせて、以下ホルムアルデヒド類と云う。
上記フェノール系樹脂には二つの型があり、上記フェノール系化合物に対してホルムアルデヒド類を過剰にしてアルカリ触媒で反応することによって得られるレゾールと、ホルムアルデヒド類に対してフェノールを過剰にして酸触媒で反応することによって得られるノボラックとがあり、レゾールはフェノールとホルムアルデヒドが付加した種々のフェノールアルコールの混合物からなり、通常水溶液で提供され、ノボラックはフェノールアルコールに更にフェノールが縮合したジヒドロキシジフェニルメタン系の種々な誘導体からなり、通常粉末で提供される。
本発明に使用されるフェノール系樹脂にあっては、まず上記フェノール系化合物とホルムアルデヒド類とを縮合させて初期縮合物とし、該初期縮合物を繊維シートに付着させた後、硬化触媒および/または加熱によって樹脂化する。
上記縮合物を製造するには、一価フェノールとホルムアルデヒド類とを縮合させて一価フェノール単独初期縮合物としてもよいし、また一価フェノールと多価フェノールとの混合物とホルムアルデヒド類とを縮合させて一価フェノール-多価フェノール初期共縮合物としてもよい。上記初期縮合物を製造するには、一価フェノールと多価フェノールのどちらか一方または両方をあらかじめ初期縮合物としておいてもよい。
上記フェノール-アルキルレゾルシン共縮合物の望ましい製造方法は、まずフェノールとホルムアルデヒド類とを反応させてフェノール系樹脂初期縮合物を製造し、次いで該フェノール系樹脂初期縮合物にアルキルレゾルシンを添加し、所望なればホルムアルデヒド類を添加して反応せしめる方法である。
上記アルキロール化トリアゾン誘導体は尿素系化合物と、アミン類と、ホルムアルデヒド類との反応によって得られる。アルキロール化トリアゾン誘導体の製造に使用される上記尿素系化合物として、尿素、チオ尿素、メチル尿素等のアルキル尿素、メチルチオ尿素等のアルキルチオ尿素、フェニル尿素、ナフチル尿素、ハロゲン化フェニル尿素、ニトロ化アルキル尿素等の単独または二種以上の混合物が例示される。特に望ましい尿素系化合物は尿素またはチオ尿素である。またアミン類としてメチルアミン、エチルアミン、プロピルアミン、イソプロピルアミン、ブチルアミン、アミルアミン等の脂肪族アミン、ベンジルアミン、フルフリルアミン、エタノールアミン、エチレンジアミン、ヘキサメチレンジアミン、ヘキサメチレンテトラミン等のアミン類のほか更にアンモニアが例示され、これらは単独でまたは二種以上の混合物として使用される。上記アルキロール化トリアゾン誘導体の製造に使用されるホルムアルデヒド類はフェノール系樹脂の初期縮合物の製造に使用されるホルムアルデヒド類と同様なものである。
上記アルキロール化トリアゾン誘導体の合成には、通常、尿素系化合物1モルに対してアミン類および/またはアンモニアは0.1~1.2モル、ホルムアルデヒド類は1.5~4.0モルの割合で反応させる。上記反応の際、これらの添加順序は任意であるが、好ましい反応方法としては、まずホルムアルデヒド類の所要量を反応器に投入し、通常60℃以下の温度に保ちながらアミン類および/またはアンモニアの所要量を徐々に添加し、更に所要量の尿素系化合物を添加し、80~90℃で2~3時間攪拌加熱して反応せしめる方法がある。ホルムアルデヒド類としては通常37%ホルマリンが用いられるが、反応生成物の濃度をあげるためにその一部をパラホルムアルデヒドに置き換えても良い。またヘキサメチレンテトラミンを用いると、より高い固形分の反応生成物が得られる。尿素系化合物と、アミン類および/またはアンモニアと、ホルムアルデヒド類との反応は通常水溶液で行われるが、水の一部または全部に代えてメタノール、エタノール、イソプロパノール、n-ブタノール、エチレングリコール、ジエチレングリコール等のアルコール類の単独または二種以上の混合物が使用されても差し支えないし、またアセトン、メチルエチルケトン等のケトン類等の水可溶性有機溶剤の単独または二種以上の混合物が添加使用出来る。上記硬化剤の添加量はホルムアルデヒド類の場合は本発明のフェノール系樹脂の初期縮合物(初期共縮合物)100質量部に対して10~100質量部、アルキロール化トリアゾン誘導体の場合は上記フェノール系樹脂の初期縮合物(初期共縮合物)100質量部に対して10~500質量部である。
水溶性フェノール系樹脂の安定性を改良するために、上記フェノール系樹脂をスルホメチル化および/またはスルフィメチル化することが望ましい。
水溶性フェノール系樹脂の安定性を改良するために使用できるスルホメチル化剤としては、例えば、亜硫酸、重亜硫酸またはメタ重亜硫酸と、アルカリ金属またはトリメチルアミンやベンジルトリメチルアンモニウム等の第四級アミンもしくは第四級アンモニウムとを反応させて得られる水溶性亜硫酸塩や、これらの水溶性亜硫酸塩とアルデヒドとの反応によって得られるアルデヒド付加物が例示される。
該アルデヒド付加物とは、ホルムアルデヒド、アセトアルデヒド、プロピオンアルデヒド、クロラール、フルフラール、グリオキザール、n-ブチルアルデヒド、カプロアルデヒド、アリルアルデヒド、ベンズアルデヒド、クロトンアルデヒド、アクロレイン、フェニルアセトアルデヒド、o-トルアルデヒド、サリチルアルデヒド等のアルデヒドと、上記水溶性亜硫酸塩とが付加反応したものであり、例えばホルムアルデヒドと亜硫酸塩からなるアルデヒド付加物は、ヒドロキシメタンスルホン酸塩である。
水溶性フェノール系樹脂の安定性を改良するために使用できるスルフィメチル化剤としては、ホルムアルデヒドナトリウムスルホキシラート(ロンガリット)、ベンズアルデヒドナトリウムスルホキシラート等の脂肪族、芳香族アルデヒドのアルカリ金属スルホキシラート類、ナトリウムハイドロサルファイト、マグネシウムハイドロサルファイト等のアルカリ金属、アルカリ土類金属のハイドロサルファイト(亜ジチオン酸塩)類、ヒドロキシメタンスルフィン酸塩等のヒドロキシアルカンスルフィン酸塩等が例示される。
スルホメチル化剤および/またはスルフィメチル化剤の添加は、縮合反応前、反応中、反応後のいずれの段階で行ってもよい。
また、上記繊維シート、延伸性紙材、及び通気性多孔質材料のうち少なくともいずれかは、難燃剤が添加されてもよい。上記難燃剤としては、例えば燐系難燃剤、窒素系難燃剤、硫黄系難燃剤、ホウ素系難燃剤、臭素系難燃剤、グアニジン系難燃剤、燐酸塩系難燃剤、燐酸エステル系難燃剤、アミノ樹脂系難燃剤、膨張黒鉛等がある。
本発明においては特に水に難溶または不溶の粉末状の固体難燃剤が使用されることが望ましい。水に難溶または不溶の粉末状の固体難燃剤は吸音性表皮材及び吸音材に耐水性、耐久性に優れた難燃性を付与する。特に本発明の繊維シートおよび通気性多孔質材料は粗構造を有しているから、上記粉末状の固体難燃剤が内部にまで円滑に浸透して高度な難燃性ないし不燃性を付与する。
本発明に使用されるコロイダルシリカは、シリカ微粒子、あるいは表面にアルミナコーティングをしたシリカ微粒子であり、通常平均粒径が1~100μm、望ましくは3~50μmである。上記コロイダルシリカは通常水に分散した分散液として提供される。
平均粒径100μmを越えるシリカ微粒子の場合は樹脂滲出層が白っぽくなるおそれがあり、平均粒径1μm未満のシリカ微粒子の場合は、表面積が過大となり、分散液の安定性が悪くなる。
上記熱可塑性樹脂を含浸または塗布した繊維シート中の熱可塑性樹脂量を調節するには、熱可塑性樹脂を含浸または塗布後、該繊維シートを絞りロールやプレス盤を使用して絞る。この場合、該繊維シートはその厚みを減少させるが、該繊維シートが低融点繊維からなるか、あるいは低融点繊維が含まれている場合には、上記熱可塑性樹脂含浸前に該繊維シートを加熱して低融点繊維を溶融させ、繊維を該溶融物によって結着しておくことが望ましい。そうすると該繊維シートは強度および剛性が更に向上し、熱可塑性樹脂含浸の際の作業性が向上し、また絞り後の厚みの復元も顕著になる。
上記繊維シートに上記熱可塑性樹脂を含浸または塗布した後は、上記繊維シートを常温または加熱して乾燥させ、熱可塑性シートとする。
ポリエステル繊維からなるニードルパンチング法による目付量80g/m2の繊維シートの裏面に、熱溶融させたポリアミド(融点:130℃)からなるホットメルト接着剤を塗布量が15g/m2になるようにスプレー塗布した後、針葉樹パルプ60質量%、広葉樹パルプ40質量%からなるクレープ加工紙を前記繊維シートのホットメルト塗布面に重ねて積層し、該積層物を表面温度が140~150℃に調整されたヒートロールにて圧接し、さらにその後、冷熱ロールにて圧接し、クレープ加工紙と繊維シートの積層物からなる吸音性表皮材を得た。前記クレープ加工紙は次に示す4種類のクレープ加工紙を用いた。
1:クレープ率15%かつ米坪量15g/m2
2:クレープ率15%かつ米坪量40g/m2
3:クレープ率30%かつ米坪量15g/m2
4:クレープ率30%かつ米坪量40g/m2
次に、ポリエステル繊維からなる芯鞘構成の低融点繊維シート(融点:160℃)を30質量%含むポリエステル繊維からなる目付量600g/m2で厚さが15mmからなるフェルトを通気性多孔質材料として用い、該フェルトの片面に上記ホットメルト接着剤をスプレー方法にて塗布量が15g/m2になるように塗布した。次に上記吸音性表皮材のクレープ加工紙面と該フェルトのホットメルト接着面とを重合させ、200℃に調整された加熱炉にて50秒間加熱した後、冷圧プレス成形し所定形状に成形させ、吸音材を得た。また、吸音性能試験用として、厚さ10mmの平板状の吸音材も同時に成形した。
実施例1におけるクレープ加工紙をエンボス加工紙に代えて、吸音性表皮材と吸音材を得た。また、吸音性能試験用として、厚さ10mmの平板状の吸音材も同時に成形した。前記エンボス加工紙は次に示す4種類のエンボス加工紙を用いた。
1:突起高さ0.2mmかつ突起数150個/cm2かつ米坪量15g/m2
2:突起高さ0.2mmかつ突起数150個/cm2かつ米坪量40g/m2
3:突起高さ1.5mmかつ突起数20個/cm2かつ米坪量15g/m2
4:突起高さ1.5mmかつ突起数20個/cm2かつ米坪量40g/m2
実施例1において、クレープ加工紙のクレープ率を5%および55%にした他は同様にして、吸音性能試験用成形物を得た。
実施例1において、クレープ加工紙の米坪量を8g/m2および55g/m2にした他は同様にして、吸音性能試験用成形物を得た。
実施例1において、クレープ加工紙に代えて、クレープ加工前の表面が平滑でフラット形状である抄紙を用いた。さらに、該抄紙は、米坪量を15g/m2および40g/m2にした。そして他は同様にして吸音性能試験用成形物を得た。
実施例2において、エンボス加工紙の突起高さを0.01mmとし、また1.5mmを2.5mmとした他は同様にして吸音性能試験用成形物を得た。
実施例2において、エンボス加工紙の突起高さを0.2mmで突起数を250個/cm2とし、また突起高さを1.5mmで突起数を10個/cm2とした他は同様にして吸音性能試験用成形物を得た。
実施例2において、エンボス加工紙の米坪量を8g/m2および55g/m2にした他は同様にして吸音性能試験用成形物を得た。
吸音率:JIS-A1405に準じ、厚さ10mmの垂直入射吸音率(%)を測定した(t=10mm)。
成形性:所定形状に成形したものについて成形性を調べた。
◎:皺、破れ等がなく、深絞り部分も良好に成形できた。
▲:深絞り部分に紙の追従性が悪く、紙の破れが発生し、吸音性表皮材表面に筋となって見られる。
△:平坦部分、及び深絞り部分に皺が発生する。
×:樹脂が吸音性表皮材表面に滲みだし、外観不良となる。
表1~3にあって、本発明の実施例1,2の試料1~8、および比較例1~6の試料9~30の試験結果から下記のことがわかった。
本発明の、クレープ加工又はエンボス加工された紙であって特性が特定の範囲内にある延伸性紙材を用いると、垂直入射吸音率(%)の各周波数における吸音率は、概ね、表4に示す範囲となった。
比較例2の試料13,15のように米坪量が小さいものは、本実施例に比べて吸音性能が劣り成形性も悪かった。試料14,16のように米坪量が大きいと、本実施例に比べて成形時に深絞り部分で皺の破れが見られた。
比較例3のように紙の表面が平滑でフラット形状であると、表皮材又は吸音材として通気抵抗が本実施例と同程度であっても、吸音率が悪かった。また成形時において深絞りの追従が悪く成形性が悪かった。
比較例4の試料19,20のように突起高さが小さいと、本実施例に比べて吸音性能が悪く、また成形性も悪かった。試料21,22のように突起高さが大きいと、これも同様に吸音性能が悪く、成形性も悪かった。
比較例5の試料23,24のように突起数が多いと、本実施例に比べて吸音性能及び成形性が悪くなった。試料25,26のように突起数が少ないと、これも同様に吸音性能及び成形性が悪くなった。
比較例6の試料27,29のように米坪量が小さいと、本実施例に比べて吸音性能が劣り成形性も悪かった。試料28,30のように米坪量が大きいと、成形時において深絞り部分で皺の破れが見られた。
以上の結果から、高性能の吸音性表皮材や吸音材を得る場合は、単に吸音性表皮材や吸音材の通気抵抗を調整するのではなく、本発明のような特定の延伸性紙材を採用すると、該延伸性紙材の表面の微細な凹凸形状が吸音性能および成形性に対して良好に作用して好適であることがわかった。また、成形物として、重量低減の観点からも非常に有用であることがわかった。
ポリエステル繊維からなるニードルパンチング法による目付量70g/m2の繊維シートを用い、該繊維シートの片面に熱溶融させたポリエステル(融点:130℃)からなるホットメルト接着剤を塗布量が10g/m2になるようにスプレー塗布した後、針葉樹パルプ80質量%、広葉樹パルプ20質量%からなるクレープ加工紙(クレープ率:30%、米坪量:20g/m2)を該ホットメルト接着剤塗布面に重ね、表面温度が140~150℃に調整されたヒートロールにて圧接した後、冷却ロールにて圧接し、クレープ加工紙を繊維シートに接着した。次に、繊維シートに接着されたクレープ加工紙面に、アクリル酸エステル/メタクリル酸エステル共重合エマルジョン(固形分:40%、MFT(造膜温度):4℃)40質量部、ホットメルト接着剤として共重合ポリエステル樹脂(融点:110℃、粒度:100~150μm)20質量部、水40質量部からなる混合溶液を固形分として18g/m2の塗布量でスプレー塗布し、120℃で4分間乾燥させ吸音性表皮材を得た。なお、この吸音性表皮材の通気抵抗は、0.63kPa・s/mであった。
次に、ポリエステル繊維70質量%、および芯鞘構成の低融点繊維シート(融点:16
0℃)30質量%からなるポリエステル繊維からなる目付量600g/m2で厚さが20mmの繊維ウエブを通気性多孔質材料として用い、該繊維ウエブの片面に上記吸音性表皮材を重合させ、200℃に調整された加熱炉にて60秒間加熱した後、直ちに冷圧プレス成形し所定形状に成形させ吸音材を得た。また、吸音性能試験用として、厚さ10mmの平板状の成形物も同時に成形した。なお、吸音性能試験用の成形物の通気抵抗は1.24kPa・s/mであった。該成形物の吸音率や成形性の試験結果は表5に示す。
実施例3において、クレープ加工紙を、抄紙させた表面がフラットの紙(米坪量:20g/m2)に代えた他は同様にして吸音材を得た。なお、この表皮材の通気抵抗は0.65kPa・s/mであり、厚さ10mmの成形物の通気抵抗は1.26kPa・s/mであった。該成形物の吸音率や成形性の試験結果は表5に示す。
実施例3において、ポリエステル繊維からなるニードルパンチング法による目付量70g/m2の繊維シートを用い、該繊維シートの片面に熱溶融させた共重合ポリエステル(融点:130℃)からなるホットメルト接着剤を塗布量が10g/m2になるようにスプレー塗布した表皮材(通気抵抗:0.03kPa・s/m)を、次の3種類の通気性多孔質材料である繊維ウエブと重合させ、200℃に調整された加熱炉にて60秒間加熱した後、直ちに冷圧プレス成形し所定形状に成形させ吸音材を得た。
1.ポリエステル繊維70質量%、および芯鞘構成の低融点繊維シート(融点:160℃)30質量%からなるポリエステル繊維からなる目付量600g/m2の繊維ウエブ
2.同ポリエステル繊維からなる目付量900g/m2の繊維ウエブ
3.同ポリエステル繊維からなる目付量1800g/m2の繊維ウエブ
また、吸音性能試験用として、厚さ10mmの平板状の成形物も同時に成形した。なお、10mm厚さの各成形物の通気抵抗は、基材目付量600g/m2のものが0.38kPa・s/m、900g/m2のものが0.56kPa・s/m、1800g/m2のものが1.28kPa・s/mであった。該成形物の吸音率や成形性の試験結果は表5に示す。
実施例3において、ポリエステル繊維からなるニードルパンチング法による目付量70g/m2の繊維シートを用い、該繊維シートの片面に、アクリル酸エステル/メタクリル酸エステル共重合エマルジョン(固形分:40%、MFT:4℃)60質量部、ホットメルト接着剤として共重合ポリエステル樹脂(融点:110℃、粒度:100~150μm)20質量部、水20質量部からなる混合溶液を固形分として250g/m2の塗布量でスプレー塗布し、吸引しながら140℃で10分間乾燥させて表皮材を得た。該表皮材の通気抵抗は0.67kPa・s/mであった。次に、ポリエステル繊維70質量%、および芯鞘構成の低融点繊維シート(融点:160℃)30質量%からなるポリエステル繊維からなる目付量900g/m2の通気性多孔質材料に上記表皮材を重合させ200℃に調整された加熱炉にて60秒間加熱した後、直ちに冷圧プレス成形し所定形状に成形させ吸音材を得た。なお、10mm厚さの成形物の通気抵抗は、1.30kPa・s/mであった。該成形物の吸音率や成形性の試験結果は表5(試料33~36)に示す。
実施例3の試料31と比較例8の試料33,34,35を比較すると、従来の表皮材として用いられるものはその成形物全体としての目付量を増やすことにより吸音性能を向上させる必要があることがわかった。実施例3の試料31と比較例8の試料35を比較すると、試料35では通気性多孔質材料の目付量が1800g/m2で、実施例3の基材目付量の600g/m2に近づくのがわかった。すなわち、従来と同程度の吸音性能を発揮させる場合において、本発明では従来構成の約1/3程度の成形物重量でよいことがわかった。また、同時に成形性も良好であった。
比較例7の試料32では、同種である紙を使用しても、その表面がフラット状であるため、吸音性表皮材及び吸音材の通気抵抗が同程度であっても吸音性能が劣り、また成形性も悪かった。このため、紙表面の微細な凹凸が吸音性能に有効であると考えられる。
比較例9の試料36では、従来の多孔質材料の通気抵抗をある程度の数値にするには、かなりの量の樹脂を塗布する必要があり、またこのため、成形時に樹脂の滲みだしが見られ成形性が劣るものとなった。
なお、本発明に係る上記吸音材は、軽く、吸音性に優れ、自動車の天井材やトランクルームマット、フロアマット、ダッシュサイレンサ等に最適である。
ポリエステル繊維からなるスパンボンド法による目付量50g/m2の繊維シートを用い、該繊維シートの裏面に、共重合ポリアミド樹脂(融点:120℃、粒径:200~250μm)からなるホットメルト接着剤パウダーをスキャタリング方式にて塗布量が10g/m2になるようにランダム散布した後、針葉樹パルプ50質量%、広葉樹パルプ50質量%からなるエンボス加工紙(突起高さ:0.10mm、突起数:72個/cm2、米坪量:15g/m2)を重ね、表面温度が140~150℃に調整されたヒートロールにて圧接した後、冷熱ロールにて圧接し、該エンボス加工紙と該繊維シートとを接着させた。次に、アクリル酸エステル/メタクリル酸エステル共重合エマルジョン(固形分:48%、Tg:-40℃、MFT:<0℃)87質量部、金雲母(粒径:10~50μm)10質量部、カーボンブラック(50%水分散液)3質量部からなる溶液を固形分として25g/m2の塗布量でスプレー塗布し、120℃で乾燥させ、吸音性表皮材を得た。次に、通気性多孔質材料として硬化剤入りノボラック型フェノール樹脂粉末が20%添加されている再生フェルト未硬化原綿(目付量50g/m2、厚さ:20mm)を用い、該再生フェルト未硬化原綿の片面に上記吸音性表皮材を重合させ200℃×60秒で熱圧プレス成形し、所定形状として吸音材を得た。
上記吸音材は、軽くて成形性及び吸音性能に優れ、自動車のフロアマットやルームパーティション等に最適である。
ポリエステル繊維からなるニードルパンチング法による目付量70g/m2の繊維シートを用い、該繊維シートの裏面に、共重合ポリアミドからなるクモノ巣状のホットメルト接着剤(融点:135℃、目付量15g/m2)を重ね、さらに針葉樹パルプ20質量%、広葉樹パルプ80質量%からなるクレープ率20%、米坪量が20g/m2のクレープ加工紙を重ね、表面温度が140~150℃に調整されたヒートロールにて圧接した後、冷熱ロールにて圧接し、該繊維シートと該クレープ加工紙とを接着させた後、レゾール型フェノール-ホルムアルデヒド初期縮合物(固形分:40%水溶液)40質量部、カーボンブラック(固形分:20%水分散溶液)1質量部、フッ素系撥水、撥油剤(固形分:20%水溶液)2質量部、リン-チッソ系難燃剤(固形分:40%水溶液)10質量部、水47質量部からなる樹脂混合溶液に固形分として20g/m2の塗布量で含浸させ、140℃で吸引しながら2分乾燥し、該レゾール型フェノール-ホルムアルデヒド初期縮合物をプレキュアさせて吸音性表皮材を得た。次に、通気性多孔質材料として、未硬化レゾール型フェノール樹脂が20質量%含有する未硬化ガラスウール原綿(目付量:450g/m2、厚さ:30mm)に上記吸音性表皮材を重合し、200℃で1分間熱圧プレス機で成形し、所定形状の吸音材を得た。この吸音材は軽量で吸音性、難燃性に優れ、成形時の皺が無く、外観における意匠性に優れた成形物であり、自動車のエンジンアンダーカバー、フードサイレンサ、ダッシュアウタサイレンサ等に有用である。
ポリエステル繊維70質量%、炭素繊維30質量%からなるニードルパンチング法による目付量70g/m2の繊維シートの裏面に、共重合ナイロン(融点:135℃、粒度:200~300μm)からなるホットメルト接着剤を塗布量が5g/m2になるようにスキャタリング法により塗布させた後、マニラ麻パルプ90質量部、レーヨン10質量部、からなるエンボス加工クレープ加工紙(クレープ率35%、突起高さ:0.2mm、突起数:50個/cm2、米坪量15g/m2)を重合し、表面温度が140~150℃に調整されたヒートロールにて圧接した後、冷熱ロールにて圧接し、該繊維シートとエンボス加工クレープ加工紙とを接着させた積層物をスルホメチル化フェノール-アルキルレゾルシン-ホルムアルデヒド初期縮合物(固形分:45%水溶液)40質量部、カーボンブラック(固形分:20%水分散溶液)1質量部、フッソ系撥水、撥油剤(固形分:20%水溶液)2質量部、リン-チッソ系難燃剤(固形分:40%水溶液)10質量部、水47質量部からなる樹脂混合溶液に固形分として15g/m2の塗布量になるように含浸させ、さらにエンボス加工クレープ加工紙側に、アクリル酸エステル/メタクリル酸エステル共重合エマルジョン(固形分:48%、Tg:-40℃、MFT:<0℃)30質量部、ホットメルト接着剤としてポリアミド(粒度:50~100μm、軟化点:130℃)10質量部、難燃剤としてリン-チッソ系難燃剤(固形分:40%水溶液)20質量部、分散剤としてポリアクリル酸ソーダ0.3質量部、および水39.7質量部からなる水溶液を固形分として10g/m2の塗布量でスプレー塗布し、140℃で2分乾燥させ、該スルホメチル化フェノール-アルキルレゾルシン-ホルムアルデヒド初期縮合物をプレキュアさせた吸音性表皮材を得た。次に、通気性多孔質材料として目付量250g/m2、厚さ25mmからなるメラミン発泡体シートの両面に上記吸音性表皮材を重合し、200℃で50秒間熱圧プレス成形し所定形状の吸音材を得た。該吸音材は耐候性が良く、しかも軽量で吸音性、難燃性に優れ、成形時の皺が無く、外観における意匠性に優れた成形物であり、自動車のエンジンアンダーカバー、シリンダーヘッドカバー、フードサイレンサ、ダッシュアウタサイレンサ、フェンダーライナー等に有用である。
ポリエステル繊維からなるニードルパンチング法による目付量80g/m2の繊維シートに、スルフィメチル化フェノール-アルキルレゾルシン-ホルムアルデヒド初期縮合物(固形分:45%水溶液)40質量部、カーボンブラック(固形分:20%水分散溶液)1質量部、フッソ系撥水、撥油剤(固形分:20%水溶液)2質量部、リン-チッソ系難燃剤(固形分:40%水溶液)10質量部、水47質量部からなる混合液を固形分として30g/m2の塗布量になるように含浸させ、150℃で2分乾燥させ、該初期縮合物をプレキュアさせた後、該繊維シートの裏面に、共重合ポリアミドからなるクモノ巣状のホットメルト接着剤(融点:135℃、目付量15g/m2)を重ね、さらにその上にエンボス加工紙(突起高さ:0.05mm、突起数:225個/cm2、米坪量:25g/m2)を重ね、さらに該ホットメルト接着剤を重ねて積層し、該積層物を目付量340g/m2で厚さ17mmからなる発泡ウレタンフォームの両面に重合し、180℃で50秒間熱圧プレス成形し所定形状の吸音材を得た。該吸音材は耐候性が良く、しかも軽量で吸音性、難燃性に優れ、成形時の皺が無く、外観における意匠性に優れた成形物であり、自動車のエンジンアンダーカバー、シリンダーヘッドカバー、フードサイレンサ、ダッシュアウタサイレンサ、フェンダーライナー等に有用である。
ポリエステル繊維80質量%、ポリプロピレン繊維20質量%からなるサーマルボンド法による目付量30g/m2の繊維シートの裏面に、共重合ポリエステルからなるクモノ巣状のホットメルト接着剤(融点:110℃、目付量15g/m2)を重ねて積層し、該積層物の上にマニラ麻パルプ90質量部、レーヨン10質量部からなるエンボス加工クレープ加工紙(クレープ率:45%、突起高さ:0.1mm、突起数:64個/cm2、米坪量15g/m2)を重合し、表面温度が140~150℃に調整されたヒートロール圧に圧接した後、冷熱ロールにて圧接し、さらにその上に上記のクモノ巣状のホットメルト接着剤を重ね、120℃で10秒加熱し、吸音性表皮材を得た。次に、ポリエステル繊維70質量%、および芯鞘構成の低融点繊維シート(融点:130℃)30質量%からなるポリエステル繊維からなる目付量300g/m2の繊維ウエブを通気性多孔質材料とし、該繊維ウエブの両面に上記吸音性表皮材を重合し、200℃で60秒間加熱後、冷圧プレスにて厚さ5mmの板状の吸音材を得た。該吸音材は断熱性に優れ、建物の合板や石膏ボード等に貼り合わせて用いられる。
ポリエステル繊維からなるニードルパンチング法による目付量80g/m2の繊維シートを、アクリルエマルジョン(固形分:45%)30質量部、コロイダルシリカ(無水珪酸含有量:20%水溶液)、水65質量部からなる混合溶液に固形分として30g/m2の塗布量になるように含浸させ、120℃で2分乾燥させプレキュアさせた。次に、該繊維シートの裏面に、共重合ポリアミドからなるクモノ巣状のホットメルト接着剤(融点:110℃、目付量:15g/m2)を重ね、さらにその上に針葉樹パルプ80質量%、広葉樹パルプ20質量%からなるクレープ加工紙(クレープ率:30%、米坪量20g/m2)を該ホットメルト接着剤塗布面に重ね、表面温度が120~125℃に調整されたヒートロールに圧接した後、冷却ロールにて圧接し、該繊維シートにクレープ加工紙を接着した。次に、該繊維シートのクレープ加工紙側に、アクリル酸エステル/メタクリル酸エステル共重合エマルジョン(固形分:40%、MFT:4℃)40質量部、ホットメルト接着剤として共重合ポリアミド樹脂(融点:110℃、粒度:100~150μm)20質量部、水40質量部からなる混合溶液を固形分として18g/m2の塗布量でスプレー塗布し、120℃で4分間乾燥させ吸音性表皮材を得た。次に、通気性多孔質材料として硬化剤入りノボラック型フェノール樹脂粉末が20%添加されている再生フェルト未硬化原綿(目付量500g/m2、厚さ:20mm)を用い、該基材の片面に上記吸音性表皮材を重合させ200℃×60秒熱圧プレス成形して所定形状とし吸音材を得た。該吸音材は、軽くて成形性及び吸音性能及び難燃性に優れ、成形時の皺が無く外観における意匠性に優れた成形物であり、自動車のエンジンアンダーカバー、シリンダーヘッドカバー、フードサイレンサ、ダッシュアウタサイレンサ、ダッシュインナサイレンサ、フェンダーライナー等に有用である。
ケナフ繊維60質量%、ポリエステル繊維15質量%、および芯鞘構成の低融点ポリエステル繊維(融点:160℃)25質量%からなる目付量400g/m2の繊維ウエブを、スルホメチル化フェノール-アルキルレゾルシン-ホルムアルデヒド初期縮合物(固形分:45%水溶液)40質量部、ポリリン酸アンモニウム粉末10質量部、水50質量部からなる樹脂混合溶液に固形分として200g/m2の塗布量になるように含浸させ、吸引しながら110℃で10分乾燥し、該スルホメチル化フェノール-アルキルレゾルシン-ホルムアルデヒド初期縮合物をプレキュアさせた厚さ20mmの通気性多孔質材料を得た。次に、実施例6で用いた吸音性表皮材と、該通気性多孔質材料を重合し、200℃で50秒間熱圧プレス成形し所定形状の吸音材を得た。この吸音材は耐候性がよく、しかも軽量で吸音性、難燃性に優れ、成形時の皺が無く外観における意匠性に優れた成形物であり、自動車のエンジンアンダーカバー、シリンダーヘッドカバー、フードサイレンサ、ダッシュアウタサイレンサ、フェンダーライナー等に有用な成形物である。
Claims (15)
- 繊維シートの片面または両面に、表面に多数の凹凸が形成された延伸性紙材が積層されていることを特徴とする吸音性表皮材。
- 繊維シートの片面または両面に、クレープ加工によって多数の皺状凹凸が形成された延伸性紙材が積層されていることを特徴とする吸音性表皮材。
- 繊維シートの片面または両面に、エンボス加工によって多数の突起が形成された延伸性紙材が積層されていることを特徴とする吸音性表皮材。
- 繊維シートの片面または両面に、クレープ加工によって多数の皺状凹凸が形成され、かつ、エンボス加工によって多数の突起が形成された延伸性紙材が積層されていることを特徴とする吸音性表皮材。
- 前記クレープ加工によって多数の皺状凹凸が形成されている延伸性紙材にあっては、クレープ率が10~50%である請求項2又は請求項4記載の吸音性表皮材。
- 前記エンボス加工によって多数の突起が形成されている延伸性紙材にあっては、突起高さが0.02~2.00mmかつ突起数が20~200個/cm2である請求項3又は請求項4記載の吸音性表皮材。
- 前記延伸性紙材の米坪量は10~50g/m2である請求項1乃至請求項6のいずれか1項に記載の吸音性表皮材。
- 前記繊維シートと前記延伸性紙材とが多孔性接着剤層を介して積層されている請求項1乃至請求項7のいずれか1項に記載の吸音性表皮材。
- 前記繊維シート及び/又は前記延伸性紙材には、合成樹脂が塗布及び/又は含浸されている請求項1乃至請求項8のいずれか1項に記載の吸音性表皮材。
- 前記延伸性紙材の通気抵抗が少なくとも0.060kpa・s/m以上である請求項1乃至請求項9のいずれか1項に記載の吸音性表皮材。
- 通気抵抗が0.100~1.000kpa・s/mである請求項1乃至請求項10のいずれか1項に記載の吸音性表皮材。
- 請求項1乃至請求項11のいずれか1項に記載の吸音性表皮材にシート状の通気性多孔質材料が積層されていることを特徴とする吸音材。
- 前記繊維シート、前記延伸性紙材、及び前記通気性多孔質材料のうち少なくともいずれかに合成樹脂が塗布及び/又は含浸されている請求項12記載の吸音材。
- 通気抵抗が、0.400~20.000kpa・s/mである請求項12又は請求項13記載の吸音材。
- 所定形状に成形されている請求項12乃至請求項14のいずれか1項に記載の吸音材。
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/866,784 US8312963B2 (en) | 2008-02-14 | 2008-05-23 | Sound absorbing skin material and sound absorbing material utilizing the same |
AU2008350434A AU2008350434B2 (en) | 2008-02-14 | 2008-05-23 | Sound absorbing skin material and sound absorbing material utilizing the same |
CA2709794A CA2709794C (en) | 2008-02-14 | 2008-05-23 | Sound absorbing skin material and sound absorbing material utilizing the same |
EP08764578.4A EP2236286B1 (en) | 2008-02-14 | 2008-05-23 | Sound absorbing skin material and sound absorbing material utilizing the same |
CN2008801267722A CN101945762B (zh) | 2008-02-14 | 2008-05-23 | 吸音性表皮材及使用了该吸音性表皮材的吸音材 |
TW097124487A TWI441160B (zh) | 2008-02-14 | 2008-06-30 | 吸音性表皮材,及使用此吸音性表皮材的吸音材 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2008-033432 | 2008-02-14 | ||
JP2008033432 | 2008-02-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2009101712A1 true WO2009101712A1 (ja) | 2009-08-20 |
Family
ID=40956756
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2008/059532 WO2009101712A1 (ja) | 2008-02-14 | 2008-05-23 | 吸音性表皮材、及びそれを用いた吸音材 |
Country Status (9)
Country | Link |
---|---|
US (1) | US8312963B2 (ja) |
EP (1) | EP2236286B1 (ja) |
JP (1) | JP4462636B2 (ja) |
KR (1) | KR101611334B1 (ja) |
CN (1) | CN101945762B (ja) |
AU (1) | AU2008350434B2 (ja) |
CA (1) | CA2709794C (ja) |
TW (1) | TWI441160B (ja) |
WO (1) | WO2009101712A1 (ja) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2007500235A (ja) * | 2003-05-28 | 2007-01-11 | スティーフェル ラボラトリーズ インコーポレイテッド | 起泡性医薬組成物および障害の治療方法 |
JP2010094990A (ja) * | 2008-09-22 | 2010-04-30 | Nagoya Oil Chem Co Ltd | 非浸透性表皮材、成形シート材料、および該成形シート材料の製造方法 |
JP2011084855A (ja) * | 2009-09-15 | 2011-04-28 | Nagoya Oil Chem Co Ltd | 熱接着性不織布、吸音性繊維シートおよび吸音材料 |
Families Citing this family (61)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110027534A1 (en) * | 2008-03-14 | 2011-02-03 | Masanori Ogawa | Mold release sheet and molded articles |
EP2480753A4 (en) * | 2009-09-25 | 2017-12-06 | Services Pétroliers Schlumberger | Multi-layered sound attenuation mechanism |
JP5060621B2 (ja) * | 2009-10-13 | 2012-10-31 | 名古屋油化株式会社 | 自動車用内装材 |
JP2011090060A (ja) * | 2009-10-20 | 2011-05-06 | Nagoya Oil Chem Co Ltd | 吸音材および遮音壁パネル |
JP5455574B2 (ja) * | 2009-11-17 | 2014-03-26 | 株式会社イノアックコーポレーション | 自動車用フロアスペーサ一体フロアダクト |
CN102164777B (zh) * | 2009-12-22 | 2016-01-20 | 名古屋油化株式会社 | 隔热防音材以及车辆的隔热防音构造 |
JP2011186115A (ja) * | 2010-03-08 | 2011-09-22 | Nagoya Oil Chem Co Ltd | パイプの吸音構造 |
JP5838493B2 (ja) * | 2010-04-08 | 2016-01-06 | 名古屋油化株式会社 | 吸音材料の製造方法 |
JP5760230B2 (ja) * | 2010-12-27 | 2015-08-05 | 名古屋油化株式会社 | クッション性シート、吸音材及びフィルター、並びに上記クッション性シートの製造方法 |
JP2012141405A (ja) * | 2010-12-28 | 2012-07-26 | Nagoya Oil Chem Co Ltd | 緩衝吸音材 |
JP5772126B2 (ja) * | 2011-03-24 | 2015-09-02 | トヨタ紡織株式会社 | 車両用天井材 |
JP2012215369A (ja) * | 2011-04-01 | 2012-11-08 | Nagoya Oil Chem Co Ltd | 気体送通ダクトの挿入材および気体送通ダクト |
CA2835178A1 (en) * | 2011-04-08 | 2012-10-11 | House 119 Inc. | Sound absorbing member lamination structure |
CN103298658B (zh) * | 2011-07-05 | 2015-09-30 | 丰和纤维工业株式会社 | 车辆后窗台 |
DE102011081734A1 (de) * | 2011-08-29 | 2013-02-28 | Siemens Aktiengesellschaft | Verfahren zur Erzeugung eines Magnetresonanzbildes mit einer Magnetresonanz-Tomographieanlage |
ES2635425T3 (es) * | 2011-09-05 | 2017-10-03 | Roki Co., Ltd. | Conducto de entrada de aire |
WO2013102208A1 (en) | 2011-12-29 | 2013-07-04 | Firestone Building Products Co., LLC | Roofing membranes with expandable graphite as flame retardant |
JP5861960B2 (ja) * | 2012-02-01 | 2016-02-16 | アロン化成株式会社 | 防音材 |
FR2986998A3 (fr) * | 2012-02-20 | 2013-08-23 | Renault Sa | Rideau acoustique pour vehicule |
CN103510342A (zh) * | 2012-06-29 | 2014-01-15 | 海尔集团公司 | 洗衣机 |
US9441140B2 (en) | 2012-07-12 | 2016-09-13 | Firestone Building Products Co., LLC | Asphaltic sheet materials including expandable graphite |
US8968853B2 (en) | 2012-11-07 | 2015-03-03 | Firestone Building Products Company, Llc | Pressure-sensitive adhesives including expandable graphite |
US10017943B1 (en) | 2013-02-14 | 2018-07-10 | Firestone Building Products Co., LLC | Liquid coatings including expandable graphite |
WO2014141418A1 (ja) * | 2013-03-14 | 2014-09-18 | 名古屋油化株式会社 | 断熱吸音材、および断熱吸音材成形物 |
DE112013006984B4 (de) * | 2013-04-26 | 2022-03-10 | Autonetworks Technologies, Ltd. | Mit einem schalldämmenden Material ausgerüstete Verkabelung |
JP6153220B2 (ja) * | 2013-05-21 | 2017-06-28 | 栗田煙草苗育布製造株式会社 | 難燃性吸音材の製造方法 |
CN104216547B (zh) | 2013-06-04 | 2017-12-01 | 宸鸿科技(厦门)有限公司 | 一种触控面板及其制造方法 |
CN104424941B (zh) * | 2013-09-05 | 2018-04-03 | 上海泰瑞电子科技有限公司 | 一种吸音材料及其制备方法 |
US10415249B2 (en) | 2014-07-03 | 2019-09-17 | Firestone Building Products Co., LLC | EPDM roofing membranes with expandable graphite as flame retardant |
EP2990557B1 (en) * | 2014-08-29 | 2018-07-18 | Mascagni S.P.A. | Panel for walls, ceilings, false ceilings, floor surfaces, furnishing elements and the like |
CN104499592A (zh) * | 2014-12-09 | 2015-04-08 | 常熟市石林木材有责任限公司 | 隔热性好的吸音板 |
BR112017023873B1 (pt) | 2015-05-05 | 2021-12-07 | 3M Innovative Properties Company | Composição curável, filme, filme forrado, composição curada, filme de barreira acústica e método para fabricação do filme de barreira acústica |
BR112017023677A2 (pt) * | 2015-05-05 | 2018-07-17 | 3M Innovative Properties Company | cobertor de isolamento térmico e acústico |
CN104816678A (zh) * | 2015-05-27 | 2015-08-05 | 南通加隆塑胶有限公司 | 一种内贴消声垫片的车座椅储物盒 |
US10960580B2 (en) * | 2016-02-29 | 2021-03-30 | Sekisui Plastics Co., Ltd. | Molded foam, method for manufacturing molded foam, mold and method for manufacturing mold |
JP6548597B2 (ja) * | 2016-03-09 | 2019-07-24 | 倉敷紡績株式会社 | 繊維強化樹脂積層シート及びその製造方法 |
JP6650297B2 (ja) * | 2016-03-09 | 2020-02-19 | 倉敷紡績株式会社 | 繊維強化樹脂積層シート及びその製造方法 |
JP6671685B2 (ja) * | 2016-06-17 | 2020-03-25 | ユニチカ株式会社 | 高空隙積層ボードの製造方法 |
CN106409276A (zh) * | 2016-10-08 | 2017-02-15 | 常州大学 | 一种氦气隔音板 |
KR102018734B1 (ko) * | 2017-02-01 | 2019-09-04 | 주식회사 금토일산업 | 칸막이용 내장 패널 제조 시스템 |
KR102260615B1 (ko) * | 2017-04-03 | 2021-06-07 | 케스케이드 엔지니어링 인코퍼레이티드 | 음향 섬유 사일렌서 |
JP6526922B2 (ja) | 2017-05-15 | 2019-06-05 | 名古屋油化株式会社 | 吸音性表皮材、吸音材 |
CN107310822A (zh) * | 2017-06-08 | 2017-11-03 | 太仓通乾印务有限公司 | 环保瓦楞彩盒及其包装方法 |
DE102017210091A1 (de) * | 2017-06-16 | 2018-12-20 | Volkswagen Aktiengesellschaft | Textilgebilde für ein Verkleidungselement eines Kraftfahrzeugs und Verfahren zu dessen Herstellung |
US10119779B1 (en) | 2017-06-27 | 2018-11-06 | Smith & Wesson Corp. | Suppressor for firearm and baffle cup therefor |
US10741159B2 (en) | 2017-09-10 | 2020-08-11 | Douglas Peter Magyari | Acoustic-absorber system and method |
CN107501832A (zh) * | 2017-10-09 | 2017-12-22 | 常州美帛纺织品有限公司 | 一种吸音材料的制备方法 |
CN108501835B (zh) * | 2018-02-10 | 2024-05-28 | 保定市宏腾科技有限公司 | 一种轻量化汽车阻尼胶片的生产模具及制作工艺 |
CN108281132A (zh) * | 2018-03-13 | 2018-07-13 | 吉林大学 | 具有柱形凹坑仿生非光滑表面聚氨酯泡沫板及制备方法 |
EP3608601B1 (en) * | 2018-08-06 | 2024-06-12 | Zephyros Inc. | Gas-duct with a sound absorbing component |
CN109880315A (zh) * | 2019-02-25 | 2019-06-14 | 谭桂容 | 一种阻燃耐老化吸音棉的制备方法 |
DE102019126429A1 (de) * | 2019-07-26 | 2021-01-28 | Schaeffler Technologies AG & Co. KG | Verfahren zur Herstellung von Nasslaufreibpapier und Nasslaufreibpapier |
DE202019104350U1 (de) | 2019-08-07 | 2020-11-10 | Profümed Karlheinz Lohr e. K. | Thermobehältnis |
JP2021050672A (ja) * | 2019-09-25 | 2021-04-01 | 株式会社Roki | 吸気ダクト |
MX2020011446A (es) * | 2019-10-31 | 2021-05-03 | Gold Bond Building Products Llc | Panel de yeso que contiene una capa acanalada. |
CN110942760B (zh) * | 2019-11-12 | 2022-12-13 | 哈尔滨工程大学 | 一种基于功能梯度板的水下声学覆盖层 |
JP7383504B2 (ja) * | 2020-01-22 | 2023-11-20 | 株式会社イノアックコーポレーション | デッキボード |
CN111635594A (zh) * | 2020-06-29 | 2020-09-08 | 温州德邦高分子科技有限公司 | 一种吸振性能良好的车用隔音材料及制备方法 |
CN112026937B (zh) * | 2020-09-15 | 2021-06-08 | 蒙城佳仕龙机械制造有限公司 | 一种汽车的前围板 |
EP4000916A1 (en) * | 2020-11-13 | 2022-05-25 | Ivc Bv | Floor covering and method for manufacturing thereof |
CN113022092A (zh) * | 2021-03-29 | 2021-06-25 | 东莞雅康宁纤维制品有限公司 | 一种纤维制作立体墙面吸音板制作工艺 |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6313004Y2 (ja) * | 1983-04-11 | 1988-04-13 | ||
JPH0543198U (ja) * | 1991-10-31 | 1993-06-11 | 日本特殊塗料株式会社 | 軽量成形防音材 |
JPH06270362A (ja) * | 1993-03-19 | 1994-09-27 | Ikeda Bussan Co Ltd | 内装基材 |
JPH0941296A (ja) * | 1995-05-24 | 1997-02-10 | Achilles Corp | 凹凸模様のある装飾シート材およびその製造方法 |
JPH10510886A (ja) | 1994-12-02 | 1998-10-20 | ザ、プロクター、エンド、ギャンブル、カンパニー | 柔軟なクレープ紙 |
JP2002327399A (ja) | 2001-04-27 | 2002-11-15 | Kuraray Co Ltd | 粘着テープ用クレープ紙 |
JP2003081028A (ja) | 2001-09-10 | 2003-03-19 | Kasai Kogyo Co Ltd | 自動車用インシュレータ |
JP2004325973A (ja) | 2003-04-28 | 2004-11-18 | Japan Vilene Co Ltd | 自動車用内装材及びその製造方法 |
JP2005195989A (ja) | 2004-01-09 | 2005-07-21 | Nippon Tokushu Toryo Co Ltd | 吸音フェルト |
JP5029547B2 (ja) * | 2008-09-15 | 2012-09-19 | 株式会社デンソー | 吸気冷却システム |
Family Cites Families (23)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2075835A (en) * | 1931-08-17 | 1937-04-06 | Wood Conversion Co | Coated paper or sheet |
GB468106A (en) * | 1936-08-07 | 1937-06-29 | Paper Patents Co | A new felted fibrous cellulosic sheet product |
US4077821A (en) * | 1975-09-15 | 1978-03-07 | Detroit Gasket Company | Method of forming foam laminates and headliners |
DE7619090U1 (de) * | 1976-06-16 | 1976-11-18 | Dynamit Nobel Ag, 5210 Troisdorf | Selbsttragendes Formteil für Kraftfahrzeuge |
JPS5312968A (en) * | 1976-07-21 | 1978-02-06 | Nissan Motor | Process for making packing material of corrugated cardboard |
JPS5318878A (en) * | 1976-08-06 | 1978-02-21 | Nissan Motor Co Ltd | Interior member made of shaped corrugated cardboard and method of making the same |
JPH0543198Y2 (ja) * | 1985-11-18 | 1993-10-29 | ||
JP2569313B2 (ja) | 1986-07-03 | 1997-01-08 | 光信 宮城 | 偏波性光導波素子 |
US4734308A (en) * | 1986-10-27 | 1988-03-29 | Corra-Board Products Co., Inc. | High strength paperboard panel |
JPH03133624A (ja) * | 1989-10-19 | 1991-06-06 | Inoue Mtp Co Ltd | 座席用表皮材 |
US5134014A (en) * | 1991-01-28 | 1992-07-28 | Eften, Inc. | Moldable foam composite |
JPH0529547A (ja) | 1991-07-19 | 1993-02-05 | Oki Electric Ind Co Ltd | 半導体素子の製造方法 |
JPH07110760B2 (ja) | 1991-08-15 | 1995-11-29 | 日本郵船株式会社 | フォークリフト |
US5503903A (en) * | 1993-09-16 | 1996-04-02 | Indiana Acoustical Components | Automotive headliner panel and method of making same |
US5866235A (en) * | 1997-02-21 | 1999-02-02 | Eften, Inc. | All synthetic fiber interior trim substrate |
US5939212A (en) * | 1997-06-09 | 1999-08-17 | Atd Corporation | Flexible corrugated multilayer metal foil shields and method of making |
US5892187A (en) * | 1997-12-17 | 1999-04-06 | United Technologies Corporation | Tunable recyclable headliner |
US6253995B1 (en) * | 2000-05-16 | 2001-07-03 | Burrows Paper Corporation | Insulated containers and sidewalls having laterally extending flutes, and methods |
US7297390B2 (en) * | 2002-01-28 | 2007-11-20 | Simmons Richard A | Structural polymer core assembly, method of manufacture and method of use |
TWI239344B (en) * | 2002-07-03 | 2005-09-11 | Nagoya Oilchemical | Adhesive sheet |
JP2004062074A (ja) * | 2002-07-31 | 2004-02-26 | Toyota Motor Corp | 吸音装置 |
US6951264B2 (en) * | 2003-03-04 | 2005-10-04 | Lear Corporation | Acoustically attenuating headliner and method for making same |
JP2005290363A (ja) * | 2004-03-12 | 2005-10-20 | Nagoya Oil Chem Co Ltd | 難燃処理用液剤 |
-
2008
- 2008-05-23 AU AU2008350434A patent/AU2008350434B2/en active Active
- 2008-05-23 US US12/866,784 patent/US8312963B2/en active Active
- 2008-05-23 WO PCT/JP2008/059532 patent/WO2009101712A1/ja active Application Filing
- 2008-05-23 EP EP08764578.4A patent/EP2236286B1/en active Active
- 2008-05-23 CA CA2709794A patent/CA2709794C/en active Active
- 2008-05-23 CN CN2008801267722A patent/CN101945762B/zh active Active
- 2008-05-23 KR KR1020107013841A patent/KR101611334B1/ko active IP Right Grant
- 2008-06-30 TW TW097124487A patent/TWI441160B/zh active
-
2009
- 2009-02-05 JP JP2009024830A patent/JP4462636B2/ja active Active
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6313004Y2 (ja) * | 1983-04-11 | 1988-04-13 | ||
JPH0543198U (ja) * | 1991-10-31 | 1993-06-11 | 日本特殊塗料株式会社 | 軽量成形防音材 |
JPH06270362A (ja) * | 1993-03-19 | 1994-09-27 | Ikeda Bussan Co Ltd | 内装基材 |
JPH10510886A (ja) | 1994-12-02 | 1998-10-20 | ザ、プロクター、エンド、ギャンブル、カンパニー | 柔軟なクレープ紙 |
JPH0941296A (ja) * | 1995-05-24 | 1997-02-10 | Achilles Corp | 凹凸模様のある装飾シート材およびその製造方法 |
JP2002327399A (ja) | 2001-04-27 | 2002-11-15 | Kuraray Co Ltd | 粘着テープ用クレープ紙 |
JP2003081028A (ja) | 2001-09-10 | 2003-03-19 | Kasai Kogyo Co Ltd | 自動車用インシュレータ |
JP2004325973A (ja) | 2003-04-28 | 2004-11-18 | Japan Vilene Co Ltd | 自動車用内装材及びその製造方法 |
JP2005195989A (ja) | 2004-01-09 | 2005-07-21 | Nippon Tokushu Toryo Co Ltd | 吸音フェルト |
JP5029547B2 (ja) * | 2008-09-15 | 2012-09-19 | 株式会社デンソー | 吸気冷却システム |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2007500235A (ja) * | 2003-05-28 | 2007-01-11 | スティーフェル ラボラトリーズ インコーポレイテッド | 起泡性医薬組成物および障害の治療方法 |
JP2010094990A (ja) * | 2008-09-22 | 2010-04-30 | Nagoya Oil Chem Co Ltd | 非浸透性表皮材、成形シート材料、および該成形シート材料の製造方法 |
JP2011084855A (ja) * | 2009-09-15 | 2011-04-28 | Nagoya Oil Chem Co Ltd | 熱接着性不織布、吸音性繊維シートおよび吸音材料 |
Also Published As
Publication number | Publication date |
---|---|
TW200935398A (en) | 2009-08-16 |
KR20100130582A (ko) | 2010-12-13 |
CN101945762B (zh) | 2013-11-06 |
CA2709794A1 (en) | 2009-08-20 |
JP2009214871A (ja) | 2009-09-24 |
EP2236286A4 (en) | 2016-03-16 |
CA2709794C (en) | 2014-11-18 |
EP2236286A1 (en) | 2010-10-06 |
AU2008350434A1 (en) | 2009-08-20 |
EP2236286B1 (en) | 2020-12-23 |
CN101945762A (zh) | 2011-01-12 |
US20100320030A1 (en) | 2010-12-23 |
JP4462636B2 (ja) | 2010-05-12 |
KR101611334B1 (ko) | 2016-04-12 |
TWI441160B (zh) | 2014-06-11 |
AU2008350434B2 (en) | 2013-12-05 |
US8312963B2 (en) | 2012-11-20 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
WO2009101712A1 (ja) | 吸音性表皮材、及びそれを用いた吸音材 | |
WO2010038491A1 (ja) | 吸音材料、複層吸音材料、複層吸音材料成形物、吸音性内装材料及び吸音性床敷材料 | |
JP4908084B2 (ja) | 吸音性表面材料およびそれを使用した成形物 | |
JPWO2009001483A1 (ja) | 自動車用床裏被覆材、及び自動車用床裏被覆材の製造方法 | |
JP4773520B2 (ja) | 繊維シート、積層繊維シート、および繊維シート成形物 | |
WO2009113204A1 (ja) | 離型性シートおよび成形物 | |
JP2008012783A5 (ja) | ||
WO2011013427A1 (ja) | 接着性吸音シート、吸音表皮材、吸音材料および吸音材料成形物 | |
KR20070003856A (ko) | 난연성 다공질재료 시트, 그 성형물 및 자동차용 난연성흡음재료 | |
JP2005290363A (ja) | 難燃処理用液剤 | |
JP5838493B2 (ja) | 吸音材料の製造方法 | |
WO2011111182A1 (ja) | 難燃性繊維材料およびその製造方法 | |
JP5330791B2 (ja) | 吸音材料 | |
JP2013054379A (ja) | 吸音材料 | |
JP5274190B2 (ja) | 不燃性繊維シート | |
JP3383368B2 (ja) | 構造材 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
WWE | Wipo information: entry into national phase |
Ref document number: 200880126772.2 Country of ref document: CN |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 08764578 Country of ref document: EP Kind code of ref document: A1 |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2709794 Country of ref document: CA |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2008350434 Country of ref document: AU |
|
ENP | Entry into the national phase |
Ref document number: 20107013841 Country of ref document: KR Kind code of ref document: A |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2008764578 Country of ref document: EP |
|
ENP | Entry into the national phase |
Ref document number: 2008350434 Country of ref document: AU Date of ref document: 20080523 Kind code of ref document: A |
|
WWE | Wipo information: entry into national phase |
Ref document number: 12866784 Country of ref document: US |
|
NENP | Non-entry into the national phase |
Ref country code: DE |