WO2018097327A1

WO2018097327A1 - Sound absorbing material comprising non-woven fabric

Info

Publication number: WO2018097327A1
Application number: PCT/JP2017/042684
Authority: WO
Inventors: 伊林　邦彦; 知生平井; 小西　宏明; 峻之椎名; 遠藤　健; 昌弘若山
Original assignee: Ｊｘｔｇエネルギー株式会社
Priority date: 2016-11-28
Filing date: 2017-11-28
Publication date: 2018-05-31

Abstract

This sound absorbing material comprising non-woven fabric includes a non-woven fabric laminate obtained by stacking a plurality of layers of long-fiber non-woven fabric which have a plurality of stretched long-fiber filaments aligned along one direction. The most common value among the distribution of the fiber diameters of the plurality of long-fiber filaments is 1-4 μm. This sound absorbing material comprising non-woven fabric can improve sound absorbing performance at relatively lower frequency bands compared to the prior art.

Description

Non-woven sound absorbing material

The present invention relates to a non-woven sound absorbing material, and more particularly to a non-woven sound absorbing material that can exhibit sound absorbing performance in a relatively low frequency band.

As an example of a conventional nonwoven fabric sound-absorbing material, Patent Document 1 includes a relatively thick fine fiber and a relatively thin fine fiber, and the fine fiber distribution center of the thick fiber is the thin fiber. A non-woven sound-absorbing material that is twice or more the fineness distribution center is described.

Japanese Patent Laying-Open No. 2015-28230

The nonwoven fabric sound absorbing material described in Patent Document 1 exhibits sound absorbing performance in a high frequency band, and cannot meet the needs for sound absorption in a relatively low frequency band of, for example, 4000 Hz or less.

Therefore, an object of the present invention is to provide a non-woven fabric sound-absorbing material that can improve sound-absorbing performance in a relatively low frequency band as compared with the prior art.

The present inventor has found that sound absorption performance can be exhibited in a predetermined low frequency band of 4000 Hz or less by stacking a plurality of long fiber nonwoven fabrics satisfying specific conditions. The present invention has been made based on such knowledge.

That is, the sound absorbing material made of nonwoven fabric according to the present invention includes a nonwoven fabric laminate in which a plurality of long fiber nonwoven fabrics having a plurality of long fiber filaments stretched and arranged along one direction are stacked, and the fibers of the long fiber filaments The mode of the diameter distribution is 1 to 4 μm.

According to the present invention, it is possible to provide a nonwoven fabric sound absorbing material that can exhibit high sound absorbing performance in a predetermined low frequency band of 4000 Hz or less.

It is an enlarged photograph (magnification: 1000 times) by the scanning electron microscope of the unidirectional array nonwoven fabric which is an example of the long-fiber nonwoven fabric which comprises the nonwoven fabric sound-absorbing material by this invention. (A) is a schematic sectional drawing which shows 1st Embodiment of the nonwoven fabric sound-absorbing material by this invention, (B) is schematic sectional drawing which shows 2nd Embodiment of the nonwoven fabric sound-absorbing material by this invention. It is a figure (partial cross section figure) which shows schematic structure of an example of the manufacturing apparatus of the longitudinally-arranged long-fiber nonwoven fabric which is 1st Embodiment of the said nonwoven fabric for sound-absorbing materials. It is a figure (partial cross section figure) which shows schematic structure of the 1st manufacturing apparatus of the transverse arrangement long fiber nonwoven fabric which is 2nd Embodiment of the said nonwoven fabric for sound-absorbing materials. It is a figure which shows the principal part structure of the 2nd manufacturing apparatus of the manufacturing apparatus of the said horizontal array long fiber nonwoven fabric, (A) is a front view (partial sectional drawing) of the 2nd manufacturing apparatus of the said horizontal array long fiber nonwoven fabric, (B) is a side view (partial cross-sectional view) of a second production apparatus for the transversely aligned long-fiber nonwoven fabric. It is a figure which shows the spinning head used with the 2nd manufacturing apparatus of the said transversely-arranged long-fiber nonwoven fabric shown by FIG. 5, (A) is sectional drawing of a spinning head, (B) is a spinning head lower side. It is the figure seen from. It is a figure which shows the modification of the said spinning head, (A) is sectional drawing of the spinning head which concerns on a modification, (B) is the figure which looked at the spinning head which concerns on a modification from the lower side, (C) is FIG. 5 is a cross-sectional view in a direction perpendicular to (A) of a spinning head according to a modification. It is a table | surface which shows the physical property of the said longitudinally-aligned long fiber nonwoven fabric. It is a figure which shows the fiber diameter distribution of the said longitudinally-arranged continuous fiber nonwoven fabric. It is a graph which shows the measurement result of the normal incidence sound absorption coefficient of Example 1 (Examples 1-1 and 1-2) and a comparative example. It is a graph which shows the measurement result of normal incidence sound absorption coefficient of Example 2 (Examples 2-1 and 2-2) and a comparative example. It is a graph which shows the measurement result of the normal incidence sound absorption coefficient of Example 3 (Examples 3-1, 3-2, 3-3), a reference example, and a comparative example.

The present invention provides a sound absorbing material made of nonwoven fabric. A nonwoven fabric sound absorbing material according to the present invention includes a nonwoven fabric laminate in which a plurality of long fiber nonwoven fabrics having a plurality of long fiber filaments stretched and arranged in one direction are stacked, and the fiber diameter distribution of the long fiber filaments Is the mode value of 1 to 4 μm. The nonwoven fabric sound-absorbing material according to the present invention, as will be described later, can exhibit higher sound-absorbing performance than the conventional one in a predetermined low frequency band of 4000 Hz or less.

In the nonwoven fabric sound-absorbing material according to the present invention, the long-fiber non-woven fabric constituting the non-woven fabric laminate, that is, the long-fiber non-woven fabric having a plurality of long-fiber filaments stretched and arranged along one direction is stretched, for example. Moreover, it may be a “unidirectionally arranged non-woven fabric” in which a plurality of long fiber filaments are arranged along one direction. The one direction does not have to be strictly one direction, and may be generally one direction. Such a unidirectionally arranged nonwoven fabric is produced through a production process including, for example, arranging a plurality of long fiber filaments along one direction and stretching the arranged plurality of long fiber filaments in the one direction. Can be done.

Here, “arranging a plurality of long fiber filaments along one direction” means arranging a plurality of long fiber filaments so that each length direction (axial direction) is one direction, that is, arrangement That is, each of the plurality of long fiber filaments extended substantially in one direction. For example, when the unidirectionally arranged nonwoven fabric is produced as a long sheet, the one direction is a longitudinal direction of the long sheet (also referred to as a vertical direction), a direction inclined from the longitudinal direction of the long sheet, It may be a direction inclined from a width direction (also referred to as a horizontal direction) of the long sheet or a horizontal direction of the long sheet. Further, “stretching a plurality of arranged long fiber filaments in the one direction” means stretching each of the arranged long fiber filaments generally in the axial direction thereof. In addition, by stretching a plurality of long fiber filaments arranged along one direction in one direction, the constituent molecules of each long fiber filament are stretched in one direction, that is, the axial direction of each long fiber filament. Will be arranged.

FIG. 1 is an enlarged photograph (magnification: 1000 times) of an example of the unidirectionally arranged nonwoven fabric by a scanning electron microscope. In the unidirectionally arranged nonwoven fabric shown in FIG. 1, each of the plurality of long fiber filaments is generally arranged along the vertical direction.

Moreover, the long fiber nonwoven fabric used for the sound absorbing material made of nonwoven fabric according to the present invention is stretched and stretched in addition to the plurality of long fiber filaments (first long fiber filaments) arranged along one direction, and the You may further have a some 2nd long fiber filament arranged along the direction orthogonal to one direction. That is, the long-fiber non-woven fabric used in the non-woven fabric sound-absorbing material according to the present invention is an “orthogonal array non-woven fabric” having a configuration in which each of a plurality of stretched long-fiber filaments is aligned along one of two orthogonal directions. obtain. The two orthogonal directions do not need to be strictly orthogonal, but may be approximately orthogonal. Such an orthogonally arranged nonwoven fabric can be produced, for example, by laminating and fusing two unidirectionally arranged nonwoven fabrics so that their long fiber filaments are orthogonal to each other. Here, in the orthogonal array nonwoven fabric, the mode value of the fiber diameter distribution of the plurality of first long fiber filaments arranged along the one direction may be 1 to 4 μm, and orthogonal to the one direction. The mode value of the fiber diameter distribution of the plurality of second long filaments arranged in the direction to be not necessarily required to be 1 to 4 μm. For example, in the orthogonal array nonwoven fabric, the mode value of the fiber diameter distribution of the plurality of first long fiber filaments arranged along the one direction is 1 to 4 μm, while the direction orthogonal to the one direction The mode value of the fiber diameter distribution of the plurality of second long fiber filaments arranged along the line may be 4 to 11 μm.

The non-woven fabric sound-absorbing material according to the present invention includes a non-woven fabric laminate in which a plurality of the long-fiber non-woven fabrics are stacked as described above. The nonwoven fabric laminate is formed by stacking, for example, 50 or more, preferably 100 or more, long fiber nonwoven fabrics. In addition, in the said nonwoven fabric laminated body, the axial direction of the long fiber filament of each laminated nonwoven fabric may be the same, and may be random.

The non-woven fabric laminate only needs to be formed by stacking a plurality of the long-fiber non-woven fabrics in the thickness direction, and may be a state in which the plurality of long-fiber non-woven fabrics are simply stacked (non-compressed state). Alternatively, a plurality of the long fiber nonwoven fabrics may be stacked and compressed (compressed state). Further, in the nonwoven fabric laminate, the plurality of long fiber nonwoven fabrics may be in a state of being separable from each other, for example, by fixing the edges of each other (including fusion or adhesion). Part or all may be integrated. Therefore, the said nonwoven fabric laminated body can be comprised by the number of said long-fiber nonwoven fabrics from which it differs with respect to the same installation space (height dimension) etc., for example. In other words, the nonwoven fabric sound-absorbing material according to the present invention can adjust the number of the long-fiber nonwoven fabrics constituting the laminate when installed in a predetermined installation space or the like. Further, the orthogonally arranged nonwoven fabric can be said to be the long fiber nonwoven fabric constituting the nonwoven fabric laminate, and the two unidirectionally arranged nonwoven fabrics are laminated so that the long fiber filaments are orthogonal to each other and fused as described above. It can be said that it is the said nonwoven fabric laminated body when produced by doing.

The sound absorbing material made of nonwoven fabric according to the present invention can be formed only of the nonwoven fabric laminate. However, it is not restricted to this, For example, it can be formed with the said nonwoven fabric laminated body and the member which accommodates or hold | maintains this. As said member which accommodates or hold | maintains the said nonwoven fabric laminated body, the package which packages the said nonwoven fabric laminated body corresponds, for example. The packaging body only needs to be formed of a material that does not impair the sound absorption performance of the nonwoven fabric laminate, for example, the long-fiber nonwoven fabric constituting the nonwoven fabric laminate or a nonwoven fabric with higher air permeability or porosity than that. Can be done. Moreover, the nonwoven fabric sound absorbing material according to the present invention can be used in combination with other sound absorbing materials such as a porous sound absorbing material. For example, the nonwoven fabric sound absorbing material according to the present invention can be stacked on another sound absorbing material (arranged on the surface of the other sound absorbing material) or be disposed between two other sound absorbing materials.

FIG. 2 (A) is a schematic cross-sectional view showing a first embodiment of a nonwoven fabric sound absorbing material according to the present invention, and FIG. 2 (B) is a schematic cross section showing a second embodiment of the nonwoven sound absorbing material according to the present invention. FIG. As shown in FIG. 2A, the nonwoven fabric sound absorbing material according to the first embodiment is formed by stacking a plurality of long fiber nonwoven fabrics 51 having a configuration in which a plurality of stretched long fiber filaments are arranged along one direction. It consists of the non-woven fabric laminate 52. The nonwoven fabric sound-absorbing material according to the first embodiment can be installed, for example, in a predetermined installation space in an uncompressed state or a compressed state. Moreover, as shown in FIG. 2B, the nonwoven fabric sound absorbing material according to the second embodiment includes a plurality of long fiber nonwoven fabrics 51 having a configuration in which a plurality of stretched long fiber filaments are arranged along one direction. The laminated nonwoven fabric 52 and the package 53 which packages the nonwoven fabric laminated body 52 are included. The nonwoven fabric sound-absorbing material according to the second embodiment may be installed side by side in a non-compressed state or a compressed state in a predetermined installation space, or may be installed in an overlapping manner.

Next, the long-fiber nonwoven fabric constituting the nonwoven fabric laminate will be specifically described. As described above, the long fiber nonwoven fabric constituting the nonwoven fabric laminate may be the unidirectionally aligned nonwoven fabric or the orthogonally aligned nonwoven fabric. In the following description, “longitudinal direction” refers to the machine direction (MD direction) when producing the long fiber nonwoven fabric, that is, the feeding direction (corresponding to the length direction of the long fiber nonwoven fabric), The “lateral direction” refers to a direction perpendicular to the longitudinal direction (TD direction), that is, a direction orthogonal to the feeding direction (corresponding to the width direction of the long fiber nonwoven fabric). In the following description, the long fiber filament may be simply referred to as a filament.

[Unidirectional non-woven fabric]
1. Longitudinal long fiber nonwoven fabric A longitudinal long fiber nonwoven fabric, which is an example of the unidirectionally aligned nonwoven fabric, has a plurality of long fiber filaments made of thermoplastic resin arranged along the vertical direction, that is, the length direction of each long fiber filament. It is obtained by arranging so that (axial direction) substantially coincides with the longitudinal direction, and stretching a plurality of arranged long fiber filaments in the longitudinal direction (axial direction). In such a longitudinally aligned long fiber nonwoven fabric, the constituent molecules of each long fiber filament are oriented in the longitudinal direction. Here, the stretching ratio of the plurality of long fiber filaments in the longitudinal direction is 3 to 6 times. Further, the mode value of the fiber diameter distribution of the plurality of long fiber filaments (that is, a plurality of drawn long fiber filaments) constituting the longitudinally aligned long fiber nonwoven fabric is 1 to 4 μm, preferably 2 to 3 μm. is there. Further, the plurality of long fiber filaments constituting the longitudinally arranged long fiber nonwoven fabric have an average fiber diameter of 1 to 4 μm, preferably 2 to 3 μm, and the plurality of long fibers constituting the longitudinally arranged long fiber nonwoven fabric. The variation coefficient of the fiber diameter distribution of the filament is 0.1 to 0.3, preferably 0.15 to 0.25. The coefficient of variation is a value obtained by dividing the standard deviation of the fiber diameters of the plurality of long fiber filaments constituting the longitudinally aligned long fiber nonwoven fabric by the average (average fiber diameter).

The long fiber filament is not particularly limited as long as it is substantially a long fiber, but may be a fiber (filament) having an average length exceeding 100 mm, for example. The long fiber filaments may have an average fiber diameter in the range of 1 to 4 μm. The longitudinally aligned long fiber nonwoven fabric may be a long fiber filament having a fiber diameter of less than 1 μm or a long fiber filament having a fiber diameter of more than 4 μm. May be included. In addition, the length and the fiber diameter of the long fiber filament can be measured from, for example, an enlarged photograph of the longitudinally aligned long fiber nonwoven fabric photographed by a scanning electron microscope, and from N (for example, 50) measured values. An average fiber diameter and a standard deviation can be obtained, and a coefficient of variation in fiber diameter distribution can be obtained by dividing the standard deviation by the average fiber diameter.

The weight basis weight (hereinafter referred to as “weight basis”) w of the longitudinally aligned long-fiber nonwoven fabric is 5 to 60 g / m ² , preferably 5 to 40 g / m ² , more preferably 10 to 30 g / m ² . The basis weight is calculated from an average value of, for example, preparing a plurality of non-woven sheets cut out to 300 mm × 300 mm, measuring the respective weights. Moreover, the thickness t of the longitudinally aligned long fiber nonwoven fabric is 10 to 110 μm, preferably 25 to 60 μm, and the specific volume t / w, which is a value obtained by dividing the thickness t of the longitudinally aligned long fiber nonwoven fabric by the basis weight w. (Cm ³ / g) is 2.0 to 3.5. When the specific volume t / w is in the range of 2.0 to 3.5, it means that the length of the longitudinally aligned long fiber nonwoven fabric is thinner than the basis weight. Further, the air permeability of the longitudinally aligned long fiber nonwoven fabric is 5 to 250 cm ³ / cm ² / s, preferably 10 to 70 cm ³ / cm ² / s.

Moreover, the folding width of the filament when producing the longitudinally aligned long fiber nonwoven fabric is preferably 300 mm or more. This is because the folding width needs to be large to some extent in order for the filament to function as a long fiber. In addition, the folding width of the filament is an average length of a substantially straight line portion between the turning points when the spun filament is vibrated in the vertical direction and placed on the conveyor as described later, It shall be the length that can be visually observed in the state of being drawn into the longitudinally aligned long-fiber nonwoven fabric. Such a folding width can be changed in the manufacturing method (manufacturing apparatus) described later depending on, for example, the flow velocity of the high-speed airflow and / or the rotational speed of the airflow vibration mechanism.

The long fiber filament is obtained by melt spinning a thermoplastic resin. The thermoplastic resin is not particularly limited as long as it is a resin that can be melt-spun, but is mainly polyester, and particularly has an intrinsic viscosity IV of 0.43 to 0.63, preferably 0.48 to 0.00. Polyethylene terephthalate which is 58 is used. Alternatively, polypropylene may be used as the thermoplastic resin. This is because the spinnability in the melt blow method is good. The thermoplastic resin may contain about 0.01 to 2% by weight of additives such as antioxidants, weathering agents and colorants. In addition, as the thermoplastic resin, a flame retardant resin, for example, a flame retardant polyester made flame retardant by copolymerizing a phosphorus-based flame retardant component may be used.

Next, an example of a method for producing the longitudinally aligned long fiber nonwoven fabric will be described. The method for producing the longitudinally aligned long fiber nonwoven fabric includes a step of producing a nonwoven fabric web having a configuration in which a plurality of long fiber filaments are arranged along the longitudinal direction, and the produced nonwoven fabric web (that is, aligned along the longitudinal direction). A plurality of long fiber filaments) are uniaxially stretched in the machine direction to obtain a longitudinally arranged long fiber nonwoven fabric.

Specifically, the step of producing the nonwoven web includes a nozzle group for extruding a plurality (many) of filaments, a conveyor belt for collecting and transporting the filaments extruded from the nozzle groups, and a high-speed air current blown to the filaments. A step of preparing an airflow vibration means for vibrating the nozzles, a step of pushing a plurality (a large number) of filaments from the nozzle group toward the conveyor belt, and a step of causing each filament pushed from the nozzle group to accompany the high-speed airflow. And a step of periodically changing the direction of the high-speed airflow in the running direction (that is, the longitudinal direction) of the conveyor belt by the airflow vibrating means, and a plurality of filaments run on the conveyor belt. A nonwoven web arranged along the direction (longitudinal direction) is produced. Moreover, the process of obtaining the said longitudinally-arranged long fiber nonwoven fabric uniaxially stretches the nonwoven fabric web produced at the process of producing the said nonwoven fabric web to the vertical direction, and thereby obtains the said longitudinally-arranged long fiber nonwoven fabric. The draw ratio is 3 to 6 times.

Here, regarding the nozzle group, the number of nozzles, the number of nozzle holes, the pitch P between nozzle holes, the nozzle hole diameter D, and the nozzle hole length L can be arbitrarily set, but the nozzle hole diameter D is 0.1 to 0. .2 mm and L / D are preferably 10 to 40.

FIG. 3 is a schematic configuration diagram of an example of an apparatus for producing the longitudinally aligned long fiber nonwoven fabric. The production apparatus shown in FIG. 3 is configured to produce the longitudinally aligned long-fiber nonwoven fabric by the melt blow method, and includes a melt blow die 1, a conveyor belt 7, an air flow vibration mechanism 9, stretching

cylinders

12a and 12b, and a take-off nip roller 16a. 16b and the like.

First, in the front stage of the apparatus, a thermoplastic resin (here, a thermoplastic resin mainly composed of polyester or polypropylene) is put into an extruder (not shown), melted, extruded, and sent to the melt blow die 1. .

The melt blow die 1 has a large number of nozzles 3 arranged at the front end (lower end) thereof in a direction perpendicular to the paper surface, that is, perpendicular to the running direction of the conveyor belt 7. A large number of filaments 11 are formed (spun) by the molten resin 2 sent to the meltblowing die 1 being pushed out from each nozzle 3 by a gear pump (not shown) or the like. In FIG. 3, the melt blow die 1 is shown in a sectional view, so that only one nozzle 3 is shown. In the melt blow die 1,

air reservoirs

5a and 5b are provided on both sides of each nozzle 3, respectively. The high-pressure heated air heated to the melting point of the thermoplastic resin or higher is fed into the

air reservoirs

5a and 5b, and then communicated with the

air reservoirs

5a and 5b and opened at the tip of the melt blow die 1 with

slits

6a and 6b. Erupted from. As a result, a high-speed air flow that is substantially parallel to the extrusion direction of the filament 11 from the nozzle 3 is formed below the nozzle 3. The filament 11 extruded from the nozzle 3 is maintained in a draftable molten state by the high-speed airflow, and the filament 11 is drafted (ie, the filament 11 is pulled) by the frictional force of the high-speed airflow. 11 is reduced in diameter. The diameter of the filament 11 immediately after spinning is preferably 10 μm or less. The temperature of the high-speed airflow formed below the nozzle 3 is set to be 20 ° C. or higher, preferably 40 ° C. or higher, higher than the spinning temperature of the filament 11.

In the method of forming the filament 11 using the melt blow die 1, the temperature of the filament 11 immediately after being extruded from the nozzle 3 can be made sufficiently higher than the melting point of the filament 11 by increasing the temperature of the high-speed airflow. This makes it possible to reduce the diameter of the filament 11.

A conveyor belt 7 is disposed below the meltblowing die 1. The conveyor belt 7 is wound around a conveyor roller 13 and other rollers that are rotated by a drive source (not shown). By driving the conveyor belt 7 by the rotation of the conveyor roller 13, the filament 11 extruded from the nozzle 3 and collected on the conveyor belt 7 is conveyed in the arrow direction (right direction) in FIG. 3.

In a predetermined position between the melt blow die 1 and the conveyor belt 7, specifically, in the vicinity of the flow area of the high-speed airflow formed by the high-pressure heated air ejected from the

slits

6 a and 6 b on both sides of the nozzle 3. An airflow vibration mechanism 9 is provided. The airflow vibration mechanism 9 has an elliptical column part having an elliptical section and a support shaft 9a extending from each of both ends of the elliptical column part, and the conveying direction of the filament 11 by the conveyor belt 7 (the traveling direction of the conveyor belt 7). Is arranged substantially parallel to the width direction of the longitudinally aligned long-fiber nonwoven fabric to be manufactured. The airflow vibration mechanism 9 is configured such that the elliptical column portion rotates in the direction of arrow A when the support shaft 9a is rotated. Thus, by arranging the elliptical columnar airflow vibration mechanism 9 in the vicinity of the high-speed airflow and rotating it, the direction of the high-speed airflow can be changed using the Coanda effect as will be described later. Note that the number of airflow vibration mechanisms 9 is not limited to one, and a plurality of airflow vibration mechanisms 9 may be provided as necessary to increase the swing width of the filament 11.

The filament 11 flows along the high-speed airflow. The high-speed airflow is formed by the combination of high-pressure heated air ejected from the

slits

6 a and 6 b and flows in a direction substantially perpendicular to the conveying surface of the conveyor belt 7. By the way, it is generally known that when a wall exists near a high-speed jet of gas or liquid, the jet tends to flow near the wall. This is called the Coanda effect. The airflow vibration mechanism 9 uses the Coanda effect to change the direction of the high-speed airflow, that is, the flow of the filament 11.

The width of the airflow vibration mechanism 9 (the elliptical column part), that is, the length of the airflow vibration mechanism 9 in the direction parallel to the support shaft 9a is 100 mm or more larger than the width of the filament group spun by the melt blow die 1. desirable. If the width of the airflow vibration mechanism 9 is smaller than this, the flow direction of the high-speed airflow cannot be sufficiently changed at both ends of the filament group, and the arrangement along the longitudinal direction of the filament 11 at both ends of the filament group is not good. This is because there is a risk of becoming sufficient. Further, the distance between the peripheral wall surface 9b of the airflow vibration mechanism 9 (the elliptical column portion) and the airflow axis 100 of the high-speed airflow is 25 mm or less, preferably 15 mm or less at the minimum. If the distance between the airflow vibration mechanism 9 and the airflow shaft 100 is longer than this, the effect that the high-speed airflow is attracted to the airflow vibration mechanism 9 is reduced, and the filament 11 may not be sufficiently shaken. is there.

Here, the swing width of the filament 11 depends on the flow velocity of the high-speed airflow and the rotational speed of the airflow vibration mechanism 9. Therefore, the speed of the high-speed air flow is set to be 10 m / sec or more, preferably 15 m / sec or more. If the speed is less than this, the high-speed air current is not sufficiently attracted to the peripheral wall surface 9b of the air-flow vibration mechanism 9, and as a result, the filament 11 may not be sufficiently shaken. The rotational speed of the airflow vibration mechanism 9 may be set such that the frequency of the peripheral wall surface 9b is the frequency that maximizes the swing width of the filament 11. Such a frequency varies depending on the spinning conditions, and therefore is appropriately determined according to the spinning conditions.

In the manufacturing apparatus shown in FIG. 3, a spray nozzle 8 is provided between the melt blow die 1 and the conveyor belt 7. The spray nozzle 8 sprays mist-like water or the like in the high-speed air stream, and the filament 11 is cooled by the spray of water or the like by the spray nozzle 8 and rapidly solidifies. Although a plurality of spray nozzles 8 are actually installed, only one spray nozzle 8 is shown in FIG. 3 in order to avoid complexity.

The solidified filaments 11 are accumulated on the conveyor belt 7 while being shaken in the vertical direction, and are partially folded in the vertical direction and continuously collected. The filament 11 on the conveyor belt 7 is conveyed by the conveyor belt 7 in the arrow direction (right direction) in FIG. 3, and is nipped between the stretching cylinder 12a and the pressing roller 14 heated to the stretching temperature, and transferred to the stretching cylinder 12a. It is. Thereafter, the filament 11 is nipped between the stretching cylinder 12b and the pressing rubber roller 15 and transferred to the stretching cylinder 12b, and is in close contact with the two stretching

cylinders

12a and 12b. In this way, the filament 11 is sent while being in close contact with the

drawing cylinders

12a and 12b, so that the filament 11 becomes a nonwoven fabric web in which adjacent filaments are fused while being partially folded in the vertical direction. .

The non-woven web is then taken up by take-up nip

rollers

16a and 16b (the take-up nip roller 16b in the subsequent stage is made of rubber). The peripheral speed of the take-up nip

rollers

16a and 16b is set to be larger than the peripheral speed of the stretching

cylinders

12a and 12b, and the nonwoven web is stretched 3 to 6 times in the longitudinal direction. In this way, the longitudinally aligned long fiber nonwoven fabric 18 is manufactured. The nonwoven web may be further subjected to post-treatment such as partial adhesion treatment such as heat treatment or hot embossing as necessary. Moreover, a draw ratio can be defined by the following formula with the mark put into the nonwoven fabric web before extending | stretching at a fixed space | interval, for example.
Stretch ratio = “Length between marks after stretching” / “Length between marks before stretching”

As described above, the average fiber diameter of the filaments constituting the longitudinally arranged long fiber nonwoven fabric 18 is 1 to 4 μm (preferably 2 to 3 μm). The variation coefficient of the fiber diameter distribution is 0.1 to 0.3. In addition, the longitudinally aligned long fiber nonwoven fabric 18 may have some elasticity in the fiber direction, that is, the longitudinal direction that is the axial direction of the long fiber filaments and the stretching direction. Furthermore, the tensile strength in the longitudinal direction of the longitudinally arranged long fiber nonwoven fabric 18 is 20 N / 50 mm or more. The tensile strength is a value measured by JIS L1096 8.14.1 A method.

2. Horizontally-aligned long-fiber nonwoven fabric A transversely-aligned long-fiber nonwoven fabric, which is another example of the unidirectionally-arranged nonwoven fabric, is a plurality of long-fiber filaments made of thermoplastic resin along the lateral direction, that is, the length direction of each long-fiber filament It is obtained by arranging so that (axial direction) substantially coincides with the transverse direction, and stretching a plurality of arranged long fiber filaments in the transverse direction (axial direction). In such a transversely arranged long fiber nonwoven fabric, the constituent molecules of each long fiber filament are oriented in the transverse direction. Here, as in the case of the longitudinally aligned long fiber nonwoven fabric, the draw ratio of the long fiber filament is 3 to 6 times. The mode value of the fiber diameter distribution of the plurality of long fiber filaments constituting the transversely arranged long fiber nonwoven fabric is 1 to 4 μm, preferably 2 to 3 μm. Further, the plurality of long fibers constituting the transversely arranged long fiber nonwoven fabric has an average fiber diameter of 1 to 4 μm, preferably 2 to 3 μm, and the plurality of long fibers constituting the transversely arranged long fiber nonwoven fabric. The variation coefficient of the fiber diameter distribution of the filament is 0.1 to 0.3, preferably 0.15 to 0.25.

Further, the basis weight w of the laterally aligned long-fiber nonwoven fabric is 5 to 60 g / m ² , preferably 5 to 40 g / m ² , more preferably 10 to 30 g / m ² , and the thickness of the laterally-aligned long fiber nonwoven fabric is t is 10 to 110 μm, preferably 20 to 70 μm, and the specific volume t / w (cm ³ / g), which is a value obtained by dividing the thickness t of the transversely aligned long fiber nonwoven fabric by the basis weight w, is 2.0. ~ 3.5. Further, the air permeability of the transversely aligned long fiber nonwoven fabric is 5 to 250 cm ³ / cm ² / s, preferably 10 to 70 cm ³ / cm ² / s.

In addition, below, description about what may be the same as that of the case of the longitudinally aligned long fiber nonwoven fabric will be omitted as appropriate.

Next, an example of a method for producing the transversely aligned long fiber nonwoven fabric will be described. The method for producing the transversely aligned long-fiber nonwoven fabric includes a step of producing a nonwoven fabric web in which a plurality of long-fiber filaments are arranged along the transverse direction, and a produced nonwoven web (that is, a plurality of filaments arranged along the transverse direction). To obtain a transversely aligned long-fiber nonwoven fabric by uniaxially stretching the long-fiber filaments) in the transverse direction.

Specifically, the step of producing the nonwoven web includes a nozzle group for extruding a plurality (many) of filaments, a conveyor belt for collecting and transporting the filaments extruded from the nozzle groups, and a high-speed air current blown to the filaments. A step of preparing an airflow vibration means for vibrating the nozzle, a step of extruding a plurality (many) of filaments from the nozzle group toward the conveyor belt, and causing each filament extruded from the nozzle group to accompany the high-speed airflow A step of reducing the diameter, and a step of periodically changing the direction of the high-speed air flow in the direction perpendicular to the traveling direction of the conveyor belt (that is, the lateral direction) by the air flow vibration means, A non-woven web arranged in a direction (lateral direction) perpendicular to the traveling direction of the conveyor is produced. Moreover, the process of obtaining the said laterally arranged long fiber nonwoven fabric carries out the uniaxial stretching of the nonwoven fabric web produced at the process of producing the said nonwoven fabric web to a horizontal direction, and, thereby, obtains the said laterally arranged long fiber nonwoven fabric. The draw ratio is 3 to 6 times.

FIG. 4 is a schematic configuration diagram of an example of a production apparatus (hereinafter referred to as “first production apparatus”) of the laterally arranged long fiber nonwoven fabric. The transversely long continuous nonwoven fabric first manufacturing apparatus is configured to manufacture the laterally aligned long fiber nonwoven fabric by a melt blowing method. As shown in FIG. 4, a melt blow die 101, a conveyor belt 107, an air flow vibration, and the like. A mechanism 109 and a drawing device (not shown) are included. In FIG. 4, the melt blow die 101 is shown in cross section so that the internal structure can be seen.

First, in the front stage of the apparatus, a thermoplastic resin (here, a thermoplastic resin mainly composed of polyester or polypropylene) is put into an extruder (not shown), melted, extruded, and sent to the melt blow die 101. .

The meltblowing die 101 has a large number of nozzles 103 arranged at the tip (lower end) thereof in a direction perpendicular to the paper surface, that is, along the traveling direction of the conveyor belt 107. A large number of filaments 111 are formed (spun) by the molten resin sent to the meltblowing die 101 being pushed out from each nozzle 103 by a gear pump (not shown) or the like.

Air reservoirs

105a and 105b are provided on both sides of each nozzle 103, respectively. The high-pressure heated air heated to the melting point of the thermoplastic resin or higher is fed into the

air reservoirs

105a and 105b, and then communicated with the

air reservoirs

105a and 105b and opened at the tip of the melt blow die 101. Erupted from. As a result, a high-speed air flow substantially parallel to the extrusion direction of the filament 111 from the nozzle 103 is formed below the nozzle 103, and the filament 111 extruded from the nozzle 103 is maintained in a draftable molten state by this high-speed air flow. At the same time, a draft is given to the filament 111 by the frictional force of the high-speed air flow, and the filament 111 is reduced in diameter. The temperature of the high-speed airflow is set to 20 ° C. or higher, preferably 40 ° C. or higher, higher than the spinning temperature of the filament 111.

As in the case of the longitudinally aligned long-fiber nonwoven fabric, by increasing the temperature of the high-speed airflow, the temperature of the filament 111 immediately after being extruded from the nozzle 103 can be made sufficiently higher than the melting point of the filament 111, Thereby, the diameter of the filament 111 can be reduced.

A conveyor belt 107 is disposed below the meltblowing die 101. The conveyor belt 107 is wound around a conveyor roller and other rollers (both not shown) rotated by a drive source not shown. By driving the conveyor belt 107 by the rotation of the conveyor roller, the filament 111 pushed out from the nozzle 103, more specifically, the nonwoven fabric web 120 in which the filament 111 is accumulated on the conveyor belt 107 is formed on the paper surface in FIG. It is conveyed from the back to the front or from the front to the back.

In a predetermined position between the meltblowing die 101 and the conveyor belt 107, specifically, in a high-speed airflow basin formed in the vicinity of the high-pressure heated air ejected from the

slits

106a and 106b (in the vicinity) An airflow vibration mechanism 109 is provided. The airflow vibration mechanism 109 has an elliptical column part having an elliptical cross section and support shafts 109a extending from both ends of the elliptical column part, and is arranged in parallel with the conveying direction of the filament 111 (web 120) by the conveyor belt 107. Has been. The airflow vibration mechanism 109 is configured such that the elliptical column portion rotates in the direction of arrow A when the support shaft 109a is rotated.

The airflow vibration mechanism 109 can change the direction of the high-speed airflow (flow of the filament 111) using the Coanda effect, similarly to the airflow vibration mechanism 9 of FIG. That is, the filament 111 can be periodically vibrated by rotating the airflow vibration mechanism 109. Since the support shaft 109a of the airflow vibration mechanism 109 is arranged in parallel with the conveying direction of the filament 111 (web 120) by the conveyor belt 107, the filament 111 is manufactured in a direction perpendicular to the conveying direction by the conveyor belt 107, that is, manufactured. It vibrates in the width direction of the transversely aligned long fiber nonwoven fabric. Thereby, the nonwoven fabric web 120 of width S in which the filament 111 was arranged along the width direction is produced on the conveyor belt 107.

The distance between the airflow axis 100 and the peripheral wall surface 109b when the peripheral wall surface 109b of the airflow vibration mechanism 109 is closest to the airflow axis 100 of the high-speed airflow is L1. Further, the distance between the lower end surface of the meltblowing die 101 that is substantially flush with the tip of the nozzle 103 and the center of the support shaft 109a of the airflow vibration mechanism 109 is L2. Basically, the smaller the L1 and L2, the larger the width S of the nonwoven web 120 produced on the conveyor belt 107. However, if L1 is too small, troubles such as winding of the filament 111 around the airflow vibration mechanism 109 may occur, and L2 is naturally limited by the size of the cross section of the airflow vibration mechanism 109 and the like. On the other hand, if L1 and L2 are too large, the effect of vibration of the filament 111 by the peripheral wall surface 109b of the airflow vibration mechanism 109 is reduced. Considering the above, L1 is preferably 30 mm or less, more preferably 15 mm or less, and most preferably 10 mm or less. L2 is preferably 80 mm or less, more preferably 55 mm or less, and most preferably 52 mm or less. However, the airflow vibration mechanism 109 needs to be disposed at a position where it does not collide with the filament 111.

Further, the swing width of the filament 111 (width S of the nonwoven fabric web 120) also depends on the flow velocity of the high-speed air flow and the rotation speed of the air flow vibration mechanism 109. When the fluctuation of the distance between the airflow axis 100 and the peripheral wall surface 109b due to the rotation of the airflow vibration mechanism 109 is the vibration of the peripheral wall surface 109b, there is a frequency of the peripheral wall surface 109b that maximizes the swing width of the filament 111. Other than this frequency, the vibration frequency of the peripheral wall 109b and the inherent frequency of the high-speed air flow are different, so that the swing width of the filament 111 is also reduced. This frequency varies depending on the spinning conditions, but when vibrating the filament 111 spun by a general spinning means, a range of 5 Hz to 30 Hz is preferable, more preferably 10 Hz to 20 Hz, and most preferably 12 Hz. The range is 18 Hz or less. The speed of the high-speed airflow is 10 m / sec or more, preferably 15 m / sec or more. This is because at a speed lower than this, the filament 111 may not be sufficiently shaken.

The length of the airflow vibration mechanism 109 is desirably 100 mm or more larger than the width of the filament group spun by the melt blow die 101. If the length of the airflow vibration mechanism 109 is shorter than this, the flow direction of the high-speed airflow cannot be sufficiently changed at both ends of the filament group, and the arrangement along the lateral direction of the filament 111 at both ends of the filament group is not possible. This is because there is a risk of becoming insufficient.

The non-woven web 120 on the conveyor belt 107 is conveyed by the conveyor belt 107 toward the front of the paper or toward the back of the paper, and then stretched 3 to 6 times in the lateral direction by a stretching device (not shown). In this way, a transversely aligned long fiber nonwoven fabric is produced. Examples of the stretching device include, but are not limited to, a pulley-type stretching device and a tenter stretching device. Note that the nonwoven fabric web 120 may be further subjected to post-treatment such as partial adhesion treatment such as heat treatment or hot embossing as necessary. In addition, the 1st manufacturing apparatus (FIG. 4) of a horizontal arrangement long fiber nonwoven fabric sprays mist-like water etc. in order to quench a filament similarly to the manufacturing apparatus (FIG. 3) of a longitudinal arrangement long fiber nonwoven fabric. A spray nozzle or the like may be provided.

FIG. 5 is a diagram showing a configuration of a main part of another example (hereinafter referred to as “second manufacturing apparatus”) of the apparatus for manufacturing the transversely long continuous nonwoven fabric. FIG. 5 (A) is a front view of the second apparatus for producing a horizontally arranged long fiber nonwoven fabric, and FIG. 5 (B) is a side view of the second apparatus for producing a horizontally arranged long fiber nonwoven fabric. As shown in FIGS. 5 (A) and 5 (B), the second device for producing a transversely long continuous nonwoven fabric includes a spinning head 210, a conveyor belt 219, a drawing device (not shown), and the like. 5A and 5B, the spinning head 210 is shown in a sectional view so that the internal structure can be seen. Moreover, in this manufacturing apparatus, the conveyor belt 219 is arrange | positioned below the spinning head 210, and is comprised so that it may drive | work in the arrow direction (left direction) in FIG. 5 (A).

FIG. 6 shows the spinning head 210. 6A is a cross-sectional view of the spinning head 210, and FIG. 6B is a view of the spinning head 210 as viewed from below.

The spinning head 210 includes an air ejection part 206 and a cylindrical spinning nozzle part 205 disposed inside the air ejection part 206. A spinning nozzle 201 that extends in the direction of gravity and opens at the lower end surface of the spinning nozzle portion 205 is formed inside the spinning nozzle portion 205. The nozzle hole diameter Nz of the spinning nozzle 201 can be arbitrarily set, and is, for example, 0.1 to 0.7 mm. The spinning head 210 is disposed above the conveyor belt 219 such that the spinning nozzle 201 is located approximately at the center in the width direction of the conveyor belt 219. The spinning nozzle 201 is supplied with molten resin from the upper side thereof by a gear pump (not shown) or the like, and the supplied molten resin is pushed downward from the lower opening end of the spinning nozzle 201 through the spinning nozzle 201. A filament 211 is formed (spun).

A concave portion having two

inclined surfaces

208a and 208b is formed on the lower surface of the air ejection portion 206. The bottom surface of the recess constitutes a horizontal plane 207 perpendicular to the direction of gravity. One slope 208a is disposed on one end side of the horizontal plane 207 in the running direction of the conveyor belt 219, and the other slope 208b is a conveyor. The belt 219 is disposed on the other side of the horizontal plane 207 in the traveling direction. The two

inclined surfaces

208a and 208b are arranged symmetrically with respect to a plane orthogonal to the horizontal plane 207 and passing through the center line of the spinning nozzle 201, and are formed to be inclined so that the distance from each other gradually increases. Has been.

The lower end surface of the spinning nozzle unit 205 is disposed so as to protrude from the horizontal surface 207 at the center of the horizontal surface 207 of the air ejection unit 206. The amount of protrusion H from the horizontal surface 207 at the lower end surface of the spinning nozzle portion 205 can be arbitrarily set, and is, for example, 0.01 to 1 mm. Further, an annular primary air slit 202 for ejecting high temperature primary air is formed between the outer peripheral surface of the spinning nozzle portion 205 and the air ejection portion 206. The outer diameter of the spinning nozzle portion 205, that is, the inner diameter d of the primary air slit 202 can be arbitrarily set, and is, for example, 2.5 to 6 mm. Although not shown in the drawing, in order to make the speed and temperature of the primary air ejected mainly from the primary air slit 202 uniform, at least a part of the clearance is 0.1 to 0.5 mm inside the spinning head 210. The high temperature primary air is supplied to the primary air slit 202 through the slit-shaped flow path.

High temperature primary air is supplied to the primary air slit 202 from above, and the supplied primary air passes through the primary air slit 202 at a high speed downward from the opening end on the horizontal plane 207 side of the primary air slit 202. Erupted. Thus, the primary air is ejected from the primary air slit 202 at a high speed, so that a reduced pressure portion is generated below the lower end surface of the spinning nozzle portion 205, and the filament 211 pushed out from the spinning nozzle 201 is vibrated by this reduced pressure.

Furthermore, the air ejection part 206 is formed with secondary

air ejection ports

204a and 204b for ejecting high temperature secondary air. The secondary air is ejected in order to spread and arrange the filaments 211 that vibrate by the primary air ejected from the primary air slit 202 in one direction. The secondary air outlet 204a is formed in the inclined surface 208a and extends perpendicularly to the inclined surface 208a toward the inside of the air ejection portion 206. Similarly, the secondary air jet outlet 204b is formed in the slope 208b, and extends perpendicularly to the slope 208b toward the inside of the air ejection portion 206. The

secondary air outlets

204 a and 204 b are arranged symmetrically with respect to a plane that is orthogonal to the horizontal plane 207 and that passes through the center line of the spinning nozzle 201. The diameter r of the

secondary air outlets

204a and 204b can be arbitrarily set, but is preferably 1.5 to 5 mm. In the present embodiment, the

secondary air outlets

204a and 204b are each formed in two, but the present invention is not limited to this, and the number of

secondary air outlets

204a and 204b can be arbitrarily set. .

Secondary air is jetted slightly downward from the horizontal direction from each of the secondary

air jet outlets

204a and 204b. The secondary air ejected from the secondary air ejection port 204a and the secondary air ejected from the secondary air ejection port 204b collide below the spinning nozzle 201 and spread in the width direction of the conveyor belt 219. . Thereby, the filament 211 falling while vibrating spreads in the width direction of the conveyor belt 219.

Also, a plurality of small holes 203 extending in parallel with the spinning nozzle 201 and opening in the horizontal plane 207 are formed on both sides of the spinning nozzle portion 205. The plurality of small holes 203 are arranged in a line on a straight line orthogonal to the center line of the spinning nozzle 201, and the same number (three in this case) is provided on each of the

secondary air outlets

204a and 204b side of the spinning nozzle unit 205. ) Is formed. The plurality of small holes 203 are configured to eject high-temperature air downward from the open end of the horizontal plane 207, thereby stabilizing the spinning of the filament 211. The diameter q of the small hole 203 can be arbitrarily set, but is preferably about 1 mm. The high-temperature air ejected from each small hole 203 may be guided from a primary air generation source for ejecting from the primary air slit 202, or may be ejected from the secondary

air ejection ports

204a and 204b. It may be derived from a source of secondary air. Alternatively, high-temperature air different from primary air and secondary air may be supplied to each small hole 203.

Furthermore, a pair of cooling nozzles 220 is provided between the spinning head 210 and the conveyor belt 219. In the present embodiment, one cooling nozzle 220 is disposed on the upstream side of the traveling direction of the conveyor belt 219 of the filament 211 spun from the spinning nozzle 201, and the other cooling nozzle 220 is spun from the spinning nozzle 201. The filament 211 is arranged on the downstream side in the traveling direction of the conveyor belt 219. Each cooling nozzle 220 sprays atomized water or the like on the filament 211 before reaching the conveyor belt 219, whereby the filament 211 is cooled and solidified. The number and arrangement of the cooling nozzles 220 can be set arbitrarily.

The solidified filaments 211 are arranged in the width direction of the conveyor belt 219 and accumulated on the conveyor bell 219, whereby a nonwoven web 218 in which a plurality of filaments 211 are arranged in the width direction is formed on the conveyor belt 219. Produced.

The nonwoven web 218 produced on the conveyor belt 219 is conveyed in the direction of the arrow in FIG. 5A by the conveyor belt 219, and then stretched 3 to 6 times in the lateral direction by the stretching device (not shown). The In this way, the transversely aligned long fiber nonwoven fabric is manufactured.

FIG. 7 shows a modification of the spinning head 210. 7A is a cross-sectional view of a spinning head 210 according to a modified example, FIG. 7B is a view of the spinning head 210 according to the modified example as viewed from below, and FIG. FIG. 8 is a cross-sectional view of a spinning head 210 according to a modified example in a direction perpendicular to FIG. 7A.

As shown in FIGS. 7A to 7C, in the spinning head 210 according to the modification, a plurality of small holes 203 are arranged so as to surround the spinning nozzle portion 205 (spinning nozzle 201) in a circle. . Each small hole 203 is formed to be slightly inclined with respect to the horizontal plane, and high temperature air is ejected from each small hole 203 in the direction of the arrow in FIG. The spinning of the filament 211 is also stabilized by ejecting high-temperature air from such a plurality of small holes 203.

As described above, the average fiber diameter of the filaments constituting the manufactured transversely arranged long fiber nonwoven fabric is 1 to 4 μm (preferably 2 to 3 μm). The variation coefficient of the fiber diameter distribution is 0.1 to 0.3. Moreover, the produced transversely arranged long fiber nonwoven fabric may have some elasticity in the fiber direction, that is, the axial direction of the long fiber filaments and the transverse direction which is the stretching direction. Moreover, the tensile strength in the transverse direction of the produced transversely arranged long fiber nonwoven fabric is 5 N / 50 mm or more, preferably 10 N / 50 mm or more, more preferably 20 N / 50 mm or more.

[Orthogonal array nonwoven fabric]
The orthogonally aligned non-woven fabric is basically formed by (1) laminating and fusing the vertically aligned long-fiber non-woven fabric and the transversely-aligned long-fiber non-woven fabric, and (2) One of them is formed by laminating and fusing by 90 °, or (3) One of the two transversely arranged long fiber nonwoven fabrics is laminated by fusing by 90 ° and formed by fusing Is done. However, the present invention is not limited to these. For example, (4) the longitudinally-aligned long-fiber nonwoven fabric, the basis weight is the same as that of the laterally-aligned long-fiber nonwoven fabric, and the average fiber diameter of the constituent fibers is that of the laterally-aligned long-fiber nonwoven fabric. It may be formed by laminating and fusing a larger laterally aligned long fiber nonwoven fabric. The fusion is not particularly limited, but is generally performed by thermocompression using an embossing roll or the like.

[Nonwoven fabric laminate]
The nonwoven fabric laminate is basically composed of a plurality of longitudinally aligned long fiber nonwoven fabrics stacked in the thickness direction, and a plurality of the horizontally aligned long fiber nonwoven fabrics stacked in the thickness direction, or a plurality The orthogonally arranged nonwoven fabrics may be stacked in the thickness direction. However, it is not restricted to these, The said nonwoven fabric laminated body may be comprised also by arbitrary combinations of the said longitudinally-arranged long-fiber nonwoven fabric, the said horizontal-arranged long-fiber nonwoven fabric, and the said orthogonally-arranged nonwoven fabric.

Hereinafter, the nonwoven fabric sound absorbing material according to the present invention will be described with reference to examples. However, the present invention is not limited to the following examples.

[Long fiber nonwoven fabric]
A longitudinally aligned long-fiber non-woven fabric was produced using the production apparatus shown in FIG. As the melt blow die, a nozzle having a nozzle diameter of 0.15 mm, a nozzle pitch of 0.5 mm, L / D (nozzle hole length / nozzle hole diameter) = 20, and a spinning width of 500 mm is used as a conveyor. It was arranged perpendicular to the belt running direction. Polyethylene terephthalate (CHUNG SHING TEXTILE CO., LTD.) Having an intrinsic viscosity IV of 0.53 and a melting point of 260 ° C. was used as the filament raw material (thermoplastic resin). The filament was extruded from the melt blow die at a discharge rate of 40 g / min per nozzle and a die temperature of 295 ° C. The high-speed airflow for reducing the diameter by drafting the filament extruded from the nozzle had a temperature of 400 ° C. and a flow rate of 0.4 m ³ / min. Further, the filament was cooled by spraying mist water from the spray nozzle. The air flow vibration mechanism was arranged so that the distance from the extension line of the nozzle of the melt blow die was a minimum of 20 mm. The airflow vibration mechanism was rotated at 900 rpm (frequency at the peripheral wall of the airflow vibration mechanism was 15.0 Hz), and the filaments were collected on the conveyor belt in a state of being arranged along the vertical direction. The filaments collected on the conveyor belt were heated with a drawing cylinder and drawn 4.5 times in the longitudinal direction to obtain a longitudinally arranged long fiber nonwoven fabric. Then, a longitudinally aligned long fiber nonwoven fabric having a basis weight of 5 to 40 g / m ² was obtained by appropriately changing the running speed of the conveyor belt. Here, a longitudinally aligned long fiber nonwoven fabric having a basis weight of 5 to 40 g / m ² was prepared, but a longitudinally aligned long fiber nonwoven fabric having a basis weight of up to 60 g / m ² was prepared by changing the running speed of the conveyor belt. It has been confirmed that it can be done.

The physical properties of the obtained longitudinally aligned long fiber nonwoven fabric are shown in FIG. Moreover, the fiber diameter distribution of the longitudinally-aligned long-fiber nonwoven fabric having a basis weight of 10 g / m ^{2 and} the longitudinally-aligned long-fiber nonwoven fabric having a basis weight of 20 g / m ² is shown in FIG. As shown in FIG. 9, in any longitudinally aligned long fiber nonwoven fabric, the mode value of the fiber diameter distribution was about 2.5 μm, and the average fiber diameter was also about 2.5 μm. Since only the running speed of the conveyor belt at the time of production is different, the mode value and the average fiber diameter of the fiber diameter distribution are almost the same as those in FIG. 9 for the longitudinally aligned long fiber nonwoven fabric having a basis weight of 5 to 60 g / m ² . It will be the same.

Example 1
A nonwoven fabric laminate obtained by stacking 100 vertically aligned long-fiber nonwoven fabrics having a basis weight of 15 g / m ² was defined as Example 1. Specifically, Example 1-1 is a nonwoven fabric laminate (non-compressed nonwoven fabric laminate, thickness: about 12 mm) in which only 100 longitudinally aligned long-fiber nonwoven fabrics having a basis weight of 15 g / m ² are stacked. A laminated body compressed in the thickness direction with respect to Example 1-1 (compressed nonwoven fabric laminated body, thickness: about 8 mm) was designated as Example 1-2.

(Example 2)
A nonwoven fabric laminate in which 200 longitudinally aligned long-fiber nonwoven fabrics having a basis weight of 15 g / m ² were stacked was designated as Example 2. Specifically, Example 2-1 is a nonwoven fabric laminate (non-compressed nonwoven fabric laminate, thickness: about 22 mm) obtained by simply stacking 200 longitudinally aligned long-fiber nonwoven fabrics having a basis weight of 15 g / m ^2. A laminated body compressed in the thickness direction with respect to Example 2-1 (compressed nonwoven fabric laminated body, thickness: about 14 mm) was designated as Example 2-2.

(Example 3)
A nonwoven fabric laminate in which a plurality of longitudinally aligned long fiber nonwoven fabrics having a basis weight of 20 g / m ² was stacked was designated as Example 3. Specifically, a nonwoven fabric laminate in which 50 vertically aligned long fiber nonwoven fabrics having a basis weight of 20 g / m ² were stacked was used as Example 3-1, and 100 vertically aligned long fiber nonwoven fabrics having a basis weight of 20 g / m ² were stacked. A nonwoven fabric laminate was designated as Example 3-2, and a nonwoven fabric laminate comprising 200 longitudinally aligned long fiber nonwoven fabrics having a basis weight of 20 g / m ² was designated as Example 3-3.

(Comparative example, reference example)
A commercially available non-woven acoustic material (manufactured by 3M, trade name “Synsalate”, TAI-2047, basis weight: 200 g / m ² , thickness: 10 mm) was used as a comparative example. Moreover, the nonwoven fabric laminated body which laminated | stacked 20 longitudinally-aligned long fiber nonwoven fabrics with a fabric weight of 20 g / m < ² > was made into the reference example.

[Sound absorption test]
Using a normal incident sound absorption coefficient measurement system WinZacMTX manufactured by Nippon Acoustic Engineering Co., Ltd., normal incident sound absorption coefficient defined in JIS A1405-2 for each of Example 1, Example 2, Example 3, Reference Example and Comparative Example Was measured. FIG. 10 shows the measurement results of the normal incident sound absorption coefficient of Example 1 and the comparative example, FIG. 11 shows the measurement results of the normal incident sound absorption coefficient of Example 2 and the comparative example, and FIG. The measurement result of the normal incidence sound absorption coefficient of a reference example and a comparative example is shown. Although the measurement results of the comparative example in FIGS. 10 and 11 and the measurement result of the comparative example in FIG. 12 are slightly different, this is due to measurement variations in the system.

As shown in FIG. 10, Example 1 (Examples 1-1 and 1-2) has a higher normal incident sound absorption coefficient than the comparative example in a predetermined frequency band of approximately 4000 Hz or less, and is shown in FIG. Thus, Example 2 (Examples 2-1 and 2-2) has a higher normal incident sound absorption coefficient than the comparative example in a predetermined frequency band of approximately 3000 Hz or less. Also, as shown in FIG. 12, Example 3 (Examples 3-1, 3-2, 3-2) has a higher normal incident sound absorption coefficient than the comparative example in a predetermined frequency band of approximately 2000 Hz or less. It was confirmed.

Further, as shown in FIGS. 10 to 12, it was confirmed that all of Examples 1 to 3 had a peak of normal incident sound absorption coefficient with a normal incident sound absorption coefficient of 50% or more at a frequency of 2000 Hz or less. . Specifically, Example 1 has a peak of the normal incident sound absorption coefficient that is 50% or more from 900 to 2000 Hz, and Example 2 has a normal incident sound absorption coefficient of 50% from 400 to 1000 Hz. It was confirmed that the peak of the normal incident sound absorption coefficient was as described above, and Example 3 had a peak of the normal incident sound absorption coefficient at a normal incident sound absorption coefficient of 50% or more at 300 to 2000 Hz.

Furthermore, as shown in FIG. 12, as the number of the longitudinally aligned long fiber nonwoven fabrics constituting the nonwoven fabric laminate (the number of laminated layers) increases, the peak of the normal incident sound absorption coefficient shifts to the low frequency side, and It was confirmed that a higher normal incidence sound absorption coefficient can be obtained in a narrower frequency range. Therefore, for example, by measuring the frequency of the sound to be absorbed in advance and adjusting the number of longitudinally aligned long-fiber nonwoven fabrics constituting the nonwoven fabric laminate according to the measured frequency, the optimum sound absorbing material is individually formed. It is also possible to do.

The sound absorbing material including the nonwoven fabric for sound absorbing material according to the present invention can be used in various places. For example, the sound absorbing material including the nonwoven fabric for sound absorbing material according to the present invention is used as a sound absorbing material for automobile engine rooms and a sound absorbing material for interiors, as a sound absorbing protective material for automobiles, home appliances, various motors, etc. Or as a sound absorbing material installed on the ceiling, etc., as a sound absorbing material for interiors of machine rooms, etc., as a sound absorbing material for various soundproof walls, and / or as a sound absorbing material for office automation equipment such as copying machines and multifunction devices. obtain.

51 Long-fiber nonwoven fabric 52 Non-woven fabric laminate 53 Packaging

Claims

A non-woven fabric laminate in which a plurality of long-fiber non-woven fabrics having a plurality of long-fiber filaments stretched and arranged along one direction are stacked, and the mode of fiber diameter distribution of the plurality of long-fiber filaments is 1 to Non-woven sound absorbing material at 4 μm.
The draw ratio of the plurality of long fiber filaments is 3 to 6 times, the average fiber diameter of the plurality of long fiber filaments is 1 to 4 μm, and the variation coefficient of the fiber diameter distribution of the plurality of long fiber filaments is 0. The sound absorbing material made of nonwoven fabric according to claim 1, wherein the sound absorbing material is 1 to 0.3.
The nonwoven fabric sound-absorbing material according to claim 1, wherein the basis weight of the long-fiber nonwoven fabric is 5 to 60 g / m 2 .
The specific volume of the long-fiber nonwoven fabric, which is a value obtained by dividing the thickness of the long-fiber nonwoven fabric by the basis weight of the long-fiber nonwoven fabric, is 2.0 to 3.5 (cm 3 / g). Non-woven sound absorbing material.
The nonwoven fabric sound-absorbing material according to claim 1, wherein a tensile strength of the long-fiber nonwoven fabric in the stretching direction of the plurality of long-fiber filaments is 20 N / mm or more.
The nonwoven fabric sound-absorbing material according to claim 1, wherein the long-fiber nonwoven fabric has an air permeability of 5 to 250 cm 3 / cm 2 / s.
The nonwoven fabric sound-absorbing material according to claim 1, wherein the nonwoven fabric laminate is formed by stacking 50 to 200 pieces of the long-fiber nonwoven fabric.
The nonwoven fabric sound-absorbing material according to claim 1, wherein there is a peak of the normal incident sound absorption coefficient at a frequency of 2000 Hz or less, and the normal incident sound absorption coefficient at the peak is 50% or more.
The nonwoven fabric sound-absorbing material according to claim 1, wherein each of the plurality of long fiber filaments is a long fiber filament mainly composed of polyester or polypropylene.
The nonwoven fabric sound absorbing material according to claim 9, wherein the polyester is polyethylene terephthalate having an intrinsic clay IV of 0.43 to 0.63.
The nonwoven fabric sound-absorbing material according to claim 1, wherein the long-fiber nonwoven fabric further includes a plurality of second long-fiber filaments that are stretched and arranged along a direction orthogonal to the one direction.