WO2009125742A1 - 複合吸音構造体 - Google Patents
複合吸音構造体 Download PDFInfo
- Publication number
- WO2009125742A1 WO2009125742A1 PCT/JP2009/057058 JP2009057058W WO2009125742A1 WO 2009125742 A1 WO2009125742 A1 WO 2009125742A1 JP 2009057058 W JP2009057058 W JP 2009057058W WO 2009125742 A1 WO2009125742 A1 WO 2009125742A1
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- WIPO (PCT)
- Prior art keywords
- sound absorbing
- skin layer
- layer
- absorbing structure
- flow resistance
- Prior art date
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- 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
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- 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
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- 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
- B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- 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
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- 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
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- 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
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- 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
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- 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
- B32B2509/00—Household appliances
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- 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
Definitions
- the present invention relates to a novel invention relating to a sound absorbing structure using a fibrous porous material.
- polyester fiber-based sound absorbing materials are the most commonly used as a base material.
- Glass wool has long been preferred as a fiber-based sound absorbing material
- polyester fiber-based sound absorbing materials have been used because of environmental problems, recycling, sound absorbing performance, work environment preservation, long-term durability, and the like.
- this polyester fiber-based sound absorbing material is treated with a non-woven fabric composed of polyester fibers to adjust the water repellency, durability, and sound absorbing properties, and the heat-melt material is heat-sealed to the base material layer. It is used by arranging the side surface on the sound incident side.
- flow resistance due to the base material layer and the skin layer is adjusted to provide sound absorption characteristics
- practical use such as strength, durability, processability, etc.
- sound absorption performance there are problems in terms of sound absorption performance as well, but in terms of sound absorption performance, there is a limit in trying to obtain higher sound absorption performance within a certain limited thickness. was there.
- porous materials such as glass wool and polyester fibers exhibit sound absorption properties because sound waves incident from the surface of the porous material vibrate air in a three-dimensionally formed interstice between fibers.
- viscous resistance is generated, and incident acoustic energy is consumed as heat energy, and as a result, it is the main sound absorption mechanism that reflected acoustic energy is suppressed.
- the unit area flow resistance is defined by the following equation from the velocity when a constant minute air flow V flows in the direction perpendicular to the surface of the material and the pressure difference between the two surfaces of the material.
- R ⁇ P / (V ⁇ d)
- ⁇ P Pressure difference between both sides of the material
- V Air flow rate per unit area [m 3 / (m 2 / sec)]
- d Thickness of sample (m)
- the flow resistance of the composite determines the sound absorption coefficient of the sound absorbing material.
- This flow resistance is a: of the porous material which is a base material layer Changing the density, b: changing the diameter or blending ratio of fibers constituting the porous material, c: changing the fiber characteristics constituting the porous material, d: non-woven fabric of the skin layer (for example, spunbond) It can be controlled by changing characteristics and specifications, but at present it can not be said that it is optimized in the prior art.
- the diameter of the single fiber constituting the nonwoven fabric of the skin layer is recommended to be 10 ⁇ m or less, preferably 5 ⁇ m or less (Japanese Patent No. 3494332).
- Japanese Patent No. 3494332 Japanese Patent No. 3494332
- it is easy to obtain the sound absorbing performance there are many extremely inconvenient aspects such as strength, durability, composite manufacture with the base material layer, and difficulty in handling on a processed surface (such as wrinkles) in practical use.
- a film structure may be inserted or formed between the surface layer and the base material layer, and the sound absorption performance in the middle and low frequency bands is considerable. Although it improves, on the other hand, the sound absorption performance in the high frequency band generally decreases, and it is not suitable for the purpose of improving the sound absorption performance in a wide frequency band from the middle and low frequency bands to the high frequency band.
- the present invention has been made in view of the prior art as described above, and its object is to use a non-woven fabric using a specific single fiber diameter, and a skin layer and polyester made of one or more non-woven fabric.
- a porous sound absorbing material in which the sound absorbing performance is further improved in a wide frequency band from low to high bands without complexing the fiber or the matrix layer mainly composed thereof and thickening the volume as a sound absorbing structure It is to provide at an appropriate cost.
- the first aspect of the present invention is a composite integration of a skin layer on which at least one non-woven fabric of a polymeric material such as polyester, polyethylene, nylon, etc. is laminated, and a matrix layer mainly composed of a porous polymer fiber material.
- the composite sound absorbing structure is characterized in that the unit area flow resistance of the composite of the skin layer and the base material layer is preferably 1 ⁇ 10 4 to 7 ⁇ 10 4 N ⁇ sec / m 4 .
- the polymer fiber-based porous material of the matrix layer is mainly made of polyester fibers, and the orientation of this material is either longitudinal orientation, transverse orientation, or irregular orientation.
- the polymer fiber-based porous material is a melt fiber having a melting point at 100 to 200 ° C. and one having a fiber diameter of 2 to 20 denier appropriately mixed to have an area density of 500 to 2500 g / m 2 integrally.
- a heat-molded product is exemplified, and the unit area flow resistance of the base material layer is 0.5 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 .
- the nonwoven fabric used for the skin layer has a cross-sectional shape of single fiber of circular or flat shape, equivalent single fiber diameter is 11 to 35 ⁇ m, and area density is 50 to 130 g / m 2 Or a single layer of non-woven fabric which is coated or transferred in advance, or two or more non-woven fabrics are laminated and heat-sealed to form a single-layer non-woven fabric.
- the unit area flow resistance of the skin layer is 3.5 ⁇ 10 5 to 7 ⁇ 10 6 N ⁇ sec / m 4 .
- the non-woven fabric is, of course, the same type but it is also possible to use different types.
- polyester, polyethylene or nylon having a basis weight of 20 to 120 g / m 2 is selected.
- the second composite sound absorbing structure of the present invention is characterized in that the first invention is further characterized, and it comprises an outer skin layer made of a non-woven fabric of a polymeric material and a matrix layer made of a porous polymer fiber material.
- a composite sound absorbing structure in which a skin layer of a non-woven fabric is disposed on the incident side of sound, and the skin layer is A non-woven fabric selected from polyester, polyethylene, and nylon with a cross-sectional shape of single fiber of circular or flat shape, equivalent single fiber diameter of 11 to 35 ⁇ m, and surface density of 50 to 130 g / m 2.
- a hot melt material selected from powdery or comb-like (network) shape of 20 to 120 g / m 2 and having a unit area flow resistance of 3 .5 ⁇ 10 5 to 7 ⁇ 10 6 N ⁇ sec / m 4, and the matrix layer is a polymeric fiber-based porous material mainly composed of polyester fibers, It is a base material layer having a unit area flow resistance of 0.5 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 , and a unit area flow resistance of the obtained composite is 1 ⁇ 10 4 to 7 ⁇ It is a composite sound absorbing structure adjusted to be 10 4 N ⁇ sec / m 4 .
- the skin layer is preferably formed by laminating two or more non-woven fabrics on which a hot melt material such as powdery or comb-like (reticulated) is previously applied or transferred on the back surface and integrated by heat fusion.
- the present invention is, for example, a polyester fiber-based sound absorbing material with good sound absorbing performance, which comprises a non-woven fabric to be a skin layer with a single fiber diameter of 11 ⁇ m or more, withstands practical use, and meets needs such as weight reduction and space narrowing.
- a polyester fiber-based sound absorbing material with good sound absorbing performance which comprises a non-woven fabric to be a skin layer with a single fiber diameter of 11 ⁇ m or more, withstands practical use, and meets needs such as weight reduction and space narrowing.
- the present invention can be applied in the field of (1), and can provide a sound absorbing material excellent in sound absorbing characteristics with a thickness reduced as much as possible.
- FIG. It is the schematic which shows the state which attached the sound absorbing material A to the rigid wall surface P.
- FIG. It is a perspective view showing the 1st example of the compound sound absorption structure of the present invention. It is a perspective view which shows the 2nd example of the compound sound absorption structure of this invention.
- (B) Composite sound absorbing structure having a skin layer formed by stacking two different non-woven fabrics It is a graph which shows the sound absorption performance of samples A and B. It is a graph which shows the sound absorption performance of sample A, B, C1. It is a graph which shows the sound absorption performance of sample B, BC, and BS. It is a graph which shows the sound absorption performance of sample B, C2, and D. It is a graph which shows the sound absorption performance of sample B, B25-3. It is a graph which shows the sound absorption performance of sample B25-2.
- Japanese Patent No. 3494332 has already been present as a sound absorbing material composed of the non-woven fabric of the skin layer and the matrix layer.
- the diameter of the single fiber constituting the skin layer is preferably 10 ⁇ m or less, preferably 5 ⁇ m or less.
- the fiber diameter is thin, the flow resistance is increased, so it can be said that the sound absorbing performance is relatively improved, but practically, the strength, the durability, the composite production with the base material layer, the processed surface
- the nonwoven fabric of the skin layer is composited with the base material layer by hot melt, the fiber diameter is small, and clogging easily occurs. For this reason, the sound absorption coefficient tends to decrease in the high tone range, and there is a problem that the data is easily changed by a small amount.
- the present invention is intended to provide a highly practicable structure as a sound absorbing material, and is excellent in practicality as a non-woven fabric of the skin layer, good in availability, and preferably inexpensive.
- the sound absorption characteristics can be greatly improved by applying a special method to the surface layer when composited with the base material layer, using a single fiber diameter of 11 to 35 ⁇ m, and a superior and inexpensive composite sound absorption It is possible to provide a structure.
- the main part of the technology of the present invention is a polyester fiber or a nonwoven fabric having a single fiber diameter of 11 to 35 ⁇ m which can withstand practical use, such as good strength, durability, processability and appearance as a skin layer. It is possible to obtain stable sound absorption characteristics from middle to low frequency bands to high frequency bands by devising a method of combining with a base material mainly composed of It is in.
- the flow resistance of the composite structure of the skin layer and the base material is 1 ⁇ 10 4 to 7 ⁇ 10 4 is N ⁇ sec / m 4, particularly draws excellent sound absorbing performance in a wide band, preferably the flow resistance of the complex 2 ⁇ 10 4 ⁇ 3.5 ⁇ 10 4 N ⁇ sec / m 4 It has been found that it is extremely effective to achieve the object to achieve the object, and the present invention has been made. As a sound absorbing material, the flow resistance when made into a composite is important, but even in that case, it is more effective to improve the sound absorbing performance by adjusting the flow resistance in the skin layer.
- the constituent material of the invention is mainly a polyester fiber material, which exhibits a novel, wide band and excellent sound absorbing performance, is highly practical in strength, durability, economy and the like, and is recyclable, environmental protection, safety And so on. The same effect can be obtained with other polymer fiber materials such as polyethylene and nylon.
- the basic configuration of the invention is a sound absorbing structure in which a skin layer (spun-bonded non-woven fabric) and a base material are heated and pressed through a hot melt material (hower-like, spider-like, etc.) to form a composite.
- the spunbonded nonwoven fabric constituting the skin layer is one having a single fiber diameter or an equivalent single fiber diameter of 11 to 35 ⁇ m, The practicality is particularly high around 15 ⁇ m. If the fiber diameter is 10 ⁇ m or less, it is thin, and wrinkles etc. are easily generated when combined with the base material layer, and handling and processability are not good, and if it exceeds 35 ⁇ m, the nonwoven fabric feels fluffy and the base material The rigidity after compounding with the layer is increased, and the adaptability becomes worse when being made to follow a curved surface part or the like.
- Flow resistance adjustment means 1 As a skin layer, a polymeric hot melt material with a basis weight (weight per unit area) of 20 to 120 g / m 2 is applied or transferred to the back of one spun bond nonwoven fabric and disposed on the base material layer, Heat and pressure are adjusted to adjust the integrated combined flow resistance to a desired value.
- Flow resistance adjustment means 2 Two or more spun bond non-woven fabrics are laminated as a skin layer, placed on a base material layer, heated and pressed, and integrated so that the flow resistance after combined becomes a desired value.
- the plurality of spunbonded nonwoven fabrics may have the same specifications or may have different specifications in combination.
- the number of two spunbond nonwoven fabrics on the top of the skin layer is a fiber whose cross section is circular (area density 100 g / m 2 , single fiber diameter 15 ⁇ m), and the second spunbond nonwoven fabric is a fiber
- Two different spunbond non-woven fabrics having a flat cross section area density 90 g / m 2 , equivalent single fiber diameter 14.5 ⁇ m) superimposed on a base material, heated and pressed, and composited; If the composite sound absorbing structure has a value of 2.7 ⁇ 10 4 N ⁇ sec / m 4 , excellent sound absorbing performance can be obtained in a wide frequency band.
- fiber diameters other than those specified in the present invention can be used as nonwoven fabrics other than the skin layer.
- FIG. 1 shows a state in which a sound absorbing material A made of a porous material is attached to a hard wall surface P.
- Reference numeral 1 denotes a skin layer
- 2 denotes a base material layer
- 3 denotes a hot melt material for integrating the two.
- the velocity of the air particles is maximum at 40 mm or more, so adjusting the flow resistance with the skin layer 1 up to about 40 mm thick is more viscous By the resistance, the conversion efficiency from acoustic reflection energy to heat energy becomes high, and the sound absorption performance can be efficiently enhanced.
- FIG. 2 is a sound absorbing material shown in FIG. 2, which is a single layer non-woven fabric used for the skin layer 1, that is, the cross section of single fiber is circular or flat.
- the hot melt material 3 is previously applied or transferred, and the flow resistance as the skin layer is a combination such that 3.5 ⁇ 10 5 to 7 ⁇ 10 6 N ⁇ sec / m 4 .
- the base material layer 2 is a non-woven fabric mainly composed of polyester fibers, and has a flow resistance of 0.5 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 .
- a hot melt material such as powdery or comb-like (mesh) shape is applied or transferred in advance to the back surface of the non-woven fabric, and the application or transfer amount is adjusted with a fabric weight of 20 to 120 g / m 2 It will be.
- the skin layer 1 and the base material layer 2 are stacked via the hot melt material 3, heated and pressed, and the two are thermally fused to form an integral composite, and the flow resistance as a composite is 1 ⁇ 10 4 It is a sound absorbing structure set to 7 to 10 ⁇ 10 4 N ⁇ sec / m 4 .
- the flow resistance may be adjusted to 2 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 .
- FIG. 3 a flow resistance of 0.5 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 .
- the back surface of a base material layer 2 made of a polymer fiber-based porous material and a non-woven fabric 1 having a single fiber with a circular or flat cross section and an equivalent single fiber diameter of 11 to 35 ⁇ m and a surface density of 50 to 130 g / m 2 2 or more sheets in the example shown in FIG. 3 (A), the same non-woven fabric as described in FIG. 2 is used).
- the flow resistance of the skin layer 1 is 3.5 ⁇ 10 5 to 7 ⁇ 10 6 N ⁇ sec / m 4 when the sheets (1a, 1b, 1c) are stacked and integrated by heat fusion into multiple layers. It is a non-woven fabric adjusted. Then, the two are stacked, heated and pressurized, and heat fusion integrated into a composite, so that the flow resistance as the composite is 1 ⁇ 10 4 to 7 ⁇ 10 4 N ⁇ sec / m 4 to increase the sound absorption coefficient. Sound absorption structure.
- the surface layer 1 is used on the sound incident side.
- non-woven fabrics it is also possible to use different types of non-woven fabrics as the skin layer 1, and the composite shown in FIG. 3B uses the same non-woven fabric 1a as the non-woven fabric described in FIG.
- an example 1d one having a flat cross section, an equivalent single fiber diameter of 11 to 35 ⁇ m, and an area density of 50 to 130 g / m 2 and using the same hot melt treatment on the back surface is used.
- Sound absorbing structure A composed only of matrix layer 2 (bulk density 44 kg / m 3 , thickness 35 mm, flow resistance 1 ⁇ 10 4 N ⁇ sec / m 4 ) composed of polyester fiber, and the product of the present invention Using a spunbond non-woven fabric (area density 100 g / m 2 ) 1 composed of a polyester fiber system having a single fiber diameter of about 15 ⁇ m, and applying a powdery hot melt material (20 g / m 2 basis weight) on the back side;
- the composite sound absorbing structure B (flow resistance: 1.5 ⁇ 10 4 N ⁇ sec / m 4 ) is shown in comparison with the base material layer 2 of (1) by overlapping, heating and pressurizing, and integrated.
- FIG. 4 is a graph showing the sound absorption performance of the two samples A and B described above. Even in the case of the product B of the present invention, even when using a polyester fiber non-woven fabric having a fiber thickness of 15 ⁇ m which is practically sufficient for single fiber diameter, it is appropriately treated and composited with an appropriate matrix layer 2 It proves that it is possible to obtain a large sound absorption performance if it is done.
- This sound absorbing performance is, for example, comparable to glass wool (bulk density 32 kg / m 3 , thickness 40 to 50 mm) which is normally used as a sound absorbing material.
- the sound absorption performance is shown by the measurement by the normal incidence method (ISO 10543 ⁇ 2).
- the powdery hot-melt material of sample B shown in FIG. 4 is doubled in weight (40 g / m 2 basis weight) and one sample of sample A is composited, and the flow resistance of the composite is 3
- the sound absorption performance of the composite sound absorption structure C1 with 2 ⁇ 10 4 N ⁇ sec / m 4 is shown by comparison, but the sound absorption performance in the middle and low frequency bands is significantly improved compared to Sample A. I understand.
- the flow resistance of the composite sound absorbing structure is 3 ⁇ 10 4 N ⁇ sec / m by the application amount of the hot melt material on the back surface.
- excellent sound absorption characteristics can be obtained in a wide frequency band.
- the flow resistance is further increased, it is also possible to shift to the low frequency side.
- the present invention demonstrates the superiority, flexibility, and applicability of the present invention which is extremely practical and still provides excellent sound absorption performance.
- the flow resistance of the composite sound absorption structure is adjusted.
- the skin layer 1 and the base material layer are more than inserting the spunbond non-woven fabric 1 (the same as the skin layer 1 of sample B and the same hot melt treatment) in the middle of the base material layer 2 even with almost the same flow resistance. It is shown that it is more effective to insert between the two and increase the flow resistance of the skin layer 1.
- sample BC is a composite sound absorbing structure in which the same spunbond nonwoven fabric as the skin layer is inserted in the center of the base material of sample B, and the flow resistance of the composite is 2.0 ⁇ 10 4 N ⁇ sec / m It was four .
- Sample BS is a composite sound absorbing structure in which the same spunbond non-woven fabric as the skin layer is inserted between the surface layer of sample B and the base material, and the two sheets are laminated, and the flow resistance of the composite is 2.2 ⁇ It was 10 4 N ⁇ sec / m 4 .
- the composite sound absorbing structure D is a structure in which four sheets of the same spunbond non-woven fabric are inserted and the flow resistance as the composite sound absorber is 3.9 ⁇ 10 4 N ⁇ sec / m 4. Although the performance is improved, the sound absorption coefficient in the band of 630 Hz or higher tends to decrease.
- the adjustment range of the flow resistance as a practical composite sound absorbing structure is 1 ⁇ 10 4 to 7 ⁇ 10 4 N ⁇ sec / m 4 , and 2 ⁇ 10 4 to improve sound absorbing performance in a wide band. It is desirable that the value be 3.5 to 10 4 N ⁇ sec / m 4 .
- the flow resistance may be adjusted in the range of 1 ⁇ 10 4 to 7 ⁇ 10 4 N ⁇ sec / m 4 . That is, the flow resistance is increased to improve the low frequency sound absorption performance, and the flow resistance is decreased to improve the high frequency sound absorption performance. This is true of the other method described above.
- an appropriate base material can be selected, and thereafter, the skin layer can adjust the flow resistance of the composite sound absorbing structure to provide a sound absorbing material having appropriate sound absorbing performance. became.
- Solid absorption test 4 In the sound absorption test 1, a composite sound absorption structure is formed by adjusting the flow resistance with the application amount of the hot melt material for compounding with the base material on the back surface of one spun bond nonwoven fabric forming the skin layer of the present invention In 2 and 3, two or more spunbond non-woven fabrics (on the back surface coated with a hot melt material) that form the skin layer are laminated on the base material to form a composite sound absorbing structure with flow resistance adjusted. In particular, if the flow resistance of the composite sound absorbing structure is adjusted to 2 ⁇ 10 4 to 3.5 ⁇ 10 4 N ⁇ sec / m 4 , excellent sound absorbing performance can be obtained in a wide range from low frequency band to high frequency band.
- the sample B according to the present invention which is an example of the present invention, is comparable to the commonly used glass wool (bulk density 32 kg / m 3 , thickness 40 to 50 mm).
- Composite sound absorbing structure sample B25-3 (flow resistance 2.6) obtained by overlapping the skin layer with three same spunbond nonwoven fabrics on the same base material (thickness 25 mm) as sample B by applying one of the methods described above Sound absorption performance equal to or higher than 10 4 N ⁇ sec / m 4 ) can be obtained, which can be said to show a great advantage of the present invention. This will be able to provide sound absorbing materials with a good space factor, and will also meet the needs of society.
- the flow resistance of the sample B25-3 and the sample B25-2 as a composite sound absorbing structure is adjusted to 2.6 ⁇ 10 4 N ⁇ sec / m 4 as the former, By adjusting the latter to approximately the same 2.7 ⁇ 10 4 N ⁇ sec / m 4 , the two can obtain approximately the same sound absorption performance (the latter slightly exceeds), and different spunbond nonwoven fabrics as the skin layer By combining the two, it is possible to provide a sound absorbing material which is even more superior to the sample B25-3 even with two spunbonded nonwoven fabrics. This not only excels in practical strength and sound absorption performance in a wide frequency band, but also contributes to economy.
- the material used in the present invention is excellent in recyclability and environment because both the skin layer and the base material use a polyester fiber system as a standard.
- the present invention can provide a highly practical sound absorbing material having a thin thickness, a wide band, and high sound absorbing performance as compared with the conventional porous sound absorbing material.
- the composite sound absorbing structure of the present invention is superior in weight reduction, recyclability, economy, environmental conservation, etc., and has high versatility, so it can be used in construction machinery, agricultural machinery, pneumatic machinery and other industries. It can be used in a wide range of fields, including civil engineering, such as fields, railways, roads, and various construction works, construction fields, and home appliances.
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Abstract
Description
R=ΔP/(V・d)
R:単位面積流れ抵抗[N・sec/m4 ]
ΔP:材料両面間の圧力差
V:単位面積当たりの空気流量[m3 /(m2/sec)]
d:試料の厚み(m)
(ポイント1)
発明の構成材料は、主としてポリエステル繊維系の材料であり、新規で、広帯域で優れた吸音性能が発揮され、強度、耐久性、経済性などで実用性が高く、リサイクル性、環境保全、安全性などの観点から選択されたものである。尚、ポリエチレン、ナイロンなど他の高分子繊維系の材料でも同様の効果をあげることが出来る。
発明の基本構成は、表皮層(スパンボンド不織布)と母材をホットメルト材(ハウダー状、くもの巣状など)を介して、加熱・加圧して、複合した吸音構造体である。
表面強度、耐久性、加工・製造のしやすさ、外観性など実用面から、表皮層を構成するスパンボンド不織布は、単繊維径あるいは等価単繊維径が11~35μmのものを用いるもので、15μm前後が特に実用性が高い。繊維径が10μm以下では、細く、母材層との複合の際にしわなどが出やすく、ハンドリングや加工性が良くなく、又、35μmを越えると、不織布にごわごわ感が出てきて、母材層との複合後の剛性が上がり、曲面部などへ沿わせる際に適応性が悪くなってしまう。
(ポイント3)のスパンボンド不織布を用いると、従来技術では、吸音性能上は不利になるといわれている点を、本発明では次の二つの手段で音の入射側に配する表皮層に手を打ち、母材を含めた複合吸音構造体として流れ抵抗を調整することで解決できることを発見し、その流れ抵抗を好ましくは2×104~3.5×104 N・sec/m4 位に調整すれば、広い周波数帯域で優れた吸音特性を有する複合吸音構造体を提供できることを実証した。
表皮層としてスパンボンド不織布一枚の裏に、目付け(単位面積あたりの重量)が20~120g/m2の高分子系ホットメルト材を塗布あるいは転写して、母材層の上に配し、加熱・加圧し、一体化した複合後の流れ抵抗が所望の値になるように調整する。
表皮層としてスパンボンド不織布を二枚以上複数枚重ね、母材層の上に配し、加熱・加圧し、一体化した複合後の流れ抵抗が所望の値になるように調整する。
複数枚のスパンボンド不織布は同じ仕様のものでも良いし、異なった仕様のものを組み合わせても良い。例えば、二枚でも、表皮層の一番上のスパンボンド不織布を繊維の断面が円形状のもの(面密度100g/m2、単繊維径15μm)とし、第二層目のスパンボンド不織布を繊維の断面を扁平状(面密度90g/m2 、等価単繊維径14.5μm)とした二枚の異なったスパンボンド不織布を母材に重ね、加熱・加圧し、複合したものであり、流れ抵抗が2.7×104N・sec/m4 である複合吸音構造体にすれば、広い周波数帯域で優れた吸音性能が得られる。尚、表皮層として複数枚の不織布を用いる場合、表皮層以外の不織布として本発明で特定される以外の繊維径を用いることができることは勿論である。
主として本発明の複合吸音構造体の吸音性能が有効であることを証明する。
本発明品Bにあって、単繊維径が15μmという実用上十分な繊維太さのポリエステル繊維系不織布を用いた場合でも、これを適切に処理し、かつ、適当な母材層2と複合化すれば、大きく吸音性能を出すことが可能であることを証明している。
この吸音性能は、例えば、標準的に吸音材として使われているグラスウール(かさ密度32kg/m3、厚さ40~50mm)に匹敵する。尚、吸音性能は、垂直入射法(ISO 10543・2)で計測したもので示した。
主として、音の入射側に一番近い表皮層1を二枚以上複数枚重ね、加熱・加圧して一体化した複合吸音構造体の吸音性能が有効であることを証明する。
更に、本発明の有効性を図7に示す。図4に示したサンプルBの広い周波数帯域の吸音特性を向上させるのに、サンプルBの表皮層1のスパンボンド不織布と母材層2との間に、同じスパンボンド不織布(裏面のホットメルト処理も同じ)を二枚挿入して重ね、加熱・加圧して複合吸音構造体C2とし、その流れ抵抗を2.9×104 N・sec/m4 としたものであるが、サンプルBよりさらに吸音性能が広い周波数帯域で飛躍的に向上していることが分かり、本発明の方法の有効性が実証されている。
吸音試験1では、本発明の表皮層を形成するスパンボンド不織布一枚の裏面に母材と複合するためのホットメルト材の塗布量で流れ抵抗を調整してなる複合吸音構造体とし、吸音試験2及び3では、表皮層を形成するスパンボンド不織布(裏面はホットメルト材を塗布)を二枚以上複数枚を母材に重ね、流れ抵抗を調整してなる複合吸音構造体としたが、いずれも複合吸音構造体としての流れ抵抗を特に2×104~3.5×104 N・sec/m4 に調整すれば、低周波数帯域~高周波数帯域まで広い帯域で優れた吸音性能が得られることを明らかにした。このことは、図8に示すように、標準的に使われているグラスウール(かさ密度32kg/m3、厚さ40~50mm)に匹敵する本発明の一例であるサンプルBでも、本発明で提案した手法の一つを適用して表皮層を同じスパンボンド不織布三枚をサンプルBと同じ母材(厚さ25mm)上に重ねて得た複合吸音構造体サンプルB25-3(流れ抵抗2.6×104N・sec/m4 )と同等以上の吸音性能を出せることになり、本発明の大きな利点を示すものといえる。これは、スペースファクターのよい吸音材を提供できることになり、社会のニーズにも応えることになる。
表皮層のスパンボンド不織布として、表皮一枚目に図8のサンプルB25-3と同じもの(面密度:100g/m2、単繊維径:円形状15μm)、二枚目に異なった仕様のスパンボンド不織布(面密度:90g/m2 、等価単繊維径:扁平形状14.5μm)を重ね、この二枚のスパンボンド不織布と、サンプルB25-3と同じ母材とで複合吸音構造体B25-2を形成した。図9に示すように、サンプルB25-3、サンプルB25-2の複合吸音構造体としての流れ抵抗は前者が2.6×104N・sec/m4 に調整してあるのに対して、後者もほぼ同じ2.7×104 N・sec/m4 に調整してあることにより、両者はほぼ同じ吸音性能(後者がやや上回っている)が得られ、表皮層として異種のスパンボンド不織布を組み合わせることで二枚のスパンボンド不織布でもサンプルB25-3をさらに上回る吸音材を提供できるのである。このことは実用面での強度、広い周波数帯域での吸音性能に優れるだけでなく、経済性でも貢献している。
本発明で用いる材料は、表皮層、母材とも標準的にはポリエステル繊維系を用いるので、リサイクル性、環境性にも優れている。
Claims (17)
- 高分子材料の不織布を1層以上重ねた表皮層と、高分子繊維系多孔質材料を主体とする母材層を、複合一体化したことを特徴とする複合吸音構造体。
- 表皮層に用いる不織布の高分子材料が、ポリエステル、ポリエチレン、又はナイロンである請求項1記載の複合吸音構造体。
- 母材層の高分子繊維系多孔質材料が、ポリエステル繊維である請求項1記載の複合吸音構造体。
- 母材層の高分子繊維系多孔質材料の配向は、縦配向、横配向、又は、不規則配向のいずれかである請求項1記載の複合吸音構造体。
- 母材層は、ポリエステル繊維を主体として、100~200℃に融点を有するメルトファイバーで繊維径が2~20デニールのものを適宜混合して、面密度を500~2500g/m2に一体に熱成型したものである請求項1記載の複合吸音構造体。
- 母材層の単位面積流れ抵抗が、0.5×104~3.5×104N・sec/m4 である請求項1記載の複合吸音構造体。
- 表皮層に用いる不織布は、単繊維の断面形状が円形状あるいは扁平状で、等価単繊維径が11~35μm、面密度が50~130g/m2 である請求項1記載の複合吸音構造体。
- 表皮層が、裏面にパウダー状、蜘蛛の巣状、又は網目状のホットメルト材を予め塗布あるいは転写した一層の不織布である請求項1記載の複合吸音構造体。
- 表皮層が、裏面にパウダー状、蜘蛛の巣状、又は網目状のホットメルト材を予め塗布あるいは転写した一層の不織布である請求項7記載の複合吸音構造体。
- 表皮層が、裏面にパウダー状、くもの巣状、又は網目状のホットメルト材を予め塗布あるいは転写した不織布を二枚以上複数枚重ね、熱融着したものである請求項1記載の複合吸音構造体。
- 表皮層が、裏面にパウダー状、くもの巣状、又は網目状のホットメルト材を予め塗布あるいは転写した不織布を二枚以上複数枚重ね、熱融着したものである請求項7記載の複合吸音構造体。
- 表皮層が、異種又は同種の不織布を用いたものである請求項11記載の複合吸音構造体。
- 表皮層の単位面積流れ抵抗が、3.5×105~7×106N・sec/m4 である請求項1記載の複合吸音構造体。
- 表皮層と母材層を複合一体化するホットメルト材として、目付けが20~120g/m2であるポリエステル、ポリエチレン、又はナイロンを用いる請求項1記載の複合吸音構造体。
- 表皮層と母材層との複合体の単位面積流れ抵抗が、1×104~7×104N・sec/m4 である請求項1記載の複合吸音構造体。
- 高分子材料の不織布からなる表皮層と、高分子繊維系多孔質材料からなる母材層とを、ホットメルト材を介して重ね合わせ、加熱・加圧し、熱融着して一体複合化し、不織布の表皮層が音の入射側に配される複合吸音構造体であって、
前記表皮層は、単繊維の形状が円形状あるいは扁平状で等価単繊維径が11~35μm、面密度が50~130g/m2 にあるポリエステル、ポリエチレン、及びナイロンから選ばれた不織布であり、その裏面に、目付けが20~120g/m2のパウダー状、蜘蛛の巣状、又は網目状としたポリエステル、ポリエチレン、及びナイロンから選ばれたホットメルト材を予め塗布あるいは転写して得られ、単位面積流れ抵抗が3.5×105~7×106 N・sec/m4 である表皮層であり、
前記母材層は、ポリエステル繊維を主体とした高分子繊維系多孔質材料であり、この多孔質材料の単位面積流れ抵抗が0.5×104~3.5×104 N・sec/m4 である母材層であり、
得られた複合体の単位面積流れ抵抗が1×104~7×104N・sec/m4 となるように調整したことを特徴とする複合吸音構造体。 - 表皮層が、裏面にパウダー状、くもの巣状、又は網目状のホットメルト材を予め塗布あるいは転写した二枚以上の不織布を重ね、熱融着により一体化した表皮層である請求項16記載の複合吸音構造体。
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JP2014529524A (ja) * | 2011-08-25 | 2014-11-13 | サン−ゴバンアドフォル | 熱及び音響快適性のための壁面被覆 |
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