KR101404579B1 - Sound-absorbing material for vehicle - Google Patents

Abstract

The present invention relates to a sound absorbing material for automobiles, which comprises a first sound absorbing layer composed of a fibrous material and a second sound absorbing layer composed of a fibrous material and absorbing noise in a low frequency band which is transmitted through the first sound absorbing layer .
The automotive sound absorbing material improves the sound absorption performance against noise in the high frequency band because the sound insulating layer is not formed between the first sound absorbing layer and the second sound absorbing layer as well as the sound absorbing performance against the noise in the low frequency band due to the formation of the second sound absorbing layer A sound absorbing material for automobiles capable of reducing indoor noise of a vehicle is provided.
In addition, since the first sound-absorbing layer and the second sound-absorbing layer of the automobile sound absorbing material are made of fibrous materials, it is possible to provide a sound absorbing material for automobiles that is not only lightweight but also easy to recycle.

Description

{SOUND-ABSORBING MATERIAL FOR VEHICLE}

The present invention relates to a sound absorbing material for automobiles, and more particularly to a sound absorbing material for automobiles, which comprises a first sound absorbing layer composed of a fibrous material and a first sound absorbing layer for absorbing noise and a second sound absorbing material for absorbing a low frequency band noise transmitted through the first sound absorbing layer Layer is not formed between the first sound-absorbing layer and the second sound-absorbing layer as well as the sound-absorbing performance against the noise in the low-frequency band, so that the sound-absorbing performance against the noise in the high-frequency band is improved, And a sound absorbing material for an automobile which is lightweight and easy to recycle.

The present invention comprises a first sound-absorbing layer composed of a fibrous material and absorbing noise, and a second sound-absorbing layer composed of a fibrous material and absorbing a low-frequency noise transmitted through the first sound-absorbing layer.

When driving a car, various noises are generated. The noise generated from the engine room and the noise caused by friction between the tire and the road surface are transmitted to the interior of the vehicle through the air.

In order to reduce noise transmitted to the room, a sound absorbing material for automobile interior is used, and it is applied to a dash isolation pad of a vehicle or a floor carpet, thereby reducing the noise of a vehicle interior .

In the case of a conventional sound absorbing material for a vehicle, a method of using a soft material as a sound absorbing layer and a hard material as a sound insulating layer according to a method of blocking noise, a method of using a hard material as a sound insulating layer between soft materials composed of a sound absorbing layer A method of inserting a thin film layer and a sound insulating coating layer between sound-absorbing layers constituted of fibrous materials, and the like have been used.

The first method is a sound absorbing layer which is composed of a soft material such as polyurethane and a sound insulating layer which is composed of hard materials such as PVC (Poly Vinyl Chloride), EVA (Ethylene Vinyl Acetate) and EPDM (Ethylene Propylene Diene M- However, there is a disadvantage in that the weight of the sound absorbing material is increased, the performance of the low frequency noise is lowered, and the recyclability due to the compounding of the materials is difficult to pollute the environment.

The second method is to use PVC (Poly Vinyl Chloride), EVA (Ethylene Vinyl Acetate), EPDM (Ethylene Propylene Diene M) as a sound insulating layer between the sound absorbing layer made of soft soft material such as polyurethane and the soft sound absorbing layer made of fibrous material -class) rubber is used, which is problematic in that it is difficult to recycle due to a high production cost, an increase in the weight of a sound absorbing material, a lack of barrier against low-frequency noise, and a complex composition of materials .

A third method is to solve this problem by inserting a thin film layer and a sound insulating coating layer between a first sound absorbing layer and a second sound absorbing layer which are made of fibrous materials and bonding the first sound absorbing layer and the second sound absorbing layer to each other The sound absorption effect of the low frequency band is deteriorated due to the film layer and the sound insulation coating layer formed between the sound absorption layers.

An object of the present invention is to provide a sound absorbing material for automobiles, which has breathability between a first sound-absorbing layer and a second sound-absorbing layer and is excellent in sound-absorbing performance against noise in a low-frequency band.

Another object of the present invention is to provide a sound absorbing material for automobiles which is composed of a fibrous material and which is light in weight and easy to be recycled, with the first sound-absorbing layer and the second sound-absorbing layer.

An object of the present invention is attained by providing a sound absorbing material for a vehicle, which comprises a first sound-absorbing layer and a second sound-absorbing layer which are different in surface density and thickness from each other. For example, the second sound absorbing layer consisting of the first sound absorbing layer and the first sound absorbing layer textile merchandise in is formed in the top surface 100 to the area density of 1600g / m ² consisting of textile merchandise 400 to the area density of 2400g / m ² . The method of bonding the first sound-absorbing layer and the second sound-absorbing layer is selected from the group consisting of flame bond, polyethylene powder bond, web film bond and needle punch bond.

According to a preferred feature of the present invention, the fibrous material comprises 60 to 80 parts by weight of polyester-based fibers, 60 to 80 parts by weight of meshes and 20 to 40 parts by weight of low-melting-point polyester fibers. The fibrous material may be at least one selected from the group consisting of a carding laid method and an air laid method.

According to a further preferred feature of the present invention, the flame coupling is performed by applying a flame to one surface of the first sound-absorbing layer or the second sound-absorbing layer, which is made of thermoplastic fiber, to melt a part of the surface, And the first sound-absorbing layer and the second sound-absorbing layer are bonded to each other by passing through a compression roller.

According to a more preferred feature of the present invention, the polyethylene powder bonding is performed by scattering polyethylene powder on one surface of the first sound-absorbing layer or the second sound-absorbing layer, passing the same through an oven to melt the polyethylene powder, And then the first sound-absorbing layer and the second sound-absorbing layer are bonded to each other by passing through the pressing roller.

According to a further preferred feature of the invention, the web film combination is inserted into a net-like web film consisting of a hot-melt composition of the melt temperature below 120 between the first sound absorbing layer and second sound absorbing layer below the surface density 1200g / m ² And then passing through a belt-type oven capable of applying a predetermined pressure, thereby bonding the first sound-absorbing layer and the second sound-absorbing layer.

According to a still further preferred feature of the present invention, the needle punching coupling is performed by laminating the first sound-absorbing layer manufactured using the carding lay method on the second sound-absorbing layer manufactured using the carding lay method, the first sound-absorbing layer and the second sound-absorbing layer are bonded to each other between the fibrous materials constituting the second sound-absorbing layer by a needle-punching process.

According to an even more preferred feature of the invention, said polyester-based fibers comprise polyester fibers having a fineness of 3 to 15 denier and a group of hollow polyester fibers having a fineness of 15 to 40% with a fineness of 3 to 15 denier As shown in Fig.

According to a still further preferred feature of the present invention, the above-mentioned disposable fiber is a fiber for reusing scraps generated in the process of manufacturing parts such as fabric and non-woven fabric, and may be polyester fiber, nylon fiber, acrylic fiber, cotton fiber, wool fiber, And a silk fiber.

The sound absorbing material for automobiles according to the present invention secures the air permeability between the first sound absorbing layer and the second sound absorbing layer and exhibits an excellent sound absorbing performance against the noise in the low frequency band.

Another object of the present invention is to provide a sound absorbent article comprising a first sound absorbing layer and a second sound absorbing layer made of a fibrous material and being light in weight and easy to be recycled.

1 is an exploded perspective view showing a sound absorbing material for a vehicle according to an embodiment of the present invention.
FIG. 2 is a side view of a sound absorbing material manufactured by a flame-joining method according to a first embodiment of the present invention, on which a flame is applied and a sound absorbing material is bonded.
3 is a side view of a sound absorbing material manufactured by the polyethylene powder bonding method of Example 2 of the present invention, on which a polyethylene powder is scattered and a sound absorbing material is bonded.
FIG. 4 is a side view of a surface and a sound absorbing material to which a web film is applied to a sound absorbing material for automobile manufactured by the web film bonding method according to the third embodiment of the present invention.
5 is a side view of a bonded sound absorbing material manufactured by a needle punching method according to a fourth embodiment of the present invention.
6 is a graph showing sound absorption performance of a sound absorbing material for automobile manufactured through Examples 1 to 4 and Comparative Example 1 through a sound absorption rate test.

Hereinafter, preferred embodiments of the present invention and physical properties of the respective components will be described in detail with reference to the accompanying drawings. However, the present invention is not limited thereto, And this does not mean that the technical idea and scope of the present invention are limited.

The sound absorbing material for automobiles of the present invention comprises a first sound absorbing layer 10-1, 10-2, 10-3, 10-4 made of a fibrous material and a first sound absorbing layer 10-1, 10-2, 10- And second sound-absorbing layers 20-1, 20-2, 20-3, and 20-4 formed on the upper surface of the first sound-absorbing layers 10-1, 10-2, 10-3, and 10-4 and the second sound-absorbing layer 20-1, 20-2, 20-3, and 20-4 are formed by flame bonding, polyethylene powder bonding, And a punching bond.

The first sound-absorbing layers 10-1, 10-2, 10-3, and 10-4 manufactured by the above-described method primarily absorb noise introduced into a vehicle interior, and the second sound-absorbing layers 20-1 20-2, 20-3, and 20-4 can absorb noise in a low frequency band transmitted through the first sound absorbing layers 10-1, 10-2, 10-3, and 10-4, And finally absorb the noise.

The surface density of the fibrous material of the first sound-absorbing layer and the fibrous material of the second sound-absorbing layer are different from each other, and preferably, the surface density of the fibrous material of the first sound-absorbing layer is larger than the surface density of the fibrous material of the second sound-

For example, the first sound absorbing layer (10-1, 10-2, 10-3, 10-4) is formed of a fiber of the overburden 400 and surface density of 2400g / m ^2, said first sound absorbing layer (10-1, 10-2, 10-3, 10-4) of the second sound absorbing layer (20-1, 20-2, 20-3, 20-4) is from 100 to area density of 1600g / m ² formed on the top surface fiber merchandise And preferably the area density of the first sound-absorbing layer is higher than the area density of the second absorption layer.

The web loaded with binding when to combine the two layers into the first sound-absorbing layer when to surface density of the textile merchandise in the two layers are bonded to 1200g / m ² or less, needle punching the fibers merchandise having a surface density of 400 ~ 1600 / m ^2, The second sound-absorbing layer is preferably a fibrous material having a surface density of 100 to 1600 / m ² . In both cases, the area density of the first sound-absorbing layer is preferably higher than the area density of the second absorbing layer.

Further, the two sound-absorbing layers have different thicknesses, the first sound-absorbing layer has a thickness of 10 to 25 mm, and the second sound-absorbing layer has a thickness of 2 to 10 mm.

At this time, the flame bond is formed by melting a part of the surface by applying a flame to one surface of the first sound-absorbing layer 10-1 or the second sound-absorbing layer 20-1 made of the thermoplastic fiber, 1) and the second sound-absorbing layer 20-1 are put together and then passed through a pressing roller so that the first sound-absorbing layer 10-1 and the second sound-absorbing layer 20-1 are combined to form a low- And plays a role of improving sound absorption performance against noise.

The polyethylene powder may be formed by scattering polyethylene powder on one surface of the first sound-absorbing layer 10-2 or the second sound-absorbing layer 20-2, passing the same through an oven, melting the polyethylene powder, The first sound-absorbing layer 10-2 and the second sound-absorbing layer 20-2 are stacked while being opposed to each other and then passed through a compression roller so that the first sound-absorbing layer 10-2 and the second sound- 2) to improve the sound absorption performance against the noise of the low frequency band.

In addition, the film web is combined area density 1200g / m ² or less of the first sound absorbing layer (10-3) and a second sound-absorbing layer (20-3) to the melting temperature of the mesh type made of a hot-melt composition of less than 120 ℃ web between the After the film is inserted, the first sound-absorbing layer 10-3 and the second sound-absorbing layer 20-3 are coupled with each other through a belt-type oven capable of applying a predetermined pressure, so that the sound- .

In addition, the needle punching may be performed by laminating the first sound-absorbing layer 10-4 manufactured by the carding lay method on the second sound-absorbing layer 20-4 manufactured using the carding lay method, The fiber material constituting the first sound-absorbing layer 10-4 is bonded between the fibrous materials constituting the second sound-absorbing layer 20-4 by the needle-punching process to form the first sound-absorbing layer 10-4 ) And the second sound-absorbing layer (20-4) to improve the sound-absorbing performance against noise in the low-frequency band.

The fibrous material is composed of 60 to 80 parts by weight of polyester-based fibers, 60 to 80 parts by weight of miscellaneous fibers and 20 to 40 parts by weight of low-melting-point polyester fibers. When forming the web, at least one method selected from the group consisting of a carding laid method and an air laid method is used. However, when needle punching is used, the web is formed only by the carding laid method as described above. When a web is formed by an airlaid process, it is impossible to manufacture a product using needle punching. Further, when needle punching is used, the length of the fibers is preferably 50 to 100 mm. When the fiber length is less than 50 mm, the generation of dust is serious, resulting in deterioration of workability and deterioration of the physical properties of the sound absorbing material. If the fiber length is 100 mm or more, the fibers are dried on the carding wire during carding operation, .

In case of using other joining methods such as joining of other web films, a web can be formed by using one of the two methods or both of the two methods, and the formed webs are formed into a felt- In such a felt, a low melting point polyester fiber is partially melted in the process of manufacturing a sound absorbing material for automobiles, thereby bonding the fibers together.

The polyester-based fibers are composed of polyester fibers having a fineness of 3 to 15 denier and hollow polyester fibers having a fineness of 15 to 40% with a fineness of 3 to 15 denier, The hollow polyester fibers serve to lighten the weight of the sound absorbing material for automobiles and increase the sound absorption rate.

The above-mentioned meshed fiber is a fiber for reusing scraps generated in the process of manufacturing parts such as fabric and non-woven fabric, and may be selected from the group consisting of polyester fiber, nylon fiber, acrylic fiber, cotton fiber, wool fiber, hemp fiber and silk fiber , Which reduces the manufacturing cost of the sound absorbing material for automobiles and increases the sound absorption rate.

Hereinafter, a sound absorbing material for automobiles according to the present invention will be described by way of examples.

≪ Preparation Example 1 &

70% by weight of polyester fiber and 30% by weight of low-melting-point polyester fiber were mixed to form a first sound-absorbing layer 10-1, 10-2, 10 with a thickness of 25 mm and a surface density of 1200 g / m ² by applying a carding laid method -3, 10-4).

≪ Preparation Example 2 &

(20-1, 20-2, 20) having a thickness of 7 mm and a surface density of 1000 g / m < ² > by applying a carding laid method by mixing 70 parts by weight of a polyester fiber and 30 parts by weight of a low- -3, 20-4).

≪ Example 1 >

A part of the surface was melted by applying a flame to one surface of the second sound-absorbing layer 20-1 manufactured in Production Example 2, and the first sound-absorbing layer 10-1 produced in Production Example 1 was melted by the second sound- 1), and then passed through a compression roller set at a pressure of 5 kgf / cm ² to bond the first sound-absorbing layer 10-1 and the second sound-absorbing layer 20-1 after the atmosphere temperature at 180 ℃ with the set preheat oven molding conditions of preheating, which was transferred to a preheated sound-absorbing material with a cold press to compression molding for 60 seconds at a pressure of 80kgf / cm ² for 140 seconds for the automobile sound-absorbing material for a thickness of 20mm .

≪ Example 2 >

The polyethylene powder was scattered on one surface of the second sound-absorbing layer 20-2 prepared in Production Example 2, and then passed through an oven set at an ambient temperature of 150 to melt the polyethylene powder. by the sound-absorbing layer (10-2) passing through the second sound absorbing layer (20-2) of the polyethylene powder is a laminate process butted against each other on one side and then set at a pressure of 5kgf / cm ^2, the pressure roller of the first sound absorbing layer (10 -2) and the second sound-absorbing layer 20-2 were bonded to each other. Thereafter, a sound absorbing material for automobile having a thickness of 20 mm was produced under the molding conditions of Example 1.

≪ Example 3 >

A mesh-like structure made of a polyamide-based hot-melt component having a melting temperature of 120 ° C was prepared between the second sound-absorbing layer (20-3) prepared in Production Example 2 and the first sound-absorbing layer (10-3) after inserting the film web is passed through the oven of the belt type is set to the ambient temperature 200 ± 10 ℃ and pressure of 10kgf / cm ^2, the first sound absorbing layer (10-3) and the second sound absorbing layer 20-3 Lt; / RTI > Thereafter, a sound absorbing material for automobile having a thickness of 20 mm was produced under the molding conditions of Example 1.

<Example 4>

The first sound-absorbing layer 10-4 prepared in Production Example 1 was laminated on the second sound-absorbing layer 20-4 manufactured in Production Example 2, and then a needle having a needle density of 65.3 p / cm ² and a needle depth of 9.0 mm The fiber material constituting the first sound-absorbing layer 10-4 is bonded between the fibrous materials constituting the second sound-absorbing layer 20-4 by the needle-punching process to form the first sound-absorbing layer 10-4 ) And the second sound-absorbing layer (20-4). Thereafter, a sound absorbing material for automobile having a thickness of 20 mm was produced under the molding conditions of Example 1.

&Lt; Comparative Example 1 &

An adhesive film composed of three layers of polyethylene / polyamide / polyethylene was inserted between the second sound-absorbing layer prepared in Preparation Example 2 and the first sound-absorbing layer prepared in Production Example 1, and then the temperature was raised to 200 占 폚 and 10 kgf / cm ² through the belt-type oven to bind the first sound-absorbing layer and the second sound-absorbing layer. Thereafter, a sound absorbing material for automobile having a thickness of 20 mm was produced under the molding conditions of Example 1.

In order to confirm the sound absorbing effect of the sound absorbing material manufactured by Examples 1 to 4 and Comparative Example 1, take a specimen of 840 mm × 840 mm in width and measure the sound absorption rate of the reverberation room SRC, and Semi Reverberation Chamber) method are shown in Table 1 below.

Frequency
(Hz) 200 500 800 1000 1600 2000 2500 3150 4000 5000 6300 8000 10000 Example 1 0.19 0.58 0.76 0.88 0.92 0.90 0.88 0.90 0.96 1.01 1.06 1.18 1.08 Example 2 0.20 0.57 0.80 0.86 0.90 0.89 0.86 0.91 0.96 0.99 1.08 1.15 1.05 Example 3 0.18 0.59 0.81 0.88 0.92 0.88 0.90 0.92 0.97 1.02 1.10 1.14 1.01 Example 4 0.17 0.56 0.78 0.86 0.91 0.92 0.89 0.92 0.94 1.02 1.05 1.17 1.02 Comparative Example 1 0.10 0.22 0.37 0.50 0.58 0.70 0.76 0.79 0.83 0.88 0.90 1.04 0.94

As shown in Table 1 above, the sound absorbing material for automobile manufactured through Examples 1 to 4 of the present invention is superior to the sound absorbing material for automobile manufactured by Comparative Example 1 in sound absorption performance in all frequency bands, The sound absorbing effect is superior.

10-1, 10-2, 10-3, 10-4; The first sound-
20-1, 20-2, 20-3, 20-4; The second sound-

Claims (10)

Made of a textile merchandise, from 400 to 2400g / m ² of the first sound absorbing layer thickness represents the area density of 10 ~ 25mm (10-1, 10-2, 10-3, 10-4); And
A second sound-absorbing layer (20-1, 20-2, 20-3, 20-4) having a thickness of 2 to 10 mm and formed of a fibrous material formed on the upper surface of the first sound-absorbing layer and having a surface density lower than that of the first sound- ), &Lt; / RTI &gt;
Wherein the fibrous material comprises 60 to 80 parts by weight of polyester-based fibers, 60 to 80 parts by weight of meshes and 20 to 40 parts by weight of low-melting-point polyester fibers,
Wherein the polyester-based fibers are made of hollow polyester fibers having a hollow ratio of 15 to 40%.
delete delete delete The method according to claim 1,
The above-mentioned disposable fiber is a fiber for reusing scrap generated in the process of manufacturing parts such as fabric and non-woven fabric, and may be at least one selected from the group consisting of polyester fiber, nylon fiber, acrylic fiber, cotton fiber, wool fiber, hemp fiber and silk fiber And the sound absorbing material for automobile. The method according to claim 1,
A part of the surface is melted by applying a flame to one surface of the first sound-absorbing layer 10-1 or the second sound-absorbing layer 20-1 made of the thermoplastic fiber, and the first sound-absorbing layer 10-1 and the second Wherein the first sound-absorbing layer (10-1) and the second sound-absorbing layer (20-1) are coupled by a flame coupling that passes through the compression roller after the sound-absorbing layer (20-1) Sound absorbing material. The method according to claim 1,
Polyethylene powder is scattered on one surface of the first sound-absorbing layer 10-2 or the second sound-absorbing layer 20-2 and then melted through the oven to melt the polyethylene powder, and the first sound-absorbing layer 10 The first sound-absorbing layer 10-2 and the second sound-absorbing layer 20-2 are formed by the polyethylene powder bonding the second sound-absorbing layer 20-2 and the second sound- And a sound absorbing material for a vehicle. The method according to claim 1,
A web-shaped web film made of a hot melt component having a melting temperature of 120 ° C or less was inserted between the first sound-absorbing layer (10-3) and the second sound-absorbing layer (20-3) having a surface density of 1200 g / m ² or less, Wherein the first sound-absorbing layer (10-3) and the second sound-absorbing layer (20-3) are coupled to each other by a web film which passes through a belt-type oven capable of applying a sound. The method according to claim 1,
The first sound-absorbing layer 10-4 manufactured by the carding-lay method is laminated on the second sound-absorbing layer 20-4 manufactured using the carding laid method, and then subjected to a needle-punching process The first sound-absorbing layer 10-4 and the second sound-absorbing layer 10-4 are bonded to each other by needle punching coupling the fiber material constituting the first sound-absorbing layer 10-4 between the fibers constituting the second sound- And the second sound-absorbing layer (20-4) is bonded to the second sound- The method of claim 9,
Wherein a fiber length of the fiber material is 50 mm to 100 mm.

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