KR20030000746A - a sound absorbing and insulation material for automobile - Google Patents

Abstract

PURPOSE: Provided is a sound absorbing material for a car, which improves sound absorption power and a working condition, reduces production cost and is capable of decreasing the weight of the car. CONSTITUTION: The sound absorbing material for the car is comprised of a soft layer having low density and a hard layer having high density. An upper layer(11), the soft layer is comprised of 30-50% of PET regular type, 20-50% of PET modified cross-section rectangular type and 20-30% of one selected from the group containing PE/PE, PET/PP, PET/PA and PET/converted PET(sheath-core type binder fiber having low melting point). A middle layer(12) is comprised of 50-60% of PET having a modified cross-section, 10-30% of conjugate hollow type fiber and a binder fiber. A bottom layer(13) is comprised of 30-50% of PET regular type fiber, 40-50% of PET modified cross-section rectangular type and 20-30% of one selected from the group containing PET/PE, PET/PP, PET/PA and PET/converted PET.

Description

Sound absorbing and insulating material for automobiles

The present invention relates to a sound absorbing and insulating material for automobiles.

In particular, the sound absorbing and insulating material for automobiles according to the present invention is composed of PET (Polyester staple fiber) fiber and analyzes the sound absorbing and sound insulating performance by frequency domain by NVH (Noise, Vibration, Hashness) technology. It is to provide a sound absorbing and insulating material produced in a multi-layer structure.

Various sound absorbing and insulating materials are attached to each part of the car body, and the sound absorbing and insulating material absorbs the noise by its own physical characteristics and the sound insulation function that blocks the noise generated in the engine room or the power transmission system of the vehicle, and the noise penetrates into the vehicle. It is installed to prevent the sound absorbing and insulating design is one of the very important elements in the design of the vehicle.

The most important point in the design of sound absorbing and soundproofing of the vehicle is the most suitable material for the right place. It is very important to install the sound absorbing and soundproofing material with good sound absorbing and soundproofing. Can not.

Sound absorbing and insulating materials that have been used in the past include miscellaneous fiber felt, resin felt, wood fiber or woodstock mat, foamed urethane, PET FELT, etc. Except foamed urethane, these felts are generally PET fiber, cotton, recycled fiber , By mixing a certain amount of low-melting binder fibers with wood fibers, etc., into a single sheet, or when laminating them in two or three layers, they are attached to each other by applying an adhesive to a separate sheet, or thermoforming or needle punching by phenolic resin. It is formed by the method.

In addition, resin felt and wood felt use thermosetting resin phenolic resin as heat adhesive, which not only causes harmful pollution to the human body due to dust, gas and odor generated in the manufacturing process, but also reduces pleasant environment and noise in the cabin. For NVH performance is significantly lower, and also in the case of foamed urethane is not only expensive and can not be recycled there was a problem causing serious environmental pollution.

In addition, PET felt, which is a conventional technology, does not use various kinds of characteristics of polyester fiber, but instead adjusts the mixing ratio uniformly to make the sheet in a simple mixed form. There was a limit to achieving this.

The present invention, which has improved the above problems, is due to the multilayer structure of the soft layer and the hard layer by the high density layer and the low density layer, and the sound absorbing performance is superior to the conventional sound absorbing and insulating material, and the working environment is made of polyester fiber having excellent recycling of materials. An object of the invention is to provide a sound absorbing and insulating material for automobiles.

1 is a cross-sectional view showing a PET laminated structure according to an embodiment of the present invention.

Figure 2 is a cross-sectional view of the sound insulation plate attached to the PET laminated structure according to the present invention.

Figure 3 is a cross-sectional view showing the PET Fiber type used in the present invention

Figure 4 is a process chart drawn PET FELT manufacturing process of the present invention.

5 is an embodiment according to the present invention.

(a) shows a process of sequentially laminating by three molding machines,

(b) is an expanded sectional view which shows the structure of the 3-layer laminated body which concerns on this invention.

Figure 6 is a mold apparatus for bonding the PET FELT and Heavy Layer according to the present invention

* Explanation of symbols for main parts of the drawings

10: PET laminate 11: top layer

12: middle layer 13: bottom layer

20: Cover 25: Heavy Layer

30: upper mold 31: lower mold

PET (Polyester staple fiber) fiber used to achieve the above object is a single-sided cross-section yarn, conjugated yarn (in the range of 8 to 50% of the porosity), cis core-type low-melting binder fibers according to the predetermined fineness and length It is used by mixing at a certain ratio, and it is divided into high density layer and low density layer by varying the distribution according to the characteristics of each type, and is characterized by consisting of a WEB laminate having a multilayer structure.

The cross-section of the fiber used in the present invention is a heterogeneous cross section, such as a flat rectangle, a star shape, a peanut shell shape, including a general circular or elliptical cross-section, and fineness of 0.7 to 6 denier or less in order to maximize the surface area. As a component of the fiber, a bicomponent hollow type conjugate fiber including a mono-type regular type was used, but a hollow amount of 10 to 50% was mixed in a predetermined amount within a range of 30%. Such fibers have been generalized as a well-known fact, but in the present invention, the soft distribution and soft layer by the low density layer and the high density layer are used in the present invention so that the softness due to the hollow structure of the fiber itself and the noise absorption due to the valky properties and the resonance phenomenon are maximized. It is configured to be divided into layers to form WEB laminates so that the frictional resistance derived from acoustic disturbance of incident sound is converted from the sound energy to the heat energy to the maximum. The sound characteristics of the vehicle are analyzed and the low density layer and It is characterized in that it can be configured as a WEB laminate having a two-layer structure of a high density layer or a three-layer structure having a low density, high density, high density order, or high density, low density, high density order.

In addition, the low-melting binder fiber used to bond the WEB laminate has a bicomponent composed of mono-type PP or Cisco-type PET / PE, PET / PP, PET / PA, PET / modified PET, among those having a melting point in the range of 80 to 180 ° C. A bicomponent type of fineness of 2-10 denier was selectively used within the range of 15-50% of the total mixing ratio, and the length of these fibers is usually 30-76 mm.

In addition, the manufacturing process of the present invention comprises the steps of combining the WEB laminate composed of a soft layer and a hard layer by a high density layer and a low density layer by varying the WEB laminated by fiber characteristics;

The sound insulation plate sheet called Heavy Layer is attached to the thermoforming process.

Hereinafter, the present invention will be described in detail with reference to Examples.

1 and 5 (b) show an embodiment of the structure of the three-layer laminate 10 according to the present invention, which is composed of an upper layer 11, an intermediate layer 12, and a bottom layer 13, and different from each other. It shows the laminated state by the characteristics of the fiber.

Figure 3 shows the cross-sectional shape of each type of PET fiber used in the present invention.

The upper layer (11) is the surface layer, and PET fiber is regular 1.5-6D 30-76mm 30-50% and release cross-section 1.5-6D 30-76mm 20 ~ 50 %, Low melting point binder fibers 20 to 30% by selectively mixing to form a low density soft layer consisting of a unit weight of 100 ~ 1,200g / ㎡.

In the middle layer 12, the PET fiber 1.5-6D, 30 ~ 76 mm type with 50 to 60% of the cross-sectional structure to increase the unit area by the three denier to maximize the sound absorption even at high frequency sound pressure, and to give the porous type characteristics And conjugated hollow type fineness 1.5-6D, fiber length 30-76mm 10-30% and low melting binder fiber fineness 2-10D, fiber length 30-76mm 20-30% To achieve a high density soft layer consisting of a unit weight of 300 ~ 1,200g / ㎡.

PET fiber used for the bottom layer 13 is regular fineness 1.5-6D, 30-50% of fiber length 30-50%, and cross section 1.5-6D of hetero sectional fineness, 40-50% of fiber length 30-76mm and low melting point binder fiber. Selectively mixed within the range of 20 to 30% to constitute a high density soft layer composed of unit weight 100 ~ 1,200g / ㎡.

The low-melting binder fibers used above have a fineness of 2-10 denier and a fiber length of 30-76 mm, with a melting point of 80-180 ° C. among two components of PET / PE, PET / PP, PET / PA, and PET / modified PET fibers. It was to be composed of.

The process of manufacturing the WEB laminate 10 of the three-layer structure according to the present invention reinforces the opening ability by the denier in addition to the generally used opener (Super Cleaner or Bale Braker M / C) as shown in FIG. Fine Opener is added for the purpose, and it is configured to be fully opened and mixed at least 6-10 times while going through the Multi Mixing Room. The fiber composition is different for each carding machine through the carding machine and two to three molding machines. More specifically, the three types of mixed fibers that have been separated by the fiber characteristics and subjected to the mixed surface process are automatic weighing hoppers or shooter feeders ( It is supplied to a separate carding machine through a Shute Feeder device to repeat the combing action and the transfer action to generate a web with a thin fiber membrane state. Through the two or three molding machine (Cross Lapper) it consists of a structure in which a row sequentially stacked.

The cross-sectional structure of the three-layer laminate (Example PET 1) structure of the present invention is as shown in Figure 5b and the unit weight is composed of 500-2,000g / M², thickness 10-40mm.

The WEB laminated sheet according to the present invention has a high density layer and a low density layer formed inside the sheet, rather than a structure in which a plurality of separate sheets are bonded to each other as a single layer distribution or an adhesive material that has been conventionally implemented by performing a multi-layer structure as in the present invention. While forming the fiber distribution layer, the kinetic energy is sufficiently converted to thermal energy when the energy of the incident sound passes through the irregular microcavity in the fiber layer due to the rigid and soft forming structure according to the density to maximize the noise reduction effect.

As another embodiment according to the present invention, PET (Polyester staple fiber) fiber used in sound absorbing and insulating molding materials is an example configured as a two-layer laminate (Example PET 2) with a configuration in which the fiber specification of the three-layer structure is partially modified. .

The sound absorbing and insulating molding material is reinforced with a cover member for strength reinforcement on the outside.

The cover member may be any one of films, nonwoven fabrics, knitted fabrics, glass fiber sheets, PP bags, PVC plates, abrasion, compressed paper, and ultrathin aluminum.

Polyethylene (POLYETYLENE), polypropylene (POLYPROPYLENE), EB (EVA), polyamide (POLYAMIDE), polyester (POLYESTER), polyacrylonitrile (POLYACRYLONITRILE), polyurethane It is used for the purpose of reinforcing sound absorbing and insulating function by applying hot melt adhesive such as (POLYURETHANE) type in powder state or inserting into film.

In addition, the sound insulation plate 20 processed by any one material of ASM, EVR, PVC is attached to the front or rear of the laminate 10 is configured.

Sheet formed by the embodiment of the two-layer, three-layer structure as described above is completed to a predetermined standard through the needle punching or hot dryer by hot air circulation method.

The table below compares the three-layer laminate (PET 1) configuration and the two-layer laminate (PET 2) configuration according to the embodiment of the present invention and the sound absorption performance of PET (conventional PET) of the general-purpose monolayer structure It is shown.

The test instrument used Impedance Tube and the test data was based on the frequency analysis. As can be seen from the results, it can be seen that PET 1 of the present invention exhibits a superior sound absorption effect of 12.5% or more, as compared with conventional PET, which is a general-purpose monolayer structure, in the high frequency region of 3,150 Hz.

<Table> Sound absorption measurement results according to the embodiment of the present invention

TEST SAMPLE SPECIFICATION

division Fiber mixing rate (%) Weight (g / M²) General purpose PET Monolayer: PET (reg.) 6x51 70%, LMF 30% 1,200 Example 1 Top layer: PET (reg.) 1.5x38 40%, PET (flat) 30%, LMF 30% 400 Interlayer: 50% PET (flat), 30% Conj.3x51, 20% LMF 500 Bottom layer: PET (reg.) 1.5x38 30%, PET (flat) 40%, LMF 30% 300 Example 2 Top layer: PET (reg.) 2x51 40%, PET (flat) 30%, LMF 30% 800 Bottom layer: 50% PET (flat), 20% Conj.3x51, 30% LMF 400 Reference The weight applied to the product: 1,2kg / M², thickness: 20mm are all the same. LMF is a low melting binder fiber PET (S / C type) 4 x 51mm. 3. "" PET (flat) is a release flat rectangular cross-section yarn 1.5 x 38 mm.

The needle punching operation used in the present invention is to maintain the WEB state from the card machine uniformly and to prevent the fiber from being damaged by excessive hot air in the dryer, and is usually pre-needling to be within the density of 20-100Points / ㎠. Depending on the application, when the surface finish requires the same touch or peeling finish, 100-200Points / ㎠ goes up and down at the same time. In addition, the heat dryer by the hot air circulation method is heat-treated to the properties and specifications required by the height adjustment of the upper and lower perforated nozzle type conveyors, usually undergoing a heat treatment process for about 1 to 3 minutes at a temperature of 150 ~ 250 ℃.

Another embodiment of the present invention is the step of attaching the sound insulation plate sheet called the PET FELT and the heavy layer is divided into a PET preheating device, a heavy layer preheating device, a thermoforming mold device and a trimming process.

That is, the first step is to preheat the PET sound absorbing material by hot air oven or Infrared heat treatment oven;

The second step includes the preheating of the heavy layer by gas or electrothermal heat treatment oven;

Step 3 is the step of bonding the PET sound absorbing material and the heavy layer by the mold apparatus 30 as shown in FIG.

In the fourth step, the sound insulation plate sheet called PET FELT and Heavy Layer is attached through a process by trimming device that cuts the edges.

As such, the present invention is a significant improvement in the noise according to the physical distribution of the sound absorbing and insulating characteristics, achieves quietness and light weight in the vehicle, and is 100% recycled, which is environmentally friendly and contributes to cost reduction.

Claims (10)

In the sound absorbing and insulating molding material for automobiles installed to block the noise generated in the automobile, The sound-absorbing sound-absorbing molding material is made of a PET laminate (Polyester staple fiber) material is composed of a WEB laminate having a multi-layer structure by subdividing into a soft layer and a hard layer by a high density layer and a low density layer by varying the distribution according to the characteristics of each type Sound absorbing and insulating material for cars. According to claim 1, The sound absorbing and insulating molding material consisting of a WEB laminate of a multi-layer structure The upper layer is PET regular type 1.5-6D, 30-76mm 30 ~ 50%, PET heterosection flat rectangular 1.5-6D, 30-76mm 20 ~ 50%, Ciscocore low melting binder fiber fineness 2-10D, fiber It consists of low density soft layer consisting of unit weight of 100 ~ 1,200g / ㎡ by mixing 20 ~ 30% selectively among PET / PE, PET / PP, PET / PA, PET / modified PET TYPE which is 30-76㎜ long. In the middle layer, PET fiber 1.5-6D, 30 ~ 76mm 50 ~ 60%, and conjugate hollow type, which has a heterogeneous cross-sectional structure to expand the unit area by the three denier to maximize the sound absorption in the high frequency range, and to give porous type characteristics. (conjugate hollow type, 8 to 50%) Fineness 1.5-6D, fiber length 30-76mm 10 ~ 30% and low melting binder fiber fineness 1.5-10D, fiber length 30-76mm PET / PE, PET / PP It consists of high density soft layer composed of unit weight 300 ~ 1,200g / ㎡ by mixing 20 ~ 30% selectively among PET, PA, PET / modified PET TYPE, PET fiber regular type fineness 1.5-6D, 30 ~ 76 mm, 30 ~ 50% of fiber length, and cross section flat rectangular (S / C type) 1.5-6D 30 ~ 76mm 40 ~ 50% and PET of low melting point binder / PE, PET / PP, PET / PA, PET / modified PET TYPE, which is composed of high density soft layer composed of unit weight of 100 ~ 1,200g / ㎡ by mixing 20 ~ 30% selectively The unit weight of the three-layer laminated structure made of sound insulation material is 600-2,000g / ㎡, thickness 20-40mm. The method of claim 1, The cross-section of the cross-section fiber has a circular, oval, flat rectangular shape or peanut shell shape with fineness of 1.5 to 6 deniers, 30 to 76 mm of fiber length, and the mixing ratio is 15 to 80% of the total fiber weight. Sound absorbing and insulating material for cars, characterized in that. The method of claim 1, The conjugate yarn is composed of one to four internal holes (hollow) has a hollow ratio in the range of 8-50%, fineness is 1.5 ~ 6 denier, fiber length 30 ~ 76mm, the mixing ratio of the entire fiber A sound absorbing and insulating material for automobiles, characterized in that it is selectively configured with 10 to 30% of the weight, to give soft touch and valky properties, and to improve sound absorption performance due to porous properties. The method of claim 1, The low-melting binder fiber is a sheath core type, having a fineness of 1.5 to 10 deniers and a fiber length of 30 to 76 mm, and a mixing ratio of 10 to 50% of the total fiber weight. The sound absorbing and insulating material for automobiles, characterized in that the melting point of the PE, PET / PP, PET / PA, PET / modified PET fibers in the 80 ~ 180 ℃ range composed of polyester fibers. The method of claim 1, PET (Polyester staple fiber) fibers used in the sound absorbing and insulating molding materials are used alone or in combination with other natural fibers, chemical fibers, inorganic fibers, etc., divided into soft layers and hard layers by high density and low density, or two or three layers. Sound absorbing and insulating material for automobiles, characterized in that the layer structure. The method of claim 1, The sound absorbing and insulating molding material is a car, characterized in that the cover member made of any one of the film, non-woven fabric, knitted fabric, glass fiber sheet, PP bag, PVC plate, abrasion, compressed paper, ultra-thin aluminum to reinforce the strength inside and outside Sound absorbing and insulating material for The method of claim 1, Polyethylene (POLYETYLENE), polypropylene (POLYPROPYLENE), EB (EVA), polyamide (POLYAMIDE), polyester (POLYESTER), polyacrylonitrile (POLYACRYLONITRILE), polyurethane ( A sound absorbing and insulating material for automobiles, which is configured for reinforcing the sound absorbing and insulating function by coating or inserting a hot melt adhesive such as polylythan). The method of claim 1, A sound absorbing and insulating material for automobiles, characterized in that the sound absorbing and insulating function is reinforced by attaching a heavy layer to the laminate. The method of claim 1, Needle punching operation is to keep the web state from the card machine uniformly and to prevent the fiber from being damaged by the hot air in the dryer. It is usually pre-needling to be within 20-100Points / cm2 of needle density. In addition, when the same degree of peeling is required to finish 100-200Points / ㎠ about the top and bottom at the same time, the sound-absorbing sound absorbing material for automobiles, characterized in that to go through the main-needling work.