KR101071193B1 - Nonwoven fabric for sound absorption - Google Patents

Abstract

The present invention relates to a multi-layered nonwoven fabric in which both surfaces are filmed to absorb and block noise. More particularly, the present invention relates to a melt blown nonwoven fabric layer made of ultra-fine yarn, and laminated on both surfaces of the meltblown nonwoven fabric layer. A long-fiber spunbond nonwoven fabric layer that is thermally fused at a constant temperature and pressure to form a film, and an unmelted long-fiber nonwoven fabric layer is secured by being incorporated into a spunbond long-fiber nonwoven layer whose surface is film-formed by thermal fusion. Provided is a sound-absorbing nonwoven fabric having a bulky property and a meltblown nonwoven fabric layer made of ultra-fine yarn, which greatly improves sound absorption.

Meltblown nonwoven fabric, long fiber spanbond nonwoven fabric, microfiber, heat fusion, film formation

Description

Nonwoven fabric for sound absorption

The present invention relates to a non-woven fabric having a multi-layered structure in which both surfaces are filmed to absorb and block noise, and in particular, an unmelted sheet which is secured by being embraced by a spunbond long fiber nonwoven layer filmed by thermal fusion. It relates to a sound absorbing nonwoven fabric of which the sound absorption is greatly improved by the bulkyness of the fiber nonwoven fabric layer and the multilayer structure composed of a meltblown nonwoven fabric layer made of ultra-fine yarn.

Various types of noise sources, such as vacuum cleaners, dishwashers, washing machines, air conditioners, air cleaners, computers, and projectors, are becoming more serious, and thus, noise pollution problems are becoming more serious. Therefore, efforts are being made to block or reduce the noise generated from various noise sources in modern life, and legal regulations for regulating the noise level between floors and generations of apartment houses such as apartments are becoming more and more strict in overseas countries. . In addition, even in the case of transportation machines such as automobiles, aircraft, trains, ships, efforts are made to block noises generated from external noises or engines from reaching the space where humans live.

As a sound absorbing material conventionally used, felt, sponge, polyurethane foam, and the like are mainly used. In addition, sound absorbing materials impregnated with thermoplastic resins or thermosetting resins in compressed fibers, glass fibers, rock wool, or regenerated fibers may be enumerated. . However, most of the sound absorbing materials described above do not have sufficient sound insulation performance, and most of the sound absorbing materials contain harmful components to the human body, and many of the sound absorbing materials contain toxic substances such as formaldehyde and dioxins.

Therefore, researches on sound absorbing materials that do not contain harmful substances to the human body are actively being conducted, and research and development on various soundproofing materials which have improved sound absorption performance are being actively conducted.

For example, Korean Laid-Open Patent Publication No. 2006-4337 (name of the invention: a melt-blown nonwoven fabric having excellent sound absorption and heat insulating property) has a single structure having a density of 50 to 4000 g / m 2 composed of fibers having an average diameter of 0.1 to 20 µm. Although a meltblown nonwoven fabric has been disclosed, such a meltblown nonwoven fabric having a single structure also has a problem in that sound insulation performance is not much improved as compared with a conventional sound absorbing material.

In addition, U.S. Patent No. 5,841,081 discloses a sound absorbing material, characterized in that it contains staple fibers that can be fused by heat to the meltblown fibers in order to impart steric stability. Since the staple fibers are not filmed, there is still a problem that the sound insulation performance is insufficient.

In addition, US Patent No. 6,220,388 B1 discloses a sound absorbing material using a honeycomb-shaped structure having a plurality of spaces with meltblown fibers, but such sound absorbing material lacks soundproofing performance and lacks flexibility, thereby limiting its use. There is a problem that this is large.

Accordingly, an object of the present invention is the bulkyness of the unmelted long fiber nonwoven layer secured by inclusion in a spunbond long fiber nonwoven layer whose surface is filmed by thermal fusion, and sound absorbing by a meltblown nonwoven layer made of ultrafine fibers. The present invention provides a greatly improved sound absorbing nonwoven fabric.

In order to achieve the above object, in the present invention, a melt-blown nonwoven layer made of microfibers having an average diameter of 0.1 to 10 ㎛; And a long fiber spunbond nonwoven layer laminated on both surfaces of the meltblown nonwoven fabric layer and heat-sealed at a temperature of 110 to 150 ° C. and a pressure of 15 to 25 N / mm to form a film. Is provided.

The sound-absorbing nonwoven fabric according to the present invention is characterized by the bulkiness of the unmelted long-fiber nonwoven layer secured by inclusion in a spunbond long-fiber nonwoven layer partially filmed by thermal fusion, and by a meltblown nonwoven layer made of ultra-fine fibers. By effectively blocking the absorption has the effect that can be used for various sound absorbing materials.

In addition, the sound-absorbing nonwoven fabric according to the present invention is manufactured using a polyolefin-based synthetic resin, so the price is low, the economy is excellent, and the recyclability and eco-friendliness are excellent.

The sound-absorbing nonwoven fabric of the present invention is characterized in that a long fiber spanbond nonwoven fabric as a superficial material is formed on both surfaces of a meltblown nonwoven fabric which is a core material, and the surface of the long fiber spanbond nonwoven fabric is thermally fused at a constant temperature and pressure to form a film. have.

In addition, the sound-absorbing nonwoven fabric of the present invention comprises only a meltblown nonwoven fabric and a long fiber spanbonded nonwoven fabric, and the meltblown nonwoven fabric and the long fiber spanbonded nonwoven fabric have excellent sound absorption performance, bulky properties, and various mechanical properties with relatively good price. It is preferable to be made of polyolefin-based synthetic resins such as polypropylene, which is not only excellent in economic efficiency due to its low cost and excellent recyclability.

The sound absorbing nonwoven fabric according to the present invention will be described in detail with reference to the drawings and examples.

1 illustrates a cross-sectional structure of a sound absorbing nonwoven fabric according to the present invention.

Referring to Figure 1, the sound-absorbing nonwoven fabric of the present invention includes a meltblown nonwoven layer made of microfiber having an average diameter of 0.1 to 10 ㎛.

Polyolefin microfibers having an average diameter of 0.1 to 10 µm are formed by the strong hot air applied from both sides as the polyolefin fusion melted polyolefin resin is extruded from a plurality of orifices arranged in a line in a spinning device, and the polyolefin microfibers are self-bonded. A polyolefin meltblown nonwoven fabric having a density of 10 to 500 g / m 2 is formed, and the meltblown nonwoven fabric is disposed as a core material.

Meltblown nonwoven fabric made of microfiber has numerous micropores and has excellent sound absorption effect. A sound-absorbing nonwoven fabric is composed of a melt blown nonwoven fabric made of microfiber as described above and having a myriad of fine pores as a core material, and a long-fiber spanbond nonwoven fabric whose surface is filmed. In the meltblown nonwoven fabric layer 10, which is a core material of the sound absorbing nonwoven fabric, an action of converting a part of the noise that is not blocked by the long fiber spanbonded nonwoven fabric layer 20, which is a superficial material, into thermal energy by friction with air occurs. As a result, the meltblown nonwoven fabric layer 10 performs a sound absorbing action.

As described above, when the average diameter of the microfibers constituting the meltblown nonwoven fabric layer 10 that converts a part of the noise into thermal energy by friction with air is less than 0.1 μm, the manufacturing cost of the meltblown nonwoven fabric layer 10 is large. When the average diameter of the microfibers constituting the meltblown nonwoven fabric layer 10 exceeds 10 μm, the size of pores formed in the meltblown nonwoven fabric layer 10 is increased, thereby increasing the friction force between noise and air. It decreases and the sound absorption function falls.

In addition, when the density of the meltblown nonwoven fabric layer 10 composed of microfibers having an average diameter of 0.1 to 10 μm is less than 10 g / m 2, the sound absorbing function is deteriorated due to the lack of thickness of the meltblown nonwoven fabric layer 10. When the density of the tumbled nonwoven fabric layer 10 exceeds 500 g / m 2, it is difficult to actually produce due to the excessive density of the meltblown nonwoven fabric layer 10.

Long fiber spanbond nonwoven fabric is formed on both surfaces of the meltblown nonwoven fabric layer 10 having the above specifications, and the surface of the long fiber spanbond nonwoven fabric is filmed to form a functional sound absorbing material.

In addition, the sound absorbing nonwoven fabric of the present invention is laminated on both surfaces of the meltblown nonwoven fabric layer, and is a long-fiber spanbond nonwoven fabric which is thermally fused at a temperature of 110 to 150 ° C. and a pressure of 15 to 25 N / mm to form a film. Layer is included.

The long-fiber spanbond nonwoven fabric is face-to-face contacted to both surfaces of the meltblown nonwoven fabric layer 10, which is a core material of the sound-absorbing nonwoven fabric, to form a long-fiber spanbond nonwoven fabric layer 20, which is a superficial material.

In the long fiber spanbonded nonwoven fabric constituting the long fiber spanbonded nonwoven fabric layer 20, which is the surface material of the sound absorbing nonwoven fabric, there are no particular restrictions on various specifications such as the average diameter of the long fibers, but the average diameter is 10 to 30. Forming the long fiber spanbonded nonwoven fabric layer 20 using a spanbonded nonwoven fabric made of a polyolefin long fiber having a thickness of μm improves the bulkiness of the long fiber spanbonded nonwoven fabric layer 20 and heat-bonds it to the surface. Since the film surface 21 having a more dense structure is formed, it is preferable in terms of improving noise blocking and absorbing functions.

The nonwoven laminate comprising the meltblown nonwoven fabric layer 10 and the long fiber spanbonded nonwoven fabric layer 20 as described above is heat-sealed at a temperature of 110 to 150 ° C. and a pressure of 15 to 25 N / mm by a thermal calender. The sound absorbing nonwoven fabric of 50-1000 g / m <2> in which the surface of the said long fiber spunbond nonwoven fabric layer 20 is formed into a film is comprised.

If the temperature at which the nonwoven fabric laminate is heat-sealed to form a sound absorbing nonwoven fabric is less than 110 ° C., the surface of the long fiber spanbonded nonwoven fabric layer 20 of the nonwoven fabric laminate is not properly heat-sealed so that the film surface 21 is not formed. When the temperature for thermal fusion of the nonwoven fabric laminate exceeds 150 ° C., deterioration may occur on the surface of the long fiber spanbonded nonwoven fabric layer 20 of the nonwoven fabric laminate. In addition, when the pressure for heat-sealing the nonwoven fabric laminate is less than 15 N / mm in order to constitute a sound-absorbing nonwoven fabric, the long-fiber spanbond nonwoven fabric layer 20 of the nonwoven fabric laminate is not properly filmed, and the noise blocking function is lowered. When the pressure for thermally bonding the nonwoven fabric laminate exceeds 25 N / mm, the bulkiness of the long fiber spanbonded nonwoven fabric layer 20 of the nonwoven fabric laminate is lowered and the noise absorption function is lowered.

The long fiber spanbonded nonwoven fabric layer 20 of the nonwoven fabric laminate comprising the long fiber spanbonded nonwoven fabric layer 20 / meltblown nonwoven fabric layer 10 / long fiber spunbonded nonwoven fabric layer 20 by the above heat fusion. The surface of the film is formed into a film surface 21, the film surface 21 blocks a significant portion of the noise, the noise that is not blocked in the film surface 21 is a long fiber spunbond nonwoven layer 20 ) Is absorbed by the microporous cell and the meltblown nonwoven fabric layer 10 to express the suction function.

In addition, if the density of the sound-absorbing nonwoven fabric formed by heat-sealing the long fiber spunbond nonwoven fabric layer 20 on both surfaces of the meltblown nonwoven fabric layer 10 having a density of 10 to 500 g / m 2 is less than 50 g / m 2. The sound absorbing function is deteriorated due to the lack of thickness of the sound absorbing nonwoven fabric, and the density of the sound absorbing nonwoven fabric formed by heat-sealing the long fiber spunbond nonwoven fabric layer 20 on both surfaces of the meltblown nonwoven fabric layer 10 is 1000 g / m 2. If it exceeds, due to the excessive density of the sound-absorbing nonwoven fabric, it is difficult to produce practically and its use is also limited.

The sound absorbing nonwoven fabric configured as described above has a multi-layered structure that can effectively absorb and block noise, can be easily manufactured using a nonwoven fabric, and is not only inexpensive in manufacturing cost but also excellent in recyclability and eco-friendliness.

Hereinafter, the manufacturing process of the sound absorbing nonwoven fabric of the present invention will be described in more detail based on the following examples. However, the following examples are only for illustrating the present invention in detail, and do not limit the present invention.

<Examples>

1. A polypropylene melt, in which a polypropylene resin is melted, is extruded from a plurality of orifices arranged in a row in a spinning device, and a strong hot air is applied from both sides to form a polypropylene microfiber having an average diameter of 5 μm, and the polypropylene microfiber is self-bonded. To form a meltblown nonwoven fabric having a density of 60 g / m 2.

2. A nonwoven laminate was formed by facing the surface of the meltblown nonwoven fabric with a spunbonded nonwoven fabric having a density of 70 g / m 2, each made of polypropylene long fibers having an average diameter of 20 μm.

3, The nonwoven fabric laminate was heat-sealed with a heat calender adjusted to a temperature of 120 ° C. and a pressure of 20 N / mm to prepare a sound absorbing nonwoven fabric having a density of 200 g / m 2.

<Comparative Example 1>

A nonwoven fabric was formed by forming a meltblown nonwoven fabric having a density of 60 g / m 2 and contacting both surfaces of the meltblown nonwoven fabric with a spunbond nonwoven fabric having a density of 97.5 g / m 2, which is made of polypropylene long fibers each having an average diameter of 20 μm. It is the same as that of Example 1 except forming a sieve.

<Comparative Example 2>

The nonwoven fabric laminate was the same as in Example 1 except that the nonwoven fabric laminate was thermally fused with a thermal calender adjusted to a temperature of 100 ° C. and a pressure of 20 N / mm to produce a sound absorbing nonwoven fabric having a density of 200 g / m 2.

<Comparative Example 3>

The nonwoven fabric laminate was the same as in Example 1 except that the nonwoven fabric laminate was thermally fused with a thermal calender adjusted to a temperature of 160 ° C. and a pressure of 20 N / mm to produce a sound absorbing nonwoven fabric having a density of 200 g / m 2.

Evaluation of various physical properties of the sound absorbing nonwoven fabric prepared according to the above-described examples and comparative examples was carried out in the following manner.

1. Thickness: The sample was taken from the sound absorbing nonwoven fabric manufactured by the Example and the comparative example, and the said sample was measured 20 times over the full width using the thickness gauge.

2. Noise reduction coefficient (NRC): The sample was taken in the same manner as the thickness test, and the sound absorption was measured in the reverberation chamber according to the method described in KSF 2805.

The physical property test results of the sound absorbing nonwoven fabric as described above are shown in Table 1 below.

<Table 1> Comparison of process conditions and physical property test results of sound absorbing nonwovens

division Example Comparative Example 1 Comparative Example 2 Comparative Example 3 Density (g / ㎡)
Spanbond 140 195 140 140 Melt blown 60 6 60 60 Calendar
Condition Temperature (℃) 120 120 100 160 Pressure (N / mm) 20 20 20 20 Thickness (mm) 2.4 2.7 2.6 1.9 Noise Reduction Factor (NRC) 0.69 0.33 0.53 0.58

Referring to Table 1, the nonwoven fabric according to the embodiment of the present invention is provided with excellent sound absorption characteristics by the melt-blown nonwoven fabric, although the thickness is small compared to the nonwoven fabric of the comparative examples, and also the long fiber span according to the calendar conditions It can be seen that the surface of the long fiber spunbond nonwoven layer is filmed to provide a sound insulation effect while controlling the thickness of the bond nonwoven layer. This resulted in higher sound absorption performance when compared with the same thickness as conventional sound absorbing materials made of glass fiber or polyester material.

The present invention is not limited to the above-described specific preferred embodiments, and various modifications can be made by those skilled in the art without departing from the gist of the present invention as claimed in the claims. Of course, such changes will fall within the scope of the claims.

1 is a cross-sectional view of the sound absorbing nonwoven fabric according to the present invention.

* Explanation of symbols for the main parts of the drawings

10: melt blown nonwoven fabric layer

20: long fiber spanbond nonwoven layer

21: film side

Claims (5)

In the sound absorbing nonwoven fabric, The sound-absorbing nonwoven fabric is composed of a microfiber of an average diameter of 0.1 to 10 ㎛, meltblown nonwoven layer having a density of 10 to 500 g / ㎡; And A long fiber spunbond nonwoven layer laminated on both surfaces of the meltblown nonwoven fabric layer and thermally fused at a temperature of 110 to 150 ° C. and a pressure of 15 to 25 N / mm to form a film on the surface; A sound absorbing nonwoven fabric having a density of 70 to 1000 g / m 2. 2. The sound absorbing nonwoven fabric as claimed in claim 1, wherein the meltblown nonwoven fabric layer and the long fiber spunbond nonwoven fabric layer are made of a polyolefin-based synthetic resin. delete The sound absorbing nonwoven fabric according to claim 1, wherein the long fiber spanbonded nonwoven fabric layer is a spanbonded nonwoven fabric composed of polyolefin long fibers having an average diameter of 10 to 30 µm. delete

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