Thin, lightweight, flexible textile surface that provides high sound insulation and production method

Abstract

The present invention relates to the production of a sound-insulating textile surface comprising two fabric layers laminated to each other with the coated surfaces remaining on the inner surface, while the fabric surfaces remain on the outer surface. Providing benefits such as preventing noise pollution, improving sound acoustics and increasing privacy in many sectors from construction sites to production facilities, from homes to offices, from automobiles to industrial areas. The versatility of this fabric offers significant advantages, both aesthetically and functionally.

Description

Technical Field The present invention relates to a thin, lightweight, flexible textile surface providing high sound insulation and to a production method. In particular, the present invention provides an insulating textile surface fabric, which can be used on ceilings, floors and door panels to provide sound insulation and reduce noise pollution in construction sites, in offices, homes, concerts, events or temporary infrastructure projects to reduce sound pollution, or in conference halls, hotel rooms and other noise-sensitive environments, to reduce engine and road noise in vehicles. In addition to preventing sound from leaking out, it is also suitable for reducing echo and noise levels indoors. Besides, it is beneficial in terms of energy efficiency, because sound insulation materials also increase thermal insulation. The thin and flexible fabric, which provides sound insulation, has a wide range of uses. It can provide benefits such as preventing noise pollution, improving sound acoustics and increasing privacy in many sectors from construction sites to production facilities, from homes to offices, from automobiles to industrial areas. The versatility of this fabric offers significant advantages, both aesthetically and functionally. State of the Art Curtains / fabrics that provide sound insulation show their effectiveness depending on the density of the fabrics used, layer structures and added acoustic materials. Ideal sound insulation is usually obtained from heavy, multi-layered fabrics and soundabsorbing materials. Many sound-insulating curtains / fabrics contain additional layers. These layers are felt, cork, rubber coating etc. layers added to the back of the fabric. These layers are hung in front of each other in different numbers and rows according to the desired sound insulation level and usage feature. Multi-layer curtain / fabric textures created for the desired sound insulation have thicknesses ranging from 5 to 10 cm. STC and Rw are measurements that evaluate the sound insulation performance of a material or building element and are based on different standards. Both values are used to determine how much the material blocks airborne sound. The desired value for good sound insulation is measured by STC (Sound Transmission Class - ASTM £2611:2009 I ASTM £413 )and Rw (Weighted Sound Reduction Index - ASTM £2611:2009 / ISO 717-1 ). , The STC value and the Rw value measure the sound insulation of the material, the value usually varies between 10 and 40 for fabrics. STC and Rw values of a normal fabric are between 5 and 10. This value range provides thermal sound absorption but is not sufficient for sound insulation. In thick blackout fabrics, STC value is between 10-20 and Rw value is between 15-20 dB. The larger the number is, the better the sound insulation. The STC and Rw values of specially designed multi-layered, consecutively hung heavy fabrics vary between 20 and 35. Fabric textures with high sound insulation levels are heavy, thick, multi-layered and contain special sound absorbing materials. These insulation values are usually provided by 3 or 4 layers, 5 to 10 cm thick and heavy curtain / fabric structures, using different materials such as felt, acoustic foam, rubber, aluminium coating, and fibreglass. A patent application numbered "TR2020 / 20245" relates to a multilayer fabric structure for sound attenuation of high-frequency sound waves, characterized by comprising: at least two plies consisting of at least two rows of upper weft yarns, at least one row of lower weft yarns, upper warp yarns liaising between said upper weft yarns and lower warp yarns liaising between said lower weft yarns, a gap structure between two successive plies, a feather structure that enables the formation of a porous form by increasing the surface area on at least one upper weft yarn, upper weft yarn, lower weft yarns, upper warp yarns and at least one of the lower warp yarns, at least one of which passes diagonally between the upper weft yarns and the lower warp yarns to form the said hollow structure The deficiency in the curtain fabrics in the state of the art is that the curtain / fabric textures that provide the desired sound insulation are too heavy, too thick, too spaceconsuming, costly, not environmentally friendly because too much material is used, aesthetically inadequate or limiting fabrics. As a result, due to the above-mentioned disadvantages and the inadequacy of the existing solutions, a development in the relevant technical field has become necessary. Object of the Invention The present invention aims to solve the above-mentioned negativities and it is inspired by the current situation The primary object of the present invention is to provide a fabric texture that provides a thin, lightweight, flexible structure while effectively providing sound insulation and offering an aesthetically harmonious solution. The textile surface fabric of the present invention offers thin and flexible fabric structure, high sound insulation due to its special structure, ease of assembly and use, design structure that can be diversified esthetically, practical use with its low weight and thin structure, bidirectional use and flame retardancy in line with demand. The present invention comprises a structure consisting of a combination of two layers of fabric. Each fabric layer is a fine textured fabric with high density and stretch properties. The yarns, densities and finishing processes used in the fabric structure support the acoustic feature. The fabric texture is coated with chemicals such as acrylate / polyurethane etc. to provide sound insulation without disturbing the elasticity of the fabric and functional filling materials to increase sound insulation. In this coating process, coating materials ranging from one to three times the fabric weight can be used. This amount varies according to the amount of insulation demanded in the end use of the fabric. Two coated fabric layers are bonded (glued) together by lamination with the coated parts in the centre. The fabric texture provided by the invention is such that it is both flexible and thin, and is single-layered to the touch. This feature provides comfort when using the fabric and increases the ease of assembly. At the same time, since both outer surfaces of the fabric are made of fabric, it offers an aesthetically harmonious solution for all spaces. Despite its thin, light and flexible structure, its sound insulation performance is effective. The sound insulation values of our thin, light, flexible fabric give very good results compared to multi-layer, thick, heavy fabric textures and Rw : 30-40 dB / STC : It has 30-40 features. In order to fulfil the above-mentioned objects, the invention is a thin, light, flexible textile surface providing high sound insulation and a production method; comprises two fabric layers laminated to each other with coated surfaces remaining on the inner surface so that the fabric surfaces remain on the outer surface. The acoustic fabric production method which is the subject of the invention comprises the following steps in its most basic form: i. formation of fabric structure, ii. coating process on the fabric structure, iii. laminating the coated fabrics to each other through the coating surfaces. The structural and characteristic features of the present invention will be understood clearly by the following figures and the detailed description made with reference to these figures and therefore the evaluation shall be made by taking these figures and the detailed description into consideration. Description of the Figures Figure 1, is a view of an acoustic curtain which is an embodiment of the invention. Figure 2, is a layered overview of the acoustic fabric structure. Description of Part References 100 acoustic curtain 10 fabric surface 20 coating surface 30 lamination surface Detailed Description of the Invention In this detailed description, the acoustic textile surface and preferred embodiments which is the subject of the invention are explained only for the purpose of better understanding the subject. The present invention is a thin, lightweight, flexible textile surface providing high sound insulation and production method, comprising two fabric layers laminated to each other with coated surfaces remaining on the inner surface so that the fabric surfaces remain on the outer surface. The acoustic fabric production method which is the subject of the invention comprises the following steps in its most basic form: i. formation of fabric structure, ii. performing coating process on the fabric structure, iii. laminating the coated fabrics to each other through the coating surfaces. (i) Fabric Structure Formation: While creating the fabric structure, yarn selections were preferably made to support the acoustic feature. High filament count, fine yarns and staple fibre, preferably polyester yarns, are used to support low weight. Apart from polyester yarns, polyamide can be used to obtain flexible acoustic fabric textures with its elastic structure; polyproplene yarns and blended yarns obtained from them can also be used to improve light, more cost-effective and sound absorption properties. Polyester fibres, which are durable and have good sound absorption properties, were preferred as material selection. In order to minimise the passage of sound waves in the air, tight weaves with a low number of pores were preferred as the weave structure. Preferably satin / twill / plain weave weaves are used. Because satin weaves have a smooth surface, the fabric woven with satin weave is both aesthetically stylish and allows the sound to slide on the surface. Twill weaves allow more durable acoustic panels to be obtained due to their diagonal structure. Plain weaves, on the other hand, prevent sound transmission as they form a tighter surface with low pore rate. In the finishing processes applied to the fabric, it was ensured that the fabric was gathered in the width and length direction. As a result of all these, non-porous and tightly textured fabrics are formed. Additional chemical treatments are also carried out in order to increase the softness of the fabric. The fabric thus obtained is both tight and non-porous in structure and very thin and soft. The values of the polyester / polyamide / polypropylene fabric properties available within the scope of the invention were analysed as follows: Thinness = 0,20 mm-0,40 mm Weight (Grammage) = 80g / m2 - 130 g / m2 Stiffness (Handle-O-Meter Stiffness Test (Warp / Weft) (gf)) = Weft: 1-21 Warp: 3-4 Acoustic value of the fabric = Rw: 4-5 dB ISTC: 4-5 (ii) Coating on the Fabric Structure: A thin but stable coating is applied on the woven and dyed fabric structure. In order to reduce high intensity sound transmission or to improve ambient acoustics, a plurality of thin layers were formed during the coating process. The foam density and blade height were adjusted to achieve the desired insulation value. Thus, the coated fabric surface obtained becomes both thin, flexible and non-porous to increase the insulation value. By obtaining fabrics with acoustic properties by coating method, both the echo in the interior can be reduced and a large part of the noise coming from the external environment can be prevented. Coating paste was prepared using functional particles to increase sound insulation. Details of the coating process are below; 1. Layer Coating: 80-100 g / m2 - 0,008-0,012 mm a. Titanium dioxide (2-8%) b. Antimony trioxide (1-9%) c. Disodium n-ketostearyl sulfosuccinamate (1-10%) d. Methanol (0-0,4%) When preparing the first layer coating paste, one of the following filling materials or their combinations are weighed and added, and the remaining part is completed with blackout chemicals to reach 100%. By using these filling materials, the desired high values in sound insulation are achieved with a thin and light coating surface. Table 1, Coating Filling Material Properties Filling Material Percent Particle Size Cork oak-cork 5% 200 pm Zinc Borate 2% 5 pm Calcium Carbonate 3% 3 pm Barium Sulphate 1% 2 pm CORK OAK (CORK): The cork oak (Quercus sober) is a tree species that is particularly native to the Mediterranean climate and is also known as ‘cork oak’. This tree is famous for the natural material obtained from its bark, which is called ‘cork’. Cork is used in many industrial and commercial applications because it is lightweight, flexible, water resistant, insulating and environmentally friendly. Cork oak (Quercus suber) and the cork material derived from it have strong acoustic properties. These properties are due to the unique cellular structure and natural flexibility of the cork. By using this material in the coating paste, a high value in sound insulation is achieved with a thin and light coating layer. The cellular structure of the cork (90% air-containing cells) has the ability to absorb and trap sound waves. This prevents the transmission of sound to other surfaces or environments. The low density of the material limits the passage of sound waves and reduces reverberation. Cork can absorb sound waves on its surface and reduce reverberation. This feature is particularly useful in open offices, conference rooms and movie theatres. The flexible structure of the cork absorbs sound vibrations, effectively reducing noise. Zinc Borate (2ZnO.3B2O3.3,5H2O): Zinc is an inorganic compound composed of the elements boron and oxygen. Although Zinc Borate is mainly known for its flame retardant, antifungal and protective properties, we used this chemical in the coating paste with the view that it can also have an effect on acoustic properties when used as a filling material. These effects are due to the physical and chemical structure of zinc borate. However, it is not a material used to provide direct sound insulation or sound absorption. Rather, it can improve the acoustic performance of composites in which it is used as a filling material. With the help of its halogen-free structure, it is used as an environmentally friendly additive in acoustic insulation products. The density and particle structure of zinc borate may somewhat inhibit the propagation of sound through the material. However, this effect is usually not dependent on zinc borate alone, but on the composite materials in which it is incorporated. Zinc borate can contribute to the absorption of sound waves due to its microstructure. However, this feature is limited compared to other acoustic materials with porous structure. Calcium Carbonate (CACO3): It is a common filling material with indirect effects on acoustic properties. Although it is not used directly as a sound insulation or sound absorption material, it can improve acoustic performance in composites and building materials where it is used as a filler. For this reason, it is used to support high sound insulation in the coating paste. As calcium carbonate is a dense material, it can increase the mass of composites when used as filler. Heavier materials reduce the transmission of low-frequency sounds (e.g. bass sounds). When used in materials such as plaster, plasterboard or concrete, polymers can create an acoustic barrier by increasing sound transmission loss. The surface roughness and micro-grain structure of calcium carbonate can absorb some of the sound waves. However, this feature is limited compared to porous materials. Rather, it supports the acoustic properties of the matrix in which it is located. Calcium carbonate is widely used because it is cost-effective filler. It improves sound transmission blocking performance by increasing the density of the material. In some applications, it is a part of composite systems that offer heat and sound insulation together. Barium Sulphate (BAS04): It is a filling material that can have an effect on acoustic performance due to its high density and chemical stability. Although it is not directly used for sound insulation or sound absorption, it can improve acoustic performance in composite and building materials. High sound insulation values were achieved by using this material in the coating paste. Barium sulphate has a density of about 4.5 g / cm3, which effectively limits the transmission of low-frequency sounds (e.g. bass sounds) by increasing the mass of the composite materials. When polymers are used as fillers in systems such as rubber or concrete, they increase the sound transmission loss and strengthen the sound insulation capacity of the material. Although barium sulphate does not have a porous structure, it can slightly increase the sound absorption performance of the material with its dense filling feature. Dense materials effectively block the transmission of sound waves. Barium sulphate can therefore be used as part of acoustic barriers. It increases vibration damping capacity in polymer or rubber-based materials. Since barium sulphate is a chemically stable material, it provides long-term durability in different environmental conditions. 2nd Layer Coating: 60-80 g / m2 - 0,006-0,008 mm a. Titanium dioxide (2-8%) b. Antimony trioxide (1-9%) c. Disodium n-cetostearyl sulfosuccinamate (1-10%) d. Methanol (0-0,4%) e. Carbon black (20-30%) f. Ethanediol (2-4%) g. Ammonia (0,4) h. 1,2- benzisothiazol-3(2h)-on (0,004) In the Second layer coating paste, a 100% blackout (light-proof) structure is created by using carbon black material. The product formed in this way is very thin, light, provides sound insulation and at the same time provides ease of use by preventing light transmission. Foam coating method is a very common technique in blackout production. Blackout fabrics are usually produced with foam or paste-based coatings to provide lightproofing and thermal insulation. The use of foam is particularly preferred to obtain a light and homogenous coating. For this reason, the foam density was adjusted as 200300 g / lt in both coating pastes. In blackout coating processes, viscosity is a critical parameter that determines 5 production quality and coating performance. Viscosity refers to the degree of fluidity of the coating material used and affects both the evenness of the coating process and the adhesion performance to the fabric. For this reason, the viscosity of both coating pastes was set to 1000 cps. 10 By using this foam density and viscosity, better sound insulation is achieved in a thin coating layer. Table 2. Properties of Coating Chemical Percentage Content of Coating Paste Drape Chemical Titanium dioxide 2-8% Antimony trioxide 1-9% Disodium n-cetostearyl sulphosuccinnamate 1-10% Methanol 0-0,4% Black Pigment Carbon black 20-30 % Ethanediol 2-4% Ammonia 0,4 1,2- benzisothiazol -3(2h)-on 0,004 Foam Density: 300 g / l Viscosity 1000 cps Blackout Feature: 100% Table 3. Coating Filling Material Properties Filling Material Percent Particle Size Cork oak-cork 5% 200 pm Zinc Borate 2% 5 pm Calcium Carbonate 3% 3 pm Barium Sulphate 1% 2 pm The available coated fabric texture values within the scope of the invention are analysed as follows Thinness = 0,22-0,32 mm weight (Grammage) = 250-300 g / m2 Stiffness (Handle-O-Meter Stiffness Test (Warp / Weft) (gf)) = Weft: 10-12 / Warp: 45-50 Acoustic value of the fabric = Rw: 8-10 dB / STC: 8-10 (iii) Laminating Coated Fabrics to Each Other: The coated fabric surfaces are laminated to each other through the coating surfaces, leaving the fabric side on the outside. As a result of this lamination process, the two coated surfaces are bonded to each other in such a way that no gaps remain. The resulting single-layer light, flexible and thin structure forms a fabric texture in which sound insulation reaches very high levels with the help of the coating surfaces and the fabric layer that supports acoustics. When viewed or touched from the outside, it gives the feeling of a thin, flexible and light fabric structure. Since the end product is flexible in both length and width directions, it can be used as fabric in both directions according to the customer's usage demand. If the end use is curtains, the pleated fabric can be formed into curtains with both warp yarn and weft yarn vertical. With the help of this process, since both the front and back sides of the fabric are fabric, it can be diversified in terms of colour / texture / weave etc. and can be made with different fabrics on the front and back according to demand, providing advantages and personalisation options in use. The final product acoustic fabric texture values preferred within the scope of the invention were analysed as follows: Thinness = 0,47-0,67 mm Weight (Grammage) = 10-610 g / m2 Stiffness (Handle-O-Meter Stiffness Test (Warp / Weft) (gf)) = Weft: 150-250 I Warp: 450-600 Acoustic value of the fabric = Rw: 30-40 dB / STC: 35-40 Table 4, Sample Quality Analysis Results Thickness (mm) Weight (g / m2) Hom (handle-o-meter) Acoustic values Warp Weft RW STC Textile Surface Fabric 0,2-0,4 80-130 3-4 1-2 4-5 4-5 Coated single layer 0,22-0,32 250-300 45-50 10-12 8-10 8-10 Lamination 0,47-0,67 510-610 450-600 150 250 30-40 35-40 Lamination is the process of joining different materials together using heat, pressure and adhesive. This method is used to protect and increase the durability of materials such as paper, fabric and plastics. The material to be laminated is cleaned and dust or dirt is removed from the surface. This is extremely important for proper adhesion. Depending on the selected lamination method, the adhesive is applied to the surface of the material. Adhesives can be water-based, solvent-based or hot melt (hotmelt). After applying the adhesive, the second layer of material is carefully placed. At this stage, care should be taken to avoid the formation of air bubbles. Using laminating machines, materials are joined together under heat and pressure. This ensures that the adhesive is activated and the layers are firmly adhered to each other. In fabric lamination in particular, high heat and pressure are used to mould layers of fabric into a single layer. After the lamination process is completed, the material is cooled and cut to the desired dimensions. Extrusion Lamination, (Hot Melt) Lamination, Adhesive Lamination, Thermal Lamination can be used as lamination methods. In our invention, Hot Melt (Hotmelt) Lamination method is used as a production method for joining fabric plies. Hot melt lamination is the process of heating thermoplastic adhesives to a molten state and using them to join different materials. Hot melt lamination has a wide range of applications in industry as a fast, efficient and environmentally friendly method. With the right choice of adhesive and equipment, it is possible to obtain high quality and durable products. This method is widely preferred especially in textile, automotive, packaging and furniture industries. The production process of the hot melt lamination method is as follows: Thermoplastic adhesive is melted by heating to a certain temperature before application. Depending on the type of adhesive used, the melting point and application temperature may vary. For example, polyamide-based hot melt adhesives are used for textile fabric lamination and have melting points of around 900. The melt adhesive is applied evenly and in a controlled manner to the surfaces of the materials to be laminated. This process can be carried out by roll, spray or extrusion methods. The viscosity and fluidity of the adhesive during application is critical for process efficiency. After the adhesive is applied, the layers to be joined are overlapped and pressed under a certain pressure. This pressure ensures that the adhesive is distributed homogeneously between the materials and a strong bond is formed. After the pressing process, the materials are left to cool. During cooling, the adhesive solidifies, forming the final bond. Some hot melt adhesives undergo an additional curing process by reacting with surrounding moisture, which increases the durability of the bond. Reactive Polyurethane (PUR) hot melt adhesives are thermoplastic adhesives that offer superior bond strength and durability in lamination applications. These adhesives are widely used especially in the textile, automotive, furniture and packaging sectors. For this reason, in our invention, hot melt lamination method and Reactive Polyurethane (PUR) adhesive are preferred. PUR adhesives create strong and permanent bonds between different materials with high bond strength. It provides stability over a wide temperature range from -400 to 1500. After curing, it becomes waterproof and is resistant to exposure to moisture and water. With the help of its flexible structure, it can be used in different applications and is resistant to solvents. Reactive Polyurethane (PUR) adhesives used in Hot Melt Lamination method are generally applied at low temperatures such as 900 to 1200 and while the viscosity of the applied adhesive is approximately 10,000±2,000 mPas at 1000, the viscosity value decreases as the temperature increases and becomes more fluid, reaching a value of approximately 5,000 mPas. When applying this method, the ambient temperature should preferably be at least 200. Application speed varies depending on the equipment and materials used. In general, it is recommended that the application speed be between 10-40 m / min. Higher speeds may prevent the adhesive from spreading sufficiently; lower speeds may reduce production efficiency. The pressure applied during lamination should be adjusted depending on the 5 properties of the materials and the viscosity of the adhesive. In general, a pressure of 0,5-2,0 N / mm2 is recommended. Especially for sensitive materials, it is important to adjust the pressure in a way that does not damage the product. The lamination layer in the final product is 0,02-0,03 mm thick and weighs 8-10 g / m2. 10

Claims

1. A textile surface that provides high sound insulation with a thin, light and flexible structure characterized by comprising; two fabric layers whose coated surfaces are laminated to each other on the inner surface while the fabric surfaces remain on the outer surface.

2. The textile surface according to claim 1, characterized in that; the said fabric is Polyester / polyamide / polypropylene based with a fineness 0,20-0,40 mm, weight 80-130 g / m2, weft hardness: 1 -2 / warp: 3-4; acoustic value Rw: 4-5 dB / STC 4-5.

3. The textile surface according to claim 1, characterized in that; the said coated fabric is Polyester / polyamide / polypropylene based with a fineness 0,22-0,32 mm, weight 250-300 g / m2, weft hardness: 10-12 / warp: 45-50; acoustic value Rw: 8-10dB / STC 8-10.

4. The textile surface according to claim 1, characterized in that; the final product comprising two laminated coated fabric layers is polyester / polyamide / polypropylene based with a fineness of 0,47-0,67 mm, weight 510-610 g / m2, and weft hardness: 150-250 / warp: 450-600; acoustic value Rw: 30-40 dB I STC 35-40.

5. A method of producing a textile surface according to one of claims 1 to 4, characterized by comprising the process steps of:i. formation of fabric structure,ii. performing coating process on the fabric structure,iii. laminating the coated fabrics to each other through the coating surfaces.

6. The method according to claim 5, characterized in that; it is polyester / polyamide / polypropylene based.

7. The method according to claim 5, characterized in that; the fabric is formed from the yarns using satin / twill / plain weaves.

8. The method according to claim 5, characterized in that; as the 1st layer coating; 80-100 g / m2 - 0,008-0,012 mm thin coating is made with Titanium dioxide, Antimony trioxide, Disodium n-cetostearyl sulfosuccinamate, Methanol chemicals and filling materials selected from Cork oak, Zinc Borate, Calcium5          Carbonate, Barium Sulphate.

9. The method according to claim 5, characterized in that; as the 2nd layer coating: 60-80 g / m2 - 0,006-0,008 mm thin coating is made with Titanium dioxide, Antimony trioxide, Disodium n-cetostearyl sulfosuccinamate, Methanol,10          Carbon black, Ethanediol, Ammonia, 1,2-benzisothiazol-3(2h)-one chemicals.

10. The method according to claim 5, characterized in that; lamination is carried out with Reactive Polyurethane (PUR) adhesives at temperatures of 900 -1200 with a thickness of 0,02-0,03 mm and a weight of 8-10 g / m2

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