Soundproof panel with Anti-glare function

Abstract

To provide a soundproof panel which is transparent and, in addition to having a soundproof function, can prevent glare by diffusely reflecting incident light.SOLUTION: A soundproof panel with an anti-glare function comprises a base layer and anti-glare protrusions integrally formed on one side of the base layer by a co-extrusion method, wherein the base layer contains polycarbonate or polymethyl methacrylate, and the anti-glare protrusions contain anti-glare particles with a particle size of 10-40 μm.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a soundproof panel having an anti-glare function, and more particularly to a soundproof panel that can be used to prevent noise generated along roads or in residential areas.

Background Art

[0002] Light pollution refers to a state in which excessive light due to inappropriate use of lighting or light leaking outside the lighting area to be illuminated interferes with people's health and comfortable life or causes damage to the environment. Light pollution damage occurs not only by artificial lighting but also by sunlight. As an example, there is damage caused by sunlight reflected by the glass windows of high-rise buildings. The sunlight reflected by the glass windows of high-rise buildings induces glare to neighboring residents and pedestrians and obstructs the field of vision. To solve such problems, methods of adhering a film to the glass window or coating the surface of the glass have been devised.

[0003] As an example of reducing the light reflection of glass by attaching a film to the glass window, Korean Patent No. 10-1994490 (published on June 28, 2019) includes a glazing substrate and a reflective polarizing film article attached to the glazing substrate. The reflective polarizing film article includes a reflective polarizing film and a reflection inhibitor layer. The reflective polarizing film article reduces the transmittance of light polarized in a horizontal polarization blocking axis, and the reflective polarizing film article reduces horizontally polarized light to 90% or less of the incident visible light polarized horizontally.

[0004] Also, as an example of reducing the light reflection effect of glass by applying a coating to the surface of the glass, Korean Patent No. 10-2500410 (announced on February 17, 2023) is a coated glass article, and the coated glass article includes a glass substrate and a coating deposited on the glass substrate. The coating includes: i) a first inorganic metal oxide layer deposited on the main surface of the glass substrate (where the refractive index of the first inorganic metal oxide layer is 1.8 or more); ii) a second inorganic metal oxide layer deposited on the first inorganic metal oxide layer (where the refractive index of the second inorganic metal oxide layer is 1.6 or less). Here, the coated glass article discloses a coated glass article having a total visible light reflectance of 6.5% or less.

[0005] However, the technology of attaching a film to the surface of glass or coating the surface of glass has a problem that when the glass is exposed to the outside for a long time, the film and the coating may peel off. That is, the durability is not good, and there is the trouble that the peeled film and coating must be restored again.

[0006] On the other hand, a soundproof wall refers to a structure installed along roads or in residential areas to prevent noise caused by vehicle traffic.

[0007] The soundproof panels that make up the soundproof wall are generally made of transparent materials considering the aesthetics of areas along roads or in residential areas. However, these soundproof panels have a problem of generating light reflection, which causes glare to automobile drivers and residents.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0009] The problem to be solved by the present invention is to provide a soundproof panel that is transparent, has a soundproof function, and can prevent glare by diffusely reflecting incident light.

Means for Solving the Problems

[0010] According to an embodiment of the present invention, there is provided a soundproof panel composed of a base material layer and anti-glare protrusions integrally formed on one surface of the base material layer by a co-extrusion method. The base material layer includes polycarbonate or polymethyl methacrylate, and the anti-glare protrusions include anti-glare particles with a particle size of 10 to 40 μm, providing a soundproof panel with an anti-glare function.

[0011] Also, the base material layer may have a thickness of 6 to 20 mm.

[0012] Also, the anti-glare protrusions may protrude to an average height of 10 to 200 μm based on one surface of the base material layer.

[0013] Also, the longitudinal cross-section of the anti-glare protrusions may have one or more shapes including a conical shape, a semi-circular shape, or a semi-elliptical shape.

[0014] Also, the anti-glare protrusions may include polycarbonate or polymethyl methacrylate.

[0015] Also, the anti-glare protrusions may further include a UV stabilizer.

[0016] Also, the anti-glare particles may be polystyrene beads or polymethyl methacrylate beads.

[0017] Also, the anti-glare particles may be contained in an amount of 10 to 60% by volume based on 100% by volume of the anti-glare protrusions.

[0018] In addition, the anti-glare particles may be included in a form in which a part protrudes from the surface of the anti-glare protrusions.

[0019] In addition, the protruding portion of the anti-glare particles may be 0 to 30% of the average particle diameter of the anti-glare particles.

Advantages of the Invention

[0020] The soundproof panel having an anti-glare function according to the present invention is transparent, and not only has a soundproof function, but also can prevent glare by diffusely reflecting incident light.

[0021] In addition, the soundproof panel having an anti-glare function by the co-extrusion method of the present invention can be manufactured by the co-extrusion method, so the process is simple, the base material layer and the anti-glare protrusions are integrally formed, and it can be used for a long time without replacement work.

[0022] In addition, the anti-glare protrusions contain anti-glare particles, and the anti-glare effect can be further improved.

[0023] In addition, even if the anti-glare protrusions are worn by the external environment, the anti-glare effect can be maintained for a long time without reduction due to the anti-glare particles contained in the protrusions.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0025] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those having ordinary knowledge in the technical field to which the present invention pertains can easily implement it. However, the present invention can be realized in various different embodiments and is not limited to the embodiments described herein. Throughout the specification, the same reference numerals are given to the same parts.

[0026] Conventional sound insulation walls are mainly constructed with a sound insulation panel 100 made of a transparent material composed of synthetic resin. However, the transparent sound insulation panel 100 has a problem that the incident light is reflected, causing glare to automobile drivers or residents. Therefore, the present inventors have developed a sound insulation panel 100 that is transparent, has a sound insulation function, and can diffuse-reflect the incident light to prevent glare.

[0027] FIG. 1 is a cross-sectional view showing a sound insulation panel 100 having an anti-glare function according to an embodiment of the present invention.

[0028] As shown in FIG. 1, in one embodiment, the present invention provides a sound insulation panel 100 composed of a base material layer 10 and anti-glare protrusions 20 integrally formed on one surface of the base material layer 10 by a co-extrusion method. The base material layer 10 includes polycarbonate or polymethyl methacrylate, and the anti-glare protrusions 20 include anti-glare particles 22 with a particle size of 10 to 40 μm, providing a sound insulation panel 100 (hereinafter referred to as the sound insulation panel 100) having an anti-glare function.

[0029] The sound insulation panel 100 can exhibit a glossiness of 15 to 52 GU with respect to light incident at 20 to 85°, specifically, it can exhibit a glossiness of 20 to 45 GU, and more specifically, it can exhibit a glossiness of 30 to 40 GU.

[0030] The sound insulation panel 100 mainly includes a base material layer 10 and anti-glare protrusions 20 formed on one surface of the base material layer 10. The base material layer 10 and the anti-glare protrusions 20 are integrally formed by a co-extrusion method.

[0031] The base material layer 10 is made of a synthetic resin with excellent durability and transparency in order to prevent damage or deformation from external impacts. The type thereof is not limited as long as it is a synthetic resin, but specifically, it can be made of polycarbonate or polymethyl methacrylate, and if it has a diffuse reflection effect by itself, it can exhibit a more excellent effect.

[0032] As an example, polycarbonate and polymethyl methacrylate, which are thermoplastic plastics, have the advantages of excellent durability and excellent weather resistance, are colorless and transparent, and when the soundproof panel 100 is manufactured using polycarbonate or polymethyl methacrylate, there is an advantage that the aesthetics of the surrounding environment is not impaired by the soundproof panel 100.

[0033] The base material layer 10 can be formed with a thickness of 6 to 20 mm, specifically 6 to 15 mm, and more specifically 6 to 12 mm.

[0034] If the thickness of the base material layer 10 is less than 6 mm, the shape of the soundproof panel 100 can be distorted or deformed. If the thickness of the base material layer 10 exceeds 20 mm, the workability during the installation of the soundproof wall decreases, the manufacturing cost increases, and the soundproof and anti-glare effects with respect to the thickness do not meet expectations.

[0035] The soundproof panel 100 includes anti-glare protrusions protruding from one surface of the base material layer 10.

[0036] The anti-glare protrusions 20 can protrude to a height of 10 to 200 μm based on one surface of the base material layer 10, specifically 50 to 150 μm, and more specifically 80 to 120 μm.

[0037] If the height of the anti-glare protrusions 20 is less than 10 μm, the anti-glare effect cannot be exerted. If the height exceeds 200 μm, there is a problem that the content of the anti-glare particles 22 described later increases and the manufacturing cost increases.

[0038] The anti-glare protrusions 20 play an anti-glare role by diffusely reflecting the light incident on the soundproof panel 100.

[0039] The longitudinal section of the anti-glare projection can have one shape selected from the group consisting of a conical shape, a semi-circular shape, or a semi-elliptical shape, and specifically, it may be a conical shape. Further, the projections may be arranged irregularly or regularly, but in order to enhance the diffuse reflection effect, it is preferably formed irregularly.

[0040] Since the light incident on the sound insulation panel 100 must not hit and reflect off the sound insulation panel 100 by the anti-glare projections 20, the higher the transmittance of the material, the more the effect can be improved. Further, since a plurality of anti-glare projections 20 are formed on one surface of the base material layer 10, a material having relatively excellent moldability can be used.

[0041] That is, as long as the material is excellent in transparency and moldability, the type thereof is not limited, but specifically, it may be one or more selected from the group consisting of polyethylene, polyvinyl chloride, polyvinyl alcohol, polystyrene, polycarbonate, and polymethyl methacrylate. More specifically, it may be polycarbonate or polymethyl methacrylate.

[0042] In order to further improve the diffuse reflection effect of the sound insulation panel 100, the closer the base material layer 10 and the anti-glare projection 20 have similar refractive indices of light or are made of similar materials, the more the effect can be further improved.

[0043] As an example, when the base material layer 10 is formed of polycarbonate, the anti-glare projection 20 can be formed of polycarbonate, and when the base material layer 10 is formed of polymethyl methacrylate, the anti-glare projection 20 can be polymethyl methacrylate.

[0044] The anti-glare projection 20 can further contain a UV stabilizer, and the UV stabilizer serves to block or reduce the ultraviolet absorption of the base material layer 10 or the anti-glare projection 20. That is, the UV stabilizer serves to prevent the decomposition or yellowing of the base material layer 10 or the anti-glare projection 20 with respect to light.

[0045] UV stabilizers can use ultraviolet absorbers that absorb ultraviolet rays and convert them into thermal energy, quenchers that absorb the energy of chromophores and release it as thermal energy, Hals systems that terminate free radical reactions during decomposition reactions by ultraviolet rays, etc. Among these, Hals-based UV stabilizers with excellent surface protection effects and applicable to thin articles can be used. In addition, Hals-based UV stabilizers have the advantage of not degrading the physical properties of polycarbonate or polymethyl methacrylate.

[0046] The anti-glare protrusion 20 can contain anti-glare particles 22. The anti-glare particles 22 can be dispersed in the anti-glare protrusion to maximize the light diffused reflection effect, thereby preventing glare.

[0047] The anti-glare particles 22 can have a particle size of 10 - 40 μm, specifically, they may have a particle size of 15 - 25 μm, and more specifically, they may have a particle size of 20 μm.

[0048] If the particle size of the anti-glare particles 22 is less than 2 μm, there is a problem that the probability of light reaching the soundproof panel 100 passing between the anti-glare particles 22 is high, so the diffused reflection effect cannot be maximally exerted. If the particle size of the anti-glare particles 22 exceeds 40 μm, there is a problem that the heat resistance decreases, and the light reflected by the anti-glare particles 22 can be reflected by other anti-glare particles 22 again, so the diffused reflection effect can be weakened.

[0049] When the particle size of the anti-glare particles 22 is within the above range, the soundproof panel 100 can exhibit a glossiness of 15 - 52 GU at a light incident angle of 20 - 85°.

[0050] The anti-glare particles 22 may be contained inside the anti-glare protrusion 20, or may be in a form where a part protrudes from the surface of the anti-glare protrusion 20. Since the surface of the anti-glare particles 22 protruding from the surface of the anti-glare protrusion 20 can improve the diffused reflection effect, glare caused by the reflected light can be prevented.

[0051] The protruding portion of the anti-glare particles 22 is 0 to 30% of the average particle size of the anti-glare particles, specifically 10 to 30%, and more specifically 15 to 30%. When it exceeds 30%, there is a problem that the anti-glare particles 22 are likely to fall off, so the above range is preferable.

[0052] That is, as the anti-glare protrusions 20 wear due to the long-term use of the soundproof panel 100 and the anti-glare particles 22 protrude more, the diffuse reflection of light is further improved or the initial level can be maintained.

[0053] In order to effectively mix the anti-glare particles 22 into the anti-glare protrusions and maximize the diffuse reflection effect of light, beads with a refractive index similar to that of the anti-glare protrusions 20 can be used as the anti-glare particles 22. Specifically, polystyrene beads or polymethyl methacrylate beads can be used. As an example, when the anti-glare protrusion 20 is formed of polycarbonate, polystyrene beads can be used as the anti-glare particles 22, and when the anti-glare protrusion 20 is polymethyl methacrylate, polymethyl methacrylate beads can be used as the anti-glare particles 22.

[0054] The anti-glare particles 22 can occupy 10 to 60% by volume, specifically 20 to 50% by volume, and more specifically 30 to 40% by volume, based on 100% by volume of the anti-glare protrusions 20.

[0055] If the volume of the anti-glare particles 22 is less than 10% by volume, the content of the anti-glare particles 22 protruding from the anti-glare protrusions 20 is small and the diffuse reflection effect cannot be maximized. If the volume of the anti-glare particles 22 exceeds 60% by volume, not only is the dispersion of the anti-glare particles 22 not completely achieved in the manufacturing process of the final soundproof panel 100, but also the anti-glare protrusions 20 cannot be easily formed and there is a problem of reduced workability.

[0056] As another embodiment of the present invention, a method for manufacturing a soundproof panel 100 having an anti-glare function is provided.

[0057] Next, a manufacturing method of the soundproof panel 100 having an antiglare function will be briefly described.

[0058] First, materials for forming the base material layer 10 and the antiglare protrusions 20 are prepared. Then, antiglare particles 22 are mixed into the material for forming the antiglare protrusions 20 to prepare a mixture. And a UV stabilizer can be further included as a material for the antiglare layer. The materials for the base material layer 10 and the antiglare protrusions 20 are respectively put into separate extruders and melted. The melted materials are co-extruded to integrally form the antiglare protrusions 20 on one surface of the base material layer 10. Since the base material layer 10 and the antiglare protrusions 20 are integrally formed, there is an advantage that the antiglare protrusions 20 do not easily fall off compared to the conventional film or coating method, have good durability, and do not need to be frequently replaced.

[0059] As described above, the co-extruded antiglare protrusions 20 are formed on the surface of the base material layer 10 by a roll crimping process. In the roll crimping process, the antiglare protrusions 20 are passed through in contact with a roll formed in the same shape as the antiglare protrusions 20. The roll can be formed of metal or rubber.

[0060] Hereinafter, the present invention will be described in more detail using examples. These examples are merely for explaining the present invention more specifically, and it is obvious to those having ordinary knowledge in the technical field that the scope of the present invention is not limited thereby.

[0061] <Example>

[0062] Example 1

[0063] First, a mixture for manufacturing protrusions was manufactured so that polystyrene beads having a particle size of 20 μm accounted for 30% by volume based on 100% by volume of the polycarbonate resin.

[0064] The prepared mixture for manufacturing protrusions and the polycarbonate (for manufacturing the base material layer) resin were put into respective inlets of a co-extruder, melted, and then co-extruded to manufacture a sheet in which a preliminary layer for manufacturing antiglare protrusions was formed on one surface of the base material layer.

[0065] Finally, a soundproof panel was manufactured by pressing a preliminary layer for manufacturing anti-glare protrusions with a roll to form anti-glare protrusions.

[0066] At this time, the temperature of the extruder cylinder was set to about 275 - 285°C, the temperature of the T-die was set to about 260 - 273°C, the speed of the cooling roll was set to about 3.6 rpm, and the speed of the take-up roll was set to 5.5 rpm.

[0067] Example 2

[0068] It was manufactured in the same manner as in Example 1, but a soundproof panel was manufactured such that the volume of the polystyrene beads was 10%.

[0069] Example 3

[0070] It was manufactured in the same manner as in Example 1, but a soundproof panel was manufactured such that the volume of the polystyrene beads was 60%.

[0071] Example 4

[0072] It was manufactured in the same manner as in Example 1, but a soundproof panel was manufactured using polystyrene beads with a particle size of 10 μm.

[0073] Example 5

[0074] It was manufactured in the same manner as in Example 1, but a soundproof panel was manufactured using polystyrene beads with a particle size of 30 μm.

[0075] Example 6

[0076] It was manufactured in the same manner as in Example 1, but a soundproof panel was manufactured using polystyrene beads with a particle size of 40 μm.

[0077] <Comparative Example>

[0078] Comparative Example 1

[0079] Manufactured in the same manner as in Example 1, but a soundproof panel was manufactured such that the volume of the polystyrene beads was 5%.

[0080] Comparative Example 2

[0081] Manufactured in the same manner as in Example 1, but a soundproof panel was manufactured such that the volume of the polystyrene beads was 70%.

[0082] Comparative Example 3

[0083] Manufactured in the same manner as in Example 1, but a soundproof panel was manufactured using polystyrene beads with a particle size of 5 μm.

[0084] Comparative Example 4

[0085] Manufactured in the same manner as in Example 1, but a soundproof panel was manufactured using polystyrene beads with a particle size of 50 μm.

[0086] <Test Example>

[0087] Test Example 1: Analysis of the anti-glare effect depending on the particle size of the beads

[0088] The scattering effect depending on the particle size of the beads was analyzed and shown in Fig. 4.

[0089] Referring to Fig. 4, it can be confirmed that the scattering effect does not increase as the particle size of the beads increases. In the case of Comparative Example 4 where the particle size of the beads was 40 μm, a problem occurred in heat resistance and a defect of turning yellow occurred.

[0090] It can be confirmed that Examples 1, 4, 5, and 6 with a bead particle size of 10 to 40 μm have an excellent scattering effect compared to Comparative Examples 3 and 4. In particular, it can be confirmed that the scattering effect of Example 1 with a bead particle size of 20 μm is the most excellent.

[0091] In summary, it can be confirmed that the soundproof panel having an anti-glare function of the present invention can maximize the anti-glare effect by including beads of a specific size.

[0092] Test Example 2: Analysis of Glossiness

[0093] The glossiness of the sound insulation panels produced by the examples and comparative examples was analyzed.

[0094] Glossiness analysis method: Samples were produced using the sound insulation panels produced by the examples and comparative examples, and light was incident on the surface of the samples at 20°, 60°, and 85° to analyze the amount of incident light that was specularly reflected.

[0095] The glossiness measurement was carried out in accordance with KS M ISO2813 through the Korea Institute of Chemical Fusion Testing and Research, an accredited testing institution, and is shown in Table 1 below.

[0096]

Table 1

[0097] Referring to Table 1, as a result of confirming the glossiness of the examples and comparative examples, it was confirmed that Comparative Example 4 with a large bead size is excellent in glossiness. However, in the case of Comparative Example 4, it was confirmed that there is a problem that the sound insulation panel is discolored by the incident light.

[0098] However, in Examples 1, 3, 5, and 6, excellent glossiness could be confirmed at all incident angles compared to Comparative Example 1. From the above results, it can be confirmed that the sound insulation panel is excellent in glossiness when it contains a specific particle size.

[0099] Test Example 3: Anti-Glare Effect by Bead Content

[0100] The anti-glare effect by the bead content of the sound insulation panels produced according to Examples 1 to 3, Comparative Example 1, and Comparative Example 2 was analyzed and is shown in Table 2 below.

[0101] The analysis method was to analyze the anti-glare effect (diffuse reflection) as very excellent, excellent, good, or poor after irradiating the manufactured soundproof panel with light at 60°.

[0102]

Table 2

[0103] Referring to Table 2, it can be confirmed that the anti-glare effects of Examples 1 to 3 are superior to those of Comparative Example 1 and Comparative Example 2. Specifically, Comparative Example 1 with a low bead content did not show an anti-glare effect, and in the case of Comparative Example 2 with a high bead content, it was measured as good. This is presumably because when the bead content is too high, the diffuse reflection effect decreases due to reflection between the beads. In contrast, in the case of Examples 1 to 3, it can be confirmed that they show excellent anti-glare effects, and in particular, in the case of Example 1, a very excellent diffuse reflection effect can be confirmed.

Explanation of Reference Signs

[0104] 100 Soundproof panel 10 Base material layer 20 Anti-glare protrusions 22 Anti-glare particles

Claims

1. A base layer; and an anti-glare protrusion integrally formed on one surface of the base layer by a co-extrusion method. the substrate layer comprises polycarbonate or polymethyl methacrylate; The soundproof panel has an anti-glare function, and the anti-glare protrusions contain anti-glare particles having a particle size of 10 to 40 μm.

2. The soundproof panel having an antiglare function according to claim 1, wherein the base layer has a thickness of 6 to 20 mm.

3. 2. The soundproof panel having an anti-glare function according to claim 1, wherein the anti-glare protrusions protrude to an average height of 10 to 200 μm from one surface of the base layer.

4. 2. The soundproof panel having an anti-glare function according to claim 1, wherein the cross section of the anti-glare protrusion has one or more shapes selected from the group consisting of a cone shape, a semicircle shape, and a semi-ellipse shape.

5. 2. The soundproof panel having anti-glare function according to claim 1, wherein the anti-glare protrusions comprise polycarbonate or polymethyl methacrylate.

6. The soundproofing panel with anti-glare function according to claim 5 , wherein the anti-glare protrusions further comprise a UV stabilizer.

7. 2. The soundproof panel having an antiglare function according to claim 1, wherein the antiglare particles are polystyrene beads or polymethyl methacrylate beads.

8. 2. The soundproof panel having an anti-glare function according to claim 1, wherein the anti-glare particles are contained in an amount of 10 to 60 volume % relative to 100 volume % of the anti-glare protrusions.

9. 2. The soundproof panel having an anti-glare function according to claim 1, wherein the anti-glare particles are contained in a form in which a part of the anti-glare particles protrudes from the surface of the anti-glare protrusions.

10. 10. The soundproof panel having an antiglare function according to claim 9, wherein the protruding portions of the antiglare particles are 0 to 30% of the average particle size of the antiglare particles.

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