Grained acoustical insulation

Abstract

To provide a stone grain pattern soundproof material which can be formed not by printing but by a conventional soundproof material.SOLUTION: A soundproof material 1A having a stone grain pattern on a design surface 11 includes a first nonwoven fabric layer 10 having the design surface 11, and a fiber material layer 20 positioned on a surface opposite to the design surface 11 of the first nonwoven fabric layer 10 and including a fiber material 21 and a plurality of resins 22 having uneven sizes. A basis weight W1 (g / cm2) of the first nonwoven fabric 10, a content C (g / cm3) of the resinous material 22 per unit volume in the fibrous material layer 20, and a concentration d (g / cm3) of the fibrous material layer 20 satisfy a relationship of the following formula 1:0.34 ≤ (2 - 100W1) C / d ≤ 1.34 formula 1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a stone-patterned soundproofing material. [Background technology]

[0002] A known soundproofing material has a structure in which a nonwoven fabric is laminated to a fiber material layer containing a fiber material. For example, Patent Document 1 describes a vehicle soundproofing member in which a decoupling layer and a mass layer are laminated, and the mass layer has a resin-containing layer to which a member containing a resin of a predetermined range of nonuniform size is bonded, a nonwoven fabric bonded to the decoupling layer side of the resin-containing layer, and a ventilation layer having openings and bonded to the decoupling layer side of the nonwoven fabric. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-196339 Summary of the Invention [Problem to be solved by the invention]

[0004] However, although the vehicle soundproofing material in Patent Document 1 has excellent soundproofing properties, the surface design has not been taken into consideration. Recently, design has been taken into consideration even for functional components such as soundproofing materials, and products with a stone grain pattern are commercially available, but the stone grain pattern is simply printed on the surface, which has the problem of lacking a luxurious feel.

[0005] In view of the above problems, the present invention aims to provide a stone-patterned soundproofing material that can be formed from conventional soundproofing materials, rather than being printed. [Means for solving the problem]

[0006] In order to achieve the above object, the soundproofing material with a pebble pattern according to the present invention is a soundproofing material with a pebble pattern on the design surface, comprising: a first nonwoven fabric having a design surface; and a fiber material layer located on the opposite side of the first nonwoven fabric layer from the design surface and including a fiber material and a plurality of resin materials of non-uniform size, wherein the resin materials are melted and impregnated into the first nonwoven fabric, and the basis weight W1 (g / cm ) of the first nonwoven fabric is 2 ) and the content C (g / cm 3 ) of the resin material per unit volume in the fiber material layer 3 ) and the density d (g / cm 3 ) and the following equation 1: 0.34≦(2-100W1)C / d≦1.34...Equation 1 Satisfy the relationship.

[0007] The resin material has an area of ​​9 to 400 mm 2 The resin material may be a plate-shaped material.

[0008] The soundproofing material of the present invention may further comprise a second nonwoven fabric on the opposite side of the fibrous layer from the first nonwoven fabric.

[0009] The fabric layer may be non-breathable.

[0010] The melting point of the resin material is preferably lower than that of the fiber material of the fiber material layer and that of the first nonwoven fabric. [Effects of the Invention]

[0011] Thus, according to the present invention, by setting the basis weight of the first nonwoven fabric, the resin material content per unit volume in the fiber material layer, and the density of the fiber material layer so as to satisfy the relationship of the above-mentioned formula 1, multiple resin materials of non-uniform size dispersed in the fiber material in the fiber material layer melt and impregnate the first nonwoven fabric, thereby forming a stone pattern on the design surface of the first nonwoven fabric. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view schematically showing one embodiment of a stone-patterned soundproofing material according to the present invention. [Figure 2] 1 is an image showing the design surface of one embodiment of a stone-patterned soundproofing material according to the present invention. [Figure 3] 10 is a cross-sectional view schematically showing another embodiment of the stone-patterned soundproofing material according to the present invention. FIG. [Figure 4] 10 is an image showing the design surface of Test Example 4. [Figure 5] 10 is an image showing the design surface of Test Example 8. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, an embodiment of a stone-patterned soundproofing material according to the present invention will be described with reference to the accompanying drawings.

[0014] As shown in Fig. 1, the stone-patterned soundproofing material 1A of this embodiment includes a first nonwoven fabric 10 having a design surface 11, and a fibrous material layer 20 located on the side of the first nonwoven fabric 10 opposite to the design surface 11. The fibrous material layer 20 includes a fibrous material 21 and a plurality of resin materials 22 of non-uniform sizes. Note that the soundproofing material 1A in Fig. 1 is in a state prior to heat and pressure treatment.

[0015] Fig. 2 shows the design surface 11 of soundproofing material 1B after the soundproofing material 1A in Fig. 1 has been subjected to a heat and pressure treatment. By performing the heat and pressure treatment, the plurality of resin materials 22 of non-uniform size dispersed in the fiber material layer 20 melt and impregnate the first nonwoven fabric 10, and as shown in Fig. 2, the melted resin 22a appears on the design surface 11 as a stone pattern.

[0016] The soundproofing material 1B having such a stone pattern has a basis weight W1 (g / cm 2 ) and the content C (g / cm 3 ) of the resin material 22 per unit volume in the fiber material layer 20 3 ) and the density d (g / cm 3 ) of the fibrous material layer 20 3 ) satisfies the following formula 1. 0.34≦(2-100W1)C / d≦1.34...Equation 1

[0017] In Equation 1, (2-100W1) is an index showing the ease with which the molten resin 22a can pass through the first nonwoven fabric 10. The smaller the basis weight W1 of the first nonwoven fabric 10, the larger the value of (2-100W1), and the easier it is for the molten resin 22a to pass through the first nonwoven fabric 10. Furthermore, C / d in Equation 1 is an index showing the ease with which the molten resin 22a can move from the fiber material layer 20 to the first nonwoven fabric 10. The higher the ratio of the content C of the resin material 22 per unit volume in the fiber material layer 20 to the overall density d of the fiber material layer 20, the larger the value of C / d, and the easier it is for the molten resin 22a to move to the first nonwoven fabric 10.

[0018] Tests in the examples described in this specification have shown that the above two indices are related to each other in order to form a stone grain pattern on the design surface 11 of the soundproofing material 1B. As shown in Equation 1, the value of (2-100W1)C / d is 0.34 g / cm 2 If the value of (2-100W1)C / d is less than 1.34 g / cm, the molten resin 22a does not easily move from the fiber material layer 20 to the first nonwoven fabric 10 and does not easily pass through the first nonwoven fabric 22a, so the amount of molten resin 22a that can reach the design surface 11 is small, and the stone pattern cannot be formed. 2 If the thickness exceeds this value, a large amount of molten resin 22a moves from the fiber material layer 20 to the first nonwoven fabric 10 and passes through the first nonwoven fabric 22a, so that the amount of molten resin 22a that reaches the design surface 11 becomes too large and the stone pattern cannot be formed.

[0019] The material used for the first nonwoven fabric 10 is not particularly limited, but may be, for example, a resin fiber such as polyethylene terephthalate (PET), a natural fiber such as cotton, or a combination of these. If the resin fiber melts when the resin material 22 of the fiber material layer 20 is heated, it becomes difficult for the molten resin 22a to pass through to the design surface 11. Therefore, a resin fiber with a higher melting point than the resin material 22 is preferred, such as PET. Various types of nonwoven fabrics, such as spunbond, spunlace, or needlepunch, may also be used.

[0020] The basis weight W1 of the first nonwoven fabric 10 is not particularly limited as long as it satisfies the above formula 1, but is, for example, 0.0015 to 0.02 g / cm 2 The range of 0.0015 to 0.013 g / cm is preferable. 2 The range is more preferable.

[0021] The fiber material 21 used in the fiber material layer 20 is not particularly limited as long as it is a fiber material conventionally used in soundproofing materials, but for example, resin fibers such as PET, natural fibers such as cotton, or a combination of these can be used. In the case of resin fibers, if the resin fibers melt when the resin material 22 is heated, it becomes difficult to move the molten resin 22a to the design surface 11. Therefore, a resin fiber with a higher melting point than the resin material 22 is preferred, and for example, PET is preferably used. The fiber material 21 may further contain commonly used additives such as colorants, antioxidants, and antistatic agents.

[0022] The resin material 22 dispersed in the fiber material layer 20 is not particularly limited as long as it is a thermoplastic resin that melts when heated. However, as described above, a material with a lower melting point than the fiber material 21 of the first nonwoven fabric 10 and the fiber material layer 20 is preferred, such as polypropylene (PP) or polyethylene (PE). The fiber material 21 and the resin material 22 may also be recycled materials such as vehicle interior carpets. For example, when a vehicle interior carpet made of a thermoformed resin fiber layer and a resin layer such as a backing material is used as the recycled material, the recycled material can be shredded to obtain a mixture of the fiber material 21 and the resin material 22. That is, the fiber material layer 20 may be formed by cutting a thermoformed product having a resin fiber layer and a resin layer, and bonding the cut product to the first nonwoven fabric 10 by a heat and pressure treatment. Alternatively, a recycled fiber material from a thermoformed fiber component may be prepared as the fiber material 21, and a recycled resin component may be prepared as the resin material 22, and the resulting cut scraps may be mixed together.

[0023] The shape of the resin material 22 is not particularly limited, but a plate-like shape is preferable in order to form a stone grain pattern on the design surface 11. The size of the resin material 22 needs to be non-uniform in order to form a stone grain pattern on the design surface 11. For example, in the case of a plate-like resin material 22, the area is set to 9 to 400 mm 2 It is preferable that the resin material 22 be non-uniform in size within the range of 1. Such non-uniform size resin material 22 can be obtained, for example, by crushing and pulverizing a sheet-like resin.

[0024] The content C of the resin material 22 per unit volume in the fiber material layer 20 is not particularly limited as long as it satisfies the above formula 1, but is, for example, 0.1 to 0.63 g / cm 3 The range of 0.27 to 0.63 g / cm is preferable. 3 The overall density d of the fiber material layer 20 is not particularly limited as long as it satisfies the above formula 1, but may be, for example, 0.30 to 0.91 g / cm 3 The range of 0.57 to 0.91 g / cm is preferable. 3 The range is more preferable.

[0025] In addition, it is preferable that the fiber material layer 20 is non-breathable. 3 In the above cases, the soundproofing material 1B can be said to be non-breathable. By making the fiber material layer 20 non-breathable, the soundproofing material 1B can have sound insulation performance. In order to make the fiber material layer 20 non-breathable, for example, the density d of the fiber material layer 20 is set to 0.5 g / cm 3 The above is all that is needed.

[0026] The soundproofing material 1B shown in Fig. 2 can be obtained by subjecting the soundproofing material 1A shown in Fig. 1 to a heating and pressurizing treatment, for example, using a heat press or the like. The heating and pressurizing treatment conditions are such that the temperature is preferably equal to or higher than the melting point of the resin material 22 of the fiber material layer 20 and lower than the melting points of the fiber material 21 of the fiber material layer 20 and the first nonwoven fabric 10, for example, 50 to 200°C. The pressure is not particularly limited as long as it is a pressure that allows the fiber material 21 mixed with the resin material 22 of non-uniform size and arranged in layers on the first nonwoven fabric 10 to be formed into a sheet, but may be, for example, 0.39 to 1.96 MPa.

[0027] By carrying out the heat and pressure treatment in this manner, the resin material 22 of non-uniform size dispersed in the fiber material layer 20 melts and impregnates the first nonwoven fabric 10, and this molten resin 22a reaches the design surface 11 of the first nonwoven fabric 10, thereby forming a stone pattern on the design surface 11. Furthermore, by impregnating the first nonwoven fabric 10 from the fiber material layer 20 with the molten resin 22a in this manner, the first nonwoven fabric 10 and the fiber material layer 20 can be firmly bonded together.

[0028] The pebble-patterned soundproofing material of the present invention is not limited to the configuration shown in FIG. 1 , and may be, for example, a soundproofing material 1A further including a second nonwoven fabric 30 on the opposite side of the fiber material layer 20 from the first nonwoven fabric 10, as shown in FIG. 3 . The material of the second nonwoven fabric 30 may be the same as that of the first nonwoven fabric 10. Unlike the first nonwoven fabric 10, the basis weight of the second nonwoven fabric 30 does not need to satisfy the above formula 1. By using a second nonwoven fabric 30 with a larger basis weight, a soundproofing material without a pebble pattern on the surface of the second nonwoven fabric 30 may be obtained.

[0029] Similarly to the first nonwoven fabric 10, the basis weight W2 of the second nonwoven fabric 30 is determined by the relationship between the content C of the resin material 22 and the density d of the fiber material layer 20 as shown in the following formula 2: 0.34≦(2-100W2)C / d≦1.34...Equation 2 When formula (1) and formula (2) are satisfied, it is possible to obtain a reversible soundproofing material having a pebbled pattern on both sides of the first and second nonwoven fabrics 10 and 30. The basis weight W1 of the first nonwoven fabric 10 and the basis weight W2 of the second nonwoven fabric 30 may be the same, but by making a difference between the basis weight W1 of the first nonwoven fabric 10 and the basis weight W2 of the second nonwoven fabric 30 within a range that satisfies formula (1) and formula (2) above, it is also possible to change the appearance of the pebbled pattern on each side.

[0030] The soundproofing material 1A provided with the second nonwoven fabric 30 in this manner can also be molded into a three-layer sheet-like soundproofing material 1B having a stone pattern on the design surface 11 by heating and pressurizing using a heat press or the like, as described above. [Example]

[0031] Examples of the present invention will be described below, but the present invention is not limited to these examples.

[0032] The first nonwoven fabric is a PET fiber spunlace nonwoven fabric, the fiber material of the fiber material layer is PET fiber, and the resin material dispersed in the fiber material layer is crushed and crushed to an area of ​​approximately 9 to 400 mm. 2 Using this PP plate, soundproofing materials were produced by adjusting the basis weight W1 of the first nonwoven fabric, the resin content C per unit volume in the fiber material layer, and the density d of the fiber material layer as shown in Table 1 (Test Examples 1 to 12). The heat and pressure treatment was carried out using a heat press under conditions of a temperature of 200°C and a pressure of 1.47 MPa. The design surface of the first nonwoven fabric was then evaluated for the formation of a stone grain pattern. The results are also shown in Table 1. Images of the design surface of Test Example 4 are shown in Figure 4, and images of the design surface of Test Example 8 are shown in Figure 5. Table 1 also shows the configurations and evaluation results of conventional soundproofing materials comprising commercially available nonwoven fabrics and fiber material layers.

[0033] [Table 1]

[0034] As shown in Table 1, the (2-100W1)C / d value is 0.34 to 1.36 g / cm 2 In test examples 1 to 4 and 8 to 11, which were within the range, a beautiful stone grain pattern was formed on the design surface. 2 In Test Example 4, which had a (2-100W1)C / d value of 0.01g, it was confirmed that a beautiful stone grain pattern consisting of molten resin 22a was formed in places on the design surface 11, as shown in Figure 4. In Test Examples 5, 6, and 12 and the conventional material, which had smaller values ​​of (2-100W1)C / d, the molten resin did not reach the design surface, or if it did reach it, it was only in small amounts, and it was not possible to create what could be called a stone grain pattern.

[0035] On the other hand, the value of (2-100W1)C / d is the upper limit of 1.34 cm 2In Test Example 8, where the (2-100W1)C / d value was 0.01, it was confirmed that a beautiful stone grain pattern consisting of molten resin 22a was formed over the entire design surface 11, as shown in Figure 5. In Test Example 7, where the (2-100W1)C / d value was larger, most of the design surface was made of molten resin, and this also did not have the appearance of a stone grain pattern. [Explanation of symbols]

[0036] 1B Stone-patterned soundproofing material 10. First nonwoven fabric 20 Fiber layer 21 Fiber materials 22 Resin material of uneven size 30 Second nonwoven fabric

Claims

1. a first nonwoven fabric having a designed surface; a fiber material layer located on the opposite side of the first nonwoven fabric layer from the design surface, the fiber material layer including a fiber material and a plurality of resin materials having non-uniform sizes; A soundproofing material having a stone grain pattern on the design surface, the resin material is melted and impregnated into the first nonwoven fabric, The basis weight W of the first nonwoven fabric １ (g / cm ２ ) and the content C (g / cm ) of the resin material per unit volume in the fiber material layer ３ ) and the density d (g / cm ３ ) and the following formula 1: 0.34≦(2-100W １ C / d≦1.34 ・・・Equation 1 Soundproofing material that meets the requirements.

2. The resin material has an area of ​​9 to 400 mm ２ 2. The soundproofing material according to claim 1, comprising a plate-shaped resin material.

3. 3. The soundproofing material according to claim 1, further comprising a second nonwoven fabric on the opposite side of the fibrous layer from the first nonwoven fabric.

4. 3. The soundproofing material according to claim 1, wherein the fibrous material layer is non-breathable.

5. 3. The soundproofing material according to claim 1, wherein the melting point of the resin material is lower than that of the fiber material of the fiber material layer and that of the first nonwoven fabric.

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