Sound absorbing material, multilayer sound absorbing material, molded product of multilayer sound absorbing material, sound absorbing interior material, and sound absorbing floor covering material

• US 8,393,438 B2
• Filed: 03/18/2009
• Issued: 03/12/2013
• Est. Priority Date: 10/02/2008
• Status: Active Grant

• Current Assignee: Nagoya Oilchemical Co., Ltd.
• Original Assignee: Nagoya Oilchemical Co., Ltd.
• Inventors: Ogawa, Masanori, Fujii, Makoto, Mizutani, Naohiro
• Primary Examiner(s): LUKS, JEREMY AUSTIN
• Application Number:
  US13/122,287
• Publication Number:
  US 20110186381A1
• Time in Patent Office: 1,455 Days
• Field of Search: 181/210, 181/286, 181/290
• US Class Current: 181/290
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: G10K 11/162 Selection of materials

Abstract

The object of the present invention is to provide a sound absorbing material having a light weight and excellent sound absorbing performance, and a sound absorbing material consisting of a fiber sheet made of fibers containing at least 50% by mass of a porous fiber having many minute pores, each minute pore opening onto the surface of the porous fiber, and having an airflow resistance in the range of between 0.05 and 3.0 kPa·s/m.

The porous fiber having many minute pores, each one opening onto the surface of the porous fiber, has air-permeability, and so a sound absorbing property in itself, and a sheet made of the porous fiber having air-permeability and sound absorbing property has even further sound absorbing properties created by the spaces between the porous fibers, resulting in the sheet becoming a sound absorbing material with extremely great sound absorbing efficiency.

Claims

1. A multilayered sound absorbing material comprising a sound absorbing material and a porous sheet wherein said sound absorbing material consists of a fiber sheet made of fibers containing at least 50% by mass of a porous fiber having many minute pores, each minute pore opening onto the surface of said fiber, said sound absorbing material having a unit weight in the range of between 10 and 50 g/m² and an airflow resistance in the range of between 0.05 and 3.0 kPa·

s/m, wherein said porous fiber is a porous pulp fiber having a beating or refining degree in the range of between 350 and 650 ml on the basis of Canadian Standard Freeness (CFS) provided in JIS P 8121-1995-4 Canadian Standard Freeness, or in the range of between 15 and 30°

SR on the basis of Schopper-Riegler Freeness provided in JIS P 8121-1995-5 Schopper-Riegler Type Freeness Test Method, and said fiber sheet has contraction and expansion properties by carrying out crepe processing on said fiber sheet to provide a crepe processed fiber sheet having a creping degree in the range of between 10 and 50%, or carrying out embossing on said fiber sheet to provide an embossed fiber sheet having many projections, the height of each projection being in the range of between 0.02 and 2.00mm, with the number of said projections being between 20 and 200 projections/cm² and said porous sheet consists of a fiber sheet in which a thermoplastic fiber having a melting point below 180°

C. is partially or wholly used and said sound absorbing material and said porous sheet are bonded together by an air-permeable hotmelt adhesive layer to secure the air-permeability of the resulting mutilayered sound absorbing material.

2. A multilayered sound absorbing material in accordance with claim 1, wherein the air-flow resistance of said fiber sheet is adjusted by coating or impregnating or mixing a synthetic resin or a synthetic resin precursor on or into said fiber sheet.

3. A multilayered sound absorbing material in accordance with claim 1, wherein said fiber sheet covers an under layer and is appropriately colored to conceal the color of the under layer which said fiber sheet covers.

4. A multilayered sound absorbing material in accordance with claim 1, wherein said fiber sheet(s), which is (are) sound absorbing material(s), is (are) laminated onto one or both sides of a porous sheet.

5. A multilayered sound absorbing material in accordance with claim 1, wherein porous sheets are laminated on both sides of said fiber sheet, which is sound absorbing material.

6. A multilayered sound absorbing material in accordance with claim 4, wherein the airflow resistance of the multilayered sound absorbing material is in the range of between 0.08 and 6.0 kPa·

s/m.

7. A multilayered sound absorbing material in accordance with claim 4, wherein a synthetic resin or a synthetic resin precursor is (are) coated or impregnated or mixed on or into said porous sheet.

8. A molded multilayered sound absorbing material, wherein said multilayered sound absorbing material in accordance with claim 4 is molded into a prescribed shape.

9. A sound absorbing interior finishing material consisting of a laminated material, wherein said multilayered sound absorbing material in accordance with claim 4 is used as a surface material and said surface material is laminated onto the surface of a porous base sheet wherein the airflow resistance of said laminated material is set to be in the range of between 0.08 and 6.0 kPa·

s/m.

10. A sound absorbing floor covering material consisting of a carpet, onto the backside of which said multilayered sound absorbing material in accordance with claim 4 is laminated.

11. A multilayered sound absorbing material in accordance with claim 2, wherein said fiber sheet covers an under layer and is appropriately colored to conceal the color of the under layer which said fiber sheet covers.

12. A multilayered sound absorbing material in accordance with claim 2, wherein said fiber sheet(s), which is (are) sound absorbing material(s), is (are) laminated onto one or both sides of a porous sheet.

13. A multilayered sound absorbing material in accordance with claim 3, wherein said fiber sheet(s), which is (are) sound absorbing material(s), is (are) laminated onto one or both sides of a porous sheet.

14. A multilayered sound absorbing material in accordance with claim 5, wherein said fiber sheet and said porous sheet are bonded together through an air permeable adhesive layer, the airflow resistance of the resulting multilayered sound absorbing material being in the range of between 0.08 and 6.0 kPa·

s/m.

15. A multilayered sound absorbing material in accordance with claim 5, wherein a synthetic resin and/or a synthetic resin precursor is (are) coated or impregnated or mixed on or into said porous sheet.

16. A multilayered sound absorbing material in accordance with claim 6, wherein a synthetic resin or a synthetic resin precursor is (are) coated or impregnated or mixed on or into said porous sheet.

17. A molded multilayered sound absorbing material, wherein said multilayered sound absorbing material in accordance with claim 5 is molded into a prescribed shape.

18. A molded multilayered sound absorbing material, wherein said multilayered sound absorbing material in accordance with claim 6 is molded into a prescribed shape.

19. A sound absorbing interior finishing material consisting of a laminated material, wherein said multilayered sound absorbing material in accordance with claim 8 is used as a surface material and said surface material is laminated onto the surface of a porous base sheet wherein the airflow resistance of said laminated material is set to be in the range of between 0.08 and 6.0 kPa·

s/m.

20. A sound absorbing floor covering material consisting of a carpet, onto the backside of which said multilayered sound absorbing material in accordance with claim 8 is laminated.