Sound absorbing and insulating material with superior moldability and appearance and method for manufacturing the same

• US 9,805,708 B2
• Filed: 04/03/2014
• Issued: 10/31/2017
• Est. Priority Date: 12/19/2013
• Status: Active Grant

• Current Assignee: Hyundai Motor Company (Hyundai Motor Group)
• Original Assignee: Hyundai Motor Company (Hyundai Motor Group)
• Inventors: Kim, Keun Young
• Primary Examiner(s): Phillips, Forrest M
• Application Number:
  US15/105,920
• Publication Number:
  US 20160322041A1
• Time in Patent Office: 1,307 Days
• Field of Search: 181290
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/10 Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/738 Thermoformability
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/14 : characterised by the properties of the layers
• CPC Class Codes: B32B 38/12 : Deep-drawing
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• 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 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/08 : Insulating elements, e.g. for sound insulation sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178
• CPC Class Codes: D04H 1/4374 : using different kinds of webs, e.g. by layering webs
• CPC Class Codes: F16L 59/02 : Shape or form of insulating materials, with or without coverings integral with the insulating materials
• CPC Class Codes: G10K 11/168 : Plural layers of different materials, e.g. sandwiches

Abstract

The present invention relates to a sound absorbing and insulating material with superior moldability and appearance and a method for manufacturing the same, more particularly to a sound absorbing and insulating material consisting of an inner sound absorbing and insulating layer 1 formed of a first nonwoven fabric mainly formed of a heat-resistant fiber and a binder uniformly distributed inside the first nonwoven fabric and maintaining the three-dimensional structure inside the first nonwoven fabric and an outer sound absorbing and insulating layer 2′, 2″ formed of a second nonwoven fabric mainly formed of a heat-resistant fiber, wherein the outer sound absorbing and insulating layer is stacked on one or both sides of the inner sound absorbing and insulating layer, and a method for manufacturing the same. The sound absorbing and insulating material of the present invention has superior sound-absorbing property, flame retardancy, heat resistance, heat-insulating property and high-temperature moldability. In addition, there is no concern of deterioration of surface appearance caused by leakage of the binder due to the presence of the outer sound absorbing and insulating layer.

Claims

1. A sound absorbing and insulating material comprising:

an inner sound absorbing and insulating layer comprising a first nonwoven fabric comprising 30-100 wt % of a heat-resistant fiber and a binder present in the same layer as the first nonwoven fabric and maintaining a three-dimensional structure inside the nonwoven fabric,

wherein the binder is uniformly distributed and attached to the surface of a fiber yarn of the nonwoven fabric and maintains or further forms micro cavities of the nonwoven fabric; and

an outer sound absorbing and insulating layer for preventing leakage of the binder included in the inner sound absorbing and insulating layer comprising a second nonwoven fabric that does not comprise a binder and comprises 30-100 wt % of a heat-resistant fiber,

wherein the outer sound absorbing and insulating layer is stacked on one or both sides of the inner sound absorbing and insulating layer, and a thickness of the outer sound absorbing and insulating layer is thinner than a thickness of the inner sound absorbing and insulating layer.

2. The sound absorbing and insulating material according to claim 1, wherein, the stacking between the inner sound absorbing and insulating layer and the outer sound absorbing and insulating layer is achieved by an adhesive, heat or pressure.

3. The sound absorbing and insulating material according to claim 1, wherein an adhesive is coated on one side of the outer sound absorbing and insulating layer and then the outer sound absorbing and insulating layer is stacked by contacting the adhesive-coated side with the inner sound absorbing and insulating layer.

4. The sound absorbing and insulating material according to claim 3, wherein the adhesive used for the stacking between the inner sound absorbing and insulating layer and the outer sound absorbing and insulating layer is the binder contained in the first nonwoven fabric.

5. The sound absorbing and insulating material according to claim 4, wherein the adhesive is a thermosetting resin.

6. The sound absorbing and insulating material according to claim 1, wherein the heat-resistant fiber constituting the first nonwoven fabric or the second nonwoven fabric has a limiting oxygen index (LOI) of 25% or greater and a heat resistance temperature of 150°

C. or greater.

7. The sound absorbing and insulating material according to claim 6, wherein the heat-resistant fiber is one or more selected from a group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile (oxi-PAN) fiber, a polyimide (PI) fiber, a polybenzimidazole (PBI) fiber, a polybenzoxazole (PBO) fiber, a polytetrafluoroethylene (PTFE) fiber, a polyketone (PK) fiber, a metallic fiber, a carbon fiber, a glass fiber, a basalt fiber, a silica fiber and a ceramic fiber.

8. The sound absorbing and insulating material according to claim 7, wherein the heat-resistant fiber is an aramid fiber.

9. The sound absorbing and insulating material according to claim 1, wherein the first nonwoven fabric or the second nonwoven fabric is formed of an aramid fiber having a fineness of 1-15 denier and is a single-layered nonwoven fabric having a thickness of 3-20 mm.

10. The sound absorbing and insulating material according to claim 1, wherein the first nonwoven fabric or the second nonwoven fabric has a density of 100-2000 g/m².

11. The sound absorbing and insulating material according to claim 10, wherein the nonwoven fabric has a density of 200-1200 g/m².

12. The sound absorbing and insulating material according to claim 1, wherein the inner sound absorbing and insulating layer is formed of a single layer or multiple layers.

13. The sound absorbing and insulating material according to claim 1, wherein the binder included in the inner sound absorbing and insulating layer is a thermosetting resin.

14. The sound absorbing and insulating material according to claim 5, wherein the thermosetting resin is an epoxy resin.

15. The sound absorbing and insulating material according to claim 14, wherein the epoxy resin is one or more epoxy resin selected from a group consisting of bisphenol A diglycidyl ether, bisphenol B diglycidyl ether, bisphenol AD diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, polyoxypropylene diglycidyl ether, a bisphenol A diglycidyl ether polymer, phosphazene diglycidyl ether, bisphenol A novolac epoxy, a phenol novolac epoxy resin and an o-cresol novolac epoxy resin.

16. The sound absorbing and insulating material according to any of claim 1, wherein the sound absorbing and insulating material is molded to have a three-dimensional shape corresponding to that to which the sound absorbing and insulating material is applied.

17. The sound absorbing and insulating material according to claim 16, wherein the sound absorbing and insulating material is for an automobile.

18. A method for manufacturing the sound absorbing and insulating material according to claim 1, comprising:

a) immersing a first nonwoven fabric comprising 30-100 wt % of a heat-resistant fiber in a binder solution;

b) forming an inner sound absorbing and insulating layer 1 by drying the first nonwoven fabric; and

c) forming an outer sound absorbing and insulating layer 2′

, 2″

by stacking a second nonwoven fabric comprising 30-100 wt % of a heat-resistant fiber on one or both sides of the inner sound absorbing and insulating layer 1.

19. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein which further comprises, after c), d) molding the sound absorbing and insulating material at high temperature.

20. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the drying in b) is performed at a temperature of 70-200 and the inner sound absorbing and insulating layer formed by the drying comprises 1-300 parts by weight of a binder based on 100 parts by weight of the nonwoven fabric.

21. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the stacking in c) is achieved by an adhesive, heat or pressure.

22. The method for manufacturing the sound absorbing and insulating material according to claim 21, wherein the stacking is performed by coating an adhesive on one side of the second nonwoven fabric and then contacting the side on which the adhesive has been coated with the inner sound absorbing and insulating layer.

23. The method for manufacturing the sound absorbing and insulating material according to claim 22, wherein the adhesive is a binder included in the first nonwoven fabric.

24. The method for manufacturing the sound absorbing and insulating material according to claim 23, wherein the adhesive is a thermosetting resin.

25. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the heat-resistant fiber constituting the first nonwoven fabric or the second nonwoven fabric has a limiting oxygen index (LOI) of 25% or greater and a heat resistance temperature of 150 degree °

C. or greater.

26. The method for manufacturing the sound absorbing and insulating material according to claim 25, wherein the heat-resistant fiber is one or more selected from a group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile (oxi-PAN) fiber, a polyimide (PI) fiber, a polybenzimidazole (PBI) fiber, a polybenzoxazole (PBO) fiber, a polytetrafluoroethylene (PTFE) fiber, a polyketone (PK) fiber, a metallic fiber, a carbon fiber, a glass fiber, basalt fiber, a silica fiber and a ceramic fiber.

27. The method for manufacturing the sound absorbing and insulating material according to claim 25, wherein the heat-resistant fiber is an aramid fiber having a fineness of 1-15 denier and a yarn length of 20-100 mm.

28. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the first nonwoven fabric or the second nonwoven fabric has a thickness of 3-20 mm and a density of 100-2000 g/m².

29. The method for manufacturing the sound absorbing and insulating material according to claim 28, wherein the first nonwoven fabric or the second nonwoven fabric is an aramid nonwoven fabric having a thickness of 3-20 mm, formed by needle punching of a heat-resistant aramid fiber having a fineness of 1-15 denier.

30. The method for manufacturing the sound absorbing and insulating material according to claim 29, wherein the nonwoven fabric is formed by continuously performing up-down needling, down-up needling and up-down needling.

31. The method for manufacturing the sound absorbing and insulating material according to claim 29, wherein the nonwoven fabric is formed with a needle stroke of 30-350 times/m².

32. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the binder solution comprises 1-60 wt % of a binder, 0.1-10 wt % of a curing agent, 0.01-5 wt % of a catalyst, 1-40 wt % of an additive and a solvent as the remainder.

33. The method for manufacturing the sound absorbing and insulating material according to claim 32, wherein the binder solution comprises 1-30 wt % of a binder, 0.1-10 wt % of a curing agent, 0.01-5 wt % of a catalyst, 1-30 wt % of a flame retardant and 40-95 wt % of a solvent.

34. The method for manufacturing the sound absorbing and insulating material according to claim 33, wherein the binder is a thermosetting resin.

35. The method for manufacturing the sound absorbing and insulating material according to claim 34, wherein the thermosetting resin is an epoxy resin.

36. The method for manufacturing the sound absorbing and insulating material according to claim 35, wherein the epoxy resin is one or more selected from a group consisting of bisphenol A diglycidyl ether, bisphenol B diglycidyl ether, bisphenol AD diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, polyoxypropylene diglycidyl ether, a bisphenol A diglycidyl ether polymer, phosphazene diglycidyl ether, bisphenol A novolac epoxy, a phenol novolac epoxy resin and an o-cresol novolac epoxy resin.

37. The method for manufacturing the sound absorbing and insulating material according to claim 18, wherein the sound absorbing and insulating material is for an automobile.

38. A method for reducing noise of a noise-generating device, comprising:

i) checking a three-dimensional shape of a noise-generating device;

ii) preparing and molding the sound absorbing and insulating material according to claim 1 so as to correspond to the three-dimensional shape of the device partially or entirely; and

iii) bringing the sound absorbing and insulating material adjacent to the noise-generating device.

39. The method for reducing noise of a noise-generating device according to claim 38, wherein the device is a motor, an engine or an exhaust system.

40. The method for reducing noise of a noise-generating device according to claim 39, wherein the sound absorbing and insulating material is brought adjacent to the noise-generating device by attaching the sound absorbing and insulating material to the noise-generating device, providing the sound absorbing and insulating material with a distance from the noise-generating device, or molding the sound absorbing and insulating material as a part of the noise-generating device.