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

Patent metadata

Field	Value
Publication number	US-9805708-B2
Application number	US-201415105920-A
Country	US
Kind code	B2
Filing date	Apr 3, 2014
Priority date	Dec 19, 2013
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

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.

First claim

What is claimed is:

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/m 2 .

11. The sound absorbing and insulating material according to claim 10 , wherein the nonwoven fabric has a density of 200-1200 g/m 2 .

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

Assignees

• Hyundai Motor Co Ltd

Inventors

• Kim Keun Young

Classifications

• B32B2605/00

  Vehicles · CPC title

• B60R13/08

  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 title

• G10K11/168 Primary

  Plural layers of different materials, e.g. sandwiches · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B37/06

  characterised by the heating method · CPC title