method for manufacturing a highly heat resistant sound absorbing and insulating material; and method

专利摘要:
METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT INSULATING AND SOUND ABSORBING MATERIAL; AND METHOD FOR NOISE REDUCTION FROM A NOISE GENERATION DEVICE. The present invention relates to a method for manufacturing a highly heat resistant sound absorbing and insulating material, more specifically to a method including a beating and mixing step, a meshing step, a stacking step. mesh, a needle piercing step, a binder impregnation step and a solvent recovery step. The highly heat resistant sound absorbing and insulating material manufactured by the method according to the present invention can be installed in a location closer to the noise source of a mechanism or an exhaust system to reduce radiated noise from the engine or of the exhaust system, thus improving peace of mind inside a vehicle and can be applied to a location adjacent to a piece of metal that is at a temperature of 200 °C or greater to perform the thermal insulation function, thus, protecting nearby plastic and rubber parts.
公开号:BR112015010321B1
申请号:R112015010321-9
申请日:2013-11-06
公开日:2021-05-11
发明作者:Keun Young Kim；Jung Wook Lee；Won Jin Seo；Won Ku Lee；Su Nam Lee；Byung Cheol Cho
申请人:Hyundai Motor Company；Kia Motors Corporation；
IPC主号:

专利说明:

HISTORY OF THE INVENTION TECHNICAL FIELD
[001] The present invention relates to a method for manufacturing an insulating and sound absorbing material highly resistant to heat. More specifically, it refers to a method for manufacturing a highly heat resistant sound absorbing and insulating material that does not experience shape change even under a high temperature environment of 200 °C or greater and meets UL flame retardancy. 94V-0, which includes a whipping and mixing step, a meshing step, a mesh stacking step, a needle piercing step, a binder impregnation step, and a solvent recovery step. PRIOR TECHNIQUE
[002] Various noises are generated while driving a vehicle. Vehicle noise is mainly generated from a mechanism or an exhaust system and is transferred to the interior of a vehicle by air. An insulating and sound absorbing material is used to reduce the noise generated from the engine and exhaust system being transferred into the vehicle interior. An insulating panel, an insulating panel plate and the like used to block noise radiating from the engine being transferred into the vehicle interior and a tunnel damper, floor mat and the like are used to block the noise generated from the exhaust system and the floor from being transferred to the interior of the vehicle.
[003] As sound-absorbing materials for a vehicle, Korean Patent Publication No. 2004-0013840 discloses an insulating and sound-absorbing material with a thickness of 20 mm having a PET fiber layer on which a synthetic resin film layer having a thickness of 40-100 µm in the longitudinal direction is inserted and Korean Patent Publication No. 2002-0089277 discloses a process for preparing a sound-absorbing insulation material from a non-woven fabric form by cutting and beating of a polyester fiber and an acrylic fiber, mixed with a polyester fiber with a low melting point in a specific ratio and molding and heating it. And Korean Patent Publication No. 2006-0043576 discloses a method of coating at least one of a top layer and a bottom layer of a polyester felt (PET) with a resin, using a fiber blend of a fiber. with a low melting point (LMF) and a regular fiber.
[004] The insulating and sound absorbing materials for vehicles reported so far are limited in that the weight is inevitably increased to reduce radiated noise from the engine or exhaust system and the noise reduction efficiency within the vehicle is low when considering weight gain. In order to overcome this limitation, it is necessary to install the insulating and sound absorbing material in a location closer to the engine or exhaust system. To install the insulating and sound absorbing material at the location closest to the engine or exhaust system, the shape change should not take place even under a high temperature environment of 200 °C or greater and flame retardancy must be ensured. For this reason, the insulating and sound absorbing materials currently used for vehicles cannot be used for such applications. SUMMARY OF THE INVENTION
[005] The present invention relates to the provision of a method for the manufacture of a highly heat-resistant sound absorbing and insulating material that does not undergo a change in shape at a location closer to the noise source of a mechanism or a system of exhaust under a high temperature environment of 200 °C or greater and meets UL 94V-0 flame retardancy.
[006] The present invention also relates to the provision of a method for manufacturing a highly heat-resistant sound absorbing and insulating material that is applied at a location adjacent to a piece of metal that is at a temperature of 200 °C or larger to protect nearby plastic and rubber parts.
[007] The present invention also relates to the provision of a method for the effective fabrication of a new concept of highly heat resistant sound absorbing and insulating material that can be molded as it is.
[008] In one aspect, the present invention provides a method for manufacturing a highly heat resistant sound absorbing and insulating material, including: a step of beating and beating mixing and mixing of a fiber material containing a resistant fiber to heat; a network-forming step of forming a network of the whipped and blended fiber material; a net stacking step of stacking the formed net; a needle piercing step of forming a non-woven fabric by moving a needle up and down through the stacked net; a binder impregnation step of forming a binder-impregnated nonwoven fabric by dipping the nonwoven fabric into a binder solution; and a solvent recovery step of removing a solvent from the binder impregnated nonwoven fabric to obtain a nonwoven fabric used as an insulating and sound absorbing material.
[009] In another aspect, the present invention provides a method for manufacturing a highly heat-resistant sound absorbing and insulating material, including: a step of beating and beating and mixing and mixing of a fiber material containing: a fiber heat resistant; a network-forming step of forming a network of the whipped and blended fiber material; a net stacking step of stacking the formed net; a needle piercing step of forming a non-woven fabric by moving a needle up and down through the stacked net; a binder impregnation step of forming a binder-impregnated nonwoven fabric by dipping the nonwoven fabric into a binder solution; a solvent recovery step of removing a solvent from the binder-impregnated nonwoven fabric; and a step of shaping the dry non-woven fabric into an insulating and sound absorbing material having a desired shape.
[010] In an exemplary embodiment of the present invention, the beating and mixing step may include beating a fiber material having a limiting oxygen index (LOI) of 25% or greater and a thermal resistance temperature of 200 °C or larger, having 1-10 folds/cm and having a diameter of 1-33 µm and a length of 20-100 mm, the blend of one or more fiber materials having a limiting oxygen index (LOI) of 25% or larger and a thermal resistance temperature of 200°C or greater, having 1-10 folds/cm and having a diameter of 1-33 µm and a length of 20-100 mm or carrying out beating and mixing under the conditions described above.
[011] In another exemplary embodiment of the present invention, the fiber material may include one or more selected from the group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile fiber (oxy-PAN) ), a polyimide (PI) fiber, a polybenzimidazole (PBI) fiber, a polybenzoxazole (PBO) fiber, a polytetrafluoroethylene (PTFE) fiber, a polyketone (PK) fiber, a metallic fiber, a fiber of carbon, a fiberglass, a basalt fiber, a silica fiber and a ceramic fiber.
[012] In an exemplary embodiment of the present invention, the meshing step can be a step in which the fiber material is beaten and mixed in a beating step and the mixture is placed on a winch having workers on both sides and a cylinder of a carding machine as a wheel preferably at high speed and the fiber is carded to form a continuous net in the form of a thin sheet and can be performed by the carding method.
[013] In an exemplary embodiment of the present invention, the net stacking step may be a step in which the net formed in the net formation step is stacked with each other by overlapping on a conveyor belt to form a stacked net and it can be carried out at a rate of 10 m/min or less using a horizontal package in order to prevent scattering of the net due to air resistance and net breakage on the conveyor belt.
[014] In an exemplary embodiment of the present invention, the needle piercing step may be a step in which the stacked net formed in the net stacking step is connected together by moving a needle up and down through the stacked net and can be performed by one or more selected from the group consisting of single down needle punching, single up needle punching, double down needle punching and double up needle punching.
[015] In another exemplary embodiment of the present invention, the needle piercing step may include forming a non-woven fabric with a needle stroke of 30-350 times/m2.
[016] In another exemplary embodiment of the present invention, the needle punching step may include forming a non-woven fabric having a single layer thickness of 3-20 mm and a density of 100-2000 g/m2.
[017] In an exemplary embodiment of the present invention, the binder impregnation step may include immersing the non-woven fabric formed in the needle piercing step in a binder solution wherein the thermosetting binder resin having a thermal resistance temperature of 200°C or greater is dispersed in an organic solvent at a concentration of 5-70% by weight, based on the total weight of the binder solution.
[018] In another exemplary embodiment of the present invention, the binder impregnation step may further include compressing the nonwoven fabric impregnated with binder at a pressure of 1-20 kgf/cm2 to form a binder impregnated nonwoven fabric having a density of 1,000-3,000 g/m2.
[019] In another exemplary embodiment of the present invention, the binder impregnation step may include the impregnation of 20-80 parts by weight of a thermosetting binder resin in 20-80 parts by weight of the nonwoven fabric.
[020] In another exemplary embodiment of the present invention, the binder solution may contain 5-70% by weight of a binding resin, 0.1-10% by weight of a curing agent, 0.01-5% by weight of a catalyst, 1-40% by weight of an additive and a solvent as the balance, based on the total weight of the binder solution.
[021] In another exemplary embodiment of the present invention, the binder resin may be an epoxy resin.
[022] In another exemplary embodiment of the present invention, the epoxy resin can be one or more selected from the 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, bisphenol A diglycidyl ether polymer, phosphazene diglycidyl ether, bisphenol A novolac epoxy, phenol novolac epoxy resin, and o-cresol novolac epoxy resin.
[023] In another exemplary embodiment of the present invention, the organic solvent may be one or more selected from the group consisting of methyl ethyl ketone (MEK) and dimethyl carbonate (DMC).
[024] In an exemplary embodiment of the present invention, the solvent recovery step can be performed using a drying oven at 70-200 °C for 1-10 minutes in order to form a thermosetting felt in which only the binder resin Thermosetting is present in the nonwoven fabric by evaporation of organic solvent from the binder impregnated nonwoven fabric formed in the binder impregnation step.
[025] In another exemplary embodiment of the present invention, the unwoven fabric that has gone through the solvent recovery step may contain 1-300 parts by weight of a binder based on 100 parts by weight of the unwoven fabric.
[026] In an exemplary embodiment of the present invention, the molding step can be performed at 150-300 °C.
[027] In another aspect, the present invention provides a method for reducing noise from a noise generating device, including: i) identifying the three-dimensional shape of a noise generating device; ii) the fabrication and molding of an insulating and sound absorbing material so as to correspond partially or totally to the three-dimensional shape of the device; and iii) dragging of the insulating and sound absorbing material adjacent to the noise generating device.
[028] In an exemplary embodiment of the present invention, the device can be a motor, a mechanism or an exhaust system.
[029] In an exemplary embodiment of the present invention, said dragging of the insulating and sound absorbing material adjacent to the noise generating device may include the close attachment of the insulating and sound absorbing material to the noise generating device, installing the material insulating and sound absorbing to be spaced from the noise generating device or molding the insulating and sound absorbing material as a part of the noise generating device.
[030] In the highly heat resistant sound absorbing and insulating material manufactured by the method according to the present invention, the binder is impregnated into the non-woven fabric having irregular vent holes with a complicated three-dimensional labyrinth structure and is cured while maintaining the structure three-dimensional inside the non-woven fabric without blocking the vent holes. Therefore, the physical properties of the non-woven fabric, including the performance of the sound absorption property, are improved and molding into a desired shape is possible during the curing of the binder.
[031] Likewise, since the highly heat resistant sound absorbing and insulating material manufactured by the method according to the present invention in which the binder is impregnated into the non-woven fabric formed from the heat resistant fiber exhibits superior retardation property from flame, thermal resistance, and thermal insulation in affliction to sound absorption performance, the insulating and sound absorbing material does not deform or denaturate when applied to a noise generating device that is maintained at temperatures of 200 °C or greater.
[032] In addition, the method for manufacturing a highly heat-resistant sound absorbing and insulating material according to the present invention provides an effect of simplifying the manufacturing process due to the use of thermosetting resin as the binder allows molding into a desired shape while the thermosetting resin is cured.
[033] In addition, the method for molding a highly heat resistant insulating and sound absorbing material according to the present invention provides a highly heat resistant insulating and sound absorbing material that is installed in a location closer to a source of noise from an engine or an exhaust system and reduces noise radiating from the engine or exhaust system.
[034] In addition, the method for manufacturing a highly heat resistant insulating and sound absorbing material according to the present invention provides an insulating and sound absorbing material that is applied to a location adjacent to a piece of metal that is at a temperature of 200 °C or higher to protect nearby plastic and rubber parts.
[035] Consequently, the insulating and sound absorbing material, manufactured by the method of the present invention, is useful for applications that require the retention, absorption or isolation of sound, including electrical appliances such as air conditioner, refrigerator, washing machine, lawn mower and the like, transportation such as vehicle, ship, plane and the like and building materials such as wall material, floor material and the like. In particular, the sound absorbing and insulating material manufactured by the method of the present invention is useful for a noise generating device maintained at high temperatures of 200°C or greater. More particularly, when the sound absorbing and insulating material manufactured by the method of the present invention is used in a vehicle, it can be closely attached to a vehicle parts noise generating device such as engine, exhaust system, the like. , installed to be spaced apart from the noise generating device or molded as a part of the noise generating device. BRIEF DESCRIPTION OF THE DRAWINGS
[036] Figure 1 shows a flowchart describing a method for manufacturing a highly heat-resistant sound absorbing and insulating material exemplary of the present invention.
[037] Figure 2 shows electron microscopic images (x 300) of non-woven fabrics before and after impregnation of a binder. Figure 2(A) is an image of a non-woven fabric prepared by needle punching. Figure 2(B) and Figure 2(C) show images of non-woven fabric impregnated with binders. Figure 2(B) is an image of a non-woven fabric impregnated with binder in which 20 parts by weight of a binder is impregnated into 80 parts by weight of a non-woven fabric, and Figure 2(C) is an image of a non-woven fabric impregnated with binder in which 50 parts by weight of a binder is impregnated in 50 parts by weight of a non-woven fabric.
[038] Figure 3 shows a highly heat resistant insulating and sound absorbing material manufactured by a method for manufacturing a highly heat resistant insulating and sound absorbing material according to an exemplary embodiment of the present invention and a heat shield of existing aluminum.
[039] Figure 4 shows a highly heat resistant insulating and sound absorbing material manufactured by a method for manufacturing a highly heat resistant insulating and sound absorbing material according to an exemplary embodiment of the present invention and a heat shield of existing aluminum, which are installed respectively to reduce the radiated noise of an exhaust system.
[040] Figure 5 schematically shows an example in which an insulating and sound absorbing material is molded and applied to a vehicle noise generating device. Figure 5(a) shows an image of an insulating and sound absorbing material molded for use in a vehicle engine and Figure 5(b) shows an image of an insulating and sound absorbing material installed in a part of an engine. of vehicle.
[041] Figure 6 schematically shows an example in which an insulating and sound absorbing material is applied to a noise generating device of a vehicle to be spaced from the noise generating device. Figure 6(a) shows an image of an insulating and sound absorbing material molded for use in a lower part of a vehicle and Figure 6(b) shows an image of an insulating and sound absorbing material installed in a lower part. of a vehicle.
[042] Figure 7 compares the sound absorption performance of an insulating and sound absorbing material depending on the density of a non-woven fabric.
[043] Figure 8 compares the thermal insulation performance of a highly heat resistant insulating and sound absorbing material manufactured according to a method for manufacturing a highly heat resistant insulating and sound absorbing material according to an embodiment example of the present invention with that of an existing aluminum thermal insulation board. DETAILED DESCRIPTION OF THE INVENTION
[044] In the following, specific exemplary embodiments of the present invention will be described in detail. However, they are only intended to describe the present invention in detail such that those skilled in the subject to which the present invention belongs can easily realize the invention and the technical idea and scope of the present invention are not limited by them.
[045] The present invention provides a method for manufacturing a highly heat resistant sound absorbing and insulating material, including: a step of beating and mixing of beating and mixing of a fiber material comprising a heat resistant fiber having a limiting oxygen index (LOI) of 25% or greater and thermal resistance temperature of 200 °C or greater; a web-forming step of forming the whipped and mixed fiber material in a whipping and mixing step into a continuous web in the form of a thin sheet; a net stacking step of stacking the formed net; a net-stacking step of forming a stacked net by overlaying and stacking the net formed in the net-forming step with one another; a needle piercing step of forming a non-woven fabric by connecting the stacked net formed in the net stacking step together by moving a needle up and down through the stacked net; a binder impregnation step of forming a binder-impregnated nonwoven fabric by immersing the nonwoven fabric formed in the needle piercing step in a binder solution wherein the thermosetting binder resin having a heat resistance temperature of 200°C or greater is dispersed in an organic solvent; and a solvent recovery step of forming a thermosetting felt for use as an insulating and sound absorbing material by removing the solvent from the nonwoven fabric impregnated with binder formed in the binder impregnation step such that only the binder resin thermosetting remains.
[046] The method for manufacturing a highly heat-resistant sound absorbing and insulating material according to the present invention may further include, after the solvent recovery step, a step of molding the conformation of the dry non-woven fabric in an insulating and sound absorbing material having a desired shape by molding at 150-300°C.
[047] A sound absorbing and insulating material manufactured by the method according to the present invention has a binder evenly distributed over the entire fiber strand of the non-woven fabric containing a heat resistant fiber and has smaller sized vent holes formed when compared to before impregnation of the binder. Consequently, it exhibits superior sound absorption, flame retardancy, thermal resistance and thermal insulation performance properties and can be molded into a desired three-dimensional shape due to the binder located in the same layer as a non-woven fabric.
[048] As seen from Figure 1, the method for manufacturing a highly heat resistant sound absorbing and insulating material according to the present invention includes an S101 beating and mixing step, an S103 meshing step , an S105 mesh stacking step, a S107 needle punching step, an S109 binder impregnation step and a S111 solvent recovery step.
[049] The method for manufacturing a highly heat resistant sound absorbing and insulating material according to the present invention will be described in detail with reference to the flowchart of figure 1.
[050] An S101 beating and mixing step may include beating a fiber material having a limiting oxygen index (LOI) of 25% or greater and a thermal resistance temperature of 200°C or greater, having 1-10 bends /cm and having a diameter of 1-33 µm and a length of 20-100 mm, blend of one or more fiber materials having a limiting oxygen index (LOI) of 25% or greater and a thermal resistance temperature of 200 °C or greater, having 1-10 folds/cm and having a diameter of 1-33 µm and a length of 20-100 mm or beating and mixing under the conditions described above. Air blow can be conducted to evenly disperse the fiber.
[051] The fiber material used in an S101 beating and mixing step of the present invention is a highly heat resistant sound absorbing and insulating material base material and serves to reduce the noise transferred to the interior of a vehicle by the absorption of the noise radiating from an exhaust mechanism or system.
[052] In the present invention, a heat resistant fiber having a limiting oxygen index (LOI) of 25% or greater and a thermal resistance temperature of 150 °C or greater is used as the fiber material. The heat resistant fiber can be any one that has superior durability in order to harden high temperature and ultra high temperature conditions. Specifically, a heat resistant fiber having a limiting oxygen index (LOI) of 25-80% and a thermal resistance temperature of 150-3000 °C can be used. More specifically, a heat resistant fiber having a limiting oxygen index (LOI) of 25-70% and a thermal resistance temperature of 200-1000 °C can be used. And, the heat resistant fiber can have a fineness of 1-15 denier, specifically 1-6 denier, and a yarn length of 20-100 mm, specifically 40-80 mm. When the yarn length is too short, the binding strength of the non-woven fabric may become weak due to difficulty in the yarn bridge during needle piercing. And when the yarn length is too long, the yarn cannot be transferred as desired during carding, although the nonwoven fabric may have good bond strength.
[053] As heat resistant fiber, one known as 'superfiber' in the related art can be used. Specifically, the superfiber can be one or more selected from the group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile (oxy-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 fiber. basalt, a silica fiber and a ceramic fiber. Specifically, an aramid fiber can be used as the heat resistant fiber in the present invention. Specifically, an aramid metafiber, an aramid parafiber or a mixture thereof can be used as the heat resistant fiber in the present invention.
[054] Aramid fiber is an aromatic polyamide fiber in which aromatic rings, such as the benzene ring, are linked together by amide groups. Aromatic polyamide fiber is typically referred to as 'aramid' and distinguished from an aliphatic polyamide, eg nylon. Aramid fiber can be prepared by spinning aromatic polyamide and classified as meta-aramid (m-aramid) and para-aramid (p-aramid) depending on the location of the amide bonds in the aromatic ring. [Chemical formula 1]

[055] The meta-aramid (m-aramid) represented by Chemical Formula 1 can be prepared by dry spinning after dissolving isophthaloyl chloride and mphenylenediamine in a solvent of dimethylacetamide (DMAc). Meta-aramid has a relatively high elongation tensile at break of 22-40% due to the irregular polymer structure. Likewise, it can be dyed and can be easily prepared into fibers. Meta-aramid is commercially available as Nomex™ (DuPont) and Conex™ (Teijin).
[056] The para-aramid (p-aramid) represented by Chemical Formula 2 can be prepared by wet spinning after dissolving terephthaloyl chloride and p-phenylenediamine in an N-methylpyrrolidone (NMP) solvent. Para-aramid has high strength due to its highly oriented linear molecular structure, about 3-7 times greater compared to meta-aramid. For this reason, p-aramid is used for reinforcement and protection materials. Likewise, p-aramid has strong chemical resistance, reduced thermal shrinkage, superior dimensional stability and high tear strength as well as flame resistance and self-extinguishing property. Para-aramid is commercially available as Kevlar™ (DuPont), Twaron™ (Teijin) and Technora™ (Teijin).
[057] Aramid is provided in the form of filament, wool or cotton fiber, yarn and the like and is used for reinforcement materials (eg transformer, motor and the like), insulation materials (eg paper insulation, electrical tape, and the like), heat resistant fibers (eg, fireproof clothing, fireproof gloves, and the like), high temperature filters, or the like.
[058] Although a heat resistant fiber is used as the fiber material for the preparation of the insulating and sound absorbing material in the present invention, yet another fiber can be included in addition to the strand of the heat resistant fiber for the purpose of reduction cost, weight reduction, functionality and the like. That is, although the insulating and sound-absorbing material of the present invention is prepared from a heat-resistant fiber such as a yarn, it is not limited to an insulating and sound-absorbing material consisting only of a heat-resistant fiber. The heat resistant fiber strand included in the insulating and sound absorbing material of the present invention may be included in an amount of 30-100% by weight, more specifically 60-100% by weight, based on the total weight of the fiber material. .
[059] In the S103 meshing step, the beaten and mixed fiber material in an S101 beating and mixing step is placed on a winch having workers on both sides and a cylinder of a carding machine as a wheel preferably at high speed and the fiber is carded to form a continuous net in the form of a thin sheet. This step, which is carried out by the carding method, provides volume to the formed net and minimizes weight dispersion by maximizing fiber modification efficiency.
[060] In the net stacking step S105, the net formed in the net formation step S103 is stacked together by overlapping on a conveyor belt to form a stacked net and is performed at a rate of 10 m/min or less using a horizontal package in order to prevent net dispersion due to air resistance and net breakage on the conveyor belt.
[061] The S107 needle punching step is a step in which the stacked net formed in the S105 mesh stacking step is bonded together by moving a needle up and down through the stacked net in a perpendicular direction or oblique or both to the surface of the stacked net and is performed by one or more selected from the group consisting of single down needle punching, single up needle punching, double needle down punching and double needle up punching. In this step, the binding strength of the non-woven fabric is increased as the stacked net arranged in a horizontal direction is partially arranged vertically.
[062] The non-woven fabric formed in the S107 needle punching step has a single layer thickness of 3-20 mm and a density of 100-2000 g/m2. Sound absorption performance may vary depending on the thickness and density of the non-woven fabric. Sound absorption performance is expected to increase with increasing thickness and density of the unwoven fabric. In considering the industrial application and the like of the insulating and sound absorbing material of the present invention, it is preferred that the non-woven fabric has a thickness of 3-20 mm. When the thickness of the non-woven fabric is less than 3 mm, the durability and moldability of the insulating and sound absorbing material may be unsatisfactory. And, when the thickness is greater than 20mm, productivity can decrease and production cost can increase during fabrication and processing of the nonwoven fabric. In addition, the density of the non-woven fabric can be 100-2000 g/m2, specifically 200-1200 g/m2, more specifically 300-800 g/m2, in terms of performance and cost.
[063] Aramid non-woven fabric is formed by stacking a 30-100 g/m2 net that is formed by the carding method 2 to 12 times and continuously performing pre-needling up and down, needling down and up and needling up and down, thereby forming physical bridges and providing the desired thickness, bond strength and other desired physical properties. The needle used to carry out needling can be a felt needle having a working blade of 0.5-3 mm and a needle length (distance outside the crank point) of 70-120 mm. Specifically, the needle usage can be 30-350 times/m2.
[064] More specifically, yarn fineness for non-woven fabric can be 1.5-8.0 denier, pile layer thickness can be 6-13 mm, needle usage can be 120-250 times/ m2, and the density of non-woven fabric can be 300-800 g/m2.
[065] The S109 binder impregnation step includes immersing the nonwoven fabric formed in the S107 needle punching step in a binder solution in which a thermosetting binder resin having a thermal resistance temperature of 200 °C or greater is dispersed in an organic solvent at a concentration of 5-70% by weight. The step of impregnating the S109 binder may further include, if necessary, compressing the non-woven fabric impregnated with the binder. Compression is performed to control the content of the thermosetting binder resin in the nonwoven fabric. Specifically, compression can be carried out at a pressure of 1-20 kgf/cm2 using a commonly used compression roller in order to form a binder-impregnated nonwoven fabric having a density of 1000-3,000 g/m2. Specifically, compression can be carried out using a compression roller, for example a squeeze roller, at a pressure of 5-15 kgf/cm2 to form a non-woven fabric impregnated with binder having a density of 1000-2000 g/m2.
[066] The impregnation step of the S109 binder includes the impregnation of 20-80 parts by weight of a thermosetting binder resin in 20-80 parts by weight of the nonwoven fabric.
[067] The impregnation step of the S109 binder not only improves sound insulation absorption performance, but also allows molding into an insulating and sound absorbing material having a desired shape.
[068] The non-woven fabric has a structure in which the fibers are randomly arranged in three dimensions, although there may be some variations depending on the method of fabrication. Therefore, the interior of the non-woven fabric may have a very complicated interconnected three-dimensional labyrinth structure, which is formed of regularly and irregularly arranged fibers, may instead be bundles of independent capillary tubes. Thus, the non-woven fabric formed in the step of piercing with the S107 needle has irregular vent holes (micro-cavities) formed as the strands containing the heat resistant fiber loosely cross one another.
[069] In the present invention, by carrying out the impregnation step of the binder S109 of immersing the non-woven fabric in the binder solution, the binder is evenly distributed over the entire fiber strand of the non-woven fabric containing the heat resistant fiber and, as As a result, vent holes with a smaller size compared to prior to binder impregnation are formed while substantially maintaining the intrinsic three-dimensional pore structure of the non-woven fabric. The formation of fine vent holes in the internal structure of the non-woven fabric provides an extended noise resonance path and thus provides improved sound absorption performance. When the binder resin forms a three-dimensional network structure as it is cured, sound absorption performance can be further improved by forming more and finer vent holes within the non-woven fabric. Consequently, since the non-woven fabric can maintain the intrinsic (original) three-dimensional shape as the binder is uniformly impregnated into the non-woven fabric, and additionally since thinner vent holes (micro-cavities) can be formed as the binder is cured, the insulating and sound absorbing material of the present invention may have considerably improved sound absorption performance due to maximized noise absorption through increased noise resonance in non-woven fabric.
[070] In the non-woven fabric impregnated with binder that has gone through the S109 binder impregnation step, the binder is located in the same layer as the non-woven fabric in order to maintain the three-dimensional structure within the non-woven fabric. Consequently, the binder used in the present invention can be any binder as long as it can maintain the three-dimensional structure within the non-woven fabric. The expression 'maintaining the three-dimensional structure within the non-woven fabric' means that the binder, which is impregnated into the non-woven fabric, is evenly distributed over the entire strand of the fiber surface of the non-woven fabric and maintains or even forms irregular vent holes , thus, maintaining the intrinsic three-dimensional shape of the non-woven fabric.
[071] Although a binder generally refers to a material used to bond or join two materials, the binder used in the present invention refers to a material impregnated into the non-woven fabric formed from the heat resistant fiber.
[072] Various materials can be used as the binder impregnated into the non-woven fabric. First of all, a thermoplastic resin or a thermosetting resin can be considered as the binding material.
[073] Thermoplastic resin such as a polyamide based resin has polar crystalline groups like aramid fiber which is a representative heat resistant fiber. When a thermoplastic binder is impregnated into the non-woven fabric formed from the heat resistant thermoplastic fiber, a solid interfacial layer is formed between the thermoplastic binder and the heat resistant thermoplastic fiber due to face-to-face contact between their crystalline polar groups, thus, blocking or partially covering the non-woven fabric bleed holes. As a consequence, when a thermoplastic resin is used as the impregnated binder in the nonwoven fabric formed from the heat resistant fiber, the sound absorption performance may be reduced due to the partial blocking of the vent holes of the nonwoven fabric. At a glance, one might think that the sound isolation performance would be improved if the vent holes were blocked. However, since noise is not eliminated within the non-woven fabric, but is transmitted through other pathways, improved sound absorption performance cannot be obtained if the thermoplastic binder is impregnated into the non-woven fabric. In addition, when the thermoplastic binder is impregnated into a non-woven fabric formed from the heat resistant inorganic fiber, an adhesive additive has to be added due to the poor adhesive property between them.
[074] In contrast, a thermosetting binder is a material having significantly different physical and chemical properties than heat-resistant thermoplastic fiber. Consequently, when a thermosetting binder is impregnated into the non-woven fabric formed from the heat resistant thermoplastic fiber, an interfacial layer is formed by edge-to-edge contact due to different properties. As a result, the non-woven fabric bleed holes remain open. Therefore, when a thermosetting resin is used as the binder impregnated into the non-woven fabric formed from the heat resistant fiber, the three-dimensional structure within the non-woven fabric can be maintained. Consequently, a thermosetting resin can be used as the binder in the present invention.
[075] In addition, the thermosetting resin is curable by light, heat or a curing agent and its shape does not change even under a high temperature condition. Consequently, according to the present invention, the shape of the sound-absorbing material can be maintained even under a high temperature condition after molding by employing the heat resistant fiber and the thermosetting binder under specific conditions. As a consequence, when thermosetting resin binder is used as the impregnated binder in the nonwoven fabric, molding into a desired shape is possible during resin curing and the shape can be maintained even under a high temperature condition.
[076] As described above, when thermosetting resin is used as the binder impregnated into the non-woven fabric formed from the heat resistant fiber, the three-dimensional structure within the non-woven fabric can be maintained and molding into a desired shape is possible during curing the binder resin.
[077] Specifically, an epoxy resin can be used as the binder. Epoxy resin is one of thermosetting resins and is cured to a polymer material having a three-dimensional network structure. Consequently, since the epoxy resin forms a mesh structure and other vent holes when cured within the nonwoven fabric, additional fine vent holes can be formed within the nonwoven fabric and sound absorption performance can be further improved.
[078] When curing is performed in the presence of a curing agent, a more complicated three-dimensional network structure can be formed and thus the sound absorption effect can be further improved. In detail, a three-dimensional network structured polymer can be formed as epoxy groups or hydroxyl groups of the epoxy resin react with functional groups of the curing agent such as amine groups or carboxylic acid groups to form covalent crosslinks. The curing agent serves as a catalyst that catalyzes the curing reaction and is involved in the reaction and bound to the chemical groups in the epoxy resin. Consequently, the size and physical properties of the vent holes can be controlled by selecting different curing agents.
[079] The epoxy resin can be one or more epoxy resin selected from the 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, polymer of bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, phenol novolac epoxy resin and o-cresol novolac epoxy resin, and the like. More specifically, the epoxy resin can have an epoxy equivalent of 70-400. When the epoxy equivalent is too low, the intermolecular bond may be too weak to form the three-dimensional network structure or the physical properties of the insulating and sound absorbing material may become unsatisfactory due to the reduced adhesion with the heat resistant fiber. In contrast, when the epoxy equivalent is too high, the sound absorption performance can be unsatisfactory due to an excessively dense mesh structure being formed.
[080] When thermosetting resin is used as the binder in the present invention, a curing agent can be further included in the binder solution. As the curing agent, a compound having a functional group that can readily react with the functional groups of the thermosetting binder resin, such as epoxide groups or hydroxyl groups, can be used. For example, an aliphatic amine, an aromatic amine, an acid anhydride, urea, an amide, imidazole and the like can be used as the curing agent. As specific examples of the curing agent, one or more selected from the group consisting of diethyltoluenediamine (DETDA), diaminodiphenylsulfone (DDS), boron trifluoride-monoethylamine (BF3^MEA), diaminocyclohexane (DACH), methyltetrahydrophthalic anhydride (MTHPA) , methyl-5-norbornene-2,3-dicarboxylic anhydride (NMA), dicyandiamide (Dicy), 2-ethyl-4-methylimidazole and the like can be used. More specifically, an aliphatic amine or amide based curing agent can be used due to improved crosslinking ability and much superior chemical resistance and weatherability. In particular, dicyandiamide (Dicy) can be used taking into account crosslinking ability, flame retardancy, thermal resistance, storage stability, processability and the like. Since dicyandiamide (Dicy) has a high melting point above 200 °C, it can provide superior storage stability after being mixed with the epoxy resin and can ensure sufficient processing time for curing and molding.
[081] In the present invention, a catalyst that facilitates the cure of the thermosetting resin used as the binder can be used. The catalyst can be one or more selected from the group consisting of urea, dimethylurea, a quaternary DBU tetraphenylborate salt and quaternary phosphonium bromide. The catalyst can be contained in the binder-containing solution.
[082] In addition, various additives, for example, a flame retardant, a heat resistance improver, a water repellant and the like can be used to provide additional functionalities to the insulating and sound absorbing material. The additive can be contained in the binder solution and thus no additional surface material to provide functionalities to the insulating and sound absorbing material will be needed.
[083] The flame retardant can be a melamine, a phosphate, a metal hydroxide and the like. Specifically, the flame retardant can be one or more selected from the group consisting of melamine, melamine cyanide, melamine polyphosphate, phosphazene, ammonium polyphosphate, and the like. More specifically, the flame retardant can be melamine, which enhances flame retardancy and heat resistance simultaneously.
[084] The heat resistance enhancer can be alumina, silica, talc, clay, glass powder, fiberglass, metal powder and the like.
[085] And, one or more fluorine-based water repellants can be used as the water repellant.
[086] In addition, additives commonly used in the related art can be selected depending on the desired purposes.
[087] The binder solution used in the S109 binder impregnation step contains, in addition to the binder resin, a commonly used curing agent, a catalyst, an additive and a solvent.
[088] The binder, the curing agent, the catalyst and the additive contained in the binder solution are the same as described above. The solvent used to prepare the binder solution can be one or more selected from the group consisting of a ketone, a carbonate, an acetate, a cellosolve, and the like. Specifically, the solvent can be one or more selected from the group consisting of acetone, methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), dimethylcarbonate (DMC), ethyl acetate, butyl acetate, methyl cellosolve, ethyl cellosolve, butyl cellosolve, and the similar ones.
[089] Specifically, the binder solution contains 5-70% by weight of a binder and a solvent as the balance. The binder solution used in the present invention may further contain other additives including a curing agent and a catalyst. In this case, the binder solution may contain 5-70% by weight of a binder resin, 0.1-10% by weight of a curing agent, 0.01-5% by weight of a catalyst, 1-40% by weight of weight of an additive and a solvent as the balance, based on the total weight of the binder solution. More specifically, the binder solution may contain 1-30% by weight of a binder, 0.1-10% by weight of a curing agent, 0.01-5% by weight of a catalyst, 1-30% by weight of a catalyst of a flame retardant as an additive and 40-95% by weight of a solvent, based on the total weight of the binder solution.
[090] In the present invention, the degree of impregnation in the non-woven fabric can be controlled with the concentration of the binding solution. For example, the binder solution can be prepared to have a solid content of 160% by weight, more specifically 20-50% by weight, based on the total weight of the binder solution. When the binder solution is too dilute, the purpose of the present invention cannot be realized because the content of the binder impregnated in the nonwoven fabric is small. In contrast, when the binding solution is highly concentrated, the non-woven fabric can become stiff and may not serve as an insulating and sound-absorbing material.
[091] In addition, when the content of the curing agent contained in the binder solution is too small, molding into a desired shape can be difficult because the binder curing cannot be completed. As a result, the effect of improving the mechanical strength of the insulating and sound absorbing material may not be achieved. And, when the content of the curing agent is too large, the insulating and sound absorbing material may become hard and storage stability or the like may be unsatisfactory. Furthermore, when the catalyst content is too small, the effect for facilitating the reaction may not be sufficiently provided. In contrast, when the catalyst content is too large, storage stability and the like may be unsatisfactory. The additive can be one or more additives commonly used in the related art, which is selected from a flame retardant, a heat resistance improver, a water repellent and the like. The content of these additives can be adjusted accordingly depending on the purpose of addition. When the amount of additives is less than the range described above, the desired effect may not be achieved. And, when the amounts of additives are greater than the range described above, it is undesirable in terms of economy and unwanted side effects can be caused.
[092] Figure 2 shows electron microscopic images that show the three-dimensional structure within non-woven fabrics before and after impregnation of a binder.
[093] Figure 2 (A) is an electron microscopic image showing the internal structure of a non-woven fabric before impregnation of a binder. You can see the heat resistant fiber strands cross to form irregular vent holes. Figures 2 (B) and (C) are electron microscopic images showing the internal structure of the non-woven tissue after impregnation with a binder. It can be seen that the binder is thin and evenly distributed and fixed to the heat resistant fiber strands and that the binder content on the strand surface increases as the binder content increases.
[094] As can be seen from the electron microscopic images of Figure 2, in the insulating and sound absorbing material of the present invention, the binder is evenly distributed on the surface of the heat resistant fiber strands that constitute the non-woven fabric.
[095] The S111 solvent recovery step is a step in which a thermosetting felt in which only the thermosetting binder resin is present is formed by evaporating the organic solvent from the nonwoven fabric impregnated with binder formed in the binder impregnation step S109. The S111 solvent recovery step can be carried out using a drying oven at 70-200 °C, specifically 100-150 °C, for 1-10 minutes.
[096] Through the S111 solvent recovery step, hazardous materials, which can be generated as the organic solvent is evaporated, can be removed and the physical properties of the insulating and sound absorbing material can be controlled by controlling the content of the binder in the non-woven fabric. The content of binder contained in dry non-woven fabric is an important factor affecting the size, shape and distribution of vent holes within the insulating and sound absorbing material and the sound absorption performance and mechanical property of the insulating and absorbing material Sound can be controlled with it. In the present invention, the final content of binder contained in the non-woven fabric can be controlled up to 1-300 parts by weight, more specifically 30-150 parts by weight, based on 100 parts by weight of the non-woven fabric through the drying process. . Through the drying process, the non-woven fabric can be prepared into a thermosetting felt having a density of 300-1500 g/m2, specifically 300-1000 g/m2. And, the final binder content in the thermosetting felt can be controlled up to 50-800 g/m2, specifically 100-500 g/m2.
[097] The present invention also provides a method for the manufacture of an insulating and sound absorbing material, which further includes, after the S111 solvent recovery step, an S121 molding step of preparing an insulating and sound absorbing material by molding dry non-woven fabric at high temperature.
[098] Specifically, the method for manufacturing a highly heat resistant sound absorbing and insulating material in accordance with the present invention includes an S101 beating and mixing step, an S103 meshing step, an S103 stacking step. S105 mesh, an S107 needle punching step, an S109 binder impregnation step, an S111 solvent recovery step and an S121 molding step.
[099] In the S121 molding step, the dry non-woven fabric obtained in the S111 solvent recovery step is prepared in an insulating and sound-absorbing material having a desired shape by molding at high temperature. High temperature molding also involves curing the thermosetting binder and is carried out at 150-300 °C, more specifically 170-230 °C.
[0100] The internal structure of the insulating and sound absorbing material, manufactured in accordance with the method of the present invention, can be identified by electronic microscopic images. An electron microscopic image reveals that, within the insulating and sound absorbing material of the present invention, vent holes with sizes of 1100 µm are evenly or irregularly distributed with a spacing of 0.1-500 µm.
[0101] Figure 3 compares the highly heat-resistant sound absorbing and insulating material manufactured by the method of the present invention with an existing aluminum heat shield.
[0102] The present invention also provides a method for reducing noise from a noise generating device, including: i) identifying the three-dimensional shape of a noise generating device; ii) the fabrication and molding of an insulating and sound absorbing material so as to correspond partially or totally to the three-dimensional shape of the device; and iii) dragging the adjacent insulating and sound absorbing material to the noise generating device.
[0103] Device refers to any noise generating device including a mechanism, a motor, an exhaust system and the like. However, the device of the present invention is never limited to the equipment, engine and exhaust system. The insulating and sound absorbing material can be manufactured to partially or fully match the three-dimensional shape of the device. Since the insulating and sound absorbing material of the present invention can be molded during the curing of the binder, the insulating and sound absorbing material of the present invention can be molded to partially or fully match the three-dimensional shape of the device.
[0104] As used herein, the term "adjacent" can mean the close attachment of the sound absorbing material to the noise generating device, installing the insulating and sound absorbing material to be spaced from the noise generating device or molding the insulating and sound absorbing material as a part of the noise generating device. Additionally, the term "adjacent" in the present invention may include installing the sound absorbing material on a member (e.g., another insulating and sound absorbing material) connected to the noise generating device.
[0105] Figure 4, Figure 5 and Figure 6 schematically show representative examples in which the insulating and sound absorbing material of the present invention is applied to a vehicle noise generating device.
[0106] Figure 4 shows a highly heat-resistant sound absorbing and insulating material manufactured by the method of the present invention and an existing aluminum thermal shield, which are installed respectively to reduce radiated noise from an exhaust system.
[0107] Figure 5 schematically shows an example in which an insulating and sound absorbing material is molded and applied to a vehicle noise generating device. Figure 5(a) shows an image of an insulating and sound absorbing material molded for use in a vehicle engine and Figure 5(b) shows an image of an insulating and sound absorbing material installed in a part of an engine. of vehicle.
[0108] Figure 6 schematically shows an example in which an insulating and sound absorbing material is applied to a noise generating device of a vehicle to be spaced from the noise generating device. Figure 6(a) shows an image of an insulating and sound absorbing material molded for use in a lower part of a vehicle and Figure 6(b) shows an image of an insulating and sound absorbing material installed in a lower part. of a vehicle.
[0109] As described above, since the insulating and sound absorbing material of the present invention, in which a binder is impregnated into a non-woven fabric to maintain the three-dimensional structure within it, has superior sound absorption performance property , flame retardancy, thermal resistance and thermal insulation, it can exert its inherent sound absorption and insulation effect when applied to a noise generating device maintained not only at normal temperatures but also at high temperatures of 200 °C or greater without the deformation of the molded product. EXAMPLES
[0110] The present invention will be described in more detail through the examples. However, the present invention is not limited by the examples.
[0111] In the following, a method for manufacturing a highly heat resistant insulating and sound absorbing material according to the present invention and an effect of the highly heat resistant insulating and sound absorbing material will be described through the examples. EXAMPLE 1. PREPARATION OF HIGHLY HEAT RESISTANT SOUND ABSORBING AND INSULATING MATERIAL 1) PREPARATION OF NON-ENTTWINED FABRIC
[0112] A meta-aramid (m-aramid) fiber having 6 plies/cm and a fineness of 2 denier and a length of 76 mm was tapped by air insufflation and formed into a net of 30 g/m2 by carding . The net was stacked by overlapping 10 times on a conveyor belt operated at 5 m/min using a horizontal package. A non-woven fabric having a density of 300 g/m2 and a thickness of 4 mm was prepared by performing single-up needle punching, double-down needle punching, and then double-up needle punching in a perpendicular direction. to the surface of the stacked net. 2) PREPARATION OF THE THERMOCURE BINDING RESIN SOLUTION
[0113] The thermosetting resin binder solution was prepared by mixing an epoxy resin consisting of a mixture of bisphenol A diglycidyl ether, polyoxypropylene diglycidyl ether and phosphazene diglycidyl ether with 10% by weight of a cyanoguanidine-based curing agent. epoxy resin, 8% by weight of a bisdimethyl urea compound based on the epoxy resin and 30% by weight of a melamine cyanurate flame retardant based on the epoxy resin. 3) PREPARATION OF THERMOCURE FELT
[0114] The thermosetting resin binder solution prepared in 2) was dispersed in an organic solvent of dimethylcarbonate (DMC) such that the concentration of the thermosetting resin binder was 25% by weight. After dipping the unwoven fabric prepared in 1) into it, a binder impregnated unwoven fabric having a density of 1500 g/m2 was formed by pressing at a pressure of 8 kgf/cm2 using a wringer. The binder impregnated non-woven fabric was passed through a first drying oven set at 100°C, a second drying oven set at 120°C, a third drying oven set at 150°C and a fourth drying oven set at 150 °C at a speed of 5 m/min, thereby removing 900 g/m2 of the organic solvent such that 300 g/m2 of the thermosetting binder resin remained. As a result, a thermosetting felt having a density of 600 g/m2 was prepared. COMPARATIVE EXAMPLE 1. PREPARATION OF EXISTING ALUMINUM THERMAL PROTECTOR
[0115] A heat shield was prepared from 1 mm thick aluminum, which is commonly used to insulate the heat generated from an exhaust system, using a mold of the heat shield. COMPARATIVE EXAMPLE 2 . PREPARATION OF INSULATING AND SOUND ABSORBING MATERIAL FORMED FROM ARAMID NON-ENTTWINED FABRIC
[0116] An aramid nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching in the same manner as described in example 1, 1). COMPARATIVE EXAMPLE 3 . PREPARATION OF INSULATING AND SOUND ABSORBING MATERIAL FORMED FROM EPOXY RESIN COATED NON-ENTROWNING FABRIC
[0117] An aramid nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching in the same manner as described in example 1, 1). Next, molding was carried out after coating an epoxy resin on the surface of the nonwoven fabric such that the binder content was 50 parts by weight based on 100 parts by weight of the nonwoven fabric and drying at 150°C.
[0118] The coating solution contained 8% by weight bisphenol A diglycidyl ether, 2% by weight bisphenol A diglycidyl ether polymer, 0.2% by weight dicyandiamide, 0.02% by weight dimethylurea, 10% by weight melamine cyanurate and 79.78% by weight dimethylcarbonate, based on the total weight of the coating solution. COMPARATIVE EXAMPLE 4. PREPARATION OF INSULATING AND SOUND ABSORBING MATERIAL MADE FROM ARAMID NON-ENTANGED TISSUE IMPREGNATED WITH THERMOPLASTIC RESIN
[0119] An aramid nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching in the same manner as described in example 1, 1), immersed in a binding solution, dry and then molded.
[0120] A thermoplastic resin solution containing 10% by weight of polyethylene resin, 10% by weight of melamine cyanurate and 80% by weight of a dimethylcarbonate (DMC), based on the total weight of the thermoplastic resin solution, was used as the binding solution. COMPARATIVE EXAMPLE 5. PREPARATION OF INSULATING AND SOUND ABSORBING MATERIAL MADE FROM PET NON-ENTANGED FABRIC IMPREGNATED WITH EPOXY RESIN
[0121] An unwoven fabric of polyethylene terephthalate (PET) having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching in the same manner as described in example 1, 1), immersed in a solution binder, dried and then molded.
[0122] The PET nonwoven fabric of Preparation Example 5 showed thermal deformation due to the heat of reaction generated during the epoxy curing process and showed complete thermal deformation during the drying and thermal molding processes. As a result, molding into a desired shape was impossible.
[0123] A test specimen of the highly heat resistant sound absorbing and insulating material 3 mm thick was prepared by hot pressing 600 g/m2 of thermosetting felt prepared in Example 1 at 200 °C for 200 seconds with a pressure of 100 kgf/cm2.
[0124] The sound absorption rate of the test specimen of the highly heat resistant sound absorbing and insulating material was measured according to the ISO R 354 method, Alpha Cabin. The average sound absorption rate measured for the three specimens is given in Table 1. TABLE 1

[0125] The aluminum material showed a sound absorption rate of 0. In contrast, as shown in Table 1, the highly heat resistant sound absorbing and insulating material prepared according to the method for manufacturing an insulating material and highly heat resistant sound absorber according to the present invention has shown excellent noise reduction effect inside a vehicle by reducing radiated noise from an engine and an exhaust system when applied to a location closer to the engine and the system. of exhaustion and the source of the noise.
[0126] By applying heat from a heat source maintained at 250 °C to the highly heat resistant sound absorbing and insulating material that was prepared by molding the thermosetting felt having a density of 600 g/m2 prepared in Example 1 to 200 °C for 200 seconds at a pressure of 100 kgf/cm2 using a mold of the heat shield and the aluminum heat shield prepared in Comparative Example 1, the temperature was measured on the opposite side. The result is shown in Table 2. In addition, to evaluate the performance of the highly heat resistant insulating and sound absorbing material prepared in Example 1, a 3rd WOT PG gear test was conducted on a diesel vehicle (U2 1.7) . The result is shown in Table 3. Additionally, a result of measuring noise inside the vehicle under a gear at neutral is shown in Table 4. TABLE 2

[0127] From Table 2, it can be seen that the highly heat-resistant sound-absorbing and insulating material prepared according to the method for manufacturing a highly heat-resistant sound-absorbing and insulating material in accordance with the This invention not only improves noise inside a vehicle, but can also protect nearby plastic and rubber parts by insulating heat, when applied in place of the aluminum heat shield that is commonly used to insulate heat. TABLE 3

[0128] As can be seen from Table 3 and Table 4, when the highly heat resistant insulating and sound absorbing material prepared according to the method for manufacturing a highly heat resistant insulating and sound absorbing material of according to the present invention was applied instead of the aluminum thermal shield, the increasing noise was improved by 1.4-2% and the noise inside the vehicle was improved by 1 dB(A). TEST EXAMPLES EVALUATION OF PHYSICAL PROPERTIES OF INSULATING AND SOUND ABSORBING MATERIAL
[0129] The physical properties of insulating and sound absorbing materials were measured and compared as follows. 1. THERMAL RESISTANCE ASSESSMENT
[0130] To assess the thermal resistance, the insulating and sound absorbing material was aged in an oven at 260 °C for 300 hours. After holding in a standard state (23±2 °C, 50±5% relative humidity) for at least 1 hour, the appearance was inspected and the tensile strength measured. Appearance was visually inspected for shrinkage, deformation, surface peeling, fluff or cracking. Tensile strength was measured for five sheets of randomly selected test specimens of iron-type #1 at a speed of 200 mm/min under a standard condition. 2. THERMAL CYCLE EVALUATION
[0131] The durability of the insulating and sound absorbing material was evaluated by a thermal cycle test. Durability was determined after performing five cycles. 1) CONDITION OF A CYCLE
[0132] Ambient temperature alta high temperature (150°C x 3 hr) ambient temperature low temperature (30°C x 3 hr) ambient temperature humid condition (50 °C x 95% RH). 2) DURABILITY EVALUATION STANDARD
[0133] After the thermal cycle test, the change in appearance was inspected. For example, surface damage, swelling, breakage and discoloration were inspected. If there was no change in appearance, it was assessed as 'no abnormality'. 3. FLAME RETARDANCE ASSESSMENT
[0134] The flame retardancy of the insulating and sound absorbing material was measured according to the ISO 3795 flammability test. 4. NON-FLAMMABILITY EVALUATION
[0135] The non-flammability of the insulating and sound absorbing material was measured according to the UL94 vertical burn test. 5. ASSESSMENT OF SOUND ABSORPTION PROPERTY
[0136] The sound absorption performance of the insulating and sound absorbing material was measured according to ISO354. 6. AIR PERMEABILITY ASSESSMENT 1) ASSESSMENT METHOD
[0137] The test specimen was mounted in a Frazier type tester and the amount of air flowing through the test specimen vertically was measured. The area of the test specimen through which the air passed was 5 cm2 and the applied pressure was set at 125 pascals (Pa).
[0138] Test Example 1. Comparison of properties of insulating and sound absorbing materials depending on heat resistant fibers
[0139] In Test Example 1, the physical properties of insulating and sound absorbing materials prepared with different strands of heat resistant fiber were compared. Sound absorbing and insulating materials were prepared according to the Method of Example 1. For needle piercing, threads having a fineness of 2 denier and a length of 51 mm were used (see Table 5).
[0140] The results of measuring the properties of insulating and sound absorbing materials prepared with different heat-resistant fibers are shown in Table 5 and Table 6.


[0141] As seen from Table 5 and Table 6, all insulating and sound absorbing materials prepared in accordance with the present invention using heat resistant fibers having a limiting oxygen index of 25% or greater and a resistance temperature thermal resistance of 150 °C or greater showed satisfactory thermal resistance, durability, flame retardancy, non-flammability, and sound absorption performance. Consequently, it can be seen that any commonly used heat resistant fiber can be used for the non-woven fabric which constitutes the insulating and sound absorbing material of the present invention.
[0142] Test Example 2. Comparison of the properties of insulating and sound absorbing materials depending on the density of non-woven fabrics
[0143] In Test Example 2, the physical properties of insulating and sound absorbing materials depending on the density of non-woven fabrics were compared. Sound absorbing and insulating materials were prepared according to the method of Example 1. The density of non-woven fabrics was varied in the needle piercing step. The sound absorption performance of prepared insulating and sound absorbing materials is shown in figure 7.
[0144] As seen from figure 7, the sound absorption performance of the insulating and sound absorbing material was superior when non-woven fabric having a density of 600 g/m2 was used when compared to when non-woven fabric having a density of 300 g/m2 was used.
[0145] Test Example 3. Evaluation of physical properties of insulating and sound absorbing materials
[0146] In Test Example 3, the physical properties of the insulating and sound-absorbing materials depending on the type of application of the thermosetting binder on the non-woven fabric when preparing the sound-absorbing materials were compared.
[0147] That is, the sound absorption rate of insulating materials and sound absorbers prepared by applying the thermosetting binder to the fabric not woven by impregnation (Example 1) or coating (Comparative Example 3) was measured. Table 7 shows the sound absorption rate measurement results for the insulating and sound absorbing material prepared from a non-woven fabric (Comparative Example 2), the insulating and sound absorbing material prepared from a thermosetting-non-fabric binder coated woven fabric (Comparative Example 3) and the insulating and sound absorbing material prepared from a non-woven thermosetting fabric impregnated with binder (Example 1). TABLE 7


[0148] As seen from Table 7, the sound absorbing and insulating material of Example 1 according to the present invention exhibits superior sound absorption rate in all frequency ranges when compared to Comparative Example 2 in which the fabric non-woven non-impregnated with a thermosetting binder was used as the insulating and sound absorbing material. In contrast, the sound absorbing and insulating material of Comparative Example 3 in which the non-woven fabric coated with thermosetting binder resin was used exhibits lower sound absorption rate in the 400-5000 Hz frequency range as compared to Comparative Example 2 .
[0149] Test Example 4. Evaluation of thermal insulation performance of insulating and sound absorbing materials
[0150] In Test Example 4, the thermal insulation performance of the insulating and sound absorbing materials prepared in Example 1 (where thermosetting resin impregnated non-woven aramid fabric was used), Comparative Example 2 (where the Aramid nonwoven fabric was used) and Comparative Example 4 (wherein aramid nonwoven fabric impregnated with thermoplastic resin was used). After applying 1000 °C heat to one side of a sample of 25 mm thick insulating and sound absorbing material for 5 minutes, the temperature was measured on the opposite side of the sample.
[0151] The temperature measured on the opposite side of the insulating and sound absorbing material was 250 °C for Example 1 and 350 °C for Comparative Example 2. Consequently, it can be seen that the insulating and sound absorbing material of the The present invention in which the thermosetting resin is impregnated has improved thermal insulation performance. In contrast, the sound absorbing and insulating material of Comparative Example 4 in which a thermoplastic resin was impregnated was deformed as the thermoplastic resin was melted once heat of 1000°C was applied.
[0152] These results show that the insulating and sound absorbing material of the present invention has much superior thermal insulation property.
[0153] Test Example 5. Comparison of thermal insulation performance with aluminum thermal insulation board
[0154] In Test Example 5, the thermal insulation performance of the insulating and sound absorbing material of Example 1 was compared with that of an aluminum thermal insulation board. While applying the same heat to one side of the insulating and sound absorbing material and the thermal insulation board at 250 °C, the temperature on the opposite side was measured with time. The results are shown in Figure 8.
[0155] As seen from figure 8, the insulating and sound absorbing material according to the present invention exhibited better thermal insulation performance at 11 °C or greater when compared to the aluminum thermal insulation board.
[0156] Test Example 6. Comparison of properties of insulating and sound absorbing materials depending on the content of the thermosetting binder resin
[0157] Sound absorbing and insulating materials were prepared as described in Example 1. The non-woven aramid fabric impregnated with epoxy resin was dried to have different binder contents. The binder content was represented as parts by weight of the binder included in the insulating and sound absorbing material based on 100 parts by weight of the dry non-woven fabric.
[0158] The results of comparing the mechanical properties and sound absorption rate of insulating materials and sound absorbers prepared with different binder contents are shown in Table 8 and Table 9. TABLE 8


[0159] From Table 8 and Table 9, it can be seen that the impregnation of the binder in the non-woven fabric provides improved sound absorption rate when compared to the non-woven fabric in which the binder is not impregnated. In addition, it can be seen that the sound absorption rate of the insulating and sound absorbing material can be controlled with the binder content.
[0160] Test Example 7. Comparison of properties of insulating and sound absorbing materials depending on the types of binders
[0161] Sound absorbing and insulating materials in which 50 parts by weight of a binder were impregnated on the basis of 100 parts by weight of an aramid nonwoven fabric were prepared according to the method of Example 1. The resins described in the Table 10 were used as the binder.
[0162] The results of comparing the mechanical properties and sound absorption rate of insulating materials and sound absorbers prepared with different binders are shown in Table 10. TABLE 10 Sound absorption rate of insulating materials and sound absorbers with different binders binders Binder Resin Epoxy Phenol Urea Melamine Polyurethane Thermal resistance temperature (°C x 1 hr) 300 260 190 300 200 Tensile strength (kg/cm2) 200 165 180 180 170 Flame retardancy Self-extinguishing Self-extinguishing Self-extinguishing Self-extinguishing Self-extinguishing Non-flammable Non-flammable Not flammable Not flammable Not flammable

权利要求:
Claims (26)
[0001]
1. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, characterized in that it comprises: a step of beating and mixing of beating and mixing a fiber material comprising a heat resistant fiber; a network-forming step of forming a network of the whipped and blended fiber material; a net stacking step of stacking the formed net; a needle piercing step of forming a non-woven fabric by moving a needle up and down through the stacked net; a binder impregnation step of forming a binder-impregnated nonwoven fabric by dipping the nonwoven fabric into a binder solution and; a solvent recovery step of removing a solvent from the nonwoven fabric impregnated with binder to obtain a nonwoven fabric used as an insulating and sound absorbing material, wherein the binder impregnation step is comprised of the immersion of the nonwoven fabric formed in the needle piercing step in a binder solution wherein the thermosetting binder resin having a thermal resistance temperature of 200 °C or greater is dispersed in an organic solvent at a concentration of 5 to 70 % by weight, and wherein the binder impregnation step is further comprised of compressing the binder impregnated nonwoven fabric at a pressure of 1 to 20 kgf/cm2 to form a binder impregnated nonwoven fabric having a density of 1000 to 3000 g/m2.
[0002]
2. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, characterized in that it comprises: a step of beating and mixing, beating and mixing a fiber material comprising a heat resistant fiber; a network-forming step of forming a network of the whipped and blended fiber material; a net stacking step of stacking the formed net; a needle piercing step of forming a non-woven fabric by moving a needle up and down through the stacked net; a binder impregnation step of forming a binder-impregnated nonwoven fabric by dipping the nonwoven fabric into a binder solution; a solvent recovery step of removing a solvent from the binder-impregnated nonwoven fabric; and a molding step of shaping the dry non-woven fabric into an insulating and sound-absorbing material having a desired shape, wherein the binder impregnation step is comprised of immersing the non-woven fabric formed in the needle piercing step in a binder solution in which the thermosetting binder resin having a thermal resistance temperature of 200°C or greater is dispersed in an organic solvent at a concentration of 5 to 70% by weight, and wherein the binder impregnation step is further comprised by compressing the binder impregnated nonwoven fabric at a pressure of 1 to 20 kgf/cm2 to form a binder impregnated nonwoven fabric having a density of 1000 to 3000 g/m2.
[0003]
3. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL, according to claim 1, in which the beating and mixing step is characterized by comprising the beating, mixing or beating and mixing of a material of fiber having a limiting oxygen index (LOI) of 25% or greater and a thermal resistance temperature of 200°C or greater.
[0004]
4. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, in which the beating and mixing step is characterized by comprising beating a fiber material having 1-10 folds /cm and having a diameter of 1-33 µm and a length of 20-100 mm or mixture of one or more fiber materials having 1-10 folds/cm and having a diameter of 1-33 µm and a length of 20- 100 mm.
[0005]
5. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND ABSORBING AND INSULATING MATERIAL according to claim 3, wherein the fiber material is characterized by comprising one or more selected from the group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile (oxy-PAN) fiber, a polyimide (PI) fiber, a polybenzimidazole (PBI) fiber, a polybenzoxazole (PBO) fiber, a fiber. polytetrafluoroethylene (PTFE), a polyketone (PK) fiber, a metallic fiber, a carbon fiber, a glass fiber, a basalt fiber, a silica fiber and a ceramic fiber.
[0006]
6. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL according to claim 5, wherein the fiber material is characterized by comprising one or more selected from the group consisting of a meta-fiber. aramid (m-aramid) and a fiber of para-aramid (p-aramid).
[0007]
7. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL, according to claim 1, characterized in that the network formation step is performed by the carding method.
[0008]
8. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND ABSORBING AND INSULATING MATERIAL, according to claim 1, characterized in that the network stacking step is performed at a rate of 10 m/min or less using a horizontal package.
[0009]
9. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the needle perforation step is performed by one or more selected from the group consisting of downward perforation needle single, single up needle punch, double needle down punch and double needle up punch.
[0010]
10. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 9, wherein the needle piercing step is characterized by comprising the formation of a non-woven fabric with a needle stroke of 30-350 times/m2.
[0011]
11. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the non-woven fabric formed in the needle perforation step has a single layer thickness of 3-20 mm and a density of 100-2000 g/m2.
[0012]
12. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND ABSORBING AND INSULATING MATERIAL, according to claim 1, in which the binder impregnation step is characterized by comprising the impregnation of 20-80 parts by weight of a resin thermosetting binder in 20-80 parts by weight of nonwoven fabric.
[0013]
13. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL, according to claim 1, wherein the binding solution is characterized by comprising 5-70% by weight of a binding resin, 0.1- 10% by weight of a curing agent, 0.01-5% by weight of a catalyst, 1-40% by weight of an additive and a solvent as the balance.
[0014]
14. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL, according to claim 13, wherein the binding solution is characterized by comprising 1-30% by weight of a binding resin, 0.1- 10% by weight of a curing agent, 0.01-5% by weight of a catalyst, 1-30% by weight of a flame retardant and 40-95% by weight of a solvent.
[0015]
15. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the thermosetting binder resin is an epoxy resin.
[0016]
16. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 15, characterized in that the epoxy resin is one or more selected from bisphenol A diglycidyl ether, bisphenol B diglycidyl ether, bisphenol AD diglycidyl ether , bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, polyoxypropylene diglycidyl ether, bisphenol A diglycidyl ether polymer, phosphazene diglycidyl ether, bisphenol A novolac epoxy, phenol novolac epoxy resin, and o-cresol novolac epoxy resin.
[0017]
17. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND ABSORBING AND INSULATING MATERIAL, according to claim 1, in which the solvent recovery step is characterized by comprising the evaporation of the organic solvent by drying in a drying oven at 70-200 °C for 1-10 minutes.
[0018]
18. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 17, in which the non-woven fabric that has undergone the solvent recovery step is characterized by comprising 1-300 parts by weight of a binder based on 100 parts by weight of the nonwoven fabric.
[0019]
19. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 17, characterized in that the organic solvent is one or more selected from the group consisting of methylethylketone (MEK) and dimethylcarbonate (DMC).
[0020]
20. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 2, characterized in that the molding step is carried out at 150-300 °C.
[0021]
21. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that it comprises: a beating and mixing step S101 of beating and mixing a fiber material having an index of limiting oxygen (LOI) of 25% or greater and a thermal resistance temperature of 200 °C or greater; a meshing step S103 of forming the whipped and blended fiber material in a step of whipping and blending into a continuous mesh in the form of a thin sheet; a net-stacking step S105 of forming a stacked net by overlaying and stacking the net formed in the net-forming step with one another; a needle punching step S107 of forming a non-woven fabric by connecting the stacked net formed in the net stacking step together by moving a needle up and down through the stacked net; a S109 binder impregnation step of forming a binder-impregnated nonwoven fabric by immersing the nonwoven fabric formed in the needle piercing step in a binder solution wherein the thermosetting binder resin having a thermal resistance temperature of 200° C or greater is dispersed in an organic solvent and; a S111 solvent recovery step of forming a thermosetting felt for use as an insulating and sound absorbing material by removing the solvent from the nonwoven fabric impregnated with binder formed in the binder impregnation step such that only the binder resin thermosetting remains.
[0022]
22. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 21, characterized in that it further comprises, after the solvent recovery step S111, a molding step S121 of non-fabric conformation dry braided in an insulating and sound absorbing material having a desired shape by molding at 150-300 °C.
[0023]
23. METHOD FOR THE MANUFACTURING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND SOUND ABSORBING MATERIAL, according to claim 1, characterized in that the insulating and sound absorbing material has the binder evenly distributed over the entire fiber strand of the non-woven fabric and have smaller sized purge holes formed when compared to before binder impregnation.
[0024]
24. METHOD FOR THE NOISE REDUCTION OF A NOISE GENERATION DEVICE, characterized in that it comprises: i) the identification of the three-dimensional shape of a noise generation device; ii) the fabrication and molding of an insulating and sound absorbing material by the method as defined in any one of claims 1 or 2 so as to correspond partially or totally with the three-dimensional shape of the device and; iii) dragging of the insulating and sound absorbing material adjacent to the noise generating device.
[0025]
25. METHOD, according to claim 24, characterized in that the device is a motor, a mechanism or an exhaust system.
[0026]
26. The METHOD according to claim 24, wherein said dragging of the insulating and sound absorbing material adjacent to the noise generating device is characterized in that it comprises the close attachment of the insulating and sound absorbing material to the noise generating device , installing the insulating and sound absorbing material to be spaced from the noise generating device or molding the insulating and sound absorbing material as a part of the noise generating device.

类似技术:

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BR112015010321B1|2021-05-11|method for manufacturing a highly heat resistant sound absorbing and insulating material; and method for noise reduction of a noise generating device

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同族专利:

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公开号 | 公开日

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US20150283960A1|2015-10-08|

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EP2918450B1|2019-01-09|

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JP6385354B2|2018-09-05|

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RU2629867C2|2017-09-04|

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CN104903152B|2017-06-13|

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BR112015010321A2|2017-07-11|

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EP2918450A1|2015-09-16|

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KR101449340B1|2014-10-13|

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WO2014073860A1|2014-05-15|

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BR112015010321A8|2019-10-01|

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MX2015005749A|2015-09-16|

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ES2716053T3|2019-06-07|

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RU2015121629A|2016-12-27|

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JP2016505865A|2016-02-25|

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CA2890350A1|2014-05-15|

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KR20140059141A|2014-05-15|

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US20150314738A1|2015-11-05|

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CN104903152A|2015-09-09|

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IN2015DN03908A|2015-10-02|

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EP2918450A4|2016-07-06|

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TR201903607T4|2019-04-22|

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US9956927B2|2018-05-01|

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法律状态:
2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-03-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-04-20| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-05-11| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 06/11/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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KR20120124945|2012-11-06|

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KR10-2012-0124945|2012-11-06|

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PCT/KR2013/010027|WO2014073860A1|2012-11-06|2013-11-06|Method for manufacturing highly heat-resistant sound absorbing and screening material|

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