• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    method for molding a highly heat resistant insulating and sound absorbing material, and method for reducing noise of a noise generating device The present invention relates to a method for molding a highly insulating and sound absorbing material heat resistant, which uses a sound absorbing material containing 20-80 parts by weight of a fibrous material having an oxygen limiting index (loi) of 25% or greater and a heat resistance temperature of 200°C or greater and 20 -80 parts by weight of a thermosetting binder resin having a heat resistance temperature of 200°C or greater and be installed in an engine cylinder block and an automotive body panel above a vehicle muffler. more specifically, the method includes a step of coating release agent by coating a release agent into a hot die, a hot compression molding step for setting a shape, and a cold compression step. for format stabilization. the highly heat-resistant sound absorbing and insulating material molded according to the method can reduce noise inside a vehicle by blocking radiated noise, which is generated in the engine and exhaust system, from being transferred to the vehicle interior by an automotive body panel, being able to maintain its shape even in a high temperature environment of 200°C or greater generated by the engine and exhaust system, and being able to satisfy the flame retardancy of the ul 94v-0.
    公开号:BR112015010325B1
    申请号:R112015010325-1
    申请日:2013-11-06
    公开日:2021-06-15
    发明作者:Keun Young Kim；Won Jin Seo；Jong Beom Seo；Chi Man Cho；Ki Dong Lee；Su Nam Lee
    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 molding a highly heat-resistant sound absorbing and insulating material, which uses a sound absorbing material containing 20-80 parts by weight of a fibrous material, having a limiting index of oxygen (LOI) of 25% or more and a heat resistance temperature of 200 °C or more, and 20-80 parts by weight of a thermosetting binder resin, having a heat resistance temperature of 200 °C or more and being installed in an engine cylinder block and an automotive body panel above a vehicle's muffler. More specifically, the method includes a step of coating release agent by coating a release agent into a hot die, a hot compression molding step for setting a shape, and a cold pressing step. for format stabilization. PRIOR TECHNIQUE
    [002] Various noises are generated while driving a vehicle. Vehicle noise is mainly generated by an engine or an exhaust system and is transferred to the interior of the vehicle by the air. An insulating and sound absorbing material is used to reduce the noise generated by the engine and exhaust system that is transferred to the interior of the vehicle. An insulating panel, a panel isolation pad are used to block the noise radiating from the engine and prevent it from being transferred to the interior of the vehicle, a tunnel pad, mat and the like are used to block the noise generated by the system hood and floor, so that it is not transferred to the interior of the vehicle.
    [003] As sound absorbing materials for a vehicle, Korean Patent Publication No. 2004-0013840 discloses a 20-mm thick material, insulator and sound absorber, having a PET fiber layer in which a film is inserted. of synthetic resin having a thickness of 40-100 µm in the length direction, and Korean Patent Publication No. 2002-0089277 discloses a process for preparing a material for sound absorption made in the shape of a non-woven fabric by means of cutting and beating a polyester fiber and an acrylic fiber, mixed in a certain proportion with a polyester fiber with a low melting point, and this being molded and heated. And, Korean Patent Publication No. 2006-0043576 discloses a method for coating at least an upper layer and a lower layer of a polyester felt (PET) with a resin, using the fiber of a blend of a lower fiber. melting point (LMF) and a common fiber.
    [004] However, for the existing insulation and insulation panel covering, although a resin felt can be molded using phenolic powder as a binder, or a glass wool or a semi-crystalline polyurethane foam product using a phenolic resin as a binder simply through a 60-second hot compression molding process, they cannot maintain their shapes in an environment with a high temperature of 200 °C or more or do not have great flame retardancy. For this reason, they cannot be installed directly on an engine cylinder block or an automotive body panel above a muffler.
    [005] In addition, the panel insulation pad, tunnel pad and mat using a low melting polyethylene terephthalate (LM-PET) fiber, which a thermoplastic binder, has poor flame retardancy. Although a thermosetting resin binder having a heat resistance temperature of 200 °C or more must be used for direct installation into an engine cylinder block or an automotive body panel above the muffler, molding the product is impossible by means of preheating followed by cold compression molding. SUMMARY OF THE INVENTION
    [006] The present invention is directed to the provision of a method for molding a highly heat resistant sound absorbing and insulating material that does not change its shape in a high temperature environment of 200 °C or more being adjacent to the source of noise from an engine or exhaust system, and meets UL 94V-0 flame retardance.
    [007] The present invention is also directed to the provision of a method for reducing noise by applying the insulating and sound absorbing material to a noise generating device.
    [008] In one aspect, the present invention provides a method for molding a highly heat-resistant sound absorbing and insulating material, which includes: i) a step of coating release agent by coating a release agent onto the inside a hot matrix; ii) a hot compression molding step for fixing a shape of a sound-absorbing material by installing a sound-absorbing material containing 20-80 parts by weight of a fibrous material having an oxygen-limiting index ( LOI) of 25% or more and a heat resistance temperature of 200 °C or more and 20-80 parts by weight of a thermosetting binder resin having a heat resistance temperature of 200 °C or more in the hot matrix coated by the release agent; and iii) a cold compression step for stabilizing the shape of the compressed material for sound absorption.
    [009] In an exemplary embodiment of the present invention, in one step of coating the release agent i), a nebulizer-type release agent, prepared by diluting an emulsion with water to a concentration of 1090% can be uniformly coated on the top and bottom surfaces inside a hot die in an amount of 20-100 g/m2.
    [010] In another exemplary embodiment of the present invention, the emulsion may be one or more selected from the group consisting of a silicone emulsion and a fluorinated emulsion.
    [011] In an exemplary embodiment of the present invention, in a hot compression molding step ii), the sound absorbing material can be installed in a hot matrix coupled to a heated press and a hot compression performed at a pressure of 60-200 kgf/cm2 for 60300 seconds with the surface temperature of the hot die kept at 150-230 °C to fix its shape.
    [012] In another exemplary embodiment of the present invention, the sound-absorbing material may contain a non-woven fabric containing a fibrous material and a thermosetting binder resin that is located in the same layer as the non-woven fabric, being impregnated into the non-woven fabric maintaining a three-dimensional structure inside the non-woven fabric, the thermosetting binder resin being evenly distributed in all the fiber strands of the non-woven fabric and forming vent holes of smaller size when compared to the situation prior to the impregnation of the binder.
    [013] In another exemplary embodiment of the present invention, the sound-absorbing material can be prepared by immersing the non-woven fabric in a thermosetting binder resin solution, compressing it at a pressure of 1-20 kgf/cm2.
    [014] In another exemplary embodiment of the present invention, the sound absorbing material can be one in which 1300 parts by weight of a thermosetting binder resin is impregnated based on 100 parts by weight of the non-woven fiber.
    [015] In another exemplary embodiment of the present invention, the fibrous material may be one or more selected from the group consisting of an aramid fiber, a polyphenylene sulfide fiber (PPS), an oxidized polyacrylonitrile fiber (oxy-PAN), a polyimide fiber (PI), a polybenzimidazole fiber (PBI), a polybenzoxazole (PBO) fiber, a polytetrafluoroethylene (PTFE) fiber, a polyketone (PK) fiber, a metallic fiber, a carbon fiber, a fiber of glass, a basalt fiber, a silica fiber and a ceramic fiber.
    [016] In another exemplary embodiment of the present invention, the fibrous material may be one or more selected from the group consisting of a meta-aramid fiber (m-aramid) and a para-aramid fiber (p-aramid).
    [017] In another exemplary embodiment of the present invention, the nonwoven fabric may be a single layer nonwoven fabric formed of an aramid fiber having a fineness of 1-15 denier and a thickness of 3-20 mm.
    [018] In another exemplary embodiment of the present invention, the nonwoven fabric can have a density of 100-2000 g/m2.
    [019] In another exemplary embodiment of the present invention, the thermosetting binder resin may contain an epoxy resin, 1-20% by weight of a curing agent based on the weight of the epoxy resin, 1-10% by weight of a catalyst with based on the weight of the epoxy resin and 10-40% by weight of a flame retardant based on the weight of the epoxy resin.
    [020] In another exemplary embodiment of the present invention, the epoxy resin may be one or more selected from the group consisting of bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, polyoxypropylene diglycidyl ether, phosphazene diglycidyl ether, phenol novolac epoxy, o-cresol novolac epoxy and bisphenol A novolac epoxy.
    [021] In an exemplary embodiment of the present invention, in the cold compression step iii), the sound absorbing material can be installed in a cold matrix coupled to an item selected from the group consisting of a cold press and a compression jig and cold compression can be done for 5 seconds or more with the cold matrix surface temperature maintained at 20-40 °C.
    [022] In another exemplary embodiment of the present invention, cold compression can be done for 30-60 seconds.
    [023] In another aspect, the present invention provides a method for reducing noise of a noise generating device, which includes: i) identifying the three-dimensional shape of a noise generating device; ii) the molding of an insulating and sound absorbing material by the method, so as to correspond partially or totally to the three-dimensional shape of the device; and iii) bringing the sound absorbing and insulating material adjacent to the noise generating device.
    [024] In an exemplary embodiment of the present invention, the device can be an electric motor, a motor or an exhaust system.
    [025] In an exemplary embodiment of the present invention, said bringing the insulating and sound absorbing material to adjacent the noise generating device may include intimately attaching the insulating and sound absorbing material to the noise generating device, installing the insulating material and sound absorbing so as to distance itself from the noise generating device or molding the insulating and sound absorbing material as part of the noise generating device.
    [026] The method for molding a highly heat resistant sound absorbing and insulating material according to the present invention provides a highly heat resistant sound absorbing and insulating material, which is installed adjacent to the noise source of an engine or an exhaust system and reduces noise radiating from the engine or exhaust system. BRIEF DESCRIPTION OF THE DRAWINGS
    [027] FIGURE 1 shows a flowchart describing a method for molding a highly heat resistant sound absorbing and insulating material according to an exemplary embodiment of the present invention.
    [028] FIGURE 2 shows images in an electron microscope (x 300) of non-woven fabrics before and after the impregnation of a thermosetting binding resin. FIGURE 2(A) is an image of a non-woven fabric prepared by needle punch. FIGURES 2(B) and 2(C) show images of non-woven fabrics impregnated with binder. FIGURE 2(B) is an image of a nonwoven fabric impregnated with binder in which 20 parts by weight of a thermosetting binder resin is impregnated into 80 parts by weight of a nonwoven fabric, and FIGURE 2(C) is an image of a non-woven fabric impregnated with a binder in which 50 parts by weight of a thermosetting binder resin is impregnated into 50 parts by weight of a non-woven fabric.
    [029] FIGURE 3 schematically shows an example in which an insulating and sound absorbing material is molded and applied to a noise generating device of a vehicle. FIGURE 3(a) shows an image of an insulating and sound absorbing material molded for use in a vehicular engine, and FIGURE 3(b) shows an image of an insulating and sound absorbing material installed in a part of a vehicle. schematically shows an example in which an insulating and sound absorbing material is applied to a noise generating device of a vehicle in order to distance itself from the noise generating device. FIGURE 4(a) shows an image of an insulating and sound absorbing material molded for use in a lower part of a vehicle, and FIGURE 4(b) shows an image of an insulating and sound absorbing material installed in a lower part. of a vehicle.
    [030] FIGURE 4 schematically shows an example in which an insulating and sound absorbing material is applied to a noise-generating device of a vehicle, so as to distance itself from the noise-generating device. FIGURE 4(a) shows an image of an insulating and sound absorbing material molded for use in a lower part of a vehicle, and FIGURE 4(b) shows an image of an insulating and sound absorbing material installed in a lower part of a vehicle.
    [031] FIGURE 5 compares the sound absorption performance of an insulating and sound absorbing material depending on the density of a non-woven fabric.
    [032] FIGURE 6 compares the thermal insulation performance of a highly heat resistant insulating and sound absorbing material manufactured according to a method for molding a highly heat resistant insulating and sound absorbing material according to an embodiment example of the present invention with that of an existing aluminum plate for thermal insulation. DETAILED DESCRIPTION
    [033] Hereinafter, specific exemplary embodiments of the present invention will be described in detail. However, they are only intended to describe the present invention in detail so that those skilled in the subject for which the present invention is intended can easily carry out the invention, and the idea and technical scope of the present invention are not limited by them.
    [034] A method for molding a highly heat resistant sound absorbing and insulating material in accordance with the present invention includes: a step of coating the release agent S101 of coating a release agent within a hot matrix ; an S103 hot compression molding step for fixing a shape of a sound absorbing material; and an S105 cold compression step for shape stabilization.
    [035] In the S101 release agent coating step, a nebulizer-type release agent prepared by diluting an emulsion with water to a concentration of 10-90% is evenly coated on the upper and lower surfaces in the inside a hot matrix in an amount of 20-100 g/m2. The release agent serves to prevent the highly heat resistant sound absorbing and insulating material from being attached to the hot die during molding. When the amount of release agent coating is less than 20 g/m2, severe fluffing can occur when the highly heat resistant sound absorbing and insulating material sets in the hot matrix. And, when the amount of release agent coating is greater than 100 g/m2, the surface of the highly heat resistant sound absorbing and insulating material may be contaminated. Thus, the aforementioned range is preferred.
    [036] Specifically, the emulsion can be one or more among those selected from the group consisting of a silicone emulsion and a fluoridated emulsion.
    [037] In an S103 hot compression molding step, a sound absorbing material containing 20-80 parts by weight of a fibrous material having an oxygen limiting index (LOI) of 25% or more and a resistance temperature to heat of 200 °C or more and 20-80 parts by weight of a thermosetting binder resin having a heat resistance temperature of 200 °C or more is installed in a hot matrix, which is coupled to the heated press, and a compression is performed hot at a pressure of 60-200 kgf/cm2 for 60-300 seconds with the surface temperature of the hot die maintained at 150-230 °C. As a result, the shape of the highly heat resistant sound absorbing and insulating material is fixed. When the surface temperature of the hot matrix is below 150 °C, exfoliation can occur when the thermosetting binder resin that exists in the center of the highly heat resistant sound absorbing and insulating material is not cured. And, when the surface temperature of the hot matrix is above 230 °C, discoloration can occur due to the darkening of the thermosetting binder resin, thus causing a problem in appearance quality. When the pressure is less than 60 kgf/cm2, exfoliation may occur in part of the volume of the highly heat-resistant sound absorbing and insulating material. And, when the pressure is greater than 200 kgf/cm2, there may be a problem in appearance quality when the surface of the compressed part of the highly heat resistant insulating and sound absorbing material becomes slippery. When the hot pressing time is less than 60 seconds, exfoliation can occur when the thermosetting bonding resin inside the highly heat resistant sound absorbing and insulating material is not cured. And, when the hot compression time is greater than 300 seconds, a problem in appearance quality can occur when discoloration due to darkening of the thermosetting binder resin occurs and when the surface of the compressed part of the highly resistant insulating and sound absorbing material occurs when heat becomes slippery. Thus, the aforementioned tracks are preferred.
    [038] In the present invention, as a fibrous material that constitutes the sound absorbing material, a heat resistant fiber having an oxygen limiting index (LOI) of 25% or more and a heat resistance temperature of 200° is used C or more. The heat resistant fiber can be any one that has great durability in order to withstand high temperature and ultra high temperature conditions. Specifically, a heat resistant fiber having an oxygen limiting index (LOI) of 25-80% and a heat resistance temperature of 200-3000 °C can be used. More specifically, a heat resistant fiber having an oxygen limiting index (LOI) of 25-70% and a heat 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 fiber length of 20-100 mm, specifically 40-80 mm.
    [039] As a fibrous material, one known as 'superfiber' in the prior 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 polyimide fiber. polybenzimidazole (PBI), 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 fiber of silica and a ceramic fiber. Specifically, an aramid fiber can be used as the heat resistant fiber of the present invention. Specifically, a meta-aramid (m-aramid) fiber, a para-aramid (p-aramid) fiber or a mixture thereof can be used as the heat resistant fiber of the present invention. The fibrous material is a highly heat-resistant sound absorbing and insulating material base material and serves to reduce noise transferred into a vehicle's interior by absorbing noise radiating from an engine or an exhaust system.
    [040] Although the heat resistant fiber is used as the fibrous material that constitutes the sound absorbing material in the present invention, another fiber may be included in addition to the heat resistant fiber strand for the purpose of cost reduction, reduction of weight, functionality, and others. That is, although the sound absorbing material of the present invention is prepared from a heat resistant fiber such as a yarn, it is not limited to a sound absorbing material consisting only of a heat resistant fiber. The heat resistant fiber strands included in the 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.
    [041] In the present invention, a non-woven fabric prepared by needle punch to have a thickness of 3-20 mm and a density of 100-2000 g/m2 can be used as the fibrous material. Sound absorption performance may vary depending on the thickness and density of the unwoven fabric. Sound absorption performance is expected to be increased with the increased thickness and density of non-woven fabric. In considering the industrial and other application of the insulating and sound absorbing material of the present invention, it is preferable that the non-woven fabric has a thickness of 3-20 mm. When the thickness of the non-woven fabric is less than 3mm, the durability and moldability of the insulating and sound absorbing material may be unsatisfactory. And when the thickness is greater than 20mm, productivity can be reduced and production costs can increase during fabrication and processing of the nonwoven fabric. Furthermore, the density of the non-woven fabric can be 100-2000 g/m2, specifically 2001200 g/m2, more specifically 300-800 g/m2, in terms of performance and cost. The non-woven fabric can be formed by stacking a 30-100 g/m2 net which is formed by carving 2 to 12 times and continuously performing pre-needling up and down, needling and down and down. up and needling up and down, thus forming physical bridges and giving the desired thickness, adding strength and other desired physical properties. The needle used to carry out needling can be a barb-type needle having a working blade of 0.5-3 mm and a needle length (distance from outside the crank to the stitch) of 70-120 mm. Specifically, the needle stroke can be 30-350 times/m2. More specifically, yarn fineness for non-woven fabric can be 1.5-8.0 denier, pile layer thickness can be 613 mm, needle stroke can be 120-250 times/m2, and the density of non-woven fabric can be 300-800 g/m2.
    [042] The sound absorption material of the present invention still contains a thermosetting binder resin in addition to the fibrous material.
    [043] Specifically, a 'binder-impregnated nonwoven fabric' may be used which contains a nonwoven fabric containing 30-100% by weight of the heat resistant fiber based on the total weight of the nonwoven fabric, a thermosetting binder resin which locates in the same layer as the non-woven fabric and is impregnated into the non-woven fabric while maintaining its three-dimensional shape as the sound absorbing material of the present invention. The thermosetting bonding resin, which is impregnated into the non-woven fabric, is evenly distributed over the entire surface of the fiber strands 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 .
    [044] 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 three-dimensionally interconnected labyrinthine structure, which is formed by the fibers arranged in a regular or irregular shape, which may be, instead of bundles of independent capillary tubes. Thus, the non-woven fabric formed by the needle punch may have irregular breathing holes (micro-cavities) formed as the threads containing the cross-loose heat resistant fiber therebetween. When the non-woven fabric is immersed in a thermosetting binder resin solution, the binder can be thin and evenly distributed and fixed to the surface of the non-woven fabric strands, thus forming vent holes of smaller size when compared to the situation before impregnation. The formation of fine vent holes in the internal structure of the non-woven fabric provides an extended noise resonance trajectory, and thus, provides better sound absorption performance. When the thermosetting binder resin forms a three-dimensional network structure when it is cured, sound absorption performance can be further improved by forming finer vent holes within the non-woven fabric. Thus, as the non-woven fabric can maintain the intrinsic three-dimensional shape when the thermoset binder resin is uniformly impregnated into the nonwoven fabric and, moreover, as finer vent holes (microcavities) can be formed when the thermoset binder resin is cured, the sound absorbing and insulating material of the present invention can have excellent and remarkable sound absorption performance due to maximized noise absorption through increased noise resonance in the non-woven fabric.
    [045] The thermosetting binder resin is a material that has chemical and physical properties totally different when compared to the heat resistant fiber used as the fibrous material in the present invention. Therefore, when the thermosetting binder resin is impregnated into the non-woven fabric formed by the heat-resistant thermoplastic fiber, an interface layer is formed through edge-to-edge contact due to the difference in properties and, as a result, the fabric vent holes non-interlaced remain open. That is, the thermosetting binder resin, impregnated into the nonwoven fabric formed by the heat resistant fiber, can maintain the three-dimensional structure within the nonwoven fabric.
    [046] Furthermore, the thermosetting binder resin is curable with light, heat or a curing agent, and its shape does not change even under high temperature conditions. Thus, according to the present invention, the shape of the sound absorbing material can be maintained, even under high temperature conditions after molding, by employing the heat resistant fiber and the thermosetting binder resin under specific conditions. As a result, when the non-woven fabric is impregnated with binder, where the thermosetting binder resin is impregnated into the non-woven fabric formed by the heat-resistant fiber when the sound absorbing material is used, molding into the desired shape during resin curing is possible. thermosetting binder and can be kept in shape even under high temperature conditions.
    [047] Specifically, the thermosetting binder resin can be an epoxy resin. Epoxy resin is one of the thermosetting binder resins, being cured into a polymeric material having a three-dimensional network structure. Thus, as the epoxy resin forms a mesh structure and other vent holes when cured within the nonwoven fabric, other fine vent holes can be formed within the nonwoven fabric and sound absorption performance can be further improved.
    [048] The epoxy resin can be one or more of the epoxy resins 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 bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, phenol novolac epoxy resin and o-cresol novolac epoxy resin. More specifically, the epoxy resin can have an epoxy equivalent of 70-400. When the epoxy equivalent is too low, the intermolecular agglutination 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 poor adhesion with the heat resistant fiber. In contrast, when the epoxy equivalent is too high, the sound absorption performance can be unsatisfactory due to the formation of an excessively dense mesh structure.
    [049] When curing is done 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 when the epoxy groups or hydroxyl groups of the epoxy resin react with the functional groups of the curing agent, such as amine groups or carboxylic acid groups to form covalent cross-links. The curing agent serves as a catalyst that catalyzes the curing reaction by being involved in the reaction and bonded to the chemical groups in the epoxy resin. Thus, the size and physical properties of the vent holes can be controlled by selecting different curing agents.
    [050] The thermosetting binder resin may also contain additives in common use, such as a curing agent and a catalyst and solvents, in addition to the epoxy resin. Specifically, the thermosetting binder resin may contain an epoxy resin, 1-20% by weight of a curing agent based on the weight of the epoxy resin, 1-10% by weight of a catalyst based on the weight of the epoxy resin, and 10- 40% by weight of a flame retardant based on the weight of the epoxy resin. The thermosetting bonding resin serves as a material that binds the fibrous material that constitutes the highly heat resistant sound absorbing and insulating material and maintains the shape of the highly heat resistant sound absorbing and insulating material.
    [051] 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 epoxy groups or hydroxyl groups can be used. For example, an aliphatic amine, an aromatic amine, an acid anhydride, urea, an amide, imidazole, etc. can be used. as a healing 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 can be used. More specifically, an aliphatic amine- or amide-based curing agent can be used due to the better crosslinking ability and much superior chemical and environmental resistance. In particular, dicyandiamide (Dicy) can be used in consideration of crosslinking ability, flame retardancy, thermal resistance, storage stability, processability, and others. As dicyandiamide (Dicy) has a high melting point above 200°C it can provide greater storage stability after being mixed with the epoxy resin and can ensure sufficient processing time for curing and molding.
    [052] In the present invention, a catalyst is used that facilitates the cure of the thermosetting binder resin used as a binder. The catalyst may be one or more selected from the group consisting of urea, dimethylurea, a tetraphenylborate salt of quaternary DBU, and quaternary phosphonium bromide. The catalyst may be contained in the binder containing solution.
    [053] In addition, various additives, for example, a flame retardant, a heat resistance improver, a water repellant and the like can be used to provide other functionalities to the insulating and sound absorbing material. The additive can be contained in the binder solution, and thus, no other surface material is needed to provide functionality to the sound-absorbing and insulating material. The flame retardant can be a melamine, a phosphate, a metal hydroxide, and others. Specifically, the flame retardant can be one or more selected from the group consisting of melamine, melamine cyanourate, melamine polyphosphate, phosphazene, ammonium polyphosphate, and others. More specifically, the flame retardant can be melamine, which simultaneously increases flame retardancy and thermal resistance. The heat resistance improver can be alumina, silica, talc, plaster, glass powder, fiberglass, metal powder, and so on. And one or more fluorinated water repellants can be used as a water repellant. Furthermore, additives commonly used in the prior art can be selected depending on the desired purposes. The solvent can be one or more selected from the group consisting of a ketone, a carbonate, an acetate, a cellosolve, and others. Specifically, the solvent may be one or more selected from the group consisting of acetone, methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), dimethyl carbonate (DMC), ethyl acetate, butyl acetate, methyl cellosolve, ethyl cellosolve and butyl cellosolve.
    [054] The content of the thermosetting binder resin in the sound absorbing material can be contained by the compression pressure during immersion in the binder solution and the temperature during drying. Specifically, compression can be done at a pressure of 1-20 kgf/cm2 using a commonly used compression roller. As a result, a non-woven fabric impregnated with binder having a density of 1000-3,000 g/m 2 can be formed. Specifically, compression can be done using a pressure roller, for example a calender, 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. And drying can be done in an oven at 70-200 °C, specifically 100-150 °C, for 1-10 minutes.
    [055] The content of the thermosetting binder resin in the sound absorbing material can determine the size, shape and distribution of the vent holes within the insulating and sound absorbing material. Thus, the sound absorption property and the mechanical properties of the insulating and sound absorbing material can thus be controlled. Specifically, the compressed and dried and binder-impregnated nonwoven fabric may contain 1-300 parts by weight, more specifically 30-150 parts by weight, of a thermosetting binder resin based on 100 parts by weight of the nonwoven material.
    [056] FIGURE 2 shows electron microscope images that indicate the three-dimensional shape of non-woven fabrics before and after the impregnation of a thermosetting binder resin.
    [057] FIGURE 2 (A) is an electron microscope image showing the internal structure of a non-woven fabric before the impregnation of a thermosetting binder resin. It can be seen that the strands of heat resistant fibers intersect to form irregular vent holes. Figures 2 (B) and (C) are electron microscope images showing the internal structure of the non-woven fabric after impregnation of a thermosetting binding resin. It can be seen that the binder is fine and evenly distributed and fixed to the heat resistant fiber strands and that the binder content on the strand surface increases with increasing binder.
    [058] As can be seen in the electron microscope images of FIGURE 2, in the insulating and sound absorbing material of the present invention, the thermosetting binder resin is evenly distributed on the surface of the heat-resistant fiber strands, which constitute the non-woven fabric .
    [059] In the S105 cold compression step, the highly heat-resistant sound-absorbing material whose shape is fixed in the S103 hot compression molding step is installed in a cold matrix coupled to an item selected from the group consisting of a cold press and a compression jig, then cold pressing for 5 seconds or more with the cold die surface temperature maintained at 20-40 °C. In this step, the shape of the highly heat-resistant sound absorbing and insulating material that was fixed loose in the S103 hot compression molding step is stabilized. It costs a lot to keep the die surface temperature cool at 20°C or less. And, when the surface temperature of the cold matrix is greater than 40 °C, the stiffness of the highly heat-resistant sound absorbing and insulating material may be reduced. Thus, the range described above is preferred. When the cold compression time is less than 5 seconds, the shape of the highly heat resistant sound absorbing and insulating material may not be completely stabilized. Thus, to ensure product rigidity and quality stabilization, the cold pressing time can be maintained for 5 seconds or more, in particular for 30-60 seconds.
    [060] The present invention also provides a method for reducing noise from a noise generating device, which includes: i) identifying the three-dimensional shape of a noise generating device; ii) molding an insulating and sound absorbing material by the method according to any of claims 1 to 15, so as to correspond partially or totally to the three-dimensional shape of the device; and iii) bringing the sound absorbing and insulating material adjacent to the noise generating device.
    [061] Device refers to any noise generating device that includes an electric motor, a motor, an exhaust system, and others. However, the device of the present invention would not be limited to the electric motor, the motor, the exhaust system and others. The sound absorbing and insulating material can be manufactured to partially or fully match the three-dimensional structure of the device. As the insulating and sound absorbing material of the present invention can be molded during the curing of the thermosetting binder resin, 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.
    [062] As used herein, the term "adjacent" can mean the intimate attachment of the sound-absorbing material to the noise-generating device, installing the insulating and sound-absorbing material in a way that distances itself from the noise-generating device or shaping the sound absorbing and insulating material as part of the noise generating device. Furthermore, the term "adjacent" in the present invention may include the installation of the sound absorbing material in a member (e.g., another insulating and sound absorbing material) connected to the noise generating device.
    [063] FIGURE 3 and FIGURE 4 schematically show representative examples in which the insulating and sound absorbing material of the present invention is applied to a noise generating device of a vehicle.
    [064] FIGURE 3 schematically shows an example in which the insulating and sound absorbing material is molded and applied as part of a vehicle noise generating device. (a) shows an image of the insulating and sound absorbing material molded for use in a vehicular engine, and (B) shows an image of the insulating and sound absorbing material installed in a part of a vehicular engine.
    [065] And, FIGURE 4 schematically shows an example in which the sound absorbing and insulating material is applied to a noise-generating device of a vehicle, in order to distance itself from the noise-generating device. (a) shows an image of the insulating and sound absorbing material molded for use in a part in the underside of a vehicle, and (B) shows an image of the insulating and sound absorbing material installed in a part in the underside of a vehicle .
    [066] As described above, as the insulating and sound absorbing material of the present invention has better performance in sound absorption, flame retardancy, thermal resistance and thermal insulating properties, it can exert its inherent effect of insulation and sound absorption when applied to a noise generating device maintained not only at normal temperatures, but also at high temperatures of 200 °C or more, without deformation of the molded product. EXAMPLES
    [067] Hereinafter, a method for preparing a sound-absorbing material used to manufacture a highly heat-resistant sound absorbing and insulating material according to the present invention, and a method for molding the insulating and absorbing material will be described. using sound absorbing material by means of the Preparation Examples and examples.
    [068] [Preparation Examples] Preparation of sound absorption material.
    [069] Preparation Example 1. Laminated aramid sound absorbing material impregnated with epoxy resin.
    [070] A sound-absorbing material was prepared by nebulizing a thermosetting epoxy-based binder resin on one side of a sound-absorbing material containing 67 parts by weight of a meta-aramid fiber (m-aramid) and 33 parts by weight of an epoxy-based thermosetting binder resin and having a surface density of 450 g/m2 to 30 g/m2 being laminated on top of this other sound-absorbing material containing 67 parts by weight of a meta-aramid fiber (m -aramid) and 33 parts by weight of a thermosetting binder resin based on epoxy and having a surface density of 450 g/m2.
    [071] Preparation Example 2. Aramid non-woven fabric sound absorbing material.
    [072] A short fiber meta-aramid having an oxygen limiting index (LOI) of 40%, a heat resistance temperature of 300 °C, a fineness of 2 denier and a length of 51 mm was beaten by means of Air blowing and formed into a 30 g/m2 net by the carding method. The mesh was stacked by overlapping 10 times on a conveyor belt operated at 5 m/min using a horizontal wrapper. An aramid nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by the continued operation of up and down needling, down and up needling and up and down needling with a stroke of 150 times needle/m2.
    [073] Preparation Example 3. Non-woven fabric sound absorbing material impregnated with epoxy resin.
    [074] The aramid nonwoven fabric prepared in Preparation Example 2 was immersed in a binding solution with 1 dip 1 nip (contagion rate = 300%). The binder solution contained 8% by weight of bisphenol A diglycidyl ether, 2% by weight of bisphenol A diglycidyl ether polymer, 0.2% by weight of dicyandiamide, 0.02% by weight of dimethylurea, 10% by weight of cyanourate. melamine and 79.78% by weight of dimethyl carbonate, based on the total weight of the binder solution. A 1,500 g/m2 binder impregnated nonwoven fabric was prepared by compressing the aramid nonwoven fabric at a pressure of 8 kgf/cm2 using a calender. The organic solvent was removed by drying the non-woven fabric impregnated with binder at 150 °C, so that 300 g/m 2 of the binder remained. As a result, a heat-stable 600 g/m2 felt was prepared.
    [075] Preparation Example 4. Aramid nonwoven fabric sound absorbing material coated with epoxy resin.
    [076] The aramid nonwoven fabric prepared in Preparation Example 2 was coated with an epoxy resin so that the coating amount of the binder was 50 parts by weight based on 100 parts by weight of the nonwoven and then dried at 150 °C.
    [077] The coating solution contained 8% by weight of bisphenol A diglycidyl ether, 2% by weight of polymer bisphenol A diglycidyl ether, 0.2% by weight of dicyandiamide, 0.02% by weight of dimethylurea, 10% by weight weight of melamine cyanourate and 79.78% by weight of dimethyl carbonate.
    [078] Preparation Example 5. Aramid non-woven fabric sound absorbing material impregnated with thermoplastic resin.
    [079] An aramid nonwoven fabric impregnated with thermoplastic resin was prepared by immersing the aramid nonwoven fabric prepared in Preparation Example 2 in a solution of thermoplastic binder resin.
    [080] The thermoplastic binder resin solution contained 10 % by weight polyethylene resin, 10 % by weight melamine cyanourate and 80 % by weight dimethyl carbonate (DMC), based on the total weight of the thermoplastic binder solution.
    [081] Preparation Example 6. Non-woven PET fabric sound absorbing material impregnated with epoxy resin.
    [082] A polyethylene terephthalate (PET) nonwoven fabric having a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punch as described in Preparation Example 3, which was then immersed in a binding solution. to prepare an epoxy resin impregnated PET non-woven fabric.
    [083] The binding solution contained 8% by weight of bisphenol A diglycidyl ether, 2% by weight of polymer bisphenol A diglycidyl ether, 0.2% by weight of dicyandiamide, 0.02% by weight of dimethylurea, 10% by weight of melamine cyanourate and 79.78% by weight of dimethyl carbonate, based on the total weight of the binder solution.
    [084] [Examples] Preparation of insulating and sound absorbing material.
    [085] Example 1.
    [086] A nebulizer-type release agent prepared by diluting a silicone emulsion with water to a concentration of 33% on the upper and lower surfaces within a hot matrix in an amount of 60 g/m2 was uniformly coated. Then, the sound absorbing material prepared in Preparation Example 1 was hot compression molded by compression for 200 seconds at a pressure of 150 kgf/cm2 with the surface temperature of the hot matrix maintained at 195 ± 5°C, thus fixing the shape of the sound absorbing material. Subsequently, the shape of the sound absorbing material was stabilized by performing cold compression for 60 seconds at the surface temperature of the cold matrix coupled to a compression template maintained at 30 °C. As a result, a highly heat resistant sound absorbing and insulating material was molded.
    [087] Examples 2-6.
    [088] Highly heat resistant sound absorbing and insulating materials were molded in the same way as in Example 1, except that the sound absorbing materials prepared in Preparation Examples 2-6 were respectively used.
    [089] The PET nonwoven fabric of Preparation Example 6 demonstrated thermal deformation due to the heat of reaction generated during the epoxy curing process and showed complete thermal deformation during the hot compression molding process. As a result, molding into the desired shape was impossible.
    [090] Comparative Example 1.
    [091] A highly heat resistant sound absorbing and insulating material was molded in the same manner as in Example 1, except that the release agent was coated on the top and bottom surfaces inside the hot matrix in an amount of less than 20 g /m2.
    [092] Comparative Example 2.
    [093] A highly heat resistant sound absorbing and insulating material was molded in the same manner as in Example 1, except that the release agent was coated onto the top and bottom surfaces inside the hot matrix in an amount greater than 100 g /m2.
    [094] Comparative Example 3.
    [095] A highly heat resistant sound absorbing and insulating material was molded in the same way as in Example 1, except that the surface temperature of the hot matrix was kept below 150 °C.
    [096] Comparative Example 4.
    [097] A highly heat resistant sound absorbing and insulating material was molded in the same way as in Example 1, except that the surface temperature of the hot matrix was maintained above 230 °C.
    [098] The shape of the insulating and sound absorbing materials molded in Example 1 and Comparative Examples 1-4 is shown in Table 1.

    [099] As can be seen from Table 1, the molded heat according to the present invention has superior appearance quality.
    [0100] To evaluate the performance of the highly heat resistant sound absorbing and insulating material prepared in Example 1, a full accelerated PG 3rd gear test was performed on a diesel vehicle (U2 1.7). The result is shown in Table 2. In addition, the result of the noise measured inside the vehicle at neutral idling speed is shown in Table 3.


    [0101] As can be seen in Table 2 and Table 3, when the molded highly heat resistant sound absorbing and insulating material was applied according to the method for molding a highly heat resistant insulating and sound absorbing material of According to the present invention, resonant noise improved by 2-3.8% and vehicle interior noise improved by 0.9-1.2 dB(A) when 66 g of the highly sound absorbing and insulating material were applied. Heat resistant.
    [0102] [Example of Tests]
    [0103] <Assessment of the physical properties of the insulating and sound absorbing material>
    [0104] The physical properties of insulating and sound absorbing materials were measured and compared as follows. 1. Evaluation of thermal resistance
    [0105] To assess the thermal resistance, the sound absorbing and insulating material was aged in an oven at 260 °C for 300 hours. After being kept in a standard state (23±2 °C, with a relative humidity of 50±5%) for at least 1 hour, the appearance was inspected and the tensile strength measured. Appearance was visually inspected for shrinkage, deformation, surface peeling, fluffing, or cracking. Tensile strength was measured with five plates of randomly selected dumbbell-No.1 specimens at a speed of 200 mm/min in standard condition.
    [0106] 2. Evaluation of the thermal cycle.
    [0107] The durability of the insulating and sound absorbing material was evaluated through a thermal cycle test. Durability was determined after performing five cycles.1) Condition of one cycle.
    [0108] Ambient temperature → high temperature (150 °C x 3 hr) → room temperature → low temperature (30 °C x 3 hr) → room temperature → humid condition (50 °C x 95% RH).
    [0109] 2) Durability assessment standard.
    [0110] After the thermal cycle test, the change in appearance was inspected. For example, surface damage, swelling, breakage and discoloration were inspected. In case there was no damage to appearance, the assessment was 'no abnormality'.
    [0111] 3. Evaluation of flame retardancy.
    [0112] The flame retardancy of the insulating and sound absorbing material was measured according to the ISO 3795 flammability test.
    [0113] 4. Assessment of non-flammability.
    [0114] The non-flammability of the sound absorbing and insulating material was measured according to the UL94 vertical burn test.
    [0115] 5. Evaluation of the Sound absorption property.
    [0116] The sound absorption performance of the insulating and sound absorbing material was measured according to ISO 354.
    [0117] 6. Assessment of air permeabilities.
    [0118] The specimen was mounted on a Frazier type tester and measured the amount of air that flowed vertically through the specimen. The area of the specimen through which the air passed was 5 cm2 and the applied pressure was set at 125 pascals (Pa).
    [0119] Test Example 1. Comparison of the properties of insulating and sound absorbing materials depending on heat resistant fibers.
    [0120] In Test Example 1, the physical properties of sound absorbing and insulating materials prepared with different strands of heat-resistant fibers were compared as sound absorbing materials. The epoxy resin impregnated nonwoven fabrics prepared in Preparation Example 3 were used as sound absorbing materials. For the needle puncture, threads having a fineness of 2 denier and a length of 51 mm were used (see Table 5). Then, the insulating and sound absorbing materials were molded according to the method described in Example 1.
    [0121] The results of measuring the properties of insulating and sound absorbing materials prepared with different heat-resistant fibers as sound absorbing materials are shown in Table 4 and Table 5.


    [0122] As seen in Table 4 and Table 5, all sound absorbing and insulating materials prepared using heat resistant fibers having an oxygen limiting index of 25% or greater and a heat resistance temperature of 150 °C or higher showed satisfactory thermal resistance, durability, flame retardancy, non-flammability and sound absorption performance. Thus, it can be seen that any commonly used heat resistant fiber can be used as the sound absorbing material which constitutes the sound absorbing and insulating material of the present invention.
    [0123] Test Example 2. Comparison of the properties of insulating and sound absorbing materials depending on the density of non-woven fabrics. .
    [0124] In Test Example 2, the physical properties of insulating and sound absorbing materials were compared depending on the density of non-woven fabric. Non-woven fabrics impregnated with epoxy resin were prepared according to the method of Preparation Example 3 as sound absorbing materials. The density of non-woven fabrics varied in the needle puncture step. Then, the sound-absorbing and insulating materials were molded according to the method described in Example 1. The sound absorption performance of the prepared sound-absorbing and insulating materials is shown in FIGURE 5.
    [0125] As seen in Figure 5, the sound absorption performance of the insulating and sound absorbing material was superior when using non-woven fabric having a density of 600 g/m2 when compared to when using non-woven fabric having a density 300 g/m2.
    [0126] Test Example 3. Evaluation of the performance of sound absorption of insulating and sound absorbing materials depending on the type of binder application.
    [0127] In Test Example 3, the sound absorption performances of insulating and sound absorbing materials were compared depending on the type of application of the thermosetting binder resin in the non-woven fabric when preparing the sound absorbing material.
    [0128] That is, the sound absorption rate of insulating and sound absorbing materials prepared with the application of thermosetting binder resin to the non-woven fabric by impregnation or coating was measured. Table 6 shows the sound absorption rate measurement results for the sound absorbing and insulating material prepared from a non-woven fabric (Preparation Example 2), the sound absorbing and insulating material prepared from a non-woven fabric. braid impregnated with thermosetting binding resin (Preparation Example 3) and the sound absorbing and insulating material prepared from a nonwoven fabric coated with thermosetting binding resin (Preparation Example 4).


    [0129] As seen in Table 6, the sound insulating and absorbing material of Preparation Example 3 prepared using the non-woven aramid fabric impregnated with thermosetting bonding resin as the sound absorbing material, exhibits superior sound absorption rate in all ranges of frequency when compared to Preparation Example 2 (where aramid nonwoven fabric was used as the sound absorbing material). In contrast, the sound absorbing and insulating material of Preparation Example 4, in which the non-woven fabric coated with thermosetting binder resin was used, exhibits a lower sound absorption rate in the 400-5000 Hz frequency range as compared to the Example of Preparation 2.
    [0130] Test Example 4. Evaluation of thermal insulation performance of insulating and sound absorbing materials impregnated with binders.
    [0131] In Test Example 4, the thermal insulation performance of the insulating and sound absorbing materials prepared in Example 2 (where aramid nonwoven fabric was used as the sound absorbing material) and in Example 3 (in that aramid nonwoven fabric impregnated with thermosetting bonding resin was used as the sound absorbing material). 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.
    [0132] The temperature measured on the opposite side of the insulating and sound absorbing material was 250 °C for example 2 and 350 °C for example 3. Thus, it can be seen that the use of the fibrous material impregnated with thermosetting binder resin as the sound absorbing material provides better thermal insulation performance.
    [0133] These results show that the insulating and sound absorbing material of the present invention has superior thermal insulation properties.
    [0134] Test Example 5. Comparison of thermal insulation performance with aluminum plate for thermal insulation.
    [0135] In Test Example 5, the thermal insulation performance of the insulating and sound absorbing material from Example 2 was compared to that of an aluminum plate for thermal insulation. Despite 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 over time. The results are shown in Figure 6.
    [0136] As seen in Figure 6, the sound absorbing and insulating material according to the present invention demonstrated better thermal insulation performance at 11 °C or more when compared to the aluminum plate for thermal insulation.
    [0137] Test Example 6. Comparison of the properties of insulating and sound absorbing materials depending on the content of thermosetting binder resin.
    [0138] Sound absorbing materials were prepared as described in Preparation Example 2. The non-woven aramid fabric impregnated with epoxy resin was dried to have different contents of the thermosetting binder resin. The thermosetting binder resin content was represented as parts by weight of the binder included in the sound absorbing and insulating material based on 100 parts by weight of the dry nonwoven fabric.
    [0139] The results of the comparison of the mechanical properties and sound absorption rate of insulating and sound absorbing materials, prepared with different contents of thermosetting binder resin, are shown in Table 7 and Table 8.


    [0140] From Table 7 and Table 8, it can be seen that the impregnation of thermosetting binder resin in the non-woven fabric that is used as sound absorption material provides a better rate of sound absorption. Furthermore, it can be seen that the sound absorption rate of the insulating and sound absorbing material can be controlled with the content of the thermosetting binder resin.
    [0141] Test Example 7. Comparison of the properties of insulating and sound absorbing materials depending on the types of binders.
    [0142] Sound-absorbing and insulating materials were prepared in which 50 parts by weight of a binder were impregnated on the basis of 100 parts by weight of an aramid nonwoven fabric according to the method of Preparation Example 3. resins described in Table 9 as binders.
    [0143] The results of comparing the mechanical properties and sound absorption rate of insulating and sound absorbing materials prepared with different binders are shown in Table 9.
    权利要求:
    Claims (16)
    [0001]
    1. METHOD FOR MOLDING A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, comprising: i) a step of coating the coating release agent of a release agent inside a hot matrix; ii) a step hot compression molding for fixing a shape of a sound absorbing material by installing a sound absorbing material comprising, based on the total weight of the sound absorbing material, 20 to 80 parts by weight of a material fibrous having an oxygen limiting index (LOI) of 25% or greater and a heat resistance temperature of 200°C or greater and 20 to 80 parts by weight of a thermosetting binder resin having a heat resistance temperature of 200° C or greater in a hot matrix coated with release agent; eiii) a cold compression step for stabilizing the shape of the compressed material for sound absorption, characterized in that the sound absorbing material comprises a non-woven fabric comprising a fibrous material and a thermosetting binder resin located in the same layer of the fabric non-woven, being impregnated into the non-woven fabric while maintaining a three-dimensional structure within the non-woven fabric, the thermosetting binder resin being evenly distributed across all fiber strands of the non-woven fabric and forming smaller vent holes when compared to the situation prior to impregnation of the binder, wherein the thermosetting binder resin comprises an epoxy resin, 1 to 20% by weight of a curing agent based on the weight of the epoxy resin, 1 to 10% by weight of a catalyst based on the weight of the epoxy resin and 10 to 40% by weight of a flame retardant based on the weight of the epoxy resin.
    [0002]
    2. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized by the step of coating the release agent i), a nebulizer-type release agent, prepared by diluting a emulsion with water to a concentration of 10 to 90% is uniformly coated on the upper and lower surfaces within the hot matrix in an amount of 20 to 100 g/m2.
    [0003]
    3. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 2, characterized in that the emulsion is one or more selected from the group consisting of a silicone emulsion and a fluoridated emulsion.
    [0004]
    4. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the sound absorbing material, in the hot compression molding step ii), is installed in a hot matrix coupled to a heated press, with a hot compression being made at a pressure of 60 to 200 kgf/cm2 for 60 to 300 seconds with the temperature of the surface of the hot matrix maintained at 150 to 230 °C for the fixation of its shape.
    [0005]
    5. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 4, characterized in that the sound absorption material is prepared by immersing the non-woven fabric in a solution of thermoset binding resin, compressing it. at a pressure of 1 to 20 kgf/cm2 and then drying at 70 to 200 °C.
    [0006]
    6. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 5, characterized in that the sound absorption material is one in which 1 to 300 parts by weight of the thermosetting binder resin are impregnated with base in 100 parts by weight of non-woven fabric.
    [0007]
    7. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the fibrous material is one or more selected from 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 basalt fiber, a silica fiber and a ceramic fiber.
    [0008]
    8. METHOD FOR MOLDING A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 7, characterized in that the fibrous material is one or more selected from the group consisting of a meta-aramid fiber (m-aramid ) and a para-aramid fiber (p-aramid).
    [0009]
    9. METHOD FOR MOLDING A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the non-woven fabric is a single-layer non-woven fabric formed from an aramid fiber having a fineness of 1 to 15 denier and a thickness of 3 to 20 mm.
    [0010]
    10. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the non-woven fabric has a density of 100 to 2000 g/m2.
    [0011]
    11. METHOD FOR MOLDING A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that the epoxy resin comprises one or more selected from the group consisting of bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, polyoxypropylene diglycidyl ether, phosphazene diglycidyl ether, phenol novolac epoxy, o-cresol novolac epoxy and bisphenol A novolac epoxy.
    [0012]
    12. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that, in the cold compression step iii), the sound absorption material is installed in a coupled cold matrix to an item selected from the group consisting of a cold press and a compression jig, and the cold compression is done for 5 seconds or more with the surface temperature of the cold matrix maintained at 20 to 40 °C.
    [0013]
    13. METHOD FOR THE MOLDING OF A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL, according to claim 1, characterized in that, in the cold compression step iii), the cold compression is done for 30 to 60 seconds.
    [0014]
    14. 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 generating device; ii) the molding of an insulating and sound absorbing material by the method as defined in any one of claims 1 to 13, so as to correspond partially or entirely to the three-dimensional shape of the device; eiii) bring the sound absorbing and insulating material adjacent to the noise generating device.
    [0015]
    15. METHOD FOR NOISE REDUCTION OF A NOISE GENERATING DEVICE, according to claim 14, characterized in that the device is an electric motor, a motor or an exhaust system.
    [0016]
    16. METHOD FOR THE REDUCTION OF NOISE OF A NOISE GENERATION DEVICE, according to claim 14, characterized in that said sending of the insulating and sound absorbing material to adjacent to the noise generating device comprise the intimate fixation of the insulating and absorbing material of sound to the noise generating device by installing the insulating and sound absorbing material so as to distance it from the noise generating device or molding the insulating and sound absorbing material as part of the noise generating device.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112015010325B1|2021-06-15|METHOD FOR MOLDING A HIGHLY HEAT RESISTANT SOUND INSULATING AND ABSORBING MATERIAL AND METHOD FOR REDUCING THE NOISE OF A NOISE GENERATING DEVICE
    BR112016014046B1|2021-06-29|SOUND ABSORBENT AND INSULATING MATERIAL; METHOD FOR MANUFACTURING SOUND ABSORBENT AND INSULATING MATERIAL; AND METHOD TO REDUCE NOISE FROM A NOISE GENERATING DEVICE
    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
    JP6290198B2|2018-03-07|Sound absorbing and insulating material and method for manufacturing the same
    RU2671058C1|2018-10-29|Sound-absorbing and insulating material having improved heat resistance and mouldability and method for producing same
    同族专利:
    公开号 | 公开日
    US9498904B2|2016-11-22|
    US20150266214A1|2015-09-24|
    JP6199405B2|2017-09-20|
    KR101428422B1|2014-08-08|
    CN105142869B|2019-06-14|
    EP2926966B1|2018-01-10|
    RU2654021C2|2018-05-15|
    EP2926966A4|2016-08-17|
    KR20140059142A|2014-05-15|
    IN2015DN03907A|2015-10-02|
    CA2890349A1|2014-05-15|
    US9492955B2|2016-11-15|
    WO2014073859A1|2014-05-15|
    US20150352758A1|2015-12-10|
    CN105142869A|2015-12-09|
    EP2926966A1|2015-10-07|
    JP2016504209A|2016-02-12|
    RU2015121631A|2016-12-27|
    MX2015005746A|2015-09-16|
    BR112015010325A2|2017-07-11|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US4481124A|1983-01-07|1984-11-06|Ngk Insulators, Ltd.|Thermal shock resistant porous sound absorbing body|
    JPH07114387A|1993-10-18|1995-05-02|Nippon Tokushu Toryo Co Ltd|High-performance sound insulating material|
    US5945643A|1995-06-16|1999-08-31|Casser; Donald J.|Vibration dampening material and process|
    KR0161818B1|1996-04-19|1999-01-15|한정광|Method for making fiber board using waste fiber|
    JPH09296535A|1996-05-01|1997-11-18|Yamaha Corp|Sound absorbing board and its manufacture|
    WO1998030375A1|1997-01-08|1998-07-16|Owens Corning|Molding media and process of making same|
    JPH10205021A|1997-01-24|1998-08-04|Nippon Steel Chem Co Ltd|Soundproof laminate plate and production thereof|
    KR100241133B1|1997-06-30|2000-03-02|이한중|Production method of synchronizer|
    US6651726B2|2000-07-31|2003-11-25|Denso Corporation|Method of attaching mold releasing agent to molding die, molding apparatus and molding die|
    JP2002287767A|2001-03-23|2002-10-04|Shinnikka Rock Wool Kk|Acoustic material for vehicle and method of manufacturing the same|
    US6659223B2|2001-10-05|2003-12-09|Collins & Aikman Products Co.|Sound attenuating material for use within vehicles and methods of making same|
    JP4029963B2|2001-12-27|2008-01-09|河西工業株式会社|Sound absorbing material|
    JP2003293256A|2002-03-29|2003-10-15|Sanyo Electric Co Ltd|Method of producing core material for vacuum heat insulation material|
    KR100475872B1|2002-08-08|2005-03-10|현대자동차주식회사|Soundproofing material for automobile and process of preparing the same|
    KR100541362B1|2002-11-06|2006-01-11|삼원|The manufacturing method of the sound absorption insulation of car interior and that the sound absorption insulation|
    US6875066B2|2003-02-28|2005-04-05|Polymer Technologies, Inc.|Sound insulation for outboard motors|
    JP2004330534A|2003-05-02|2004-11-25|Kanegafuchi Chem Ind Co Ltd|Molded acoustic material obtained by recycled tile carpet|
    WO2004107314A1|2003-05-28|2004-12-09|Clion Ireland Holding Ltd.|Sound absorbent|
    US7360519B2|2003-07-10|2008-04-22|Dow Global Technologies, Inc.|Engine intake manifold assembly|
    AU2004267301A1|2003-08-25|2005-03-03|Du Pont-Toray Company, Ltd.|Sound absorbing material|
    ZA200601215B|2003-08-25|2007-05-30|Takayasu Co Ltd|Sound absorbing material|
    KR100588757B1|2004-05-25|2006-06-14| 화인테크놀리지|Polyester Staple Fiber bases of Head liner for Vehicle and Method of the Same|
    RU2268380C1|2004-05-31|2006-01-20|Федеральное государственное унитарное предприятие Пермский завод "Машиностроитель"|Method of producing sound-absorbing structure|
    KR100587916B1|2004-07-05|2006-06-08|한일이화주식회사|Sound-absorbing material for interior of automobile|
    FR2873719B1|2004-07-30|2006-11-17|Cera|METHOD OF MAKING A PREFINISHED VOLUME MASS MATTRESS IN TWO THERMOLIAGE STEPS|
    JP4722436B2|2004-09-02|2011-07-13|株式会社イノアックコーポレーション|Sound absorbing material and manufacturing method thereof|
    JP2006138935A|2004-11-10|2006-06-01|Takayasu Co Ltd|Heat-resistant acoustic material|
    CN100591550C|2005-02-23|2010-02-24|Li&S株式会社|The member for headliner on motor vehicles of multilayer structure|
    US20070299218A1|2006-06-22|2007-12-27|Syh-Tau Yeh|Solder-resistant flexible thermosetting epoxy resin system|
    JP2008026517A|2006-07-20|2008-02-07|Central Glass Co Ltd|Sound absorptive lamination structure and method for manufacturing the same|
    CN101153428A|2006-09-27|2008-04-02|张华康|Acoustic absorption nonwoven fabrics and method for producing same|
    KR100874262B1|2006-12-29|2008-12-16|에스케이케미칼주식회사|PET sound-absorbing material using a mixed yarn felt|
    JP4893324B2|2007-01-17|2012-03-07|セントラル硝子株式会社|Sound insulating laminated structure and manufacturing method thereof|
    KR100832358B1|2007-03-07|2008-05-26|엔브이에이치코리아|The manufacturing method of soundproofing material for automobile interior|
    JP4767209B2|2007-03-30|2011-09-07|ニチアス株式会社|Soundproof cover|
    DE102007020832B4|2007-05-02|2009-02-26|Bayer Materialscience Ag|Lightweight, sound-insulating panel for a body part of a motor vehicle and method for its production|
    US20090056668A1|2007-09-05|2009-03-05|Gm Global Technology Operations, Inc.|Acoustic Side Cover for an Engine|
    RU2369495C2|2007-11-20|2009-10-10|Закрытое акционерное общество Научно-производственное предприятие "Тэкникал консалтинг"|Car body noise insulating upholstery|
    WO2010038486A1|2008-10-02|2010-04-08|名古屋油化株式会社|Sound absorbing material, multilayer sound absorbing material, molded multilayer sound absorbing material, sound absorbing interior material, and sound absorbing floor covering material|
    US8122867B2|2008-11-17|2012-02-28|GM Global Technology Operations LLC|Engine with oil pump muffler and noise damper|
    KR101153936B1|2009-11-19|2012-06-08|마이크로컨텍솔루션|Car heater protector Pannel making method|
    KR101154054B1|2010-03-10|2012-06-07|엔브이에이치코리아|Manufacturing method of sound insulating material for vehicle|
    CN102985964A|2010-07-14|2013-03-20|旭玻璃纤维股份有限公司|Sound-absorbing member, method for producing sound-absorbing member, and sheet for sound-absorbing member|
    RU2442705C1|2010-08-27|2012-02-20|Государственное образовательное учреждение высшего профессионального образования "Тольяттинский государственный университет"|Shell volume absorber of acoustic energy produced by transportation vehicle|
    JP2012126045A|2010-12-16|2012-07-05|Sekisui Chem Co Ltd|Resin molding and method of manufacturing the same|
    JP2012152982A|2011-01-25|2012-08-16|Quadrant Plastic Composites Japan Ltd|Laminated sheet and molded body|
    PL2502788T3|2011-03-23|2014-08-29|Autoneum Man Ag|Production process for a moulded multilayer lining|
    JP5740199B2|2011-03-30|2015-06-24|積水化学工業株式会社|Method for producing composite molded body|
    US9190045B2|2012-06-20|2015-11-17|Hyundai Motor Company|Noise-absorbent fabric for vehicle and method for manufacturing the same|
    EP2918450B1|2012-11-06|2019-01-09|Hyundai Motor Company|Method for manufacturing highly heat-resistant sound absorbing and screening material|
    KR101438926B1|2012-11-29|2014-09-15|현대자동차주식회사|High temperature resistant sound absorbing materials for vehicle|KR101655522B1|2014-07-30|2016-09-07|현대자동차주식회사|Method for manufacturing for soundproofing board components having excellent sound absorbtion function|
    CN104538020A|2014-11-19|2015-04-22|崔悦|Super-microporous ceramic sound absorption plate|
    CN105133320A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Light antibacterial sound absorbing cotton and preparing method|
    CN105200785A|2015-09-23|2015-12-30|芜湖环瑞汽车内饰件有限公司|High-toughness tear-resistant sound-absorbing cotton and preparation method thereof|
    CN105133335A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Fireproof flame-retardant sound-absorbing cotton and preparation method thereof|
    CN105155272A|2015-09-23|2015-12-16|芜湖环瑞汽车内饰件有限公司|Muyu stone powder modified composite sound-absorbing cotton and preparation method thereof|
    CN105133330A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Anti-radiation sound-absorbing cotton and preparation method thereof|
    CN105133329A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Sound absorption cotton having air purification function and preparation method thereof|
    CN105178016A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Anti-allergic environment-friendly sound absorbing cotton and preparation method thereof|
    CN105133337A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Moistureproof air-permeable sound-absorbing cotton and preparation method thereof|
    CN105178018A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Health-care deodorizing sound absorption cotton and manufacturing method thereof|
    CN105178015A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|High-elasticity anti-aging sound absorption cotton and preparing method thereof|
    CN105178017A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Dustproof anti-mite sound absorption cotton and preparation method thereof|
    CN105133336A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Abrasion-resistant and corrosion-resistant sound-absorbing cotton and preparation method thereof|
    CN105178019A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Moxa floss composite sound-absorbing cotton and preparation method thereof|
    CN105133339A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Seaweed carbon fiber composite sound absorption cotton and preparation method thereof|
    CN105178013A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Absorbent cotton for automotive trim and preparing method thereof|
    CN105178014A|2015-09-23|2015-12-23|芜湖环瑞汽车内饰件有限公司|Kapok fiber composite sound absorbing cotton and preparing method thereof|
    CN105220493A|2015-09-23|2016-01-06|芜湖环瑞汽车内饰件有限公司|A kind of heat-resisting ageing-resisting acoustical cotton and preparation method thereof|
    CN105133334A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Low temperature-resistant cold-proof sound-absorbing cotton and preparation method thereof|
    CN105133338A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Sound absorption cotton for heat preservation and decoration and preparation method thereof|
    CN105133340A|2015-09-23|2015-12-09|芜湖环瑞汽车内饰件有限公司|Ultraviolet-proof sound-absorbing cotton and preparation method thereof|
    US10450742B2|2016-01-11|2019-10-22|Owens Corning Intellectual Capital, Llc|Unbonded loosefill insulation|
    KR101875579B1|2016-03-28|2018-07-09|주식회사 서연이화|Manufacturing method for vehicle interior parts|
    KR101915971B1|2016-09-30|2018-11-07|주식회사 서연이화|Composite material and manufacturing method of automotive interior material using the same|
    KR20180063392A|2016-12-01|2018-06-12|대한솔루션|Manufacturing method of high temperature resistant sound-insulating materials for vehicle|
    KR101977300B1|2017-01-23|2019-08-28|한국생산기술연구원|Apparatus for forming 3d fabric parts|
    IT201700019746A1|2017-02-22|2018-08-22|Sapa S R L|MULTIPLE PHASE OF THE PRODUCTION OF A COMPOSITE COMPONENT FOR VEHICLES AND A PRODUCT SO OBTAINED.|
    US20200173072A1|2017-07-14|2020-06-04|3M Innovative Properties Company|Noise control article|
    KR102257840B1|2018-10-10|2021-05-28|대한민국|Frame Structure of Flame Retardant Tent|
    EP3789174A1|2019-09-05|2021-03-10|Motherson Innovations Company Limited|Internal trim component with a three-dimensional shape for a motor vehicle and device and method for producing said type of internal trim component|
    CN111171543A|2019-12-23|2020-05-19|上海普利特伴泰材料科技有限公司|Reinforced PC/ABS composite material for sound absorption and damping and preparation method thereof|
    法律状态:
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2020-03-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-05-25| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-06-15| 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:
    申请号 | 申请日 | 专利标题
    KR10-2012-0124955|2012-11-06|
    KR20120124955|2012-11-06|
    PCT/KR2013/010026|WO2014073859A1|2012-11-06|2013-11-06|Method for molding highly heat-resistant sound absorbing and screening material|
    [返回顶部]