SOUND ABSORBENT AND INSULATING MATERIAL; METHOD FOR MANUFACTURING SOUND ABSORBENT AND INSULATING MAT

专利摘要:
sound absorbing and sound insulation material: method for manufacturing the sound absorbing and sound insulating material; and method for reducing noise from a noise generating device. the present invention relates to a sound absorbing and insulating material with superior moldability and appearance, and a method for manufacturing this, more particularly to a sound absorbing and insulating material consisting of an internal sound absorbing and insulating layer. made of a first non-woven fabric, mainly made of a heat resistant fiber, and a binder evenly distributed within the first non-woven fabric and maintaining the three-dimensional structure within the first non-woven fabric, and an external sound absorbing and insulating layer 2 ', 2'' made of a second non-woven fabric, principally made of a heat resistant fiber, in which the outer sound-absorbing and insulating layer is stacked on one or both sides of the inner sound-absorbing and insulating layer, and a method for manufacturing this. The sound absorbing and insulating material of the present invention has superior absorption property, flame retardancy, heat resistance, heat insulating property and high temperature moldability. in addition, there is no concern about deterioration of surface appearance caused by binder leakage due to the presence of the external sound absorbing and insulating layer.
公开号:BR112016014046B1
申请号:R112016014046-0
申请日:2014-04-03
公开日:2021-06-29
发明作者:Keun Young Kim
申请人:Hyundai Motor Company；
IPC主号:

专利说明:

HISTORIC (a) TECHNICAL FIELD
[001] The present invention relates to a sound absorbing and insulating material with superior moldability and appearance, and a method for manufacturing this, more particularly, to a sound absorbing and insulating material consisting of an absorbing and insulating layer of internal sound 1 made of a first non-woven fabric, mainly made of a heat resistant fiber, and a binder evenly distributed within the first non-woven fabric and maintaining the three-dimensional structure within the first non-woven fabric, and an absorbent and insulating layer of 2', 2" outer sound made of a second non-woven fabric, primarily made of a heat resistant fiber, in which the outer sound absorbing and insulating layer is stacked on one or both sides of the inner sound absorbing and insulating layer , and a method for making it. The sound absorbing and insulating material of the present invention has superior absorption property, flame retardancy, heat resistance, heat insulating property and high temperature moldability. Furthermore, there is no concern about deterioration of surface appearance caused by leakage of the binder due to the presence of the external sound absorbing and insulating layer. (b) TECHNICAL HISTORY
[002] Noise, an unwanted side effect of industrial development, gradually causes more damage. A variety of measures are taken to avoid noise. As a way of such noise prevention, research into the development of new sound absorbing and insulating materials capable of trapping, absorbing or isolating sound is conducted in several ways.
[003] Representative industrial sectors that need sound absorbing and insulating materials include electrical appliances such as an air conditioner, a refrigerator, a washing machine, a lawn mower and the like, transportation such as an automobile, a ship, an airplane and the like, building materials such as a wall material, a paving material and the like, and so on. Sound absorbing and insulating material is also needed in many other industrial fields. In general, sound absorbing and insulating materials used in industries require, in addition to good sound absorption property, low weight, flame retardancy, heat resistance and heat insulating property, depending on the specific applications. Specifically, flame retardancy and heat resistance may additionally be required for sound absorbing and insulating materials used in engines, exhaust systems and the like, maintained at high temperatures of 200 °C or more. Currently, an aramid fiber is gaining attention for sound absorbing and insulating materials with superior heat resistance,
[004] In addition, to provide features such as flame retardancy, water repellency, and the like, to a sound absorbing and insulating material, many sound absorbing materials, in which a non-woven fabric containing aramid fibers and a functional fur material are stacked, have been developed.
[005] For example, Korean Patent Publication No. 2007-0033310 discloses a flame retardant sound absorbing material, wherein a non-woven fabric layer in which a heat resistant short aramid fiber and a short thermoplastic polyester fiber they are bridged, and a layer of skin material made of a wetted non-woven fabric consisting of a short aramid fiber, are stacked.
[006] And Japanese Patent Publication No. 2007-0039826 discloses a water-repellent sound-absorbing material, wherein a non-woven fabric layer of a heat resistant short aramid fiber or a mixture of a short aramid fiber and a short thermoplastic polyester fiber and a layer of skin material treated with a water repellant are stacked.
[007] And Japanese Patent Publication No 2007-0138953 discloses a heat-resistant sound-absorbing material, wherein a non-woven fabric layer consisting of a heat-resistant aramid fiber and a skin material layer made of a sheet of fiber containing a heat resistant aramid fiber are stacked.
[008] Since the sound-absorbing materials described above have a structure in which a layer of skin material is laminated to one side of a non-woven fabric to provide features such as flame retardancy, water repellency, and the like, a hot press process to integrate the non-woven fabric layer and the skin material layer is required. Therefore, the general process is complicated and problematic, and a flame retardant, a water repellant, and the like, included as additives, can cause the production of toxic gases as a result of combustion during the hot pressing process. Furthermore, the deformation of the internal structure of the non-woven fabric that can occur during the hot pressing process can lead to deterioration of the sound absorption property. SUMMARY
[009] In order to solve the above-described problem of the existing art, the inventors of the present invention have long researched to develop a new sound absorbing and insulating material with superior sound absorption property, flame retardancy, heat resistance and property of heat insulation and with superior moldability and surface appearance. As a result, they have developed a new sound absorbing and insulating material, which provides the effects that the physical properties of a nonwoven fabric, including sound absorption property, are improved because a binder penetrates the nonwoven fabric with irregular micro-cavities with a complicated three-dimensional labyrinth structure, without blocking the micro-cavities, and is cured while maintaining the three-dimensional structure within the non-woven fabric, molding into a desired shape is possible during binder cure, and casting of the impregnated binder into the non-woven fabric to the surface of the molded product can be avoided at the same time.
[010] Therefore, the present invention is aimed at providing a sound absorbing and insulating material with superior sound absorption property, flame retardancy, heat resistance and heat insulating property, being moldable into a desired shape during curing of the binder impregnated in the non-woven fabric made of a heat resistant fiber and capable of providing superior appearance of the molded product and reducing the contamination of a mold even after repeated moldings, due to the presence of an external sound absorbing and insulating layer.
[011] The present invention is also directed to providing a method for the manufacture of a sound absorbing and insulating material, including a step of preparing an internal sound absorbing and insulating layer by immersing a first non-woven fabric made of a resistant fiber to heat in a binder solution and then dry, and a step of stacking a second non-woven fabric made of a heat resistant fiber on one or both sides of the internal sound absorbing and insulating layer.
[012] The present invention is also aimed at providing a method for reducing noise using the sound absorbing and insulating material in a noise generating device.
[013] In one aspect, the present invention provides a sound absorbing and insulating material including: an inner sound absorbing and insulating layer 1 including a first non-woven fabric containing 30 to 100% by weight of a heat resistant fiber and a binder present in the same layer as the first non-woven fabric, and maintaining a three-dimensional structure within the non-woven fabric; and a 2', 2" outer sound absorbing and insulating layer including a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber, wherein the 2', 2" outer sound absorbing and insulating layer is stacked on one or both sides of the inner sound-absorbing and insulating layer 1.
[014] In another aspect, the present invention provides a method for manufacturing a sound absorbing and insulating material, including: (a) a step of immersing a first non-woven fabric containing 30 to 100% by weight of a resistant fiber to heat in a binding solution; (b) a step of forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; and (c) a step of forming an external sound absorbent and insulating layer 2', 2" by stacking a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and internal sound insulator 1.
[015] In another aspect, the present invention provides a method for reducing noise of a noise generating device, including: (i) a step of verifying a three-dimensional format of a noise generating device; (ii) a step of preparing and molding an absorbent and sound-insulating material to match the three-dimensional shape of the device partially or completely; and (iii) a step of bringing the sound absorbing and insulating material adjacent to the noise generating device.
[016] The sound-absorbing and insulating material of the present invention, in which a binder is impregnated into the first non-woven fabric made of a heat-resistant fiber, is advantageous in that the sound-absorbing and insulating material has sound-absorbing property superior, flame retardant, heat resistance and heat insulating property, and can be molded into a three-dimensional shape due to the binder.
[017] Furthermore, the sound absorbing and insulating material of the present invention is advantageous in that, due to the external sound absorbing and insulating layer made of a second non-woven fabric, it is stacked on one or both sides of the absorbing and insulating layer of internal sound, leakage of the binder included in the internal sound absorbing and insulating layer during molding is avoided, and the molded product has superior appearance without the contamination of a mold.
[018] Furthermore, the sound absorbing and insulating material of the present invention is advantageous in that, if the second sound absorbing and insulating material is prepared by additionally including a functional additive in a binding solution, the desired functionality can be provided to the sound absorbing and insulating material without piling up additional skin material.
[019] The sound-absorbing and insulating material of the present invention is also advantageous in that, since the flame retardancy, heat resistance and heat-insulating property are superior, in addition to the sound-absorbing property, the Sound absorbing and insulating material is not warped or denatured, even when used in a noise generating device maintained at high temperatures of 200 °C or more.
[020] Furthermore, the absorbent and sound-insulating material of the present invention is advantageous in that, if a thermosetting resin is used as the binder, molding into a desired shape is possible during curing of the thermosetting resin. That is, the overall process can be simplified as curing and molding of the thermosetting resin are achieved simultaneously.
[021] In addition, the sound absorbing and insulating material of the present invention is advantageous in that, since a non-woven fabric made of a heat resistant fiber is used, the thermal deformation of the non-woven fabric due to the heat of reaction Thermal curing does not occur, even when a thermosetting resin is used as the binder.
[022] Therefore, the sound absorbing and insulating material of the present invention is useful as a sound absorbing and insulating material in applications that require trapping, absorbing or insulating sound, including electrical appliances such as an air conditioner, a refrigerator, washing machine, lawn mower, and the like, transportation, such as automobile, ship, airplane, and the like, building materials, such as wall material, paving material, and the like, and so on. The sound absorbing and insulating material of the present invention is useful as a sound absorbing and insulating material for a noise generating device maintained at high temperatures of 200°C or more. In particular, when the sound absorbing and insulating material of the present invention is used in an automobile, it can be closely attached to an automobile noise generating device, such as an engine, exhaust system and the like, provided at a distance from the noise generating device, or molded as part of the noise generating device. BRIEF DESCRIPTION OF THE DRAWINGS
[023] Figures 1A-1B schematically show the cross-sectional structure of a sound absorbing and insulating material of the present invention. Figure 1A shows the cross-sectional structure of a sound absorbing and insulating material, in which a second non-woven fabric not impregnated with a binder is stacked on one side of a first non-woven fabric uniformly impregnated with a binder, with an adhesive layer arranged among these. Figure 1B shows the cross-sectional structure of a sound absorbing and insulating material, in which two second non-woven fabrics not impregnated with a binder are stacked on both sides of a first non-woven fabric uniformly impregnated with a binder, with adhesive layers arranged among these.
[024] Figures 2A-2C show electron microscopy images (x300) of a first non-woven fabric before and after an impregnation of a binder. Figure 2A is an image of a first non-woven fabric prior to impregnation of a binder, Figure 2B is an image of a first non-woven fabric in which 20 parts by weight of a binder have been impregnated into 100 parts by weight of the fabric. non-woven, and Figure 2C is an image of a first non-woven fabric in which 50 parts by weight of a binder has been impregnated into 100 parts by weight of the non-woven fabric.
[025] Figures 3A-3B schematically show an example of a sound absorbing and insulating material applied to a noise generating device of an automobile after molding as a part. Figure 3A is an image of a molded sound absorbing and insulating material for use in an automobile engine, and Figure 3B shows an example in which a sound absorbing and insulating material is applied to a part of an automobile engine.
[026] Figures 4A-4B schematically show an example in which a sound absorbing and insulating material is applied to a noise generating device of an automobile at a certain distance. Figure 4A is an image of a molded sound absorbing and insulating material for use in an automobile underside, and Figure 4B shows an example in which a sound absorbing and insulating material is attached to an automobile underside .
[027] Figure 5 is a graph comparing the sound absorption performance of a sound absorbing and insulating material depending on the density of a non-woven fabric.
[028] Figure 6 is a graph comparing the heat insulating performance of an aluminum heat insulating board with that of a sound absorbing and insulating material of the present invention. [Detailed Description of Main Elements] 1: 2', 2" internal sound absorbing and insulating layer: external sound absorbing and insulating layer 3: adhesive layer DETAILED DESCRIPTION
[029] The present invention relates to a sound absorbing and insulating material with superior moldability and appearance, and a method for manufacturing this. The sound absorbing and insulating material of the present invention has superior sound absorption property, flame retardancy, heat resistance, heat insulation property, it is moldable into a desired three-dimensional shape using a binder present in the same layer as a non-woven fabric. braided made from a heat resistant fiber, and is free from the problem of the appearance of a molded product caused by the leakage of the binder during molding.
[030] In one aspect, the present invention provides a sound absorbing and insulating material including: an inner sound absorbing and insulating layer 1 including a first non-woven fabric containing 30 to 100% by weight of a heat resistant fiber and a binder present in the same layer as the first non-woven fabric, and maintaining a three-dimensional structure within the non-woven fabric; and a 2', 2" outer sound absorbing and insulating layer including a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber, wherein the 2', 2" outer sound absorbing and insulating layer is stacked on one or both sides of the inner sound-absorbing and insulating layer 1.
[031] In an exemplary embodiment of the present invention, the stacking between the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer can be achieved by an adhesive, heat or pressure.
[032] In an exemplary embodiment of the present invention, an adhesive can be applied on one side of the external sound absorbing and insulating layer and then the external sound absorbing and insulating layer can be stacked by bringing the adhesive coated side in contact with the internal sound absorbing and insulating layer.
[033] In an exemplary embodiment of the present invention, the adhesive used for stacking between the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer can be the binder contained in the first non-woven fabric.
[034] In an exemplary embodiment of the present invention, the adhesive may be a thermosetting resin.
[035] In an exemplary embodiment of the present invention, the heat resistant fiber can have an oxygen limiting index (LOI) of 25% or more, and a heat resistance temperature of 150 °C or more.
[036] In one embodiment of the present invention, the heat resistant fiber can be one or more selected from a 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. carbon, a fiberglass, a basalt fiber, a silica fiber and a ceramic fiber.
[037] In another exemplary embodiment of the present invention, the heat resistant fiber may be an aramid fiber.
[038] In an exemplary embodiment of the present invention, the first non-woven fabric or the second non-woven fabric may be made of an aramid fiber having a fineness of 0.11 to 1.65 mg/meter (1-15 denier) , and can be a single layer non-woven fabric with a thickness of 3 to 20 mm.
[039] In an exemplary embodiment of the present invention, the first non-woven fabric or the second non-woven fabric may have a density of 100-2000 g/m2.
[040] In another exemplary embodiment of the present invention, the first non-woven fabric or the second non-woven fabric may have a density of 200-1200 g/m2.
[041] In an exemplary embodiment of the present invention, the internal sound absorbing and insulating layer may be made of a single layer or two or more layers.
[042] In an exemplary embodiment of the present invention, the binder may be a thermosetting resin.
[043] In another exemplary embodiment of the present invention, the thermosetting resin can be an epoxy resin capable of forming a three-dimensional network structure in the internal structure of the first non-woven fabric.
[044] In another exemplary embodiment of the present invention, the epoxy resin can be one or more 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, a polymer of bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, a novolac phenol epoxy resin, and a novolac o-cresol epoxy resin.
[045] The structure of the sound absorbing and insulating material according to the present invention is described in greater detail with reference to Figures 1A-1B and Figures 2A-2C.
[046] Figures 1A-1B schematically show the cross-sectional structure of a sound absorbing and insulating material of the present invention. Figure 1A shows the cross-section of a sound-absorbing and insulating material, wherein an outer sound-absorbing and insulating layer 2' is formed as a second non-woven fabric is stacked on one side of an external sound-absorbing and insulating layer. internal sound 1 including a first non-woven fabric and a binder, with an adhesive layer disposed therebetween. Figure 1B shows the cross-section of a sound absorbing and insulating material, in which 2', 2" external sound absorbing and insulating layers are formed as two second non-woven fabrics are stacked on both sides of an absorbent layer. and internal sound insulator 1 including a first non-woven fabric and a binder, with adhesive layers disposed therebetween.
[047] Figures 2S-2C show electron microscopy images showing the three-dimensional structure within the first non-woven fabric constituting the internal sound absorbing and insulating layer 1.
[048] Figure 2A shows an electron microscopy image showing the internal structure of the first non-woven tissue before the impregnation of the ligand. It can be seen that the heat resistant fiber strands cross to form irregular micro-cavities. Figures 2B and 2C are electron microscopy images after ligand impregnation into the first non-woven fabric. It can be seen that the binder is finely and evenly distributed and attached to the strands of the heat resistant fiber. Furthermore, it can be seen that the binder content on the surface of the strands increases as the binder content increases.
[049] Although there may be differences depending on the method of preparation, the fibers are arranged randomly and three-dimensionally in the first non-woven fabric or in the second non-woven fabric used for the preparation of the absorbent and sound insulating material in the present invention. Therefore, the pore structure within a non-woven fabric tends to be a very complicated labyrinth structure (maze system) in which regularly or irregularly arranged fibers are interconnected three-dimensionally rather than in bundles of independent capillary tubes. That is, the non-woven fabric used in the present invention has irregular micro-cavities (micro-cavities) formed as strands made of heat-resistant fiber cross loosely.
[050] If the binder is impregnated into the non-woven fabric, the binder is finely and evenly distributed and attached to the surface of the non-woven fabric strands made of heat resistant fiber, thus forming much finer micro-cavities than before the impregnation. The formation of fine micro-cavities in the internal structure of the non-woven fabric means greater noise resonance and thus better sound absorption property. If the binder forms a three-dimensional network structure as it cures, the sound absorption property can be further improved as finer micro-cavities can be formed within the non-woven fabric.
[051] Therefore, since the non-woven fabric can maintain the intrinsic three-dimensional structure as the binder is uniformly impregnated into the non-woven fabric and, in addition, since thinner micro-cavities can be formed as the binder is When cured, the sound absorbing and insulating material of the present invention has remarkably improved sound absorption performance due to maximized noise absorption through increased resonance in the nonwoven fabric.
[052] As seen in the electron microscopy images of Figures 2A2C, the internal sound absorbing and insulating layer of the present invention has an internal structure in which the binder is uniformly dispersed and distributed over the surface of the heat resistant fiber strands that constitute the non-woven fabric.
[053] Below, the constituents of the absorbent and sound insulating material according to the present invention having such an internal structure are described in greater detail.
[054] In the present invention, a heat resistant fiber is used as the main fiber that constitutes the first non-woven fabric or the second non-woven fabric.
[055] Heat resistant fiber can be any one that has superior durability and is capable of withstanding high temperature and ultra high temperature conditions. Specifically, the heat resistant fiber can be one that has an oxygen limiting index (LOI) of 25% or more, and a heat resistance temperature of 150 °C or more. More specifically, the heat resistant fiber can be one that has an oxygen limiting index (LOI) of 25-80% and a heat resistance temperature of 150-30000 °C. More specifically, the heat resistant fiber can be one that has an oxygen limiting index (LOI) of 25-70% and a heat resistance temperature of 200-1000 °C. And, the heat resistant fiber can have a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier), specifically, 0.11 to 0.66 mg/meter (1 to 6 denier) and a length of 20 to 100 mm wire, specifically 40 to 80 mm.
[056] Heat resistant fiber may be a 'superfiber' as commonly called in the related art. Specifically, the superfiber can be one or more selected from a 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, basalt fiber, a silica fiber and a ceramic fiber.
[057] Specifically, an aramid fiber can be used as the heat resistant fiber in the present invention. More specifically, meta-aramid, para-aramid or a mixture thereof can be used as the heat resistant fiber in the present invention. The aramid fiber used as the yarn of the non-woven fabric in the present invention may have a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier), specifically, 0.11 to 0.66 mg/meter ( 1 to 6 denier), and a yarn length of 20 to 100 mm, specifically 40 to 80 mm. If the thread length is too short, the bridging of threads can be difficult during needle punching. As a result, the cohesion of the non-woven fabric can be poor. And if the yarn length is too long, the cohesiveness of the non-woven fabric may be greater, but yarn movement may be difficult during carding.
[058] Aramid fiber is an aromatic polyamide fiber, in which aromatic rings, such as benzene ring, are linked together by amide groups. To distinguish it from an aliphatic polyamide (eg nylon), polyamide fiber is called 'aramid'. Aramid fiber is prepared by spinning aromatic polyamide, and is classified into meta-aramid and para-aramid depending on the location of the amide bonds.

[059] The meta-aramid (m-aramid) represented by Chemical Formula 1 is prepared by dry spinning after dissolving isophthaloyl chloride and m-phenylenediamine in a solvent of dimethylacetamide (DMAc). Meta-aramid has a relatively high elongation at breakage of 22 to 40%, due to the irregular polymer structure, is dryable and can be easily prepared into fiber. Meta-aramid is commercially available under the trade names Nomex™ (DuPont) and Conex™ (Teijin).
[060] The para-aramid (p-aramid) represented by Chemical Formula 2 is prepared by dry 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. Being about 3 to 7 times stronger than meta-aramid, it is used for reinforcement or protection materials. Furthermore, para-aramid exhibits strong chemical resistance, less thermal shrinkage and superior dimensional stability, as well as high tensile strength, flame resistance and self-extinguishing property. Para-aramid is commercially available under the trade names Kevlar™ (DuPont), Twaron™ (Teijin) and Technora™ (Teijin).
[061] Aramid is provided in the form of a filament, staple, wire, and the like, and is used for reinforcement materials (transformer, motor, and the like), insulating materials (insulating paper, insulating tape, and the like), fibers heat resistant (fireproof clothing, gloves, and the like), high temperature filters, or the like.
[062] Although the nonwoven fabric that constitutes the sound absorbing and insulating material of the present invention is practically prepared from heat resistant fiber yarns, nonwoven fabrics additionally prepared by adding other fibers to the heat resistant fiber yarn heat, to reduce costs or provide reduced weight, functionality, and the like, to the nonwoven fabric, may also be included within the scope of the present invention. That is, although the nonwoven fabric of the present invention is prepared from heat resistant fiber yarns, the present invention is never limited to the nonwoven fabric made of heat resistant fiber only. The non-woven fabric of the present invention may include the heat resistant fiber strand in an amount of 30 to 100% by weight, more preferably 60 to 100% by weight, based on the weight of the non-woven fabric.
[063] In addition, the internal sound absorbing and insulating layer of the sound absorbing and insulating material of the present invention includes the binder, which is present in the same layer as the non-woven fabric and maintains the three-dimensional structure within the non-woven fabric. . The binder used in the present invention can be any one capable of maintaining 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 has been impregnated into the non-woven fabric, is uniformly distributed and attached to the fiber strand surface of the non-woven fabric, and maintains or additionally forms micro-cavities irregular, thus maintaining the original three-dimensional structure within the non-woven fabric.
[064] Although a binder generally refers to a material used to adhere or join two materials, the term binder used in the present invention refers to a material impregnated into the non-woven fabric made of heat resistant fiber.
[065] Many materials can be used as the impregnated binder in the non-woven fabric. First, a thermoplastic resin or a thermosetting resin can be considered as the binding material.
[066] The thermoplastic resin, which is represented by a polyamide-based resin, has polar crystalline groups, such as aramid fiber, as a representative heat resistant fiber. As such, if a thermoplastic binder is impregnated into the non-woven fabric made of the thermoplastic heat-resistant fiber, a strong interface layer is formed between them through face-to-face contact between similar crystalline polar groups, which partially blocks the microcavities of the non-woven fabric. That is, if a thermoplastic resin is used as the impregnated binder in the non-woven fabric made of the thermoplastic heat-resistant fiber, the sound absorption performance is reduced, due to the partial blocking of the micro-cavities of the non-woven fabric. At first glance, one might think that sound absorption performance would be improved if the micro-cavities were blocked. However, since noise is not quenched within the non-woven fabric, but rather is transmitted through other pathways, improvement in sound absorption performance cannot be expected if the thermoplastic binder is impregnated. And, if the thermoplastic binder is to be impregnated into a non-woven fabric made from the inorganic heat resistant fiber, an adhesive additive must be added as well, due to the poor bond.
[067] In contrast, a thermosetting binder has totally different physical and chemical properties than thermoplastic heat resistant fiber. Therefore, if a thermoset binder is impregnated into the non-woven fabric made of the thermoplastic heat resistant fiber, an interface layer is formed through end-to-end contact, due to the difference in characteristics. As a result, the micro-cavities of the non-woven fabric remain open. That is, if a thermosetting resin is used as the impregnated binder in the non-woven fabric made of the heat resistant fiber, the three-dimensional structure within the non-woven fabric can be maintained. Therefore, a thermosetting resin can preferably be used as the binder in the present invention.
[068] In addition, the thermosetting resin has the characteristics of being curable with light, heat or a curing agent, and its shape is not deformed, even at high temperatures. Therefore, by using heat resistant fiber and thermosetting binder with a specific condition, the present invention is advantageous in that the shape of the sound absorbing and insulating material can be maintained even at high temperatures. Therefore, if a thermosetting resin is used as the binder impregnated into the nonwoven fabric, molding into a desired shape can be achieved during resin curing, and the resulting shape can be maintained even at high temperatures.
[069] As described above, if a thermosetting resin is used as the binder impregnated into the non-woven fabric made of heat resistant fiber, the effects of maintaining the three-dimensional structure within the non-woven fabric and molding into a desired shape during curing of the binder resin can be expected.
[070] More specifically, an epoxy resin can be used as the binder. Epoxy resin is a type of thermosetting resin, and it is curable into a polymeric material with a three-dimensional network structure. Therefore, since the epoxy resin can form a mesh structure and thus micro-cavities, when cured within the non-woven fabric, thinner micro-cavities can be formed within the non-woven fabric, and sound absorption performance can be improved. further.
[071] Furthermore, since a three-dimensional network structure can be formed if curing is performed in the presence of a curing agent, the sound absorption effect can be further improved. That is, a three-dimensional network structure polymer is formed as the epoxy groups or hydroxy 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 crosslinks. The curing agent not only serves as a catalyst that catalyzes the curing reaction, but it is also directly involved in the reaction, and is bound to the epoxy resin molecule. Therefore, the size and physical properties of microcavities can be controlled by selecting different curing agents.
[072] 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, a polymer of bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, novolac phenol epoxy resin, novolac o-cresol epoxy resin, and the like. The epoxy resin may be one that has an epoxy equivalent of 70 to 400. If the epoxy equivalent is too low, the intermolecular bond may be too weak to form a three-dimensional network structure or the physical properties of the absorbent and insulating material of sound may be unsatisfactory due to poor adhesion with the heat resistant fiber. And if the epoxy equivalent is too high, the physical properties of the sound absorbing and insulating material may be unsatisfactory because a very dense mesh structure is formed.
[073] If a thermosetting resin is used as the binder in the present invention, the curing agent can be included in a binder solution. The curing agent can be one that has functional groups that can readily react with the functional groups of the binder, such as epoxy groups or hydroxy groups. As the curing agent, an aliphatic amine, an aromatic amine, an acid anhydride, urea, an amine, imidazole, and the like can be used. Specifically, the curing agent can be one or more selected from a group consisting of diethyltoluenediamine (DETDA), diaminodiphenylsulfone (DDS), boron-monoethylamine trifluoride (BF3^MEA), diaminocyclohexane (DACH), methyltetrahydrophthalic anhydride (MTHPA), methyl-5-norbornene-2,3-dicarboxylic anhydride (NMA), dicyandiamide (Dicy), 2-ethyl-4-methylimidazole, and the like. More specifically, an aliphatic amine or amide based curing agent can be used because they have relatively good crosslinking ability and much superior chemical resistance and weather resistance. More specifically, dicyandiamide (Dicy) can be used in consideration of crosslinking ability, flame retardancy, heat resistance, storage stability, processability, and the like. Because dicyandiamide (Dicy) has a melting point above 200 °C, it retains superior storage stability after being mixed with the epoxy resin, and can ensure sufficient processing time for curing and molding.
[074] In addition, a catalyst that facilitates the cure of the thermosetting resin used as the binder can be used in the present invention. The catalyst can be one or more selected from the group consisting of urea, dimethylurea, a quaternary DBU tetraphenylborate salt, quaternary phosphonium bromide, and the like. The catalyst can be included in the binder containing solution.
[075] In addition, various additives, for example, a flame retardant, a heat resistance improver, a water repellent, and the like, can be used to provide functionalities to the absorbent and sound insulating material. The additive is included in the binding solution, and no additional skin material to improve the functionalities of the sound absorbing and insulating material is required.
[076] The flame retardant can be melamine, a phosphate, a metal hydroxide, and the like. Specifically, one or more selected from the group consisting of melamine, melamine cyanurate, melamine polyphosphate, phosphazene, ammonium polyphosphate, and the like, can be used as the flame retardant. More specifically, the flame retardant can be melamine, which can improve flame retardancy and heat resistance at the same time.
[077] The heat resistance enhancer can be alumina, silica, talc, clay, glass powder, fiberglass, metal powder, and the like.
[078] One or more fluorine-based water repellents can be used as the water repellant.
[079] In addition, additives typically used in the technique can be selected and used depending on the objectives.
[080] The internal sound absorbing and insulating layer of the sound absorbing and insulating material of the present invention may be made of a single layer or two or more layers. The inner sound absorbing and insulating layer can be made of a single layer or multiple layers to control the overall thickness of the sound absorbing and insulating material. The single-layer or multi-layer structure of the internal sound absorbing and insulating layer is not particularly limited in the present invention.
[081] In the sound absorbing and insulating material of the present invention, the outer sound absorbing and insulating layer made of a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber is stacked on one or both sides of the internal sound absorbing and insulating layer. As the outer sound-absorbing and insulating layer is stacked on the outer surface of the inner sound-absorbing and insulating layer, the appearance problem due to leakage of the binder included in the inner sound-absorbing and insulating layer during molding and contamination of a mold due to repetitive molding can be avoided.
[082] The external sound absorbing and insulating layer can be stacked using an adhesive layer containing an adhesive or using heat or pressure. For example, when stacking is performed using an adhesive, an adhesive can be applied onto one side of the nonwoven fabric and then the second nonwoven fabric can be stacked by contacting the internal sound absorbing and insulating layer. The adhesive can be any one typically used in the art. Because the binder impregnated in the internal sound absorbing and insulating layer of the present invention also possesses adhesive property, the binder can also be used as the adhesive. Specifically, when the binder is used as the adhesive, a thermosetting resin can be used, because a stronger adhesive effect is expected since the thermosetting resin is cured by the heat applied during molding. More specifically, an epoxy resin can be used as the adhesive. The amount of adhesive used is not particularly limited in the present invention. The amount can be controlled within an allowable range for the adhesion of the two layers.
[083] In another aspect, the present invention provides a method for manufacturing a sound absorbing and insulating material, including: (a) a step of immersion of a first non-woven fabric containing 30 to 100% by weight of a resistant fiber to heat in a binding solution; (b) a step of forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; and (c) a step of forming an external sound absorbent and insulating layer 2', 2" by stacking a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and internal sound insulator 1.
[084] Next, the steps of the method for manufacturing an absorbent and sound insulating material according to the present invention are described in detail.
[085] In step (a), a first non-woven fabric made of a heat resistant fiber is immersed in a binder solution.
[086] In the present invention, the first non-woven fabric is immersed in the binder solution in order to improve sound absorption and sound insulation performance, and to allow molding of the sound absorbing and sound insulating material into a desired shape. The binder solution, in which the first non-woven fabric is immersed, contains, in addition to a binder resin, a curing agent, a catalyst, typically used additives, and a solvent. The binder, curing agent, catalyst and additives typically used 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), dimethyl carbonate (DMC), ethyl acetate, butyl acetate, methyl cellosolve , ethyl cellosolve, butyl cellosolve, and the like.
[087] Specifically, the binder solution used in the present invention may contain 1 to 60% by weight of a binder and a solvent as the remainder. The binder solution used in the present invention may additionally contain a curing agent and other additives, including a catalyst. In this case, the binding solution may contain 1 to 60% by weight of a binder, 0.1 to 10% by weight of a curing agent, 0.01 to 5% by weight of a catalyst, 1 to 40% by weight of additives and a solvent as the rest. More specifically, the binder solution may contain 1 to 30% by weight of a binder, 0.1 to 10% by weight of a curing agent, 0.01 to 5% by weight of a catalyst, 1 to 30% by weight of a flame retardant as an additive, and 40 to 95% by weight of a solvent.
[088] The degree of impregnation in the non-woven fabric can be controlled by controlling the concentration of the binder solution of the present invention. Specifically, the binder solution can be prepared to have a solids content of 1 to 60% by weight, more specifically 20 to 50% by weight. If the binder solution is too thin, the purpose of the present invention cannot be realized, because the content of the impregnated binder in the nonwoven fabric is small. And, if the binder solution is too thick, the nonwoven fabric can harden and may not serve as a sound absorbing and insulating material.
[089] If the content of curing agent contained in the binder solution is too low, molding into a desired shape may be difficult because full curing of the binder cannot be expected. As a result, the effect of improving the mechanical strength of the sound absorbing and insulating material may be unsatisfactory. And if the content is too high, the sound absorbing and insulating material may become hard, and storage stability, and the like, may be unsatisfactory. If the catalyst content is too low, the effect of facilitating the reaction may be negligible. And if catalyst content is too high, storage stability, and the like, may be unsatisfactory. The additives can be one or more additive(s) commonly used in the art, including a flame retardant, a heat resistance improver, a water repellant, and the like. The content of these additives can be adjusted accordingly depending on the purpose of the addition. If the amount of addition is too small, the desired effect may not be achieved. And, an amount of addition that is too large can be economically unfavorable, and can cause unwanted side effects.
[090] In step (b), an internal sound absorbing and insulating layer is prepared by drying the first non-woven fabric.
[091] The drying in the present invention is performed by removing the first non-woven fabric from the binder solution and removing the solvent. Drying can be carried out at appropriate temperatures under pressure. Specifically, the drying process can include a process of removing the unwoven fabric and controlling the binder content in the unwoven fabric by compressing at a pressure of 1 to 20 kgf/cm2 . In addition, the drying process may include a process of removing non-woven fabric and evaporating the solvent by heating to a temperature of 70 to 200°C. In addition, the drying process may include a process of compressing the nonwoven fabric at a pressure of 1 to 20 kgf/cm2 and then heating to a temperature of 70 to 200°C after removing the nonwoven fabric.
[092] The drying in the present invention is a process by which the content of the binder in the non-woven fabric is controlled. With this, the physical properties of the sound absorbing and insulating material can be controlled. The content of binder included in the nonwoven fabric after drying is an important factor in determining the size, shape, and distribution of micro-cavities within the sound absorbing and insulating material. Therefore, the sound absorption property and the mechanical property of the sound absorbing and insulating material can be controlled with the process. In the present invention, drying can be carried out so that the final content of binder included in the nonwoven fabric is 1 to 300 parts by weight, more specifically 30 to 150 parts by weight, based on 100 parts by weight of the nonwoven fabric. intertwined.
[093] In step (c), an external sound absorbing and insulating layer is formed by stacking a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent and insulating layer of built-in sound. That is, when stacking the outer sound absorbing and insulating layer made of a non-woven fabric on one or both sides of the inner sound absorbing and insulating layer, the appearance problem is due to leakage of the binder included in the absorbing and insulating layer of Internal sound during molding and contamination of a mold due to repetitive molding can be avoided.
[094] Stacking can be accomplished through gluing using an adhesive or using heat or pressure. For example, when stacking is performed using an adhesive, an adhesive can be applied to one side of the outer sound absorbing and insulating layer and then stacking the outer sound absorbing and insulating layer over the outer sound absorbing and insulating layer of built-in sound.
[095] The method for manufacturing a sound absorbing and insulating material according to the present invention may additionally include, after step (c), (d) a step of molding the sound absorbing and insulating material at high temperature.
[096] Specifically, the method for manufacturing a sound absorbing and insulating material including step (d) may include: (a) a step of immersing a first non-woven fabric containing 30 to 100% by weight of a strong fiber to heat in a binding solution; (b) a step of forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; (c) a step of forming a 2', 2" external sound absorbent and insulating layer by stacking a second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and built-in sound insulator 1; and (d) a step of molding the high temperature sound absorbing and insulating material.
[097] In step (d), the sound absorbing and insulating material is molded at high temperature after stacking the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer. High temperature molding also considers the curing of the thermosetting binder, and is carried out at a temperature of 150 to 300 °C, more specifically, at a temperature of 170 to 230 °C.
[098] The method for manufacturing a sound absorbing and insulating material according to the present invention may additionally include, prior to step (a), a step of forming a first non-woven fabric or a second non-woven fabric by a process needle punch using a heat resistant fiber. For example, in step (a-1), an unwoven fabric having a thickness of 3 to 20 mm can be formed by a needle punching process of a heat resistant aramid fiber having a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier).
[099] For example, the method for manufacturing a sound absorbing and insulating material according to the present invention including step (a-1) may include: (a-1) a step of forming a first non-woven fabric or a second non-woven fabric by a needle piercing process using a heat resistant fiber; (a) a step of immersing the first nonwoven fabric containing 30 to 100% by weight of a heat resistant fiber in a binder solution; (b) a step of forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; and (c) a step of forming an external sound absorbent and insulating layer 2', 2" by stacking the second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and internal sound insulator 1.
[0100] For example, the method for manufacturing a sound absorbing and insulating material according to the present invention including step (a-1) may also include: (a-1) a step of forming a first non-woven fabric or a second non-woven fabric by a needle piercing process using a heat resistant fiber; (a) a step of immersing the first nonwoven fabric containing 30 to 100% by weight of a heat resistant fiber in a binder solution; (b) a step of forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; (c) a step of forming a 2', 2" external sound absorbent and insulating layer by stacking the second non-woven fabric containing 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and built-in sound insulator 1; and (d) a step of molding the high temperature sound absorbing and insulating material.
[0101] The non-woven fabric used for the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer in the present invention is a non-woven fabric prepared by a needle punching process, which contains 30 to 100% by weight of a heat resistant fiber. The sound absorption property may vary depending on the thickness and density of the non-woven fabric. It is expected that the sound absorption property will improve as the thickness and density of the unwoven fabric is increased.
[0102] The first non-woven fabric or the second non-woven fabric used in the present invention may have a thickness of 3 to 20 mm, when considering the industrial field, and the like, in which the sound absorbing and insulating material is used. If the thickness of the non-woven fabric is less than 3mm, the durability and moldability of the sound absorbing and insulating material may be unsatisfactory. And, if the thickness exceeds 20mm, productivity may decrease, and production cost may increase. And, the density of the non-woven fabric can be 100-2000 g/m2 specifically 200-1200 g/m2 more specifically 300-800 g/m2 when considering performance and cost.
[0103] Non-woven fabric is made by stacking a web of 30 to 100 g/m2 made by carding two 2 to 12 times and continuously performing top-down pre-needling, bottom-up needling and top-down needling, like this , forming physical bridges that provide the required thickness, bond strength, and other desired physical properties. The needle used to carry out the needling can be a barbed-type needle, having a working blade of 0.5 to 3 mm, and a needle length (the distance from the outer crank to the point) of 70 to 120 mm. Specifically, the needle stroke can be 30-350 times/m2.
[0104] More specifically, the yarn fineness of the non-woven fabric can be 0.165 to 0.88 mg/meter (1.5 to 8.0 denier), the stack layer thickness can be 6 to 13 mm, the stroke needle size can be 120 to 250 times/m2 and the density of non-woven fabric can be 300 to 800 g/m2.
[0105] The internal structure of the sound absorbing and insulating material manufactured by the method described above can be confirmed using an electron microscope. When viewed with an electron microscope, the sound absorbing and insulating material of the present invention has microcavities ranging from 1 to 100 μm distributed within it. The microcavities are evenly or irregularly distributed with a spacing of 0.1 to 500 µm.
[0106] In another aspect, the present invention provides a method for reducing noise from a noise generating device, including: i) verifying a three-dimensional shape of a noise generating device; ii) preparing and molding a sound absorbing and insulating material to match the three-dimensional shape of the device partially or completely; and iii) bringing the sound absorbing and insulating material adjacent to the noise generating device.
[0107] Device refers to a noise generating device including an electric motor, an engine, an exhaust system, and the like. However, the scope of the device is never limited to the electric motor, engine and exhaust system. The sound absorbing and insulating material can be manufactured to match the three-dimensional shape of the device, partially or completely. Since the sound absorbing and insulating material of the present invention is moldable during the curing of the binder, the sound absorbing and insulating material can be molded to match the three-dimensional shape of the device partially or completely.
[0108] The term “adjacent” means intimately attaching the sound absorbing and insulating material to the noise generating device, providing it at a distance from the noise generating device, or molding it as part of the noise generating device. Adjacent expression also includes mounting the sound absorbing and insulating material to a member connected to the noise generating device (e.g., other sound absorbing and insulating material).
[0109] Figure 3A-3B and Figure 4A-4B show representative examples, in which the sound absorbing and insulating material of the present invention is applied to a noise generating device of an automobile.
[0110] Figures 3A-3B show an example in which a sound absorbing and insulating material is molded as one piece and applied to a noise generating device of an automobile. Figure 3A is an image of a sound absorbing and insulating material molded for use in an automobile engine, and Figure 3B shows an example in which the sound absorbing and insulating material is applied to a part of an automobile engine. .
[0111] Figures 4A-4B schematically show an example in which a sound absorbing and insulating material is applied to a noise generating device of an automobile. Figure 4A is an image of a sound absorbing and insulating material molded for use in a lower part of an automobile, and Figure 4B shows an example in which the sound absorbing and insulating material is attached to a lower part of an automobile. car.
[0112] As described above, the sound absorbing and insulating material of the present invention, in which the binder is impregnated to maintain the three-dimensional structure within the non-woven fabric, has superior sound absorption property, flame retardancy, heat resistance and heat insulating property, and can exhibit the desired sound absorption performance without deformation after molding when applied directly to a noise generating device maintained at high temperatures of 200°C or above. Furthermore, due to stacking the outer sound absorbing and insulating layer made of non-woven fabric on one or both sides of the inner sound absorbing and insulating layer, the appearance problem is due to leakage of the binder included in the absorbing and insulating layer Internal sound during molding and contamination of a mold due to repetitive molding can be avoided. EXAMPLES
[0113] Below, the present invention is described in greater detail through examples. However, the scope of the present invention is not limited to the examples. [EXAMPLES] PREPARING A SOUND ABSORBING AND INSULATING MATERIAL EXAMPLE 1. PREPARING A SOUND ABSORBING AND INSULATING MATERIAL IN WHICH EXTERNAL SOUND ABSORBING AND INSULATING LAYERS ARE STACKED ON BOTH SIDES 1) Preparation of first non-woven aramid fabric impregnated with epoxy resin
[0114] A short meta-aramid fiber with an oxygen limiting index (LOI) of 40%, a heat resistance temperature of 300 °C, a fineness of 0.22 mg/meter (2 denier) and a length 51 mm was inflated with air and molded into a 30 g/m2 web by carding. The web was stacked by overlapping it 10 times on a conveyor belt operated at 5 m/min using a horizontal wrap. A first non-woven aramid fabric with a density of 300 g/m2 and a thickness of 6 mm was prepared by continuously performing top-down needling, bottom-up needling and top-down needling with a needle stroke of 150 times/m2. 2) Preparation of internal sound absorbent and insulating layer
[0115] The first prepared nonwoven fabric was immersed in a binder solution with 1 dip and 1 squeeze (300% pickup). 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 melamine cyanurate and 79.78% by weight of dimethyl carbonate.
[0116] The non-woven fabric was removed from the binder solution, compressed at a pressure of 8 kgf/cm2 using a roller, and then dried by passing through drying ovens at a temperature of 100 °C, 120 °C and 150 °C at a speed of 5 m/min. The dry non-woven fabric, i.e., an internal sound absorbing and insulating layer, contained 50 parts by weight of a binder based on 100 parts by weight of the non-woven fabric. 3) Preparation of a second non-woven aramid fabric
[0117] A short meta-aramid fiber with an oxygen limiting index (LOI) of 40%, a heat resistance temperature of 300 °C, a fineness of 0.22 mg/meter (2 denier) and a length of 51 mm was inflated with air and molded into a 30 g/m2 web by carding. The web was stacked by overlapping it 10 times on a conveyor belt operated at 5 m/min using a horizontal wrap. A second non-woven aramid fabric with a density of 120 g/m2 and a thickness of 2 mm was prepared by continuously performing top-down needling, bottom-up needling and top-down needling with a needle stroke of 150 times/m2 . 4) Preparation of sound-absorbing and insulating material in which external sound-absorbing and insulating layers are stacked on both sides
[0118] Two felts were prepared by rotogravure treatment on one side of the second non-woven fabric prepared in 3) with an adhesive solution and then drying at a temperature of 50 °C. The adhesive solution contained 16% by weight of bisphenol A diglycidyl ether, 4% by weight of bisphenol A diglycidyl ether polymer, 0.2% by weight of dicyandiamide, 0.02% by weight of dimethylurea and 79.78% by weight of of dimethyl carbonate.
[0119] The two prepared felts were stacked on both sides of the internal sound absorbing and insulating layer prepared in 2) so that the side on which the adhesive was applied came in contact with the internal sound absorbing and insulating layer. The prepared sound absorbing and insulating material was molded into a desired shape by curing at a temperature of 200 °C for 2 minutes. COMPARATIVE EXAMPLE 1. PREPARATION OF SOUND ABSORBING AND SOUND INSULATING MATERIAL MADE OF NON-LATLED ARAMID FABRIC
[0120] An aramid nonwoven fabric with a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching as described in Example 1 for use as a sound absorbing and insulating material. COMPARATIVE EXAMPLE 2. PREPARATION OF SOUND ABSORBING AND SOUND INSULATING MATERIAL MADE OF EPOXY RESIN COATED NON-ENTROWN ARAMID FABRIC
[0121] An aramid nonwoven fabric with a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching as described in Example 1. Subsequently, a coating solution containing an epoxy resin was applied to the surface. of the nonwoven fabric, so that the content of a binder was 50 parts by weight, based on 100 parts by weight of the nonwoven fabric. Then, the non-woven fabric was molded after drying at a temperature of 150 °C.
[0122] The coating 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 melamine cyanurate and 79.78% by weight of dimethyl carbonate. COMPARATIVE EXAMPLE 3. PREPARATION OF SOUND ABSORBING AND SOUND INSULATING MATERIAL MADE OF NON-LATLED ARAMINE FABRIC IMPREGNATED WITH THERMOPLASTIC RESIN
[0123] An aramid nonwoven fabric with a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching as described in Example 1. The nonwoven fabric was immersed in a binder solution, dried, and then molded.
[0124] The binder solution was a thermoplastic resin binder solution containing 10% by weight polyethylene resin, 10% by weight melamine cyanurate and 80% by weight dimethyl carbonate (DMC). COMPARATIVE EXAMPLE 4. PREPARATION OF SOUND ABSORBING AND SOUND INSULATING MATERIAL MADE OF PET NON-ENTANGED FABRIC IMPREGNATED WITH EPOXY RESIN
[0125] A polyethylene terephthalate (PET) nonwoven fabric with a density of 300 g/m2 and a thickness of 6 mm was prepared by needle punching as described in Example 1. The nonwoven fabric was immersed in a solution of binder, dried, and then molded.
[0126] The PET nonwoven fabric prepared in Comparative Example 4 was thermally deformed due to the heat of reaction produced during epoxy curing, and could not be molded into a desired shape because it was completely and thermally deformed during the drying and drying processes. thermal molding. [TEST EXAMPLE] EVALUATION OF PHYSICAL PROPERTIES OF SOUND ABSORBENT AND INSULATING MATERIALS
[0127] The physical properties of absorbent and sound insulating materials were measured and compared as follows. 1. ASSESSMENT OF HEAT RESISTANCE
[0128] To assess the heat resistance, the absorbent and sound insulating material was aged in an oven at a temperature of 260 °C for 300 hours. After keeping in a standard state (temperature 23±2 °C, 50±5% relative humidity) for at least 1 hour, the appearance was inspected, and the tensile strength was measured. It was visually inspected for shrinkage or deformation, surface peeling, wear and cracking. Tensile strength was measured using a type #1 dumbbell for five randomly selected test sample sheets at a speed of 200 mm/min under a standard condition. 2. THERMAL CYCLE EVALUATION
[0129] The durability of the sound absorbing and insulating material was evaluated by the thermal cycle test method. Durability was determined after running five cycles under the following conditions. 1) Condition of a cycle
[0130] Ambient temperature → high temperature (150 °C x 3 h) → room temperature → low temperature (30 °C x 3 h) → room temperature → humid condition (50 °C x 95% RH). 2) Durability Assessment Standard
[0131] After the thermal cycle test, the appearance change was inspected. For example, surface damage, swelling, breakage and discoloration were inspected. If there was no change in appearance, the sound absorbing and insulating material was evaluated as 'no abnormality'. 3. FIRE DELAY ASSESSMENT
[0132] The flame retardancy of the sound absorbing and insulating material was measured according to the ISO 3795 flammability test method. 4. EVALUATION OF NON-FLAMMABILITY
[0133] The non-flammability of the absorbent and sound-insulating material was measured according to the UL94 vertical burn test. 5. ASSESSMENT OF SOUND ABSORPTION PROPERTY
[0134] The sound absorption property of the sound absorbing and insulating material was measured according to the ISO 354 flammability test method. 6. AIR PERMEABILITY ASSESSMENT 1) Assessment method
[0135] The test sample was placed on top of a Frazier type tester, and the amount of air flowing through the sample vertically was measured. The area of the test sample through which the air passed was 5 cm2, and the applied pressure was set at 125 pascals (Pa). TEST EXAMPLE 1 . COMPARISON OF THE PROPERTIES OF SOUND ABSORBENT AND SOUND INSULATING MATERIALS DEPENDING ON HEAT RESISTANT FIBERS
[0136] In Test Example 1, the physical properties of sound absorbing and insulating materials prepared with different strands of heat resistant fiber were compared. The internal sound absorbing and insulating layer was formed by preparing first non-woven fabrics with a density of 300 g/m2 and a thickness of 6 mm by a needle punching process as described in Example 1, immersing them in a solution of binder, drying them and then molding. Non-woven fabrics were prepared using yarns with a fineness of 0.22 mg/meter (2 denier) and a length of 51 mm, which are described in Table 1.
[0137] As external sound absorbing and insulating layers, second non-woven fabrics with a density of 120 g/m2 and a thickness of 2 mm prepared by a needle punching process as in Example 1 were used. The sound-absorbing and insulating material was prepared by stacking the outer sound-absorbing and insulating layers on both sides of the inner sound-absorbing and insulating layer as described in Example 1.
[0138] The physical properties of the sound absorbing and insulating materials were measured as described above. The result of measuring the properties of sound absorbing and insulating materials prepared with different heat resistant fibers is shown in Table 1 and Table 2.


[0139] As seen in Table 1 and Table 2, all sound absorbing and insulating materials prepared using heat resistant fibers with an oxygen limiting index of 25% or more, and a heat resistance temperature of 150 ° C or more as disclosed by the present invention exhibited satisfactory heat resistance, durability, flame retardancy, non-flammability and sound absorption property. Therefore, it has been confirmed that common heat resistant fibers known as superfibers can be used as the non-woven fabric material of the sound absorbing and insulating material in accordance with the present invention. TEST EXAMPLE 2. COMPARISON OF THE PROPERTIES OF SOUND ABSORBENT AND SOUND INSULATING MATERIALS DEPENDING ON THE DENSITY OF THE NON-RELATED TISSUE
[0140] In Test Example 2, sound absorbing and insulating materials were prepared in the same way as in Example 1 using first non-woven fabrics with different densities. The sound absorption performance of the prepared sound absorbing and insulating materials is shown in Figure 5.
[0141] As seen in Figure 5, the sound absorption performance of the sound absorbing and insulating material was superior when a first non-woven fabric with a density of 600 g/m2 was used, compared to when a first non-woven fabric with a density of 300 g/m2 was used. TEST EXAMPLE 3. ASSESSMENT OF PHYSICAL PROPERTIES OF SOUND ABSORBENT AND INSULATING MATERIALS
[0142] In Test Example 3, the properties of sound-absorbing and sound-insulating materials depending on the method by which a thermoset binder was applied to a non-woven fabric made of a heat-resistant fiber were compared.
[0143] That is, the sound absorption rate of the sound absorbing and insulating material prepared by forming an internal sound absorbing and insulating layer by impregnating the thermoset binder in the first non-woven fabric (Example 1), the absorbing and insulating material of sound made from the first non-woven fabric (Comparative Example 1) and the sound absorbing and insulating material prepared by applying the thermoset binder on the first non-woven fabric (Comparative Example 2) was compared. The result of measuring the sound absorption rate of the sound-absorbing and insulating material made of the sound-absorbing and insulating material made of the non-woven fabric (Comparative Example 1), the sound-absorbing and insulating material prepared by applying the thermoset binder on the surface of the non-woven fabric (Comparative Example 2) and the sound absorbing and insulating material prepared using the inner sound absorbing and insulating layer, where the binder is impregnated into the non-woven fabric (Example 1) is shown in Table 3.

[0144] As seen in Table 3, the sound absorbing and insulating material according to the present invention had a higher sound absorption rate in all frequency ranges, compared to Comparative Example 1, in which the non-woven fabric non-impregnated with the thermosetting binder was used as the non-woven fabric. In contrast, the sound-absorbing and insulating material of Comparative Example 2, in which the non-woven fabric onto which the thermoset binder was applied, had a lower sound absorption rate than the non-woven fabric (Comparative Example 1) in the frequency range from 400 to 5000 Hz. TEST EXAMPLE 4. EVALUATION OF HEAT INSULATION PERFORMANCE OF SOUND ABSORBENT AND SOUND INSULATING MATERIALS
[0145] In Test Example 4, the heat insulating performance of the sound absorbing and insulating materials prepared in Example 1, Comparative Example 1 and Comparative Example 3 was evaluated. After applying 1000 °C heat to one side of a 25 mm thick sample of each sound absorbing and insulating material for 5 minutes, the temperature was measured on the opposite side of the sample.
[0146] The temperature measured on the opposite side of the sound-absorbing and insulating material was 250 °C for the surface layer of Example 1, and 350 °C for the sound-absorbing and insulating material of Comparative Example 1. Therefore, it was confirmed that the sound absorbing and insulating material of the present invention in which the thermosetting resin has been impregnated exhibits better heat insulation performance. In contrast, the thermoplastic resin impregnated sound absorbing and insulating material of Comparative Example 3 melted and deformed as soon as heat at a temperature of 1000°C was applied.
[0147] Therefore, it can be seen that the sound absorbing and insulating material of the present invention has much superior heat insulation property. TEST EXAMPLE 5 . COMPARISON OF HEAT INSULATION PERFORMANCE WITH ALUMINUM HEAT INSULATION PLATE
[0148] In Test Example 5, the heat insulating performance of the sound absorbing and insulating material of Example 1 was compared with that of an aluminum heat insulating board. While applying the same heat to one side of the sound absorbing and insulating material and the heat insulating board at a temperature of 250 °C, the temperature on the opposite side was measured over time. The result is shown in Figure 6.
[0149] As seen in Figure 6, the sound absorbing and insulating material according to the present invention showed better heat insulation performance, with the heat resistance temperature at least 11 °C lower, compared to the plate of aluminum heat insulation. TEST EXAMPLE 6. COMPARISON OF SOUND ABSORBING AND SOUND INSULATING MATERIAL PROPERTIES DEPENDING ON BINDER CONTENT
[0150] Sound absorbent and insulating materials were prepared in the same manner as in Example 1. The first non-woven aramid fabric impregnated with epoxy resin was dried to have different final binder contents. Binder content was represented as parts by weight of the binder included in the sound absorbing and insulating material, based on the weight of 100 parts by weight of the dry nonwoven fabric.
[0151] The result of comparing the mechanical properties and sound absorption rate of sound absorbing and insulating materials prepared with different binder contents is shown in Table 4 and Table 5.



[0152] As seen in Table 4 and Table 5, the sound absorption rate was improved as the binder was impregnated into the nonwoven fabric when compared to the nonwoven fabric not impregnated with the binder. Furthermore, it was confirmed that the sound absorption rate of the sound absorbing and insulating material could be controlled with the binder content. TEST EXAMPLE 7 . COMPARISON OF THE PROPERTIES OF THE SOUND ABSORBING AND INSULATING MATERIAL DEPENDING ON THE BINDERS
[0153] Sound absorbent and insulating materials, in which 50 parts by weight of a binder were impregnated on the basis of 100 parts by weight of a first non-woven aramid fabric, were prepared in the same manner as in Example 1. The described resins in Table 6 were used as the binder.
[0154] The result of comparing the mechanical properties and sound absorption rate of sound absorbing and insulating materials prepared with different binders is shown in Table 6.

权利要求:
Claims (40)
[0001]
1. SOUND ABSORBENT AND INSULATING MATERIAL, characterized in that it comprises: an internal sound absorbing and insulating layer comprising a first non-woven fabric comprising 30 to 100% by weight of a heat resistant fiber and a binder present in the same layer as the first non-woven fabric, and maintaining a three-dimensional structure within the non-woven fabric; and an outer sound-absorbing and insulating layer comprising a second non-woven fabric comprising 30 to 100% by weight of a heat resistant fiber, wherein the outer sound-absorbing and insulating layer is stacked on one or both sides of the absorbent layer. and internal sound insulating, and wherein the binder impregnated in the first non-woven fabric is evenly distributed and attached to the fiber strand surface of the first non-woven fabric.
[0002]
2. MATERIAL according to claim 1, characterized in that the stacking between the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer is obtained by an adhesive, heat or pressure.
[0003]
3. MATERIAL according to claim 1, characterized in that an adhesive is applied on one side of the external sound absorbing and insulating layer and then the external sound absorbing and insulating layer is stacked by bringing the adhesive coated side in contact with the internal sound absorbing and insulating layer.
[0004]
4. MATERIAL according to claim 3, characterized in that the adhesive used for stacking between the internal sound absorbing and insulating layer and the external sound absorbing and insulating layer is the binder contained in the first non-woven fabric.
[0005]
MATERIAL according to claim 4, characterized in that the adhesive is a thermosetting resin.
[0006]
6. MATERIAL according to claim 1, characterized in that the heat resistant fiber constituting the first non-woven fabric or the second non-woven fabric has an oxygen limiting index (LOI) of 25% or more, and a temperature of heat resistance of 150 °C or more.
[0007]
7. MATERIAL according to claim 6, characterized in that the heat resistant fiber is one or more selected from a group consisting of an aramid fiber, a polyphenylene sulfide (PPS) fiber, an oxidized polyacrylonitrile (oxy) fiber. -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 fiber of carbon, a fiberglass, a basalt fiber, a silica fiber and a ceramic fiber.
[0008]
8. MATERIAL according to claim 7, characterized in that the heat resistant fiber is an aramid fiber.
[0009]
Material according to claim 1, characterized in that the first non-woven fabric or the second non-woven fabric is made of an aramid fiber with a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier) , and be a single layer non-woven fabric with a thickness of 3 to 20 mm.
[0010]
The material of claim 1, characterized in that the first non-woven fabric or the second non-woven fabric has a density of 100 to 2000 g/m 2 .
[0011]
MATERIAL according to claim 10, characterized in that the non-woven fabric has a density of 200 to 1200 g/m 2 .
[0012]
12. MATERIAL according to claim 1, characterized in that the internal sound absorbing and insulating layer is made of a single layer or multiple layers.
[0013]
13. MATERIAL according to claim 1, characterized in that the binder included in the internal sound absorbing and insulating layer is a thermosetting resin.
[0014]
14. MATERIAL according to claim 5, characterized in that the thermosetting resin is an epoxy resin.
[0015]
15. MATERIAL according to claim 14, characterized in that the epoxy resin is one or more epoxy resins selected from a group consisting of bisphenol A diglycidyl ether, bisphenol B diglycidyl ether, bisphenol AD diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, polyoxypropylene diglycidyl ether, a polymer of bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, a novolac phenol epoxy resin, and a novolac o-cresol epoxy resin.
[0016]
The material according to any one of claims 1 to 13, characterized in that the sound absorbing and insulating material is shaped to have a three-dimensional shape corresponding to which the sound absorbing and insulating material is applied.
[0017]
17. MATERIAL according to claim 16, characterized in that the absorbent and sound-insulating material is for an automobile.
[0018]
18. METHOD FOR MANUFACTURING THE SOUND ABSORBING AND INSULATING MATERIAL, as defined in claim 1, characterized in that it comprises: (a) immersing a first non-woven fabric comprising 30 to 100% by weight of a heat resistant fiber in a solution of binder; (b) forming an internal sound absorbing and insulating layer 1 by drying the first non-woven fabric; and (c) forming an external sound absorbent and insulating layer 2', 2" by stacking a second non-woven fabric comprising 30 to 100% by weight of a heat resistant fiber on one or both sides of the absorbent layer and built-in sound insulator 1; and wherein the binder solution in a) impregnated into the first non-woven fabric is evenly distributed and attached to the fiber strand surface of the first non-woven fabric.
[0019]
19. METHOD according to claim 18, further characterized in that it comprises, after (c), (d) the molding of the absorbent and sound insulating material at high temperature
[0020]
20. METHOD, according to claim 18, characterized in that the drying in (b) is carried out at a temperature of 70 to 200 °C and the internal sound absorbing and insulating layer made by drying in which it comprises 1 to 300 parts by weight of a binder based on 100 parts by weight of the nonwoven fabric.
[0021]
21. METHOD according to claim 18, characterized in that the stacking in (c) is obtained by an adhesive, heat or pressure.
[0022]
22. METHOD according to claim 21, characterized in that the stacking is performed by applying an adhesive on one side of the second non-woven fabric and then bringing the side on which the adhesive was applied into contact with the absorbent and insulating layer of built-in sound.
[0023]
23. METHOD according to claim 22, characterized in that the adhesive is a binder included in the first non-woven fabric.
[0024]
24. METHOD, according to claim 23, characterized in that the adhesive is a thermosetting resin.
[0025]
25. The method according to claim 18, characterized in that the heat resistant fiber constituting the first non-woven fabric or the second non-woven fabric has an oxygen limiting index (LOI) of 25% or more, and a temperature of heat resistance of 150 °C or more.
[0026]
26. METHOD according to claim 25, characterized in that the heat resistant fiber is one or more selected from a 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 fiber of carbon, a fiberglass, basalt fiber, a silica fiber and a ceramic fiber.
[0027]
27. METHOD according to claim 25, characterized in that the heat resistant fiber is an aramid fiber with a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier) and a yarn length of 20 to 100 mm.
[0028]
28. The method according to claim 18, characterized in that the first non-woven fabric or the second non-woven fabric has a thickness of 3 to 20 mm and a density of 100 to 2000 g/m2.
[0029]
29. The method of claim 28, characterized in that the first non-woven fabric or the second non-woven fabric is an aramid non-woven fabric having a thickness of 3 to 20 mm, made by needle punching a strong aramid fiber heat to a fineness of 0.11 to 1.65 mg/meter (1 to 15 denier).
[0030]
30. The method according to claim 29, characterized in that the non-woven fabric is formed by continuously performing top-down needling, low-up needling and top-down needling.
[0031]
31. METHOD according to claim 29, characterized in that the non-woven fabric is formed with a needle stroke of 30 to 350 times/m2.
[0032]
The method according to any one of claims 18 or 19, wherein the binder solution is characterized in that it comprises 1 to 60% by weight of a binder, 0.1 to 10% by weight of a curing agent. .01 to 5% by weight of a catalyst, 1 to 40% by weight of an additive and a solvent as the remainder.
[0033]
33. The method according to claim 32, wherein the binder solution is characterized in that it comprises 1 to 30% by weight of a binder, 0.1 to 10% by weight of a curing agent, 0.01 to 5 % by weight of a catalyst, 1 to 30% by weight of a flame retardant and 40 to 95% by weight of a solvent.
[0034]
34. METHOD, according to claim 33, characterized in that the binder is a thermosetting resin.
[0035]
35. METHOD according to any one of claims 24 or 34, characterized in that the thermosetting resin is an epoxy resin.
[0036]
36. METHOD according to claim 35, characterized in that the epoxy resin is one or more selected from a group consisting of bisphenol A diglycidyl ether, bisphenol B diglycidyl ether, bisphenol AD diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether , polyoxypropylene diglycidyl ether, a polymer of bisphenol A diglycidyl ether, phosphazene diglycidyl ether, bisphenol A novolac epoxy, a novolac phenol epoxy resin, and a novolac o-cresol epoxy resin.
[0037]
37. METHOD according to any one of claims 18 to 31, 33, 34 or 36, characterized in that the absorbent and sound insulating material is for a car.
[0038]
38. METHOD TO REDUCE NOISE OF A NOISE GENERATING DEVICE, characterized in that it comprises: (i) the verification of a three-dimensional format of a noise generating device; (ii) preparing and molding the sound absorbing and insulating material as defined in any one of claims 1 to 13 so as to correspond to the three-dimensional shape of the device partially or completely; and (iii) positioning the sound absorbing and insulating material adjacent to the noise generating device.
[0039]
39. METHOD according to claim 38, characterized in that the device is an electric motor, an engine or an exhaust system.
[0040]
40. METHOD according to claim 39, characterized in that the sound absorbing and insulating material is brought adjacent to the noise generating device by attaching the sound absorbing and insulating material to the noise generating device, providing the sound absorbing and insulating material at a distance from the noise generating device, or molding the sound absorbing and insulating material as part of the 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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US10304437B2|2019-05-28|

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CA2933597C|2021-03-30|

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US9805708B2|2017-10-31|

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RU2666429C1|2018-09-07|

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RU2016129197A|2018-01-24|

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CN105848875A|2016-08-10|

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JP6276861B2|2018-02-07|

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BR112016014046A2|2017-08-08|

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MX2016007827A|2016-09-07|

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US20160322041A1|2016-11-03|

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EP3085526A4|2017-09-06|

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JP2017503201A|2017-01-26|

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EP3085526A1|2016-10-26|

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AU2014367640A1|2016-07-07|

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CA2933597A1|2015-06-25|

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US20160297174A1|2016-10-13|

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AU2014367640B2|2018-08-30|

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WO2015093689A1|2015-06-25|

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CN105848875B|2018-09-14|

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KR101439066B1|2014-09-05|

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MX360859B|2018-11-20|

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2021-06-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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