Sound-absorbing material with excellent sound-absorbing performance and method for manufacturing thereof

Abstract

The present invention provides a sound-absorbing material with excellent sound-absorbing performance and a method for manufacturing thereof. More particularly, it relates to a sound-absorbing material, which can improve sound absorption coefficient and transmission loss by forming large surface area and air layer, so as to induce viscosity loss of incident sound energy, may make light-weight design possible because it can express excellent sound-absorbing performance even using reduced amount of fiber, and can improve sound-absorbing performance by using binder fiber having rebound resilience, so as to maintain enough strength between fiber and also to maximize viscosity loss of sound energy transmitted to fiber structure; and a method for manufacturing thereof.

What is claimed is: 
     
         1 . A method for manufacturing a sound-absorbing material, comprising
 forming a fiber aggregate in a nonwoven fabric form,   wherein the fiber aggregate comprises:   a non-circular shaped fiber satisfying the following Formula 1; and   a binder fiber that partly binds a plurality of the non-circular shaped fibers,   
       
         
           
             
               
                 
                   
                     1.5 
                     ≤ 
                     
                       P 
                       
                         
                           4 
                           × 
                           π 
                           × 
                           A 
                         
                       
                     
                   
                 
                 
                   
                     Formula 
                      
                     
                         
                     
                      
                     1 
                   
                 
               
             
           
         
         wherein A is a fiber cross sectional area (μm 2 ), P is a circumference length of fiber cross section (μm). 
       
     
     
         2 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the sound-absorbing material is manufactured by using the non-circular shaped fiber satisfying the value of the Formula 1 of 2.6 or greater. 
     
     
         3 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the non-circular shaped fiber is at least one selected from the group consisting of six-pointed star shape, 3-bar flat type, 6-leaf type, 8-leaf type and wave type. 
     
     
         4 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the non-circular shaped fiber is 35 to 65 mm in length. 
     
     
         5 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the binder fiber comprises a low melting (LM) elastomer having elastic recovery modulus of 50 to 80%. 
     
     
         6 . The method for manufacturing a sound-absorbing material of  claim 5 , wherein the binder fiber is a conjugated fiber which is conjugate-spun by using the LM elastomer as one component. 
     
     
         7 . The method for manufacturing a sound-absorbing material of  claim 5 , wherein the LM elastomer is at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer, a polystyrene-based polymer, a polyvinylchloride-based polymer and a polyurethane-based polymer. 
     
     
         8 . The method for manufacturing a sound-absorbing material of  claim 5 , wherein the LM elastomer is manufactured by esterification and polymerization steps using dimethyl terephthalate(DMT) and dimethyl isophthalate(DMI) or terephthalic acid(TPA) and isophthalic acid(IPA) as an acid ingredient(Diacid), and 1,4-butanediol(1,4-BD), polytetramethyleneglycol(PTMG) as a diol ingredient (Diol). 
     
     
         9 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the sound-absorbing material is manufactured by using the non-circular shaped fiber of 50 to 80 wt % based on the total weight of the sound-absorbing material and the binder fiber of 20 to 50 wt % based on the total weight of the sound-absorbing material. 
     
     
         10 . The method for manufacturing a sound-absorbing material of  claim 1 , wherein the non-circular shaped fiber satisfies the value of the Formula 1 of 3.0 or greater. 
     
     
         11 . A sound-absorbing material, comprising:
 a non-circular shaped fiber satisfying the following Formula 1; and   a binder fiber that partly binds a plurality of the non-circular shaped fibers,   
       
         
           
             
               
                 
                   
                     1.5 
                     ≤ 
                     
                       P 
                       
                         
                           4 
                           × 
                           π 
                           × 
                           A 
                         
                       
                     
                   
                 
                 
                   
                     Formula 
                      
                     
                         
                     
                      
                     1 
                   
                 
               
             
           
         
         wherein A is a Fiber cross sectional area (μm 2 ),), P is a Circumference length of fiber cross section (μm). 
       
     
     
         12 . The sound-absorbing material of  claim 11 , wherein the non-circular shaped fiber satisfies the value of the Formula 1 of 2.6 or greater. 
     
     
         13 . The sound-absorbing material of  claim 11 , wherein the non-circular shaped fiber is at least one selected from the group consisting of six-pointed star shape, 3-bar flat type, 6-leaf type, 8-leaf type and wave type. 
     
     
         14 . The sound-absorbing material of  claim 11 , wherein the non-circular shaped fiber is 35 to 65 mm in length. 
     
     
         15 . The sound-absorbing material of  claim 11 , wherein the non-circular shaped fiber is 1.0 to 7.0 De in fineness. 
     
     
         16 . The sound-absorbing material of  claim 11 , wherein the binder fiber comprises a low melting (LM) elastomer having elastic recovery modulus of 50 to 80%. 
     
     
         17 . The sound-absorbing material of  claim 16 , wherein the binder fiber is conjugated fiber which is conjugate-spun by using the LM elastomer as one component. 
     
     
         18 . The sound-absorbing material of  claim 16 , wherein the LM elastomer is at least one selected from the group consisting of a polyester-based polymer, a polyamide-based polymer and a polyurethane-based polymer. 
     
     
         19 . The sound-absorbing material of  claim 11 , which comprises the non-circular shaped fiber of 50 to 80 wt % based on the total weight of the sound-absorbing material and the binder fiber of 20 to 50 wt % based on the total weight of the sound-absorbing material. 
     
     
         20 . The sound-absorbing material of  claim 11 , wherein the non-circular shaped fiber satisfies the value of the Formula 1 of 3.0 or greater.