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JP3661845B2 - Flame retardant sound absorbing material - Google Patents
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JP3661845B2 - Flame retardant sound absorbing material - Google Patents

Flame retardant sound absorbing material Download PDF

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Publication number
JP3661845B2
JP3661845B2 JP2000402331A JP2000402331A JP3661845B2 JP 3661845 B2 JP3661845 B2 JP 3661845B2 JP 2000402331 A JP2000402331 A JP 2000402331A JP 2000402331 A JP2000402331 A JP 2000402331A JP 3661845 B2 JP3661845 B2 JP 3661845B2
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Japan
Prior art keywords
nonwoven fabric
dtex
melting point
absorbing material
fiber nonwoven
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JP2000402331A
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Japanese (ja)
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JP2002202780A (en
Inventor
保 榎原
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Toyobo Co Ltd
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Toyobo Co Ltd
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  • Soundproofing, Sound Blocking, And Sound Damping (AREA)

Description

【0001】
【発明の属する技術分野】
本発明は、軽量・高性能であり更にリサイクル可能で、なお且つ低コストの自動車用に好適な難燃性吸音材に関するものである。
【0002】
【従来の技術】
現在、高性能吸音用途では、良好な吸音性能が要求されており、従来用いられている吸音材料としては、以前より最近では、熱可塑性繊維(主として、ポリエステル系繊維)及び芯鞘型(芯;高融点、鞘;低融点)繊維混綿、熱成形(熱融着)不織布等の特許が提案されている。
【0003】
しかしながら自動車用吸音材の吸音性能の要求レベルは、年々高くなっており、特に中高音領域(800〜2000Hz)での性能レベルのアップが要求されている。この要求に答えるため、目付けのアップが考えられるが、重量増加につながってしまう。また、熱可塑性繊維使用熱成形不織布についても、2〜7dtexの比較的細い繊維を用いれば、吸音性能のレベルアップは可能であるものの、それでも重量の増加は免れない。
【0004】
そこで、本発明者らは、1.0〜10dtexの有機繊維で面密度100〜1000g/m2の不織布に、面密度が20〜100g/m2であるメルトブロー法による極細繊維不織布を積層すると軽量で吸音性に優れた構造体が得られることを見出してはいるものの、難燃性が要求される場合には、更なる改良が必要であることが判明した。その対策として、有機繊維不織布に難燃繊維を用いる事が考えられるが、コスト上昇及び重量増加が問題である。
【0005】
【発明が解決しようとする課題】
本発明は、上記課題を解決するために見出されたものであり、重量の増加をおさえると共に、優れた吸音性及び難燃性を併せ持つ安価な自動車用に好適な難燃性吸音材を得ようとするものである。
【0006】
【課題を解決するための手段】
即ち、本発明は、1.0〜12dtexの有機繊維を用いた面密度が100〜500g/m2の有機繊維不織布の片面に、主に1.0dtex以下の繊維で構成された面密度が50g/m2以上である極細繊維不織布を、該極細繊維不織布の融点より低い融点の熱可塑性接着剤で接着されてなり、自動車用難燃規格(FMVSS.No.302)において自消性であることを特徴とする難燃性吸音材である。
【0007】
さらに、前記熱可塑性接着剤の量が10〜30g/m2であることを特徴とする前記に記載の難燃性吸音材である。
【0008】
【発明の実施の形態】
本発明におけるメルトブロー不織布の素材は、熱可塑性樹脂接着剤よりも融点が高い熱可塑性樹脂であれば特に限定はない。しかしながら、ドリップ性向上による難燃性向上の観点及び紡糸性の安定性から、融点が120〜200℃程度のエチレンやプロピレンなどのオレフィン類の重合体や共重合体などのポリオレフィン系熱可塑性樹脂であることが好ましい。
【0009】
また、メルトブローン不織布の構成繊維の繊度は、1dtex以下である。1dtexを超えると十分な通気度の低下が起こり難い。好ましくは0.5dtex以下であり、紡糸性の面から0.0001dtex以上が好ましい。
【0010】
熱可塑性樹脂接着剤は、メルトブロー不織布の素材の融点より低い融点であれば特に限定されないが、着火時のドリップ性がより向上する観点から、メルトブロー不織布の素材の融点よりも更に低い110℃以下のものが好ましい。特に、ポリオレフィン系熱可塑性樹脂が好ましく、ポリエチレン系熱可塑性樹脂接着剤が低融点であり、なお且つ安価であることからより好ましい。
【0011】
有機繊維不織布とメルトブロー不織布を積層、接着するには、溶融接着法が採用できるが、この場合、加熱温度は、熱可塑性樹脂接着剤の融点以上であれば問題ないが、熱可塑性樹脂接着剤を均一に熔融させる事が接着強度の点から必要であること及び有機繊維不織布の軟化・熔融(オレフィン系)、収縮(ポリエステル系)等が問題になるため、100〜140℃の範囲が最適である。この場合、荷重をかけてもかけなくても差し支えないが、積層体の厚みの過度の低下を防ぐため、貼合せ時に所定厚みのクリアランスを設定し、加熱溶融、貼合せる事が望ましい。
【0012】
有機繊維不織布は、1.0〜10dtexの短繊維を用い、面密度100〜500g/m2の不織布であれば良いが、吸音性の点で、2〜7dtexの短繊維が望ましく、またメルトブロー不織布より高融点の繊維を用いる事がより望ましい。更に、より拘束点の少ないニードルパンチ不織布であることが望ましい。尚、有機繊維不織布の面密度が100g/m2未満でも加工は可能であるが、この場合十分な吸音性が得られない。
【0013】
次に本発明における難燃の機構について簡単に説明すると以下の様になる。まずメルトブロー不織布と有機繊維不織布との積層体の有機繊維不織布の面密度が500g/m2以上であれば、目付効果により特に難燃処理を行わなくても十分な難燃性が得られる。
【0014】
しかしながら、有機繊維不織布の面密度100〜500g/m2の領域では、目付効果が小さくなるため、メルトブロー不織布と有機繊維不織布との積層体の難燃性は低下し、FMVSS.No.302(自消性)を合格しなくなる。もしくは、仮に合格しても不安定(物により合格、不合格の評価結果が混在)になる。
【0015】
そこで、メルトブロー不織布と有機繊維不織布とをメルトブロー不織布の融点よりも低い融点のポリエチレン系樹脂などの熱可塑性樹脂接着剤を用いて溶融接着すると、メルトブロー不織布単独のドリップ効果では、十分な難燃効果が得られないのに対し、低い融点の熱可塑性樹脂接着剤が有機繊維不織布に溶融接着(介在)されている事により、両者のドリップ効果が大きく、更に粘度が小さいため、有機繊維不織布の各繊維に着火した炎が、ドリップ物と共に素早く落下するため、両者のドリップによる相乗効果が得られ、難燃性がより向上し安定化するものと考えられる。
【0016】
以上の加工により、難燃性が向上し、有機繊維不織布の面密度が500g/m2未満でも、自動車用難燃規格であるFMVSS.No.302法を安定して合格する事が出来る。更に、家庭インテリア用途の規格である45度傾斜法(ミクロバーナー法)についても併せて合格する事が出来る。
【0017】
【実施例】
以下に、本発明の実施例、比較例を用いて更に詳細に説明する。
なお、実施例、比較例における評価方法は以下の方法によった。
【0018】
(評価方法)
吸音率:垂直入射法;JIS A 1405法により実施した。
難燃性:自動車用難燃性規格FMVSS.No.302法及び45度傾斜法(ミクロバーナー法)により実施した。
【0019】
(実施例1)
単糸dtexが0.0001〜0.2dtexであり、目付けが70g/m2であるポリプロピレン製メルトブローン不織布を作成した。更に2.2dtex70%及び6.7dtex30%を混合したポリエステル短繊維を用い、目付け200g/m2、厚み5mmの不織布を、ニードルパンチ法を用いて作成し、上記の2種類の不織布を積層し、ポリエチレン系接着剤粉末(宇部興産社製UM8510、融点104℃)を25g/m2均一に分散、介在させてを用いて、接着クリアランス4mm、温度120℃×30秒にて溶融接着させ評価試料とした。評価結果を表1に示した。
【0020】
(実施例2)
単糸dtexが0.0001〜0.2dtexであり、目付けが50g/m2であるポリプロピレン製メルトブローン不織布を作成した。更に2.2dtex70%及び6.7dtex30%を混合したポリエステル短繊維を用い、目付け300g/m2、厚み6mmの不織布を、ニードルパンチ法を用いて作成し、上記の2種類の不織布を積層、ポリエチレン系接着剤粉末(宇部興産社製UM8510、融点104℃)を25g/m2均一に分散、介在させてを用いて、接着クリアランス5mm、温度120℃×30秒にて溶融接着させ評価試料とした。評価結果を表1に示した。
【0021】
(比較例1)
単糸dtexが0.0001〜0.2dtexであり、目付けが70g/m2であるポリプロピレン製メルトブローン不織布を作成した。更に2.2dtex70%及び6.7dtex30%を混合したポリエステル短繊維を用い、目付け200g/m2、厚み5mmの不織布を、ニードルパンチ法を用いて作成し、上記の2種類の不織布を積層、ニードルパンチ法を用いて貼合せを実施し、評価試料とした。評価結果を表1に示した。
【0022】
(比較例2)
単糸dtexが0.0001〜0.2dtexであり、目付けが70g/m2であるポリプロピレン製メルトブローン不織布を作成した。更に2.2dtex70%及び6.7dtex30%を混合したポリエステル短繊維を用い、目付け300g/m2、厚み6mmの不織布を、ニードルパンチ法を用いて作成し、更に上記の2種類の不織布を積層しニードルパンチ法を用いて貼合せを実施し、評価試料とした。評価結果を表1に示した。
【0023】
(比較例3)
単糸dtexが0.0001〜0.2dtexであり、目付けが70g/m2であるポリプロピレン製メルトブローン不織布を作成した。更に2.2dtexのポリエステル短繊維を用い、目付け500g/m2、厚み6mmの不織布を、ニードルパンチ法を用いて作成し、上記の2種類の不織布を積層し、ニードルパンチ法を用いて貼合せを実施し、評価試料とした。評価結果を表1に示した。
【0024】
【表1】

Figure 0003661845
【0025】
【表2】
Figure 0003661845
【0026】
(実施例3)
実施例1において、ポリエチレン系接着剤をダンヒューズ7211(日東紡社製、融点85℃)に代える以外は実施例1と同様にして評価試料とした。評価結果は、FMVSS No.302法が自消性であり、45度傾斜法(ミクロバーナー法)は合格であった。また、垂直入射法による吸音率(%)は、実施例1と同様のパターンを示し、吸音性が良好であることが確認できた。
【0027】
上記結果の通り、実施例は、比較例と同じ目付けでありながら、自動車用難燃規格であるFMVSS.No.302を合格することが出来る。そればかりでなく、インテリア用途等で使用されている45度傾斜法(ミクロバーナー法)についても合格することが出来る。なお且つ、吸音性については、吸音製品と同レベル以上を維持し、良好な吸音材であることがわかる。
【0028】
【発明の効果】
本発明は、特定の面密度の有機繊維不織布の片面に、極細繊維不織布を積層、接着するに際し、該極細繊維不織布の融点より低い融点の熱可塑性接着剤で接着した軽量な積層体であり、自動車用難燃規格(FMVSS.No.302)において自消性であるため、優れた吸音性で難燃性を併せ持った安価な自動車用に好適な吸音材を提供することが出来る。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a flame-retardant sound-absorbing material that is lightweight, high-performance, recyclable, and suitable for low-cost automobiles.
[0002]
[Prior art]
Currently, good sound absorption performance is required for high-performance sound absorption applications, and conventionally used sound absorption materials are thermoplastic fibers (mainly polyester fibers) and core-sheath type (core; Patents for high melting point, sheath; low melting point) fiber blended cotton, thermoformed (heat fusion) nonwoven fabric, and the like have been proposed.
[0003]
However, the required level of the sound absorbing performance of the sound absorbing material for automobiles is increasing year by year, and in particular, an increase in the performance level in the middle and high sound region (800 to 2000 Hz) is required. In order to respond to this request, the basis weight can be increased, but this leads to an increase in weight. In addition, for thermoformed nonwoven fabrics using thermoplastic fibers, if relatively thin fibers of 2 to 7 dtex are used, the sound absorption performance can be improved, but still an increase in weight is inevitable.
[0004]
Therefore, the inventors of the present invention are lightweight when an ultrafine fiber nonwoven fabric is laminated by a melt blow method having an area density of 20 to 100 g / m 2 on a nonwoven fabric having an area density of 100 to 1000 g / m 2 and organic fibers of 1.0 to 10 dtex. Although it has been found that a structure excellent in sound absorbing property can be obtained, it has been found that further improvement is required when flame retardancy is required. As a countermeasure, it is conceivable to use a flame retardant fiber for the organic fiber nonwoven fabric, but the problem is an increase in cost and an increase in weight.
[0005]
[Problems to be solved by the invention]
The present invention has been found to solve the above-mentioned problems, and it is possible to obtain a flame-retardant sound-absorbing material suitable for an inexpensive automobile, which has an excellent sound-absorbing property and flame-retardant property while suppressing an increase in weight. It is about to try.
[0006]
[Means for Solving the Problems]
That is, the present invention has a surface density of 50 g mainly composed of fibers of 1.0 dtex or less on one side of an organic fiber nonwoven fabric having an area density of 100 to 500 g / m 2 using organic fibers of 1.0 to 12 dtex. It is self-extinguishing in a flame retardant standard for automobiles (FMVSS. No. 302), which is formed by adhering an ultrafine fiber nonwoven fabric having a melting point of / m 2 or more with a thermoplastic adhesive having a melting point lower than that of the ultrafine fiber nonwoven fabric. Is a flame-retardant sound-absorbing material.
[0007]
Furthermore, the flame-retardant sound-absorbing material as described above, wherein the amount of the thermoplastic adhesive is 10 to 30 g / m 2 .
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The material of the melt blown nonwoven fabric in the present invention is not particularly limited as long as it is a thermoplastic resin having a melting point higher than that of the thermoplastic resin adhesive. However, from the viewpoint of flame retardancy improvement by improving drip and the stability of spinnability, it is a polyolefin-based thermoplastic resin such as a polymer or copolymer of olefins such as ethylene and propylene having a melting point of about 120 to 200 ° C. Preferably there is.
[0009]
The fineness of the constituent fibers of the melt blown nonwoven fabric is 1 dtex or less. When it exceeds 1 dtex, a sufficient decrease in air permeability is unlikely to occur. Preferably it is 0.5 dtex or less, and 0.0001 dtex or more is preferable from the viewpoint of spinnability.
[0010]
The thermoplastic resin adhesive is not particularly limited as long as it has a melting point lower than the melting point of the material of the meltblown nonwoven fabric. However, from the viewpoint of further improving the drip property at the time of ignition, Those are preferred. In particular, a polyolefin-based thermoplastic resin is preferable, and a polyethylene-based thermoplastic resin adhesive has a low melting point and is more preferable because it is inexpensive.
[0011]
In order to laminate and bond the organic fiber nonwoven fabric and the melt blown nonwoven fabric, a melt bonding method can be adopted. In this case, there is no problem if the heating temperature is equal to or higher than the melting point of the thermoplastic resin adhesive, but the thermoplastic resin adhesive is not used. The range of 100 to 140 ° C. is optimal because it is necessary to melt uniformly from the viewpoint of adhesive strength, and the softening / melting (olefin type), shrinkage (polyester type), etc. of the organic fiber nonwoven fabric becomes a problem. . In this case, it does not matter if a load is applied or not. However, in order to prevent an excessive decrease in the thickness of the laminate, it is desirable to set a clearance of a predetermined thickness at the time of bonding, and heat-melt and bond.
[0012]
The organic fiber non-woven fabric may be a non-woven fabric having a surface density of 100 to 500 g / m 2 using a short fiber of 1.0 to 10 dtex, but a short fiber of 2 to 7 dtex is desirable in terms of sound absorption, and a melt blown non-woven fabric. It is more desirable to use higher melting point fibers. Furthermore, it is desirable that the needle punched nonwoven fabric has fewer restraint points. In addition, although the processing is possible even if the surface density of the organic fiber nonwoven fabric is less than 100 g / m 2 , sufficient sound absorption is not obtained in this case.
[0013]
Next, the flame retardant mechanism in the present invention will be briefly described as follows. First, if the surface density of the organic fiber nonwoven fabric of the laminate of the melt blown nonwoven fabric and the organic fiber nonwoven fabric is 500 g / m 2 or more, sufficient flame retardancy can be obtained even if no flame retardant treatment is performed due to the basis weight effect.
[0014]
However, in the area of the surface density of 100 to 500 g / m 2 of the organic fiber nonwoven fabric, the basis weight effect is reduced, so that the flame retardancy of the laminate of the melt blown nonwoven fabric and the organic fiber nonwoven fabric is reduced. No. 302 (self-extinguishing) will not pass. Or, even if it passes, it becomes unstable (the evaluation result of pass or fail is mixed depending on the object).
[0015]
Therefore, if the melt blown nonwoven fabric and the organic fiber nonwoven fabric are melt bonded using a thermoplastic resin adhesive such as polyethylene resin having a melting point lower than the melting point of the melt blown nonwoven fabric, the drip effect of the melt blown nonwoven fabric alone has a sufficient flame retardant effect. In contrast, because the thermoplastic resin adhesive with a low melting point is melt bonded (intervened) to the organic fiber nonwoven fabric, both the drip effect and the viscosity are low. Since the flame that ignited in the water quickly drops together with the drip, it is considered that the synergistic effect of both the drip is obtained and the flame retardancy is further improved and stabilized.
[0016]
The above processing improves the flame retardancy, and even if the surface density of the organic fiber nonwoven fabric is less than 500 g / m 2 , FMVSS. No. Can pass the 302 method stably. Furthermore, the 45-degree tilt method (micro burner method), which is a standard for home interior applications, can also be passed.
[0017]
【Example】
Below, it demonstrates still in detail using the Example of this invention and a comparative example.
In addition, the evaluation method in an Example and a comparative example was based on the following method.
[0018]
(Evaluation methods)
Sound absorption coefficient: Normal incidence method; JIS A 1405 method was used.
Flame retardancy: Automotive flame retardance standard FMVSS. No. It implemented by 302 method and 45 degree | times inclination method (micro burner method).
[0019]
(Example 1)
A polypropylene meltblown nonwoven fabric having a single yarn dtex of 0.0001 to 0.2 dtex and a basis weight of 70 g / m 2 was prepared. Furthermore, using polyester short fibers mixed with 2.2 dtex 70% and 6.7 dtex 30%, a nonwoven fabric having a basis weight of 200 g / m 2 and a thickness of 5 mm was prepared using a needle punch method, and the above two types of nonwoven fabrics were laminated, A polyethylene adhesive powder (UM8510 manufactured by Ube Industries Co., Ltd., melting point: 104 ° C.) was uniformly dispersed and interposed at 25 g / m 2, and melt-bonded at an adhesive clearance of 4 mm and a temperature of 120 ° C. × 30 seconds. did. The evaluation results are shown in Table 1.
[0020]
(Example 2)
A polypropylene meltblown nonwoven fabric having a single yarn dtex of 0.0001 to 0.2 dtex and a basis weight of 50 g / m 2 was prepared. Furthermore, using polyester short fibers mixed with 2.2 dtex 70% and 6.7 dtex 30%, a non-woven fabric having a basis weight of 300 g / m 2 and a thickness of 6 mm was prepared by using a needle punch method, and the above two types of non-woven fabrics were laminated. -Based adhesive powder (UM8510, Ube Industries, Ltd., melting point: 104 ° C.) is uniformly dispersed and intervened at 25 g / m 2, and melt-bonded at an adhesion clearance of 5 mm and a temperature of 120 ° C. for 30 seconds to obtain an evaluation sample. . The evaluation results are shown in Table 1.
[0021]
(Comparative Example 1)
A polypropylene meltblown nonwoven fabric having a single yarn dtex of 0.0001 to 0.2 dtex and a basis weight of 70 g / m 2 was prepared. Furthermore, using polyester short fibers mixed with 2.2 dtex 70% and 6.7 dtex 30%, a nonwoven fabric having a basis weight of 200 g / m 2 and a thickness of 5 mm was prepared using the needle punch method, and the above two types of nonwoven fabrics were laminated. Lamination was performed using a punch method to obtain an evaluation sample. The evaluation results are shown in Table 1.
[0022]
(Comparative Example 2)
A polypropylene meltblown nonwoven fabric having a single yarn dtex of 0.0001 to 0.2 dtex and a basis weight of 70 g / m 2 was prepared. Furthermore, using polyester short fibers mixed with 2.2 dtex 70% and 6.7 dtex 30%, a nonwoven fabric having a basis weight of 300 g / m 2 and a thickness of 6 mm was prepared using the needle punch method, and the above two types of nonwoven fabric were laminated. Lamination was carried out using a needle punch method to obtain an evaluation sample. The evaluation results are shown in Table 1.
[0023]
(Comparative Example 3)
A polypropylene meltblown nonwoven fabric having a single yarn dtex of 0.0001 to 0.2 dtex and a basis weight of 70 g / m 2 was prepared. Furthermore, a non-woven fabric having a basis weight of 500 g / m 2 and a thickness of 6 mm is made using a 2.2 dtex polyester short fiber using the needle punch method, and the above two types of non-woven fabrics are laminated and bonded using the needle punch method. Was used as an evaluation sample. The evaluation results are shown in Table 1.
[0024]
[Table 1]
Figure 0003661845
[0025]
[Table 2]
Figure 0003661845
[0026]
(Example 3)
In Example 1, an evaluation sample was prepared in the same manner as in Example 1 except that the polyethylene-based adhesive was replaced with Dunfuse 7211 (manufactured by Nittobo Co., Ltd., melting point 85 ° C.). The evaluation result is FMVSS No. The 302 method was self-extinguishing and the 45 degree tilt method (micro burner method) passed. Further, the sound absorption rate (%) by the normal incidence method showed the same pattern as in Example 1, and it was confirmed that the sound absorption was good.
[0027]
As shown in the above results, the example has the same basis weight as that of the comparative example, but FMVSS. No. 302 can be passed. Not only that, it can also pass the 45-degree tilt method (micro burner method) used in interior applications. In addition, the sound absorption is maintained at a level equal to or higher than that of the sound absorbing product, and it can be seen that the sound absorbing material is a good sound absorbing material.
[0028]
【The invention's effect】
The present invention is a lightweight laminate bonded with a thermoplastic adhesive having a melting point lower than the melting point of the ultrafine fiber nonwoven fabric when laminating and adhering the ultrafine fiber nonwoven fabric to one surface of the organic fiber nonwoven fabric having a specific surface density, Since it is self-extinguishing in the flame retardant standard for automobiles (FMVSS. No. 302), it is possible to provide a sound absorbing material suitable for an inexpensive automobile having excellent sound absorption and flame retardancy.

Claims (2)

1.0〜12dtexの有機繊維を用いた面密度が100〜500g/m2の有機繊維不織布(A)の片面に、主に1.0dtex以下の繊維で構成された面密度が50g/m2以上であるポリオレフィン系熱可塑性樹脂よりなる極細繊維不織布(B)を、該極細繊維不織布の融点より低く、且つ110℃以下の融点である熱可塑性接着剤で接着されてなることを特徴とする難燃性吸音材。A surface density mainly composed of fibers of 1.0 dtex or less is 50 g / m 2 on one side of an organic fiber nonwoven fabric (A) having an area density of 100 to 500 g / m 2 using organic fibers of 1.0 to 12 dtex. The difficulty is characterized in that the ultrafine fiber nonwoven fabric (B) made of the polyolefin-based thermoplastic resin is bonded with a thermoplastic adhesive having a melting point lower than the melting point of the ultrafine fiber nonwoven fabric and not higher than 110 ° C. Flammable sound absorbing material. 前記有機繊維不織布(A)が短繊維よりなるニードルパンチ不織布であって、前記熱可塑性接着剤の量が10〜30g/m2であることを特徴とする請求項1記載の難燃性吸音材。 The organic fiber nonwoven fabric (A) is a needle-punched nonwoven fabric made of short fibers, flame-retardant sound absorbing material according to claim 1 wherein the amount of said thermoplastic adhesive is 10 to 30 g / m 2 .
JP2000402331A 2000-12-28 2000-12-28 Flame retardant sound absorbing material Expired - Fee Related JP3661845B2 (en)

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