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1 ISSN(Print) 한국염색가공학회지제23권제4호 2011 년 ISSN(Online) X Textile Coloration and Finishing Vol. 23, No. 4, 2011 연구논문( 학술) 멜트블로운부직포의후가공공정에의한흡음재의제조와특성 송인희 2 김진수 1 홍영기 2 ( 주) 선진인더스트리, 1 건양대학교컴퓨터학과, 건양대학교패션디자인산업학과 Manufacture and Characteristics of Sound Absorption Materials by Finishing of Meltblown Nonwovens In-Hee Song 2, Jin-Soo Kim 1 and Young-Ki Hong 2 Sun Jin, Inc., 496 Sapo-Ri, Yeunsan-Myeon, Nonsan-Si, Chungnam , Korea 1 Department of Computer Science & Engineering, Konyang University, Nonsan, ChungNam , Korea Department of Fashion Design & Apparel Industry, Konyang University, Nonsan, ChungNam , Korea (Received: November 30, 2011/Revised: December 14, 2011/Accepted: December 19, 2011) Abstract For sound absorption and sound insulation in automobile industry, the sound absorption materials based on meltblown nonwovens were prepared by SMS (spunbond-meltblown-spunbond) technique. And the sound absorption coefficient ( α) of the meltblown nonwoven, produced with isotatic-polypropylene(pp), was examined for the various processing conditions such as die-to-collector distance(dcd), nonwoven weight(gsm), and air suction conditions. The meltblown nonwoven for sound absorption materials was composed of bulky microfiber web, increasing with increases in weight and DCD. The sound absorption coefficient( α) was excellent as a sound absorption materials of PAD type composed of SMS(spunbond-meltblownspunbond) nonwovens. Keywords: sound absorption materials, meltblown, sound absorption coefficient, spunbond, isotatic-polypropylene 1. 서 론 소음으로인한환경오염은최근여러산업분야에서장차미래산업에미칠영향으로보아많은주목을받고있다. 특히자동차나항공산업분야에서는소음저감을위하여다각적인측면에서노력을기울이고있으며, 그중새로운흡음재적용에따른흡음이나차음에관한연구 1-3) 가활발히진행되고있다. 최근에는고분자복합체를이용하여흡음의효과를향상 4,5) 하거나, 흡음재의구조를변경하여다층형태의흡음재인 elastic 및 poroelastic과 airspace의혼합체로써흡음효과를극대화하는연구 6-8) 가발표되었다. 이러한흡음재의고유특성은특성임피던스와전파상수에의해결정 9-11) 되며, 새로운흡음재를개발하거나개발된흡음재의음향특성을평가할때는흡음재의특성 임피던스와전파상수에대한정보가반드시필요하다. 일반적으로자동차및건축분야에서많이사용되는흡음재료에는유리면이나펠트 (felt) 와같은섬유재료와폴리우레탄폼과같은발포재료가있고, 그중섬유재료가 50% 이상을점유하고있다. 그러나최근들어환경과안전문제가사회적으로강력하게대두됨에따라전통적으로사용되던소음저감용흡음재의패턴이상당히바뀌고있다. 즉종래의대표적흡음재인유리섬유는탁월한흡음성능을보유하고있음에도불구하고, 인체에유해한문제점때문에법적으로사용규제를받고있으며, 또한유리섬유와대등한흡음성능을갖는폴리우레탄폼은화재의위험성때문에적용범위의제한을받고있다. 따라서이러한흡음재를보다효율적으로대체하기위해최근극세사섬유집합체를응용한멜트블로운부직포를자동차 Corresponding author. Tel.: ; Fax.: ; ymhong@konyang.ac.kr c2011 The Korean Society of Dyers and Finishers / / Ⅰ304Ⅰ
2 멜트블로운부직포의후가공공정에의한흡음재의제조와특성 Ⅰ305Ⅰ 산업분야의내장재및흡음재에활용하는것으로 많은관심을보이고있다. 멜트블로운(meltblown) 부직포는직경이 10μm이하인미세섬유들이상 호결합하여거미줄과같은구조형태를가지는 3차원적구조의섬유집합체이다. 일반적으로열 가소성수지로섬유를형성하는고분자를수백 또는수천개의오리피스(orifice) 로형성된방사 구금을 통해 방사되는 공정으로, 방사노즐로 압출된고분자는용융상태에서방사구금의양 옆에서고속으로분사되는열풍에의해초극세 화된섬유가수집체에적층되어우수한흡 차 음성능을갖는자기결합형(self-bonding) 부직포 를형성한다. 이와같이구조화된멜트블로운 부직포는극세화된섬유집합체가벌크한구조 로형성되어기능적특성을갖기때문에본연 구에서는이러한멜트블로운부직포를흡음재 적용재료로선택하였다. 현재 3M사의초극세사특허기술로만들어진 신슐레이트 (Thinsulate TM ) 가성능이우수하여자 동차의흡음재분야에서주로사용되고있으며, 진동소음과타이어소음, 하체소음, 상체소 음, 엔진음소음등의외부소음감소및내부 소음을방지하며, 극세섬유를사용한가벼운 부직포재질로차체중량이나연비에전혀영 향을주지않기때문에포드 GM 폴크스바겐 토 요타 혼다 닛산 피아트 다임러크라이슬러 등 세 계유명자동차에사용되고있다. 본연구에서는이러한연구배경을바탕으로 비중이 0.91인폴리프로필렌흡음재용멜트블 로운부직포를공정상의제조조건에따라구조 분석을하였다. 그리고이와같은조건으로제 조된흡음재는잔향실법에의해흡음특성을평 가하였고, 또한현재상용화되어사용되고있 는 M사의흡음재와흡음특성을비교평가하여 폴리프로필렌 멜트블로운 부직포의 자동차용 흡음재로적용가능성을검토하기위해체계적 으로기초적인연구를수행하였다. 2. 실험및방법 : melt flow rate) 을 1,500으로조절한초고유동성 isotatic 폴리프로필렌수지를사용하였다. 2.2 멜트블로운부직포제조장치 본실험에있어서실험계획의최적조건별흡음재제조를위한멜트블로운제조장치는현장의생산라인에서가동중인멜트블로운시스템(J&M Labs., USA) 을사용하였다. 2.3 흡음재제조 Fig. 1은현장에서생산되는부직포웹제조조건을바탕으로최적의흡음재를생산하기위해본실험의계획법에따른흡음재제조시영향인자와전반적인제조공정을고려해서흐름도를작성하여나타낸것이다. 따라서본실험에서는이와같은흐름도를바탕으로하여최적의자동차용흡음재를제조하였다. Table 1은최적의흡음재를얻기위한멜트블로운부직포제조공정인자를바탕으로작성하여생산한멜트블로운시스템의조작조건을나타낸것이다. 본실험에서흡음재부직포웹의중량은 150, 200, 300, 400GSM으로변화시켰으며, DCD는 25, 45, 65cm 로변화시켰고, 수집체하부에서공기흡입은 1.0m 3 /min로흡입판을열어흡입시키거나 0m 3 /min로정지시킨후흡입판을닫아공기흡입을차단시켜웹을제조하였다. 그리고이때기류의영향으로웹이잘 GSM (150, 200, 300, 400) Spun bond nonwoven Preparation of meltblown nonwoven Meltblown nonwoven sample SM type DCD (25, 45, 65) Hot melt bond SMS type Suction (ON, OFF) 2.1 재료 Sound absorption Pad 실험에사용된흡음재원료로는멜트블로운방사용폴리프로필렌수지에 2,5-Dimethyl-2,5-di-(tertbutylperoxy)-hexane을사용하여용융지수 (MFR Sound absorption Test Fig. 1. Flow chart for experiment and preparation of sound absorption materials. Textile Coloration and Finishing, Vol. 23, No. 4
3 Ⅰ306Ⅰ 송인희 김진수 홍영기 Table 1. Operation conditions selected for meltblown nonwoven process Operation parameter Operation condition Basic weight(g/m 2 ) 150, 200, 300, 400 Die tip temperature( ) 230 ~ 265 Air flow rate(m 3 /min) 2.0 ~ 6.0 Amount of production(cc/min/hole) 0.8 Die to collector distance ; DCD(cm) 25, 45, 65 Below wire exhaust ; Suction(m 3 /min) 1.0(open), 0(close) Accessory air temperature( ) Ambient condition 형성되지않는것을방지하기위해연신구간에실온의공기를송풍시켜벌키성을향상시키고웹형태를안정되도록조건을설정하였다. Fig. 2는흡음재를연속공정으로얻기위해멜트블로운부직포웹제조공정에연속시스템을설계제작하여연결시킨제조공정완성도를나타낸것이다. 이것은기존의멜트블로운공정의후가공에서웹의형태안정성을부여하기위해스펀본드부직포를라미네이팅시키는방법으로하여 SMS 흡음재를제조하였다. 2.4 흡음특성평가 흡음재의흡음률을측정하기위해서는잔향실에서잔향시간을측정할필요가있다. 잔향실은벽에서소리의반사가불규칙하게잘일어나서내부에서확산음장이형상되는공간을말한다. 지금까지의잔향실은집을짓듯이건설공사를하여서비교적큰잔향실을제작하였으므로가격이비싸고이동이곤란하므로실용적이지못하여별로호응을얻지못하였다. 최근에는자동차회사를중심으로저렴하고이동이편리한간이잔향실에의한소음평가가이루어지고있다. 간이잔향실의단점은실내공간의크기가작아저주파수에서의소음평가가조금은곤란하다는것이단점이기도하다. 그러나간이잔향실도 400Hz 이상의소음평가에는문제가없는것으로알려져있고, 일반적으로 200Hz와같은낮은소음평가는별로필요로하지않는것이현실이다. 따라서 Fig. 3 은본실험에서제조된흡음재의흡음특성평가를위해공인된시스템으로설계제작하여실험에사용한잔향실법 12) 에의한흡음특성평가시스템의상세도를나타낸것이다. Hopper Gear pump Vacuum pump Extruder Filter T-DIE NOZZLE Material Additive Screen High Temperature High Pressure Air Compressor Blower Collector S/B R/O Fig. 2. Winding Chamber I Chamber II Package Hotmelt S/B R/O Manufacturing processes of meltblown system for sound absorption materials. 한국염색가공학회지제 23권제 4호
4 멜트블로운 부직포의 후가공 공정에 의한 흡음재의 제조와 특성Ⅰ307Ⅰ S o u n d S o u rc e T ype 4224 S a m p le P U L S E s y s te m Fig. 3. Schematic diagram of sound absorption evaluation system by reverberation room method12). (A) Surface( 100) (B) Surface( 3,500) (C) Cross section( 300) (D) Cross section( 3,500) Fig. 4. SEM microphotographs of meltblown nonwoven for sound absorption materials. 3. 결과 및 고찰 3.1 멜트블로운 흡음재의 구조 본 연구의 자동차용 흡음재 제조를 위한 멜 트블로운 부직포 제조장치는 수직방사형으로 최신 Melt-Blown System(JM Labs., USA)을 사 용하였고, 자동차용 흡음재의 최적 운전조건으 로 멜트블로운 부직포 웹을 제조하였다. 이와 같이 극세섬유로 구조화된 자동차용 흡음재 부 직포 형상 전자현미경 사진을 Fig. 4에 나타내 었다. 그림에서 보는바와 같이 부직포는 일정한 공극을 가지면서 극세섬유 간 자기접착으로 형 성된 벌크성 웹상태의 구조를 확인할 수 있었 다. 따라서 이와 같은 벌크성 웹상태의 구조는 멜트블로운 방사조건에 따라 여러 형태의 구조 와 물성이 가능하므로13) 후 가공 공정을 통해 다양한 용도전개가 가능할 것으로 판단된다. 3.2 부직포 웹의 흡음특성 평가 Fig. 5는 일정한 DCD 65cm에서 중량변화에 따른 흡음재의 흡읍특성을 나타낸 것으로 150GSM, 200GSM, 300GSM, 400GSM으로 중량이 증가할 Textile Coloration and Finishing, Vol. 23, No. 4
5 Ⅰ308Ⅰ 송인희 김진수 홍영기 수록 흡음특성이 향상되는 것이 확인되었다. 이것은같은 DCD의조건에서극세화된부직포 의웹의중량이증가할수록벌크한구조를갖 게됨으로써흡음특성이향상되는것으로멜트 블로운부직포흡음재의일반적인경향임을알 수있다. Fig. 6은멜트블로운시스템의공정조건으로 DCD가흡음특성에미치는영향에대하여알아 보기위한실험으로, 중량 200GSM 부직포웹 을 25, 45, 65cm의 DCD 조건으로변화시켜흡 음재를제조하여평가한결과를나타낸것이다. 이때수집체하부에서의공기흡입(suction) 은일 정한상태였고, DCD는변화를갖게되었는데 DCD가증가할수록부직포웹의두께가더두 꺼워지는경향을확인할수있었다. 이는 DCD 를증가시킬수록웹내부기공의함량이증가 14) 되어벌키한구조의웹이형성된다고생각한다. Fig. 6으로부터 DCD를증가시킬수록우수한흡 음특성을갖게됨을확인할수있었다. 한편, 본연구의수직방사형생산라인제조조건상의 한계로 DCD를 65cm 이상늘리지못하였으나, 수평방사로하여 DCD를늘린다면어느한계치 까지는더벌크한구조가되어더욱향상된흡 음특성을나타내리라예상할수있었다. 그러 나제조공정상 DCD는 65cm로하여흡음재를 제조하였다. Fig. 7 은수집체에가해지는공기흡입(suction) 이부직포흡음재의흡음특성에미치는영향을 알아보기위하여실험한결과이다. 제조공정상 의최적조건으로흡음특성을향상시키기위해 서벌키한구조를가지면서두께를증가시키는 방법으로수집체하부의공기흡입을가동하지 않고제조조건을설정하였다. 또한자기접착에 의한결합력이약해져웹의형성이어려워지는 현상을막기위해서연신구간에악세서리에어 로실온의공기를불어주는방법 15) 으로최적의 제조조건을설정하였다. 그림에서알수있는 바와같이주어진실험의주파수범위에서공 기흡입장치가닫혀있을때흡음특성이우수함 을알수있었다. 이것은또한흡음재부직포 웹의형성에공기흡입의조작도웹의두께를 증가시켜 16) 흡음특성에주요한인자로영향을 준다는것을확인할수있었다. Fig. 8은최적조건으로제조된 200GSM의흡 음재의흠음특성을나타낸것이다. 여기서 DCD 는 65cm, 수집체의공기흡입은잠그고, 연신구간에는실온의악세서리에어를불어주며제조된것이다. 그림에서알수있는바와같이멜트블로운부직포흡음재의 ,000Hz 주파수별흡음특성을나타낸것으로저주파수대에비해고주파수대에서우수한흡음특성을보이고있다. Fig. 5. Comparison of sound absorption coefficient with different GSM(DCD65cm). Fig. 6. Comparison of sound absorption coefficient with different DCD(200GSM, suction open). Fig. 7. Comparison of sound absorption coefficient with different air suction. 한국염색가공학회지제 23권제 4호
6 멜트블로운부직포의후가공공정에의한흡음재의제조와특성 Ⅰ309Ⅰ Fig. 8. Sound absorption coefficient of meltblown nonwoven manufactured by the selected conditions. 특히주파수대범위 2,000Hz이상에서부터높은흡음특성을나타내고있는데이는멜트블로운부직포의섬유극세화와벌크구조가고효율의흡음특성에기인한것으로멜트블로운부직포를이용한흡음재는고주파수대범위의흡음특성에보다효과적이고효율적 17,18) 이라는것을확인할수있었다. 3.3 흡음재PAD 의특성평가 자동차용흡음재가최종목적으로사용되는형태로는 PAD형으로본연구에서는스펀본드멜트블로운스펀본드의 SMS형 PAD를제조하여특성평가를측정하였다. 실험은국내 S사의자동차흡음재 PAD시험용스펙인 MS341-17(C-1 Type) 으로규정하여특성평가하였다. 시험의표준상태는온도 23±2, 상대습도 50±5% 에서실시하였으며, 시험편은적어도 24시간이상표준상태로유지한후시험에사용하여측정하였다. 시험편의두께는일정하였으며, 중량은 mm의샘플을임의의위치에서 3 매취하여중량측정후 1m2의중량을평균치로나타낸것이다. Table 2는본연구에서사용한자동차용흡음재 PAD의물성시험및흡음특성시험결과를나타낸것으로자동차용흡음재의기술표준요구규격에만족할만한결과를확인할수있었다. 한편, 주파수영역 1,000Hz에서 5,000Hz범위의흡음특성평가치는표에서알수있는바와같이요구규격에따른결과치모두높은값을얻을수있었다. 이는앞에서도언급했듯이극세사멜트블로운부직포웹의흡음특성이크게기여하고있음을알수있다. Fig. 9는벌키한구조의흡음재를얻기위해최적조건으로제조된멜트블로운부직포웹에스펀본드부직포를붙여패드형태로제조된흡음재의흡음특성을나타낸것이다. 시료는 200GSM 멜트블로운부직포웹, 190GSM 멜트블로운부직포웹의양쪽에 17GSM 폴리프로필렌스펀본드부직포를모두합지시킨것과, 190GSM 멜트블로운부직포웹의한쪽에 17GSM의폴리프로필렌스펀본드부직포를다른한쪽에 17GSM의저융점 PET를합지시킨것으로제조하여평가하였다. Table 2. Results of physical properties on PAD test for sound absorption materials Item Requirements Results Thickness (mm) ±10% 6.0 Basic weight (g/ m2) 200 ± Strength (kgf/ cm2) 0.1 L:0.32 W:0.31 Thermal Strength (kgf/ cm2) 0.1 L:0.32 W:0.31 resistance Shrinkage (%) 2 L:+0.1 W:+0.2 Wet Strength (kgf/ cm2) 0.1 L:0.36 W:0.35 resistance Shrinkage (%) 5 L:+0.1 W:+0.4 Water absorption (%) 10 0 Compressive modulus (%) Thermal resistance Wet resistance ,000 Hz Sound absorption 3,000 Hz coefficient 3,150 Hz ,000 Hz Odor 4 grade 4.0 Haze 10% 1.4 Burining test 80mm/min SE Textile Coloration and Finishing, Vol. 23, No. 4
7 Ⅰ310Ⅰ 송인희 김진수 홍영기 Fig. 9. Sound absorption coefficients of various pads. 주파수영역의모든범위에있어서모두자동차기술표준의요구규격에만족할만한흡음특성을확인할수있었다. 따라서자동차용흡음재의적용가능성으로는무엇보다도흡음재기질의섬유극세화와벌키성향상이매우중요함을알수있었다. Fig. 10은현재상업적으로사용되고있는 M 사의흡음재와본연구에서개발한흡음재의저주파수영역 400Hz에서부터고주파수영역 10,000Hz의범위에서의흡음특성평가를비교하여나타낸것이다. 그림에서나타낸것과같이자동차적용을위한최종패드형흡음재의우수한흡음특성경향과결과로부터제품화활용가능성및국산화개발에대한기초적인연구를확립할수있었다. 4. 결 론 본연구에서는현재널리사용되고있는자동차용흡음재를국산화로대체하기위해현재상업적으로사용되고있는 M사의흡음재와유사한흡음특성을갖도록멜트블로운부직포웹을바탕으로흡음재를제조하여각각의제품에대하여비교평가하고, 이러한흡음재를최종용도인자동차산업분야에활용가능하도록기초적인연구를수행한결과다음과같은결론을얻었다. 자동차용흡음재폴리프로필렌멜트블로운부직포제조를위한최적조건을설정하여흡음재를제조하였으며, 우수한흡음특성을갖기위한구조조건으로는섬유극세화와부직포웹의벌크성으로전자현미경사진을통하여확인할수있었다. Fig. 10. Sound absorption coefficients of various pads. 제조된멜트블로운부직포웹의흡음특성은고중량이고, DCD 가클수록, 그리고수집체의공기흡입을하지않고실온의악세서리공기를불어주는것이우수한성능을나타냈으며, 최종패드형에서는 SM 타입보다는 SMS 타입이더욱우수한특성을나타내었다. 자동차용흡음재의안정성평가를위해현재자동차산업분야의흡음재적용관련규정항목에맞추어각각의특성에대하여평가한결과기술표준요구규격에모든항목이매우만족한결과를얻었다. Pad 실험결과최적조건으로제조된 SMS 흡음재패드의흡읍특성은 400Hz의저주파수영역에서부터 10,000Hz의고주파수영역에이르기까지현재상업적으로이용되고있는 M사의흡음재와유사한경향의흡음특성을확인함으로써자동차용흡음재의적용가능성및국산화개발의기초적인연구를확립할수있었다. 참고문헌 1. N. Atalla and P. Raymond, The Effects of Multilayer Sound-absorbing Treatments on the Noise Field Inside a Plate Backed Cavity, Noise Control Eng. J., 44(5), (1996). 2. W. E. Zorumski, Aircraft Flyover Noise Prediction, Proc. Noise Con. 77, p.205, J. G. Lee, I. D. Kim, and Y. S. Lee, Effective Application of Insulations and Deadeners Improving the Vehicle Interior Noise, J. Korea Soc. Automotive Engineers, 14(4), 68-78(1992). 4. R. Moulder, Sound-absorptive Material in Handbook of Acoustical Measurement and Noise 한국염색가공학회지제 23권제 4호
8 멜트블로운부직포의후가공공정에의한흡음재의제조와특성 Ⅰ311Ⅰ Control, ed. by C. M. Harris, McGraw-Hill, N. Y., pp.78-82, R. F. Gibson, Principles of Composite Material Mechanics, McGraw-Hill, N. Y., pp , S. J. Hwang and R. F. Gibson, The Use of Strain Energy-based Finite Element Techniques in the Analysis of Various Aspects of Damping of Composite Materials and Structures, J. Composite Mat., 26(3), (1992). 7. S. S. Jung, W. S. Lee, M. J. Jho, and S. J. Suh, A Study on the Sound Absorption Coefficient by Varying Sample Size, Transactions of the Korean Society for Noise and Vibration Engineering, 11(5), 83-88(2001). 8. D. J. Kang, W. S. Lee, J. W. Lee, J. K. Hong, and Y. H. Jo, Characteristics of Absorption Performance of Sound Absorptive Materials according to Test Conditions, Transactions of the Korean Society for Noise and Vibration Engineering, 16(7), (2006). 9. J. F. Allard and Y. Champoux, New Empirical Equations for Sound Propagation in Rigid Frame Fibrous Materials, J. Acoust. Soc. Am., 91(6), (1992). 10. J. F. Allard, Y. Champoux, and C. Depollier, Modelization of Layered Sound Absorbing Materials with Transfer Matrices, J. Acoust. Soc. Am., 82(5), (1987). 11. C. H. Hwang, S. S. Jung, and H. J. Eun, A New Method for Measuring Characteristic Impedance and Propagation Constant of Soundabsorbing Materials, Transactions of the Korean Society for Noise and Vibration Engineering, 7(5), (1997). 12. ASTM C 423, Standard Test Method for Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method. 13. H. S. Shin, L. Jin, and J. H. Yoo, Effect of Manufacturing Conditions on the Properties of Oil-absorbable Melt Blown Nonwoven, Textile Coloration and Finishing(J. Korean Soc. Dyers and Finishers), 21(6), 22-28(2009). 14. R. R. Bresee, U. A. Qureshi, and M. C. Pelham, Influence of Processing Conditons on Melt Blown Web Structure : Part 2 - Primary Airflow Rate, International Nonwovens Journal, 14(2), 11-18(2005). 15. X. Wang and Q. Ke, Experimental Investigation of Adhesive Meltblown Web Production Using Accessory Air, Polymer Engineering and Science, 46, 1-7(2006). 16. J. W. Lee, S. N. Lee, J. H. Shim, P. K. Jung, W. K. Lee, and B. J. Bang, The Study on Improvement of Acoustic Performance for Automobile Sound-absorbing Materials Using Hollow Fiber, Transactions of the Korean Society for Noise and Vibration Engineering, 21(9), (2011). 17. H. S. Shin, J. H. Yoo, and L. Jin, A Study on Oil Absorption Rate and Oil Absorbency of Melt-blown Nonwoven, Textile Coloration and Finishing(J. Korean Soc. Dyers and Finishers), 22(3), (2010). 18. J. D. Lee, Y. K. Hong, and K. S. Bae, Development of Composite Filter With High Performance Meltblown Non-woven, Textile Coloration and Finishing(J. Korean Soc. Dyers and Finishers), 17(2), 40-45(2005). Textile Coloration and Finishing, Vol. 23, No. 4
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