Acoustic vibrational material

Abstract: This invention provides an acoustic vibrational material containing various fibres as the reinforcement material and having an epoxy resin as a matrix resin, wherein the epoxy resin is modified by a polybutadiene base elastomer containing not less than 90 mole percent of 1, 2-­ linked units. The epoxy resin modified with the above polybutadiene elastomer exhibits a maximum value of loss coefficient in the temperature region near room temperature. This region is much higher than that of the conventional epoxy resin modified with polybutadiene elastomer mainly including 1, 4-linked unit. Decrease in elastic modulus of the epoxy resin with increase of temperature is reducer in the epoxy resin of the present invention, whereas it is larger in the conventional one. Thus compatibility between large internal loss and high elastic modulus is achieved.

Description: This invention relates to an acoustic vibrational material formed of a fibre reinforced epoxy resin, suitable for fabricating a loudspeaker, a diaphragm or the like. Various properties are required of the acoustic vibrational materials used in loudspeakers, diaphragms, etc, in pursuit of higher quality reproduced sound. One of these is the larger longitudinal wave propagation velocity [ = (specific modulus of elasticity) 1/2 = (Young's modulus/density 1/2 ]. To this end, a material having a higher Young's modulus and a lower density is preferred. Simultaneously a larger internal loss is also required for absorbing abnormal sounds and distortion components produced by break-up of the diaphragm and other unwanted vibrational modes. Customary materials having a higher Young's modulus and a larger longitudinal wave propagation velocity tend to exhibit lower internal losses so that it is difficult to satisfy these desirable, though contradictory, requirements simultaneously in a single material. Therefore, the present situation is that one of these properties has to be preferred depending on the application, such as low sound reproduction or high sound reproduction. It has recently been attempted to solve the above problem by use of a combination of several materials. An example is the use of a composite material having various fibres, such as the carbon, aramid, glass or polyolefin resin fibres, as a reinforcement material embedded in a matrix. Above all, attention is directed to ultra-drawn polyethylene fibres as the fibre reinforcement material because they undergo larger internal losses and exhibit superior transient characteristics while reducing colouration of the reproduced sound. In most cases, it is used in a composite form with epoxy resin. For instance JP-A-62157500 discloses the use of ultra-drawn polyethylene fibres in a honeycomb aluminium structure or cross-laid tapes for use in a acoustic diaphram. However, the above mentioned composite materials cannot be said to ensure the practical properties satisfactorily. Although fibre reinforcement materials consisting of a material undergoing larger internal losses has recently been evolved, the present situation is that, since the epoxy resin matrix does not have sufficiently high internal losses, the shortfall in internal losses has to be compensated by constructional artifices in the diaphragm or fine adjustment of various parts after speaker assembly. It is therefore an object of the present invention to provide an acoustic vibrational material in which internal losses can be increased without unduly compromising the modulus of elasticity. According to the present invention, there is provided an acoustic vibrational material containing a fibre reinforcement material bound by an epoxy resin modified by reaction with a polybutadiene elastomer, characterised in that said epoxy resin is modified by reaction with the polybutadiene elastomer in an amount of 10 to 25 mole percent of the epoxy resin and containing not less than 90 mole percent of 1, 2-linked units. In view of the necessity for optimum compatibility between the internal losses and the modulus of elasticity, it is necessary to inspect the temperature dependency of the two to select the material which will give the best balance between the two at or near room temperature. According to the present invention, the material with the contents of the 1, 2-linked units of not less than 90 mole percent is employed. The polybutadiene containing mainly 1, 2-linked units has a glass transition point of changes of various physical properties at or near 0°C such that the loss coefficient of the modified epoxy resin (elastomer modified epoxy resin) shows a temperature dependency having the maximum peak near 10°C. Although slightly lower at the room temperature (20°C), the loss coefficient is maintained at an adequately high value. On the other hand, although the modulus of elasticity is inevitably decreased with increasing temperature, the decrease in the modulus of elasticity at or near room temperature is low when the above elastomer is used. Conversely, the loss coefficient of the epoxy resin modified by polybutadiene elastomer mainly containing 1, 4-linked units shows a temperature dependency exhibiting a maximum peak in the vicinity of -50 to -30°C which is, of course, markedly lower than room temperature so that the loss coefficient at room temperature is reduced. Moreover, the decrease of the modulus of elasticity in the vicinity of room temperature is considerable. Therefore, with the epoxy resin modified by using an elastomer consisting mainly of 1, 2-linked units, it becomes possible to achieve compatibility between the high internal losses and the high modulus of elasticity at room temperature. Should the acoustic vibrational material made of such epoxy resin be applied to a speaker diaphragm, a reproduced sound of a higher quality may be achieved since the playback frequency range may be enlarged, unwanted vibrational modes may be absorbed and the transient characteristics may be improved. Attempts have been made in many fields to impart flexibility and high toughness to hard and brittle epoxy resins. One attempted modification is by the use of a polybutadiene elastomer for instance as discussed in EP-A-149357 which relates to the production of liquid resins for impregnating filament windings and JP-A-5515794 which discloses the use of a fibre-reinforced epoxy resin containing butadiene rubber for use in a speaker cone. However, with the conventional elastomer modification, the modulus of elasticity of the epoxy resin is reduced so that a satisfactory longitudinal wave propagation velocity cannot be obtained. Thus the conventional elastomer modification is unsuitable where the application under consideration is an acoustic vibrational material. As a result of the investigations by the present inventors into the elastomer modification properties of the epoxy resins having suitable properties for acoustic vibrational materials, it has been found that the modulus of elasticity is decreased markedly at room temperature mainly when the units of the polybutadiene elastomer are 1, 4-linked and the internal losses may be increased without markedly imparing the modulus of elasticity when not less than 90 mole percent of the units are 1, 2-linked, whereas the case in which the contents of the 1, 2-linked units are less than 90 mole percent is not desirable because of the reduction in modulus of elasticity. According to the present invention, elastomer modification is accomplished by incorporating a polybutadiene elastomer into the molecular chains of the epoxy resin by a preliminary reaction or by simply blending the epoxy resin and the polybutadiene elastomer and reacting part or all of the polybutadiene elastomer during curing. Which of these methods is employed depends on working methods and usage. When incorporating the elastomer into the molecular chains of the epoxy resin during the preliminary reaction, it is necessary for the polybutadiene elastomer to have functional groups capable of reacting with an epoxy resin at both terminals of the principal chains. For example, a reactive polybutadiene elastomer having functional groups such as hydroxyl groups, carboxyl groups or thiol groups or structures such as primary, secondary or tertiary amines or acid anhydrides at the terminals of the principal chain may be employed. The polybutadiene elastomers are employed in a range of 10 to 25 mole percent based on the epoxy resin. With the elastomer amount lower than the above range, the effect of addition of the polybutadiene elastomer is not displayed, whereas, when the elastomer amount is above the above range, the lowered relative contents of the epoxy resin may impare the intrinsic properties of the epoxy resin. General purpose materials may be used as the epoxy resin without any limitation. Any customary materials may be employed as the fibre reinforcement materials, such as aramid glass, carbon or ultra-drawn polyethylene fibres, or polyallylates (liquid crystal polymers). A preferred embodiment of the present invention will be explained with reference to experimental examples. Initially, the epoxy monomer and the elastomer were reacted preliminarily to produce the elastomer modified epoxy resin. As the epoxy monomer, the tri-functional glycidyl amine epoxy monomer (prepared by Sumitomo Chemical Co Ltd; trade name, Sumi-epoxy ELM-100) was used, whereas, as the elastomer, CTB (produced by Nippon Soda Co Ltd; trade name, Nisso Polybutadiene C-1000) was used. The contents of the 1, 2-linked units in the elastomer were 95 mole percent. The structure of the epoxy monomer and the elastomer are as follows:- The above epoxy monomer and the elastomer were mixed in the ratio shown in Table 1 and reacted under stirring at 110°C. The progress of the reaction was followed by measuring the decrease of the concentration of the carboxyl groups by titration with a 0.1N KOH solution in methanol. The synthesised elastomer modified epoxy resin presented a transparent single phase. To the above elastomer modified epoxy resin were added 4-methylhexahydrophthalic anhydride (prepared by Shin-Nippon Rika Co Ltd; trade name, MH-700) as a hardener and 2, 4, 6-tris (dimethylaminomethyl)phenol were added as an accelerator at the ratio shown in Table 1. After moulding, heating and curing was made at 120°C for 20 minutes to produce test pieces a to d each 5 mm wide, 50 mm long and 2 mm thick. The designation, phr (per hundred resin) in the columns of the hardener and the accelerator in Table 1 stands for the units of addition (weight parts) to 100 weight parts of the elastomer modified epoxy resin. Table 1 shows the results of measurement of the dynamic viscoelasticity and Q value (reciprocal of the internal loss tan δ) with the aid of a viscoelasticity meter (manufactured by the Orientec Co Ltd; trade name, Rheo Vibron). The measurement conditions are 110 Hz and 20°C. For comparison, a test piece e was similarly prepared using an unmodified epoxy resin and tested in the similar manner. The results are also shown in Table 1. test pieces epoxy monomer (molar ratio) elastomer C-1000 (molar ratio) hardener MH-700 (phr) accelerator (phr) dynamic viscoelasticity (dyn/cm²) Q value a 3.0 1 49 2 1.04 x 10¹⁰ 9.4 b 4.0 1 55 2 1.37 x 10¹⁰ 12.1 c 5.3 1 72 2 1.67 x 10¹⁰ 15.4 d 6.7 1 81 2 1.93 x 10¹⁰ 19.6 e 100 160 2 2.97 x 10¹⁰ 34.5 It is seen from Table 1 that the value of the dynamic viscoelasticity and the Q value are both lowered with a relative increase in the amount of the elastomer employed, the rate of decrease of the dynamic viscoelasticity being small as compared with the rate of decrease of the Q value and that the internal losses are increased in a ratio exceeding the rate of decrease of the dynamic viscoelasticity. The elastomer modified epoxy resin as the matrixresin was impregnated in a cloth woven from the ultra-drawn polyethylene fibres, referred to hereinafter as SDPE cloth, to produce a composite material. The SDPE cloth is prepared by using ultra-drawn polyethylene fibres (1000 denier/100 filaments, yarn diameter 40 µm; produced by Mitsui Petrochemicals Industries Ltd; trade name, Techmilon) at a density of 17 yarns/25 mm for both the warp and the weft yarn and subsequently subjected to plasma processing. The elastomer modified epoxy resins used at the time of preparing the above mentioned test pieces c and d were used as the matrix resin. For preparing the composite material, two SDPE cloths were cut to a size of 100 x 100 mm and impregnated with the matrix resin. They were then clamped between two teflon-coated iron plates heated to 120°C with a spacer 0.5 mm thick in between to perform a heat curing process for 20 minutes. They were then cut each to a size of 5 x 50 mm to produce test pieces C and D of the composite material. By way of a comparative example, a test piece E of the component material having the unmodif ied epoxy resin used for preparing the test piece e as the matrix resin was similarly produced. The values of the dynamic viscoelasticity and the Q values of the test prices C, D and E of the composite material thus produced were measured to produce the results shown in Table 2. test pieces matrix resin dynamic viscoelasticity (dyn/cm²) Q value C c (elastomer modified) 10.3 x 10¹⁰ 45.3 D d (elastomer modified) 10.7 x 10¹⁰ 49.2 E e (unmodified) 10.2 x 10¹⁰ 60.6 The values of the dynamic viscoelasticity of the text pieces C and D of the above composite material were increased markedly as compared with the values of the text pieces c, d and e compared with the values of the test pieces c, d and e composed of the elastomer modified epoxy resins or only of epoxy resins. It is noted that the values of the dynamic viscoelasticity of the test pieces C and D of the composite material are similar despite the difference in the relative amount of addition of the elastomers and are equivalent to the value of the test piece E of the composite material employing the unmodif ied epoxy resin. It follows from this that the modulus of elasticity of the fibre reinforced epoxy resin is not substantially changed by the elastomer modification. On the other hand, the Q value is decreased with increase in the relative amount of addition of the elastomer so that the internal losses are increased. Meanwhile, with the above mentioned elastomer modified epoxy resin, observation through an electron microscope revealed that the portion of reduced polarity due to elastomer introduction is coagulated to produce a micro phase separation in the resin and that the coagulated portion intruded into the micro-pores on the surface of the ultra-drawn polyethylene fibres. It was seen from a further test that adhesivity between the matrix resin and the fibre reinforcement material was markedly improved by the above intrusion and it may be thought that the effect in reducing the distortion on application to an acoustic diaphragm would be outstanding.

Claims: An acoustic vibrational material containing a fibre reinforcement material bound by an epoxy resin modified by reaction with a polybutadiene elastomer, characterised in that said epoxy resin is modified by reaction with the polybutadiene elastomer in an amount of 10 to 25 mole percent of the epoxy resin and containing not less than 90 mole percent of 1, 2-linked units. An acoustic vibrational material according to claim 1 wherein said fibre reinforcement material is any one of the material selected from aramid fibre, glass fibre, carbon fibre, ultra-drawn polyethylene fibre and liquid crystal polymer. A method of manufacturing an acoustic vibrational material containing a fibre reinforcement material bound by an epoxy resin modified by reaction with a polybutadiene elastomer, characterised by modifying said epoxy resin by reaction with said polybutadiene elastomer in an amount of 10 to 25 mole percent of the epoxy resin and containing not less than 90 mole percent of 1,2-linked units. A method according to claim 3 wherein said elastomer modified epoxy resin is formed by incorporating the elastomer into molecular chains of the epoxy resin in a preliminary reaction. A method according to claim 3 or 4, wherein said elastomer has functional groups capable of reacting with epoxy groups at both terminals of the principal chains. A method according to claim 3, 4 or 5, wherein said elastomer modified epoxy resin is formed by blending the epoxy resin and the elastomer and allowing a part or all of the elastomer to react during curing. A loudspeaker diaphragm fabricated of a material according to claim 1 or 2, or a material made by the method of any one of claims 3 to 6.

Inventors: MATSUURA SEIJI, TOKURA KUNIHIKO, URYU MASARU, MATSUURA, SEIJI, TOKURA, KUNIHIKO, URYU, MASARU
Applicants: SONY CORP, SONY CORPORATION
Application year: 1990
Main classification: C08L63
IPC codes: H04R7, C08G59, C08L63