CN103342029A - 高吸声系数的膨体聚四氟乙烯复合纤维棉 - Google Patents

高吸声系数的膨体聚四氟乙烯复合纤维棉 Download PDF

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CN103342029A
CN103342029A CN2013103107561A CN201310310756A CN103342029A CN 103342029 A CN103342029 A CN 103342029A CN 2013103107561 A CN2013103107561 A CN 2013103107561A CN 201310310756 A CN201310310756 A CN 201310310756A CN 103342029 A CN103342029 A CN 103342029A
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film layer
expanded ptfe
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张云
丁荣华
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PAN ASIAN MIROVENT TECH (CHANGZHOU) Co Ltd
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Priority to KR1020167002217A priority patent/KR20160070052A/ko
Priority to JP2016526415A priority patent/JP2016531315A/ja
Priority to PCT/CN2014/077162 priority patent/WO2015010489A1/zh
Priority to EP14829501.7A priority patent/EP3025861A4/en
Priority to US14/993,115 priority patent/US9969151B2/en
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Abstract

本发明公开了一种高吸声系数的膨体聚四氟乙烯复合纤维棉，包括：熔喷高聚物纤维层和膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层，膨体聚四氟乙烯改性薄膜层是将膨体聚四氟乙烯薄膜改性处理形成膨体聚四氟乙烯的膨体聚四氟乙烯改性薄膜层；高吸声系数的膨体聚四氟乙烯复合纤维棉是将熔喷高聚物纤维层和膨体聚四氟乙烯膜层复合制成，或将熔喷高聚物纤维层和膨体聚四氟乙烯改性薄膜层复合制成。通过上述方式，本发明能够具有了更好的全频吸音能力，全频吸音效果十分明显，可以大面积粘接应用或填塞在汽车的引擎盖、车身架或汽车后备箱的里侧面，可以大幅度的吸收汽车噪音，同时兼具化学惰性、防水防尘性、透气过滤性（内外压力平衡）、长寿命和可焊接性等优点。

Description

高吸声系数的膨体聚四氟乙烯复合纤维棉
技术领域
本发明涉及吸音棉领域，特别是涉及一种高吸声系数的膨体聚四氟乙烯复合纤维棉。
背景技术
虽然汽车外形都已呈流线型，曲面顺滑连接，外形很是漂亮，但汽车噪声污染问题仍是一大难题，声音是由于物体表面的震动，而引起空气分子来回运动而产生，这导致了空气密度局部的压缩和扩张的变化并传播；可是汽车行进中产生的噪声影响车内人员的舒适度，加速人的疲劳发困，常导致事故的发生；降低噪声污染的方法有吸收、屏蔽或阻隔。
国外有些车型如Ford, GM, VW等已用纤维复合无纺布或铝膜构成的新型吸声材料，由于噪声经微纤维多孔质材料内部的“摩擦”从而导致通过的声音的能量的衰减。通过复合无纺布或铝膜的反射回声波来降低声音能量的传播，最终微纤维技术吸音材料将大部分噪声能量转化成热能，大大降低车内的噪音。国内有些车型设计也开始使用此降噪新技术，可是汽车吸声制品需大量进口且被国外吸音棉垄断。
发明内容
本发明主要解决的技术问题是提供一种高吸声系数的膨体聚四氟乙烯复合纤维棉，能够全频率范围内吸收噪音，使用在汽车上，可以大面积粘接应用或填塞在汽车的引擎盖、车身架或汽车后备箱的里侧面，可以大幅度的吸收汽车噪音，传递给汽车的噪音被吸收程度大，其车内环境噪声将极大地降低，提供一个舒适的驾车环境。
为解决上述技术问题，本发明采用的一个技术方案是：提供一种高吸声系数的膨体聚四氟乙烯复合纤维棉，包括：熔喷高聚物纤维层和膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层；
所述熔喷高聚物纤维层是将聚合物利用高速热空气进行热熔，再将熔融的聚合物牵伸拉长成超细纤维，然后将超细纤维进行熔喷，最后冷却固化形成纤维网层；
所述膨体聚四氟乙烯改性薄膜层是将膨体聚四氟乙烯薄膜改性处理形成膨体聚四氟乙烯改性薄膜层；
高吸声系数的膨体聚四氟乙烯复合纤维棉是将熔喷高聚物纤维层和膨体聚四氟乙烯膜层复合制成，或将熔喷高聚物纤维层和膨体聚四氟乙烯改性薄膜层复合制成。
在本发明一个较佳实施例中，熔喷高聚物纤维层的单面通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
在本发明一个较佳实施例中，熔喷高聚物纤维层的正反两面均通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
在本发明一个较佳实施例中，熔喷高聚物纤维层利用熔喷后高聚物纤维的余热及牵伸热空气使纤维直接热熔接在膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层上。
在本发明一个较佳实施例中，熔喷高聚物纤维层的单面或正反两面通过胶粘剂层粘接复合有所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
在本发明一个较佳实施例中，熔喷高聚物纤维层通过粘接或焊接复合在所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层的正反两面。
在本发明一个较佳实施例中，加热或超声波焊接以及热熔接的接合面温度控制在210℃~230℃范围内。
在本发明一个较佳实施例中，胶粘剂层是指聚氨酯胶水或是由醋酸乙烯与乙烯不饱和单位多元共聚物胶水。
在本发明一个较佳实施例中，包括以下加工工艺：
1）工艺准备，包括准备熔喷高聚物纤维层、膨体聚四氟乙烯薄膜层和膨体聚四氟乙烯改性薄膜层；
2）将熔喷高聚物纤维层、膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层进行放卷；
3）将熔喷高聚物纤维层与膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层进行复合，并调整厚度；
4）最后对完成加工的膨体聚四氟乙烯复合纤维棉进行检验测试，合格则进行包装。
在本发明一个较佳实施例中，膨体聚四氟乙烯改性薄膜层是采用电晕处理将膨体聚四氟乙烯薄膜与改性层复合连接，形成可胶接或熔接的膨体聚四氟乙烯改性薄膜层。
本发明的有益效果是：本发明高吸声系数的膨体聚四氟乙烯复合纤维棉具有了更好的全频吸音能力，全频吸音效果十分明显，尤其对中低频噪音吸收更好，可以大面积粘接应用或填塞在汽车的引擎盖、车身架或汽车后备箱的里侧面，可以大幅度的吸收汽车噪音，同时兼具化学惰性、防水防尘性、透气过滤性（内外压力平衡）、长寿命和可焊接性等优点。
附图说明
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其它的附图，其中：
图1是本发明高吸声系数的膨体聚四氟乙烯复合纤维棉一较佳实施例的结构示意图；
图2是本发明高吸声系数的膨体聚四氟乙烯复合纤维棉另一较佳实施例的结构示意图；
图3是本发明高吸声系数的膨体聚四氟乙烯复合纤维棉另一较佳实施例的结构示意图；
图4是本发明高吸声系数的膨体聚四氟乙烯复合纤维棉另一较佳实施例的结构示意图；
图5是本发明高吸声系数的膨体聚四氟乙烯复合纤维棉另一较佳实施例的结构示意图；
附图中各部件的标记如下：1、熔喷高聚物纤维层，2、膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层，3、胶粘剂层，4、接收装置，5、熔喷设备。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
请参阅图1-图5，本发明实施例包括：
一种高吸声系数的膨体聚四氟乙烯复合纤维棉，包括：熔喷高聚物纤维层1和膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2；
熔喷高聚物纤维层1，是将聚合物利用高速热空气进行热熔，高速热空气的温度控制在310℃~374℃之间，再将熔融的聚合物牵伸拉长成为25~100mm、平均直径<18μm 的超细纤维，然后将超细纤维进行熔喷，最后在接收装置4冷却固化形成纤维网层；其中，聚合物可为PP聚丙烯或PET聚酯。
膨体聚四氟乙烯改性薄膜层是将膨体聚四氟乙烯薄膜改性处理形成膨体聚四氟乙烯改性薄膜层；
膨体聚四氟乙烯薄膜层是将聚四氟乙烯分散树脂与液体助挤剂按比例混合，予压成柱体毛坯，通过压延法将柱体毛坯制成薄片，经脱去助挤剂、拉伸、热定型，最终制得膨体聚四氟乙烯微孔薄膜层。
该高分子材料富有弹性和柔韧性，具有微细纤维连接而形成的网状结构，这些微细纤维形成无数消声细孔，消声吸声微孔径在1～30μm。
膨体聚四氟乙烯改性薄膜层具有了更好的惰性、防水性、透气性、阻燃性、高吸声系数、长寿命和可焊接性。
高吸声系数的膨体聚四氟乙烯复合纤维棉是将熔喷高聚物纤维层1和膨体聚四氟乙烯薄膜层复合制成，或将熔喷高聚物纤维层1和膨体聚四氟乙烯改性薄膜层复合制成。
熔喷高聚物纤维层1和膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2复合后，它的结构性是：材料中具有大量的、互相贯通的、从表到里的微孔，也即具有一定的透气性。多微孔质吸音材料的吸音原理为振动空气从狭孔中进出时，空气分子与材料和自身摩擦，把声能变换成热能，噪声能量在此新复合材料中消耗掉了。孔越多越密，吸音能力更强，形成了一种高性能的——全频吸音的特殊功能新材料，当声波入射到此多微孔新材料表面时，引起微孔中的空气振动，由于摩擦阻力和空气的黏滞阻力以及热传导作用，将相当一部分声能转化为热能，音响声压在全频范围内降低了5~7dB，全频吸音效果十分明显，尤其对低、中频噪音吸收更好，将其应用在汽车吸音降噪零部件上，可以全频率范围内吸收噪音，使用在汽车上，传递给汽车的噪音被吸收程度大，其车内环境噪声将极大地降低，给人一个舒适的驾车环境。
实施例1：如图1所示，
熔喷高聚物纤维层1的单面通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2，最终制得高吸声系数的膨体聚四氟乙烯复合纤维棉。
两种材料加热或超声波焊接的接合面的温度控制在210℃~230℃，此温度焊接的强度最好。
实施例2：如图2所示，
熔喷高聚物纤维层1的正反两面均通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2，最终制得高吸声系数的膨体聚四氟乙烯复合纤维棉。
两种材料加热或超声波焊接的接合面的温度控制在210℃~230℃，两种材料复合移动线速度0.5m/min，此温度焊接的强度最好。
实施例3：如图3所示，
熔喷高聚物纤维层1利用熔喷后高聚物纤维的余热及牵伸热空气使纤维直接热熔接在膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2上，最终制得高吸声系数的膨体聚四氟乙烯复合纤维棉。
本工艺采用国产熔融指数为12g/min,分子量为20万的聚丙烯切片，熔喷设备5的螺杆转速为8转/min,接收距离为120mm，熔体温度为318℃，喷头温度为325℃，空气温度为305℃，平均直径<18μm 的超细纤维，接收装置4线速度为2m/min，纤维层厚度控制为< 23mm，直接熔喷接着在膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2上冷却固化形成纤维棉。
实施例4，如图4所示，
熔喷高聚物纤维层1的单面或正反两面通过胶粘剂层3粘接复合有所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2，最终制得高吸声系数的膨体聚四氟乙烯复合纤维棉。
胶粘剂是指聚氨酯胶水或是由醋酸乙烯与乙烯不饱和单位多元共聚物胶水，适用于手喷自动喷或滚轮涂布上胶, 或是反应型聚氨酯热熔胶。特性：复合型胶水有优异的粘接强度、耐高温、耐洗水、干洗. 优异的柔软性、环保、无异味、不含甲醛与游离酚。
实施例5，如图5所示，
熔喷高聚物纤维层1通过粘接或焊接复合在所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2的正反两面，最终制得高吸声系数的膨体聚四氟乙烯复合纤维棉。
焊接的接合面的温度控制在210℃~230℃，粘结使用的胶粘剂是指聚氨酯胶水或是由醋酸乙烯与乙烯不饱和单位多元共聚物胶水，适用于手喷自动喷或滚轮涂布上胶, 或是反应型聚氨酯热熔胶。
一种高吸声系数的膨体聚四氟乙烯复合纤维棉的加工工艺，包括，
1）工艺准备，包括准备熔喷高聚物纤维层1、膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2；
2）将熔喷高聚物纤维层1、膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2进行放卷；
3）将熔喷高聚物纤维层1与膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层2进行复合，并调整厚度；
4）最后对完成加工的膨体聚四氟乙烯复合纤维棉进行检验测试，合格则进行包装。
膨体聚四氟乙烯改性薄膜层是采用电晕处理将膨体聚四氟乙烯薄膜与改性层复合连接，形成可胶接或熔接的膨体聚四氟乙烯改性薄膜层。
本发明高吸声系数的膨体聚四氟乙烯复合纤维棉具有了更好的全频吸音能力，全频吸音效果十分明显，尤其对中低频噪音吸收更好，同时兼具化学惰性、防水防尘性、透气过滤性（内外压力平衡）、长寿命和可焊接性等优点。具体包括：
1）一种高吸声系数的膨体聚四氟乙烯复合纤维棉复合材料，当声波入射到此多微孔新材料表面时，引起微孔中的空气振动，由于摩擦阻力和空气的黏滞阻力以及热传导作用，将相当一部分声能转化为热能，噪声波经膨体聚四氟乙烯膜及其改性薄膜的更小微孔进一步衰减转化为热能后，音响声压在全频范围内降低了5~7dB, 全频吸音效果十分明显，尤其对中低频噪音吸收更好，将其应用在高保真音响设备和扬声器上，可以全频率范围内吸收噪音，留下优美动听的音乐，使用在室内环境、汽车或机电设备上噪音被吸收程度大，尤其可以大面积粘接应用或填塞在汽车的引擎盖、车身架或汽车后备箱的里侧面，可以大幅度的吸收汽车噪音，其环境噪声将极大地降低，给人一个舒适的乘坐环境。   
 2）一种高吸声系数的膨体聚四氟乙烯复合纤维棉保持汽车零部件内外部空气压力平衡：减小内部元器件上的应力以延长产品的使用寿命，降低结雾凝露现象造成的电气短路事故发生，提高可靠性并延长产品的使用寿命。 
3) 环保：环保的一种高吸声系数的膨体聚四氟乙烯复合纤维棉材料，白色无毒无异味，无挥发性气体，无公害污染，不含致癌物质；操作无类似玻璃纤维对皮肤的刺激性，可进行冲切加工，不像其他产品产生粉尘碎屑等。
4) 阻燃性：一种高吸声系数的膨体聚四氟乙烯复合纤维棉具有优良的耐热性，可在100度左右长期使用。高吸声系数的膨体聚四氟乙烯复合纤维棉具有良好的耐热性，防火性能（阻燃性）材料完全符合汽车内饰要求。提高人生及财产安全性。 
5) 防潮：一种高吸声系数的膨体聚四氟乙烯复合纤维棉疏水性，无发霉，细菌滋生，腐烂以及难闻气味的产生，确保长期稳定性。在潮湿环境下，吸音率不变，吸水量不超过自身重量的1%，且易干。
6) 防老化：一种高吸声系数的膨体聚四氟乙烯复合纤维棉在120℃的环境下，吸音无变化。
7) 可塑性：一种高吸声系数的膨体聚四氟乙烯复合纤维棉密度小，操作简便,可压缩及可变形性适用于不同规格或者紧密空间，给产品设计提供了更大的灵活性。产品质地柔软，重量很轻，可任意裁剪，.易于安装。可使用喷胶、压敏胶带、超声波焊接、热粘贴或者推针粘贴
8）高绝缘：一种高吸声系数的膨体聚四氟乙烯复合纤维棉具有优良的绝缘性能，由于它几乎不吸水，故绝缘性能不受湿度的影响。
9）保温性：一种高吸声系数的膨体聚四氟乙烯复合纤维棉能有效存住更多的隔绝空气并反射外界热量，更快的达到内部舒适的温度，用更少的能量保持内部的温度，有比羽绒更优越的保温性能。在冬天能保护汽车内部热量的流失，在夏天能阻隔外部热量的流入，减少汽车用空调的能耗，为21世纪的低碳安静生活引入新的复合材料。
10）阻燃性，符合强制性国标GB8410-2006的燃烧特性满足燃烧速度不大于100 mm/min。
11）节约能源，一种高吸声系数的膨体聚四氟乙烯复合纤维棉轻量化降低汽车动力消耗。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所作的等效结构或等效流程变换，或直接或间接运用在其它相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

1.一种高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，包括：熔喷高聚物纤维层和膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层；
所述熔喷高聚物纤维层是将聚合物利用高速热空气进行热熔，再将熔融的聚合物牵伸拉长成超细纤维，然后将超细纤维进行熔喷，最后冷却固化形成纤维网层；
所述膨体聚四氟乙烯改性薄膜层是将膨体聚四氟乙烯薄膜改性处理形成膨体聚四氟乙烯改性薄膜层；
高吸声系数的膨体聚四氟乙烯复合纤维棉是将熔喷高聚物纤维层和膨体聚四氟乙烯膜层复合制成，或将熔喷高聚物纤维层和膨体聚四氟乙烯改性薄膜层复合制成。
2.根据权利要求1所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，熔喷高聚物纤维层的单面通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
3.根据权利要求1所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，熔喷高聚物纤维层的正反两面均通过加热或超声波焊接复合连接所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
4.根据权利要求1所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，熔喷高聚物纤维层利用熔喷后高聚物纤维的余热及牵伸热空气使纤维直接热熔接在膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层上。
5.根据权利要求1所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，熔喷高聚物纤维层的单面或正反两面通过胶粘剂层粘接复合有所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层。
6.根据权利要求1所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，熔喷高聚物纤维层通过粘接或焊接复合在所述膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层的正反两面。
7.根据权利要求2或3或4所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，加热或超声波焊接以及热熔接的接合面温度控制在210℃~230℃范围内。
8.根据权利要求5或6所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，胶粘剂层是指聚氨酯胶水或是由醋酸乙烯与乙烯不饱和单位多元共聚物胶水。
9.根据权利要求1-6任一所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，包括以下加工工艺：
1）工艺准备，包括准备熔喷高聚物纤维层、膨体聚四氟乙烯薄膜层和膨体聚四氟乙烯改性薄膜层；
2）将熔喷高聚物纤维层、膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层进行放卷；
3）将熔喷高聚物纤维层与膨体聚四氟乙烯薄膜层或膨体聚四氟乙烯改性薄膜层进行复合，并调整厚度；
4）最后对完成加工的膨体聚四氟乙烯复合纤维棉进行检验测试，合格则进行包装。
10.根据权利要求9所述的高吸声系数的膨体聚四氟乙烯复合纤维棉，其特征在于，膨体聚四氟乙烯改性薄膜层是采用电晕处理将膨体聚四氟乙烯薄膜与改性层复合连接，形成可胶接或熔接的膨体聚四氟乙烯改性薄膜层。
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