CN106042544A - 一种多层不同密度的非织造吸音复合材料及其制备方法 - Google Patents

一种多层不同密度的非织造吸音复合材料及其制备方法 Download PDF

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CN106042544A
CN106042544A CN201610387191.0A CN201610387191A CN106042544A CN 106042544 A CN106042544 A CN 106042544A CN 201610387191 A CN201610387191 A CN 201610387191A CN 106042544 A CN106042544 A CN 106042544A
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sound absorption
cloth
woven
surface density
preparation
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晏雄
陈夕方
杨旭东
张慧萍
陈静
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DANYANG YUSHENG TEXTILE NEW MATERIAL Co Ltd
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DANYANG YUSHENG TEXTILE NEW MATERIAL Co Ltd
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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Abstract

本发明涉及一种多层不同密度的非织造吸音复合材料及其制备方法，包括以下具体步骤：A．将多孔涤纶纤维开松，梳理，成网；B．将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成布料，所述布料的厚度为4mm～40mm，面密度为40g/m2～500g/m 2；C．将2～6层布料层叠设置，进行热压复合，然后冷却。选择多孔涤纶为主要原料设计内外层密度不同、厚度不同，增强对噪声的全面吸收，使得材料获得了很好的吸声效果。热压的温度为100℃～120℃，以及由该方法制成的吸声针刺非织造复合材料。本发明的吸声针刺非织造复合材料经热压复合后吸声性能显著提升，且轻薄、强度高、生产成本低。

Description

一种多层不同密度的非织造吸音复合材料及其制备方法
本申请是分案申请，原申请的申请号：201410076392.X，申请日：2014-03-04，发明创造名称《一种吸声针刺非织造复合材料及其制备方法》。
技术领域
本发明涉及一种多层不同密度的非织造吸音复合材料及其制备方法，尤其是一种针刺非织造吸声材料及其制备方法，属于吸声材料技术领域。
背景技术
随着科学技术进步，人们在享受高效率的社会活动同时，也给自己带来了更多的社会问题，其中环境污染已经成为制约人类社会发展的主要瓶颈之一。同时噪音污染随着现代高速的交通运输和企业生产已经严重影响人们的生活水平。降噪已经成为一个关乎人民生活水平、协调发展的重要课题。降噪主要有两个发展方向：一个是隔音技术，另外一个是吸声技术。隔音技术发展缺陷是造成二次或多次污染，而且往往材料属于高密度材料，成本较高。吸声技术是利用声波能量的耗散手段，降低环境中噪音，真正达到消除污染的目的。吸声材料又以多孔性材料为主，材料是以纤维材料为基石。纺织材料加工技术就是用纤维形态的材料制作各种外观形态的用品，这些用品大多是多孔性的材料，而随着不同的加工技术、材料的孔径形态、密度以及其分布有很大的区别，这些区别导致材料吸声性能不同。针刺非织造材料作为纤维材料加工的一种技术，其材料构造形式决定了材料的吸声降噪性能优越，而且其加工成本低、产量高、加工环境污染小等特点，是一种较为理想的应用于吸声降噪方面的基材，近些年来已经受到广泛关注。
目前，为了提高材料的吸声性能，一般采用的方法是增加材料的厚度，但效果并不明显，而且在使用上也受到一定的限制，如使用空间的限制、材料体积和造价的限制。另外利用微穿孔板的共振吸声机理将吸声材料与微穿孔板结合，也可以提高材料的吸声效果，但微穿孔板在设计及加工上较复杂，而且吸声频带较窄。因此，吸声性能好且轻薄、加工简便的吸声材料在吸声材料领域将有着极好的发展前景。
东华大学2010 年度硕士论文《复合针刺非织造材料吸声性能研究》，作者：马永喜，该文献从吸声性能对纤维原料的要求、纤维的可加工性以及环保要求和原料成本等方面讨论了纤维原料的选用原则，探讨了针刺非织造材料的加工工艺（包括开松、混合、梳理、铺网、针刺加固工艺参数），最后重点研究了复合PET 针刺吸声材料的吸声性能及隔声性能。具体从厚度、面密度和组成纤维细度三方面分析了其对吸声性能的影响。
中国专利文献CN201310041934.5 公开了一种低频吸声针刺非织造复合材料及其制备方法和应用，复合材料包括木棉纤维/ 中空涤纶非织造布和聚乙烯膜。制备方法，包括：按质量百分比，将60%～90%的木棉纤维和40%～10%的中空涤纶纤维，混合，开松，梳理，成网；将纤维网输入针刺机中进行针刺加固，圈绕、切断，得木棉/ 中空涤纶针刺非织造布；将0.06mm～0.10mm聚乙烯膜平整地放在上述针刺非织造纤维网的一面，复合，取出，冷却，即得。该复合材料可应用于汽车内饰、建筑、高铁等领域；该吸声材料轻薄，制备方法操作简单。但是木棉纤维的强度较低约为涤纶纤维的三分之一，且木棉纤维的价格较贵，该吸声材料不利于大范围的应用。
发明内容
本发明所要解决的技术问题是提供一种热压复合后吸声性能显著提升，且轻薄、强度高、生产成本低的吸声针刺非织造复合材料以及该材料的制备方法。为了解决上述技术问题，本发明提供了一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于，包括以下具体步骤：
A．将多孔涤纶纤维开松，梳理，成网；
B．将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成布料，所述布料的厚度为4mm～40mm，面密度为40～500g/m2 ；
C． 将2～6 层布料层叠设置，进行热压复合，然后冷却，热压的温度为100℃～120℃。
上述技术方案的一种优选是：上述多孔涤纶纤维是长度为38mm至100mm的短纤维，细度为1.56 dtex～16.67dtex，多孔涤纶纤维的孔数大于等于5。为了使得热压复合的效果更好，上述技术方案的一种优选是：上述步骤C中，热压的时间为3～6min，热压的压力为1.2～1.6MPa。
为了使得复合材料获得更好的吸声性能，上述技术方案的一种优选是：上述布料有3层，外层布料的面密度大于中间层布料的面密度。
上述技术方案的进一步优选是：布料的厚度为8mm～15mm，外层布料的面密度为60g/m2～70g/m2，中间层布料的面密度为45g/m2～55g/m2。
上述技术方案的一种优选是：上述布料有3层，外层布料的面密度小于中间层布料的面密度。
上述技术方案的进一步优选是：布料的厚度为8mm～15mm，外层布料的面密度为60g/m2 ～70g/m2，中间层布料的面密度为45g/m2～55g/m2。
为了解决上述技术问题，本发明提供了一种由上述制备方法制成的吸声针刺非织造复合材料。
本发明具有积极的技术效果：
（1）本发明的吸声针刺非织造复合材料先将多孔涤纶纤维通过针刺工艺制成布料，再将层叠在一起的多层布料热压复合，使得相邻布料的表面在高温的作用下粘结在一起，制成复合材料，通过复合工艺，大大提升了材料的吸声性。材料的吸声能力和声波的频率有关，对于多孔吸声结构而言，随着声波频率的不断增加，其吸声能力也不断增加，在中频声段增加的最快，而对高频声波的吸收能力最好；对于共振吸声结构而言，随着声波频率的不断增加，材料对声波的吸收能力先增后降，对低频声波的吸收最好，在中频声段有所降低，而在高频声段的吸声能力维持在一定水平。本发明的吸声针刺非织造复合材料将共振吸声机理与多孔吸声机理相结合，将材料的吸声频段扩大，从而更有利于对噪声的全面吸收，使得材料获得了很好的吸声效果。
（2）本发明的吸声针刺非织造复合材料吸声性能优异，在频率500 ～ 5000Hz 范围的吸声系数均大于0.3，最大吸声系数可达0.9 以上。
（3）本发明的吸声针刺非织造复合材料轻薄且强度高，制备方法操作简便，生产成本较低，具有很好的经济效益，适合于工业化大规模生产。
（4）本发明的吸声针刺非织造复合材料可应用于动车内饰、汽车内装饰、建筑、音箱、高铁等多个领域。
附图说明
下面结合附图对本发明作进一步说明：
图1 为本发明的实施例1、2 与对比例1、2 的样品在不同频率下吸声系数的区别示意图。
具体实施方式
实施例1
本实施例的吸声针刺非织造复合材料的制备方法，包括以下具体步骤：
A．采用东华大学2010 年度硕士论文《复合针刺非织造材料吸声性能研究》中公开的现有的开松、梳理、铺网工艺，将多孔涤纶纤维开松，梳理，成网。多孔涤纶纤维采用中国石化仪征化纤股份有限公司生产的8.33dtex×64mm 的七孔涤纶短纤维。
B．将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成两种布料样品，一种布料样品的厚度为10mm，面密度为55g/m2，另一种布料样品的厚度为10mm，面密度为70g/m2。针刺机总针数：4800 针，面积1.2m×0.3m，针刺频率n 为1200 刺/min，纤网输出速度V2 为3.75m/min, 喂入速度V1 为2.5m/min，牵伸比i 为1 ∶ 1.5。
C．选取两块面密度为55g/m2 的布料样品和一块面密度为70g/m2 的布料样品，将三块布料样品叠合在一起，面密度为70g/m2 的布料样品位于中间。用夹具夹好，放入烘箱中，升温至110℃，保温5min 中后取出，在空气中冷却，夹具的压力为1.4MPa。
从而制得厚度为30mm，面密度为180g/m2 的吸声针刺非织造复合材料（样品3）。
实施例2
本实施例的吸声针刺非织造复合材料的制备方法，包括以下具体步骤：
A．采用东华大学2010 年度硕士论文《复合针刺非织造材料吸声性能研究》中公开的现有的开松、梳理、铺网工艺，将多孔涤纶纤维开松，梳理，成网。多孔涤纶纤维采用中国石化仪征化纤股份有限公司生产的8.33dtex×64mm 的七孔涤纶短纤维。
B．将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成两种布料样品，一种布料样品的厚度为10mm，面密度为65g/m2，另一种布料样品的厚度为10mm，面密度为50g/m2。针刺机总针数：4800 针，面积1.2m×0.3m，针刺频率n 为1200 刺/min，纤网输出速度V2 为3.75m/min, 喂入速度V1 为2.5m/min，牵伸比i 为1 ∶ 1.5。
C．选取两块面密度为65g/m2 的布料样品和一块面密度为50g/m2 的布料样品，将三块布料样品叠合在一起，面密度为50g/m2 的布料样品位于中间。用夹具夹好，放入烘箱中，升温至110℃，保温5min 中后取出，在空气中冷却，夹具的压力为1.4MPa。
从而制得厚度为30mm，面密度为180g/m2 的吸声针刺非织造复合材料（样品4）。
实施例3
本实施例的吸声针刺非织造复合材料的制备方法，其余部分与实施例1 相同，不同之处：多孔涤纶纤维采用中国石化仪征化纤股份有限公司生产10.00dtex×60mm 的七孔涤纶短纤维。
实施例4
本实施例的吸声针刺非织造复合材料的制备方法，其余部分与实施例2 相同，不同之处：多孔涤纶纤维采用中国石化仪征化纤股份有限公司生产的8.33dtex×60mm 的十孔涤纶短纤维。
对比例1
本对比例的普通涤纶针刺非织造布的制备方法，包括以下具体步骤：
A．采用现有的开松、梳理、铺网工艺，将普通涤纶纤维开松，梳理，成网。普通涤纶纤维采用中国石化仪征化纤股份有限公司生产的8.33dtex×64mm的普通涤纶纤维。
B．采用现有的针刺工艺，将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成普通涤纶针刺非织造布（样品1）。样品1 的厚度为30mm，面密度为220g/m2。
对比例2
本对比例的普通涤纶针刺非织造布的制备方法，包括以下具体步骤：
A．采用现有的开松、梳理、铺网工艺，将普通涤纶纤维开松，梳理，成网。多孔涤纶纤维采用中国石化仪征化纤股份有限公司生产的8.33dtex×64mm的七孔涤纶短纤维。
B．采用现有的针刺工艺，将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成普通涤纶针刺非织造布（样品2）。样品2 的厚度为30mm，面密度为1800g/m2。
采用东华大学2010 年度硕士论文《复合针刺非织造材料吸声性能研究》中公开的吸声性能测试方法对样品1 至4 进行吸声性能的测试，结果如图1 所示。
由图1 可知，在厚度相同情况下，多孔涤纶纤维针刺非织造布比普通涤纶纤维针刺非织造布的吸声系数高，即多孔涤纶纤维针刺非织造布比普通涤纶纤维针刺非织造布具有更好的吸声效果。在厚度和面密度都相同情况下。当频率大于500Hz 时，样品3 和样品4的吸声效果明显优于样品1 和样品2. 样品4 在频率为500～2000Hz 的范围内，吸声效果优于样品3。样品3 在频率为3000Hz以上时，吸声效果优于样品4，样品3 的最大吸声系数可达0.9 以上。本发明的吸声针刺非织造复合材料与单一结构的多孔涤纶纤维针刺非织造布相比具有更好的吸声效果。
本发明不局限于上述各实施例，上述实施例仅仅是为清楚地说明本发明所作的举例，而并非是对本发明的实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而这些属于本发明的精神所引伸出的显而易见的变化或变动仍处于本发明的保护范围之中。

Claims (7)

1.一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于，包括以下具体步骤：
A．将多孔涤纶纤维开松，梳理，成网；
B．将纤维网输入针刺机中进行针刺加固，圈绕，切断，制成布料，所述布料的厚度为4mm～40mm，面密度为40g/m2～500g/m2 ；
C．将2～6层布料层叠设置，进行热压复合，然后冷却，热压的温度为100℃～120℃。
2.根据权利要求1 所述的一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于：将权利要求1所得的布料按2～6层布料层叠设置，进行热压复合，然后冷却成型。
3.根据权利要求 2 所述的一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于：所述布料有多层，外层布料的面密度大于中间层布料的面密度。
4.根据权利要求3 所述的一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于：布料的厚度为8mm～15mm，外层布料的面密度为60g/m2 ～70g/m2，中间层布料的面密度为45g/m2～55g/m2。
5.根据权利要求1 至3 之一所述的一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于：所述布料有多层，外层布料的面密度小于中间层布料的面密度。
6.根据权利要求5所述的一种多层不同密度的非织造吸音复合材料及其制备方法，其特征在于：布料的厚度为8mm～15mm，外层布料的面密度为45g/m2～55g/m2，中间层布料的面密度为60g/m2～70g/m2。
7.按照权利要求1至6所述的制备方法制成的吸声针刺非织造复合材料，密度不同，所赋予材料吸声效果不同。
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Application publication date: 20161026