CN106079692A - 一种汽车降噪贴膜及其制备方法 - Google Patents

一种汽车降噪贴膜及其制备方法 Download PDF

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CN106079692A
CN106079692A CN201610437644.6A CN201610437644A CN106079692A CN 106079692 A CN106079692 A CN 106079692A CN 201610437644 A CN201610437644 A CN 201610437644A CN 106079692 A CN106079692 A CN 106079692A
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张开骁
马文文
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Hohai University HHU
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Abstract

本发明公开了一种汽车降噪贴膜及其制备方法，其自下而上的结构为：附着层、基材、隔热层、降噪层；在降噪层的表面设有若干进气孔以及凸出于降噪层表面的圆台，圆台的顶部设有出气孔，圆台内部中空并通过底部与进气孔相连通，进气孔大于出气孔；多层结构有助于声波在多界面形成多次反射，更有助于消噪，实现了车内人耳敏感低频波段降噪膜的薄膜化。本发明兼具耐磨、耐腐蚀、防水防雨、保温、方便使用等诸多优点。

Description

一种汽车降噪贴膜及其制备方法
技术领域
本发明涉及汽车贴膜技术领域，具体涉及一种汽车降噪贴膜及其制备方法。
背景技术
随着人们对汽车乘坐舒适性要求的提高，各国对汽车噪声要求的越来越严格,改善车辆内部声学环境、降低车内噪声水平，是各国政府和汽车生产厂家共同关心的问题。车内噪声过大将严重影响汽车的乘坐舒适性、会话清晰度、以及驾驶员对各种信号的识别能力。因此分析车内噪声情况,提出相应的降噪措施，具有重要的实际意义。如何降低车内噪声，一直是汽车设计领域多年来关注的重要课题。车内噪声主要来源于车室外的噪声源和振动源(如发动机、传动系统、进排气系统、悬架系统、风扇、轮胎、路面不平等)，这些噪声源的声能和振动经空气和结构两个途径进入车厢。第一个途径是噪声通过车厢壁板、门窗孔缝直接传入车厢内，称为空气声；第二个途径是车厢外的声源或振动(源)作用于车身壁板，激发壁板振动，并向车内发出噪声，称为结构声。一般车厢内的声压由两部分组成：一是噪声源辐射的直达声；二是由车厢壁面多次反射形成的混响声。在车厢内部增加吸声材料，能提高车身平均吸声系数，减小混响声能密度，从而降低总声压级。Sabine(赛宾)公式给出T60＝0.161V/A，其中，T60为混响时间(定义为当声源突然停止发声后，车室内声压级衰减60dB经过的时间，单位为s)；V为车身内部容积；车身吸声量A＝S·α(α为吸声系数，S为材料的表面积)。混响时间长短与车厢的容积成正比，与吸声量成反比。因此，一般用吸声性能较好的材料来降低车内噪声。吸声措施主要有：多孔性吸声材料，如玻璃纤维、聚氨酯泡沫、棉纤维、聚酯纤维、麻纤维等；薄板吸声材料，如胶合板、硬质纤维板、铅板、纸板等；薄板共振吸声结构；穿孔板吸声结构等。但是目前市场上的现有技术吸声材料都是呈现出材料单一化的特点，局限性十分明显，不能充分的吸收噪声。
发明内容
针对上述不足，本发明专利的目的是提供一种克服上述缺点、可贴附在汽车内部表面起到降噪效果的一种汽车降噪贴膜及其制备方法
下面结合附图对本发明作进一步详细描述。为达到上述目的，本发明是通过以下技术方案实现：
一种汽车降噪贴膜，其自下而上的结构为：附着层、基材、隔热层、降噪层；在降噪层的表面设有若干进气孔以及凸出于降噪层表面的圆台，圆台的顶部设有出气孔，圆台内部中空并通过底部与进气孔相连通，进气孔大于出气孔。
进一步的，圆台高度为5mm-15mm。
进一步的，所述的降噪层为聚氨酯硬质泡沫，厚度为1mm-5mm。
进一步的，所述的隔热层为膨胀珍珠岩层，厚度为0.5mm。
进一步的，所述的基材为掺有纳米二氧化硅的硅橡胶层，厚度为0.5mm。
进一步的，所述的附着层为双面胶。
汽车降噪贴膜制备方法包括如下步骤：
(1)制作基材，具体为：
1a)纳米二氧化硅的制备：
将100g的Na2SiO3·9H2O和200g的NH4NO3或NH4Cl置于研钵中混合充分研磨30min，以水为介质在超声波中分散30min，抽滤，依次用水、硝酸，无水乙醇洗涤，在温度303K下干燥2小时后得粗产品，然后将粗产品置于高温炉中于673K～1073K温度煅烧2小时，得到所需的纳米二氧化硅；
1b)将纳米二氧化硅融合到硅橡胶中，具体为：
将200g甲基乙烯基硅橡胶110-2、3g膏状硫化剂、100g纳米二氧化硅按照GB 6038-93标准开炼机上混炼均匀,；用P3555C2型盘式硫化仪测得其正硫化时间t；20小时后在25吨平板硫化机上模压成型,硫化温度为170℃；
(2)制备聚氨酯硬质泡沫作为降噪层：
将100g聚醚多元醇、3.5g的A33(质量分数为33％的三乙烯二胺溶液)、二甲乙醇胺1.7g、2g的T12钢、1.9g硬泡硅油、33.5g一氟二氯乙烷、22.6g的TCPP(三(氯异丙基)磷酸酯)、4.9g二乙醇胺、1.3g蒸馏水配成组合聚醚，以2000r/min的速率搅拌60s使其混合均匀；另取多亚甲基多苯基异氰酸酯155g置于恒温箱中保持30℃恒温10分钟，而后迅速将配好的组合聚醚和多亚甲基多苯基异氰酸混合，以2000r/min搅拌4s～5s使其充分反应得到所需聚氨酯，然后将聚氨酯通过压模得到表面带有中空凸起圆台以及进气孔的降噪层的上半层，圆台的顶面开有出气孔；降噪层的上半层固化成型脱模后再放置在表面水平的降噪层的下半层上，固化后即为完整的聚氨酯硬质泡沫塑料的降噪层；
(3)利用靶式气流粉碎机将珍珠岩粉碎作为隔热层；
(4)利用热熔胶水将基材、隔热层、降噪层从上至下依次粘合，最后将作为附着层的双面胶贴在基材的下表面待用。
与现有技术相比，本发明的有益效果主要表现在以下几个方面：，本发明在利用多孔材料降噪的基础上，针对目前低频反射降噪的困难(通常需要较厚的吸声材料)，设计了厚度较薄的降噪层，即通过较薄的微型空气腔体形成具有圆锥形状的反射气柱，较高的圆锥气柱可以吸收对应波长的声波能量，实现了降噪膜的薄膜化。此外，通过阻尼、反射、转化多种形式降低声波能量；通过多孔、空气腔、散射等形式改变声波传播方向；掺有纳米材料的硅橡胶—聚氨酯泡沫—膨胀珍珠岩的多层结构有助于声波在多界面形成多次反射，更有助于消噪。上述多种降噪机制与降噪方法相辅相成，共同作用减小噪声，同时本降噪贴膜兼具耐磨、耐腐蚀、防水防雨、保温、方便使用等诸多优点。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术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他的附图。
图1为本发明的俯视结构示意图；
图2为本发明的侧视结构示意图图；
图3为本发明去掉圆台部分的俯视截面图。
具体实施方式
下面结合附图对本发明的优选实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解，从而对本发明的保护范围做出更为清楚明确的界定。
车内主要噪声频率在500-2000Hz之间，本发明针对人耳最敏感的声音波段(频率在1000-3000Hz之间)，提出了一种有针对性的降噪贴膜及其制备方法。
如图1-图3所示，汽车降噪贴膜自下而上的结构为：附着层1、基材2、隔热层3、降噪层4。其中，降噪层结构为表面布有进气孔5与凸出表面的圆台6，圆台6顶部有出气孔7，圆台6内部中空并通过底部与进气孔5形成连通的气腔，受到压迫的空气从进气孔5进气、出气孔7出气体(进气孔5的面积远大于出气孔7)。所述的降噪层4圆台6的高度为5mm-15mm，所述的降噪层4为聚氨酯硬质泡沫，厚度为1mm-5mm；所述隔热层3为膨胀珍珠岩层，厚度为0.5mm。；所述基材2为掺有纳米二氧化硅的硅橡胶层，厚度为0.5mm；所述附着层1为永大双面胶。
汽车降噪贴膜制备方法。
首先，分别制备基材2、隔热层3、降噪层4三层膜；然后利用热熔胶水将三层膜紧密结合起来；最后再贴上双面胶1待用。
(1)掺有纳米二氧化硅的硅橡胶的制备
A：纳米二氧化硅的制备：
将100g的Na2SiO3·9H2O和200g的NH4NO3或NH4Cl置于研钵中混合充分研磨30min，以水为介质在超声波中分散30min，抽滤，依次用水、硝酸，无水乙醇洗涤，303K干燥2h后得粗产品，然后将粗产品置于高温炉中于673K～1073K温度煅烧2h，得所需的纳米二氧化硅。
B：将纳米二氧化硅融合到硅橡胶中
将200g甲基乙烯基硅橡胶110-2、硫化剂膏状双-25(DTBP，CAT-DTF30)3g、DNS-3型纳米二氧化硅100g；按照GB 6038-93标准在开炼机上混炼均匀,用P3555C2型盘式硫化仪测得其正硫化时间t；20h后在25吨平板硫化机上模压成型,硫化温度为170℃。
(2)制备聚氨酯硬质泡沫作为降噪层
将聚醚多元醇100g、3.5g的A33(质量分数为33％的三乙烯二胺溶液)、二甲乙醇胺1.7g、2g的T12钢、硬泡硅油1.9g、33.5g的HCFC-141B、22.6g的TCPP(三(氯异丙基)磷酸酯)、二乙醇胺4.9g、蒸馏水1.3g配成组合聚醚(A料)，2000r/min搅拌60s使其混合均匀。另取155g的PM200(B料)置于30℃的恒温箱中恒温10min，而后迅速将A料、B料混合，2000r/min搅拌4s～5s使其充分反应，得到所需的聚氨酯，然后将聚氨酯通过压模得到表面带有中空凸起圆台以及进气孔的降噪层的上半层，圆台的顶面开有出气孔；降噪层的上半层固化成型脱模后再放置在表面水平的降噪层的下半层上，固化后即为完整的聚氨酯硬质泡沫塑料的降噪层。
(3)膨胀珍珠岩的制备
利用靶式气流粉碎机将珍珠岩粉碎。靶式气流粉碎机工作原理：原料从料斗进入，压缩空气经过下部的喷嘴(喷嘴形状为Laval型)后，速度可达几倍音速,空气和物料在混合室内混合并以超音速与固定板(靶)相冲击，颗粒被粉碎。由于气流连续喷射，颗粒在湍流的作用下相互间可进行连续碰撞。被粉碎的颗粒经过上升管进入到分级室，细颗粒进入到收集器,粗颗粒重新回到加料斗，通过循环粉碎，从而达到超微粉碎的目的。
(4)利用热熔胶水将基材2、隔热层3、降噪层4从上至下依次粘合，最后将作为附着层1的双面胶贴在基材2的下表面待用。
以上所述，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何不经过创造性劳动想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求书所限定的保护范围为准。

Claims (7)

1.一种汽车降噪贴膜，其特征在于，其自下而上的结构为：附着层(1)、基材(2)、隔热层(3)、降噪层(4)；在降噪层(4)的表面设有若干进气孔(5)以及凸出于降噪层(4)表面的圆台(6)，圆台(6)的顶部设有出气孔(7)，圆台(6)内部中空并通过底部与进气孔(5)相连通，进气孔(5)大于出气孔(7)。
2.根据权利要求1所述的一种汽车降噪贴膜，其特征在于：圆台(6)高度为5mm-15mm。
3.根据权利要求1所述的一种汽车降噪贴膜，其特征在于：所述的降噪层(4)为聚氨酯硬质泡沫，厚度为1mm-5mm。
4.根据权利要求1所述的一种汽车降噪贴膜，其特征在于：所述的隔热层(3)为膨胀珍珠岩层，厚度为0.5mm。
5.根据权利要求1所述的一种汽车降噪贴膜，其特征在于：所述的基材(2)为掺有纳米二氧化硅的硅橡胶层，厚度为0.5mm。
6.根据权利要求1所述的一种汽车降噪贴膜，其特征在于：所述的附着层(1)为双面胶。
7.一种基于权利要求1-6所述的汽车降噪贴膜的制备方法，其特征在于，包括如下步骤：
(1)制作基材(2)，具体为：
1a)纳米二氧化硅的制备：
将100g的Na2SiO3·9H2O和200g的NH4NO3或NH4Cl置于研钵中混合充分研磨30min，以水为介质在超声波中分散30min，抽滤，依次用水、硝酸，无水乙醇洗涤，在温度303K下干燥2小时后得粗产品，然后将粗产品置于高温炉中于673K～1073K温度煅烧2小时，得到所需的纳米二氧化硅；
1b)将纳米二氧化硅融合到硅橡胶中，具体为：
将200g甲基乙烯基硅橡胶110-2、3g膏状硫化剂、100g纳米二氧化硅按照GB 6038-93标准开炼机上混炼均匀,；用P3555C2型盘式硫化仪测得其正硫化时间t；20小时后在25吨平板硫化机上模压成型,硫化温度为170℃；
(2)制备聚氨酯硬质泡沫作为降噪层(4)：
将100g聚醚多元醇、3.5g的A33、二甲乙醇胺1.7g、2g的T12钢、1.9g硬泡硅油、33.5g一氟二氯乙烷、22.6g的TCPP、4.9g二乙醇胺、1.3g蒸馏水配成组合聚醚，以2000r/min的速率搅拌60s使其混合均匀；另取多亚甲基多苯基异氰酸酯155g置于恒温箱中保持30℃恒温10分钟，而后迅速将配好的组合聚醚和多亚甲基多苯基异氰酸混合，以2000r/min搅拌4s～5s使其充分反应得到所需聚氨酯，然后将聚氨酯通过压模得到表面带有中空凸起圆台(6)以及进气孔(5)的降噪层(4)的上半层，圆台的顶面开有出气孔(7)；降噪层(4)的上半层固化成型脱模后再放置在表面水平的降噪层(4)的下半层上，固化后即为完整的聚氨酯硬质泡沫塑料的降噪层(4)；
(3)利用靶式气流粉碎机将珍珠岩粉碎作为隔热层(3)；
(4)利用热熔胶水将基材(2)、隔热层(3)、降噪层(4)从上至下依次粘合，最后将作为附着层(1)的双面胶贴在基材(2)的下表面待用。
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