CN106926518B - 空腔吸音材料阻尼板及其制备方法 - Google Patents
空腔吸音材料阻尼板及其制备方法 Download PDFInfo
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- CN106926518B CN106926518B CN201710155514.8A CN201710155514A CN106926518B CN 106926518 B CN106926518 B CN 106926518B CN 201710155514 A CN201710155514 A CN 201710155514A CN 106926518 B CN106926518 B CN 106926518B
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- cavity
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- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
本发明提供一种空腔吸音材料阻尼板及其制备方法，阻尼板由至上而下依次设置的表层、空腔层、EPDM发泡隔音层、改性环氧树脂粘合层构成。所述表层是聚氯乙烯人造革材料，上面冲有圆孔，所述空腔层设有喇叭型空腔，喇叭型空腔是上宽下窄结构。本发明带来的有益效果是:车内的噪音通过声音振动进入表层内的小圆形孔径结构，然后噪音振动再次进入喇叭形空腔内的宽部空间，噪音能量突然分散，能量损失。由于喇叭空腔的结构是上宽下窄结构，剩余声音能量进入窄部空间能量又会损失。噪音振动通过喇叭型空腔后，EPDM发泡层会吸收噪音中的振动能量而且EPDM发泡层表面粗糙噪音也会发生干涉和漫反射现象来降低噪音的传播。
Description
技术领域
本发明属于隔音降噪材料技术领域,涉及轿车用阻尼板，由其是一种空腔吸音材料阻尼板及其制备方法。
背景技术
在汽车越来越普及的今天，人们对汽车阻尼材料有了更深的认识以及对汽车的安全性舒适性有更高的要求。汽车中阻尼板的主要作用是吸音降噪，汽车在行驶过程中轮胎与地面的接触产生的噪音，发动机振动产生的噪音，车身空腔内空气快速流通产生的噪音等等都会影响车内人员的舒适性。因此在汽车上安装降噪性能优异的阻尼板就显得尤为重要了。在发动机，车棚顶部，翼子板附近安装吸音材料可以有效的降低噪音，提高乘车人员的舒适性。
通过检索，发现如下相关专利文献：
汽车阻尼板及其制作方法(CN102862527A)，将无机填料与热塑性树脂共混制备有机-无机发泡杂化复合材料，将复合材料热熔挤出制成复合型板，将复合型板与毡毯经热压得到多层复合阻尼板。由于生产过程中，未使用粘胶剂，因而，在使用过程中不会释放出毒害气体。所述的无机填料为氧化锌、碳酸钙、钛白粉、石英、金刚砂或者是植物碎片、石粉、有机废料中的一种或多种。所述的热塑性树脂是PE-聚乙烯、PVC-聚氯乙烯、PS-聚苯乙烯、PA-聚酰胺、POM-聚甲醛、PC-聚碳酸酯、聚苯醚、聚砜、橡胶或者是共聚物：共聚酰胺、聚氨酯、SIS共聚物、SBS共聚物、乙烯-醋酸乙烯共聚物EVA中的一种或多种。
一种高效隔音材料及其制作方法(CN103903608A)，高效隔音材料包括隔音层，吸音层，气泡层，所述气泡层位于隔音层与吸音层之间。所述隔音层由隔音复合物制成，所述隔音复合物由包括下述物质的原料制备而成：热塑性树脂，无机填料，发泡剂；所述无机填料15-80wt％；所述发泡剂为5-15wt％，其余为热塑性树脂。该发明中不同粒径的填料对应不同波段或频率的声波，因此对不同频率的声能的消耗比较全面。
复合阻尼板及其制备方法(CN1462772A)，复合阻尼板由面板、阻尼板、底板复合而成，阻尼层是以改性沥青为主料，再混以再生橡胶、废塑料粉、粉煤灰、矿渣等填充料制成。
目前市场主要的阻尼板是橡胶类和沥青类阻尼板，这两类阻尼板都存在着不同的问题，沥青类阻尼板在高温时会产生对人体有害的气体，不耐化学腐蚀，易老化。
通过对比，上述专利与本申请的技术方案显著不同。
发明内容
本发明所要解决的技术问题是提供一种空腔吸音材料阻尼板及其制备方法，具有结构强度高、韧性高、廉价、材质轻、减振、隔音降噪佳的优点。
为解决上述技术问题，本发明提供一种空腔吸音材料阻尼板，由至上而下依次设置的表层、空腔层、EPDM发泡隔音层、改性环氧树脂粘合层四层结构构成。所述表层是聚氯乙烯人造革材料，上面冲有圆孔，所述空腔层设有喇叭型空腔，喇叭型空腔是上宽下窄结构，空腔材料是硬质聚氯乙烯材料。
所述EPDM发泡隔音层材料的组分及重量份数为：
所述短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。
所述白砂糖或盐或淀粉的粒径为200-225目的。
所述表层材料为聚氯乙烯人造革材料，表层的厚度为0.5-1毫米，圆形孔径0.5-1.2毫米，孔间距为10-15毫米。
所述喇叭型空腔层的高度为2-3毫米，宽部直径为10-15毫米，窄部直径为2-5毫米，喇叭型空腔间距为10-15毫米。
所述EPDM发泡隔音层内的厚度为1-2毫米。
所述改性环氧树脂粘合层的厚度0.5-1毫米。
改性环氧树脂粘合层本身固化后具有阻尼作用，同时是粘合剂。改性环氧树脂粘合剂的制备方法如下：丁腈橡胶改性环氧树脂；将丁腈橡胶、促进剂M、硫磺用开炼机混炼均匀，再用醋酸乙酯溶解成为50％溶液；以高速搅拌方法加入F-44环氧树脂中，制成改性环氧树脂。
本空腔吸音材料阻尼板的制备方法包括以下步骤：
1.混炼工序：EPDM为主体材料，同时依次加入碳酸钙、N330炭黑、发泡剂OBSH、发泡助剂NaHCO3、尿素、石蜡、防老剂2246、硬脂酸、氧化锌、DCP、短玄武岩纤维、食盐或白砂糖或淀粉进行混炼，混炼均匀后出料，制成混炼EPDM胶片。
2.发泡工序：将混炼EPDM胶片放入鼓式硫化机中进行EPDM发泡层发泡。
3.煮出工序：将发泡后EPDM发泡隔音层放入水槽中沸水煮沸，干燥。
4.冲压工序：硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构。取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔。
5.热压工序：空腔结构上下两端分别浸入热熔胶U型池中，热熔胶附着在空腔端面，干燥。依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中表层的圆孔要与空腔层的喇叭型空腔结构对齐。
6.涂布工序：将改性环氧树脂粘合剂通过涂布机均匀涂布在EPDM发泡隔音层表面。
本发明带来的有益效果是:
1、车内的噪音通过声音振动进入表层内的小圆形孔径结构，然后噪音振动再次进入喇叭形空腔内的宽部空间，噪音能量突然分散，能量损失。由于喇叭空腔的结构是上宽下窄结构，剩余声音能量进入窄部空间能量又会损失。噪音振动通过喇叭形空腔后，EPDM发泡层会吸收噪音中的振动能量而且EPDM发泡层表面粗糙噪音也会发生干涉和漫反射现象来降低噪音的传播。其中EPDM发泡隔音层内具有多个微孔结构，能够更好的吸收声音在传播过程中的能量。
2、在EPDM发泡隔音层中加入直径0.01-0.05mm，长度10-20mm的短玄武岩纤维材料，使得EPDM发泡隔音层强度增加。
3、在EPDM发泡隔音层中加入粒径200-225目的食盐或白砂糖或淀粉，使得EPDM发泡隔音层材料内含有食盐或白砂糖或淀粉，在沸水煮沸的过程中食盐或白砂糖或淀粉融入沸水中，在EPDM发泡隔音层内形成新的微孔结构。淀粉或白沙糖或盐在SBR/EPDM发泡隔音层中广泛分散，煮沸的过程中产生了形状不规则的微孔结构，声音在传播过程中进入不规则微孔结构发生振动，振动强度会多有不同，声音能量在不规则的微孔结构中会有明显的减少，达到有效的阻尼降噪效果。
4、本阻尼板具有结构强度高、韧性高、廉价、材质轻、减振、隔音降噪佳的优点。
附图说明
图1为本发明的结构示意图。
图中标号为:1-表层，2-空腔层，3-EPDM发泡隔音层，4-改性环氧树脂粘合层，5-圆孔，6-喇叭型空腔。
图2为本发明俯视空腔层示意图。
图3为本发明阻尼板裁切后形状示意图。
图4为本发明阻尼板(虚线部分)粘贴在汽车翼子板内使用状态示意图。
具体实施方式
下面对结合附图对本发明的较佳实施例作详细阐述。
实施例1
如图1所示，一种空腔吸音材料阻尼板，由至上而下依次设置的表层1、空腔层2、EPDM发泡隔音层3、改性环氧树脂粘合层4构成。所述表层是聚氯乙烯人造革材料，在表层上均匀间隔制有多个圆孔5；空腔材料是硬质聚氯乙烯材料，在空腔层与表层圆孔一一对应均匀间隔制有多个喇叭型空腔6。喇叭型空腔上宽下窄。
EPDM发泡隔音层材料是由下面配方组成：EPDM：100公斤、碳酸钙：15公斤、N330炭黑：15公斤、发泡剂OBSH：5公斤、发泡助剂NaHCO3：3公斤、尿素：4公斤、石蜡：3公斤、防老剂2246：4公斤、硬脂酸：6公斤、氧化锌：10公斤、DCP：6公斤、短玄武岩纤维：7公斤、食盐：8公斤。其中短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。食盐需要进行研磨至200-225目的粒径。
1.将上述材料依次加入75升密炼机中进行混炼，混炼温度为85-90℃，混炼时间7-9min。待压延工序使用。
2.发将混炼EPDM胶片放入鼓式硫化机在140-160℃20min内对EPDM层进行发泡。
3.将发泡后的EPDM发泡隔音层放入水槽中沸水煮沸，煮沸5min，煮沸后EPDM发泡层内的食盐融入沸水中，形成新的微孔结构。后经过热风干燥，其中热风温度为98-100℃。
4.硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构。其中喇叭型空腔的高度为3毫米，宽部直径15毫米，窄部直径5毫米。取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔，其中圆形孔径1.2毫米，孔间距为15毫米。
5.冲压形成的喇叭型空腔的两端浸入热熔胶U形池中，浸入后热熔胶附着在喇叭型空腔的两端端面上，干燥，其中温度90-100℃。
6.依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中温度90-100℃，且表层的圆孔要与空腔层的喇叭型空腔结构对齐。
7.将上述材料通过高速涂布机在EPDM发泡隔音层均匀涂布改性环氧树脂粘合层，并且热风干燥，收卷。其中涂布辊间距6.8毫米，干燥温度110℃，收卷辊的收卷线速度20-22m/min。
本实施例所述表层材料为聚氯乙烯人造革，所述表层内的厚度为1毫米，圆形孔径1.2毫米，孔间距为15毫米。所述喇叭型空腔层内的高度为3毫米，宽部直径为15毫米，窄部直径为5毫米，喇叭型空腔间距为15毫米。所述EPDM发泡隔音层内的厚度为2毫米。所述改性环氧树脂粘合层的厚度1毫米。
本阻尼板模切后的形状如图3所示，主体为矩形，在主体的一角制有一弧形的缺口。
实施例2
与实施例1不同的是：
EPDM发泡隔音层材料是由下面配方组成：EPDM：100公斤、碳酸钙：5公斤、N330炭黑：5公斤、发泡剂OBSH：3公斤、发泡助剂NaHCO3：1公斤、尿素：2公斤、石蜡0.5公斤、防老剂2246：0.5公斤、硬脂酸：2公斤、氧化锌：2公斤、DCP：2公斤、短玄武岩纤维：5公斤、白砂糖：3公斤。其中短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。白砂糖需要进行研磨至200-225目的粒径。
1.将上述材料依次加入75升密炼机中进行混炼，混炼温度为85-90℃，混炼时间7-9min。待压延工序使用。
2.发将混炼EPDM胶片放入鼓式硫化机在140-160℃20min内对EPDM层进行发泡。
3.将发泡后的EPDM发泡隔音层放入水槽中沸水煮沸，煮沸5min，煮沸后EPDM发泡层内的白砂糖融入沸水中，形成新的微孔结构。后经过热风干燥，其中热风温度为98-100℃。
4.硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构。其中喇叭型空腔的高度为2毫米，宽部直径10毫米，窄部直径2毫米。取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔，其中圆形孔径0.5毫米，孔间距为10毫米。
5.冲压形成的喇叭型空腔的两端浸入热熔胶U形池中，浸入后热熔胶附着在喇叭型空腔的两端端面上，干燥，其中温度90-100℃。
6.依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中温度90-100℃，且表层的圆孔要与空腔层的喇叭型空腔结构对齐。
7.将上述材料通过高速涂布机在EPDM发泡隔音层均匀涂布改性环氧树脂粘合层，并且热风干燥，收卷。其中涂布辊间距3.8毫米，干燥温度110℃，收卷辊的收卷线速度20-22m/min。
本实施例所述表层材料为聚氯乙烯人造革，所述表层内的厚度为0.5毫米，圆形孔径0.5毫米，孔间距为10毫米。所述喇叭型空腔层内的高度为2毫米，宽部直径为10毫米，窄部直径为2毫米，喇叭型空腔间距为10毫米。所述EPDM发泡隔音层内的厚度为1毫米。所述改性环氧树脂粘合层的厚度0.5毫米。
实施例3
与实施例1不同的是：
EPDM发泡隔音层材料是由下面配方组成：EPDM：100公斤、碳酸钙：10公斤、N330炭黑：8公斤、发泡剂OBSH：3.5公斤、发泡助剂NaHCO3：2公斤、尿素：3公斤、石蜡:1公斤、防老剂2246：2公斤、硬脂酸：4公斤、氧化锌：5公斤、DCP：3公斤、短玄武岩纤维：5.5公斤、淀粉：5公斤。其中短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。淀粉需要进行研磨至200-225目的粒径。
1.将上述材料依次加入75升密炼机中进行混炼，混炼温度为85-90℃，混炼时间7-9min。待压延工序使用。
2.发将混炼EPDM胶片放入鼓式硫化机在140-160℃20min内对EPDM层进行发泡。
3.将发泡后的EPDM发泡隔音层放入水槽中沸水煮沸，煮沸5min，煮沸后EPDM发泡层内的淀粉融入沸水中，形成新的微孔结构。后经过热风干燥，其中热风温度为98-100℃。
4.硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构。其中喇叭型空腔的高度为2.2毫米，宽部直径12毫米，窄部直径3毫米。取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔，其中圆形孔径0.8毫米，孔间距为12毫米。
5.冲压形成的喇叭型空腔的两端浸入热熔胶U形池中，浸入后热熔胶附着在喇叭型空腔的两端端面上，干燥，其中温度90-100℃。
6.依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中温度90-100℃，且表层的圆孔要与空腔层的喇叭型空腔结构对齐。
7.将上述材料通过高速涂布机在EPDM发泡隔音层均匀涂布改性环氧树脂粘合层，并且热风干燥，收卷。其中涂布辊间距4.7毫米，干燥温度110℃，收卷辊的收卷线速度20-22m/min。
本实施例所述表层材料为聚氯乙烯人造革，所述表层内的厚度为0.7毫米，圆形孔径0.8毫米，孔间距为12毫米。所述喇叭型空腔层内的高度为2.2毫米，宽部直径为12毫米，窄部直径为3毫米，喇叭型空腔间距为12毫米。所述EPDM发泡隔音层内的厚度为1.3毫米。所述改性环氧树脂粘合层的厚度0.7毫米。
实施例4
与实施例1不同的是：
EPDM发泡隔音层材料是由下面配方组成：EPDM：100公斤、碳酸钙：12公斤、N330炭黑：11公斤、发泡剂OBSH：4公斤、发泡助剂NaHCO3：2.5公斤、尿素：3.5公斤、石蜡:2公斤、防老剂2246：3公斤、硬脂酸：5公斤、氧化锌：8公斤、DCP：4公斤、短玄武岩纤维：6公斤、食盐：6公斤。其中短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。食盐需要进行研磨至200-225目的粒径。
1.将上述材料依次加入75升密炼机中进行混炼，混炼温度为85-90℃，混炼时间7-9min。待压延工序使用。
2.发将混炼EPDM胶片放入鼓式硫化机在140-160℃20min内对EPDM层进行发泡。
3.将发泡后的EPDM发泡隔音层放入水槽中沸水煮沸，煮沸5min，煮沸后EPDM发泡层内的食盐融入沸水中，形成新的微孔结构。后经过热风干燥，其中热风温度为98-100℃。
4.硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构。其中喇叭型空腔的高度为2.2毫米，宽部直径12毫米，窄部直径3毫米。取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔，其中圆形孔径0.8毫米，孔间距为12毫米。
5.冲压形成的喇叭型空腔的两端浸入热熔胶U形池中，浸入后热熔胶附着在喇叭型空腔的两端端面上，干燥，其中温度90-100℃。
6.依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中温度90-100℃，且表层的圆孔要与空腔层的喇叭型空腔结构对齐。
7.将上述材料通过高速涂布机在EPDM发泡隔音层均匀涂布改性环氧树脂粘合层，并且热风干燥，收卷。其中涂布辊间距5.4毫米，干燥温度110℃，收卷辊的收卷线速度20-22m/min。
本实施例所述表层材料为聚氯乙烯人造革，所述表层内的厚度为0.8毫米，圆形孔径1毫米，孔间距为13毫米。所述喇叭型空腔层内的高度为2.5毫米，宽部直径为13毫米，窄部直径为4毫米，喇叭型空腔间距为13毫米。所述EPDM发泡隔音层内的厚度为1.5毫米。所述改性环氧树脂粘合层的厚度0.8毫米。
Claims (9)
1.一种空腔吸音材料阻尼板，其特征在于：由至上而下依次设置的表层、空腔层、EPDM发泡隔音层、改性环氧树脂粘合层构成，在表层上均匀间隔制有多个圆孔，在空腔层均匀间隔制有多个上宽下窄的喇叭形空腔，空腔与圆孔一一对应；
所述EPDM发泡隔音层材料的组分及重量份数为：
2.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述的短玄武岩纤维的直径0.01-0.05mm，长度10-20mm。
3.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述食盐或淀粉或白砂糖粒径为200-225目。
4.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述表层的厚度为0.5-1毫米。
5.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述圆孔的孔径0.5-1.2毫米，孔间距为10-15毫米。
6.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述喇叭形空腔的上宽部直径为10-15毫米，下窄部直径为2-5毫米，喇叭型空腔间距为10-15毫米，所述空腔层的厚度为2-3毫米。
7.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述EPDM发泡隔音层的厚度为1-2毫米。
8.根据权利要求1所述的空腔吸音材料阻尼板，其特征在于：所述的改性环氧树脂粘合层的厚度0.5-1毫米。
9.根据权利要求1-8任一权利要求所述的空腔吸音材料阻尼板，其特征在于：制备方法包括以下步骤：
1)混炼工序：EPDM为主体材料，同时依次加入碳酸钙、N330炭黑、发泡剂OBSH、发泡助剂NaHCO3、尿素、石蜡、防老剂2246、硬脂酸、氧化锌、DCP、短玄武岩纤维、食盐或淀粉或白砂糖进行混炼，混炼均匀后出料，制成混炼EPDM胶片；
2)发泡工序：将混炼EPDM胶片放入鼓式硫化机中进行EPDM发泡层发泡；
3)煮出工序：将发泡后EPDM发泡隔音层放入水槽中沸水煮沸，干燥；
4)冲压工序：硬质聚氯乙烯通过冲压机的模具冲成上下通透的多个喇叭型空腔结构，取表层聚氯乙烯人造革材料放置在冲孔机上进行机械冲孔；
5)热压工序：空腔结构上下两端分别浸入热熔胶U型池中，热熔胶附着在空腔端面，干燥；依次将表层，空腔层，EPDM发泡隔音层叠加放置在热压机升温进行施压，将表层，空腔层，EPDM发泡隔音层通过热熔胶合为一体，其中表层的圆孔要与空腔层的喇叭型空腔结构对齐；
6)涂布工序：将改性环氧树脂粘合剂通过涂布机均匀涂布在EPDM发泡隔音层表面。
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| CN104616648A (zh) * | 2014-12-26 | 2015-05-13 | 北京市劳动保护科学研究所 | 一种复合吸声板 |
| CN204904826U (zh) * | 2015-07-30 | 2015-12-23 | 贵州大学 | 一种二元嵌入式圆柱空腔吸声覆盖层 |
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