CN107083019B - sound insulation composite material and preparation method thereof - Google Patents
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Abstract
A sound-insulating composite material is prepared from foamed resin system and three-dimensional fibre fabric through pre-solidifying three-dimensional fibre fabric by polymer system, injecting the foamed resin system into the hollow sandwich structure of three-dimensional fibre fabric, and in-situ foaming for compounding and solidifying.
Description
Technical Field
The invention belongs to the field of functional materials, and particularly relates to sound insulation composite materials and a preparation method thereof.
Background
At present, the sound insulation and absorption material application field is more and more universal, and people also have made great development in the research of sound insulation and absorption material aspect, therefore the face of its advantage has also been shown to the combined material, when having satisfied the requirement in the aspect of sound insulation and absorption, the combined material can show good toughness, outstanding mechanical behavior, consequently, has positive impetus to the material research to the research of sound insulation and absorption combined material.
Because the sound insulation performance of the material follows the quality theorem, in the existing sound insulation material, the materials such as the sound insulation wall, the sound insulation plate and the like have the characteristics of large mass, large thickness and the like, the size can not be cut according to the requirement in practical application, the application range is narrow, the manufacturing process is complex, and a large amount of rapid production can not be realized. The sound insulation film with good performance is researched by Nippon Shijing Kogyo, can have good sound insulation performance and can be cut completely according to requirements, but the sound insulation film is high in manufacturing cost.
Disclosure of Invention
The invention aims to provide sound insulation composite materials which have excellent sound insulation performance, good rigidity and toughness, low cost of related raw materials, simple preparation method and suitability for application in .
In order to achieve the purpose, the invention adopts the technical scheme that:
A sound insulation composite material is prepared from foamed resin system and three-dimensional fabric as raw materials, which contains upper and lower surfaces and hollow sandwich layer, through coating polymer system on the upper and lower surfaces of three-dimensional fabric, solidifying, pouring foamed resin system in the hollow sandwich layer, and heating for foaming.
In the scheme, the total thickness of the sound insulation composite material is 3-50 mm.
In the scheme, the hollow interlayer between the upper surface and the lower surface of the three-dimensional fiber fabric is formed by connecting continuous fiber core columns; the thickness of the upper surface and the lower surface is 0.1-0.2mm, the aperture of the meshes of the upper surface and the lower surface is 3-5mm, the length of the fiber is 20-100cm, and the diameter is 5-30 mu m.
In the scheme, after the three-dimensional fiber fabric is cured and formed, the thickness of the upper surface and the lower surface of the three-dimensional fiber fabric is 0.3-0.6 mm.
In the scheme, the thickness of the hollow interlayer of the three-dimensional fiber fabric subjected to curing molding is 2-48 mm.
In the above scheme, the porosity of the foaming resin system is 58-79%, the pore diameter of the cells can reach 500-600 μm, and the cells are distributed uniformly.
In the above scheme, the foaming resin system comprises the following components in parts by weight: 100 parts of resin, 20-60 parts of curing agent, 2-5 parts of foaming agent A, 1-2.5 parts of foaming agent B and 2-4 parts of foam stabilizer.
In the above scheme, the polymer system comprises the following components in parts by weight: 100 parts of resin and 20-60 parts of curing agent, and the system is the same as the foaming resin system, except that no foaming agent or foam stabilizer is added.
In the above scheme, the epoxy resin, polyurethane, phenolic resin or unsaturated polyester resin; polyurethane, bisphenol A type epoxy resin, bisphenol F type epoxy resin, etc. may be used.
Preferably, the resin is bisphenol A type E-51 epoxy resin.
In the above scheme, the curing agent is a normal-temperature or high-temperature curing agent for the selected resin, and if the selected resin is bisphenol a epoxy resin, the curing agent can be modified polyamide or dicyandiamide.
In the scheme, the foaming agent A can be a physical foaming agent such as dichloromethane, trichlorotrifluoromethane or dichlorodifluoromethane; the foaming temperature of the adopted physical foaming agent is very small in difference with the temperature of the solidified gel of the epoxy resin, so that a stable porous structure can be obtained.
Preferably, the foaming agent A is dichloromethane.
In the scheme, the foaming agent B is a foaming agent with the foaming temperature 10-20 ℃ higher than that of the foaming agent A, and if the selected foaming agent A is dichloromethane, the foaming agent B can select cyclopentane, and by adopting the two foaming agents together, the closed-cell foam obtained by the original single foaming agent can be converted into open-cell foam, so that the open-cell foam material with good sound insulation can be obtained.
Preferably, the blowing agent B is cyclopentane.
In the scheme, the foam stabilizer is tween-20, silicone oil, tween-80 or L-64 and the like; the adopted stabilizer can ensure that pores obtained by foaming are fine and uniform, and when the system is in a low viscosity stage, the pore walls can be stabilized, so that the pores can grow to a proper degree.
Preferably, the foam stabilizer is silicone oil.
The preparation method of the novel sound insulation composite materials comprises the following steps:
1) firstly, uniformly coating a polymer system on the upper surface and the lower surface of the three-dimensional fiber fabric to carry out curing molding on the three-dimensional fiber fabric;
2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components are as follows: 100 parts of resin, 20-60 parts of curing agent, 2-5 parts of foaming agent A, 1-2.5 parts of foaming agent B and 2-4 parts of foam stabilizer;
3) uniformly stirring and mixing the weighed resin, foaming agent A, foaming agent B and foam stabilizer under the condition of 300-600r/min, and then adding curing agent to continuously stir uniformly to obtain a resin foaming system;
4) and (2) injecting the obtained resin foaming system into the hollow interlayer of the three-dimensional fiber fabric solidified and formed in the step 1), then heating to 40-50 ℃ for foaming for 50-60min, continuing heating to 60-80 ℃ after the resin foaming system begins to be coagulated for secondary foaming for 50-60min, and finally cooling, solidifying and forming to obtain the sound insulation composite material.
In the scheme, the addition amount of the resin foaming system is based on the space of the hollow interlayer filled with the three-dimensional fiber fabric hollow interlayer structure and filled with the three-dimensional fiber fabric hollow interlayer by in-situ foaming.
In the scheme, the injection amount of the resin foaming system can be selected to be 1.5-3 times of the mass of the three-dimensional fiber fabric.
The principle of the invention is as follows:
the porosity, the cell structure, the pore diameter and the like of the foam system are adjusted, the cell size of the obtained foam resin system can reach 500-.
Compared with the prior art, the invention has the beneficial effects that:
1) the invention adopts the three-dimensional fiber fabric as the reinforcement, compared with the traditional foam interlayer, the honeycomb interlayer and the like, the structure is more stable, and the phenomenon of separation of the surface layer and the core layer can not occur; the failure process of a three-dimensional structure is gradual and better maintains the integrity of the original structure than a two-dimensional fiber reinforced structural composite.
2) The invention adopts two types of foaming agents to prepare the foaming resin system for the first time, and carries out in-situ foaming compounding in the hollow sandwich structure of the three-dimensional fiber fabric to obtain the open-cell foam filling compound system with good sound insulation performance, and the sound insulation performance of the material is greatly improved by using very little cost.
3) The novel sound insulation composite material obtained by the invention has excellent sound insulation performance, better rigidity and toughness, low cost of related raw materials, simple preparation method and suitability for application.
Drawings
Fig. 1 is a schematic cross-sectional structure diagram of a product obtained in example 1 of the present invention, in which 1 is a cured three-dimensional fiber fabric surface layer, 2 is a fiber core column, and 3 is a resin foaming system.
FIG. 2 is a graph showing the comparison between the sound insulation properties at frequencies of 125Hz to 6000Hz of the product obtained in example 1 of the present invention and those of the foamed sound insulation material of the same size obtained in comparative example 1.
FIG. 3 is a graph showing the comparison between the sound insulation performance of the product obtained in example 2 of the present invention at a frequency of 125Hz to 6000Hz and the sound insulation performance of the foamed sound insulation material of the same size obtained in comparative example 2.
FIG. 4 is a graph showing the comparison between the sound insulation properties at frequencies of 125Hz to 6000Hz of the product obtained in example 3 of the present invention and those of the foamed sound insulation material of the same size obtained in comparative example 3.
Detailed Description
The invention is further illustrated at in conjunction with the figures and examples, but the invention is not limited to the examples below.
In the following examples, the resin used was bisphenol a type E51 epoxy resin, and the curing agent was modified polyamide; before use, bisphenol A type E51 epoxy resin and curing agent modified polyamide are cured, and the curing temperature range is determined to be 40-80 ℃ by DSC.
In the following examples, the blowing agent A used was methylene chloride, the blowing agent B was cyclopentane, and the stabilizer was silicone oil.
The adopted three-dimensional fiber fabric is a commercially available three-dimensional glass fiber fabric which is a three-dimensional braided fabric with a hollow structure formed by continuously braiding glass fibers and comprises an upper surface, a lower surface and a hollow interlayer, wherein the upper surface and the lower surface are connected by a continuous fiber core column positioned in the hollow interlayer; the thickness of the surface layer (the upper surface and the lower surface) of the fiber fabric is 0.1-0.2mm, the aperture of the meshes of the upper surface and the lower surface is 4mm, the length of the fiber is 20-100cm, the height of the fiber core column is 4.2mm, and the diameter of the fiber core column is 5-30 mu m; the thickness of the upper surface and the lower surface of the three-dimensional fiber fabric is 0.3-0.4 mm, and the three-dimensional fiber fabric is obtained by brushing a polymer system and curing and molding the upper surface and the lower surface.
Example 1
A sound insulation composite material, the preparation method comprises the following steps:
1) firstly, brushing a polymer system for a three-dimensional fiber fabric, and curing and molding the polymer system with the upper surface and the lower surface to form the three-dimensional fiber fabric with a hollow sandwich structure, wherein the polymer system is formed by uniformly mixing 100 parts by weight of resin and 30 parts by weight of curing agent;
2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components are as follows: 100 parts of resin, 30 parts of curing agent, 2 parts of foaming agent A, 1 parts of foaming agent B and 2 parts of stabilizer;
3) uniformly stirring and mixing the weighed resin, foaming agent A, foaming agent B and foam stabilizer under the condition of 300-600r/min, and then adding curing agent to continuously stir uniformly to obtain a resin foaming system;
4) and injecting the obtained resin foaming system into a hollow sandwich structure of the cured and molded three-dimensional fabric (the injection amount is 1.5 times of the mass of the three-dimensional fiber fabric), heating to 40 ℃ for foaming for 60min, continuing heating to 60 ℃ after the resin foaming system begins to coagulate for secondary foaming for 60min, and curing and molding to obtain the novel sound insulation composite material (the structural schematic diagram is shown in figure 1), wherein the total thickness of the obtained composite material is 5mm, the porosity of the resin foaming system obtained by foaming is 58%, and the pore diameter of each pore is 500-600 mu m.
Comparative example 1
foamed sound insulating material, which has the same formulation as the resin foaming system in example 1 except that no foaming agent B is added and no secondary foaming step is required in the preparation process.
The mechanical property and sound insulation performance tests of the foamed sound insulation material obtained in the embodiment and the foamed sound insulation material obtained in the comparative example are respectively carried out, and the results show that: the sound insulation volume of the product obtained by the invention can reach 48Hz at the highest at 125Hz, and the average sound insulation volume also reaches 44.54Hz (see figure 2), which is far higher than that of a foaming sound insulation system of non-composite three-dimensional fiber fabric; and the bending strength can reach 135.86MPa, which is improved by 312.4 percent compared with the comparative example 1.
Example 2
novel sound insulation composite material, the preparation method comprises the following steps:
1) firstly, brushing a polymer system for a three-dimensional fiber fabric, and curing and molding the polymer system with the upper surface and the lower surface to form the three-dimensional fiber fabric with a hollow sandwich structure, wherein the polymer system is formed by uniformly mixing 100 parts by weight of resin and 30 parts by weight of curing agent;
2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components are as follows: 100 parts of resin, 30 parts of curing agent, 3 parts of foaming agent A, 1.5 parts of foaming agent B and 3 parts of stabilizing agent;
3) uniformly stirring and mixing the weighed resin, foaming agent A, foaming agent B and foam stabilizer under the condition of 300-600r/min, and then adding curing agent to continuously stir uniformly to obtain a resin foaming system;
4) and injecting the obtained resin foaming system into a hollow sandwich structure of the cured and molded three-dimensional fabric (the injection amount is 1.5 times of the mass of the three-dimensional fiber fabric), heating to 40 ℃ for foaming for 60min, continuing heating to 60 ℃ after the resin foaming system begins to coagulate, performing secondary foaming for 60min, and curing and molding to obtain the novel sound insulation composite material, wherein the total thickness of the obtained composite material is 5mm, the porosity of the resin foaming system obtained by foaming is 68%, and the pore diameter of each pore is 500-600 mu m.
Comparative example 2
foamed sound insulation materials, which have the same formulation as the resin foaming system in example 2, except that the foaming agent B is not added and the preparation method does not need to perform a secondary foaming step.
The mechanical property and sound insulation performance of the product obtained in the embodiment and the foamed sound insulation material obtained in the comparative example 2 are respectively tested, and the results show that: the sound insulation volume of the product obtained by the invention can reach 53Hz at 125Hz, and the average sound insulation volume also reaches 50.58Hz (see figure 3), which is far higher than that of a foaming resin system of the non-composite three-dimensional fiber fabric; and the bending strength can reach 131.34MPa, which is improved by 298.6% compared with comparative example 2.
Example 3
novel sound insulation composite material, the preparation method comprises the following steps:
1) firstly, brushing a polymer system for a three-dimensional fiber fabric, and curing and molding the polymer system with the upper surface and the lower surface to form the three-dimensional fiber fabric with a hollow sandwich structure, wherein the polymer system is formed by uniformly mixing 100 parts by weight of resin and 30 parts by weight of curing agent;
2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components are as follows: 100 parts of resin, 30 parts of curing agent, 4 parts of foaming agent A, 2 parts of foaming agent B and 4 parts of stabilizing agent;
3) uniformly stirring and mixing the weighed resin, foaming agent A, foaming agent B and foam stabilizer under the condition of 300-600r/min, and then adding curing agent to continuously stir uniformly to obtain a resin foaming system;
4) and injecting the obtained resin foaming system into a hollow sandwich structure of the cured and molded three-dimensional fabric (the injection amount is 1.5 times of the mass of the three-dimensional fiber fabric), heating to 40 ℃ for foaming for 60min, continuing heating to 60 ℃ after the resin foaming system begins to coagulate, performing secondary foaming for 60min, and curing and molding to obtain the novel sound insulation composite material, wherein the total thickness of the obtained composite material is 5mm, the porosity of the resin foaming system obtained by foaming is 79%, and the pore diameter of each pore is 500-600 mu m.
Comparative example 3
foamed sound insulation materials, which have the same formulation as the resin foaming system in example 3, except that the foaming agent B is not added and the preparation method does not need to perform a secondary foaming step.
The mechanical property and sound insulation performance tests of the product obtained in the embodiment and the foamed sound insulation material obtained in the comparative example 3 are respectively carried out, and the results show that: the sound insulation volume of the product obtained by the invention can reach 45.08Hz at the highest at 125Hz, and the average sound insulation volume also reaches 42.17Hz (see figure 4), which is far higher than that of a foaming resin system of non-composite three-dimensional fiber fabric; and the bending strength can reach 128.82MPa, which is improved by 285.0% compared with the comparative example 3.
The above embodiments are merely examples for clearly illustrating the present invention and do not limit the present invention. Other variants and modifications of the invention, which are obvious to those skilled in the art and can be made on the basis of the above description, are not necessary or exhaustive for all embodiments, and are therefore within the scope of the invention.
Claims (6)
- The sound insulation composite material is characterized by taking a foaming resin system and a three-dimensional fiber fabric as raw materials, wherein the three-dimensional fiber fabric comprises an upper surface, a lower surface and a hollow interlayer, the polymer system is uniformly coated on the upper surface and the lower surface of the three-dimensional fiber fabric to cure and form the three-dimensional fiber fabric, then the prepared foaming resin system is injected into the hollow interlayer of the three-dimensional fiber fabric which is cured and formed, and then the temperature is raised to enable the foaming resin system to foam in the hollow interlayer and be compounded and cured with the three-dimensional fiber fabric to obtain the sound insulation composite material, and the specific preparation method comprises the following steps:1) firstly, uniformly coating a polymer system on the upper surface and the lower surface of the three-dimensional fiber fabric to carry out curing molding on the three-dimensional fiber fabric; the polymer system comprises the following components in parts by weight: 100 parts of resin and 20-60 parts of curing agent;2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components comprise: 100 parts of resin, 20-60 parts of curing agent, 2-5 parts of foaming agent A, 1-2.5 parts of foaming agent B and 2-4 parts of foam stabilizer;3) uniformly mixing the weighed resin, the foaming agent A, the foaming agent B and the foam stabilizer at a stirring speed of 300-600r/min, and then adding the curing agent to continuously stir uniformly to obtain a resin foaming system;4) injecting the obtained resin foaming system into the hollow interlayer of the three-dimensional fiber fabric solidified and formed in the step 1), then heating to 40-50 ℃ for foaming for 50-60min, continuing heating to 60-80 ℃ after the resin foaming system begins to coagulate, carrying out secondary foaming for 50-60min, and finally cooling and solidifying for forming to obtain the sound insulation composite material;the foaming agent A is dichloromethane or dichlorodifluoromethane; the foaming agent B is cyclopentane, vinyl chloride or fluorocarbon;the hollow interlayer between the upper surface and the lower surface of the three-dimensional fiber fabric is formed by connecting continuous fiber core columns; the thickness of the upper surface and the lower surface is 0.1-0.2mm, the aperture of the fiber woven mesh of the upper surface and the lower surface is 3-5mm, the length of the fiber is 20-100cm, and the diameter is 5-30 μm.
- 2. The sound-insulating composite of claim 1, wherein the sound-insulating composite has a thickness of 3-50 mm.
- 3. The sound-insulating composite material as claimed in claim 1, wherein the porosity of the foamed resin system is 58-79% and the cell diameter is 500-600 μm.
- 4. The sound insulating composite of claim 1, wherein the resin is an epoxy, polyurethane, phenolic, or unsaturated polyester resin.
- 5. The sound-insulating composite material according to claim 1, wherein the foam stabilizer is tween-20, silicone oil, tween-80 or L-64.
- 6. A method for preparing the sound insulation composite material as claimed in any of claims 1-5, which comprises the following steps:1) firstly, uniformly coating a polymer system on the upper surface and the lower surface of the three-dimensional fiber fabric to carry out curing molding on the three-dimensional fiber fabric;2) weighing the components of the resin foaming system according to the proportion, wherein the components and the weight parts of the components comprise: 100 parts of resin, 20-60 parts of curing agent, 2-5 parts of foaming agent A, 1-2.5 parts of foaming agent B and 2-4 parts of foam stabilizer;3) uniformly mixing the weighed resin, the foaming agent A, the foaming agent B and the foam stabilizer at a stirring speed of 300-600r/min, and then adding the curing agent to continuously stir uniformly to obtain a resin foaming system;4) injecting the obtained resin foaming system into the hollow interlayer of the three-dimensional fiber fabric solidified and formed in the step 1), then heating to 40-50 ℃ for foaming for 50-60min, continuing heating to 60-80 ℃ after the resin foaming system begins to coagulate, carrying out secondary foaming for 50-60min, and finally cooling, solidifying and forming to obtain the sound insulation composite material.
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| CN111349312B (en) * | 2018-12-24 | 2024-03-15 | 湖南莱科新材料科技有限公司 | Fiber reinforced structural foam material with three-dimensional network structure |
| CN110065287A (en) * | 2019-05-27 | 2019-07-30 | 重庆理工大学 | A kind of bubble core phase transformation sandwich structure composite material and preparation method thereof |
| CN110978672A (en) * | 2019-12-17 | 2020-04-10 | 南京工程学院 | Integrally formed sandwich structure and process |
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| CN201371607Y (en) * | 2009-01-20 | 2009-12-30 | 苏州美克思科技发展有限公司 | Phenolic foam sandwich fiber three-dimensional enhanced composite material |
| CN101717523A (en) * | 2009-11-13 | 2010-06-02 | 苏州浩海高分子材料研究所有限公司 | Manufacture process of three-dimensional sandwich fabric material filled with phenolic foam |
| CN101736476A (en) * | 2010-01-10 | 2010-06-16 | 常州同维佳业新材料科技有限公司 | Foam filled stereoscopic reinforced material |
| CN103865144A (en) * | 2012-12-13 | 2014-06-18 | 江南大学 | Mesh type three-dimensional woven grid fabric reinforced lightweight plate and preparation method thereof |
| CN105802136A (en) * | 2016-04-26 | 2016-07-27 | 东华大学 | Preparation method of three-dimensional fabric enhanced porous composite material |
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