CN107458049A - 一种新型通道里板吸音棉的制备方法 - Google Patents

一种新型通道里板吸音棉的制备方法 Download PDF

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CN107458049A
CN107458049A CN201710648997.5A CN201710648997A CN107458049A CN 107458049 A CN107458049 A CN 107458049A CN 201710648997 A CN201710648997 A CN 201710648997A CN 107458049 A CN107458049 A CN 107458049A
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layer
sound
absorbing
hole
cotton
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CN107458049B (zh
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王皆晴
何卫军
李超
李峰
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Hubei God's Will Noise Reduction Vibrationproof New Material Co Ltd
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Hubei God's Will Noise Reduction Vibrationproof New Material Co Ltd
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Abstract

本发明公开了一种新型通道里板吸音棉的制备方法，所述通道里板吸音棉包括棉芯、圆形贯穿孔、双面封边、方形贯穿孔、方形凹槽、圆底凹槽、尖形凹槽、外吸音层、中吸音层、第一吸音内层和第二吸音内层，所述棉芯的中央偏上部位置开设有圆形贯穿孔，所述棉芯的中央偏下部位置开设置有方形贯穿孔，所述棉芯、圆形贯穿孔和方形贯穿孔的外边缘设计为双面封边，所述棉芯右侧偏上部开设有方形凹槽，所述棉芯上侧开设有圆底凹槽，所述棉芯左侧下部开设有尖形凹槽，本发明新型通道里板吸音棉质量轻，材料配比科学，吸音效果和性能好，可装饰性强，折叠切刀加工方便，提升了加工的工作效率，使用绿色材质，降低了污染，提高了环保作用，便于吸音棉回收利用。

Description

一种新型通道里板吸音棉的制备方法
技术领域
本发明涉及吸音材料技术领域，具体涉及一种新型通道里板吸音棉的制备方法。
背景技术
随着社会的进步和人们消费水平不断提高，客户对于汽车吸音隔音、轻量化、舒适度等方面的也要求越来越高。传统PET(聚对苯二甲酸乙二醇酯)/PP(聚丙烯)双组份吸音棉在汽车隔音、降噪领域得到了广泛应用，极大的提升了整车NVH性能。然而，PET聚酯纤维为化学合成纤维熔点高(250℃以上)、降解困难，使得传统PET/PP双组份吸音棉制品封边模具温度高。同时，PET/PP双组份吸音棉边角废料回收困难。
现有的汽车用消音毡棉，具有消音、防火、防震、隔热等，但是消音效果还是达不到预期的效果，防震和隔热效果也不是很好，硬度不够，因此直接影响了产品的使用寿命，现有的车周围辐射较大，很容易对人体造成伤害。
发明内容
为解决上述问题，本发明提出一种新型通道里板吸音棉的制备方法。
为实现本发明目的，采用的技术方案是：一种新型通道里板吸音棉的制备方法，所述棉芯的制备方法如下：
第一步：将聚丙烯塑料放入到喷熔机内进行加热和喷丝，制备直径为2～5um的聚丙烯塑料纤维，将聚丙烯塑料纤维搭建为含有规则斜通孔结构的板型结构的第二吸音内层，将具体设置为不规则多孔片状结构的橡胶海绵层的第一吸音内层复合在第二吸音内层的上端面；
第二步：将规整排列板状结构的矿山石棉纤维层使用粘合剂复合在第一吸音内层的上端面和第二吸音内层下端面，微力压制成松软带有微孔状结构的中吸音层；
第三步：在中吸音层的上端面和下端面分别粘接上外吸音层的粗麻编织布层，使用折叠封刀模上的3mm厚的折叠切刀进行错位封边；
第四步：在设置切刀高度后，将经过折叠切刀封边后的棉芯使用连续冲压机进行断续切压、打孔和成型工艺处理，得到完整的吸音棉。
优选的，所述通道里板吸音棉包括棉芯、圆形贯穿孔、双面封边、方形贯穿孔、方形凹槽、圆底凹槽、尖形凹槽、外吸音层、中吸音层、第一吸音内层和第二吸音内层，所述棉芯的中央偏上部位置开设有圆形贯穿孔，所述棉芯的中央偏下部位置开设置有方形贯穿孔，所述棉芯、圆形贯穿孔和方形贯穿孔的外边缘设计为双面封边，所述棉芯右侧偏上部开设有方形凹槽，所述棉芯上侧开设有圆底凹槽，所述棉芯左侧下部开设有尖形凹槽，所述棉芯的层叠布置设计为外吸音层、中吸音层、第一吸音内层、第二吸音内层、中吸音层和外吸音层的依次从上到下的堆叠。
优选的，所述外吸音层设计为粗麻编织布层，粗麻编织布层的厚度设计为0.5～1.5mm。
优选的，所述中吸音层设计为矿山石棉纤维层，矿山石棉纤维层的厚度设计为2～3mm，矿山石棉纤维层具体为一种规整排列的板状结构。
优选的，所述第一吸音内层设计为橡胶海绵层，橡胶海绵层的厚度设计为2～5mm，橡胶海绵层具体设置为不规则多孔的片状结构。
优选的，所述第二吸音内层设计为聚丙烯塑料纤维层，聚丙烯塑料纤维层的厚度设计为2～5mm，聚丙烯塑料纤维层上开设有规则的斜通孔结构。
优选的，所述棉芯的背面复合有2～5块聚丙烯塑料块，其中，所述的聚丙烯塑料块焊接在钣金上的方式为超声波焊接方法。
本发明的有益效果为：本发明新型吸音棉中合理的原材料选择，合理的原材料配比，所制得的新型吸音棉质量轻，吸音效果和性能好，可装饰性强，加工方便，使用钝刀错位双面封边，增加了吸音棉的美观感受，提升了加工的工作效率，使用绿色材质，降低了污染，提高了环保作用，便于吸音棉的回收利用，迎合了市场需要，优化了工艺设计和生产。
附图说明
图1是本发明新型吸音棉结构示意图。
图2是本发明新型吸音棉内层结构示意图。
图中：1、吸音棉主体；2、方形凹槽；3、圆形贯穿孔；4、梯形凹槽；5、双面封边；6、吸音中层；7、吸音外层；8、吸音内层；9、吸音通孔；10吸音网状孔。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，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他实施例，都属于本发明保护的范围。
实施例1
请参阅图1-2所示，一种新型通道里板吸音棉，所述通道里板吸音棉包括棉芯1、圆形贯穿孔2、双面封边3、方形贯穿孔4、方形凹槽5、圆底凹槽6、尖形凹槽7、外吸音层8、中吸音层9、第一吸音内层10和第二吸音内层11，所述棉芯1的中央偏上部位置开设有圆形贯穿孔2，所述棉芯1的中央偏下部位置开设置有方形贯穿孔4，所述棉芯1、圆形贯穿孔2和方形贯穿孔4的外边缘设计为双面封边3，所述棉芯1右侧偏上部开设有方形凹槽5，所述棉芯1上侧开设有圆底凹槽6，所述棉芯1左侧下部开设有尖形凹槽7，所述棉芯1的层叠布置设计为外吸音层8、中吸音层9、第一吸音内层10、第二吸音内层11、中吸音层9和外吸音层8的依次从上到下的堆叠。
进一步地，所述外吸音层8设计为粗麻编织布层，粗麻编织布层的厚度设计为0.5～1.5mm。
进一步地，所述中吸音层9设计为矿山石棉纤维层，矿山石棉纤维层的厚度设计为2～3mm，矿山石棉纤维层具体为一种规整排列的板状结构。
进一步地，所述第一吸音内层10设计为橡胶海绵层，橡胶海绵层的厚度设计为2～5mm，橡胶海绵层具体设置为不规则多孔的片状结构。
进一步地，所述第二吸音内层11设计为聚丙烯塑料纤维层，聚丙烯塑料纤维层的厚度设计为2～5mm，聚丙烯塑料纤维层上开设有规则的斜通孔结构。
进一步地，所述棉芯1的背面复合有2～5块聚丙烯塑料块，其中，所述的聚丙烯塑料块焊接在钣金上的方式为超声波焊接方法。
本发明提供一种技术方案：一种新型通道里板吸音棉的制备方法，所述棉芯1的制备方法如下：
第一步：将聚丙烯塑料放入到喷熔机内进行加热和喷丝，制备直径为2～5um的聚丙烯塑料纤维，将聚丙烯塑料纤维搭建为含有规则斜通孔结构的板型结构的第二吸音内层11，将具体设置为不规则多孔片状结构的橡胶海绵层的第一吸音内层10复合在第二吸音内层11的上端面；
第二步：将规整排列板状结构的矿山石棉纤维层使用粘合剂复合在第一吸音内层10的上端面和第二吸音内层11下端面，微力压制成松软带有微孔状结构的中吸音层9；
第三步：在中吸音层9的上端面和下端面分别粘接上外吸音层8的粗麻编织布层，使用折叠封刀模上的3mm厚的折叠切刀进行错位封边；
第四步：在设置切刀高度后，将经过折叠切刀封边后的棉芯1使用连续冲压机进行断续切压、打孔和成型工艺处理，得到完整的吸音棉。
实施例2
一种新型通道里板吸音棉，本实施例与实施例1的区别在于，第一吸音内层10采用藻类植物纤维均匀铺设压制成型制得。
藻类植物经过榨干和烘干，得到白色的藻类植物纤维，藻类植物纤维与橡胶海绵层具有同样优异的吸音功能。
实施例3
一种新型通道里板吸音棉，本实施例与实施例1的区别在于，第一吸音内层10采用硅橡胶泡沫塑料材质制得。
硅橡胶塑料高温溶解为液状通入惰性气体后迅速冷却，内部含有气泡结构，得到硅橡胶泡沫塑料，硅橡胶泡沫塑料与橡胶海绵层具有同样优异的吸音功能。
实施例4
一种新型通道里板吸音棉，本实施例与实施例1的区别在于，第一吸音内层10采用聚乳酸酯纤维和聚碳酸酯纤维混合制得。
聚乳酸酯纤维和聚碳酸酯纤维与聚碳酸酯纤维或橡胶海绵层具有同样优异的吸音功能。
实施例5
一种新型通道里板吸音棉，本实施例与实施例1的区别在于，中吸音层9采用聚乳酸酯纤维和聚碳酸酯纤维混合制得。
聚乳酸酯纤维和聚碳酸酯纤维与聚碳酸酯纤维或矿山石棉纤维具有同样优异的吸音功能。
在本发明中，本发明新型吸音棉中合理的原材料选择，合理的原材料配比，所制得的新型吸音棉质量轻，吸音效果和性能好，可装饰性强，加工方便，使用钝刀错位双面封边，增加了吸音棉的美观感受，提升了加工的工作效率，使用绿色材质，降低了污染，提高了环保作用，便于吸音棉的回收利用，迎合了市场需要，优化了工艺设计和生产。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (7)

1.一种新型通道里板吸音棉的制备方法，其特征在于：所述棉芯(1)的制备方法如下：
第一步：将聚丙烯塑料放入到喷熔机内进行加热和喷丝，制备直径为2～5um的聚丙烯塑料纤维，将聚丙烯塑料纤维搭建为含有规则斜通孔结构的板型结构的第二吸音内层(11)，将具体设置为不规则多孔片状结构的橡胶海绵层的第一吸音内层(10)复合在第二吸音内层(11)的上端面；
第二步：将规整排列板状结构的矿山石棉纤维层使用粘合剂复合在第一吸音内层(10)的上端面和第二吸音内层(11)下端面，微力压制成松软带有微孔状结构的中吸音层(9)；
第三步：在中吸音层(9)的上端面和下端面分别粘接上外吸音层(8)的粗麻编织布层，使用折叠封刀模上的3mm厚的折叠切刀进行错位封边；
第四步：在设置切刀高度后，将经过折叠切刀封边后的棉芯(1)使用连续冲压机进行断续切压、打孔和成型工艺处理，得到完整的吸音棉。
2.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述通道里板吸音棉包括棉芯(1)、圆形贯穿孔(2)、双面封边(3)、方形贯穿孔(4)、方形凹槽(5)、圆底凹槽(6)、尖形凹槽(7)、外吸音层(8)、中吸音层(9)、第一吸音内层(10)和第二吸音内层(11)，所述棉芯(1)的中央偏上部位置开设有圆形贯穿孔(2)，所述棉芯(1)的中央偏下部位置开设置有方形贯穿孔(4)，所述棉芯(1)、圆形贯穿孔(2)和方形贯穿孔(4)的外边缘设计为双面封边(3)，所述棉芯(1)右侧偏上部开设有方形凹槽(5)，所述棉芯(1)上侧开设有圆底凹槽(6)，所述棉芯(1)左侧下部开设有尖形凹槽(7)，所述棉芯(1)的层叠布置设计为外吸音层(8)、中吸音层(9)、第一吸音内层(10)、第二吸音内层(11)、中吸音层(9)和外吸音层(8)的依次从上到下的堆叠。
3.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述外吸音层(8)设计为粗麻编织布层，粗麻编织布层的厚度设计为0.5～1.5mm。
4.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述中吸音层(9)设计为矿山石棉纤维层，矿山石棉纤维层的厚度设计为2～3mm，矿山石棉纤维层具体为一种规整排列的板状结构。
5.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述第一吸音内层(10)设计为橡胶海绵层，橡胶海绵层的厚度设计为2～5mm，橡胶海绵层具体设置为不规则多孔的片状结构。
6.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述第二吸音内层(11)设计为聚丙烯塑料纤维层，聚丙烯塑料纤维层的厚度设计为2～5mm，聚丙烯塑料纤维层上开设有规则的斜通孔结构。
7.根据权利要求1所述的一种新型通道里板吸音棉的制备方法，其特征在于：所述棉芯(1)的背面复合有2～5块聚丙烯塑料块，其中，所述的聚丙烯塑料块焊接在钣金上的方式为超声波焊接方法。
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