CN108003405A - 柔性吸声材料及其制备方法和应用 - Google Patents
柔性吸声材料及其制备方法和应用 Download PDFInfo
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Abstract
本发明公开了一种柔性吸声材料及其制备方法和应用,该柔性吸声材料包括以下重量份的组分:橡胶20~35份,塑料10~20份,增强纤维5~10份,重质粉体5~10份,发泡剂10~20份,塑化剂10~20份,热稳定剂1~2份,促进剂1~2份,硫化剂1~2份,和偶联剂1~2份。制备方法包括:(1)原料称取;(2)硫化前混炼处理;(3)硫化发泡处理;(4)剥离试样上下表面;(5)吸声通道处理。该柔性吸声材料具有重量轻、吸声效果好、强度高、阻燃和抗老化性能好、可折叠和收卷等优点,可作为吸声构件原材料或直接作为吸声构件广泛使用。
Description
技术领域
本发明属于吸声新材料技术领域,尤其涉及一种柔性吸声材料及其制备方法和应用。
背景技术
目前国内声屏障的吸声材料主要是超细玻璃棉、岩棉等无机纤维类多孔吸声材料,这类材料吸声性能非常好,但由于此类材料质轻、性脆、易折断飞扬,对施工人员刺激性大,容易造成皮肤瘤痒、刺红。再者,如果用于象声屏障这样的立面结构,由于材料下沉,容易出现漏声现象,影响使用效果。可见无机纤维类多孔吸声材料虽然仍在使用,但从长远的眼光看其使用必然要受到很大程度的限制。为了改进玻璃棉、岩棉、矿棉等传统多孔吸声材料的缺点,泡沫玻璃、泡沫金属等泡沫类多孔吸声材料,以及多孔陶瓷、多孔石膏等颗粒类吸声材料得到了迅速的发展,但上述材料重量大且吸声效果较差。因此需要开发出轻质环保的新型吸声材料。
发明内容
本发明要解决的技术问题是克服现有技术的不足,提供一种重量轻、吸声效果好、强度高、阻燃和抗老化性能好、可折叠和收卷的柔性吸声材料,还相应提供该柔性吸声材料的制备方法及应用。
为解决上述技术问题,本发明采用以下技术方案:
一种柔性吸声材料,包括以下重量份的组分:
橡胶20~35份,
塑料10~20份,
增强纤维5~10份,
重质粉体5~10份,
发泡剂10~20份,
塑化剂10~20份,
热稳定剂1~2份,
促进剂1~2份,
硫化剂1~2份,和
偶联剂1~2份。
上述的柔性吸声材料,优选的,所述增强纤维为铝纤维、碳纤维、聚酯纤维、硅酸盐纤维中的一种或多种。
上述的柔性吸声材料,优选的,所述重质粉体为超细石墨烯粉体、超细三氧化二铝粉体、超细铁粉体中的一种或多种;所述重质粉体的粒径为100nm~100μm。
上述的柔性吸声材料,优选的,还包括:杀菌剂1~2份。
上述的柔性吸声材料,优选的,所述橡胶为硅橡胶、氟橡胶、丁腈橡胶、氯丁橡胶或三元乙丙橡胶中的一种或多种;所述塑料为聚碳酸树酯、聚氯乙烯、聚丙烯、聚乙烯、聚苯乙烯、聚氨酯中的一种或多种。
上述的柔性吸声材料,优选的,所述发泡剂为碳酸氢铵、偶氮二异丁腈、偶氮二甲酰胺中的一种或多种;所述塑化剂为邻苯二甲酸二丁酯、邻苯二甲酸二辛酯、己二酸二辛酯中的一种;所述热稳定剂为钙锌粉、有机锡、有机锑中的一种;所述促进剂为二硫化二苯并噻唑、N-环已基-2-苯并噻唑次磺酰胺、四甲基二硫化秋兰姆中的一种;所述的硫化剂为升华硫、氧化锌、氧化镁中的一种或多种;所述偶联剂为铬络合物偶联剂、硅烷偶联剂、钛酸酯偶联剂中的一种。
上述的柔性吸声材料,优选的,所述抗菌剂为纳米银、载银磷酸盐、四氯苯二腈中的一种。
作为一个总的发明构思,本发明还提供一种上述的柔性吸声材料的制备方法,包括以下步骤:
(1)先将橡胶、塑料、塑化剂、热稳定剂置于开炼机中,在温度为120~180℃,速度为10~30r/min下混炼1~5min后,加入增强纤维、重质粉体和偶联剂,维持温度和转速不变,混炼2~10min,冷却至室温,得到预混料;
(2)在步骤(1)所得的预混料中加入发泡剂、促进剂和硫化剂,在30~90℃,转速为10~30r/min下混炼2~10min,室温放置12~36h后,在室温转速为10~30r/min下继续混炼2~10min,最后置于平板硫化机上模压发泡成片,模压温度为120~180℃,压力为5~15MPa,时间为10~30min,室温冷却12~36h后得到硫化试样;
(3)将步骤(2)所得的硫化试样的上下表面剥离,所述上下表面剥离厚度均为1~2mm,得到柔性吸声材料中间体;
(4)对步骤(3)所得的柔性吸声材料中间体进行物理挤压,开炼机的滚轮间距为柔性吸声材料中间体厚度的1/4~2/3,室温下转速为10~30r/min,以形成表面开孔且相邻孔洞互相连通的吸声结构,得到柔性吸声材料。
上述的柔性吸声材料,优选的,所述步骤(2)中,还包括在预混料中加入抗菌剂。
作为一个总的发明构思,本发明还提供一种上述的柔性吸声材料或上述的制备方法制得的柔性吸声材料在成型吸声构件或作为吸声构件的应用。
本发明的创新点在于:
本发明通过发泡剂化学反应产生的气体在橡胶和塑料共混物中形成气泡,然后在材料成型后通过切片和物理挤压形成表面开孔且孔洞互相连通的吸声结构,使声能进入孔洞后不断折射、反射以及摩擦生热而耗散掉。通过添加增强纤维(如为铝纤维、碳纤维、聚酯纤维、硅酸盐纤维等)和重质粉体(如石墨烯、三氧化二铝、铁粉等),既能增加材料的密度,同时分散在混料中的增强纤维和超细粉体能形成多层不同界面的声反射,增加了声能量的消耗,因此能进一步提高材料的吸声量。同时因为增强纤维的添加,通过增强纤维形成的交联网状结构,提升了材料的抗压和抗拉性能好。而且相比泡沫玻璃、泡沫金属等吸声材料,本发明的材料具有良好的粘弹性,可更好的消耗声能。
与现有技术相比,本发明的优点在于:
1、本发明的柔性吸声材料,以橡胶和塑料共混物为复合基体,以纤维增强剂和重质粉体为辅助填料以提高声能消耗,添加发泡剂形成吸声通道,以塑化剂、热稳定剂、促进剂、硫化剂、偶联剂、杀菌剂为主要助剂,所成型的柔性吸声材料具有重量轻、吸声性能好,且能方便进行折叠和收卷等优点,所成型的吸声构件和降噪设施易于安装和拆卸,尤其适用于需要快速安装和拆卸的使用环境;同时还具有阻燃、抗老化性能好、抗压和抗拉性能好等优点。
2、与常规化学方法和物理方法相比,本发明的柔性吸声材料的开孔制备方法,避免了额外增加发泡剂或外加气体等,采用剥离挤压工艺,剥除了表面致密层后,通过适当的机械压力挤压,既能破坏孔间薄弱部位形成通孔,又能不完全破坏材料联结结构而使材料破碎,因而能简单方便的实现通孔吸声结构,能显著提高吸声效果。
具体实施方式
以下结合具体优选的实施例对本发明作进一步描述,但并不因此而限制本发明的保护范围。
实施例1:
一种本发明的柔性吸声材料的制备方法,包括以下步骤:
(1)按照如下重量配比称取原料:丁腈橡胶30份,聚氯乙烯20份,铝纤维5份,超细金属铁粉(2um)10份,偶氮二甲酰胺10份,氯化石蜡15份,钙锌粉2份,二硫化二苯并噻唑2份,升华硫2份,硅烷偶联剂(KH570)2份,纳米银2份。
(2)硫化前处理:先将丁腈橡胶、聚氯乙烯、氯化石蜡、钙锌粉放入开炼机(温度为160℃,速度为20r/min)中捏合2min后,加入铝纤维、超细金属铁粉和硅烷偶联剂(KH570),继续捏合5min。
(3)硫化处理:待混料冷却至室温后,在开炼机(温度为60℃,速度为20r/min)中按相应配比添加偶氮二甲酰胺、升华硫、二硫化二苯并噻唑和纳米银,捏合5min;在室温放置24h后,在开炼机(室温,速度为20r/min)捏合5min,然后置于平板硫化机(温度为160℃,压力为10MPa)上模压发泡成型,时间为15min。
(4)硫化后处理:取出试样,室温冷却24h,用切边机将所得的片材上下两层外表层剥离,每层剥离厚度为1mm。
(5)吸声通道处理:最后将步骤(4)剥离表面后所得的中间层25mm通过开炼机的挤压使部分发泡孔壁破裂形成通孔但不破坏材料的整体结构,开炼机的滚轮间距为8mm,室温下转速为20r/min。
样品为8mm时性能参数如表1所示。
表1实施例1制备的柔性吸声材料的性能表
实施例2:
一种本发明的柔性吸声材料的制备方法,包括以下步骤:
(1)按照如下重量配比称取原料:丁腈橡胶30份,聚氯乙烯20份,碳纤维5份,纳米石墨烯粉体(200nm)10份,碳酸氢铵10份,己二酸二辛酯15份,钙锌粉2份,二硫化二苯并噻唑2份,升华硫2份,硅烷偶联剂(KH570)2份,纳米银2份。
(2)硫化前处理:先将丁腈橡胶、聚氯乙烯、己二酸二辛酯、钙锌粉放入开炼机(温度为160℃,速度为20r/min)中捏合2min后,加入碳纤维、纳米石墨烯和硅烷偶联剂(KH570),继续捏合5min。
(3)硫化处理:待混料冷却至室温后,在开炼机(温度为60℃,速度为20r/min)中按相应配比添加碳酸氢铵、升华硫、二硫化二苯并噻唑和纳米银,捏合5min;在室温放置24h后,在开炼机(室温,速度为20r/min)捏合5min,然后置于平板硫化机(温度为160℃,压力为10MPa)上模压发泡成型,时间为15min。
(4)硫化后处理:取出试样,室温冷却24h,用切边机将所得的片材上下两层外表层剥离,每层剥离厚度为1mm。
(5)吸声通道处理:最后将步骤(4)剥离表面后所得的中间层25mm通过开炼机的挤压使部分发泡孔壁破裂形成通孔但不破坏材料的整体结构,开炼机的滚轮间距8mm,室温下转速为20r/min。
样品厚度为8mm时的性能参数如表2所示。
表2实施例2制备的柔性吸声材料的性能表
实施例3:
一种本发明的柔性吸声材料的制备方法,包括以下步骤:
(1)按照如下重量配比称取原料:丁腈橡胶35份,聚氨酯15份,铝纤维5份,超细石墨烯粉体(200nm)10份,偶氮二异丁腈10份,己二酸二辛酯15份,钙锌粉2份,二硫化二苯并噻唑2份,升华硫2份,硅烷偶联剂(KH570)2份,纳米银2份。
(2)硫化前处理:先将丁腈橡胶、聚氨酯、己二酸二辛酯、钙锌粉放入开炼机(温度为160℃,速度为20r/min)中捏合2min后,加入铝纤维、超细石墨烯粉体和硅烷偶联剂(KH570),继续捏合5min。
(3)硫化处理:待混料冷却至室温后,在开炼机(温度为60℃,速度为20r/min)中按相应配比添加偶氮二异丁腈,升华硫、二硫化二苯并噻唑和纳米银,捏合5min;在室温放置24h后,在开炼机(室温,速度为20r/min)捏合5min,然后置于平板硫化机(温度为160℃,压力为10MPa)上模压发泡成型,时间为15min。
(4)硫化后处理:取出试样,室温冷却24h,用切边机将所得的片材上下两层外表层剥离,每层剥离厚度为1mm。
(5)吸声通道处理:最后将步骤(4)剥离表面后所得的中间层25mm通过开炼机的挤压使部分发泡孔壁破裂形成通孔但不破坏材料的整体结构,开炼机的滚轮间距8mm,室温下转速为20r/min。
样品厚度为8mm时的性能参数如表3所示。
表3实施例3制备的柔性吸声材料的性能表
以上所述仅是本发明的优选实施方式,本发明的保护范围并不仅局限于上述实施例。凡属于本发明思路下的技术方案均属于本发明的保护范围。应该指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下的改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种柔性吸声材料,包括以下重量份的组分:
橡胶20~35份,
塑料10~20份,
增强纤维5~10份,
重质粉体5~10份,
发泡剂10~20份,
塑化剂10~20份,
热稳定剂1~2份,
促进剂1~2份,
硫化剂1~2份,和
偶联剂1~2份。
2.根据权利要求1所述的柔性吸声材料,其特征在于,所述增强纤维为铝纤维、碳纤维、聚酯纤维、硅酸盐纤维中的一种或多种。
3.根据权利要求2所述的柔性吸声材料,其特征在于,所述重质粉体为超细石墨烯粉体、超细三氧化二铝粉体、超细铁粉体中的一种或多种;所述重质粉体的粒径为100nm~100μm。
4.根据权利要求1~3任一项所述的柔性吸声材料,其特征在于,还包括:杀菌剂1~2份。
5.根据权利要求4所述的柔性吸声材料,其特征在于,所述橡胶为硅橡胶、氟橡胶、丁腈橡胶、氯丁橡胶或三元乙丙橡胶中的一种或多种;所述塑料为聚碳酸树酯、聚氯乙烯、聚丙烯、聚乙烯、聚苯乙烯、聚氨酯中的一种或多种。
6.根据权利要求5所述的柔性吸声材料,其特征在于,所述发泡剂为碳酸氢铵、偶氮二异丁腈、偶氮二甲酰胺中的一种或多种;所述塑化剂为邻苯二甲酸二丁酯、邻苯二甲酸二辛酯、己二酸二辛酯中的一种;所述热稳定剂为钙锌粉、有机锡、有机锑中的一种;所述促进剂为二硫化二苯并噻唑、N-环已基-2-苯并噻唑次磺酰胺、四甲基二硫化秋兰姆中的一种;所述的硫化剂为升华硫、氧化锌、氧化镁中的一种或多种;所述偶联剂为铬络合物偶联剂、硅烷偶联剂、钛酸酯偶联剂中的一种。
7.根据权利要求6所述的柔性吸声材料,其特征在于,所述抗菌剂为纳米银、载银磷酸盐、四氯苯二腈中的一种。
8.一种如权利要求1~7任一项所述的柔性吸声材料的制备方法,包括以下步骤:
(1)先将橡胶、塑料、塑化剂、热稳定剂置于开炼机中,在温度为120~180℃,速度为10~30r/min下混炼1~5min后,加入增强纤维、重质粉体和偶联剂,维持温度和转速不变,混炼2~10min,冷却至室温,得到预混料;
(2)在步骤(1)所得的预混料中加入发泡剂、促进剂和硫化剂,在30~90℃,转速为10~30r/min下混炼2~10min,室温放置12~36h后,在室温转速为10~30r/min下继续混炼2~10min,最后置于平板硫化机上模压发泡成片,模压温度为120~180℃,压力为5~15MPa,时间为10~30min,室温冷却12~36h后得到硫化试样;
(3)将步骤(2)所得的硫化试样的上下表面剥离,所述上下表面剥离厚度均为1~2mm,得到柔性吸声材料中间体;
(4)对步骤(3)所得的柔性吸声材料中间体进行物理挤压,开炼机的滚轮间距为柔性吸声材料中间体厚度的1/4~2/3,室温下转速为10~30r/min,以形成表面开孔且相邻孔洞互相连通的吸声结构,得到柔性吸声材料。
9.根据权利要求8所述的柔性吸声材料的制备方法,其特征在于,所述步骤(2)中,还包括在预混料中加入抗菌剂。
10.一种如权利要求1~7任一项所述的柔性吸声材料或如权利要求8或9所述的制备方法制得的柔性吸声材料在成型吸声构件或作为吸声构件的应用。
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