CN108481861B - 一种高分子吸音复合板及其制造方法 - Google Patents

一种高分子吸音复合板及其制造方法 Download PDF

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CN108481861B
CN108481861B CN201810709815.5A CN201810709815A CN108481861B CN 108481861 B CN108481861 B CN 108481861B CN 201810709815 A CN201810709815 A CN 201810709815A CN 108481861 B CN108481861 B CN 108481861B
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刘仕宽
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Xingren County Xiangwu New Energy Saving Building Material Co ltd
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Abstract

本发明公开了一种高分子吸音复合板，包括高分子发泡层、混合气凝胶层和加强层，所述高分子发泡层两侧均依次设置混合气凝胶层和加强层，其特征在于：所述高分子发泡层包括以下重量份的组分：聚氯乙烯80‑100份、多孔陶瓷微粒15‑25份、发泡剂8‑15份、阻燃剂20‑25份、交联剂2‑3份、EVA粒子15‑25份、喷熔纤维40‑60份、发气剂2‑5份、氯化镁15‑20份。优点在于添加多孔陶瓷微粒、EVA粒子和喷熔纤维等，极大增加了消音能力，喷熔纤维直径可达微米级，其对低频低强度音波的感应强度也较强；混合气凝胶层由于其密度小，空隙多，极易产生振动将音波的能量转化为机械能或者转换为内能消散掉。因此本发明不仅对高频音波消减能力强，而且对于低频音波消减能力也较一般的吸材料更强。

Description

一种高分子吸音复合板及其制造方法
技术领域
本发明涉及高分子材料技术领域，特别涉及一种高分子吸音复合板及其制造方法。
背景技术
现有的消音材料很多，其原理基本一致，其吸声机理均为声波深入材料的孔隙，且孔隙多为内部互相贯通的开口孔，受到空气分子摩擦和粘滞阻力，以及使细小纤维作机械振动，从而使声能转变为热能。这类多孔性吸声材料的吸声系数，一般从低频到高频逐渐增大，故对高频和中频的声音吸收效果较好。由于其吸音主要是利用了震动或者摩擦将声音的能量转化为内能，所以当声音的频率和强度过低时，吸音材料的振动或者振幅也会随之降低，假设吸音材料对于低频低强度音波的感应能力不强，则其面对低频低强度音波时消音能力将会大幅下降甚至消失。
发明内容
本发明要解决的技术问题是提供一种消音性能显著，尤其是对于低频低强度声音消减能力强的高分子吸音复合板及其制造方法。
本发明的技术方案为：
一种高分子吸音复合板，包括高分子发泡层、混合气凝胶层和加强层，所述高分子发泡层两侧均依次设置混合气凝胶层和加强层，其特征在于：所述高分子发泡层包括以下重量份的组分：聚氯乙烯80-100份、多孔陶瓷微粒15-25份、发泡剂8-15份、阻燃剂20-25份、交联剂2-3份、EVA粒子15-25份、喷熔纤维40-60份、发气剂2-5份、氯化镁15-20份。
进一步的，喷熔纤维直径在0.1-10微米之间，且直径不超过4微米的喷熔纤维占总量的 70％-90％。
进一步的，阻燃剂为镁铝层状双金属氢氧化物、氢氧化镁或氢氧化铝。
进一步的，发泡剂为磷酸1-3份、2-5草酸、对偶氮二甲酰胺5-7份。
进一步的，发气剂为工业双氧水、铝粉或铝膏。
进一步的，混合气凝胶层包括以下重量份的组分：聚脲气凝胶粉体50-80份、聚氨酯气凝胶粉体40-70份、木料微粉粒30-40份、环氧树脂或酚醛树脂70-100份。
进一步的，木料微粉粒为杨树制成，其直径在10-20微米之间。
本发明提供了一种上述高分子吸音复合板的制作方法：
具体为将高分子发泡层、混合气凝胶层和加强层采用树脂胶粘接后，在其表面利用压力机施加0.2-0.4Mpa的压力2-4h，粘结后在其四周涂上水密封胶。
优选的，上述树脂胶为AB胶。
本发明还提供了一种上述高分子吸音复合板的高分子发泡层制造方法，其工艺如下：
(1)氯化镁加水溶解后加热至70-80摄氏度调成氯化镁溶液；
(2)将发泡剂、发气剂、交联剂与氯化镁溶液均匀混合形成发泡液；
(3)聚氯乙烯、多孔陶瓷微粒、阻燃剂、EVA粒子和喷熔纤维搅拌均匀制成发泡粉；
(4)将发泡粉与发泡液混合均匀，搅拌6-8分钟形成液态发泡材料；
(5)将液态发泡材料倒入模具中反应固化。
本发明还提供了一种上述高分子吸音复合板的混合气凝胶层制造方法，其工艺如下：
(1)将聚脲气凝胶粉体、聚氨酯气凝胶粉体、木料微粉粒先搅拌均匀制成混合粉；
(2)将环氧树脂或酚醛树脂加热至60-80℃；
(3)将混合粉加入加热后的环氧树脂或酚醛树脂内搅拌均匀后加入模板内经热压后冷却即成。
本发明的有益之处在于：
本发明发泡层中在传统的发泡材料制作材料中加入了多孔陶瓷微粒、EVA粒子和喷熔纤维等，由于发泡材料其内部结构都较为疏松，存在众多微小缝隙，加上多孔陶瓷微粒的纳米级或者微米级通孔，音波传递至发泡层中，在发泡层内部的微小缝隙和多孔陶瓷微粒的纳米级或者微米级通孔中反复折射与反射，逐渐消耗掉音波的能量。而且还添加了喷熔纤维，喷熔纤维直径可达微米级，其对低频低强度音波的感应强度也较强，因此添加它可以增加对低频低强度音波的削弱能力。高分子发泡层外还增加了混合气凝胶层，其密度小，内部孔洞和空间错综复杂，交叉层叠存在，音波一旦进入，就会在内部反复折射，由于其密度小，极易产生振动，从而将音波的能量转化为机械能或者转换为内能消散掉。因此本发明不仅对高频音波消减能力强，而且对于低频音波消减能力也较一般的吸材料更强。
附图说明
图1为本发明结构示意图。
图中：1-高分子发泡层，2-混合气凝胶层，3-加强层，4-水密封胶。
具体实施方式
下面结合附图对本发明的具体实施方式作进一步说明。在此需要说明的是，对于这些实施方式的说明用于帮助理解本发明，但并不构成对本发明的限定。此外，下面所描述的本发明各个实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互组合。
如图1所示：
实施例1：
高分子发泡层材料准备：聚氯乙烯100份、多孔陶瓷微粒15份、发泡剂15份(选择配方为：磷酸3份、5草酸、对偶氮二甲酰胺7份)、镁铝层状双金属氢氧化物25份、交联剂2 份、EVA粒子25份、喷熔纤维40份、工业双氧水5份、氯化镁15份。
混合气凝胶层材料准备：聚脲气凝胶粉体80份、聚氨酯气凝胶粉体40份、木料微粉粒40份、酚醛树脂100份。
其高分子发泡层制造工艺如下：
(6)氯化镁加水溶解后加热至70-80摄氏度调成氯化镁溶液；
(7)将发泡剂、发气剂、交联剂与氯化镁溶液均匀混合形成发泡液；
(8)聚氯乙烯、多孔陶瓷微粒、阻燃剂、EVA粒子和喷熔纤维搅拌均匀制成发泡粉；
(9)将发泡粉与发泡液混合均匀，搅拌6-8分钟形成液态发泡材料；
(10)将液态发泡材料倒入模具中反应固化。
其气凝胶层制造工艺如下：
(4)将聚脲气凝胶粉体、聚氨酯气凝胶粉体、木料微粉粒先搅拌均匀制成混合粉；
(5)将环氧树脂或酚醛树脂加热至60-80℃；
(6)将混合粉加入加热后的环氧树脂或酚醛树脂内搅拌均匀后加入模板内经热压后冷却即成。
其各层组合方法如下：
具体为具体为将高分子发泡层、混合气凝胶层和加强层(本实施例选择防火胶板)采用 AB胶粘接后，在其表面利用压力机施加0.2-0.4Mpa的压力2-4h(为了使其粘合根紧密)，粘结后在其四周涂上水密封胶。
实施例2：
高分子发泡层材料准备：聚氯乙烯80份、多孔陶瓷微粒25份、发泡剂8份(选择配方为：磷酸1份、2草酸、对偶氮二甲酰胺5份)、氢氧化镁20份、交联剂3份、EVA粒子15 份、喷熔纤维60份、铝粉2份、氯化镁20份。
混合气凝胶层材料准备：聚脲气凝胶粉体100份、聚氨酯气凝胶粉体70份、木料微粉粒 30份、环氧树脂70份。
加强层选择压合木板。
其余工序与实施例1相同。
实施例3：
高分子发泡层材料准备：聚氯乙烯90份、多孔陶瓷微粒20份、发泡剂12份(选择配方为：磷酸2份、4草酸、对偶氮二甲酰胺6份)、氢氧化铝22份、交联剂2.5份、EVA粒子 20份、喷熔纤维50份、铝膏4份、氯化镁20份。
混合气凝胶层材料准备：聚脲气凝胶粉体60份、聚氨酯气凝胶粉体55份、木料微粉粒 35份、酚醛树脂85份。
加强层选择铝板。
其余工序与实施例1相同。
值得一提的是，喷熔纤维直径越小其震荡作用越强，对声音的消耗能力越强，隔音效果就越好，因此喷熔纤维直径在0.1-10微米之间，且直径不超过4微米的喷熔纤维占总量的 70％-90％最好。
还有就是混合气凝胶层可以选择市售的现有产品，也可以选择本发明中提供的配方及其制造方法。
交联剂可选择苯二甲酸二烯丙脂。
由于杨树质地较为疏松，因此其微粉粒消音效果较其他木质较好，所述优选木料微粉粒为杨树制成，其直径在10-20微米之间。
相关实验数据如下表所示：
Figure GDA0002440881640000041
由上表可知吸音材料的吸音系数会随着声音频率的增大而增大，这是由于在高频振动下声音的能量更易转化为机械能或者内能，然后消散掉。对照表中测试数据可知相对于现有的一些常见吸音材料(本实验以市售PC板材、木质吸音板材作为对比例)，本发明在同等的频率下其吸音效果明显由于其他的吸音材料，在低频段吸音性能更是远远高于一般吸音材料。
以上结合附图对本发明的实施方式作了详细说明，但本发明不限于所描述的实施方式。对于本领域的技术人员而言，在不脱离本发明原理和精神的情况下，对这些实施方式进行多种变化、修改、替换和变型，仍落入本发明的保护范围内。

Claims (10)

1.一种高分子吸音复合板，包括高分子发泡层、混合气凝胶层和加强层，所述高分子发泡层两侧均依次设置混合气凝胶层和加强层，其特征在于：所述高分子发泡层包括以下重量份的组分：聚氯乙烯80-100份、多孔陶瓷微粒15-25份、发泡剂8-15份、阻燃剂20-25份、交联剂2-3份、EVA粒子15-25份、喷熔纤维40-60份、发气剂2-5份、氯化镁15-20份；所述喷熔纤维直径在0.1-10微米之间，且直径不超过4微米的喷熔纤维占总量的70％-90％。
2.根据权利要求1所述的高分子吸音复合板，其特征在于：所述阻燃剂为镁铝层状双金属氢氧化物、氢氧化镁或氢氧化铝。
3.根据权利要求1所述的高分子吸音复合板，其特征在于：所述发泡剂为磷酸1-3份、2-5草酸、对偶氮二甲酰胺5-7份。
4.根据权利要求1所述的高分子吸音复合板，其特征在于：所述发气剂为工业双氧水、铝粉或铝膏。
5.根据权利要求1所述的高分子吸音复合板，其特征在于：所述混合气凝胶层包括以下重量份的组分：聚脲气凝胶粉体50-80份、聚氨酯气凝胶粉体40-70份、木料微粉粒30-40份、环氧树脂或酚醛树脂70-100份。
6.根据权利要求5所述的高分子吸音复合板，其特征在于：所述木料微粉粒为杨树制成，其直径在10-20微米之间。
7.一种用于加工权利要求1-6任一项所述的高分子吸音复合板的制造方法，其特征在于：所述高分子发泡层、混合气凝胶层和加强层采用树脂胶粘接后，在其表面利用压力机施加0.2-0.4Mpa的压力2-4h，粘结后在其四周涂上水密封胶。
8.根据权利要求7所述的高分子吸音复合板的制造方法，其特征在于：所述树脂胶为AB胶。
9.根据权利要求7所述的高分子吸音复合板的制造方法，其特征在于：所述高分子发泡层制造工艺如下：
(1)氯化镁加水溶解后加热至70-80摄氏度调成氯化镁溶液；
(2)将发泡剂、发气剂、交联剂与氯化镁溶液均匀混合形成发泡液；
(3)聚氯乙烯、多孔陶瓷微粒、阻燃剂、EVA粒子和喷熔纤维搅拌均匀制成发泡粉；
(4)将发泡粉与发泡液混合均匀，搅拌6-8分钟形成液态发泡材料；
(5)将液态发泡材料倒入模具中反应固化。
10.根据权利要求7所述的高分子吸音复合板的制造方法，其特征在于：所述混合气凝胶层制造工艺如下：
(1)将聚脲气凝胶粉体、聚氨酯气凝胶粉体、木料微粉粒先搅拌均匀制成混合粉；
(2)将环氧树脂或酚醛树脂加热至60-80℃；
(3)将混合粉加入加热后的环氧树脂或酚醛树脂内搅拌均匀后加入模板内经热压后冷却即成。
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