CN110158236A - 一种全生物降解三组份吸音棉 - Google Patents

一种全生物降解三组份吸音棉 Download PDF

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CN110158236A
CN110158236A CN201711466397.3A CN201711466397A CN110158236A CN 110158236 A CN110158236 A CN 110158236A CN 201711466397 A CN201711466397 A CN 201711466397A CN 110158236 A CN110158236 A CN 110158236A
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acoustical cotton
fiber
layer
complete biodegradable
bamboo
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邹汉涛
张秦川
张翼
王冰
张荣波
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Wuhan Every Time Industrial Development Co Ltd
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Wuhan Every Time Industrial Development Co Ltd
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Abstract

本发明公开了一种全生物降解三组份吸音棉，为生物降解PLA微纳米纤维、竹炭纤维、竹纤维组成的吸音棉层交叉铺网而成，其中，各原料的质量百分比分别为：生物降解PLA微纳米纤维40‑65%、竹炭纤维4‑8%、竹纤维27‑56%；吸音棉层采用熔喷纤网‑干法纤网在线复合制得；生物降解PLA微纳米纤维为采用熔喷法制备的超细纤维结构；吸音棉层的两侧可根据使用需求覆盖面层，面层为PLA纺粘无纺布层或铝箔，面层和吸音棉层经复合、轧花处理和超声波封边，裁切成各种所需尺寸规格，即得到本发明的全生物降解三组份吸音棉；本发明具有优异的吸音隔音性、除异味和恶臭、阻燃性、抗菌防霉等特点，汽车废弃后吸音棉100%完全生物降解，符合环保要求。

Description

一种全生物降解三组份吸音棉
技术领域
本发明涉及吸音材料领域，具体是一种全生物降解三组份吸音棉。
背景技术
汽车噪音直接影响人们的身心健康和生活质量的提高，长期处于噪音环境中，会引起听力损失甚至可能诱发一些疾病；试验表明：80分贝会使驾驶者的注意力下降10%，90分贝时下降20%；要远离噪音，我们能做的就是吸音和隔音；吸音棉可以将车体振动所产生的中高频噪音振动能转换成吸音棉内部的细旦纤维的动能，并转化成热能而耗散掉，达到吸音降噪的功能；目前用于生产汽车吸音棉的原料包括 PP和PET，这些材料来自于石油，汽车报废后这些吸音棉暴露在空气中任其自然降解，整个过程需要大约300年的时间；大量的废弃吸音棉不仅污染环境，而且造成白色污染；聚乳酸作为一种以淀粉、纤维素等碳水化合物为原料, 经水解、发酵、纯化、聚合而成的一种合成聚酯, 原料来源广泛, 可再生能够完全生物降解, 具有与传统聚烯烃树脂相似的加工性能, 被视为在一次性消费品领域替代传统聚烯烃塑料的最佳选择；使用聚乳酸替代传统聚烯烃树脂制备环境友好型可降解吸音棉材料, 不仅能够实现吸音棉的完全生物降解, 更能减少对不可再生的石化资源的依赖,避免浪费, 意义重大。
发明内容
本发明的目的在于提供一种具有优异的吸音隔音性、除异味和恶臭、阻燃性、抗菌防霉、吸音棉废弃后100%完全生物降解的三组份吸音棉，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：
一种全生物降解三组份吸音棉，由生物降解PLA微纳米纤维、竹炭纤维和竹纤维组成的吸音棉层经交叉铺网而成。
作为本发明进一步的方案：所述吸音棉层采用熔喷纤网-干法纤网在线复合制得，具体制备方法为：将竹炭纤维和竹纤维经开松梳理成单纤维状态，通过气流引入到熔喷工艺气流牵伸场中，竹炭纤维和竹纤维被PLA微纳米纤维带到成网帘上，竹炭纤维和竹纤维干法纤网加入熔喷纤维的角度控制在75-85°，熔喷成形的PLA微纳米纤维网与竹炭纤维和竹纤维干法纤网在线复合成吸音棉层。
作为本发明再进一步的方案：所述吸音棉层按照质量百分比的成分为：生物降解PLA微纳米纤维40-65%、竹炭纤维4-8%、竹纤维27-56%。
作为本发明再进一步的方案：所述生物降解PLA微纳米纤维采用熔喷法纺丝，细度为1-5μm。
作为本发明再进一步的方案：所述竹炭纤维细度为15-25μm。
作为本发明再进一步的方案：所述竹纤维长度为55-65mm，细度为25-35μm。
作为本发明再进一步的方案：所述竹炭纤维和竹纤维经开松、梳理、成网，形成干法纤网。
作为本发明再进一步的方案：还包括面层，吸音棉层的两侧均覆盖面层，所述面层为PLA纺粘无纺布层或铝箔。
作为本发明再进一步的方案：所述PLA纺粘无纺布层采用聚合物挤压纺粘法制备，厚度为0.5-1mm。
作为本发明再进一步的方案：所述面层和吸音棉层经复合、轧花处理、超声波封边、裁切成所需尺寸规格，得到全生物降解吸音棉成品。
与现有技术相比，本发明的有益效果是：本发明提供的全生物降解三组份吸音棉具有优异的吸音隔音性、阻燃性；吸音棉中的竹炭纤维可除异味、恶臭、除湿，竹纤维除能赋予吸音棉良好的尺寸稳定性外，还具有良好抗菌功能；吸音棉中PLA纤维原料来自于可再生的植物资源中的淀粉原料，减少了对不可再生的石化资源的依赖，废弃的吸音棉掩埋在土壤中，可以被自然界中的微生物完全降解为二氧化碳和水；本发明的吸音棉的三种组分均可降解，真正实现了100%完全生物降解，符合环保要求，值得大力推广。
附图说明
图1为本发明的结构示意图；
图2为本发明的面层制备流程图；
图3为本发明中的吸音棉层制备流程图。
其中，11-面层，12-吸音棉层。
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。
请参阅图1-3，本发明实施例中，一种全生物降解三组份吸音棉，包括面层11、吸音棉层12，所述吸音棉层12为PLA微纳米纤维、竹炭纤维和竹纤维组成的复合纤维层经交叉铺网而成，吸音棉层中按照质量百分比的成分为：PLA微纳米纤维65%、竹炭纤维5%、竹纤维30%；所述吸音棉层12的两侧按照使用需求选择覆盖有面层11，面层11为PLA纺粘无纺布层或铝箔。
实施例2
本发明实施例中，一种全生物降解三组份吸音棉，包括面层11、吸音棉层12，所述吸音棉层12为PLA微纳米纤维、竹炭纤维和竹纤维组成的复合纤维层经交叉铺网而成，吸音棉层中按照质量百分比的成分为：PLA微纳米纤维65%、竹炭纤维10%、竹纤维25%；所述吸音棉层12的两侧按照使用需求选择覆盖有面层11，面层11为PLA纺粘无纺布层或铝箔。
实施例3
本发明实施例中，一种全生物降解三组份吸音棉，包括面层11、吸音棉层12，所述吸音棉层12为PLA微纳米纤维、竹炭纤维和竹纤维组成的复合纤维层经交叉铺网而成，吸音棉层中按照质量百分比的成分为：PLA微纳米纤维65%、竹炭纤维8%、竹纤维27%；所述吸音棉层12的两侧按照使用需求选择覆盖有面层11，面PLA纺粘无纺布层11为PLA纺粘无纺布层或铝箔。
实施例1-3中的面层11选用的PLA纺粘无纺布平方米克重10-20g/m2；吸音棉层12是短纤维纤网结构，为PLA微纳米纤维、竹炭纤维和竹纤维组成的复合纤维层，经交叉铺网而成。
所述PLA微纳米纤维是PLA采用熔喷法制备而成，PLA聚合物熔体由喷丝孔挤出，受到两侧高速热空气喷吹，经极度牵伸形成微纳米纤维。平均细度1-5μm。微纳米纤维结构使得全生物降解三组份吸音棉内孔径更小，孔隙率更大，并且其接近纳米级别的纤维能与声波共振来衰减能量，有利于吸音。
所述PLA微纳米纤维具体实施工艺如下：
1）加工温度：熔喷模头250-270℃；转换箱260-270℃；一区260-270℃；二区260-270℃，三区240-260℃；四区230-250℃；光辊120℃；花辊120℃；热空气一240℃；热空气二260℃；
2）热空气的喷射角控制在50-60°；热空气压力0.1-0.2MPa；接收距离25-35cm。
所述竹炭纤维细度15-25μm，长度15-35mm。竹炭纤维孔隙多、矿物质含量丰富，能释放远红外线，具有蓄热调温、抗菌除臭除异味的功效，另外其多孔结构使其具有更优异的吸音性能。
所述竹纤维细度25-35μm，长度55-65mm；竹纤维作为结构纤维，除用于控制吸音棉的厚度，还可确保产品的蓬松性及压缩回弹性外，使吸音棉具有持久的吸音降噪性能，另外其中空结构更加提高了产品的吸音性和隔热性。
所述复合纤维层采用熔喷纤网-干法纤网在线复合实现，一定配比的竹炭纤维和竹纤维经高效开松、梳理成单纤维状态，通过气流引入到熔喷工艺气流牵伸场中，竹炭纤维和竹纤维被PLA微纳米纤维带到成网帘上，竹炭纤维和竹纤维干法纤网加入熔喷纤维的角度控制在75-85°；熔喷成形的PLA微纳米纤维网与竹炭纤维和竹纤维干法纤网在线复合成复合纤维层，经交叉铺网形成具有良好弹性和吸音性、保暖性的复合吸音材料。
所述面层11和吸音棉层12经复合，轧花处理并超声波封边，裁切成各种所需尺寸规格，即得到本发明的产生负离子及高效吸附甲醛及VOC的全生物降解三组份吸音棉。
本发明的全生物降解三组份吸音棉具有更好的全频吸音能力，同时兼具蓄热调温、耐霉、环保、阻燃等性能；具体包括：
1）吸音性能：一种全生物降解三组份吸音棉组成部分中的无数2μm微小纤维无序叠加，组成迷宫式的空隙结构；声波产生的振动引起间隙的空气运动，由于与孔壁或纤维表面摩擦和空气的粘滞阻力，一部分声能转变为热能，使声波衰减；其次，小孔中空气与孔壁之间还不断发生热交换，也使声能衰减；与普通的毛毡类、聚酯海绵类吸音材料相比，本发明的全生物降解三组份吸音棉孔径更小、孔隙率更大，并且其接近纳米级别的纤维能与声波共振来衰减能量，故其吸音效果更好；与同样厚度的毛毡相比，在重量轻一半以上的情况下，吸音系数至少超出毛毡的40-50%以上，以每平米400g，厚度26mm的规格为例，对车内空间驾驶员以及乘客最为敏感的噪音频段2500Hz以下中低频部分降噪效果更加理想，降噪系数NRC为0.72，平均吸声系数（100Hz-5KHz）为0.68。
2）阻燃性：本发明的全生物降解三组份吸音棉具有优良的阻燃性能，点火15s后在5min以内停止燃烧，并且燃烧速度≤80mm/min，高于GB8410-2006的规定（燃烧速度≤100mm/min），其阻燃性能完全符合汽车内饰要求。
3）生物降解性：本发明的全生物降解三组份吸音棉中的PLA纤维原料来自于可再生的植物资源中的淀粉原料，减少了对不可再生的石化资源的依赖，废弃的吸音棉掩埋在土壤中，可以被自然界中的微生物完全降解为二氧化碳和水，该吸音棉的竹炭纤维和竹纤维也可降解，真正实现100%完全生物降解，符合环保要求。
4）高效除臭除异味：本发明的全生物降解三组份吸音棉中的竹炭纤维内外贯穿的蜂窝状微孔结构使其具有超强的吸附能力，可高效去除恶臭、二手烟及异味；异味减少率达到80-95%，同时还具有很好的天然抗菌抑菌效果，对大肠杆菌和金黄色葡萄球菌的抑菌率大于98%以上。
5）隔热性：本发明的全生物降解三组份吸音棉所特有的微纳米纤维，比毛毡类所使用的纤维要细十倍甚至几十倍，这就意味着本发明的全生物降解三组份吸音棉能隔绝更多的空气，更快的达到内部舒适的温度，达到更有效的隔热保暖效果。在冬天能保护汽车内部热量的流失，在夏天能阻隔外部热量的流入，减少汽车用空调的能耗；以每平米400g，厚度26mm的规格为例，其传热系数为1.550W/m2﹒℃，克罗值为3.793，保暖率为74.5%。
6）环保：本发明的全生物降解三组份吸音棉白色无毒无异味，无挥发性气体，无公害污染，不含致癌物质，使用过程中不会有粉状物逸出刺激皮肤，达到现行各汽车厂对车内VOC和RoSH的要求，（“使用报废后可以回收造粒，符合当前的资源重复利用政策，是环境友好性材料。”改为“使用报废后直接堆肥，即可完全生物降解为二氧化碳和水，不会造成白色污染，是环境友好性材料。”）
7）防潮防霉：本发明的全生物降解三组份吸音棉基本不吸水，其吸水量不超过自身重量的1%，不会受潮，也就不会因受潮而给霉菌提供吸收水分的机会；由于其优越的憎水性使其具备以下特点：快干、真菌不会滋生、不会分解、腐烂以及难闻气味的产生等，确保长期稳定性；按照ASTM G21方法进行测试（温度25℃，湿度75%），本发明的全生物降解三组份吸音棉发生霉变的区域个数为0，发生霉变的面积为0，而以PET为原料制作的毛毡和聚酯海绵发生霉变的区域个数分别为2个和3个，发生霉变的区域分别为15-30%和30%-45%。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外，应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其他实施方式。

Claims (10)

1.一种全生物降解三组份吸音棉，其特征在于，由生物降解PLA微纳米纤维、竹炭纤维和竹纤维组成的吸音棉层经交叉铺网而成。
2.根据权利要求1所述的全生物降解三组份吸音棉，其特征在于，所述吸音棉层采用熔喷纤网-干法纤网在线复合制得，具体制备方法为：将竹炭纤维和竹纤维经开松梳理成单纤维状态，通过气流引入到熔喷工艺气流牵伸场中，竹炭纤维和竹纤维被PLA微纳米纤维带到成网帘上，竹炭纤维和竹纤维干法纤网加入熔喷纤维的角度控制在75-85°，熔喷成形的PLA微纳米纤维网与竹炭纤维和竹纤维干法纤网在线复合成吸音棉层。
3.根据权利要求1所述的全生物降解三组份吸音棉，其特征在于，所述吸音棉层按照质量百分比的成分为：生物降解PLA微纳米纤维40-65%、竹炭纤维4-8%、竹纤维27-56%。
4.根据权利要求3所述的全生物降解三组份吸音棉，其特征在于，所述生物降解PLA微纳米纤维采用熔喷法纺丝，细度为1-5μm，。
5.根据权利要求3所述的全生物降解三组份吸音棉，其特征在于，所述竹炭纤维细度为15-25μm。
6.根据权利要求3所述的全生物降解三组份吸音棉，其特征在于，所述竹纤维长度为55-65mm，细度为25-35μm。
7.根据权利要求1所述的全生物降解三组份吸音棉，其特征在于，所述竹炭纤维和竹纤维经开松、梳理、成网，形成干法纤网。
8.根据权利要求1-3任一所述的全生物降解三组份吸音棉，其特征在于，还包括面层，吸音棉层的两侧均覆盖面层，所述面层为PLA纺粘无纺布层或铝箔。
9.根据权利要求8所述的全生物降解三组份吸音棉，其特征在于，所述PLA纺粘无纺布层采用聚合物挤压纺粘法制备，厚度为0.5-1mm。
10.根据权利要求8所述的全生物降解三组份吸音棉，其特征在于，所述面层和吸音棉层经复合、轧花处理、超声波封边、裁切成所需尺寸规格，得到全生物降解吸音棉成品。
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