CN110228243A - 一种耐磨隔音毛毡材料及其制备方法 - Google Patents

一种耐磨隔音毛毡材料及其制备方法 Download PDF

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CN110228243A
CN110228243A CN201910689563.9A CN201910689563A CN110228243A CN 110228243 A CN110228243 A CN 110228243A CN 201910689563 A CN201910689563 A CN 201910689563A CN 110228243 A CN110228243 A CN 110228243A
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felt
layers
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张晋
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Ningbo Delong Hardware Co Ltd
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Abstract

本申请第一个方面涉及一种毛毡材料，其具有三层结构，自上而下顺次为第一毛毡层、中间毛毡层和底层毛毡层，其厚度比为1:2‑3:1；第二个方面是提供了该毛毡层的制备方法：I、将第一毛毡层、中间毛毡层和底层毛毡层顺次叠合；II、在第一毛毡层和中间毛毡层之间以及中间毛毡层和底层毛毡层之间涂覆适量的固化剂；III、在烘箱中，对上述三个毛毡层进行高温烘烤，然后进行热压成型，即得到所述毛毡材料。该毛毡材料通具有良好的性能如耐磨、隔音等，可广泛应用到多个技术领域中，尤具有良好的工业化推广潜力和应用价值。

Description

一种耐磨隔音毛毡材料及其制备方法
技术领域
本发明主要提供了一种耐磨隔音毛毡材料及其制备方法，其可用于多种技术领域的耐磨、隔音、装饰等处理，具有良好的应用前景和工业化生产潜力，属于高分子材料技术领域。
背景技术
毛毡材料具有非常广泛的应用价值，例如可应用到汽车内饰、家装装修、隔音处理(例如KTV、会议室等)等多个装饰技术领域中，起到美化、隔音、提高舒适感等诸多作用，在多个领域中具有广阔的应用前景。
对于此类材料而言，通常是由高分子材料制备而成，例如可使用聚乙烯、聚丙烯、聚氯乙烯、三元橡胶等共混而得到，通常可采用注塑成型，从而使得质地紧密，且可制成多种形状(片状、丝状等)。
随着人们对于舒适性、高级感等要求的日益提高，从而对毛毡材料也提出了更高的要求，并对此进行了大量的深入研发，取得了一定的技术成果。
CN101987511A公开了一种汽车隔音垫的生产方法，所述汽车隔音垫的生产方法包括如下步骤：a、原材料铺放：将热塑性毛毡材料铺放在烘箱网链上；b、烘温软化：将热塑性毛毡材料通过烘箱网链送入烘箱内进行烘温软化，所述烘箱上加热区温度为230-250℃，下加热区温度为310-330℃，烘温时间为255-285s；c、压制成型：将经烘温软化后的热塑性毛毡进行压制冷却为半成品，压制冷却成型时，成型压力为16-17MPa，成型时间为90-110s；冷却温度为20-30℃；d、水刀切割：将压制冷却后的半成品进行定位，水刀切割，得到所需隔音垫；所述切割水压为40000-50000psi；切割气压为0.6-0.8MPa；e、检验：经检验后，装箱入库。该方法节能环保，强度高，生产效率高且能降低劳动强度。
CN104894755A公开了一种汽车导风板毛毡材料热压成型工艺，包括以下步骤：传送带式烘箱的设定、毛毡原材料的准备、毛毡的装夹固定、毛毡的加热和毛毡的模压，操作者从传送带式烘箱出口取下烘好毛毡的平板夹具，并在传送带式烘箱进口送入另一个装夹好毛毡而未烘的平板夹具，把烘好的毛毡从平板夹具上取下并放在机台上模压。通过上述方式，将装夹好毛毡的平板夹具连续送入传送带式烘箱进行加热，工作效率高，节能性好，而且毛毡在加热时被固定而不易伸缩变形，可有效减少原料的尺寸而不用担心报废，降低了原料成本。
CN105437699A公开了一种新型乘用车用外轮罩毛毡材料及其制备方法。所述毛毡材料从上至下依次为：阻尼减震层、胶粉层、吸音层、缓冲减震层和刚性支撑抗冲击层。所述毛毡生产效率高，由三台梳理机分别控制各功能层的铺网，再经过撒粉和贴合阻尼减震层，一步法制成毛毡产品；轮罩吸音性能好，轮罩毛毡的混响室测试平均吸音系数在0.65以上。
CN104797415A公开了一种吸音性以及阻燃性高并且柔软、适用于汽车、车辆的内饰材料、工业材料、衣料等的轻质毛毡材料，在所述轻质毛毡材料中，两层硬棉层分别混合有20-80％的细度为1.1分特以下的极细纤维、10-60％的赋予蓬松性的中空纤维以及10-60％的在对整体进行热处理时熔融的低熔点纤维，无纺片的纤维直径为2-20μm，单位面积的重量为20-100g/m2。
如上所述，目前的现有技术中公开了一些新型的毛毡材料和制备方法，这对于汽车和家装领域具有重要的意义，使得本领域技术人员有了更多、更好的选择。
另个方面，对于新型的毛毡材料，尤其是耐磨、隔音的新型毛毡材料，仍存在继续研发的必要和需求，这也是本发明人完成本发明的目的和意义所在。
发明内容
本申请的发明人为了提供一种新型的毛毡材料，尤其是具有良好耐磨、隔音性能的毛毡材料，进行了大量的深入研究，得到了一种新型的毛毡材料，可以用于汽车内饰、家装装修、房间隔音等多个领域，具有良好的应用前景和广泛的生产价值。
更具体的，本申请主要涉及如下几个方面。
第一个方面，提供了一种新型的毛毡材料，也即请求保护一种毛毡材料。
所述毛毡材料的特征是具有三层结构，自上而下顺次为第一毛毡层、中间毛毡层和底层毛毡层，其厚度比为1:2-3:1，例如可为1:2:1、1:3:1或1:2.5:1。
作为特别的描述，所述第一毡层是将无机纤维浸渍有机胶液而得到。
其中，所述无机纤维是质量比为1:1的玻璃纤维和碳化硅纤维的混合物，所述玻璃纤维和碳化硅纤维的直径均为0.1-0.2mm、长度均为为1-2mm。
其中，按照质量份计，所述有机胶液包括0.1-0.2份固化剂、20-30份环氧树脂、3-5份有机溶剂、0.3-0.5份增强剂和1-2份增塑剂。
所述固化剂为多种胺类化合物，最优选为二乙氨基丙胺。
所述环氧树脂为双酚A型环氧树脂，该树脂是一类非常公知的树脂，可在市场上通过商业行为而容易地得到，在此不再进行详尽的描述。
所述有机溶剂为丙酮或乙醚。
所述增强剂为聚乙烯醇缩丁醛。
所述增塑剂为邻苯二甲酸二正丁酯或邻苯二甲酸二正辛酯，或者为两者的任何比例的混合物。
作为特别的描述，所述中间毛毡层是由质量比1:1的聚(间亚苯基异邻苯二酰胺)纤维与聚亚苯基硫醚纤维通过针刺法而形成的整体毛毡层。
其中，聚(间亚苯基异邻苯二酰胺)纤维与聚亚苯基硫醚纤维均是非常公知的高分子纤维材料，可根据规格的不同而从市场上购买得到。
而针刺法，是纺织领域中一种非常公知和常规的纺织工艺，在此不再进行详尽的描述。
作为特别的描述，所述底层毛毡层是将天然纤维、合成纤维和碳纤维通过热压成型制得。
其中热压成型工艺是纺织领域非常公知的加工工艺，本领域技术人员可选择合适的热压温度和热压压力，在此不再进行详尽的描述。
其中，所述天然纤维例如可为亚麻纤维、椰子壳纤维或大麻纤维中的任意一种，或者为任何两种或三种的混合物。
其中，所述合成纤维为质量比1:2的尼龙66和聚酯的混合物。
其中，所述天然纤维、合成纤维和碳纤维的质量比为1:1-2:0.1-0.3，例如可为为1:1:0.1、1:1:0.2、1:1:0.3、1:2:01.、1:2:0.2或1:2:0.3。
本发明的第二个方面，涉及上述新型毛毡材料的制备方法，更具体而言，该制备方法如下：
I、将第一毛毡层、中间毛毡层和底层毛毡层顺次叠合；
II、在第一毛毡层和中间毛毡层之间以及中间毛毡层和底层毛毡层之间涂覆适量的固化剂，所述固化剂的描述同上；
III、在烘箱中，对上述三个毛毡层进行高温烘烤，温度为80-90℃，烘烤时间为10-20分钟，然后进行热压成型，使三个毛毡层的厚度比为1:2-3:1，最后根据需求进行尺寸切割，即得到所述毛毡材料。
如上面的详细描述，本发明得到了一种新型的毛毡材料，该毛毡材料通过独特的结构设置、成分选择，从而使得其具有良好的性能，如耐磨、隔音等，可广泛应用到多个技术领域中，尤其是汽车装饰、家装装修和房间隔音等，具有良好的工业化推广潜力和应用价值。
具体实施方式
在下面，本发明人将通过多个制备例和多个实施例对本发明的毛毡材料和制备方法进行详细的描述，但这些描述仅仅是对本发明技术方案的示例性描述，而不是用来限定和限制本发明，本领域技术人员在阅读本发明后，可以对其进行适当的改变或变型，但这些仍处于本发明的保护范围内，而不是一个全新的有别于本发明的发明。
制备例1：第一毛毡层的制备
A、以质量份计，将0.1份固化剂二乙氨基丙胺、30份环氧树脂双酚A型环氧树脂、3份有机溶剂丙酮、0.5份增强剂聚乙烯醇缩丁醛和1份增塑剂邻苯二甲酸二正丁酯进行均匀混合，得到有机胶液；
B、将质量比为1:1的玻璃纤维和碳化硅纤维的无机纤维混合物浸渍到上述有机胶液中，其中所述玻璃纤维和碳化硅纤维的直径均为0.1-0.2mm、长度均为1-2mm；
C、充分浸渍完成后，得到第一毛毡层，将其命名为D11。
制备例2：第一毛毡层的制备
A、以质量份计，将0.2份固化剂二乙氨基丙胺、20份环氧树脂双酚A型环氧树脂、5份有机溶剂乙醚、0.3份增强剂聚乙烯醇缩丁醛和2份增塑剂邻苯二甲酸二正辛酯进行均匀混合，得到有机胶液；
B、将质量比为1:1的玻璃纤维和碳化硅纤维的无机纤维混合物浸渍到上述有机胶液中，其中所述玻璃纤维和碳化硅纤维的直径均为0.1-0.2mm、长度均为1-2mm；
C、充分浸渍完成后，得到第一毛毡层，将其命名为D12。
制备例3：第一毛毡层的制备
A、以质量份计，将0.15份固化剂二乙氨基丙胺、25份环氧树脂双酚A型环氧树脂、4份有机溶剂乙醚、0.4份增强剂聚乙烯醇缩丁醛和1.5份增塑剂邻苯二甲酸二正丁酯进行均匀混合，得到有机胶液；
B、将质量比为1:1的玻璃纤维和碳化硅纤维的无机纤维混合物浸渍到上述有机胶液中，其中所述玻璃纤维和碳化硅纤维的直径均为0.1-0.2mm、长度均为1-2mm；
C、充分浸渍完成后，得到第一毛毡层，将其命名为D13。
制备例4：中间毛毡层的制备
将质量比1:1的聚(间亚苯基异邻苯二酰胺)纤维与聚亚苯基硫醚纤维通过针刺法形成整体毛毡层，即得到中间毛毡层，将其命名为D2。
制备例5：底层毛毡层的制备
将质量比1:1.5:0.2的天然纤维(为亚麻纤维)、合成纤维(为质量比1:2的尼龙66和聚酯的混合物)和碳纤维进行热压成型，即得到底间毛毡层，将其命名为D3。
实施例1
I、将第一毛毡层D11、中间毛毡层D2和底层毛毡D3层顺次叠合；
II、在第一毛毡层D11和中间毛毡层D2之间以及中间毛毡层D2和底层毛毡层D3之间涂覆适量的固化剂二乙氨基丙胺；
III、在烘箱中，对上述三个毛毡层进行高温烘烤，温度为80℃，烘烤时间为20分钟，然后进行热压成型，使三个毛毡层的厚度比为1:2:1，最后根据需求进行尺寸切割，即得到毛毡材料，将其命名为M1。
实施例2
I、将第一毛毡层D12、中间毛毡层D2和底层毛毡D3层顺次叠合；
II、在第一毛毡层D12和中间毛毡层D2之间以及中间毛毡层D2和底层毛毡层D3之间涂覆适量的固化剂二乙氨基丙胺；
III、在烘箱中，对上述三个毛毡层进行高温烘烤，温度为90℃，烘烤时间为10分钟，然后进行热压成型，使三个毛毡层的厚度比为1:3:1，最后根据需求进行尺寸切割，即得到毛毡材料，将其命名为M2。
实施例2
I、将第一毛毡层D13、中间毛毡层D2和底层毛毡D3层顺次叠合；
II、在第一毛毡层D13和中间毛毡层D2之间以及中间毛毡层D2和底层毛毡层D3之间涂覆适量的固化剂二乙氨基丙胺；
III、在烘箱中，对上述三个毛毡层进行高温烘烤，温度为85℃，烘烤时间为15分钟，然后进行热压成型，使三个毛毡层的厚度比为1:2.5:1，最后根据需求进行尺寸切割，即得到毛毡材料，将其命名为M3。
隔音性能测试
1、在标准实验室(GMW14177混响吸音室)中进行吸音性能测定，发现上述毛毡材料M1-M3的吸音系数分别为0.72、0.71和0.75，平均值高达0.726左右，具有非常优异的隔音性能。
2、根据耐磨性测试标准，发现毛毡材料M1-M3的测定值分别为3.6、3.5和3.5(标准值为大于3即可)，由此证明M1-M3具有良好的耐磨性能。
如上面的详细描述，本发明得到了一种新型的毛毡材料，该毛毡材料通过独特的结构设置、成分选择，从而使得其具有良好的性能，如耐磨、隔音等，可广泛应用到多个技术领域中，尤其是汽车装饰、家装装修和房间隔音等，具有良好的工业化推广潜力和应用价值。
但需要特别说明的是本申请的制备例和实施例仅仅是用来描述和示例性解释本发明，任何人尤其是本领域技术人员在阅读了本发明的详细描述之后，可以对其进行适当的改变或变型，但这些仍处于本发明的保护范围内，而不是一个全新的有别于本发明的发明。

Claims (10)

1.一种毛毡材料，所述毛毡材料具有三层结构，自上而下顺次为第一毛毡层、中间毛毡层和底层毛毡层，其厚度比为1:2-3:1。
2.如权利要求1所述的毛毡材料，其特征在于：所述第一毡层是将无机纤维浸渍有机胶液而得到。
3.如权利要求2所述的毛毡材料，其特征在于：所述无机纤维是质量比为1:1的玻璃纤维和碳化硅纤维的混合物，所述玻璃纤维和碳化硅纤维的直径均为0.1-0.2mm、长度均为1-2mm。
4.如权利要求2或3所述的毛毡材料，其特征在于：按照质量份计，所述有机胶液包括0.1-0.2份固化剂、20-30份环氧树脂、3-5份有机溶剂、0.3-0.5份增强剂和1-2份增塑剂。
5.如权利要求4所述的毛毡材料，其特征在于：所述固化剂为二乙氨基丙胺。
6.如权利要求4或5所述的毛毡材料，其特征在于：所述增强剂为聚乙烯醇缩丁醛。
7.如权利要求4-6任一项所述的毛毡材料，其特征在于：所述增塑剂为邻苯二甲酸二正丁酯或邻苯二甲酸二正辛酯，或者为两者的任何比例的混合物。
8.如权利要求1-7任一项所述的毛毡材料，其特征在于：所述中间毛毡层是由质量比1:1的聚(间亚苯基异邻苯二酰胺)纤维与聚亚苯基硫醚纤维通过针刺法而形成的整体毛毡层。
9.如权利要求1-8任一项所述的毛毡材料，其特征在于：所述底层毛毡层是将天然纤维、合成纤维和碳纤维通过热压成型制得。
10.权利要求1-9任一项所述毛毡材料的制备方法，所述制备方法如下：
I、将第一毛毡层、中间毛毡层和底层毛毡层顺次叠合；
II、在第一毛毡层和中间毛毡层之间以及中间毛毡层和底层毛毡层之间涂覆适量的固化剂；
III、在烘箱中，对上述三个毛毡层进行高温烘烤，温度为80-90℃，烘烤时间为10-20分钟，然后进行热压成型，使三个毛毡层的厚度比为1:2-3:1，最后根据需求进行尺寸切割，即得到所述毛毡材料。
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