CN110843292A - 一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法 - Google Patents

一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法 Download PDF

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CN110843292A
CN110843292A CN201911046959.8A CN201911046959A CN110843292A CN 110843292 A CN110843292 A CN 110843292A CN 201911046959 A CN201911046959 A CN 201911046959A CN 110843292 A CN110843292 A CN 110843292A
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马丽凤
汪熙婷
王岩松
郭辉
杨超
刘宁宁
马西沛
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Shanghai University of Engineering Science
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Abstract

本发明涉及一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法，该材料包括粘连连接的一层微孔发泡EPDM泡沫和一层带空腔的EPDM薄板；制备方法，包括：(1)将EPDM母料、发泡剂、硫化剂放入密式炼胶机中混炼，得到混合物A；(2)将混合物A放入平板硫化机压片成型，得到片状混合物B；(3)将混合物B放入鼓风烘箱中发泡，制得微孔发泡EPDM泡沫；(4)将微孔发泡EPDM泡沫与带空腔的EPDM薄板粘连连接。与现有技术相比，本发明除了满足吸声系数幅值的提高，而且能够通过改变一些变量调控吸声频率的范围，特别在中低频范围(400‑1500Hz)内吸声性能优异，而且制备工艺简单，花费成本较低，易于商业化。

Description

一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法
技术领域
本发明属于高分子材料加工领域和声学领域，尤其是涉及一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法。
背景技术
现如今，噪声污染已受到社会各方高度重视。噪声能够直接或间接地对人体的身体健康和心理稳定性等造成一定伤害。针对环境噪声，国家规章制度明确规定了声音排放标准，超过该标准，即为噪声，所有噪声都要得到有效处理，其才不会对环境产生影响。噪声的控制按技术方法分为主动降噪与被动降噪。主动降噪即通过降噪系统产生与外界噪音相等的反向声波，将噪音中和，从而实现降噪的效果。被动降噪现在运用较多，即在声音传播过程中进行降噪处理。常用吸声或隔声材料对声音进行吸收与隔离。
多孔泡沫材料常用作吸声材料。其吸声原理可归结于以下几点：(1)声波在多孔材料中来回反射消耗能量；(2)声波传入，引起空气与泡孔内壁的摩擦，消耗声能；(3)声波传播导致空气压缩而产生了热能，热能通过热交换将部分声能耗散掉。现在运用较多的多孔吸声材料如汽车内饰的吸音棉，或者其它用于机械吸声的棉麻纤维类。对于高分子多孔材料，它们广泛用于吸声、隔热、保温等方面。近几年，学者们更多地专注在EPDM泡沫结构上，但在其在声学应用尤其是噪声吸收上研究较少。国内外也有少数学者通过在EPDM泡沫中加入填料以提高吸声性能，但其吸声频率却较为固定，无法满足各种噪声环境的要求。
因此，除了要解决EPDM泡沫吸声系数的幅值问题，还应该关注吸声系数的频率问题。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种用于吸声的双层三元乙丙橡胶多孔材料及其制备方法。
本发明的目的可以通过以下技术方案来实现：
本发明提供一种用于吸声的双层三元乙丙橡胶多孔材料，包括粘连连接的一层微孔发泡EPDM泡沫和一层带空腔的EPDM薄板。
作为本发明优选的技术方案，微孔发泡EPDM泡沫的平均孔径范围为0.40～0.65mm，泡孔密度范围为15×109～27×109个/cm3，孔隙率在0.75～0.90区间内，开孔率在0.45～0.60区间内；且微孔发泡EPDM泡沫和带空腔的EPDM薄板的厚度相同。
作为本发明优选的技术方案，带空腔的EPDM薄板的空腔为孔径3～5mm的通孔。通孔的形状为圆柱形通孔。
作为本发明优选的技术方案，所述的圆柱形通孔按照圆周分布，分布于同心的多个圆周上，且从内到外，同心的多个圆周上分布的圆柱形通孔数量依次增多。
作为本发明进一步优选的技术方案，同心的多个圆周中，最小的圆周的直径为20mm，相邻两个圆周的直径相差20mm，最小的圆周上平均分布4个圆柱形通孔，从内向外，同心的多个圆周上分布的圆柱形通孔的数量依次增加2个。
本发明还提供一种用于吸声的双层三元乙丙橡胶多孔材料的制备方法，包括以下步骤：
(1)将EPDM母料、发泡剂、硫化剂放入密式炼胶机中混炼，得到混合物A；
(2)将混合物A放入平板硫化机压片成型，得到片状混合物B；
(3)将混合物B放入鼓风烘箱中发泡，制得微孔发泡EPDM泡沫；
(4)将微孔发泡EPDM泡沫与带空腔的EPDM薄板粘连连接，得到所述的用于吸声的双层三元乙丙橡胶多孔材料。
作为本发明优选的技术方案，所述的硫化剂为酚醛树脂，所述的发泡剂为4-4’-氧代双苯磺酰肼。
作为本发明优选的技术方案，所述的EPDM母料的牌号为4725P。
作为本发明优选的技术方案，所述的酚醛树脂的牌号为SP-1055。
作为本发明优选的技术方案，混合物A中，硫化剂的质量分数为2％～5％，发泡剂的质量分数为2％～6％，其余为EPDM母料。
作为本发明优选的技术方案：
步骤(1)中，密式炼胶机的设定温度为50℃，混炼时间为3min，转子转速为70转/分钟；
步骤(2)中，平板硫化机的设定温度为70℃，成型热压时间与冷压时间各为2分钟；
步骤(3)中，采用发泡模具在鼓风烘箱中发泡，鼓风烘箱的设定温度为165℃，发泡时间为10分钟。
作为本发明优选的技术方案，所述的带空腔的EPDM薄板通过在纯EPDM薄板上钻孔得到。
与现有技术相比，本发明具有以下有益效果：
本发明的复合多孔结构结合了微孔吸声原理以及圆柱空腔薄板结构吸声机理。运用化学发泡剂OBSH进行加热发泡，使单层的EPDM形成细密均匀的小泡孔。制备方法中发泡剂的含量，硫化剂的含量以及各个工艺流程的加工温度都对最后样品的性能产生重要的影响。加以带有圆柱空腔的薄板，此结构不仅能在吸声系数的幅值上表现优良，还可以通过调节上层薄板空腔的直径来改变吸声频率的范围。
本发明提供了一种新型EPDM复合微孔结构的制备方法，制得的样品具有质量轻，兼顾吸声幅值和吸声频率的优点。适用于中低频率的噪声吸收工况。
附图说明
图1为本发明用于吸声的双层三元乙丙橡胶多孔材料复合结构的微观形态图(a)及截面结构示意图(b)；
图2为本发明用于吸声的双层三元乙丙橡胶多孔材料不同结构的吸声系数对比图。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。
实施例
一种用于吸声的双层三元乙丙橡胶多孔材料，包括粘连连接的一层微孔发泡EPDM泡沫和一层带空腔的EPDM薄板。
本实施例中，微孔发泡EPDM泡沫的平均孔径为0.563mm,泡孔密度27.36×109个/cm3，孔隙率为0.87，开孔率为0.59；且微孔发泡EPDM泡沫和带空腔的EPDM薄板的厚度相同。带空腔的EPDM薄板的空腔为孔径3～5mm的通孔。通孔的形状为圆柱形通孔。
上述用于吸声的双层三元乙丙橡胶多孔材料的制备方法，包括以下步骤：
(1)将EPDM母料、发泡剂、硫化剂放入密式炼胶机中混炼，得到混合物A；
(2)将混合物A放入平板硫化机压片成型，得到片状混合物B；
(3)将混合物B放入鼓风烘箱中发泡，制得微孔发泡EPDM泡沫；
(4)将微孔发泡EPDM泡沫与带空腔的EPDM薄板粘连连接，得到所述的用于吸声的双层三元乙丙橡胶多孔材料。
其中，就反应原料而言，本实施例中，硫化剂为酚醛树脂，所述的发泡剂为4-4’-氧代双苯磺酰肼。EPDM母料的牌号为4725P。酚醛树脂的牌号为SP-1055。混合物A中，硫化剂的质量分数为3％，发泡剂的质量分数为4％，其余为EPDM母料。
圆柱形通孔按照圆周分布，分布于同心的多个圆周上，且从内到外，同心的多个圆周上分布的圆柱形通孔数量依次增多。本实施例中，同心的多个圆周中，最小的圆周的直径为20mm，相邻两个圆周的直径相差20mm，最小的圆周上平均分布4个圆柱形通孔，从内向外，同心的多个圆周上分布的圆柱形通孔的数量依次增加2个。例如同心的多个圆周的直径的分别为80mm、60mm、40mm和20mm，每个圆周依次按10、8、6和4个圆柱形通孔平均分布。
其中，就工艺参数而言，步骤(1)中，密式炼胶机的设定温度为50℃，混炼时间为3min，转子转速为70转/分钟；步骤(2)中，平板硫化机的设定温度为70℃，成型热压时间与冷压时间各为2分钟；步骤(3)中，采用发泡模具在鼓风烘箱中发泡，鼓风烘箱的设定温度为165℃，发泡时间为10分钟。
本实施例的带空腔的EPDM薄板通过在纯EPDM薄板上钻孔得到。
更具体地，本实施例中用于吸声的双层三元乙丙橡胶多孔材料的制备方法，包括以下步骤：
(a)将EPDM母料颗粒、3％质量分数的酚醛树脂粉末、4％质量分数的OBSH一起搅拌均匀，倒入密炼机进行搅拌混匀。密炼机的温度设为50℃，转速设为70转/秒。此时得到混合物A，取出冷却3小时。
(b)将平板硫化机的温度设为70℃，选用1mm厚度的压片模具，将冷却后的混合物A置于模具中，70℃预热1分钟，继而热压1分钟，最后室温冷压2分钟，得到片状混合物B，取出冷却24小时。
(c)鼓风烘箱发泡。选用的发泡模具主要由两片铜板组成，在铜板的内表面铺上黄金膜，将片状混合物B置于发泡模具中，将鼓风烘箱的温度设为165℃，时间设为10分钟，得到发泡材料C，即为微孔发泡EPDM泡沫。
如图1第四步所示，制备一份同等厚度的纯EPDM薄板，在薄板表面按圆周分布地钻孔。钻孔的直径分别为3mm、4mm、5mm。将钻好孔的纯EPDM薄板与上述发泡材料C采用3M胶水点状粘连在一起，得到用于吸声的双层三元乙丙橡胶多孔材料。
图1中的(a)是此双层复合结构的微观结构图，上层是EPDM泡沫层，下层是带空腔的EPDM薄板。为了更清楚地反应这个结构，图1(b)为一个截面结构示意图。
图2为不同空腔直径下的复合结构的吸声系数曲线，即对比例一、实施例一、实施例二、实施例三的吸声系数曲线。同等厚度与大小尺寸下，对比例一为单层的EPDM泡沫的吸声曲线，其吸声峰值约为0.75，吸声峰值所在的频率集中在1200Hz左右。实施例一为带有3mm空腔的EPDM薄板与EPDM泡沫复合结构的吸声系数曲线，其峰值与对比例相差不大，但其吸声峰值集中的频率集中在850Hz左右。实施例二为带有4mm空腔的复合结构的吸声系数曲线，其峰值与对比例相差不大，其吸声峰值集中的频率集中在900Hz左右。实施例三为带有5mm空腔的复合结构的吸声系数曲线，其峰值与对比例相差不大，其吸声峰值集中的频率集中在950Hz左右。
整体而言，同等厚度与大小尺寸下，与单层的EPDM泡沫相比，带空腔薄板的EPDM复合结构的吸声频率更往低频移动，且空腔直径越小，往低频移动地越多。
实施例四
本实施例与实施例1基本相同，不同之处在于，本实施例中，混合物A中硫化剂的质量分数为2％，发泡剂的质量分数为6％，其余为EPDM母料。微孔发泡EPDM泡沫的平均孔径范围为0.40～0.65mm，泡孔密度范围为15×109～27×109个/cm3，孔隙率在0.75～0.90区间内，开孔率在0.45～0.60区间内。
实施例五
本实施例与实施例1基本相同，不同之处在于，本实施例中，混合物A中，硫化剂的质量分数为5％，发泡剂的质量分数为2％，其余为EPDM母料。微孔发泡EPDM泡沫的平均孔径范围为0.40～0.65mm，泡孔密度范围为15×109～27×109个/cm3，孔隙率在0.75～0.90区间内，开孔率在0.45～0.60区间内。
上述对实施例的描述是为便于该技术领域的普通技术人员能理解和使用发明。熟悉本领域技术的人员显然可以容易地对这些实施例做出各种修改，并把在此说明的一般原理应用到其他实施例中而不必经过创造性的劳动。因此，本发明不限于上述实施例，本领域技术人员根据本发明的揭示，不脱离本发明范畴所做出的改进和修改都应该在本发明的保护范围之内。

Claims (10)

1.一种用于吸声的双层三元乙丙橡胶多孔材料，其特征在于，包括粘连连接的一层微孔发泡EPDM泡沫和一层带空腔的EPDM薄板。
2.根据权利要求1所述的用于吸声的双层三元乙丙橡胶多孔材料，其特征在于，微孔发泡EPDM泡沫的平均孔径范围为0.40～0.65mm，泡孔密度范围为15×109～27×109个/cm3，孔隙率在0.75～0.90区间内，开孔率在0.45～0.60区间内；且微孔发泡EPDM泡沫和带空腔的EPDM薄板的厚度相同。
3.根据权利要求1所述的用于吸声的双层三元乙丙橡胶多孔材料，其特征在于，带空腔的EPDM薄板的空腔为孔径3～5mm的通孔。
4.如权利要求1～3任一所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，包括以下步骤：
(1)将EPDM母料、发泡剂、硫化剂放入密式炼胶机中混炼，得到混合物A；
(2)将混合物A放入平板硫化机压片成型，得到片状混合物B；
(3)将混合物B放入鼓风烘箱中发泡，制得微孔发泡EPDM泡沫；
(4)将微孔发泡EPDM泡沫与带空腔的EPDM薄板粘连连接，得到所述的用于吸声的双层三元乙丙橡胶多孔材料。
5.根据权利要求4所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，所述的硫化剂为酚醛树脂，所述的发泡剂为4-4’-氧代双苯磺酰肼。
6.根据权利要求4所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，所述的EPDM母料的牌号为4725P。
7.根据权利要求5所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，所述的酚醛树脂的牌号为SP-1055。
8.根据权利要求4所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，混合物A中，硫化剂的质量分数为2％～5％，发泡剂的质量分数为2％～6％，其余为EPDM母料。
9.根据权利要求4所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于：
步骤(1)中，密式炼胶机的设定温度为50℃，混炼时间为3min，转子转速为70转/分钟；
步骤(2)中，平板硫化机的设定温度为70℃，成型热压时间与冷压时间各为2分钟；
步骤(3)中，采用发泡模具在鼓风烘箱中发泡，鼓风烘箱的设定温度为165℃，发泡时间为10分钟。
10.根据权利要求4所述的用于吸声的双层三元乙丙橡胶多孔材料的制备方法，其特征在于，所述的带空腔的EPDM薄板通过在纯EPDM薄板上钻孔得到。
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