CN111716830A - 一种空调隔音棉及其制作方法 - Google Patents
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Abstract
本发明提供一种空调隔音棉及其制作方法,所述空调隔音棉包括隔音板和布置在所述隔音板上的吸音层,其中,所述吸音层包括熔喷布,所述熔喷布至少在朝向隔音板的一侧表面上设有有凹凸附面层,使得所述吸音层与所述隔音板之间形成空腔结构。本发明提供的空调隔音棉,采用在熔喷布外表面复合凹凸附面层的吸音层作为隔音层,使得吸音层与隔音板之间产生空腔结构,提高吸音效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本,而且还解决了绒毛掉落问题。
Description
技术领域
本发明涉及空调外机消声技术领域,具体涉及一种空调隔音棉及其制作方法。
背景技术
空调室外机的噪声主要来源于压缩机与风机,压缩机本体的电机工作时传出中高频电磁噪声,压缩机转子转动时传出中低频机械噪声,各频率段的声波传播过程中相互叠加,向外辐射。目前在空调外机消声技术领域,主要是通过在空调压缩机上增加隔音棉的方式,隔音棉主要包裹在压缩机机身上,阻止声波噪音的传出。
现有隔音棉采用的吸音层主要包括具有多孔结构的针刺毛毡、碎布(绿毛毡)、熔喷布。针刺毛毡和绿毛毡价格相对便宜,但是吸音效果不如熔喷布,而且存在绒毛、树脂粉掉落现象。熔喷布孔隙度高,吸音效果优良,没有绒毛掉落现象,但是价格相对较高,限制了熔喷布吸音层的结构厚度。
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,提供一种空调隔音棉及其制作方法,采用将隔音板表面增加凹槽结构,使吸音层与隔音板之间产生空腔结构,提高吸音效果,减少吸音层和隔音板用料,控制生产成本,而且采用熔喷布制作隔音棉,解决针刺毛毡、绿毛毡绒毛掉落和树脂粉掉落问题。
为了解决上述技术问题,本发明提出的技术方案为:
一种空调隔音棉,其特征在于,包括隔音板和布置在所述隔音板上的吸音层,其中,所述吸音层包括熔喷布,所述熔喷布至少在朝向隔音板的一侧表面上设有有凹凸附面层,使得所述吸音层与所述隔音板之间形成空腔结构。
根据本发明的空调隔音棉,采用在熔喷布外表面复合凹凸附面层的吸音层作为隔音层,使得吸音层与隔音板之间产生空腔结构,提高吸音效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本,而且采用熔喷布制作隔音棉,解决针刺毛毡、绿毛毡绒毛掉落和树脂粉掉落问题。
对于上述技术方案,还可进行如下所述的进一步的改进。
根据本发明的空调隔音棉,在一个优选的实施方式中,所述隔音板的其中一侧表面上设有吸音层。
这种结构形式的空调隔音棉,在满足隔音效果的同时能够尽可能的节省生产制造成本。
进一步地,在另一个优选的实施方式中,所述隔音板的两侧表面上均设有吸音层。
这种结构形式的空调隔音棉,能够极大程度上提高整个隔音棉的隔音效果。
具体地,在一个优选的实施方式中,所述凹凸附面层上均匀布置有多个凸起,相邻凸起之间具有凹槽。
这种结构形式,在保证提高整个隔音棉的整体效果的前提下,能够使得吸音层与隔音板之间的接触面积分布均匀,从而便于隔音板与吸音层之间的稳定连接。
进一步地,在一个优选的实施方式中,所述凸起包括但不限于正六边形凸起或方形凸起。
这种结构形式的吸音层,不仅能够确保隔音板与吸音层之间的连接稳定可靠,而且能够尽可能增加隔音板与吸音层之间的空腔结构从而极大程度上提高隔音效果。
进一步地,在一个优选的实施方式中,所述凹凸附面层的凹凸高度差为0.5mm。
这个深度的凹槽结构,能够进一步确保吸音层与隔音板之间的胶接工艺操作容易。
进一步地,在一个优选的实施方式中,所述凹凸附面层的凹凸高度差为0.02mm~5mm。
这种凹凸高度差的凹凸附面层,能够有利于吸音层与隔音板之间的复合工艺的操作。
进一步地,在一个优选的实施方式中,隔音板的材质包括PVC、乙丙橡胶和丁基橡胶。
这种材质的隔音板,不仅隔音效果好,而且成本低。
本发明第二方面的空调隔音棉的制作方法,包括如下步骤:
S01:将熔喷布的至少一侧表面与凹凸附面层复合制作成吸音层;
S02:将吸音层具有凹凸附面层的一侧表面贴合在隔音板的至少一侧表面;
S03:按照预设尺寸进行切割;
S04:包装入库。
根据本发明的制作方法,由于采用了外表面上设有凹凸附面层的吸音层从而使得吸音层与隔音板之间形成空腔结构,因此能够有效提高吸音效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本。
进一步地,在一个优选的实施方式中,在步骤S02中,吸音层具有凹凸附面层的一侧表面与隔音板的至少一侧表面通过热熔胶进行贴合。热熔胶的胶黏性好,成本较低。
相比现有技术,本发明的优点在于:由于采用了具有凹凸附面层的吸音层从而使得吸音层与隔音板之间形成空腔结构,因此能够有效提高吸音效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本,还解决了绒毛掉落问题。经过试验结果证明,采用表面具有凹凸附面层的熔喷布作为吸音层,同等厚度吸音效果提高5~20%;同等吸音效果前提下成本降低10~20%。
附图说明
在下文中将基于实施例并参考附图来对本发明进行更详细的描述。其中:
图1示意性显示了本发明实施例的熔喷布的表面视图;
图2示意性显示了本发明实施例1的组合结构的示意图;
图3示意性显示了本发明实施例2的组合结构的示意图。
在附图中,相同的部件使用相同的附图标记。附图并未按照实际的比例绘制。
具体实施方式
下面将结合附图和具体实施例对本发明作进一步详细说明,但并不因此而限制本发明的保护范围。
图1示意性显示了本发明实施例的熔喷布1的表面视图。图2示意性显示了本发明实施例1的组合结构的示意图。图3示意性显示了本发明实施例2的组合结构的示意图。
实施例1
如图1和图2所示,本发明实施例的空调隔音棉10,包括隔音板1和布置在隔音板1上的吸音层2,其中,所述吸音层2主要由熔喷布形成,并且所述熔喷布至少在朝向隔音板1的一侧表面上设置有凹凸附面层21,使得吸音层2与隔音板1之间形成空腔结构。在另一实施例中,所述熔喷布的两侧表面上均设置有凹凸附面层。
根据本发明实施例的空调隔音棉,采用在熔喷布外表面复合凹凸附面层的吸音层作为隔音层,使得吸音层与隔音板之间产生空腔结构,额外增加了空气层,相当于增大了吸音层的有效厚度,提高了对噪声的吸收效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本。
如图2所示,优选地,在本实施例中,吸音层2在朝向隔音板1的一侧表面上设有凹凸附面层21。这种结构形式的空调隔音棉,在满足隔音效果的同时能够尽可能的节省生产制造成本。
具体地,如图1所示,在本实施例中,凹凸附面层21均匀间隔布置在熔喷布上。这种结构形式,在保证提高整个隔音棉的整体效果的前提下,能够使得吸音层与隔音板之间的接触面积分布均匀,从而便于隔音板与吸音层之间的稳定连接。凸凹附面层可以选用任何形状的均匀布置的凸起,且相邻凸起之间具有凹槽。优选地,在本实施例中,凹凸附面层21均匀布置的正六边形凸起。凹凸附面层还可采用均匀布置的方形凸起。这种结构形式的隔音板,不仅能够确保隔音板与吸音层之间的连接稳定可靠,而且能够尽可能增加隔音板与吸音层之间的空腔结构从而极大程度上提高隔音效果。
众所周知,多孔材料的吸声性能,主要受材料的流阻、孔隙率、结构因子、厚度、堆密度、材料表面的装饰处理、空气间隙层结构以及使用的外部条件等的影响。熔喷布具有比针刺毛毡或绿毛毡更高的孔隙率和流阻,所以吸音效果更好,这在实验和实际应用中都得到验证。
在其他条件相同的情况下,多孔材料背后空气层的厚薄,对吸声性能具有重要影响。当多孔材料距离刚性壁留有一定的空腔时,空气层起到空气弹簧的作用,对声波产生干涉,吸收声波能量,就相当于增大了材料的有效厚度,改变了对噪声的吸收效果。根据理论计算,空气层厚度等于声波波长λ的1/4的奇数倍时,可获得最大的吸声系数。
频率s-1 | 600 | 1600 | 2600 | 3600 | 4600 | 5600 | 6600 | 7600 | 8600 | 9600 | 10600 |
波长mm | 566.7 | 212.5 | 130.8 | 94.44 | 73.91 | 60.71 | 51.52 | 44.74 | 39.53 | 35.42 | 32.08 |
1/4波长mm | 141.7 | 53.13 | 32.69 | 23.61 | 18.48 | 15.18 | 12.88 | 11.18 | 9.88 | 8.85 | 8.02 |
其中,λ=V/f;λ为声波波长;V为音速(340米/秒);f为声波频率。
因此,得出的结论是:空气层越厚,越接近声波的1/4波长,吸音系数越高。但是凸起越高,材料成本也会越高,工艺操作性变得困难。因此,发明人选取0.02mm~5mm的凹凸高度。
在本实施例中,凹凸附面层21的凹凸高度差即为0.02mm~5mm。这种深度的凹凸结构,能够有利于吸音层与隔音板之间的复合工艺操作。进一步地,当凸凹附面层的的凸起为正六边形时,凹凸高度差优选为0.5mm。这个深度范围内的凹凸结构,能够进一步确保吸音层与隔音板之间的胶接工艺操作容易。
在另一实施例中,虽然采用熔喷布作为吸音层替代针刺毛毡或绿毛毡,然而所述的凹凸附面层可用针刺毡、绿毛毡等隔音产品在制作。
在本实施例中,隔音板1为PVC胶板。这种材质的隔音板,不仅隔音效果好,而且成本低。
实施例2
如图1和图3所示,本发明实施例的空调隔音棉10’,包括隔音板1和布置在隔音板1两侧的吸音层2,其中所述熔喷布至少在朝向隔音板1的一侧表面上设置有凹凸附面层21,使得吸音层2与隔音板1之间形成空腔结构。根据本发明实施例的空调隔音棉,采用在熔喷布外表面复合凹凸附面层的吸音层作为隔音层,使得吸音层与隔音板之间产生空腔结构,额外增加了空气层,相当于增大了吸音层的有效厚度,提高了对噪声的吸收效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本。
在另一实施例中,熔喷布1的两侧表面上均设有凹凸附面层21。这种结构形式的空调隔音棉,能够极大程度上提高整个隔音棉的隔音效果。
实施例3
本发明实施例的空调隔音棉的制作方法,包括如下步骤:
S01:将熔喷布的至少一侧表面与凹凸附面层复合制作具有凹凸面结构的吸音层;
S02:将吸音层具有凹凸附面层的一侧表面喷涂热熔胶或其他胶黏剂,将其贴合在隔音板的至少一侧表面;
也可以在隔音板的至少一侧表面上喷涂胶黏剂,直接与吸音层具有凹凸附面层的一侧表面贴合;
S03:按照预设尺寸进行切割;
S04:包装入库。
根据本发明实施例的制作方法,由于采用了具有凹凸附面层的吸音层从而使得吸音层与隔音板之间形成空腔结构,因此能够有效提高吸音效果,在满足隔音效果的前提下,可以减少吸音层和隔音板的材料用量,从而有效降低生产成本,还解决了绒毛掉落问题。经过试验结果证明,采用表面具有凹凸附面层的熔喷布作为吸音层,同等厚度吸音效果提高5~20%;同等吸音效果前提下成本降低10~20%。
虽然已经参考优选实施例对本发明进行了描述,但在不脱离本发明的范围的情况下,可以对其进行各种改进并且可以用等效物替换其中的部件。尤其是,只要不存在结构冲突,各个实施例中所提到的各项技术特征均可以任意方式组合起来。本发明并不局限于文中公开的特定实施例,而是包括落入权利要求的范围内的所有技术方案。
Claims (10)
1.一种空调隔音棉,其特征在于,包括隔音板和布置在所述隔音板上的吸音层,其中,所述吸音层包括熔喷布,所述熔喷布至少在朝向隔音板的一侧表面上设有有凹凸附面层,使得所述吸音层与所述隔音板之间形成空腔结构。
2.根据权利要求1所述的空调隔音棉,其特征在于,所述隔音板的其中一侧表面上设有吸音层。
3.根据权利要求1所述的空调隔音棉,其特征在于,所述隔音板的两侧表面上均设有吸音层。
4.根据权利要求1至3中任一项所述的空调隔音棉,其特征在于,所述凹凸附面层上均匀布置有多个凸起,相邻凸起之间具有凹槽。
5.根据权利要求4所述的空调隔音棉,其特征在于,所述凸起包括但不限于正六边形凸起或方形凸起。
6.根据权利要求5所述的空调隔音棉,其特征在于,所述凹凸附面层的凹凸高度差为0.5mm。
7.根据权利要求1至3中任一项所述的空调隔音棉,其特征在于,所述凹凸附面层的凹凸高度差为0.02mm~5mm。
8.根据权利要求1至3中任一项所述的空调隔音棉,其特征在于,所述隔音板的材质包括PVC、乙丙橡胶和丁基橡胶。
9.一种根据权利要求1至8中任一项所述的空调隔音棉的制作方法,其特征在于,包括如下步骤:
S01:将熔喷布的至少一侧表面与凹凸附面层复合制作成吸音层;
S02:将吸音层具有凹凸附面层的一侧表面贴合在隔音板的至少一侧表面;
S03:按照预设尺寸进行切割;
S04:包装入库。
10.根据权利要求9所述的空调隔音棉的制作方法,其特征在于,在步骤S02中,吸音层具有凹凸附面层的一侧表面与隔音板的至少一侧表面通过热熔胶进行贴合。
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