CN111844956A - 一种穿孔蜂窝铝夹层板及其制造方法 - Google Patents
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Abstract
本发明公开了一种穿孔蜂窝铝夹层板及其制造方法,穿孔蜂窝铝夹层板包括一定厚度的穿孔金属面板和穿孔金属背板,穿孔金属面板和穿孔金属背板上开有一定孔隙率及一定孔间距的微孔,微孔孔径0.5‑4mm,穿孔金属面板和穿孔金属背板的一侧贴覆有一层专用胶膜,胶膜另一侧粘接一层具有一定空腔容积的铝蜂窝芯。本发明中的穿孔蜂窝铝夹层板,整体重量轻,整体强度高,具有共振吸声的效果,主材均采用金属材料,具有耐候性好,价格低廉,外形可以着色处理,美观度高等优点,本发明中的方法,降低了制造成本,提高了生产效益。
Description
技术领域
本发明涉及墙面装饰及环保降噪领域,更为具体地,涉及一种穿孔蜂窝铝夹层板及其制造方法。
背景技术
目前墙面装饰,特别是户外墙面装饰,大多选用铝单板或秀壁板、瓷砖等材料,其中铝单板价格偏高,秀壁板不是金属材质,耐候性较差,瓷砖重量较大、易碎。
为解决上述材料存在的各种问题,市面上逐渐出现了一些新型外墙装饰材料,蜂窝铝夹层板就是其中之一。现市面上的蜂窝铝夹层板均为铝板+蜂窝芯+铝板的形式,整体质量轻、强度高、装饰性好,但由于表面无声音进入所需要的空洞,不具备吸声降噪效果。
生活中噪声治理一般采用在噪声源与受体之间设置吸隔声屏体的方式。现目前吸隔声屏体的主要采用金属板加工成型,在吸声板面积与厚度比例较大时,需要在吸隔声屏体背部设置骨架以提高其整体强度,该种方式虽保证了整体安全性,但既增加了成本,也降低了整体美观性。
发明内容
本发明的目的在于克服现有技术的不足,提供一种蜂窝铝夹层板及其制造方法,既能作为吸隔声屏体面板使用,又能作为外墙装饰板材使用,且整体重量轻,整体强度高,具有共振吸声的效果,耐候性好,价格低廉,外形美观,且降低了制造成本,提高了生产效益等。
本发明的目的是通过以下技术方案来实现的:
一种穿孔蜂窝铝夹层板,包括穿孔金属面板,所述穿孔金属面板开有设定孔隙率及设定孔间距的微孔,所述穿孔金属面板的一侧粘接有一层胶膜,所述胶膜的另一侧粘接有一层设定厚度并具有设定空腔容积的铝蜂窝芯,所述铝蜂窝芯的另一侧通过胶膜粘接有一层穿孔金属背板,所述穿孔金属背板开设有设定孔隙率及设定孔间距的微孔。
进一步的,所述穿孔金属面板、穿孔金属背板表面上均布设有多个孔径0.5~4mm的微孔。
进一步的,所述穿孔金属面板、铝蜂窝芯、穿孔金属背板的材质均为金属铝材质。
进一步的,所述胶膜、胶膜材质为丙烯酸,聚乙烯,聚酯,环氧,酚醛,聚氨酯,双马来酰亚氨,氨基丙烯酸,不饱和聚酯,有机硅等,优选聚氨酯弹性体橡胶。
进一步的,所述胶膜4、胶膜5的厚度范围为0.2mm-0.8mm,优选0.5mm。
进一步的,所述穿孔金属面板表面开孔率为20%-30%,厚度为0.2mm-2mm,优选0.5mm。
进一步的,所述穿孔金属背板表面开孔率为30%-40%,厚度为0.2mm-2mm,优选0.5mm。
进一步的,所述铝蜂窝芯的空腔为六边形空腔。
进一步的,所述铝蜂窝芯的厚度为4mm-50mm,优选5mm,所述六边形空腔的边长为4mm-20mm,优选7mm,所采用铝箔厚度为0.04mm-0.1mm,优选0.04mm。
一种穿孔蜂窝铝夹层板的制造方法,包括:
第一、选用设定厚度的金属板,利用热压机,压力1.5-2.5MPa,温度180~220℃,对金属板进行加热、校平13~17min;
第二、将胶膜平铺于金属板上,利用热压机,压力0.3~0.7kPa,温度180~220℃,压住金属板和胶膜3~7min,使胶膜处于半融化状态,并粘接与金属板上,自然冷却至120℃以下;
第三、利用龙门冲床,在已覆膜金属板表面按一定的孔径及开孔率进行开孔,制作成已覆膜的穿孔金属面板和已覆膜的穿孔金属背板,冲孔完成后进行校平;
第四、将已覆膜的穿孔金属背板、已完全拉开的铝蜂窝芯、已覆膜的穿孔金属面板分层置于热压机底板上,热压机压力1.9~2.1kPa,温度220~240℃,压制4~5min,自然冷却至120℃以下,再保持压力14~16min,使胶膜及胶膜完全固化,将孔金属面板、穿孔金属背板和铝蜂窝芯粘接一体,制成穿孔蜂窝铝夹层板。
进一步的,包括:
第五、在第四步后,冷却至常温,然后利用锯床将穿孔蜂窝铝夹层板锯切成需求大小,至此,完成所有加工。
本发明的有益效果是:
(1)本发明提供的穿孔蜂窝铝夹层板,整体重量轻,整体强度高,具有共振吸声的效果,耐候性好,价格低廉,外形美观,具体的,通过设置穿孔金属面板、穿孔金属背板、铝蜂窝芯等,具备了一定的共振吸声功能;由于采用铝蜂窝芯替代现有外墙装饰板和吸隔声屏体中的支撑结构,在保证穿孔蜂窝铝夹层板整体强度的同时,大大降低了穿孔蜂窝铝夹层板的整体重量,有效降低了运输成本;本穿孔蜂窝铝夹层板所有零部件均采用金属铝材质,整体耐候性能优异,着色效果好,整体美观度高。
(2)本发明提供的制造方法降低了制造成本,提高了生产效益。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动性的前提下,还可以根据这些附图获得其他的附图。
图1为本发明中提出的一种穿孔蜂窝铝夹层板整体截面图;
图2为本发明中提出的一种穿孔蜂窝铝夹层板内部结构图;
图3为本发明中提出的一种穿孔蜂窝铝夹层板穿孔金属面板图;
图4为本发明中提出的一种穿孔蜂窝铝夹层板穿孔金属背板图;
图5为本发明中提出的一种穿孔蜂窝铝夹层板铝蜂窝芯结构图;
图6为本发明中提出的一种穿孔蜂窝铝夹层板金属面板覆胶膜图;
图7为本发明中提出的一种穿孔蜂窝铝夹层板金属背板覆胶膜图;
图8为本发明中提出的一种穿孔蜂窝铝夹层板金属面板和金属背板覆上胶膜后冲孔完成示意图;
图9为本发明中提出的一种穿孔蜂窝铝夹层板各层层铺示意图;
图10为本发明中提出的一种穿孔蜂窝铝夹层板热压成型图;
图中,1-穿孔金属面板、2-铝蜂窝芯、3-穿孔金属背板、4-面板胶膜、5-背板胶膜、1a-面板微孔、2a-蜂窝芯六边形空腔、2b-蜂窝芯铝箔、3a-背板微孔。
具体实施方式
下面结合附图进一步详细描述本发明的技术方案,但本发明的保护范围不局限于以下所述。本说明书中公开的所有特征,或隐含公开的所有方法或过程中的步骤,除了互相排斥的特征和/或步骤以外,均可以以任何方式组合。
本说明书(包括任何附加权利要求、摘要和附图)中公开的任一特征,除非特别叙述,均可被其他等效或具有类似目的的替代特征加以替换。即,除非特别叙述,每个特征只是一系列等效或类似特征中的一个例子而已。
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作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。
在对实施例进行描述之前,需要对一些必要的术语进行解释。例如:
若本申请中出现使用“第一”、“第二”等术语来描述各种元件,但是这些元件不应当由这些术语所限制。这些术语仅用来区分一个元件和另一个元件。因此,下文所讨论的“第一”元件也可以被称为“第二”元件而不偏离本发明的教导。应当理解的是,若提及一元件“连接”或者“联接”到另一元件时,其可以直接地连接或直接地联接到另一元件或者也可以存在中间元件。相反地,当提及一元件“直接地连接”或“直接地联接”到另一元件时,则不存在中间元件。
在本申请中出现的各种术语仅仅用于描述具体的实施方式的目的而无意作为对本发明的限定,除非上下文另外清楚地指出,否则单数形式意图也包括复数形式。
当在本说明书中使用术语“包括”和/或“包括有”时,这些术语指明了所述特征、整体、步骤、操作、元件和/或部件的存在,但是也不排除一个以上其他特征、整体、步骤、操作、元件、部件和/或其群组的存在和/或附加。
如图1~10所示,一种穿孔蜂窝铝夹层板,包括穿孔金属面板1,所述穿孔金属面板1开有设定孔隙率及设定孔间距的微孔1a,所述穿孔金属面板1的一侧粘接有一层胶膜4,所述胶膜4的另一侧粘接有一层设定厚度并具有设定空腔容积的铝蜂窝芯2,所述铝蜂窝芯2的另一侧通过胶膜5粘接有一层穿孔金属背板3,所述穿孔金属背板3开设有设定孔隙率及设定孔间距的微孔3a。
进一步的,所述穿孔金属面板1、穿孔金属背板3表面上均布设有多个孔径0.5~4mm的微孔。
进一步的,所述穿孔金属面板1、铝蜂窝芯2、穿孔金属背板3的材质均为金属铝材质。
进一步的,所述胶膜4、胶膜5材质为丙烯酸,聚乙烯,聚酯,环氧,酚醛,聚氨酯,双马来酰亚氨,氨基丙烯酸,不饱和聚酯,有机硅等,优选聚氨酯弹性体橡胶。
进一步的,所述胶膜4、胶膜5的厚度范围为0.2mm-0.8mm,优选0.5mm。
进一步的,所述穿孔金属面板1表面开孔率为20%-30%,厚度为0.2mm-2mm,优选0.5mm。
进一步的,所述穿孔金属背板表面开孔率为30%-40%,厚度为0.2mm-2mm,优选0.5mm。
进一步的,所述铝蜂窝芯2的空腔为六边形空腔2a。
进一步的,所述铝蜂窝芯2的厚度为4mm-50mm,优选5mm,所述六边形空腔2a的边长为4mm-20mm,优选7mm,所采用铝箔厚度为0.04mm-0.1mm,优选0.04mm。
一种穿孔蜂窝铝夹层板的制造方法,包括:
第一、选用设定厚度的金属板,利用热压机,压力1.5-2.5MPa,温度180~220℃,对金属板进行加热、校平13~17min;
第二、将胶膜平铺于金属板上,利用热压机,压力0.3~0.7kPa,温度180~220℃,压住金属板和胶膜3~7min,使胶膜处于半融化状态,并粘接与金属板上,自然冷却至120℃以下;
第三、利用龙门冲床,在已覆膜金属板表面按一定的孔径及开孔率进行开孔,制作成已覆膜的穿孔金属面板1和已覆膜的穿孔金属背板3,冲孔完成后进行校平;
第四、将已覆膜的穿孔金属背板3、已完全拉开的铝蜂窝芯2、已覆膜的穿孔金属面板1分层置于热压机底板上,热压机压力1.9~2.1kPa,温度220~240℃,压制4~5min,自然冷却至120℃以下,再保持压力14~16min,使胶膜4及胶膜5完全固化,将孔金属面板1、穿孔金属背板3和铝蜂窝芯2粘接一体,制成穿孔蜂窝铝夹层板。
进一步的,包括:
第五、在第四步后,冷却至常温,然后利用锯床将穿孔蜂窝铝夹层板锯切成需求大小,至此,完成所有加工。
工作原理:在使用时,穿孔金属面板1、铝蜂窝芯2、穿孔金属背板3采用耐候、防火性能好的金属铝材质,其中穿孔金属面板1、铝蜂窝芯2、孔金属背板3起到保持外形尺寸,提高强度的作用,微孔1a起到阻抗吸声的作用,六边形空腔2a起到共振吸声的作用,胶膜4、胶膜5分别起到将穿孔金属面板1、穿孔金属背板3和铝蜂窝芯2连为一体的作用,本发明中的穿孔蜂窝铝夹层板,整体重量轻,整体强度高,具有共振吸声的效果,耐候性好,价格低廉,外形美观。
制备方法:第一、选用一定厚度的金属板,利用热压机,压力1.5-2.5MPa,可以上2.2MPa,温度200℃,对金属板进行加热、校平15min;第二、将胶膜平铺于金属板上,利用热压机,压力0.5kPa,温度200℃,压住金属板和胶膜5min,使胶膜处于半融化状态,并粘接与金属板上,自然冷却至120℃以下;第三、利用龙门冲床,在已覆膜金属板表面按一定的孔径及开孔率进行开孔,制作成已覆膜的穿孔金属面板1和已覆膜的穿孔金属背板3,冲孔完成后进行校平;第四、将已覆膜的穿孔金属背板3、已完全拉开的铝蜂窝芯2、已覆膜的穿孔金属面板1分层置于热压机底板上,热压机压力2kPa,温度230℃,压制5min,自然冷却至120℃以下,再保持压力15min,使胶膜4及胶膜5完全固化,将孔金属面板1、穿孔金属背板3和铝蜂窝芯2粘接一体,制成穿孔蜂窝铝夹层板;第四、冷却至常温后,利用锯床将穿孔蜂窝铝夹层板锯切成需求大小,至此,完成所有加工。
对于前述的方法实施例,为了简单描述,故将其都表述为一系列的动作组合,但是本领域技术人员应该知悉,本申请并不受所描述的动作顺序的限制,因为依据本申请,某一些步骤可以采用其他顺序或者同时进行。其次,本领域技术人员也应该知悉,说明书中所描述的实施例均属于优选实施例,所涉及的动作和单元并不一定是本申请所必须的。
以上所述仅是本发明的优选实施方式,应当理解本发明并非局限于本文所披露的形式,不应看作是对其他实施例的排除,而可用于各种其他组合、修改和环境,并能够在本文所述构想范围内,通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围,则都应在本发明所附权利要求的保护范围内。
Claims (10)
1.一种穿孔蜂窝铝夹层板,其特征在于,包括穿孔金属面板(1),所述穿孔金属面板(1)开有设定孔隙率及设定孔间距的微孔(1a),所述穿孔金属面板(1)的一侧粘接有一层胶膜(4),所述胶膜(4)的另一侧粘接有一层设定厚度并具有设定空腔容积的铝蜂窝芯(2),所述铝蜂窝芯(2)的另一侧通过胶膜(5)粘接有一层穿孔金属背板(3),所述穿孔金属背板(3)开设有设定孔隙率及设定孔间距的微孔(3a)。
2.根据权利要求1所述的一种穿孔蜂窝铝夹层板,其特征在于,所述穿孔金属面板(1)、穿孔金属背板(3)表面上均布设有多个孔径0.5~4mm的微孔。
3.根据权利要求1所述的一种穿孔蜂窝铝夹层板,其特征在于,所述穿孔金属面板(1)、铝蜂窝芯(2)、穿孔金属背板(3)的材质均为金属铝材质。
4.根据权利要求1所述的一种穿孔蜂窝铝夹层板,其特征在于,所述胶膜(4)、胶膜(5)材质均为丙烯酸,聚乙烯,聚酯,环氧,酚醛,聚氨酯,双马来酰亚氨,氨基丙烯酸,不饱和聚酯和有机硅中的任一种。
5.根据权利要求2所述的一种穿孔蜂窝铝夹层板,其特征在于,所述穿孔金属面板(1)表面开孔率为20%-30%,厚度为0.2mm-2mm。
6.根据权利要求2所述的一种穿孔蜂窝铝夹层板,其特征在于,所述穿孔金属背板表面开孔率为30%-40%,厚度为0.2mm-2mm。
7.根据权利要求2所述的一种穿孔蜂窝铝夹层板,其特征在于,所述铝蜂窝芯(2)的空腔为六边形空腔(2a)。
8.根据权利要求7所述的一种穿孔蜂窝铝夹层板,其特征在于,所述铝蜂窝芯(2)的厚度为4mm-50mm,所述六边形空腔(2a)的边长为4mm-20mm,所采用铝箔厚度为0.04mm-0.1mm。
9.一种穿孔蜂窝铝夹层板的制造方法,其特征在于,包括:
第一、选用设定厚度的金属板,利用热压机,压力1.5-2.5MPa,温度180~220℃,对金属板进行加热、校平13~17min;
第二、将胶膜平铺于金属板上,利用热压机,压力0.3~0.7kPa,温度180~220℃,压住金属板和胶膜3~7min,使胶膜处于半融化状态,并粘接与金属板上,自然冷却至120℃以下;
第三、利用龙门冲床,在已覆膜金属板表面按一定的孔径及开孔率进行开孔,制作成已覆膜的穿孔金属面板(1)和已覆膜的穿孔金属背板(3),冲孔完成后进行校平;
第四、将已覆膜的穿孔金属背板(3)、已完全拉开的铝蜂窝芯(2)、已覆膜的穿孔金属面板(1)分层置于热压机底板上,热压机压力1.9~2.1kPa,温度220~240℃,压制4~5min,自然冷却至120℃以下,再保持压力14~16min,使胶膜(4)及胶膜(5)完全固化,将孔金属面板(1)、穿孔金属背板(3)和铝蜂窝芯(2)粘接一体,制成穿孔蜂窝铝夹层板。
10.根据权利要求9所述的一种穿孔蜂窝铝夹层板的制造方法,其特征在于,包括:
第五、在第四步后,冷却至常温,然后利用锯床将穿孔蜂窝铝夹层板锯切成需求大小,至此,完成所有加工。
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