CN112721383A - 一种提高隔音棉邵氏度的方法 - Google Patents

一种提高隔音棉邵氏度的方法 Download PDF

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Publication number
CN112721383A
CN112721383A CN202011599310.1A CN202011599310A CN112721383A CN 112721383 A CN112721383 A CN 112721383A CN 202011599310 A CN202011599310 A CN 202011599310A CN 112721383 A CN112721383 A CN 112721383A
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China
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layer
soundproof cotton
sound insulation
parts
elastic
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潘建新
汪飞
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Hubei Tianyun Noise Reduction And Antivibration New Material Co ltd
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Hubei Tianyun Noise Reduction And Antivibration New Material Co ltd
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Priority to CN202011599310.1A priority Critical patent/CN112721383A/zh
Publication of CN112721383A publication Critical patent/CN112721383A/zh
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Abstract

本发明涉及一种提高隔音棉邵氏度的方法，具体步骤如下：编织得到轻质金属网层和中空金属网层；在泡沫塑料层镶嵌弹性加强筋；将弹性层贯穿钻孔并填充轻质金属纤维；在软质树脂板层内嵌混合纤维；再将混合纤维层板化处理；最后将各层按顺序叠放后热压压板得到隔音棉，再用抗老化膜封边即可；本发明设计的提高隔音棉邵氏度的方法，通过在隔音棉内部增加双层编织金属网，并在金属网之间设置有树脂板和弹性层，通过金属网、树脂板和弹性层来提高隔音棉的隔音效果和邵氏硬度，并通过此表层的混合纤维进一步补强邵氏硬度和隔音效果，从而整体上提高隔音棉的邵氏度和隔音效果，具有良好的市场潜在价值和应用前景，具有实用性和创造性。

Description

一种提高隔音棉邵氏度的方法
技术领域
本发明属于隔音棉材料技术领域，特别涉及一种提高隔音棉邵氏度的方法。
背景技术
硬度是物质受压变形程度或抗刺穿能力的一种物理度量方式。硬度可分相对硬度和绝对硬度。绝对硬度一般在科学界使用，生产实践中很少用到。我们通常使用硬度体系为相对的硬度，常用有以下几种标示方法：肖氏(也叫邵氏，邵尔，英文SHORE)、洛氏、布氏三种。邵氏一般用于橡胶类材料上；邵氏硬度是指用邵氏硬度计测出的值的读数，它的单位是“度”，其描述方法分A、D两种，分别代表不同的硬度范围，90度以下的用邵氏A硬度计测试，并得出数据，90度及以上的用邵氏D硬度计测试并得出数据，所以，一般来讲对于一个橡胶或塑料制品，在测试的时候，测试人员能根据经验进行测试前的预判，从而决定用邵氏A硬度计还是用邵氏D硬度计来进行测试。
在当今社会，噪声污染已经成为继水污染、大气污染后被世界范围所关注的主要环境污染问题之一。使用吸音隔音材料进行隔音消音是治理噪音污染的常用手段。目前市场上常用的隔音棉有玻璃纤维隔音棉、海绵、聚酯纤维隔音棉等。玻璃纤维棉容易引起皮肤瘙痒和呼吸道过敏，对人体有危害，不适合室内使用。海绵大部分是闭孔发泡材料，吸音性能有限，更适合用于保温领域。而普通聚酯纤维隔音棉吸音的频宽较窄，仅对中高频声音有良好的吸收，对低频声音的吸收效果有限。而用于汽车或家电内饰材料的隔音棉不仅需要良好的隔音性能，还需要满足安全阻燃、绿色环保、舒适耐用的等要求。
一方面，随着生活实用和消防安全要求的日益增加，人们对于隔音棉的阻燃要求也越来越高。目前阻燃技术已进入一个新的发展阶段，未来隔音材料的阻燃技术正朝着高效、经济、环保的方向发展。由于无机阻燃剂具有：毒性低，热稳定性好；不析出，有持久的阻燃效果；不产生腐蚀性气体；价格低廉；较小的发烟量等优点，因此无机阻燃剂在各个方面的应用正逐步取代有机阻燃剂，因此合成无机阻燃剂的研究意义重大；但是由于有机阻燃剂目前仍在大量使用，将无机阻燃剂与有机阻燃剂组合使用不失为一种可取的过渡的方式。
目前，社会对隔音材料的需求量迅猛增长，传统的吸声材料已无法满足人们对环保性、装饰性、阻燃性、抗老化性以及硬度的更高要求。因此，研究并开发应用新的环保吸音阻燃、抗老化的高硬度材料已成为努力的方向。
发明内容
本发明的目的在于通过在隔音棉的内部设置双层编织金属网，并在金属网之间设置树脂板和弹性层，并在最内层设置加强筋，次表层设置混合纤维，并通过抗老化膜封边，整体上提高隔音棉的邵氏硬度、隔音效果和抗老化效果。
为实现上述目的，本发明提供如下技术方案：
一种高邵氏度的隔音棉，隔音棉包括有表层的抗老化膜，抗老化膜的内层设置有混合纤维层，混合纤维层的内层设置有轻质金属网层；轻质金属网层内层设置有软质树脂板层，软质树脂板层的内层设置有弹性层；弹性层的内层设置有中空金属网层，中空金属网层的内层设置有泡沫塑料层，泡沫塑料层的内部设置有弹性加强筋；软质树脂板层的内部设置有真空隔音腔，真空隔音腔内部填装有隔音颗粒，弹性层的内部设置有隔音通道。
一种提高隔音棉邵氏度的方法，具体步骤如下：
1).编织：将组成轻质金属网层的轻质金属纤维进行正交编织，保证编织后的轻质金属网层孔隙率为0.2～0.5；
将组成中空金属网层的中空金属纤维进行正交编织，保证编织后的轻质金属网层孔隙率为0.3～0.8；
2).镶嵌：在泡沫塑料层上开设若干个方形凹槽，将合适的弹性加强筋内嵌在方形凹槽中，再将正交编织的中空金属网层贴附在泡沫塑料层的上下表面；
3).填充：将弹性层进行贯穿钻孔得到隔音通道，再在隔音通道内部填充组成轻质金属网层的轻质金属纤维，保证轻质金属纤维按照孔径贯穿弹性层并包埋填充在弹性层中；
4).内嵌：在软质树脂板层的内部开设有真空隔音腔，真空隔音腔不贯穿软质树脂板层，并往软质树脂板层内部的真空隔音腔填装混合纤维，填装后将真空隔音腔密封；
5).板化：将混合纤维层的混合纤维摆放整齐，通过热压机在180～200℃下热压10～30min，得到厚度为0.8～1.5cm的混合纤维层，再继续加力将混合纤维层厚度压至0.3～0.5cm即可；
6).压板：将混合纤维层、轻质金属网层、软质树脂板层、弹性层、中空金属网层和泡沫塑料层按照顺序叠放整齐，并在各层连接处的中部涂抹少量胶粘剂，通过热压机在60～90℃热压10～30min，紧实后降温至常温得到隔音棉层；
7).封边：将抗老化膜贴附在步骤6中得到的吸音棉层的两侧，抗老化膜(1)的边长大于吸音棉层的边长，将吸音棉层两侧的抗老化膜对齐后在150～250℃时进行热封边，封边后即得高邵氏度的隔音棉。
作为优选的，抗老化膜按重量百分比计，含有以下组成成分：石墨烯改性无卤环氧树脂25～50％、聚碳酸酯15～25％、复合抗老化剂3～8％、分散剂1～2％、弹性粉15～20％、固化剂1～5％和填料10～15％。
作为优选的，混合纤维层按重量百分比计，含有以下组成成分：合金纤维10～15％、石棉纤维15～25％、陶瓷纤维30～45％、碳纤维10～15％、橡胶纤维20～35％和填料5～15％。
作为优选的，软质树脂板层按重量百分比计，含有以下组成成分：水性弹性树脂25～35％、石墨烯改性环氧树脂15～25％、ABS树脂15～25％、天然橡胶10～25％、溶剂20～45％、分散剂1～2％、消光剂3～6％、固化剂2～5％、固化促进剂1～3％和填料5～8％。
作为优选的，填料按重量百分比计，含有以下组成成分：纳米二氧化硅20～30％、纳米碳酸钙25～30％、少层石墨烯5～15％、碳纳米管5～10％和纳米级火山灰30～45％。
作为优选的，弹性层包括有以下重量份数的组合成分：天然橡胶30～45份、石墨烯改性丁腈橡胶20～30份、碳纤维改性丁苯橡胶10～15份、改性纳米石墨烯5～15份、增韧剂3～9份、纳米白炭黑2～8份、纳米碳酸钙3～5份、偶联剂1～3份、相容剂2～4份、防霉剂0.5～1.5份、抗氧化剂1～2份、抗老化剂0.5～1.2份和紫外吸收剂0.5～1份。
作为优选的，复合抗老化剂为2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的混合物。
作为优选的，2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的质量比为1:10～15:13～18:15～20:16～25。
本发明的有益效果：本发明设计的提高隔音棉邵氏度的方法，通过在隔音棉内部增加双层编织金属网，并在金属网之间设置有树脂板和弹性层，通过金属网、树脂板和弹性层来提高隔音棉的隔音效果和邵氏硬度，并通过此表层的混合纤维进一步补强邵氏硬度和隔音效果，从而整体上提高隔音棉的邵氏度和隔音效果，具有良好的市场潜在价值和应用前景，具有实用性和创造性。
附图说明
图1为本发明高邵氏度的隔音棉的结构示意图。
图中：1、抗老化膜；2、混合纤维层；3、轻质金属网层；4、软质树脂板层；5、弹性层；6、中空金属网层；7、泡沫塑料层；8、真空隔音腔；9、隔音颗粒；10、弹性加强筋；11、隔音通道。
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。
如图1所示，一种高邵氏度的隔音棉，隔音棉包括有表层的抗老化膜1，抗老化膜1的内层设置有混合纤维层2，混合纤维层2的内层设置有轻质金属网层3；轻质金属网层3内层设置有软质树脂板层4，软质树脂板层4的内层设置有弹性层5；弹性层5的内层设置有中空金属网层6，中空金属网层6的内层设置有泡沫塑料层7，泡沫塑料层7的内部设置有弹性加强筋10；软质树脂板层4的内部设置有真空隔音腔8，真空隔音腔8内部填装有隔音颗粒9，弹性层5的内部设置有隔音通道11。
一种提高隔音棉邵氏度的方法，具体步骤如下：
1).编织：将组成轻质金属网层3的轻质金属纤维进行正交编织，保证编织后的轻质金属网层3孔隙率为0.5；
将组成中空金属网层6的中空金属纤维进行正交编织，保证编织后的轻质金属网层3孔隙率为0.3；
2).镶嵌：在泡沫塑料层7上开设若干个方形凹槽，将合适的弹性加强筋10内嵌在方形凹槽中，再将正交编织的中空金属网层6贴附在泡沫塑料层7的上下表面；
3).填充：将弹性层5进行贯穿钻孔得到隔音通道11，再在隔音通道11内部填充组成轻质金属网层3的轻质金属纤维，保证轻质金属纤维按照孔径贯穿弹性层5并包埋填充在弹性层5中；
4).内嵌：在软质树脂板层4的内部开设有真空隔音腔8，真空隔音腔8不贯穿软质树脂板层4，并往软质树脂板层4内部的真空隔音腔8填装混合纤维，填装后将真空隔音腔8密封；
5).板化：将混合纤维层2的混合纤维摆放整齐，通过热压机在200℃下热压10min，得到厚度为1.5cm的混合纤维层2，再继续加力将混合纤维层2厚度压至0.5cm即可；
6).压板：将混合纤维层2、轻质金属网层3、软质树脂板层4、弹性层5、中空金属网层6和泡沫塑料层7按照顺序叠放整齐，并在各层连接处的中部涂抹少量胶粘剂，通过热压机在90℃热压10min，紧实后降温至常温得到隔音棉层；
7).封边：将抗老化膜1贴附在步骤6中得到的吸音棉层的两侧，抗老化膜1的边长大于吸音棉层的边长，将吸音棉层两侧的抗老化膜1对齐后在200℃时进行热封边，封边后即得高邵氏度的隔音棉。
进一步地，抗老化膜1按重量百分比计，含有以下组成成分：石墨烯改性无卤环氧树脂25％、聚碳酸酯25％、复合抗老化剂8％、分散剂2％、弹性粉20％、固化剂5％和填料15％。
进一步地，混合纤维层2按重量百分比计，含有以下组成成分：合金纤维15％、石棉纤维15％、陶瓷纤维30％、碳纤维10％、橡胶纤维20％和填料10％。
进一步地，软质树脂板层3按重量百分比计，含有以下组成成分：水性弹性树脂25％、石墨烯改性环氧树脂17％、ABS树脂15％、天然橡胶10％、溶剂20％、分散剂2％、消光剂3％、固化剂2％、固化促进剂1％和填料5％。
更进一步地，填料按重量百分比计，含有以下组成成分：纳米二氧化硅20％、纳米碳酸钙25％、少层石墨烯5％、碳纳米管5％和纳米级火山灰45％。
进一步地，弹性层5包括有以下重量份数的组合成分：天然橡胶45份、石墨烯改性丁腈橡胶30份、碳纤维改性丁苯橡胶15份、改性纳米石墨烯15份、增韧剂9份、纳米白炭黑8份、纳米碳酸钙5份、偶联剂3份、相容剂4份、防霉剂1.5份、抗氧化剂2份、抗老化剂1.2份和紫外吸收剂1份。
进一步地，复合抗老化剂为2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的混合物。
更进一步地，2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的质量比为1:15:18:20:25。
实施例2
本实施例于实施例1的不同之处在于：
一种提高隔音棉邵氏度的方法，具体步骤如下：
1).编织：将组成轻质金属网层3的轻质金属纤维进行正交编织，保证编织后的轻质金属网层3孔隙率为0.2；
将组成中空金属网层6的中空金属纤维进行正交编织，保证编织后的轻质金属网层3孔隙率为0.8；
2).镶嵌：在泡沫塑料层7上开设若干个方形凹槽，将合适的弹性加强筋10内嵌在方形凹槽中，再将正交编织的中空金属网层6贴附在泡沫塑料层7的上下表面；
3).填充：将弹性层5进行贯穿钻孔，再在钻孔内部填充组成轻质金属网层3的轻质金属纤维，保证轻质金属纤维按照孔径贯穿弹性层5并包埋填充在弹性层5中；
4).内嵌：在软质树脂板层4的内部开设有真空隔音腔8，真空隔音腔8不贯穿软质树脂板层4，并往软质树脂板层4内部的真空隔音腔8填装混合纤维，填装后将真空隔音腔8密封；
5).板化：将混合纤维层2的混合纤维摆放整齐，通过热压机在180℃下热压30min，得到厚度为0.8cm的混合纤维层2，再继续加力将混合纤维层2厚度压至0.3cm即可；
6).压板：将混合纤维层2、轻质金属网层3、软质树脂板层4、弹性层5、中空金属网层6和泡沫塑料层7按照顺序叠放整齐，并在各层连接处的中部涂抹少量胶粘剂，通过热压机在60℃热压30min，紧实后降温至常温得到隔音棉层；
7).封边：将抗老化膜1贴附在步骤6中得到的吸音棉层的两侧，抗老化膜1的边长大于吸音棉层的边长，将吸音棉层两侧的抗老化膜1对齐后在180℃时进行热封边，封边后即得高邵氏度的隔音棉。
进一步地，抗老化膜1按重量百分比计，含有以下组成成分：石墨烯改性无卤环氧树脂50％、聚碳酸酯15％、复合抗老化剂7％、分散剂1％、弹性粉15％、固化剂2％和填料10％。
进一步地，混合纤维层2按重量百分比计，含有以下组成成分：合金纤维10％、石棉纤维15％、陶瓷纤维30％、碳纤维10％、橡胶纤维30％和填料5％。
进一步地，软质树脂板层3按重量百分比计，含有以下组成成分：水性弹性树脂25％、石墨烯改性环氧树脂15％、ABS树脂15％、天然橡胶10％、溶剂23％、分散剂1％、消光剂3％、固化剂2％、固化促进剂1％和填料5％。
更进一步地，填料按重量百分比计，含有以下组成成分：纳米二氧化硅20％、纳米碳酸钙25％、少层石墨烯15％、碳纳米管10％和纳米级火山灰30％。
进一步地，弹性层5包括有以下重量份数的组合成分：天然橡胶30份、石墨烯改性丁腈橡胶20份、碳纤维改性丁苯橡胶10份、改性纳米石墨烯5份、增韧剂3份、纳米白炭黑份、纳米碳酸钙3份、偶联剂1份、相容剂2份、防霉剂0.5份、抗氧化剂1份、抗老化剂0.5份和紫外吸收剂0.5份。
更进一步地，2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的质量比为1:10:13:15:16。
在本发明中，本发明设计的提高隔音棉邵氏度的方法，通过在隔音棉内部增加双层编织金属网，并在金属网之间设置有树脂板和弹性层，通过金属网、树脂板和弹性层来提高隔音棉的隔音效果和邵氏硬度，并通过此表层的混合纤维进一步补强邵氏硬度和隔音效果，从而整体上提高隔音棉的邵氏度和隔音效果，具有良好的市场潜在价值和应用前景，具有实用性和创造性。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (8)

1.一种提高隔音棉邵氏度的方法，其特征在于：所述隔音棉包括有表层的抗老化膜(1)，所述抗老化膜(1)的内层设置有混合纤维层(2)，所述混合纤维层(2)的内层设置有轻质金属网层(3)；所述的轻质金属网层(3)内层设置有软质树脂板层(4)，软质树脂板层(4)的内层设置有弹性层(5)；所述弹性层(5)的内层设置有中空金属网层(6)，中空金属网层(6)的内层设置有泡沫塑料层(7)，泡沫塑料层(7)的内部设置有弹性加强筋(10)；所述软质树脂板层(4)的内部设置有真空隔音腔(8)，真空隔音腔(8)内部填装有隔音颗粒(9)，所述弹性层(5)的内部设置有隔音通道(11)；
所述提高隔音棉邵氏度的方法的具体步骤如下：
1).编织：将组成轻质金属网层(3)的轻质金属纤维进行正交编织，保证编织后的轻质金属网层(3)孔隙率为0.2～0.5；
将组成中空金属网层(6)的中空金属纤维进行正交编织，保证编织后的轻质金属网层(3)孔隙率为0.3～0.8；
2).镶嵌：在泡沫塑料层(7)上开设若干个方形凹槽，将合适的弹性加强筋(10)内嵌在方形凹槽中，再将正交编织的中空金属网层(6)贴附在泡沫塑料层(7)的上下表面；
3).填充：将弹性层(5)进行贯穿钻孔得到隔音通道(11)，再在隔音通道(11)内部填充组成轻质金属网层(3)的轻质金属纤维，保证轻质金属纤维按照孔径贯穿弹性层(5)并包埋填充在弹性层(5)中；
4).内嵌：在软质树脂板层(4)的内部开设有真空隔音腔(8)，真空隔音腔(8)不贯穿软质树脂板层(4)，并往软质树脂板层(4)内部的真空隔音腔(8)填装混合纤维，填装后将真空隔音腔(8)密封；
5).板化：将混合纤维层(2)的混合纤维摆放整齐，通过热压机在180～200℃下热压10～30min，得到厚度为0.8～1.5cm的混合纤维层(2)，再继续加力将混合纤维层(2)厚度压至0.3～0.5cm即可；
6).压板：将混合纤维层(2)、轻质金属网层(3)、软质树脂板层(4)、弹性层(5)、中空金属网层(6)和泡沫塑料层(7)按照顺序叠放整齐，并在各层连接处的中部涂抹少量胶粘剂，通过热压机在60～90℃热压10～30min，紧实后降温至常温得到隔音棉层；
7).封边：将抗老化膜(1)贴附在步骤6中得到的吸音棉层的两侧，抗老化膜(1)的边长大于吸音棉层的边长，将吸音棉层两侧的抗老化膜(1)对齐后在150～250℃时进行热封边，封边后即得高邵氏度的隔音棉。
2.根据权利要求1所述的提高隔音棉邵氏度的方法，其特征在于：所述抗老化膜(1)按重量百分比计，含有以下组成成分：石墨烯改性无卤环氧树脂25～50％、聚碳酸酯15～25％、复合抗老化剂3～8％、分散剂1～2％、弹性粉15～20％、固化剂1～5％和填料10～15％。
3.根据权利要求1所述的提高隔音棉邵氏度的方法，其特征在于：所述混合纤维层(2)按重量百分比计，含有以下组成成分：合金纤维10～15％、石棉纤维15～25％、陶瓷纤维30～45％、碳纤维10～15％、橡胶纤维20～35％和填料5～15％。
4.根据权利要求1所述的提高隔音棉邵氏度的方法，其特征在于：所述软质树脂板层(3)按重量百分比计，含有以下组成成分：水性弹性树脂25～35％、石墨烯改性环氧树脂15～25％、ABS树脂15～25％、天然橡胶10～25％、溶剂20～45％、分散剂1～2％、消光剂3～6％、固化剂2～5％、固化促进剂1～3％和填料5～8％。
5.根据权利要求2或3或4所述的提高隔音棉邵氏度的方法，其特征在于：所述填料按重量百分比计，含有以下组成成分：纳米二氧化硅20～30％、纳米碳酸钙25～30％、少层石墨烯5～15％、碳纳米管5～10％和纳米级火山灰30～45％。
6.根据权利要求1所述的提高隔音棉邵氏度的方法，其特征在于：所述弹性层(5)包括有以下重量份数的组合成分：天然橡胶30～45份、石墨烯改性丁腈橡胶20～30份、碳纤维改性丁苯橡胶10～15份、改性纳米石墨烯5～15份、增韧剂3～9份、纳米白炭黑2～8份、纳米碳酸钙3～5份、偶联剂1～3份、相容剂2～4份、防霉剂0.5～1.5份、抗氧化剂1～2份、抗老化剂0.5～1.2份和紫外吸收剂0.5～1份。
7.根据权利要求2所述的提高隔音棉邵氏度的方法，其特征在于：所述复合抗老化剂为2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的混合物。
8.根据权利要求7所述的提高隔音棉邵氏度的方法，其特征在于：所述2-羟基-4-正辛氧基二苯甲酮、硫代二丙酸双十二烷酯、β-(3,5-二叔丁基-4-羟基苯基)丙酸正十八碳醇酯、FeTiO3-MgTiO3、Cu5FeS4的质量比为1:10～15:13～18:15～20:16～25。
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