CN113829678A - 一种轻质隔音复合板及其制备方法 - Google Patents
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Abstract
本公开提供了一种轻质隔音复合板及其制备方法,所述轻质隔音复合板从上到下依次为预浸料层、粘合剂层、蜂窝发泡材料、粘合剂层、预浸料层,所述蜂窝发泡材料为填充有发泡材料的芳纶蜂窝,所述蜂窝发泡材料的密度为200‑800kg/m3,厚度为5‑30mm;向芳纶蜂窝中以密度由高到低的顺序依次填充发泡材料,从而形成密度梯度;在所述蜂窝发泡材料的上表面和下表面分别通过粘合剂层与预浸料层连接;一体复合成型。本公开的轻质隔音复合板通过蜂窝发泡材料实现了轻量化,隔音降噪效果更好。
Description
技术领域
本公开涉及复合材料制造领域,尤其涉及一种轻质隔音复合板及其制备方法。
背景技术
随着交通运输装备的高速化、舒适化发展,使其对轻量化、隔音等要求也越来越高。当前交通运输装备一般常采用金属材料,不利于其兼具轻量化和低噪音。复合材料在轻量化、隔音方面有着一定的可设计优势。
芳纶纸蜂窝复合材料具有轻质高强、阻燃环保、耐腐蚀、抗疲劳等优异性能,广泛应用于航空航天、轨道交通、军工等高端领域。芳纶蜂窝由芳纶纸经涂胶、叠合、热压、拉伸定型、浸胶固化、片切等一系列工序制造而成,其与蒙皮材料复合成三明治结构,可大幅减轻部件质量,在有效减重、降低腐蚀、改善噪声、阻尼减震等众多方面有着无与伦比的优势。
单纯的蜂窝复合材料其隔音效果有限,不加其他隔音材料一般很难达到较高的隔音量。目前也有在蜂窝复合中引入阻尼隔音毡来提高复合板隔音量,由于阻尼隔音毡密度较大同时具有一定厚度,这使得其整体质量增加,不利于其轻量化。
发明内容
为了解决上述技术问题中的至少一个,本公开提供了一种轻质隔音复合板,从上到下依次为预浸料层、粘合剂层、蜂窝发泡材料、粘合剂层、预浸料层,
蜂窝发泡材料,所述蜂窝发泡材料为填充有发泡材料的芳纶蜂窝,所述蜂窝发泡材料的密度为200-800kg/m3,厚度为5-30mm;向芳纶蜂窝中以密度由高到低的顺序依次填充发泡材料,从而形成密度梯度;
在所述蜂窝发泡材料的上表面和下表面分别通过粘合剂层与预浸料层连接;
一体复合成型。
在一个优选的实施方式中,所述芳纶蜂窝的孔格边长为2-5mm,蜂窝壁厚度为0.045-0.15mm,芳纶蜂窝的密度为48-144kg/m3。
在一个优选的实施方式中,所述发泡材料是阻燃发泡材料。优选地,所述阻燃发泡材料优选为水凝胶发泡材料、聚氨酯发泡材料、轻质环氧发泡材料等。
在一个优选的实施方式中,所述发泡材料的密度为150-700kg/m3。
在一个优选的实施方式中,所述发泡材料与芳纶蜂窝的重量比为2-16:1。当发泡材料与芳纶蜂窝的重量比大于16:1时,则不利于减重;当发泡材料与芳纶蜂窝的重量比小于2:1时,则隔音降噪效果降低。
在一个优选的实施方式中,芳纶蜂窝由芳纶纤维和酚醛树脂复合而成,具有密度小、比强度和比刚度高等优点。
在一个优选的实施方式中,所述复合成型是通过热压、真空袋压或热压罐的工艺进行的。
在一个优选的实施方式中,所述预浸料选自纤维织物浸渍树脂材料。
预浸料是用树脂基体在严格控制的条件下浸渍连续纤维或织物,制成树脂基体与增强体的组合物,是制造复合材料的中间材料。预浸料的成分即为常见的纤维织物浸渍树脂材料,纤维织物常为玻璃纤维、碳纤维、芳纶纤维等,树脂常为阻燃环氧树脂、酚醛树脂等。热固性预浸料可以进行力学性能补强。例如碳纤环氧、玻纤环氧预浸料,其是具有较好力学性能的热固性复合材料。优选地,所述预浸料为玻纤环氧预浸料。所述预浸料层的厚度为0.25-2mm。
所述预浸料在一定温度和压力条件下经固化后形成的片材,称为复合材料蒙皮。
优选地,所述粘合剂层由粘合剂组成,所述粘合剂选自热固性树脂、反应性聚合物中的一种或多种。所述粘合剂层也可以由预浸料层替代。
本公开还提供了一种制备上述的轻质隔音复合板的制备方法,包括:
(1)采用发泡材料对芳纶蜂窝进行密度梯度填充发泡,制备具有一定密度梯度的蜂窝发泡材料,控制填充过程中压力为0.1-0.2Mpa,温度为100-120℃,时间为40-60min,得到低-高频广谱隔/吸音材料;
(2)然后按照从上到下的顺序依次铺设第一预浸料层、蜂窝发泡材料,第二预浸料层,其中预浸料层和芯材之间通过粘合剂层连接,在压力0.3-0.5MPa,温度100-120℃的条件下处理60-120min固化成型,然后进行脱模修边处理,得到一种轻质隔音复合板。
在一个优选的实施方式中,所述发泡材料的密度梯度为150-700kg/m3。设置密度梯度的目的是为了对低频和高频都能产生一定的隔音效果,从而达到广谱(低频到高频)隔音的效果。
在一个优选的实施方式中,填充发泡得到的蜂窝发泡材料的密度为200-800kg/m3。
本公开还提供了一种制备上述的轻质隔音复合板的制备方法,包括:
(1)采用发泡材料对芳纶蜂窝进行密度梯度填充发泡,制备具有一定密度梯度的蜂窝发泡材料,控制填充过程中压力为0.1-0.2Mpa,温度为100-120℃,时间为40-60min,得到低-高频广谱隔/吸音材料;
(2)将预浸料进行固化成型得到复合材料蒙皮,然后对其进行打磨,并将其铺设在蜂窝发泡材料上下面,在复合材料蒙皮与蜂窝发泡材料之间设置粘合剂层,在压力0.3-0.5MPa,温度100-120℃的条件下处理60-120min固化成型,最后进行修边处理,得到一种轻质隔音复合板。
在一个优选的实施方式中,所述发泡材料的密度梯度为150-700kg/m3。
在一个优选的实施方式中,填充发泡得到的蜂窝发泡材料的密度为200-800kg/m3。
在一个优选的实施方式中,所述填充是通过灌充的方法进行的。采用密度由高到低的顺序进行填充,这样可以设计不同层密度,从而形成密度梯度填充。
在一个优选的实施方式中,所述固化成型是通过热压、真空袋压或热压罐的工艺进行的。
本公开还提供了一种制备上述的轻质隔音复合板的制备方法,包括:
(1)采用闭孔泡沫对芳纶蜂窝进行密度梯度填充发泡,制备具有一定密度梯度的蜂窝发泡材料,控制填充过程中压力为0.1-0.2Mpa,温度为100-120℃,时间为40-60min,得到低-高频广谱隔/吸音材料;
(2)在蜂窝发泡材料上铺设纤维织物材料,然后在织物上面铺设脱模布、导流网、真空袋等辅助材料,然后通过真空导流工艺进行树脂导流成型,得到一种轻质隔音复合板。
在一个优选的实施方式中,所述闭孔泡沫的密度梯度为150-700kg/m3。
在一个优选的实施方式中,填充发泡得到的蜂窝发泡材料的密度为200-800kg/m3。
在一个优选的实施方式中,所述纤维织物材料的厚度为1mm。所述纤维织物材料为玻纤、碳纤和芳纶等。
在一个优选的实施方式中,导流成型后,树脂与玻纤织物成为一体,共同作为蒙皮。
本公开的轻质隔音复合板,适用于建筑、交通运输领域,尤其适用于民用建筑、车船装饰等。
本公开提供了一种轻质隔音复合板,其具有如下技术效果:
相对金属材料来说,本公开的轻质隔音复合板质量更轻、隔音降噪效果更好。相对于引入阻尼隔音毡复合材料来说,本公开的轻质隔音复合板质量更轻,复合工艺简单灵活。
本公开的轻质隔音复合板可以更好满足交通运输装备对轻量化、舒适化及成本要求,促进交通运输装备优化升级。
芳纶蜂窝是多孔材料,因此蜂窝密度很小。虽然单独的芳纶蜂窝芯本身并不具有隔音、隔热性能,但本公开的隔音复合板具有良好的隔音、隔热性能,在芳纶蜂窝中,通过填充不同密度的阻燃发泡材料或闭孔泡沫,这样可以设计不同层密度,从而形成密度梯度填充,因而对不同分贝的声音具有良好的隔音性能。
附图说明
附图示出了本公开的示例性实施方式,并与其说明一起用于解释本公开的原理,其中包括了这些附图以提供对本公开的进一步理解,并且附图包括在本说明书中并构成本说明书的一部分。
图1为示出了现有技术中阻尼隔音复合板的一个示例性实施方式的示意图;
图2为示出了制备本公开的蜂窝发泡材料的一个示例性实施方式的流程图;
图3为示出了本公开的蜂窝发泡材料的图片;
图4为示出了本公开的轻质隔音复合板的制备流程图;
图5为示出了本公开的轻质隔音复合板的一个示例性实施方式的示意图。
附图标记
1.预浸料层;2.粘合剂层;3.阻尼隔音毡;4.芯材;5.蜂窝发泡材料。
具体实施方式
下面结合附图和实施方式对本公开作进一步的详细说明。可以理解的是,此处所描述的具体实施方式仅用于解释相关内容,而非对本公开的限定。另外还需要说明的是,为了便于描述,附图中仅示出了与本公开相关的部分。
需要说明的是,在不冲突的情况下,本公开中的实施方式及实施方式中的特征可以相互组合。下面将参考附图并结合实施方式来详细说明本公开。
实施例
实施例1
共固化一体成型制备轻质隔音复合板。具体步骤如下:
1、将蛭石填料加入水凝胶发泡材料中,并制备不同密度的浆料,所得浆料密度为150kg/m3、250kg/m3、350kg/m3、450kg/m3。
2、将不同密度的水凝胶发泡浆料分别填充至芳纶蜂窝中;
3、对填充好发泡浆料的蜂窝放入烘箱中,在105℃下,固化干燥30min,得到厚度为20mm,密度为350kg/m3的蜂窝发泡材料。
4、采用玻纤环氧预浸料在蜂窝发泡材料上下面进行铺层,两面均铺设4层,每层预浸料层厚度为0.25mm,厚度共计1mm。
5、将铺层完成的结构连同模具板一同放入压机中,在0.3MPa,120℃,90min条件下进行复合固化成型。
6、热压固化完成后进行脱模修边处理,得到轻质隔音复合板。
实施例2
共固化一体成型制备轻质隔音复合板。具体步骤如下:
1、将蛭石填料加入水凝胶发泡材料中,并制备不同密度的浆料,所得浆料密度为300kg/m3、400kg/m3、500kg/m3、600kg/m3。
2、将不同密度的水凝胶发泡浆料分别填充至芳纶蜂窝中;
3、对填充好发泡浆料的蜂窝放入烘箱中,在105℃下,固化干燥30min,得到厚度为10mm,密度为450kg/m3的蜂窝发泡材料。
4、采用玻纤环氧预浸料在蜂窝发泡材料上下面进行铺层,两面均铺设4层,每层预浸料层厚度为0.25mm,厚度共计1mm。
5、将铺层完成的结构连同模具板一同放入压机中,在0.5MPa,110℃,90min条件下进行复合固化成型。
6、热压固化完成后进行脱模修边处理,得到轻质隔音复合板。
实施例3
二次固化胶接成型制备轻质隔音复合板。具体步骤如下:
1、将珍珠岩填料加入水凝胶发泡材料中,并制备不同密度的浆料,所得浆料密度为150kg/m3、300kg/m3、450kg/m3、600kg/m3。
2、将不同密度的水凝胶发泡浆料分别填充至芳纶蜂窝中;
3、对填充好发泡浆料的蜂窝放入烘箱中,在110℃下,固化干燥20min,得到厚度为30mm,密度为300kg/m3的蜂窝发泡材料。
4、对玻纤环氧预浸料进行模具板上铺层,层数为3层,每层预浸料层厚度为0.25mm,厚度共计0.75mm;然后放置于压机上在0.3MPa,120℃,60min条件下进行复合固化成型,得到复合材料蒙皮。
5、将复合材料蒙皮的其中一面作为胶接面进行打磨处理并施胶;
6、然后将蜂窝发泡材料放置于复合材料蒙皮胶接面之间进行复合,在0.1MPa,60℃,60min下进行固化成型,得到轻质隔音复合板。
实施例4
真空导流一体成型制备轻质隔音复合板。具体步骤如下:
1、制备不同密度的PU发泡浆料,所得浆料密度为250kg/m3、500kg/m3、550kg/m3、700kg/m3。
2、将不同密度的PU发泡浆料分别填充至芳纶蜂窝中;
3、对填充好发泡浆料的蜂窝放入烘箱中,然后在25℃下进行发泡,得到厚度为25mm,密度为600kg/m3的蜂窝发泡材料。
4、在模具上进行玻纤织物铺层,层数为3层,每层玻纤织物厚度为0.25mm,厚度共计0.75mm,然后将蜂窝发泡材料放置在织物上,同时在蜂窝发泡材料下端面再进行玻纤织物铺层,层数为3层,每层玻纤织物厚度为0.25mm,厚度共计0.75mm;最后在织物上面铺设辅助材料脱模布、导流网、真空袋。
5、对部件进行抽真空并导入调配好的阻燃环氧树脂。
6、将导流好的部件放入烘箱中,在80℃下固化100min。
7、对部件进行脱模修边处理,得到轻质隔音复合板。
对比例1
铝蜂窝复合板具体步骤如下:
1、对蒙皮用铝板(厚1mm)胶接面进行喷砂或打磨;
2、对胶接面处理好的铝板进行均匀施胶;
3、然后将裁切好的铝蜂窝(密度48kg/m3,厚度15.8mm)放置于铝板胶接面之间进行复合,在0.1MPa,60℃,60min下进行固化成型,得到铝蜂窝复合板。
对比例2
阻尼隔音复合板:具体步骤如下:
1、将预浸料热压成型制备复合材料蒙皮,并对胶接面进行均匀施胶;
2、然后按照复合材料蒙皮(厚度0.5mm,面密度600g/m2)+阻尼隔音毡(厚度2mm,面密度1.8kg/m2)+固化片(厚度0.25mm,面密度300g/m2)+蜂窝+固化片+阻尼隔音毡+复合材料蒙皮
3、在0.1MPa,60℃,60min下进行固化成型,得到阻尼隔音复合板。
测试方法
通过称重、尺寸测量进行测试其面密度;通过隔音室测量其隔音量。
表1实施例及对比例的性能测试
质量kg/m<sup>2</sup> | 隔音量dB | |
实施例1 | 8 | 35 |
实施例2 | 6 | 32 |
实施例3 | 11 | 36 |
实施例4 | 10 | 35 |
实施例5 | 6 | 31 |
对比例1 | 6 | 24 |
对比例2 | 11 | 31 |
与对比例1-2相比,本公开的轻质隔音复合板质量更轻,强度没有降低、隔音效果更优或者不变。
在本说明书的描述中,参考术语“一个实施例/方式”、“一些实施例/方式”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例/方式或示例描述的具体特征、结构、材料或者特点包含于本申请的至少一个实施例/方式或示例中。在本说明书中,对上述术语的示意性表述不必须针对的是相同的实施例/方式或示例。而且,描述的具体特征、结构、材料或者特点可以在任一个或多个实施例/方式或示例中以合适的方式结合。此外,在不相互矛盾的情况下,本领域的技术人员可以将本说明书中描述的不同实施例/方式或示例以及不同实施例/方式或示例的特征进行结合和组合。
此外,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本申请的描述中,“多个”的含义是至少两个,例如两个,三个等,除非另有明确具体的限定。
本领域的技术人员应当理解,上述实施方式仅仅是为了清楚地说明本公开,而并非是对本公开的范围进行限定。对于所属领域的技术人员而言,在上述公开的基础上还可以做出其它变化或变型,并且这些变化或变型仍处于本公开的范围内。
Claims (10)
1.一种轻质隔音复合板,从上到下依次为预浸料层、粘合剂层、蜂窝发泡材料、粘合剂层、预浸料层,其特征在于,
蜂窝发泡材料,所述蜂窝发泡材料为填充有发泡材料的芳纶蜂窝,所述蜂窝发泡材料的密度为200-800kg/m3,厚度为5-30mm;向芳纶蜂窝中以密度由高到低的顺序依次填充发泡材料,从而形成密度梯度;
在所述蜂窝发泡材料的上表面和下表面分别通过粘合剂层与预浸料层连接;
一体复合成型。
2.根据权利要求1所述的轻质隔音复合板,其特征在于,所述芳纶蜂窝的孔格边长为2-5mm,蜂窝壁厚度为0.045-0.15mm,所述芳纶蜂窝的密度为48-144kg/m3。
3.根据权利要求1所述的轻质隔音复合板,其特征在于,所述发泡材料是阻燃发泡材料;所述发泡材料的密度为150-700kg/m3。
4.根据权利要求3所述的轻质隔音复合板,其特征在于,所述阻燃发泡材料优选为水凝胶发泡材料、聚氨酯发泡材料、轻质环氧发泡材料。
5.根据权利要求1所述的轻质隔音复合板,其特征在于,所述发泡材料与芳纶蜂窝的重量比为2-16:1。
6.根据权利要求1所述的轻质隔音复合板,其特征在于,所述复合成型是通过热压、真空袋压或热压罐的工艺进行的。
7.根据权利要求1所述的轻质隔音复合板,其特征在于,所述预浸料选自纤维织物浸渍树脂材料,优选为玻纤环氧预浸料。
8.一种制备根据权利要求1所述的轻质隔音复合板的制备方法,其特征在于,包括:
(1)采用发泡材料对芳纶蜂窝进行密度梯度填充发泡,制备具有一定密度梯度的蜂窝发泡材料,控制填充过程中压力为0.1-0.2Mpa,温度为100-120℃,时间为40-60min,得到低-高频广谱隔/吸音材料;
(2)然后按照从上到下的顺序依次铺设第一预浸料层、蜂窝发泡材料,第二预浸料层,其中预浸料层和芯材之间通过粘合剂层连接,在压力0.3-0.5MPa,温度100-120℃的条件下处理60-120min固化成型,然后进行脱模修边处理,得到一种轻质隔音复合板。
9.一种制备根据权利要求1所述的轻质隔音复合板的制备方法,其特征在于,包括:
(1)采用发泡材料对芳纶蜂窝进行密度梯度填充发泡,制备具有一定密度梯度的蜂窝发泡材料,控制填充过程中压力为0.1-0.2Mpa,温度为100-120℃,时间为40-60min,得到低-高频广谱隔/吸音材料;
(2)将预浸料进行固化成型得到复合材料蒙皮,然后对其进行打磨,并将其铺设在蜂窝发泡材料上下面,在复合材料蒙皮与蜂窝发泡材料之间设置粘合剂层,在压力0.3-0.5MPa,温度100-120℃的条件下处理60-120min固化成型,最后进行修边处理,得到一种轻质隔音复合板。
10.根据权利要求1所述轻质隔音复合板的应用,其特征在于,所述复合板用于建筑、交通运输领域。
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