CN117004106A - 一种柔性橡塑开孔吸音板及其制备方法 - Google Patents
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Abstract
本发明提供了一种柔性橡塑开孔吸音板及其制备方法,属于高分子橡塑发泡技术领域。本发明的柔性橡塑开孔吸音板包括1号胶料、2号胶料、3号胶料和4号胶料,制备的吸音材料可连续生产,不需要二次加工,就能得到开孔率较高的橡塑发泡材料,吸音率高,同时材料既能满足建筑吸音要求,也能起到阻燃、防火等作用。
Description
技术领域
本发明涉及高分子橡塑发泡技术领域,尤其涉及一种柔性橡塑开孔吸音板及其制备方法。
背景技术
吸音材料又叫吸声材料,原理是通过纤维震动或多孔结构内声音多次反射等方式吸收声波,减少空间内声音反射。吸音材料往往表面多孔,质量也比较轻,正因为吸音材料的多孔结构,声音很容易吸收,所以吸音材料不仅能改善空间的声环境,而且能够防止声音传到隔壁房间,影响他人。传统的橡塑吸音材料吸音率低,而且不能连续生产,并且不能一次成型,同时生产过程复杂,具有生产效率低,生产成本高,生产不稳定等缺点。
申请号为201520419315.X的专利公布了一种开孔吸音板,其生产原理是将橡塑发泡材料粉碎成小颗粒,然后使用胶粘剂粘合模压定型得到具有开孔结构的吸音板,其生产过程复杂,需要二次加工,工业化生产效率低,成本高。
现有技术中,开孔吸音板是先生产出闭孔橡塑保温制品,然后将闭孔橡塑保温制品放入开炼机上轧,通过开炼机的两辊将闭孔压破,形成开孔橡塑吸音板。其生产效率低,开孔率低,回弹性能差,吸音效果不好。
发明内容
有鉴于此,本发明的目的是提供一种柔性橡塑开孔吸音板,包括1号胶料、2号胶料、3号胶料和4号胶料;
所述1号胶料包括以下重量份的原料:
丁腈橡胶:6.5-7.5份
乙烯醋酸乙烯共聚物(EVA):3-4份
开孔发泡剂:13-15份
氢氧化铝:43-50份
增塑剂:3.75-4.75份
炭黑:1-2份
石蜡:1.4-1.8份
硬脂酸:0.1-0.4份
硬脂酸钙:0.2-0.6份
聚乙二醇:0.3-0.9份
抗氧剂:0.2-0.4份
三氧化二锑:2.8-4.3份
分散剂:0.5-1.2份
防老剂:0.1-0.3份
N-环已基硫代邻苯二甲酞亚胺:0.2-0.7份;
所述2号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
硫磺:0.2-0.5份
苯亚磺酸锌(ZBS):0.2-0.7份
ZnO:0.05-0.15份;
所述3号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
二硫化四甲基秋兰姆(TT):0.55-1.4份;
所述4号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
N-氧联二亚乙基-2-苯并噻唑次磺酰胺(NOBS):0.55-1.4份。
上述原料中丁腈橡胶、EVA为骨料,氢氧化铝为填料,炭黑为补强剂,三氧化二锑为阻燃剂,石蜡、硬脂酸和聚乙二醇为润滑剂,氧化锌为活化剂,硫磺为硫化剂,N-环已基硫代邻苯二甲酞亚胺为防焦剂。
EVA由于在分子链中引入醋酸乙烯单体,因此降低了高结晶度,提高了韧性。因此给气孔形成支撑,使开孔橡塑具有非常好的回弹性。
3号胶料中的TT和4号胶料中的NOBS均为促进剂,NOBS为次磺酰胺类促进剂,是因为它在硫化开始的低温阶段没有促进效果,而待到高温时便迅速发生分解成硫基苯丙噻唑和胺化合物。噻唑在碱性胺的活化下发挥极大的促进效能,使硫化很快完成,并且其焦烧时间长,加工性能安全。TT为秋兰姆类促进剂,焦烧时间长,硫化温度不易过高一般不超过125-135℃。其两种促进剂结合,使硫化晚于发泡,此时胶料的门尼粘度不高,发泡剂分解冲破泡孔形成开孔。
优选的,所述开孔发泡剂由偶氮二甲酰胺(AC发泡剂)、尿素和硬脂酸按照质量比为20:1:0.5混合而成,同时AC发泡剂的粒径在4-4.5微米。此开孔发泡剂开孔率高,发泡速度易控制。偶氮二甲酰胺,分解温度200℃,分解温度高。AC发泡剂尿素和硬脂酸复合,尿素与硬脂酸通过酸碱反应促进AC发泡剂的迅速分解,降低发泡剂的分解温度到120-130℃,此时胶料的门尼粘度低,孔内的压力高,将闭孔撑破后形成开孔。
优选的,所述抗氧剂为2,6-二叔丁基-4-甲基苯酚(264抗氧剂)。
优选的,所述增塑剂为异丙苯基磷酸酯。其为阻燃型增塑剂,具有增塑效果的同时跟填料氢氧化铝协同阻燃,并起到抑烟的作用。
优选的,所述分散剂为乙撑双硬脂酸酰胺。提高填料在胶料中的分散性,增加填料的添加量,提高表面平整度降低成本。
优选的,所述防老剂二丁基二硫代氨基甲酸镍(NBC)。
本发明的另一目的是提供一种柔性橡塑开孔吸音板的制备方法,包括以下步骤:
a)按比例称取1号胶料的原料,首先将丁腈橡胶投入密炼机中,炼胶一分钟后将其余的料投入密炼机中,6分钟排气,140℃放料,将料放入开炼机中压3分钟出条,得到1号胶料;
b)按比例称取2号胶料的原料,分别加入密炼机中,当胶料升温至100℃放料,开炼压片冷却后得到2号胶料;
c)按比例称取3号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到3号胶料;
d)按比例称取4号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到4号胶料;
e)将1号胶料、2号胶料、3号胶料、4号胶料依次放入开炼机中,摆料270s后出条;将胶料喂入挤出机中通过模具挤出板材进入发泡炉进行发泡,得到所述柔性橡塑开孔吸音板。
优选的,步骤e)所述挤出机参数如下:
挤出机螺杆温度为15-20℃,喂料段温度为35~45℃,塑化段温度为45~55℃;机头段温度为30~40℃。
优选的,步骤e)所述发泡是将成型的产品置于发泡炉中,依次经过6个发泡区进行发泡处理,其中一区的传输速度为0.5-1m/min,二区的传输速度为0.65-1.14m/min,三区的传输速度为1.3-1.65m/min,四区的传输速度为1.9-2.4m/min,五区的传输速度为2.8-3.8m/min,六区的传输速度为3.5-4.5m/min。
优选的,所述发泡炉6个发泡区温度分别为:一区105-110℃,二区110-120℃,三区120-130℃,四区125-135℃,五区140-150℃,六区140-150℃。
与现有技术相比,本发明具有以下有益效果:本发明提供了一种柔性橡塑开孔吸音板及其制备方法,提供的吸音材料,可连续生产,不需要二次加工,就能得到开孔率较高的橡塑发泡材料,吸音率高,同时材料既能满足建筑吸音要求,也能起到阻燃、防火等作用。
具体实施方式
下面结合实施例对本发明作进一步说明。
实施例1
一种柔性橡塑开孔吸音板,原料组成的重量份如表1。
所述柔性橡塑开孔吸音板的制备方法,步骤如下:
a)按比例称取1号胶料的原料,首先将丁腈橡胶投入密炼机中,炼胶一分钟后将其余的料投入密炼机中,6分钟排气,140℃放料,将料放入开炼机中压3分钟出条,得到1号胶料;
b)按比例称取2号胶料的原料,分别加入密炼机中,当胶料升温至100℃放料,开炼压片冷却后得到2号胶料;
c)按比例称取3号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到3号胶料;
d)按比例称取4号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到4号胶料;
e)将1号胶料、2号胶料、3号胶料、4号胶料依次放入开炼机中,摆料270s后出条;将胶料喂入挤出机中通过模具挤出板材进入发泡炉进行发泡,得到所述柔性橡塑开孔吸音板;
所述挤出机螺杆温度为15℃,喂料段温度为40℃,塑化段温度为45℃;机头段温度为35℃;
将挤出成型胶片置于发泡炉中,依次经过6个发泡区进行发泡处理,其中一区的传输速度为0.55m/min,二区的传输速度为0.7m/min,三区的传输速度为1.35m/min,四区的传输速度为1.95m/min,五区的传输速度为2.9m/min,六区的传输速度为3.6m/min,所述发泡炉的入炉温度105℃,出口温度142℃。
泡炉按温度分成6区控制,发泡炉各区温度分别为:一区105℃,二区110℃,三区120℃,四区128℃,五区142℃,六区142℃。
实施例2
一种柔性橡塑开孔吸音板,原料组成的重量份如表1。
所述柔性橡塑开孔吸音板的制备方法,步骤如实施例1,区别在于实施例2中:
挤出机螺杆温度为18℃,喂料段温度为38℃,塑化段温度为50℃;机头段温度为38℃;
将挤出成型胶片置于发泡炉中,依次经过6个发泡区进行发泡处理,其中一区的传输速度为0.65m/min,二区的传输速度为1m/min,三区的传输速度为1.45m/min,四区的传输速度为2.2m/min,五区的传输速度为3.1m/min,六区的传输速度为3.9m/min,所述发泡炉的入炉温度108℃,出口温度145℃。
泡炉按温度分成6区控制,发泡炉各区温度分别为:一区108℃,二区115℃,三区128℃,四区130℃,五区145℃,六区145℃。
实施例3
一种柔性橡塑开孔吸音板,原料组成的重量份如表1。
所述柔性橡塑开孔吸音板的制备方法,步骤如实施例1,区别在于实施例3中:
挤出机螺杆温度为20℃,喂料段温度为45℃,塑化段温度为55℃;机头段温度为40℃;
将挤出成型胶片置于发泡炉中,依次经过6个发泡区进行发泡处理,其中一区的传输速度为0.95m/min,二区的传输速度为1.1m/min,三区的传输速度为1.6m/min,四区的传输速度为2.3m/min,五区的传输速度为3.5m/min,六区的传输速度为4.2m/min,所述发泡炉的入炉温度110℃,出口温度148℃。
泡炉按温度分成6区控制,发泡炉各区温度分别为:一区110℃,二区120℃,三区130℃,四区135℃,五区148℃,六区148℃。
表1
对比例1
根据实例1中记载的技术方案,去掉尿素和硬脂酸将开孔发泡剂换成AC发泡剂,用量为14.4,其余工艺不变,制得柔性橡塑开孔吸音板。
对比例2
根据实例2中记载的技术方案,去掉乙撑双硬脂酸酰胺,其余工艺不变,制得柔性橡塑开孔吸音板。
对比例3
根据实例3中记载的技术方案,去掉EVA,其余工艺不变,制得柔性橡塑开孔吸音板。
对实施例1-3以及对比例1-3所制备的柔性橡塑开孔吸音板的性能,结果如表2:
表2
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种柔性橡塑开孔吸音板,其特征在于,包括1号胶料、2号胶料、3号胶料和4号胶料;
所述1号胶料包括以下重量份的原料:
丁腈橡胶:6.5-7.5份
乙烯醋酸乙烯共聚物:3-4份
开孔发泡剂:13-15份
氢氧化铝:43-50份
增塑剂:3.75-4.75份
炭黑:1-2份
石蜡:1.4-1.8份
硬脂酸:0.1-0.4份
硬脂酸钙:0.2-0.6份
聚乙二醇:0.3-0.9份
抗氧剂:0.2-0.4份
三氧化二锑:2.8-4.3份
分散剂:0.5-1.2份
防老剂:0.1-0.3份
N-环已基硫代邻苯二甲酞亚胺:0.2-0.7份;
所述2号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
硫磺:0.2-0.5份
苯亚磺酸锌:0.2-0.7份
ZnO:0.05-0.15份;
所述3号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
二硫化四甲基秋兰姆:0.55-1.4份;
所述4号胶料包括以下重量份的原料:
丁腈橡胶:2-2.5份
增塑剂:1.25-1.6份
N-氧联二亚乙基-2-苯并噻唑次磺酰胺:0.55-1.4份。
2.根据权利要求1所述的柔性橡塑开孔吸音板,其特征在于,所述开孔发泡剂由偶氮二甲酰胺、尿素和硬脂酸以20:1:0.5混合而成。
3.根据权利要求1所述的柔性橡塑开孔吸音板,其特征在于,所述抗氧剂为2,6-二叔丁基-4-甲基苯酚。
4.根据权利要求1所述的柔性橡塑开孔吸音板,其特征在于,所述增塑剂为异丙苯基磷酸酯。
5.根据权利要求1所述的柔性橡塑开孔吸音板,其特征在于,所述分散剂为乙撑双硬脂酸酰胺。
6.根据权利要求1所述的柔性橡塑开孔吸音板,其特征在于,所述防老剂为二丁基二硫代氨基甲酸镍。
7.根据权利要求1所述的柔性橡塑开孔吸音板的制备方法,其特征在于,包括以下步骤:
a)按比例称取1号胶料的原料,首先将丁腈橡胶投入密炼机中,炼胶一分钟后将其余的料投入密炼机中,6分钟排气,140℃放料,将料放入开炼机中压3分钟出条,得到1号胶料;
b)按比例称取2号胶料的原料,分别加入密炼机中,当胶料升温至100℃放料,开炼压片冷却后得到2号胶料;
c)按比例称取3号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到3号胶料;
d)按比例称取4号胶料的原料,分别加入密炼机中,胶料温度升温到95℃放料,经开炼压片冷却后得到4号胶料;
e)将1号胶料、2号胶料、3号胶料、4号胶料依次放入开炼机中,摆料270s后出条;将胶料喂入挤出机中通过模具挤出板材进入发泡炉进行发泡,得到所述柔性橡塑开孔吸音板。
8.根据权利要求7所述的柔性橡塑开孔吸音板的制备方法,其特征在于,步骤e)所述挤出机参数如下:
挤出机螺杆温度为15-20℃,喂料段温度为35~45℃,塑化段温度为45~55℃;机头段温度为30~40℃。
9.根据权利要求7所述的柔性橡塑开孔吸音板的制备方法,其特征在于,步骤e)所述发泡是将成型的产品置于发泡炉中,依次经过6个发泡区进行发泡处理,其中一区的传输速度为0.5-1m/min,二区的传输速度为0.65-1.14m/min,三区的传输速度为1.3-1.65m/min,四区的传输速度为1.9-2.4m/min,五区的传输速度为2.8-3.8m/min,六区的传输速度为3.5-4.5m/min。
10.根据权利要求9所述的柔性橡塑开孔吸音板的制备方法,其特征在于,所述发泡炉6个发泡区温度分别为:一区105-110℃,二区110-120℃,三区120-130℃,四区125-135℃,五区140-150℃,六区140-150℃。
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