WO2017035987A1 - 吸音材料制备方法以及吸音材料 - Google Patents

吸音材料制备方法以及吸音材料 Download PDF

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Publication number
WO2017035987A1
WO2017035987A1 PCT/CN2015/097758 CN2015097758W WO2017035987A1 WO 2017035987 A1 WO2017035987 A1 WO 2017035987A1 CN 2015097758 W CN2015097758 W CN 2015097758W WO 2017035987 A1 WO2017035987 A1 WO 2017035987A1
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Prior art keywords
sound absorbing
absorbing material
oil
particles
preparing
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PCT/CN2015/097758
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English (en)
French (fr)
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曹晓东
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歌尔声学股份有限公司
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Priority to US16/076,693 priority Critical patent/US11107451B2/en
Publication of WO2017035987A1 publication Critical patent/WO2017035987A1/zh

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    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/02—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
    • B01J2/06—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops in a liquid medium

Definitions

  • the present invention relates to the field of material preparation technology, and more particularly to a method for preparing a sound absorbing material and a sound absorbing material.
  • such sound absorbing materials which have a good application effect include one of natural sound absorbing materials such as natural zeolite, activated carbon, white carbon black or silica powder having a silica-alumina ratio of 200 or more, or a mixture of the above materials.
  • the above powdery sound absorbing material should be prepared into particles of 0.10-10mm particle size. According to the size and structure of the rear cavity of the speaker product, the particle size is 0.10. Select a smaller interval to float within -10mm.
  • the conventional granulation methods are extrusion, boiling granulation, rolling into a ball method, and spray drying.
  • the extrusion method, the boiling granulation method, the rolling ball method have poor particle strength, poor sphericity, surface is not smooth and the particle size is uneven, physical structure and performance are limited, and the main pore volume and pore diameter are small;
  • the particles formed by the drying method are relatively small, and the particle size distribution is uneven.
  • the obtained particle size distribution range is large, the sphericity is poor, the inter-particle stacking is uneven and tight, and the unobstructed pores which are difficult to form between the particles cause the overall mass transfer resistance of the sound absorbing module to increase greatly, and the speaker (SPK)
  • SPK speaker
  • a method of making a sound absorbing material comprises the following steps:
  • the dried particles are calcined to form particles of sound absorbing material.
  • the non-foamed material slurry comprises a binder, a non-foamed powder material, a templating agent, and activated carbon fibers.
  • the non-foamed powder material is one or more of natural zeolite powder, white carbon black, activated carbon powder or molecular sieve.
  • the binder has an effective solid content of 1-35% by mass of the non-foamed material slurry.
  • the templating agent has a mass ratio of 0 to 12%; the activated carbon fiber has a mass ratio of 0.1 to 15%, and the activated carbon fiber has a length of 0.15 to 15 mm.
  • the molding oil used in the oil column forming method is one of lubricating oil, stator oil, machine tool oil, vacuum pump oil or edible oil, or the forming oil is a mixture of lubricating oil and aliphatic hydrocarbon.
  • the oil temperature of the shaped oil is 40-120 ° C;
  • the drying is carried out in air or an inert gas, the drying temperature is 40-150 ° C; the drying time is 0.5-96 hours;
  • the calcination temperature is 120-850 ° C
  • the temperature increase rate is 20-120 ° C / hour
  • the calcination time is 0.5-96 hours.
  • a sound absorbing material prepared according to the preparation method provided by the present invention.
  • a sound absorbing material which is prepared from a non-foamed material which is a spherical particle.
  • the spherical particles have a particle diameter of from 0.10 to 10 mm.
  • the method for preparing a sound absorbing material provided by the invention is simple in operation and high in reliability.
  • Oil column forming By molding, the obtained shaped particles have high sphericity and uniform particle size.
  • the prepared sound absorbing material has uniform particle size, smooth surface and good sphericity, and the particles are in contact with each other and evenly stacked, which reduces the bed resistance and significantly improves the mass transfer efficiency and sound absorption effect of the sound absorbing member. Moreover, the sphericity of the particles is high, and the wear rate between the particles is greatly reduced.
  • SPK speaker
  • the sound absorbing material provided by the invention has the characteristics of high sphericity, uniform particle size and smooth surface.
  • the particles are in point contact with each other and evenly stacked, which reduces the bed resistance and significantly improves the mass transfer efficiency and sound absorption effect of the sound absorbing member. Moreover, it is not easy to powder during use.
  • the inventors of the present invention have found that the particles obtained by the granulation method of the conventional sound absorbing material have poor sphericity, are not uniform in size, and have poor particle strength. There is no technical solution for the oil column forming method for the preparation of sound absorbing materials. Therefore, the technical task to be achieved by the present invention or the technical problem to be solved is not thought of or expected by those skilled in the art, so the present invention is a new technical solution.
  • FIG. 1 is a scanning electron micrograph of a sound absorbing material according to an embodiment of the present invention.
  • FIG. 2 is a scanning electron micrograph of a sound absorbing material prepared by a boiling granulation method.
  • the sound absorbing material particles prepared in the embodiment of the present invention 1, the sound absorbing material particles prepared in the embodiment of the present invention; 2, the sound absorbing material particles prepared by the boiling granulation method.
  • the embodiment provides a method for preparing a sound absorbing material, which is used for preparing a sound absorbing material in a speaker (SPK), and the preparation method comprises the following steps:
  • the non-foamed material slurry includes a binder, a non-foamed powder material, a templating agent, and activated carbon fibers.
  • an auxiliary agent such as a dispersing agent, a humectant or a surfactant to improve the quality of the slurry.
  • the non-foamed powder material is one or more of natural zeolite powder, white carbon black, activated carbon powder or molecular sieve.
  • the effective solid content of the binder is 1-35% by mass of the non-foamed material slurry, and the purpose of adding the binder is to increase the viscosity of the slurry to better form spherical particles.
  • One skilled in the art can set the mass ratio of the binder according to the kind and viscosity of the binder.
  • the templating agent functions as a structure guide, and the mass ratio of the templating agent is 0-12%.
  • the activated carbon fiber can form a diffusion pore structure after burning, and the specific surface area and pore volume of the sound absorbing material are improved.
  • the mass ratio of the activated carbon fiber is 0.1-15%, and the length of the activated carbon fiber is 0.15-15 mm.
  • the binder is a silicone sol-based binder, and the mass ratio of the binder is 12%.
  • a zeolite powder having a silicon to aluminum ratio of 200 or more is used as the non-foamed powder material.
  • the templating agent mass ratio is 10%.
  • the length of the activated carbon fiber is from 0.15 to 15 mm, and the mass ratio thereof is 10%.
  • an auxiliary agent such as a dispersing agent, a humectant or a surfactant is further added to improve the quality of the slurry.
  • auxiliary agent such as a dispersing agent, a humectant or a surfactant is further added to improve the quality of the slurry.
  • those skilled in the art can add other auxiliaries as needed.
  • the non-foamed material slurry is mixed to make the slurry uniform. Alternatively, methods such as quantitative addition, atomization, and the like are employed to increase slurry uniformity. The amount of each raw material added can be selected as needed
  • the mass ratio of the binder is 1%, and the non-foamed powder material
  • a mixture of natural zeolite powder, white carbon black, activated carbon powder and molecular sieve was used, and the mass ratio of the template was 12%.
  • the length of the activated carbon fiber is 0.15-15 mm, and the mass ratio thereof is 15%.
  • a non-foamed material slurry which meets the requirements is also prepared.
  • the mass ratio of the binder is 35%
  • the non-foamed powder material is a mixture of natural zeolite powder, white carbon black, activated carbon powder and molecular sieve, without adding a template.
  • the activated carbon fiber has a length of 0.15 to 15 mm and a mass ratio of 0.1%.
  • a non-foamed material slurry which meets the requirements is also prepared.
  • the non-foamed material slurry is formed by an oil column forming method to form wet particles.
  • the molding oil may be one of lubricating oil, stator oil, machine tool oil, vacuum pump oil or edible oil, or the molding oil may be a mixture of lubricating oil and aliphatic hydrocarbon.
  • the oil temperature of the molding oil is 40-120 °C. In the present embodiment, the molding oil is a lubricating oil, and the oil temperature of the molding oil is 100 °C.
  • the molding oil is a stator oil, and the oil temperature of the molding oil is 40 °C.
  • the molding can also be carried out very well.
  • the molding oil is machine tool oil, and the oil temperature of the molding oil is 120 °C.
  • the molding can also be carried out very well.
  • drying is carried out in air or an inert gas at a drying temperature of 40 to 150 ° C and a drying time of 0.5 to 96 hours. It will be readily apparent to those skilled in the art that the higher the drying temperature, the shorter the drying time; correspondingly, the lower the drying temperature, the longer the drying time.
  • the drying temperature can be set by a person skilled in the art according to the actual situation. In the present example, the drying was carried out in nitrogen at a drying temperature of 90 ° C and a drying time of 10 hours.
  • the drying is carried out in air at a drying temperature of 40 ° C and a drying time of 96 hours, again achieving a good drying effect.
  • the drying is carried out in the air at a drying temperature of 150 ° C and a drying time of 0.5 hours, which also achieves a good drying effect.
  • the calcination temperature is 120-850 ° C
  • the temperature increase rate is 20-120 ° C
  • the calcination time is 0.5-96 hours, and those skilled in the art can easily find that the lower the calcination temperature, the longer the calcination time, correspondingly, The higher the calcination temperature, the shorter the calcination time.
  • the calcination temperature used in this embodiment is 400 ° C
  • the temperature increase rate is 50 ° C. /hour
  • roasting time is 20 hours.
  • the calcination temperature is 120 ° C
  • the temperature increase rate is 20 ° C / hour
  • the calcination time is 96 hours, which also achieves a good calcination effect.
  • the calcination temperature is 850 ° C
  • the temperature increase rate is 120 ° C / hour
  • the calcination time is 0.5 hour, and a good calcination effect is also achieved.
  • the sound absorbing material provided by the present invention is prepared according to the preparation method provided by the present invention.
  • the sound absorbing material provided by the invention is prepared from a non-foaming material, and the non-foaming material has superior performance to the acoustic performance gain of the foaming material, and the sound absorbing material is spherical particles.
  • the spherical particles have a particle diameter of 0.10 to 10 mm.
  • the prepared sound absorbing material particles are first encapsulated in a PP (polypropylene) tray or a non-woven fabric; then, the packaged sound absorbing material particles are filled into the rear acoustic cavity of the speaker (SPK) to optimize the speaker (SPK) product. Acoustic performance. Of course, it is also possible to directly fill the prepared sound absorbing material particles into the rear acoustic cavity.
  • SPK polypropylene
  • the prepared sound absorbing material was subjected to scanning electron microscope (SEM) detection, and the scanning electron microscope image is shown in FIG.
  • SEM scanning electron microscope
  • the acoustic performance of the speaker (SPK) using the sound absorbing material was tested, see Table 1, in which the filling method was direct filling of the rear cavity.
  • Test items response frequency after filling (f 0 ) and particle dusting after 96 hours accelerated life test. Thirty samples were tested for each sample and the results were averaged.
  • the granulation by the boiling granulation method is carried out, and the method of the raw material ratio, the mixing method, the drying method, and the calcination method is the same as that employed in the present embodiment.
  • the prepared materials were examined by scanning electron microscopy (SEM), and the scanning electron micrographs are shown in Fig. 2.
  • SEM scanning electron microscopy
  • the acoustic performance of the speaker (SPK) using this material was tested, see Table 1, where the filling method was direct filling of the back cavity.
  • Test items response frequency after filling (f 0 ) and particle dusting after 96 hours accelerated life test. Thirty samples were tested for each sample and the results were averaged.
  • the sound absorbing material particles 1 obtained by the oil column forming method have uniform size, smooth surface and good sphericity, and the particles 1 are in contact with each other at a point, and the stacking is uniform, which reduces the bed resistance.
  • This The structure can significantly improve the mass transfer efficiency and sound absorption effect of the sound absorbing member, and the absorbing material of the sound absorbing material prepared by the oil column molding has a high sphericity, which greatly reduces the wear rate between the particles 1 and solves the use of the sound absorbing material particles 1 during use. Powdering problems caused by high frequency vibration of the speaker (SPK).
  • the absorbing material of the sound absorbing material prepared by the boiling granulation method has poor strength, poor sphericity, surface roughness and uneven particle size, and its physical structure and performance are limited, and the particles 2 are unevenly stacked. And the tightness is tight, and the smooth tunnel which is difficult to form between the particles 2 causes the overall mass transfer resistance of the sound absorbing module to increase greatly, and the high frequency airflow generated during the operation of the speaker (SPK) product is difficult to be in the sound absorbing member composed of the sound absorbing material particles 2. Smooth access, reducing the effective use of sound-absorbing parts, it is difficult to achieve the desired acoustic performance debugging effect.
  • the sound absorbing material produced by the oil column forming method reduces the response frequency f 0 of the speaker (SPK) product, that is, the difference in response frequency between the unfilled sound absorbing material and the filled sound absorbing material.
  • the value ⁇ f 0 is 122 Hz.
  • the boiling granulation method reduces the effect of the response frequency f 0 of the speaker (SPK) product, and ⁇ f 0 is 83 Hz.
  • the sound absorbing material prepared by oil column molding has no fine powder after 96 h accelerated life test, and the particles are intact.
  • the material obtained by the boiling granulation method was broken by more than 50% of the particles after the 96h accelerated life test, and the powdering phenomenon was serious.
  • the sound absorbing material prepared by the oil column forming has high sphericity, greatly reduces the wear rate between the particles, and solves the problem of powdering caused by high frequency vibration of the speaker (SPK) during the use of the sound absorbing particles.
  • the invention provides a method for preparing a sound absorbing material, which comprises preparing a non-foaming sound absorbing powder material, a binder, a templating agent, an activated carbon fiber, an auxiliary agent, etc. into a uniform slurry according to a ratio, and forming a granule by using an oil column forming method. After drying and calcination, a sound absorbing material in a final form is obtained.
  • the sound absorbing material produced by the oil column forming method has uniform particle size, smooth surface and good sphericity, and the particles are in contact with each other and evenly stacked, which reduces the bed resistance and significantly improves the mass transfer efficiency and sound absorption of the sound absorbing member. Effect, and formed by a sound absorbing material prepared by oil column molding The high sphericity of the particles greatly reduces the wear rate between the particles, and solves the problem of powdering caused by high frequency vibration of the speaker (SPK) during the use of the sound absorbing material.
  • SPK high frequency vibration of the speaker
  • Synchronization improves the specific surface area and pore volume of the sound absorbing material, improves the adsorption-desorption reaction efficiency and mass transfer efficiency of the air molecules in the sound absorbing material, and avoids secondary side reactions caused by the retention of hetero atoms and even the failure of the sound absorbing material.
  • the sound absorbing material provided by the invention has the characteristics of high sphericity, uniform particle size and smooth surface.
  • the particles are in point contact with each other and evenly stacked, which reduces the bed resistance and significantly improves the mass transfer efficiency and sound absorption effect of the sound absorbing member. Moreover, it is not easy to powder during use.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
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Abstract

提供一种吸音材料制备方法及吸音材料。该方法包括以下步骤：S1、制备非发泡材料浆料，混合均匀；S2、采用油柱成型法对非发泡材料浆料进行成型，形成湿润颗粒；S3、将湿润颗粒进行干燥，形成干燥颗粒；S4、将干燥颗粒进行焙烧，形成吸音材料颗粒。该方法操作简单，可使形成的颗粒大小均一，表面光滑且球形度好，颗粒间堆砌均匀，床程阻力小。该吸音材料由非发泡材料制备而成，为球形颗粒，具有传质效率高、吸音效果好、使用时不易起粉的特点。

Description

吸音材料制备方法以及吸音材料 技术领域
本发明涉及材料制备技术领域，更具体地，涉及一种吸音材料制备方法以及吸音材料。
背景技术
近年，随着穿戴式电子产品的日益轻薄化，传统吸音材料已不能满足扬声器(SPK)行业对声学性能调试校正的需求。针对这种情况，新型吸音材料不断被开发、尝试，经过验证，人们发现在扬声器装置后腔中放置多孔性吸音材料可以有效的改善其声学性能。目前，应用效果较好的该类吸音材料包括天然沸石、活性炭、白炭黑或硅铝比200以上的沸石粉等吸音材料中的一种，或者以上几种材料的混合物。在扬声器应用中，出于可定量性和工艺填充可实施性，需先将以上粉末态吸音材料制备成0.10-10mm粒径的颗粒，根据扬声器产品的后声腔大小、结构，颗粒粒径在0.10-10mm内选取较小区间浮动。
传统的制粒方式为挤压法、沸腾制粒法、滚动成球法和喷雾干燥法等。其中，挤压法、沸腾制粒法、滚动成球法制得的颗粒强度差、球形度差、表面不光滑且颗粒大小不均，物理结构和性能受到了限制，主要孔容和孔径小；喷雾干燥法成型的颗粒比较小，而且粒径分布不均。传统制粒方式存在所得颗粒大小分布区间较大，球形度差，颗粒间堆砌不均匀且偏紧实，颗粒间难以构成的通畅的孔道，造成吸音模块整体传质阻力大幅增加，扬声器(SPK)产品运作时产生的高频气流难以在此吸音材料颗粒构成的吸音件内通畅进出，降低了吸音件的有效利用，难以达到理想的声学性能调试效果。
发明内容
本发明的一个目的是提供一种吸音材料制备方法的新技术方案。
根据本发明的第一方面，提供了一种吸音材料制备方法。该制备方法包括以下步骤：
S1、制备非发泡材料浆料，混合均匀；
S2、采用油柱成型法对非发泡材料浆料进行成型，形成湿润颗粒；
S3、将所述湿润颗粒进行干燥，形成干燥颗粒；
S4、将所述干燥颗粒进行焙烧，形成吸音材料颗粒。
优选地，所述非发泡材料浆料包括粘结剂、非发泡粉体材料、模板剂和活性碳纤维。
优选地，所述非发泡粉体材料为天然沸石粉、白炭黑、活性炭粉末或者分子筛中的一种或多种。
优选地，所述粘结剂的有效固含量占所述非发泡材料浆料的质量比例为1-35％。
优选地，所述模板剂的质量比例为0-12％；所述活性碳纤维的质量比例为0.1-15％，所述活性碳纤维的长度为0.15-15mm。
优选地，所述油柱成型法采用的成型油为润滑油、定子油、机床油、真空泵油或者食用油中的一种，或者成型油为润滑油与脂肪烃的混合物。
优选地，在所述S2步骤中，成型油的油温为40-120℃；
在所述S3步骤中，干燥在空气或者惰性气体中进行，干燥温度为40-150℃；干燥时间为0.5-96小时；
在所述S4步骤中，焙烧温度为120-850℃,升温速度为20-120℃/小时；焙烧时间为0.5-96小时。
根据本发明的另一方面，提供了一种吸音材料，该吸音材料根据本发明提供的所述制备方法制备而成。
根据本发明的又一方面，提供了一种吸音材料，该吸音材料由非发泡材料制备而成，该吸音材料为球形颗粒。
优选地，所述球形颗粒的粒径为0.10-10mm。
本发明提供的吸音材料制备方法操作简单，可靠性高。采用油柱成型 法成型，得到的成型颗粒球形度高，颗粒大小均一。所制得吸音材料形成的颗粒大小均一，表面光滑且球形度好，颗粒间以点相互接触、堆砌均匀，减小了床程阻力，显著提高了吸音件的传质效率和吸音效果。并且，颗粒球形度高，大大降低了颗粒间的磨耗率，在扬声器(SPK)中使用时，解决了因扬声器(SPK)高频振动而导致起粉的问题。
本发明提供的吸音材料具有球形度高，颗粒大小均一，表面光滑的特点。颗粒间以点相互接触、堆砌均匀，减小了床程阻力，显著提高了吸音件的传质效率和吸音效果。并且，在使用过程中不易起粉。
本发明的发明人发现，现有吸音材料的造粒方法制得的颗粒球形度差，大小不均一，颗粒强度差。且尚未有将油柱成型法用于吸音材料制备的技术方案。因此，本发明所要实现的技术任务或者所要解决的技术问题是本领域技术人员从未想到的或者没有预期到的，故本发明是一种新的技术方案。
通过以下参照附图对本发明的示例性实施例的详细描述，本发明的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本发明的实施例，并且连同其说明一起用于解释本发明的原理。
图1是本发明实施例吸音材料的扫描电镜图；
图2是沸腾制粒法制备的吸音材料的扫描电镜图。
其中，1、本发明实施例制备的吸音材料颗粒；2、沸腾制粒法制备的吸音材料颗粒。
具体实施方式
现在将参照附图来详细描述本发明的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作 为对本发明及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步讨论。
本实施例提供了一种吸音材料制备方法，用于扬声器(SPK)中吸音材料的制备，该制备方法包括以下步骤：
S1、制备非发泡材料浆料，混合均匀。具体地，非发泡材料浆料包括粘结剂、非发泡粉体材料、模板剂和活性碳纤维。当然，还可以加入分散剂、增润剂或者表面活性剂等助剂，以提高浆料的质量。非发泡粉体材料为天然沸石粉、白炭黑、活性炭粉末或者分子筛中的一种或多种。进一步地，粘结剂的有效固含量占非发泡材料浆料的质量比例为1-35％，加入粘结剂的目的是增加浆料粘度，以更好的形成球形颗粒。本领域技术人员可以根据粘结剂的种类和粘度设定粘结剂的质量比例。模板剂起到结构导向的作用，模板剂的质量比例为0-12％。活性碳纤维在焙烧过程中，烧掉后可以形成扩散孔道结构，提高了吸音材料的比表面积和孔容，活性碳纤维的质量比例为0.1-15％，活性碳纤维的长度为0.15-15mm。
在本实施例中，粘结剂采用有机硅溶胶类粘结剂，粘结剂的质量比例为12％。采用硅铝比为200以上的沸石粉作为非发泡粉体材料。模板剂质量比例为10％。活性碳纤维的长度为0.15-15mm，其质量比例为10％。在本实施例中，还加入了分散剂、增润剂或者表面活性剂等助剂，以提高浆料的质量。当然，本领域的技术人员可以根据需要添加其他助剂。对非发泡材料浆料进行混合，使浆料均匀。可选择地，采用定量滴加、雾化加入等方法以提高浆料均匀度。各种原料的添加量可以根据需要进行选择。
在本发明的另一实施方式中，粘结剂的质量比例为1％，非发泡粉体材 料采用天然沸石粉、白炭黑、活性炭粉末和分子筛的混合物，模板剂质量比例为12％。活性碳纤维的长度为0.15-15mm，其质量比例为15％。同样制备出了符合要求的非发泡材料浆料。
在本发明的又一实施方式中，粘结剂的质量比例为35％，非发泡粉体材料采用天然沸石粉、白炭黑、活性炭粉末和分子筛的混合物，未加入模板剂。活性碳纤维的长度为0.15-15mm，其质量比例为0.1％。同样制备出了符合要求的非发泡材料浆料。
S2、采用油柱成型法对非发泡材料浆料进行成型，形成湿润颗粒。根据实际情况，成型油可采用润滑油、定子油、机床油、真空泵油或者食用油中的一种，或者成型油采用润滑油与脂肪烃的混合物。成型油的油温为40-120℃。在本实施例中，成型油采用润滑油，成型油的油温为100℃。
在本发明的另一实施方式中，成型油采用定子油，成型油的油温为40℃。同样可以很好的进行成型。
在本发明的又一实施方式中，成型油采用机床油，成型油的油温为120℃。同样可以很好的进行成型。
S3、将湿润颗粒进行干燥，形成干燥颗粒。具体地，干燥在空气或者惰性气体中进行，干燥温度为40-150℃，干燥时间为0.5-96小时。本领域技术人员很容易得出，干燥温度越高则干燥时间越短；相对应地，干燥温度越低则干燥时间越长。本领域技术人员可以根据实际情况对干燥温度进行设定。在本实施例中，干燥在氮气中进行，干燥温度为90℃，干燥时间为10小时。
在本发明的另一实施方式中，干燥在空气中进行，干燥温度为40℃，干燥时间为96小时，同样达到了好的干燥效果。
在本发明的又一实施方式中，干燥在空气中进行，干燥温度为150℃，干燥时间为0.5小时，同样达到了好的干燥效果。
S4、将干燥颗粒进行焙烧，形成吸音材料颗粒。具体地，焙烧温度为120-850℃,升温速度为20-120℃；焙烧时间为0.5-96小时，本领域技术人员很容易得出，焙烧温度越低则焙烧时间越长，相对应地，焙烧温度越高则焙烧时间越短。本实施例中采用的焙烧温度为400℃，升温速度为50℃ /小时，焙烧时间为20小时。
在本发明的另一实施方式中，焙烧温度为120℃，升温速度为20℃/小时，焙烧时间为96小时，同样达到了好的焙烧效果。
在本发明的又一实施方式中，焙烧温度为850℃，升温速度为120℃/小时，焙烧时间为0.5小时，同样达到了好的焙烧效果。
本发明提供的吸音材料根据本发明提供的制备方法制备而成。
本发明提供的吸音材料由非发泡材料制备而成，非发泡类材料较发泡类材料对声学性能增益表现更优越，吸音材料为球形颗粒。球形颗粒的粒径为0.10-10mm。
使用时，先将制备好的吸音材料颗粒用PP(聚丙烯)托盘或者无纺布封装；然后，将封装好的吸音材料颗粒填充到扬声器(SPK)的后声腔中，优化扬声器(SPK)产品的声学性能。当然，也可以将制备好的吸音材料颗粒直接填充到后声腔中。
在本实施例中，对制备好的吸音材料进行了扫描电子显微镜(SEM)检测，扫描电镜图如图1所示。并对使用了该吸音材料的扬声器(SPK)的声学性能进行了测试，参见表1，其中，填充方式为后腔直接填充。
测试项目：填充后的响应频率(f0)和96小时加速寿命试验后颗粒起粉的情况。每种样品测试30个试样，测试结果取平均值。
为了进行对比，采用沸腾制粒法进行成型制粒，原料比例、混合方式、干燥方式和焙烧方式等实施方法与本实施例中采用的方法一致。对制备好的材料进行了扫描电子显微镜(SEM)检测，扫描电镜图如图2所示。并对使用了该材料的扬声器(SPK)的声学性能进行了测试，参见表1，其中填充方式为后腔直接填充。
测试项目：填充后的响应频率(f0)和96小时加速寿命试验后颗粒起粉的情况。每种样品测试30个试样，测试结果取平均值。
通过对比可以看出：
1、外观形貌
(1)参照图1，油柱成型法所制得吸音材料颗粒1大小均一，表面光滑且球形度好，颗粒1间以点相互接触、堆砌均匀，减小了床程阻力。这 种结构可以显著提高吸音件的传质效率和吸音效果，并且，采用油柱成型制备的吸音材料颗粒1球形度高，大大降低了颗粒1间的磨耗率，解决了吸音材料颗粒1使用过程中因扬声器(SPK)高频振动而导致的起粉问题。
(2)参照图2，沸腾制粒法制粒方式制备的吸音材料颗粒2强度差，球形度差、表面不光滑且颗粒大小不均，其物理结构和性能受到了限制，颗粒2间堆砌不均匀且偏紧实，颗粒2间难以构成的通畅的孔道，会造成吸音模块整体传质阻力大幅增加，扬声器(SPK)产品运作时产生的高频气流难以在此吸音材料颗粒2构成的吸音件内通畅进出，降低了吸音件的有效利用，难以达到理想的声学性能调试效果。
2、声学效果
表1
Figure PCTCN2015097758-appb-000001
参见表1，从声学效果试验测试结果可以看出：油柱成型法所制得吸音材料降低扬声器(SPK)产品响应频率f0的效果，即无填充吸音材料和填充吸音材料的响应频率的差值△f0为122Hz。而沸腾制粒法降低扬声器(SPK)产品响应频率f0的效果，△f0为83Hz。△f0越大则吸音效果越好。可见，油柱成型法制备得到的吸音材料的吸音效果明显优于沸腾制粒法制备得到的材料的吸音效果。并且，采用油柱成型制备的吸音材料经96h加速寿命试验后无微粉，颗粒完整。而沸腾制粒法得到的材料经96h加速寿命试验后超过50％的颗粒破碎，起粉现象严重。采用油柱成型制备的吸音材料形成的颗粒球形度高，大大降低了颗粒间的磨耗率，解决了吸音颗粒使用过程中因扬声器(SPK)高频振动而导致的起粉问题。
本发明专利提供了一种吸音材料制备方法，将非发泡吸音粉体材料、粘结剂、模板剂、活性碳纤维、助剂等按照比例配制成均匀浆料，采用油柱成型法形成颗粒，再经过干燥和焙烧，得到最终形态的吸音材料。
油柱成型法所制得吸音材料形成的颗粒大小均一，表面光滑且球形度好，颗粒间以点相互接触、堆砌均匀，减小了床程阻力，显著提高了吸音件的传质效率和吸音效果，并且，采用油柱成型法制备的吸音材料形成的 颗粒球形度高，大大降低了颗粒间的磨耗率，解决了吸音材料使用过程中因扬声器(SPK)高频振动而导致的起粉问题。
在成型过程中，通过控制非发泡粉体材料和粘结剂的配比、成型工艺的调配以及干燥时间和温度的组合，得到与毫秒级吸附-脱附反应匹配的扩散孔道结构。根据吸音材料在扬声器(SPK)产品的应用测试结果，可以看出，在模板剂作用下可令吸音材料生成丰富的介孔结构，焙烧将活性碳纤维烧掉后获得更为通畅的扩散孔道结构，同步提高了吸音材料的比表面积和孔容，提高空气分子在吸音材料中吸附-脱附反应效率和传质效率，避免了因杂原子等滞留造成的二次副反应，甚至吸音材料的失效。
本发明提供的吸音材料具有球形度高，颗粒大小均一，表面光滑的特点。颗粒间以点相互接触、堆砌均匀，减小了床程阻力，显著提高了吸音件的传质效率和吸音效果。并且，在使用过程中不易起粉。
虽然已经通过例子对本发明的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本发明的范围。本领域的技术人员应该理解，可在不脱离本发明的范围和精神的情况下，对以上实施例进行修改。本发明的范围由所附权利要求来限定。

Claims (10)

  1. 一种吸音材料制备方法，其特征在于，包括以下步骤：
    S1、制备非发泡材料浆料，混合均匀；
    S2、采用油柱成型法对非发泡材料浆料进行成型，形成湿润颗粒；
    S3、将所述湿润颗粒进行干燥，形成干燥颗粒；
    S4、将所述干燥颗粒进行焙烧，形成吸音材料颗粒。
  2. 根据权利要求1所述的吸音材料制备方法，其特征在于，所述非发泡材料浆料包括粘结剂、非发泡粉体材料、模板剂和活性碳纤维。
  3. 根据权利要求2所述的吸音材料制备方法，其特征在于，所述非发泡粉体材料为天然沸石粉、白炭黑、活性炭粉末或者分子筛中的一种或多种。
  4. 根据权利要求2所述的吸音材料制备方法，其特征在于，所述粘结剂的有效固含量占所述非发泡材料浆料的质量比例为1-35％。
  5. 根据权利要求2所述的吸音材料制备方法，其特征在于，所述模板剂的质量比例为0-12％；所述活性碳纤维的质量比例为0.1-15％，所述活性碳纤维的长度为0.15-15mm。
  6. 根据权利要求1所述的吸音材料制备方法，其特征在于，所述油柱成型法采用的成型油为润滑油、定子油、机床油、真空泵油或者食用油中的一种，或者成型油为润滑油与脂肪烃的混合物。
  7. 根据权利要求1所述的吸音材料制备方法，其特征在于，
    在所述S2步骤中，成型油的油温为40-120℃；
    在所述S3步骤中，干燥在空气或者惰性气体中进行，干燥温度为40-150℃；干燥时间为0.5-96小时；
    在所述S4步骤中，焙烧温度为120-850℃,升温速度为20-120℃/小时；焙烧时间为0.5-96小时。
  8. 一种吸音材料，其特征在于，所述吸音材料根据权利要求1-7任一项所述的制备方法制备而成。
  9. 一种吸音材料，其特征在于，所述吸音材料由非发泡材料制备而 成，所述吸音材料为球形颗粒。
  10. 根据权利要求9所述的吸音材料，其特征在于，所述球形颗粒的粒径为0.10-10mm。
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